International Conference on Engineering of Tarumanagara (ICET 2013) Faculty of Engineering, Tarumanagara University, Jakarta-Indonesia, 2-3 October 2013 ISBN: 978-979-99723-9-2

DESIGN CONCEPT OF FIFO PICK AND DEPOSIT SYSTEM Richard Jonathan Salli1), Agustinus Purna Irawan1), Danardono A.S.2) 1)

Mechanical Engineering Department, Tarumanagara University, Indonesia Mechanical Engineering Department, University of Indonesia, Indonesia

2)

e-mail: [email protected], [email protected] Abstract Nowadays as the economic grow larger so does the number of goods being transported from one place to another. The high numbers of goods being transported in economic world have made the deposit and storage system become quite important and it has became necessary that an effective storage and deposit system need to be developed and designed in order to increase the work efficiency. One of system that has high efficiency is the storage and deposit system using first in-first out method which means that the goods being stored for the first time will be the first one to be out. This system also has some several advantages such as the goods delivered for the first time will not pile up for a long time of period where this event can result in some disadvantages such as expired time for goods related to food and other loss of quality, that’s why in this design, a construction of deposit and storage system using the first in first out method will be properly designed. Keywords: Goods storage and deposit system, first in-first out

INTRODUCTION The difficulty of distributing goods in warehouse has caused a low efficiency when stocking up products inside the warehouse. The lack of attention concerning this problem can slow down the distribution process. An example of the distribution problem is that many old stuffs are piling up in the warehouse that can make that old stuff become rusty. The process of distributing goods by using manpower is not efficient and has high human error, therefore it is necessary that efficient method of distributing process need to be developed. An alternative has been developed to solve the problems related to product distribution in the warehouse which is called with FIFO (first in, first out) method. Therefore in this project, a construction using FIFO method will be carefully designed and analyzed. The quality of a design can be measured by various criteria. It is important to calculate 1 or more safety factor to predict the possibility of failure [1]. Safety factor can be expressed as follows [2]:

Safety factor =

Maximum stress Working stress

(1)

Finite element method is a method that includes a cutting process of a structure to become a small elements, describing behaviors of each element and joining the nodes by bonding several elements together [3]. The static or dynamic simulation and the variety of failure criteria is the main factors that can give significant difference in finite element method [4]. Finite element method is widely used in stress analysis because it can give an accurate simulation results.

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International Conference on Engineering of Tarumanagara (ICET 2013) Faculty of Engineering, Tarumanagara University, Jakarta-Indonesia, 2-3 October 2013 ISBN: 978-979-99723-9-2

a) Stress analysis on a beam

b) Stress analysis on frame

Figure 1. Stress Analysis by using Autodesk Inventor Hydraulic system is a system that uses the pressure of a liquid to produce forces that can be used for many applications. Generally hydraulic system is used to lift heavy things. Most of hydraulic system is consisted of hydraulic pump, motor, valve, and hydraulic cylinder [5,6,7,8]. MATERIALS AND METHOD A

Designing

Consepting

Type, sizes, and weight of the product that will be loaded Load capacity of the construction

Analysis

Start Determining the type of simulation Determining the load force, moment and the loading location

Creating concept of the designed construction

Construction has enough strength

Choosing the lifting system

Creating blue print of the designed construction

Designing the load lifting system Creating 3D model of the designed construction

Blue print

N

Design is acceptable and can be made

N R

Y

End

Analysis

Y R

Choosing material and determining the safety factor of the design

Stress analysis

A

Figure 2. Flowchart of Fifo Design In this design project, the 3D modeling of the construction will be done by using autodesk inventor 2013 student version [4]. The design will designed proportional to the ME-29 | 2

International Conference on Engineering of Tarumanagara (ICET 2013) Faculty of Engineering, Tarumanagara University, Jakarta-Indonesia, 2-3 October 2013 ISBN: 978-979-99723-9-2

goods that will be stored. The goods that will be stored is a box of AC indoor unit FT25HV14. The type of lifting system that will be used is hydraulic system. It is chosen because hydraulic can produce a large force and is suitable for lifting heavy things. The material that will be used as the basic material for the construction is aluminum 6061 that has alloy of aluminum, magnesium, and silicon. It is chosen because it is relatively cheap compared to steel and because of its good strength, and corrosion resistance properties. Strength calculation will be done by using stress analysis feature of autodesk inventor. By doing stress analysis, it is hoped that we can know whether the design can withstand the given load or not and to know the exact stress values acting on the construction. RESULTS AND DISCUSSION

Figure 3. 3D model of the designed construction (in mm) [9] The work sequences of the designed construction are as follows:

Figure 4. Working Process [9] From the above picture, it can be seen that the box will be lifted as the result of the hydraulic cylinder giving the push force. The box lifted by the hydraulic force will move upwards and have physical contact with the holder component. The holder component will slide and move backward as the result of physical contact and the friction between the box and the holder. After the box pass the holder component, the hydraulic cylinder will move down to the original position slowly and is followed by the box. The box will be hold by

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International Conference on Engineering of Tarumanagara (ICET 2013) Faculty of Engineering, Tarumanagara University, Jakarta-Indonesia, 2-3 October 2013 ISBN: 978-979-99723-9-2

the holder component, this process will be continued repeatedly with the same sequences until the fourteen box.

a) Load and constrain configuration

b) Von mises stress

c) Deflection d) Safety factor Figure 5. Stress analysis results of the main construction [9] Stress analysis on the main component is done by applying the forces on the table. The assigned force is a combination of the weight of holder components, doors, frame and all other components that is sustained by the table. Table construction is very important because the table is the component that sustains all of the other component weight. So the failure of the table means the failure of the whole construction. It can be seen from the stress analysis results that the stress acting on the table is being concentrated in the middle of the upper side of the table. It is also found that the stress acting on the table is roughly about 1/15 of the material yield strength. The maximum deflection occurs in the middle upper side of the table, the values of maximum deflection is less than 0.1 mm therefore it is not significant and can be ignored.

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International Conference on Engineering of Tarumanagara (ICET 2013) Faculty of Engineering, Tarumanagara University, Jakarta-Indonesia, 2-3 October 2013 ISBN: 978-979-99723-9-2

a. Load and constrain configuration

b. Von mises stress

c. Deflection

d. Safety factor Figure 6. Stress analysis results of the holder component [9]

The process of applying load to the holder component is done by summing up the total weight of the stored box. The storage capacity of the designed construction is up to 14 boxes which can be seen from Figure 9, therefore the load is applied based on the maximum load acting on the holder component which is the weight of 14 boxes. From the analyses results, it can see that the stress occurring on the holder component is still at safety limit which is showed by the blue color on almost all components. The stress is concentrated on pin component 1 because pin 1 is the component that holds the load of 14 boxes. Stress analysis results also shows that the stress acting on the holder component is roughly about 1/15 of the material yield strength. The maximum deflection occurs at the tip end, since the occurring deflection is not more than 0.1 mm therefore it is not significant and can be ignored. The deflection phenomenon is similar to the cantilever beam phenomenon where the maximum deflection also occurs at the tip end.

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International Conference on Engineering of Tarumanagara (ICET 2013) Faculty of Engineering, Tarumanagara University, Jakarta-Indonesia, 2-3 October 2013 ISBN: 978-979-99723-9-2

Design of Hydraulics Circuit

Figure 7. Hydraulic Circuit [9] CONCLUSION From this design project, a design of FIFO pick and deposit system has been successfully designed, simulated and tested. The stress simulation results has shown that the construction can withstand the stress and load acting on the construction, therefore it can be concluded that the designed construction is safe enough to be built.

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International Conference on Engineering of Tarumanagara (ICET 2013) Faculty of Engineering, Tarumanagara University, Jakarta-Indonesia, 2-3 October 2013 ISBN: 978-979-99723-9-2

Specifications of designed construction are as follow: Storage capacity Goods type Type of lifting system Cylinder type Valve type Needed hydraulic pressure Cylinder diameter The diameter of cylinder stroke The length of cylinder stroke Total width of construction Total height of construction Construction material

: 168 kg (14 boxes @ 860 x 350 x 230 mm, 12 kg) : Box of AC indoor unit FT25HV14 : Hydraulic system : Double acting cylinder : 4/3 directional control valve hand lever : (0.344 -0.689) MPa : 84 mm : 38 mm : 540 mm : 1530 mm : 4665.69 mm : Aluminum 6061

REFERENCES [1] R.S. Khurmi. A Textbook Of Machine Design. New Delhi: Eurasia Publishing House (Pvt.) Ltd. 2005. [2] R. L. Norton. Machine Design An Integrated Approach. Worcester: Pearson Prentice Hall. 2006. [3] Wirawan, Pramono. Pneumatik – Hidrolik. Jurusan Teknik Mesin Fakultas Teknik Universitas Negeri Semarang. http://ardianzsite.files.wordpress.com/2010/02/bahanajar-tmd218-pneumatik-hidrolik.pdf. [4] Nur Hidayat, Ahmad Shanhaji. Mastering 3D Mechanical Design Autodesk Inventor Professional. Penerbit Informatika. Bandung. 2011. [5] M. S. M. Sani, et al. Stress Analysis And Modal Transient Response Of Car Chassis. International Conference On Advance Mechanical Engineering (ICAME09). 22-25 June 2009. Selangor. 2009. [6] Roslan Abd Rahman, Mohd Nasir Tamin, Ojo Kurdi. Stress Analysis of Heavy Duty Truck Chassis as a Preliminary Data for Its Fatigue Life Prediction Using FEM. Journal of Mekanikal, No. 26. December 2008. pp. 76-85. [7] Tuba Taşdemir, Adem Taşdemir, Yaprak Geçgel. Truck Chassis Structural Thickness Optimization with The Help of Finite Element Technique. The Online Journal of Science and Technology. Volume 1. Issue 3. July 2011. pp. 23-30, 2011. [8] Rusmardi. Analisis Percobaan Gesekan (Friction) Untuk Teknologi Pengereman Pada Kendaraan Bermotor. Jurnal Ilmiah Poli Rekayasa. Volume 3 No. 2. Maret 2008. pp. 82-89. [9] Richard J. Salli, Agustinus P. Irawan, Danardono A.S. Pick And Deposit System Design With A Capacity Of 168 kg. Final Project. Mechanical Engineering Department. Tarumanagara University. 2013.

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