design and development of safety pedal lock...
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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Design and Development of Safety Pedal Lock
for Manual Gear’s Car
Thesis submitted in accordance with the partial requirements of the
Universiti Teknikal Malaysia Melaka for the
Bachelor of Manufacturing Engineering (Manufacturing Process)
By
Khor Teik Lim
Faculty of Manufacturing Engineering
March 2008
UTeM Library (Pind.1/2007)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS TESIS*
JUDUL: _______________________________________________________________ _______________________________________________________________ _______________________________________________________________
SESI PENGAJIAN : _______________________
Saya _____________________________________________________________________
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka . 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran
antara institusi pengajian tinggi.
4. **Sila tandakan (√)
(HURUF BESAR)
SULIT
TERHAD
√ TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
Alamat Tetap:
Tarikh: _______________________
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan
dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
DESIGN AND DEVELOPMENT OF SAFETY PEDAL LOCK FOR MANUAL GEAR‟S CAR.
2007/08
KHOR TEIK LIM
30 JLN LEGENDA 36,
LEGENDA HEIGHTS, 08000
SG. PETANI, KEDAH.
24/03/2008
DECLARATION
I hereby, declared this thesis entitled “Design and Development
of Safety Pedal Lock for Manual Gear‟s Car” is the results of my own research
except as cited in references.
Signature : ………………………………………….
Author‟s Name : …………………………………………
Date : …………………………………………
KHOR TEIK LIM
24/03/2008
APPROVAL
This PSM submitted to the senate of UTeM and has been as partial fulfillment of the
requirements for the degree of Bachelor of Manufacturing Engineering (Process).
The members of the supervisory committee are as follow:
………………………………
(Main Supervisor)
(Official Stamp & Date)
ABSTRACT
This project studies the design and development of safety pedal lock for
manual gears‟ car. The purpose of the project is to design and analysis an anti-theft
device, Safety Pedal Lock, which to prevent the vehicle theft occurred frequently
today. Since according to the General Insurance Association of Malaysia (PIAM),
the Proton car theft was reported as 51% of the total 2436 private cars reported stolen
to insurer during the period. Therefore, it‟s to design, fabricate and assembly of
Safety Pedal Lock for manual gear car, which can provide additional security to the
users‟ vehicle because it can prevent the stolen in very shorten time. The method to
be used in the designing was Solidworks software. The software used to create a 3D
modeling and analysis the product structural such as stress, stiffness and safety factor.
A prototype was created with the helped sketching drawing. There was also had to
fabricate and assembly of the Safety Pedal Lock. Thus, the mechanical processes like
milling, drilling, welding and painting were involved. Finally, it was carried out with
a completed Safety Pedal Lock. In addition, the methodology for the development
was divided into five phases, which included planning, concept development, detail
design, fabrication and assembly, and structural analysis. At the end of each stage, its
will come out with the output like sketching, drawing detail, real modeling, complete
product and structural analysis results. This Safety Pedal Lock had more advantages
than existing such as friendly usage, easy to lock-up and release, easy for storage,
and lower cost.
ABSTRAK
Projek ini mengkaji tentang rekabentuk dan perkembangan bagi Alat Kunci
Injak untuk kereta manual gear. Tujuan utama projek ini adalah untuk merekabentuk
dan menganalisis alat kunci injak kereta yang berfungsi supaya dapat mengelakkan
kes kecurian yang semakin berleluasa hari ini. Mengikut analisa yang dilakukan oleh
Kesatuan Insurans Malaysia (PIAM), sebanyak 51% daripada 2436 kereta Proton
telah dicuri dan diloporkan kepada syarikat insurans pada tahun tersebut. Oleh yang
demikian, satu Alat Kunci Injak telah direkabentuk dan dibina untuk menjana satu
keselamatan lebihan bagi mengelakkan kes kecurian dalam masa yang singkat.
Program komputer yang akan digunakan untuk menjayakan projek ini adalah
perisian Solidworks. Program komputer ini akan digunakan bagi mengilusasikan
imej produk dengan lukisan kejuruteraannya dan juga untuk tujuan analisa tentang
ciri-ciri strukturnya seperti daya mampatan, ketegangan, dan kekerasan. Satu
prototaip telah dihasilkan sebelum proses pembentukkan produk dengan
berpandukan lakaran produk. Selain itu, produk Alat Kunci Injak perlu dibentukkan.
Jadi, proses-proses pemesinan seperti milling, drilling, kimpalan dan pengecat
diperlukan untuk projek ini. Dalam pada itu, kaedah yang digunakan telah
dibahagikan kepada 5 bahagian seperti pelan, konsep perkembangan, perician lukisan,
pembuatan produk dan analisa struktur. Selain itu, setiap peringkat akan
mengeluarkan keputusan seperti lakaran, lukisan kejuruteraan, produk sebenar dan
keputusan analisa. Akhir kata, satu Alat Kunci Injak yang berfungsi telah dihasilkan
pada hujung perkembangan pemrekabentuk ini.
DEDICATION
Specially dedicated to my beloved family
ACKNOWLEDGEMENTS
First, I would like to thank my Projek Sarjana Muda (PSM) Supervisor, Mr.
Mohd. Amran Bin Md. Ali for his continuous support during my PSM program. Mr.
Amran was always there to listen and give advice. He taught me how to accomplish
my studies and express my ideas. He also showed me special ways to approach
analysis and research problems and the need to be determined to achieve any goals.
In the meantime, I would also like to thank the other two cooperated PSM
panel, Prof. Dr Md Dan and Mr. Abd. Halim Hakim for given me an opportunity to
present my found. Then, I am also greatly thankful to UTeM‟s lecturers, for getting
me interested in design methods, introducing me to CAD programs and concepts,
and also teaching me about the entire programming skills.
Last, but not least, I would like to thank all FKP technicians that always there
to give helped to handling the machines like oxy-cutter, milling and welding machine.
They had taught me the right techniques for the welding process.
TABLE OF CONTENTS
Abstract………..…………………………………………………………...……….....i
Abstrak……………………………………………………………………………......ii
Dedication……………………………………………………………………………iii
Acknowledgements………………………………………………………..…………iv
Table of Contents……………………………………………………………………..v
List of Figures………………………………………………………………………ix
List of Tables………………………………………………………………………..xii
List of Abbreviations, Symbols, Specialized Nomenclature ………………………xiii
1. INTRODUCTION…………………………………………………………….....1
1.1 Background……………………………………………………….....…………1
1.2 Objective……………………..……………………………………………….2
1.3 Scope …………………………………………………………………………2
1.4 Problem Statement ……………………………………………………………2
2. LITERATURES REVIEW ……………………………………………………...3
2.1 Introduction……………………………………………………………………..3
2.1.1 Pedal Lock…………………………………………………………...........5
2.1.2 Steering Lock……………………………………………………………..8
2.1.3 Gear Lock…………………………………………………………………9
2.2 Type of Pedal ………………………………………………………………....10
2.3 Factors of Safety and Design Codes…………………………………………..13
2.4 Theory of Forces and Loading ………………………………………………..14
2.4.1 Definition of Force………………………………………………………14
2.4.2 Loading…………………………………………………………………..15
2.4.3 Stress…………………………………………………………………….16
2.4.4 Theory of Bending………………………………………………………20
2.5 Material………………………………………………………………………22
2.5.1 Iron………………………………………………………………………22
2.5.1.1 Cast Iron……………………………………………………………….23
2.5.1.2 Wrought Iron…………………………………………………………..24
2.5.2 Steel……………………………………………………………………...24
2.5.2.1 Carbon Steel…………………………………………………………...25
2.5.2.2 Mild Steel……………………………………………………………...25
2.5.3 Aluminium………………………………………………………………26
2.5.4 Copper…………………………………………………………………...27
2.6 Mechanical Properties of Metals……………………………………………...27
2.6.1 Brittleness……………………………………………………………….28
2.6.2 Ductility…………………………………………………………………28
2.6.3 Hardness…………………………………………………………………28
2.7 Quenching Process…………………………………………………………….29
2.8 Heat Treatment………………………………………………………………...30
2.9 Coating………………………………………………………………………...30
2.9.1 Wet Coating……………………………………………………………..31
2.9.2 Powder Coating………………………………………………………….34
2.9.3 Surface Treatment……………………………………………………….35
2.10 Machine and machine Components………………………………………….36
2.10.1 Milling Machine………………………………………………………..36
2.10.2 Welding Machine………………………………………………………37
3. METHODOLOGY……………………………………………………………...39
3.1 Introduction……………………………………………………………………39
3.2 Description of Project Development…………………………………………..39
3.2.1 Description of Study and Preparation…………………………………...42
3.2.2 Description of Design Concept………………………………………….43
3.2.3 Description of Architectural 3D Modeling Drawing……………………43
3.2.4 Description of Product Fabrication and Assembly……………………...43
3.2.5 Description of 3D Modeling Analyses………………………………….43
3.3 Study and Preparation…………………………………………………………44
3.3.1 Description of Planning and Management………………………………44
3.3.2 Description of Data Collection………………………………………….44
3.4 3D Modeling Design Concept………………………………………………...45
3.4.1 Description of Initial Design Plant Sketching…………………………..46
3.5 3D Modeling Mechanical Drawing…………………………………………...47
3.5.1 Description of Data Collection………………………………………….48
3.5.2 Description of Mechanical Drawing…………………………………….48
3.6 Product Fabrication and Assembly Development……………………………..50
3.6.1 Description of Milling Process………………………………………….50
3.6.2 Description of Drilling Process………………………………………….50
3.6.3 Description of Welding Process…………………………………………50
3.6.4 Description of Painting Process…………………………………............50
3.7 3D Modeling Analyses………………………………………………………..51
3.7.1 Description of data Collection…………………………………………..52
3.7.2 Description of Improvement…………………………………………….52
4. DESISGN, FABRICATION AND ASSEMBLY OF SAFETY PEDAL
LOCK……………………………………………………………………………….54
4.1 Introduction……………………………………………………………………54
4.2 Initial 3D Modeling Sketching………………………………………………...55
4.3 Product Prototype…...........................................................................................57
4.4 3D Modeling Drawing………………………………………………………...58
4.5 3D Modeling Structural Analysis……………………………………………59
4.6 Product Fabrication and Assembly……………………………………………62
5. DISCUSSION………………………………………………………………….67
5.1 Introduction……………………………………………………………………67
5.2 Concept Generation and Selection…………………………………………….68
5.3 Finite Element Analysis Method……………………………………………...70
6. CONCLUSION………………………………………………………………….71
7. REFERENCES…………………………………………………………………..73
APPENDICES
A Duration of PSM I Gantt-chart
B Gantt-chart of PSM I
C Duration of PSM II Gantt-chart
D Gantt-chart of PSM II
E Sketching 1 of Safety Pedal Lock
F Sketching 2 of Safety Pedal Lock
G Sketching 3 of Safety Pedal Lock
H 2D Orthographic of Safety Pedal Lock
I 2D Orthographic of Safety Pedal Lock Lower Part
J 2D Orthographic of Safety Pedal Lock Upper Part
K 3D Modeling of Safety Pedal Lock
L 3D Modeling of Safety Pedal Lock Lower Part
M 3D Modeling of Safety Pedal Lock Upper Part
N Ultimate Allowable Stress for Various Metallic Materials
O Column Formulas for Allowable Stress
LIST OF FIGURES
2.1 Steering Column Lock 4
2.2 New Lock Design 4
2.3 The Rover Sterling 800 Security Concepts Car 5
2.4 The View of Carryboy 3 Lock 6
2.5 The Main Concepts of the Carryboy 3 Lock 7
2.6 The Installation of Carryboy 3 Lock to Car Pedal 7
2.7 The view of Multiple Pedal Lock 7
2.8 The Latest Car lock System 8
2.9 The Stop-lock Steering Wheel Lock 8
2.10 The Anti-theft Steering Wheel Lock 9
2.11 Mul-T-Lock Gear Lock 10
2.12 Universal Fitting Gear Lever to Handbrake Lock 10
2.13 The Common Pedals Assembly in Car 11
2.14 The View of Nissan Silvia‟s Pedals 11
2.15 The View of Toyota KE-70‟s Pedals 12
2.16 The View of Nissan Silvia 180-SX‟s Pedals 12
2.17 Toyota Corolla AE-86‟s Pedals 12
2.18 Perodua Kelisa‟s Pedals 13
2.19 Example of Forces in Equilibrium 14
2.20 Load Classified as to Location and Method of Application 15
2.21 Example of the Deformation in a Bar under Tension 17
2.22 Short Timber Post under Compression due to Load P 17
2.23 Stress Element Showing General State of 3D Stress with origin
Placed in Center of Element
18
2.24 The Stress Element Showing 2D State of Stress 19
2.25 Stresses Acting on Octahedral Planes 19
2.26 Bending of a Beam due to Concentrated Load P 20
2.27 Example of Bending of a Simply Supported Beam Showing
Compression and Tension of the Outer Surfaces
21
2.28 Example of the Deflection in a Wood 2 x 4 beam Turned Flatwise
and Edgewise
21
2.29 Schematic of the SRV Test Configuration 29
2.30 Schematic Diagram Showing the Relationship among the
Temperature, Phase Transformation and Mechanical Response
29
2.31 The Major Components of Wet-coating 32
2.32 Typical Spray-gun and theirs Spray Techniques 34
2.33 The View of Horizontal and Vertical Milling Machine 37
2.34 The TIG Welding Circuit 38
2.35 Parts of the TIG Torch 38
3.1a Project Development Flow-chart 40
3.1b Project Development Flow-chart (continue) 41
3.1c Project Development Flow-chart (continue) 42
3.2 Flow-chart of Study and Preparation 45
3.3 Sketching View of Manual Car‟s Pedal 46
3.4 Flow-chart of Designing Concept 47
3.5 Flow-chart of Mechanical Drawing 49
3.6 Flow-chart of Fabrication and Assembly Development 51
3.7 Flow-chart of Analyses Development 53
4.1 The Application of Pedal Lock on Perodua Kelisa‟s Pedals 54
4.2 The View of Safety Pedal Lock on Relevant Pedals 55
4.3 The View of Pedals of Perodua Kelisa 55
4.4 The Upper-part Sketching 56
4.5 The Lower-part Sketching 56
4.6 The Prototype Front and Top View 57
4.7 The Product Functional 57
4.8 The Detail of Product 58
4.9 The Isometric View of Upper and Lower Parts 58
4.10 Isometric View of 3D Modeling Assembly 59
4.11 Isometric View of 3D Modeling 59
4.12 The Load Apply on 3D Modeling 60
4.13 Result of Displacement Analysis 60
4.14 Result of Stress Analysis 61
4.15 Result of Factor of Safety Analysis 61
4.16 The View of Product before Assembly 62
4.17 The View of Product after Assembly 62
4.18 The View of Product with Lock Holder 63
4.19 The View of Complete Product without coating Process 63
4.20 The Detail of Assembly Part 64
4.21 The Detail of Bottom-part Lock-up Area 64
4.22 The Detail of Upper-part Lock-up Position 64
4.23 The Detail of Pedal Holder Position 64
4.24 Safety Pedal with Under-painting 65
4.25 Product View after Fine Painting 65
4.26 Front-view of Finish Safety Pedal Lock 66
4.27 Top and Bottom View of Finish Safety Pedal lock 66
5.1 Iteration Cycle in the Product Development 67
5.2 Concept Generation Development Phase 68
5.3 Five Step Concept Generation Method 69
LIST OF TABLES
2.1 Factor Used to determine a Safety Factor for Ductile Materials 13
2.2 The Percentage of Carbon Alloyed with Iron Defines the Final
Material
22
2.3 Constitution of Various Cast Irons 23
2.4 General Rules to Classify Steel Based on its Carbon Content 25
2.5 Theoretical Coverage for a gallon of Paint 31
2.6 Functional of Pigment 33
2.7 Common Solvents used in the Formulation and Thinning of
Protective Coatings
33
LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED
NOMENCLATURE
Al - Aluminium
BDMS - Bright-drawn Mild Steel
BMS - Bright Mild Steel
Cr - Chromium
DLC - Diamond like Carbon
FCAW - Flux Cored Arc Welding
FE - Finite Element
FEM - Finite Element Method
FMVSS - Federal Motor Vehicle Safety Standards
GMAW - Gas Metal Arc Welding
LPB - Low Plasticity Burnishing
LSP - Laser Shock Processing
MEK - Methyl Ethyl Ketone
MIBK - Methylisobutyl Ketone
MIG - Metal Inert Gas
Mo - Molybdenum
Nb - Niobium
NHTSA - National Highway Traffic Safety Administration
NRMA - National Roads and Motorists‟ Association
PIAM - General Insurance Association of Malaysia
PVD - Physical vapour Deposition
SAW - Submerged Arc Welding
SMAW - Shielded Metal Arc Welding
Ti - Titanium
TIG - Tungsten Inert Gas
TiN - Titanium Nitride
W - Tungsten
3D - Three Dimensional
CHAPTER 1
INTRODUCTION
1.1 Background
This project focuses on designing and developing of safety pedal lock for manual
gear car. The Solidworks software was used to design the safety pedal lock because
the Solidworks software is easily to sketch and design however it can be used to do
analysis processed besides sketching. Furthermore, there was fabrication and
assembly work; thus the relevant machining processes such as millings, drillings, and
welding were involved. Meanwhile, there was some analysis by Solidworks software
which to improve the productivity of product. This safety pedal lock is an additional
lock for manual gear car besides gear‟s locks and steering locks.
According to the General Insurance Association of Malaysia (PIAM) analysis,
the vehicle theft was a serious problem in society today. Based on the latest statistics
from the General Insurance Association of Malaysia (PIAM) had shown that Proton
has had the highest number of cars reported stolen for the first half of the year. Theft
of Proton cars accounts for about 51 per cent of the total 2,436 private cars reported
stolen to insurers during the period [22]. This means, on average, about 7 Protons are
reported stolen every day. However, the theft prevention studied of United State
showed that the vehicle theft was the nation‟s number one property crime, which will
be occurred every 25.3 seconds and costing over 8.4 billion dollar each year [23].
1.2 Objective
The aim of this project is to design and development of safety pedal lock for manual
gear car. While the main objectives are:
1. To design and develop the safety pedal lock for manual gear car.
2. To design 3D modeling using Solidworks software.
3. To analysis 3D modeling using Solidworks software.
4. To fabricate safety pedal lock.
1.3 Scope
This safety pedal lock is helpful because it can provide an additional security to the
users‟ vehicle, which can prevent the stolen in a very short period. Besides that, the
product was advantage than the concurrent gear and steering lock because most of
the locking system solutions were being decode, therefore the safety pedal lock can
provide more security to the users.
1.4 Problem Statement
In 1989 the NRMA evaluated ten locally-made and three imported cars to test how
easily they could be stolen [24]. The statistics of Filed under cars showed that in the
first six months the year alone, 35,888 vehicles were stole, leading to RM357 million
in losses. Vehicle theft contributed 45%, which almost half of the countries overall
crime index for the first half of the year [25]. Based on the statement, the
professional thieves have spent their whole live learning how to crack alarms and
anti-theft devices. Thus, they can easily bypass even the most sophisticated theft
prevention systems. Therefore, the typical theft prevention devices were not able to
stop cars‟ theft. Even worse, the car thefts were usually not reported for hours or
even days after the crime occurred. Therefore, without any witnesses, suspects, or
other leads to investigate, car theft victims were left helpless in finding their stolen
vehicle [23].
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction
Nowadays, the vehicle theft was the nation‟s number one property crime; therefore
there were several of safety devices such as alarms system, gear lock, steering lock
and door lock that had been created to car theft.
Traditionally, car alarms were the primary resource in protected vehicle from
thieves. These alarms had been developed from silent to talking alarms; meanwhile
the car alarm industry has invented everything under the sun to put the car owners‟
minds at ease about the safety of motor vehicles. Unfortunately, car alarms were not
enough to prevent thieves from seizing a car or truck [23]. However, in the United
States a study by General Motors found that cars fitted with alarm systems as
standard equipment were 20% less likely to be stolen than equivalent cars without
alarms (Clarke 1987) [26].
In the United Kingdom, United States, West Germany and other countries,
regulations require the standard fit of a mechanical device for preventing the car
being driven away. Although a few manufacturers have opted for transmission
locking, the majority preferred the steering column lock. Based on the studied, the
steering column lock was introduced in 1970 as a standard feature on all cars
manufactured or imported into the United Kingdom. Besides, Home Office
investigations in the mid-70s found that cars without steering column locks were
three times more likely to be stolen (Home Office 1985) [26]. Similarly, the car
thefts dropped by 60% after steering column locks made compulsory on all vehicles
in West Germany in 1963 (Mayhew et al. 1976). Figure 2.1 and Figure 2.2 were
showed the common lock for car steering and car door [12].
Figure 2.1: Steering Column Lock
Figure 2.2: New Lock Designs
Furthermore, a designing of car in the manufacturing today should be considered
the factors such as safety improvement and theft prevention. Figure 2.3 shows the 14
elements that have had to consider in designing a car [13], which reproduced by
permission from Daily Mail (London) on 7th
December 1988.
Figure 2.3: The Rover Sterling 800 Security Concepts Car
2.1.1 Pedal Lock
Pedal lock was a technology that to improve the cars‟ safety and theft prevention due
to the additional safety device that can prevent the car theft in shorten time period.
Figure 2.4 shows the common car pedal lock that being marketed today [37]. This
lock had a lot of lock properties; it was a combination of eight types of lock system.
The first lock as shown in Figure 2.4 was 9 rings core code key system that 100%
protection from any unauthorized keys. Then, second lock has had a key hole which
is specially designed to spin around if drilling was attempted. It was followed by
third lock that the hardened steel padlock protected from hack-sawing or damaged by
jack. After that, the slide arm that used to lock by just pull the arm, then the first and
second locks will be engaged simultaneously within a second. Besides that, lock
body for the device was manufactured from high grade tensile steel and the lock
casing fabricated by high-grade tensile steel that with firearm grade. Finally, the lock
was fitted on floor to prevent the exhausted of steering column if attempts were made
to force entry. However, this lock was not familiar to be used because it was very
complexity and higher cost. Therefore, it was not recommended for some vehicle.
Figure 2.5 shows the main structure and function of the lock while Figure 2.6 shows
how the lock was being installed onto pedals‟ side [37].
In addition, Figure 2.7 shows the pedal that being used in market today. This lock
had a handle of first lock, security ring of second lock, and locks for clutch and break
pedal arm. Figure 2.8 was showed the summarization of common types of safety
devices that were applied in automobile technology today [39].
Figure 2.4: The View of Carryboy 3 Lock
Figure 2.5: The Main Concepts of the Carryboy 3 Lock
Figure 2.6: The Installation of Carryboy 3 Lock to Car Pedal
Figure 2.7: The View of Multiple Pedal Lock