FABRICATION AND TESTING OF A MECHANICAL ICE-SHAVER
A Thesis Proposal
Presented to the
School of Mechanical and Manufacturing Engineering
Mapua Institute of Technology
In Partial Fulfillment
of the Requirements for the Degree of
Bachelor of Science in Mechanical Engineering
By:
Moraleja, Gilbert B.
2006103018
Pascual, Dawn Premy M.
2006103977
Sabalboro, Miko C.
2006151425
Zamora, Alden E.
2006200244
8 June 2012
APPROVAL SHEET
This is to certify that we have supervised the preparation of and read the thesis report,
entitled Fabrication and Testing of a Mechanical Ice-shaver, prepared by Gilbert B.
Moraleja, Dawn Premy Pascual, Miko C. Sabalboro and Alden E. Zamora and that the said
thesis report has been submitted for final examination by the Oral Examination Committee.
Engr. Jose T. Bechayda
Advisor
As members of the Oral Examination Committee, we certify that we have examined this
thesis report, presented before the committee on June 8, 2012 and hereby recommended that it
accepted as fulfillment of the thesis report requirement for the degree in Bachelor of Science in
Mechanical Engineering.
Engr. Joel M. Aviso
Committee
Engr. Igmedio F. Isla
Committee
Engr. Mark Christian E. Manuel
Committee
This thesis report is hereby approved and accepted by the School of Mechanical and
Manufacturing Engineering as fulfillment of the thesis report requirement in Bachelor of Science
in Mechanical Engineering.
Engr. Hans Felix Bosshard
Thesis Coordinator
Dr. Manuel Belino
Dean, School of Mechanical and Manufacturing Engineering
ABSTRACT
With the ever changing weather conditions due to climate change, the already hot and humid
climate here in the Philippines is getting even hotter and more humid each year, especially
during the summer season. Hence, there has been an ever increasing demand for ice-cold
refreshments, such as “halo-halo” or any iced beverage. Finely shaved ice is rare in terms of
availability in the Philippines since fast-food restaurants only produce normally shaved ice (1.52mm diameter). The fast-food restaurants only use ice crushers or mechanical ice-shavers. Since
the quality of shaved ice is significant for the overall goodness of a shaved ice product, the ice
must be shaved very finely. The results showed an average rate of 7.819 kg/min of shaved ice
produced from an ice block weighing 16kg using a 0.25KW electric motor. The results obtained
proved that the ice-shaver had a high rate of shaving fine quality ice with the help of the speed of
the flywheel.
ACKNOWLEDEMENTS
The group would like to thank all the various individual fast food establishments that were
visited for all the information and data that were given during the survey period. This could not
have been made possible without their help and support. In addition, the group would also like to
thank their parents, relatives and friends for giving them moral support during the entire time of
the thesis process. Credits also go to the group’s advisor, Engr. Jose T. Bechayda who not only
advised the group but also suggested the thesis proposal to them. Additional credits also go the
group’s panel members and thesis coordinator for all their advice and support during the thesis
process. Lastly but certainly not the least, the group would like to thank the entire faculty and
staff of Mapua Institute of Technology School of Mechanical and Manufacturing Engineering for
all their assistance, encouragement, advice and moral support. Thank you all so much.
Table of Contents
Chapter
1
2
Page number
Introduction
1
1.1 Overview
1
1.2 Statement of the problem
3
1.3 Objectives
3
1.4 Significance of the Study
4
1.5 Scope and Limitations
4
Review of Related Literature
5
2.1History of Ice-shavers
5
2.2 Differences between Ice-shavers
7
2.3 Mechanical ice-shaver
7
2.4 Elements of an ice-shaver
8
2.41 Blades
9
2.42 Belts
9
2.43 Shaft
9
2.44 Housing
10
2.45 Motor
10
2.46 Pulley
11
2.47 Flywheel
11
3
Theoretical Background
12
3.1 Principles involved in a mechanical ice-shaver
12
3.11 V-Belts
12
3.12 Length of V-Belt (Open Belt)
13
3.13 Ratio of Driving Tensions for V-Belt
14
3.2 Shafting
3.21 Types of Shafts
16
3.22 Stresses in Shafts
17
3.23 Maximum Shear Stress Theory
17
3.3 DC Motor
18
3.31 Brushed DC electric Motor
19
3.32 Equations involved in DC Motors
19
3.4 Blade Design
19
3.5 Flywheel
20
3.51 Energy Stored in Flywheel
4
16
20
3.6 Ice testing
21
3.7 Cooling for Shaved Ice
21
Methodology
22
4.1 Flow chart of research process
22
4.2 Processes
22
4.2.1 Research and Surveys
22
4.2.2 Theoretical applications and design layout
23
5
6
4.2.2.1 Conceptual Design
23
4.2.2.2Parts used in our design
24
4.2.2.3 Design considerations
25
4.2.3 Fabrication and Customization
26
4.2.4 Assembly and Testing
26
4.2.5 Testing of Shaver operation
26
4.2.6 Absorption Test
27
4.2.7 Hot Plate Method
27
4.2.8 pH Test of shaved ice
27
Results and Discussion
28
5.1 Testing of Shaver Operation
28
5.2 Absorption Test
29
5.3 Hot Plate Method
30
5.4 pH Test of Shaved ice
31
5.5 Shaving of ice block by mechanical ice-shaver
32
5.6 Comparison of normal and shaved ice
33
Conclusion and Recommendation
6.1 Conclusion
35
35
6.2 Recommendation
37
References
38
Appendices
40
CHAPTER 1 INTRODUCTION
1.1 Overview/ Background
With the ever changing weather conditions due to climate change, the already hot and humid
climate here in the Philippines is getting even hotter and more humid each year, especially
during the summer season. Hence, there has been an ever increasing demand for ice-cold
refreshments, such as “halo-halo” or any iced beverage.
Shaved ice belongs to a large family of ice-based desserts made of fine shavings of ice or
finely crushed ice topped with sweet condiments or syrups. The dessert is consumed world-wide
in various forms and manners. Shaved ice can also be mixed with large quantities of liquid to
produce shaved ice drinks (Chozick 2009).
Shaved ices are sometimes confused with "Italian ices". The shaved ices are made from plain
ice and are flavored after being shaved at point of sale; whereas the Italian ices, also known as
"water ice", have the flavor incorporated into the ice and are usually not flavored after
production (Chozick 2009).
1
Fig. 1.1 Snow cone with cherry syrup
While many people think of shaved ices as modern treats requiring electric ice-shavers
and manufactured ice and syrup, these ices have actually been around for a long time.
In the Philippines it is known as Halo halo which consists of shaved ice topped with
sweetened beans, nata de coco and ice cream. "Halo-halò" literally means "mix-mix"
in Tagalog (Chozick 2009).
In Thailand, this kind of cold dessert is known as the very popular "Nam Kang Sai".
Compared to other countries' shaved ice, in the Thai version the mixed fruits are at the
bottom and the shaved ice is on top. There are between 20–30 varieties of mixtures that can
be prepared. Among them are those with young coconuts that have been soaked in coconut
milk, black sticky rice, chestnuts, sweetened taro, red beans, sarim (thin strands of cooked
flour that is very chewy and slippery) and many more (Chozick 2009).
2
1.2 Statement of the Problem
Finely shaved ice is rare in terms of availability in the Philippines since fast-food
restaurants only produce normally shaved ice (1.5-2mm diameter). The fast-food restaurants
only use ice crushers or mechanical ice-shavers (De Jesus 2001).
Since the quality of shaved ice is significant for the overall goodness of a shaved ice
product, the ice must be shaved very finely.
1.3 Objectives
The main objective of the proposed study was to make a mechanical ice-shaver that can
produce finely shaved ice (0.5-1mm diameter). Specifically, it tried to accomplish the following
objectives:
1.3.1 To produce finely shaved ice from our mechanical ice-shaver.
1.3.2 Conduct the pH test of the shaved ice.
1.3.3 Fabricate a blade that can produce finely shaved ice using the principles of the
mechanical ice-shaver.
1.3.4 Show comparison between fine and normally shaved ice through absorption test.
3
1.4 Significance of the Study
The grade or quality of shaved ice can be considered the second most important factor in
shaved ice products flavor.
1.5 Scope and Limitations
The scope and limitations of the proposed study were the following:
1.5.1 The mechanical ice shaver was designed specifically for small commercial fastfood establishments, not for industrial applications.
1.5.2The mechanical ice shaver can produce fine-grade shaved ice only.
1.5.3 The ice-shaver operation will have a maximum time of 2-3 hours to avoid
overheating of electric motor.
1.5.4 The ice block fed into the mechanical ice-shaver was pushed manually since no
apparatus was created to push the ice block.
4
CHAPTER 2 REVIEW OF RELATED LITERATURE
2.1 History of Ice-Shavers
During the Roman Empire (27 B.C. to A.D. 395), snow was hauled from the mountain
tops to the city. Syrup was added to make the world's first frozen dessert, the snow-cone (Bell
2009).
The first manufactured snow cone was made by hand tools such as a wood plane. Such
tools could shave a block of ice into fluffy snow. Hand-held ice shavers were designed
solely to produce snow cones. Ice shavers made by numerous manufacturers were
available in the late 1800’s (Hansen 1934).
Fig 2.1 Handheld Ice Shaver (Hansen 1934)
5
In 1934, Ernest Hansen invented and patented the first motorized ice-block shaver to
produce the New Orleans style shaved-ice. He established “Southern Snow Inc.” which
was renowned for designing ice-shavers until today. The high-volume snow production
was welcomed by the corner ice shaver vendors citywide. The first ice shaver had 3
blades attached to a flywheel inside the housing of the ice shaver. Its blades had an angle
of 27 degrees enabling the shaver to shave a huge amount of shaved ice. Its rate of
shaving was about 10 kg/day with 8 hours operation (Hansen 1934).
Fig.2.2 Motorized ice-shaver (Hansen 1934)
In 1995, the “Southern Snow Machine ” (as shown in Fig. 2.3) was created. The
Southern Snow Machine was also distributed by Southern Snow Inc. and enabled it to
produce shaved ice at a rate of 10-15 kg per day. It can shave approximately 1 kilo of ice
per hour. The angle of the blade was about 25 degrees from its rotating flywheel (Hansen
1934).
6
Fig. 2.3 Southern Snow Machine
2.2 Differences between Ice-Shavers
There are many misconceptions about what an ice-shaver really is and what defines shaved
ice. Many companies produce products that they call "ice shavers" when in reality, they grind the
ice; the end result is very different. Ice-shavers tend to be more expensive due to their more
precise mechanics, and they are usually harder to maintain. Unlike ice grinders, ice shavers
require a large cylinder of ice.
Ice grinders are the smaller, cheaper machines that take ice cubes into some sort of hopper
and grind them into small bits. Some stores interchange the terms, presumably to increase sales.
Ice made by both machines is used for snow cones (Alden Witt 2007).
2.3 Mechanical ice-shaver
A standard ice-shaver consists of a stand, a platform, a crank, a motor, a spiked plate, a
collection plate and a blade.
Before using the shaver, the users freeze a tub of water and then let it thaw slightly. When
ready, they place the cylinder of ice onto the platform. Using the hand crank, they lower the
spiked plate securely down onto the top of the ice. To shave the ice, they turn on a switch that
7
makes the motor spin the ice.
A long blade is embedded in the platform, and its edge protrudes. This edge shaves the ice
much in the same manner as a cheese grater. The shavings fall out into the collection plate
below, where the users hold a cup of some sort.
The difficulty of shaving ice lies in the preparation of the ice and the adjustment of the blade.
It takes a reasonable amount of experience to get the ice thawed to the right amount and the
blade at the perfect angle (mostly 25 to 30 degrees). Still, an amateur should be able to make
some decent shaved ice after a few tries (Alden Witt 2007).
Figure 2.4 Mechanical ice-shaver
2.4 Elements of an ice-shaver
The elements of a typical mechanical ice shaver are the blades, shaft, housing, belt,
pulley, and motor. The proposed mechanical ice shaver included all of the elements and a
flywheel to regulate the speed of the pulley.
8
2.41 Blades
Fig. 2.5 Blades for a typical mechanical ice-shaver
A blade is used to scrape the ice, creating fine ice particles. The optimal angle for the
shaving blade ranges from 25-30 degrees depending on the quality of shaved ice. The angle of
the blades of the proposed ice-shaver was adjustable which were attached to the flywheel.
2.42 Belts
There are 3 types of transmission belts. Flat belts are allowed for long distances between
shafts. V-belts are used with groove pulleys and are used for short distances between shafts.
Toothed belts are paired with toothed pulleys and used as timing belts where speed is
maintained. In the proposed ice-shaver, a V-Belt was be used (Faires 1965).
2.43
Shaft
The shaft is a rotating machine element which is used to transmit power from one place
to another and subjected to torsion or a combination of torsion, bending and axial loading. In
order to transfer the power from one shaft to another, the various members such as pulleys, gears
etc., are mounted on it. The Shaft is used for the transmission of torque and bending moment.
The various members are mounted on the shaft by means of keys or splines. The shafts are
9
usually cylindrical, but may be square or cross-shaped in section. They have solid cross-sections
but sometimes hollow shafts are also used (Faires 1965).
•
1. Transmission shafts. These shafts transmit power between the source and the
machines absorbing power. The counter shafts, line shafts, overhead shafts and all factory
shafts are transmission shafts. Since these shafts carry machine parts such as pulleys,
gears etc., they are subjected to bending in addition to twisting.
•
2. Machine shafts. These shafts form an integral part of the machine itself. The crank
shaft is an example of a machine shaft.
Standard Sizes of Transmission Shafts
•
In SI Units: 25 mm to 60 mm with 5 mm steps; 60 mm to 110 mm with 10 mm steps ;
110 mm to 140 mm with 15 mm steps ; and 140 mm to 500 mm with 20 mm steps (Faires
1965).
2.44
Housing
The housing encloses and protects the blades from rusting and ensures the safety of the
operator. It also prevents the shaved ice from being wasted after the shaving operation. In the
proposed ice-shaver, it was made of stainless steel to avoid rusting.
2.45
Motor
The motor provides the rotating motion of the shaft while the mechanical ice shaver is in
operation. It transmits motion to the pulley that moves the belts, thus transmitting motion to the
shaft.
10
2.46
Pulley
The pulley is a mechanism composed of a wheel on a shaft with a groove between two rims
around its circumference. A rope, chain, cable, or belt usually runs over the wheel and inside the
groove, if present. Pulleys are used to change the direction of an applied force, transmit
rotational motion, or realize a mechanical advantage in either a linear or rotational system of
motion (Faires 1965).
2.47
Flywheel
A flywheel is a rotating mechanical device that is used to store rotational energy. They are
typically made of steel and rotate on conventional bearings; they are generally limited to a
revolution rate of a few thousand RPM. Our proposed thesis will contain a flywheel with the
adjustable blade attached to it Its shafting has the same shafting of the pulley.
11
CHAPTER 3 THEORETICAL BACKGROUND
3.1Principles involved in a mechanical ice shaver
3.11 V-Belts
Belts are used to transmit power from one shaft to another by means of pulleys which rotate at
the same speed or at different speeds (Adams, Black 1968).
•
The V-belt is mostly used where a great amount of power is to be transmitted from one
pulley to another when the two pulleys are very near to each other (Adams, Black 1968).
•
The V-belts are made of fabric and cords moulded in rubber and covered with fabric and
rubber as shown. These belts are moulded to a trapezoidal shape and are made endless
(Adams, Black 1968).
Figure 3.1 Transverse section of a V-belt
12
3.12 Length of V-belt (open belt)
Figure 3.2 Open Belt
D1=small pulley pitch diameter
D2=large pulley pitch diameter
C=center distance
α=angle of inclination of the pulley with respect to the center line
θ1=angle of contact between belt and small pulley
θ2=angle of contact between belt and large pulley
13
sin α =
α = sin-1 θ1 = 180o- 2α
θ2 = 180o+ 2α
Figure 3.3 Angle of inclination of pulley
From Kinematics :
Lbelt ( open ) =
π
2
(D1 + D2
2
(
D2 − D1 )
) + 2C +
4C
3.13 Ratio of Driving Tensions for V-belt
F1
= e fθ csc β
F2
F1 = tension at tight side
F2 = tension at slack side
f = coefficient of friction between the belt
and sides of the groove of the V - pulley
θ = angle of contact between V - pulley and belt in radians
β = half of the groove angle in radians
Figure 3.4 Driving Tensions for V-belt
14
Table 3.1 Dimensions of standard V-belts and V grooved pulleys (Adams, Black 1968)
Table 3.2 Standard pitch lengths of V-belts (Adams, Black 1968)
15
3.2 Shafting
A shaft is a rotating machine element which is used to transmit power from one place to
another and subjected to torsion or a combination of torsion, bending and axial loading. In order
to transfer the power from one shaft to another, the various members such as pulleys, gears etc.,
are mounted on it (Faires 1965).
It is used for the transmission of torque and bending moment. They are usually cylindrical, but
may be square or cross-shaped in section. They are solid in cross-section but sometimes hollow
shafts are also used (Faires 1965).
3.21 Types of Shafts
1. Transmission shafts. These shafts transmit power between the source and the
machines absorbing power. The counter shafts, line shafts, over head shafts and all
factory shafts are transmission shafts. Since these shafts carry machine parts such as
pulleys, gears etc., therefore they are subjected to bending in addition to twisting (Faires
1965).
2. Machine shafts. These shafts form an integral part of the machine itself. The crank
shaft is an example of machine shaft (Faires 1965).
16
3.22 Stresses in Shafts
S y Su
Tr Mc
F
or
±
± α ⇒ S allow =
J
I
A
N
N
(+ ) = tension, shear
ST =
(− ) = compression
Figure 3.4 Torsional, Flexural and Axial Loads
3.23 Maximum Shear Stress Theory (Guest’s Theory)
•
This theory is applicable for ductile materials.
•
The equation shows the maximum shear stress that would result in a combination of shear
stress and normal stress applied to a machine member (Faires 1965).
•
This is also based on the assumption that a ductile material is most probably going to fail
by shearing (Faires 1965).
•
For design considerations, Ssmax is equated to the allowable stress (Faires 1965).
2
S 
S smax = (S s ) +  t 
2
where : S s = shear stress; St = normal stress
2
S smax = max . shear stress
17
For Solid Shaft:
The considered factors due to combined shock and
fatigue (from Table 3.2 )
K s = for shear; K m = for bending
S smax =
16
πD 3
(K s T )2 + ( K m M )2
⇒ S sd
Figure 3.5 Solid Shaft
Table 3.2 Recommended Values of Km and Ks (Faires 1965)
3.3 DC Electric Motor
A DC motor is an electric motor that runs on direct current (DC) electricity. The DC motor to
be used in the proposed mechanical ice-shaver system is a brushed DC electric motor.
18
3.31 Brushed DC electric motor
The brushed DC electric motor generates torque directly from DC power supplied to the
motor by using internal commutation, stationary magnets (permanent or electromagnets), and
rotating electrical magnets (Herman 2010)
3.32 Equations involved in DC motors
The power output of a rotary electric motor is:
Where P is in horsepower, N is the shaft speed in revolutions per minute and T is the torque in
foot pounds (Lander 1993).
The motor’s efficiency can be obtained by:
Where the mechanical output power is divided by the electrical input power:, where η is the
efficiency, Pe is electrical input power, and Pm is mechanical output power (Lander 1993).
3.4 Blade Design
The blade’s design is similar to a razor-blade design used in a mechanical ice-shaver. The
blade’s angle will be adjustable since it will have a screw mechanism to attain the desired angle
( between 25-30 degrees).
19
3.5 Flywheel
•
A Flywheel is a rotating member that acts as a storage reservoir for energy when work is
not “consumed” at as fast a rate as the power is supplied (Adams, Black 1968).
•
A flywheel serves as a reservoir which stores energy during the period when the supply
of energy is more than the requirement and releases it during the period when the
requirement of energy is more than supply (Adams, Black 1968).
•
The kind of energy stored by the flywheel is kinetic energy (Faires 1965).
3.51 Energy Stored in Flywheel
When a flywheel absorbs energy its speed increases and when it gives up energy its speed
decreases (Adams, Black 1968).
The mean kinetic energy of the flywheel
1 2
Iω ; I = mk 2
2
1
KE = mk 2ω 2 , N − m or joules
2
where : I = mass moment of inertia about the axis of rotation, kg-m 2
KE =
ω = mean angular speed during the cyle, rad s
m = mass of flywheel, kg
k = radius of gyration of flywheel, m
∆KE = max.KE - min.KE =
=
1 2 1 2 1
Iω1 − Iω2 = I ω12 − ω22
2
2
2
(
1
I (ω1 + ω2 )(ω1 − ω2 )
2
20
)
But, ω = mean angular speed =
∆KE = Iω (ω1 − ω2 ) = Iω 2
ω1 + ω2
2
(ω1 − ω2 )
ω
And, C s = coefficient of speed fluctuation =
(ω1 − ω2 )
ω
2
∆KE = Iω C s
Taking k = R , the mean radius of the flywheel rim
(since the thickness of the rim is relatively small as compared
to the diameter of rim)
∆KE = Iω 2C s = mk 2ω 2C s = mR 2ω 2C s = mv 2Cs → v = Rω
m=
∆KE
∆KE
= 2
2 2
R ω Cs v C s
3.6 Ice testing
The shaved ice is classified according to its size and uniformity. The ice is shaved finely
when its grains are shaved uniformly and its diameter is about 0.3-0.5 mm. If the diameter of the
shaved ice is about 1mm-2mm and grain sizes are irregular, it is considered as finely crushed ice
or partially shaved ice.
3.7 Cooling for Shaved Ice
The cooler box is the cooling medium for the shaved ice. It is made of Styrofoam.
21
CHAPTER 4 METHODOLOGY
4.1Flow Chart of Research Process
Research and Surveys
Theoretical
Applications and
Design Layout
Fabrication and
Customization
Assembly and Testing
4.2 Processes
4.2.1 Research and Surveys
The first step in the research process was conducting of numerous research and survey
activities in order to gather as much information about the ice shaver. As shown in Table 4.1, the
proposed shaved ice capacity could comply with the standard shaved ice production per day. The
average production of shaved ice per day by commercial establishments was found to be 10.8 kg;
yet the ice –shaver can operate 2 times a day so 7-10kg range was plausible for the 10.8kg
standard shaved ice capacity.
22
Table 4.1 Shaved ice capacities of commercial establishments.
Establishments
MCDO
Jollibee
KFC
Chowking
Zagu
Shaved ice
8kg/day
10kg/day
9 kg/day
12kg/day
15kg/day
capacity(kg/day)
4.2.2 Theoretical Applications and Design Layout
4.2.2.1Conceptual design
The first design was completely changed into a new one since the parts from the
first design were very complicated that made the first design very hard to fabricate and build.
The updated design was quite similar to a typical mechanical ice-shaver but a pulley was
included to increase shaving speed and efficiency of the ice-shaver. The role of the flywheel
secured the shaving blade, reducing vibrations in the shaving operation. The updated design is
shown in the figure below.
Fig 4-1 illustration of mechanical ice shaver
23
4.2.2.2 Parts used in our design
Shown below is a list of the parts used in the mechanical ice-shaver. Their
descriptions are explained after the list of parts.
Fig 4-2 Exploded View of mechanical Ice-shaver
LEGEND:
1.
2.
3.
4.
5.
6.
7.
FRAME
PULLEY
V-BELT
SWITCH AND PLUG
FLYWHEEL WITH SHAVING BLADE
ELECTRIC MOTOR
HOUSING AND ICE COMPARTMENT
24
Frame –this is a steel structure that holds all the parts together
Pulley system- its main role is to lower the speed and vibration of the ice-shaver. It
contains the V-belt and the pulleys.
Switch and Plug-it enables the electric motor to be switched on and off during operation.
Flywheel –a thick flywheel is used to avoid misalignment of the shaving blade and avoid
deformation of the flywheel.
Shaving Blade- based on our research the optimum shaving angle is 25 degrees in order
to produce quality shaved ice.
Electric motor- it transmits power to the pulley system and shaft.
Housing-it holds the ice block during the shaving operation.
Ice compartment- it collects the shaved ice in operation.
4.2.2.3 Design Consideration
Stainless steel was used to avoid corrosion and contamination due to the shaving
of ice. The angle of the shaving blade was set at 25 degrees. The motor used was 0.25KW
(1/3 hp) and the type of belt used was A-5.
There was no cooling system for the machine since the electric motor was
exposed to its surroundings, considering the ambient air would provide cooling for the
electric motor. The shaved ice was stored in a Styrofoam cooler/box after operation.
25
The mechanical ice-shaver would only produce one quality of shaved ice; finegrade or finely shaved ice.
4.2.3 Fabrication and Customization
With the optimum angle of 25 degrees for the shaving blade and dimensions for all the parts of
the mechanical ice-shaver had been made, the researchers conducted the fabrication of the
shaving blade, ice compartment, frame, flywheel, pulley and shaft based on the imposed
dimensions from the conceptual design. The v-belt and electric motor was then selected.
4.2.4 Assembly and Testing
The final step was the assembly and testing of the design. After all the parts had been fabricated
and customized as desired, these parts were then assembled together to complete the design
study. The assembled design was then tested to make sure that all the parts were functioning
properly and smoothly and that there were no minor squeaks or hindrances. Operation of iceshaver, absorption and Ph testing were then conducted to determine the quality of ice and ensure
the cleanliness of the shaved ice.
4.2.5
Testing of Shaver Operation
A comparison of shaved ice was made between the proposed mechanical ice-shaver and
the existing ice shaver through this testing process. It showed the rate of shaved ice per minute
and per 4 minutes. A total of 6 trials for the testing process was done.
26
4.2.6 Absorption Test
The absorption test showed the quality of shaved ice through absorption of the liquid
poured onto the 2 qualities of shaved ice. The quality of shaved ice was determined through the
amount of liquid absorbed. If the liquid passed through the shaved ice easily it could then be
classified as a finely shaved ice.
4.2.7
Hot plate method
It was easily defined as the process of melting the shaved ice contained in the beaker by
heating the hot plate apparatus. The shaved ice needed to be completely liquid in order to
conduct the pH test.
4.2.8
pH Test of shaved ice
PH test determined that the shaved ice was normal. For the pH test, the shaved ice could
be acidic, basic or neutral. The desired condition was near neutral. Before conducting the test,
the ice was melted using the hot plate apparatus where the shaved ice was placed in a beaker.
After the pH test had been conducted, a reading of 6.71 on the pH meter was achieved.
27
CHAPTER V RESULTS AND DISCUSSION
5.1
Testing of Shaver Operation
The testing included the data for 6 trials. The tables below show the rate of shaved ice per minute
with its respecting trial. The weight of Styrofoam box, ice block, and shaved ice were indicated
with the use of a digital balance. The factors for the shaving rate of ice were the fabricated blade,
the pushing of the ice block during operation, and the speed of the flywheel coupled to the pulley
shaft.
Table 5-1 Trial test of shaving operation per minute
TRIAL
Mass of shaved ice in
Styrofoam box per minute
8.421 kg/min
7.832 kg/min
8.122 kg/min
1
2
3
Mass of shaved ice per
minute
8.115 kg/min
7.526 kg/min
7.816 kg/min
Table 5-2 Trial test of shaving operation in 4 minutes
TRIAL
Mass of shaved ice in
Styrofoam box in 4 minutes
34.699 kg/4 mins.
34 kg/4 mins.
33.489 kg/4 mins.
1
2
3
Mass of shaved ice in 4
minutes
34.393 kg/4 mins.
33.694 kg/4 mins.
33.183 kg/4 mins.
Weight of Styrofoam box= 0.306 kg
Weight of ice block= 16 kg
Average rate of shaved ice per minute = 7.819 kg/min.
Average rate of shaved ice in 4 minutes = 33.423 kg.
28
5. 2 Absorption Test
The results showed that the shaved ice was finely shaved based on the experiments that
were conducted. The absorption test was conducted by pouring liquid simultaneously. The
amount of liquid poured was 0.1L of colored liquid per glass of shaved ice. There were 2 glasses,
one with normally shaved ice and one finely shaved ice and proved that finely shaved ice absorbs
liquid much easier than normally shaved ice.
Fig 5-1 Pouring of liquid for absorption test
29
Fig 5-2 Absorption test of finely shaved ice (left) and normal shaved ice(right)
5.3
Hot plate method
This process was conducted 3-5 minutes since the shaved ice must be melted completely.
A small glass of finely shaved ice was melted with the hot plate apparatus borrowed from the
chemical engineering laboratory.
Fig 5-3 Actual set-up of hot plate method
30
5.4
pH Test of shaved ice
The pH test was made in the chemical engineering laboratory after the hot plate method
was conducted. It lasted for 5 minutes since the reading for the pH tester must be stable. A
reading of 6.71 was achieved which was near neutral. The reading of the pH tester relied
completely on the quality of the ice block used in shaving operation.
Fig 5-4 Actual set-up of pH test
31
Fig 5-5 Actual Reading of pH Tester
5.5
Shaving of ice block by mechanical ice-shaver
The following images show the actual shaving and the final output or product of the
proposed ice-shaver.
Fig 5-6 Actual Shaving of ice by mechanical ice shaver
32
Fig 5-7 Image of Shaved ice product
5.6
Comparison of normal and finely shaved ice
Based on studies, normally shaved ice measures from 1.5-2mm in diameter and finely
shaved ice is from 0.5-1mm diameter. After inspection, the shaved ice was 0.5-1mm diameter in
range.
33
Fig 5-8 Image of normal shaved ice
Fig 5-9 Image of Finely Shaved Ice
34
CHAPTER VI CONCLUSION AND RECOMMENDATION
CONCLUSION
After several testing, the desired quality was produced and the quality was better
than ordinary shaved ice. A comparison of the quality of shaved ice was made with
videos and image and was shown in the power point presentation. The average rate of
shaved ice per minute was 7.819 kg/min. and the average rate of shaved ice in 4 minutes
was 33.423 kg/ 4 minutes which proved that the ice-shaver had a high rate of shaving fine
quality ice. The factor affecting the rate of shaved ice was the speed of the flywheel.
The absorption of the shaved ice was greater compared to normally shaved ice as
conducted in the testing. It showed that the liquid flowed easily.
A pH reading of 6.71 was obtained which was close to the optimum pH level of
water of 7. Before conducting the pH test the shaved ice must be completely melted so
hot plate method was used to completely melt the ice in the beaker before conducting the
test. The factor that affected the pH level of the shaved ice was the quality of the ice
block.
35
A blade with an optimum shaving angle of 25 degrees was fabricated to shave
the block of ice at a consistent rate. The basis of the angle was obtained thorough
research about past mechanical ice-shavers and the ideal or optimum angle for producing
quality shaved ice. The design and angle of the shaving blade strongly affected the
quality and rate of finely shaved ice.
36
RECOMMENDATIONS
It is recommended to add more blades to the flywheel in order to maximize the shaving
capacity of the machine and also save on power consumption as fewer rotations of the blade is
needed to produce sufficient amounts of shaved ice.
In addition, a Styrofoam compartment is recommended to avoid spillage and
contamination of the shaved ice. This makes it easier to wash and reuse for other shaving
operations.
It is also strongly recommended that 2 or 3 people operate the mechanical ice-shaver.
One person will start the ice-shaver; the 2nd person will push and secure the ice block during
operation.
For safety purposes, a customized apparatus for pushing the ice block is strongly
recommended. It can be operated by the 2nd person during operation or assembled with the
mechanical ice-shaver.
37
REFERENCES
Adams, Eugene and Paul Howard Black.1968. Machine Design. Third edition. New York:
McGraw-Hill Companies Inc.
Amy Chozick.2009 One Hundred Years of Craving Snow Cones from Texas to Tokyo. New
York: Wall Street Journal.
Bell, Robert. 2009.The History of the Sno-Cone. Chicago: Article Alley Inc.
De Jesus, Noel F. 2001. Ice crushers of Jollibee? http://www.mb.com.ph/articles/366905/ Ice
crushers of Jollibee?
Donald G. Fink and H. Wayne Beaty.1978. Standard Handbook for Electrical Engineer.
Eleventh edition. New York: McGraw-Hill Companies Inc.
Edwin J. Houston and Arthur Kennelly.1902.Recent Types of Dynamo-Electric Machinery. New
York: P.F. Collier and Sons Inc.
Faires, V.M.1965. Design of machine elements. Fourth edition. London: Macmillan Publishers
Ltd.
Green, Robert E.,ed.1996. Machinery's Handbook. 25th ed. New York: Industrial Press.
Hansen, Ernest. 2003. Shaved Ice: The World's oldest frozen y. http://shaved-ice.com/history1.html.
R.S. Khurmi.2005.A textbook of Machine Design. Second edition. India: Eurasia Publishing
House.
38
Tsubakimoto Chain Co., ed.1997. The Complete Guide to Chain. Japan: Kogyo Chosaki
Publishing Co.
Witt, Alden. 2007. How do ice Shavers work?. http://www.ehow.com/how-does_5087235_iceshavers-work.html (accessed November 25, 2011).
White, Jr., Lynn .1962. Medieval Technology and Social Change. Oxford: Clarendon Press
39
APPENDIX A
LEGEND:
1.
2.
3.
4.
5.
6.
ICE COMPARTMENT
FLYWHEEL WITH SHAVING BLADE
SWITCH
PULLEY SYSTEM WITH V-BELT
ELECTRIC MOTOR
FRAME
40
APPENDIX B
(EXPLODED VIEW)
LEGEND:
8. FRAME
9. PULLEY
10. V-BELT
11. SWITCH AND PLUG
12. FLYWHEEL WITH SHAVING BLADE
13. ELECTRIC MOTOR
14. ICE COMPARTMENT AND TRAY
41
APPENDIX C
Gantt Chart
ACTIVITIES
Preparation and
Planning
Thesis Title
Research
Submission of
Chapter 1
Submission of
Chapter 2
Submission of
Chapter 3
Submission of
Chapter 4
Submission of
Final Paper
Defense of
Thesis Proposal
Design of
materials to be
fabricated
Design of
assembly for ice
shaver
October
October
October
October
November
November
November
November
December
December
December
December
January
January
January
January
February
February
February
February
1st week March
2nd week March
CHART OF ACTIVITIES
42
Purchasing of the
Equipment
Fabrication of
Pulley, V-belt, ice
container and blade
Assembly and
testing in Mapua ME
shop
Final Defense of
Thesis
43
March
March
April
April
April
April
May
May
May
May
June
June
June
4th week June
1st week July
2nd week July
3rd week July
4th week July
August
August
August
August
APPENDIX D
PROPOSED BUDGET
Consumable Items
Stainless steel Flywheel
3-phase DC Electric motor
V-belt
Stainless steel sheets 14-26,0.3-1.6mm
Pulley system
Iron steel for Frame
Total Cost
Quantity
1 pc.
1 pc.
1 pc
7 pcs.
1 pc.
1 pc.
Cost (Pesos)
1000
4500
100
1500
1500
600
PHP 9200
APPENDIX E
APPROXIMATE LIST OF EQUIPMENT AND INSTRUMENTS NEEDED
Equipment and Instruments
Vice Grip
Lathe Machine
Face shield
Safety gloves
Meter Tape
Caliper
Protractor
Source
Borrowed from MIT
Borrowed from MIT
Borrowed from MIT
Borrowed from MIT
Borrowed from MIT
Borrowed from MIT
Borrowed from MIT
44