EDSGN 100 Project 1 Dumpling Roller Mark I

Transcription

1 1 EDSGN 100 Project 1 Dumpling Roller Mark I Section 10 Team 8 Submitted by Nikhil Reddy, Steven Lee, and Mitchell Ross Submitted to: Xinli Wu Date of Submission: November 3 rd. 2014

2 2 Abstract Dumplings require time and dexterity to create, and many businesses and families would prefer to use a machine to easily make dumplings. The Dumpling Roller can simplify the production of dumplings from a tedious chore to a simple task with the turn of a crank. Table of Contents Cover Page 1 msr5321@psu.edu Abstract 2 msr5321@psu.edu Introduction 3 msr5321@psu.edu Description of Task 3 msr5321@psu.edu Design Approach 4 nkr5054@psu.edu Final Design and Prototype 8 swl5570@psu.edu Engineering Analysis 16 nkr5054@psu.edu Conclusion 17 swl5570@psu.edu

3 3 Introduction With the manual production of dumplings demanding such extensive time and labor, a compact dumpling maker design suitable for in-home or commercial use would be greatly beneficial, allowing one to simplify the process without the need of an expensive and sizable industrial alternative. The aim of this project was to create an automatic or semi-automatic dumpling maker that incorporates the various steps of dumpling production into a simple and efficient process. This report presents multiple designs for such dumpling maker that all include three main stages, the production of the dough with correct thickness and width, the distribution of the filling, and the formation of the dumpling. A description of the designs along with an analysis of multiple factors including cost, safety, size, and ease of use is provided and followed by a comparison of the multiple approaches. Finally through these evaluations a best possible prototype was selected that incorporated both the design specifications and team objectives. Description of Design Task Problem Statement: The manual production of dumplings is inefficient for those making them in their homes. It requires extensive time and manual labor with an overall small output. Industrial dumpling makers solve this dilemma but are far too expensive and large for the average household. This producing a potential market for a smaller scale and simpler design better fit for a kitchen setting and regular in home use. Mission Statement: We are aiming to produce a smaller, simpler, and efficient dumpling maker suitable for average households and regular in home use.

4 4 Design Specifications: -The dumpling maker should be automatic or semi-automatic. -The dumpling maker should produce no less than 10 dumplings per minute on average. -The material cost for the dumpling maker should not exceed $200 unless it can be justified. -The dumpling maker should be safe as a food processor, easy to maintain, safe to use, dishwasher safe. Design Approach Gantt Chart: Customer Needs Assessment: We surveyed a few Chinese restaurants in downtown State College learning as much information possible about dumpling making as we could. We found that the majority of the restaurants either handmade the dumplings or bought them premade from another company. The restaurants that did handmake the dumplings told us that it was a tedious process

5 5 from start to finish. Many of the chefs said that folding and crimping the dumplings properly was tedious. The dumpling maker should be less than $200, should be machine washable and safe and easy to use. Concept Generation: Concept 1: Press with over hanging filling. Conveyor belt with dough flattner.

6 6 Concept 2: Small conveyor belt with roller, filler and press. Concept 3: Large conveyor belt with large filler and larger press

7 7 Concept 4: Roller with imprints and over hanging filling overhead rollers for dough flattening. This is the concept we decided to expand upon. Design Selection Matrices:

8 8 Final Design and Prototype Design Features: The Base: The base includes a cranking system which allows anyone to simply crank to begin making dumplings. The Roller: These specially made cylinders will mold the dough and filling into fresh dumplings that are ready to cook. Every revolution of these two rollers will produce 36 dumplings. The Dough/Filling Compartment: This container allows one to form the proper thickness for dumpling dough and inserts filling through the rollers. No extra bowls are needed to prepare dough or filling. The Pusher: This is the top of the Dough/Filling Compartment and pushes the dough and filling downwards which allows the Compartment to both form sheets of dough and the increments of filling for the dumpling. Assembly Instructions: 1.) Place the Base on any flat surface such as a table or counter. 2.) Insert the two Dowels into the bars of the base, each Dowel is placed through top holes in the bars, the dowels should be horizontal as seen in the Basic View Diagram (FIG 11). 3.) Place each Roller through the dowel so that the are aligned as seen in the Basic View Diagram (FIG 11). 4.) Place the Dough/Filling Compartment on the Top Bars, the Compartment should fit snugly and be horizontal. 5.) The Dumpling Roller is now ready for use.

9 9 Operation Instructions: 1.) Make sure all parts are set up and sanitary before rolling dumplings. 2.) Mix and prepare dough in the two peripheral containers of the Dough/Filling Compartment. 3.) Place the Pusher on top of the Compartment and begin pushing downwards so the dough sheets are pushed out of the slots beneath the Compartment 4.) When two dough sheets have started to form, place the ends of the two sheets wedged between the Rollers 5.) Mix and prepare filling in the middle container of the Compartment 6.) Place the Pusher on top of the Compartment and begin pushing downwards again, rotate the crank counter-clockwise and watch as the Dumpling Roller creates new dumplings. 7.) Rip out the dumpling shapes, and reuse the dough if necessary, the dumplings will be ready to be cooked. Prototype: The prototype is roughly in scale with the product by 1:1. Due to limitations of resources, it was difficult to emulate the dimensions of rounded parts such as the roller. The prototype did not properly follow the guidelines and could not process dough on its own. Due to this, the final product is different from the prototype, most notably by the Dough/Filling Compartment, which allows the Dumpling Roller to prepare dough correctly. Due to this, the final product is bulkier and more expensive, but will now allow anyone to prepare dough using the Dumpling Roller. More detailed changes are listed below.

10 10 Summary of Changes: -Two rollers were removed due to the redundancy in their function. -The compartment used to insert filling into the dumplings was replaced to allow anyone to use the Dumpling Roller without having to prepare the dough or filling outside of the Dumpling Roller's use. -The filling compartment was replaced by the Dough/Filling Compartment and Pusher which allows for better distribution of filling to the dumplings. -Another bar was added to the base to make the rollers stable and prevent them from slipping off. -Overall, the new prototype is more expensive, larger and heavier to accommodate for these changes. Prototype Pictures and Drawings: Figure 1 Front Image of Prototype

11 Figure 2 Side Image of Prototype 11

12 12 Figure 3 Top Image of Prototype Figure 4 Working Drawings of Prototype Working Drawings: These are the drawings for the new prototype after implementing the previously stated changes. All measurements are strictly in inches.

13 13 Figure 5 Basic Views Figure 6 Exploded View and BOM

14 14 Figure 7 Base Figure 8 Crank

15 15 Figure 9 Dough/Filling Compartment Figure 10 Pusher

16 16 Figure 11 Roller Engineering Analysis Working Mechanism: 1.) The dough is prepared in the Dough/Filling Compartment in the two side holes by mixing flour and water. 2.) The Compartment is placed on top of the Top Bars so that it is above the rollers. 3.) The Pusher will apply pressure to the dough and allow the dough to come out as two flat sheets which will have to be wedged in between the rollers, the dough creates a v-shape if the Dumpling Roller is viewed from the side. 4.) The filling is prepared in the Compartment in the single, middle hole by mixing any desired ingredients. 5.) The dumplings are formed by turning the crank, which will pull down on the dough sheets, while the crank is turning, the Pusher may be used to push the filling in between the rollers. 6.) The dumpling-shaped indents in the rollers will mold the dough and filling into dumplings as they are rotated. The roller is acts similarly to a cookie cutter to separate the dumplings from the unused dough. 7.) After all dough or filling is used up, the dumplings will have to be ripped off of the finished dough sheet, the unused dough may be used again.

17 17 Cost Analysis: Total cost $ We used mostly plastic due to its cheap cost and its being machine washable. Costs taken from McMaster-Carr. Conclusions: As with any design project, there were certain factors that posed a challenge in creating a dumpling maker. The dumpling has a unique shape, which makes it difficult to implement the shape into a pattern. For example, squares and hexagons are easy to place next to each other, but circles must have unused space. Although the Roller was created in order to minimize the unused space, there still posed a challenge of designing the Roller in Solidworks. Another challenge was placing the filling inside the dumpling, there had to be a specific amount of filling to a dumpling, otherwise the dumpling would be to big to fold, or the dumpling would lack filling. The Rollers ensure that any dumpling will not be overfilled, but there is no way to completely prevent under-filled dumplings. The initial prototype also posed an issue because it sacrificed functionality for cost, and clashed with the guidelines. More specifically, the Dumpling Roller could not prepare dumpling dough by itself, and required the use of other tools. In order to follow the guidelines, the parts which affected the dough and filling were changed. The filling compartment was changed in design to include room and functionality for dough, and some parts were also cut out due to their lack of essential functionality. Ideally, the design would have needed to be completely remade, but due to time constraints, the peripheral functionality of the Dumpling Roller was changed. This design project taught that guidelines are important and should be considered in all aspects of the design before making any other decisions. This design project was an excellent example of how a factors can have differing importance. Because there is limited time and resources, teams must choose factors and focus on those factors as a base for their product. For

18 18 example, most teams have showed products that do not rely on electricity, and focused more on other factors. Some teams focused more on ease-of-use, rather than rate of dumplings made, while some focused on the opposite. There are different ways to tackle an issue, and understanding those different ways can be essential to producing the best product. Acknowledgments: The KitchenAid Ravioli Maker served as a reference for the base of the Dumpling Roller, by using indented rollers to form ravioli. Because ravioli and dumplings are somewhat similar in concept, the design was helpful in creating the final prototype. References: "Basic Dumpling Dough Recipe." CHOW. N.p., 9 July Web. 16 Oct < Butler, Stephanie. "Delightful, Delicious Dumplings." History.com. A&E Television Networks, 28 Mar Web. 1 Nov < "KitchenAid Ravioli Maker." KitchenAid. N.p., n.d. Web. 17 Oct < 2/stand-mixer-attachments-3/-%5bKRAV%5d /KRAV/>.