MONASH UNIVERSITY SUNWAY CAMPUS ENGINEERING DESIGN II MEC2406

Assignment 1: Portable Ice-cream Maker

2013 SEMESTER 1
[COMPANY NAME] [Company address]

TABLE OF CONTENTS
Introduction ............................................................................................................................................................ 2 Background ............................................................................................................................................................. 3 Available devices in the market .......................................................................................................................... 4

Example of Devices: Type A ............................................................................................................ 5 Example of Devices: Type B ............................................................................................................ 6

Process of making ice-cream .............................................................................................................................. 7 Critical Design Specification .................................................................................................................................... 8 Design Evolution ................................................................................................................................................... 10 Morphology Chart ............................................................................................................................................ 10 Initial Concept Generation................................................................................................................................ 12 Secondary Concept Generation ........................................................................................................................ 14 Tertiary Concept Generation ............................................................................................................................ 16 Design Matrix (Pugh Concept Selection) .......................................................................................................... 18 Analysis of Design Matrix and Concept Selection ............................................................................................. 18 Final Design ....................................................................................................................................................... 19

Parts of the device ........................................................................................................................ 20 Inner mechanism of the device..................................................................................................... 25

Design Analysis ..................................................................................................................................................... 26 Material Selection ............................................................................................................................................. 26 Manufacturing Process ..................................................................................................................................... 32 Engineering Specifications and Analysis ........................................................................................................... 32 Conclusion ............................................................................................................................................................ 36 References ............................................................................................................................................................ 37 Index ..................................................................................................................................................................... 39

Abstract This report details the conception and design of a portable ice-cream maker intended to be used outdoors during recreational activities such as camping, picnicking and etc. After much research of the available products within the market and looking into consumer insights we have tailored our design to meet with the clients requirement while keeping the end user (customer) in mind. Working within these parameters our engineering team was able to design and conceptualize 3 different concepts within which 1 was chosen and improved to be the final design presented to the clients. This report documents the design process including a detailed description and critique of the functionality of the final design. Index Terms Portable, Ice Cream Machine, Outdoors

INTRODUCTION
The main convention of a portable ice-cream machine (within the consumer market) is to allow the consumers to conveniently make fresh, good quality ice-cream with the flavor of their choice wherever and whenever they so please. While there are ready made ice-cream available in supermarkets, convenient stores and well established ice-cream parlors (i.e. Baskin Robins and Haagen Daz), the critical aspect of this project is to tailor the design to meet the following criterias; fast, convenient, and innovative. Fast is something very critical in the design of the product, if takes a day to make a batch like with most salt solutions based device the product becomes less appealing to the customer. As the ice-cream is made on site the freshness of the ice-cream is only second to that of the freshness of the ingredients used to make it and it takes only 20 minutes. Convenience can be described in the ergonomics of the device this particular device makes its stand out against other competing devices within the market. One of the major point is the portability of the device, also other aspects of the device like the putting in the ingredients and cleaning it has all been taken into account. Innovative is something that we want in our product to set it apart from its competitors. Aside from being able to work in the outdoors the device as also able to directly mix the raw ingredients and then churn it, which no other device in the market can claim to do (albeit only liquid ingredients).

BACKGROUND
Malaysia sits near the equator belt, making its climate tropical in nature. This mean its normally hot and humid within the country, making ice-cream a year round treat as oppose to countries with temperate climate. According to Malaysian-German Chamber of Commerce and Industry, Malaysia has a population of 28.25 million with an unemployment rate of 3.7% as of 2009. The table below show the consumption of store bought packaged icecream in volume and price;

Table 1: Consumption of packaged food in Malaysia (Volume in Tonnes) in 2011

Table 2: Consumption of packaged food in Malaysia (Value in Million Ringgit) in 2011

Both tables 1 and 2 shows a fairly good amount of at home ice-cream consumption within the country with an average growth rate of 2.49%.

AVAILABLE DEVICES IN THE MARKET

There are many commercial ice-cream making machine available within the market. Our research has shown that there are mainly 2 types/class of ice cream making machine available; A common low end device that uses a salt solution lined within the inner walls of the mixing bowl that requires it to be kept within the freezer for 4-5 hours (though most users recommend 24 hours as the bowl is not able to reach near freezing temperatures)before use. The main appeal of this device is that its cheap and yields the same quality ice-cream as higher end device. We have dubbed this class of ice-cream maker as Type A. A high end device that uses a compressor which supersedes the need to pre-freeze the mixing bowl and normally take within 20-50 minutes to make a batch depending on the compressor used, we have dubbed this class Type B. Below are a few examples of the devices based on their class, the examples varies from the high end to the low end within its own class;

EXAMPLE OF DEVICES: TYPE A

Hamilton Beach Half Pint TM Soft Serve Ice-cream Maker Dimensions: 188 x 188 x 236.22 mm Weight: 2.72 kg Batch size: 0.35 L Price: $15

Tier: Low end Power Source: Battery

Figure 1

Cuisinart ICE-30BC Dimensions: 203 x 208 x 285 mm Weight: 5.44 kg Batch Size: 1.89 L Price: $89.95 Tier: Middle end Power Source: Power outlet
Figure 2

Cuisineart ICE-45 Mix It In Soft Serve Ice Cream Maker Dimensions: 248 x 229 x 462 mm Weight: 7.0 kg Price: $99.95 Tier: Mid to High end Batch Size: 1.42 L Power source: Power Outlet
Figure 3

EXAMPLE OF DEVICES: TYPE B

NewAir AIC-210 1 Quart Ice Cream & Sorbet Maker Dimensions: 386 x 345 x 320 mm Weight: 11.0 kg Price: $159 Tier: Mid-end Batch Size: 0.95 L Power Source: Power Outlet

Figure 4

Lello 4080 Musso Lussino 1.5-Quart Ice Cream Maker Dimensions: 305 x 457 x 279 Weight: 18 kg Price: $699 Tier: High end Batch Size: 1.42 L Power Source: Power Outlet
Figure 5

With that being said, most of these products (especially the Type B devices) are not available within the Malaysian market and those seeking to purchase them would have to seek overseas or through online market. This opens a window of opportunity for this product within the Malaysian market. However this can also be a double edged sword for us, as the lack of availability of the product within the market leads very little data available to us on what the local consumer expects out of the product as they would most likely had little to no experience with an appliance of this nature, thus creating a problem for us in evolving the design of the product.

PROCESS OF MAKING ICE-CREAM

Ice cream is fundamentally a frozen mixture of (i) Fat, (ii) Non-fat milk solids (NMS), (iii) Sweetener, (iv) Emulsifier, (v) Stabilizer, and (vi) Air. icecreamscience.com There are many variants to ice-cream such as gelato, frozen custard, soft-served, hardserved, semifreddo and the list continues. However, they are fundamentally made the same way, the difference come the percentage of its main elements and the temperature it is frozen at. In-corporation of 20% air bubble in the mixture at low temperature of -15C yields the perfect hard served ice-cream, whereas 70% of air bubble at -4C results in a more fluffy soft served ice-cream. The quality of an ice-cream is determined by the size of the ice crystal formed during the freezing process, smaller ice crystals means a smoother and better tasting ice cream while large ice crystal generally means bad ice-cream. The churning process reduces the size of the ice crystals and makes the ice cream smoother, the longer the churning process the smaller the ice crystals formed, the smoother the ice cream tastes. One of the main issue that our team came across was the fact that most ice-cream machine in the market does not dispense the ice-cream unless its soft-served (i.e. Cusineart ICE-45). Most conventional ice-cream machine produces what the industry calls hard served ice-cream (normal ice-cream). This is mainly due to the fluid properties of the ice-cream, as the hardserved is denser (having less air bubbles) than its soft counterpart making it harder to dispense. Our research has shown patent designs of a dispenser that allows us to dispense hard served ice-cream. The mechanism of the device works with a similar principle to that of a syringe. The hard served icecream is introduced into the dispensing chamber by means of gravitational force and vacuum pull created when the lever is pulled. When the ice-cream enters the chamber, piston like gage pushes the ice-cream out through the nozzle and dispenses it. After some discussion he have opted for a design that dispenses soft served ice-cream instead after deciding that pursuing a hard served ice-cream dispensing machine would lead to a higher building cost and thus would not meet the critical design specifications.

Figure 6 : Hard ice-cream dispenser by Savage, Don H. (11889 S. Hidden Valley Club Dr., Sandy, UT, US)

Thus to ensure a working dispensing mechanism we have tailored the design on the machine to create soft served ice-cream by mimicking the required condition for it.

CRITICAL DESIGN SPECIFICATION

To effectively design the requested ice-cream making machine, a list of client expectation for the final product was produced, along with a morphology chart to allow an easier conceptualization of the design.

TABLE 3 CLIENT REQUIREMENTS WITH CORRESPONDING ENGINEERING SPECIFICATIONS Importance Client Requirement (1 low, 5 high) Engineering Specifications

Safety

Minimum no. of exposed hazards

Affordable

Production cost of below RM600

Portable

Weighs around 10 16 kg, outdoor use

Convenience

Electrically operated moving parts

Attractive

Visually pleasing

Fast

Batch time of 30-40 minutes

Safety The device is used in a family friendly environment, which is to assume that children would have access to it. To ensure that the device is child friendly the design will not include any exposed hazards (i.e. moving dasher, sharp edges). Since, the safety of the device is imperative to its marketing and functionality it is given a high importance rating of 5. Affordable With most of the available mid-range Type B product within the market having a price range of $150-$299 (RM450-RM910), it is critical that the manufacturing cost of the device be as competitive as possible to meet with consumer expectations, thus a importance rating of 5 is given. Portable The device is meant to be used outdoors as per the clients request. As such, it would need to as light weight as possible. Given that portability would be on the key feature of the device an importance rating of 5 is assigned to this criteria. Convenience According to client demand the need of a battery and/or electrically powered device is a must in the design as the end user would not be expected to do much work and would be able to make the ice-cream with just a push of a button or dial. As such a high importance rating of 5 is given to ensure that the concept design and the final design would incorporate these features. Attractive The final look of the device is imperative to its marketing. The client demands a visually pleasing device to ensure customers satisfaction, as with most consumer grade product. A rating of 4 is given to ensure that the final is able to attract customers without neglecting the main mechanism within the device. Fast The time taken for the mixture to get go from liquid to ice-cream is known in the industry as batch time. The average batch time of most of the ice-cream machine in market that we have surveyed is around 30 minutes. The batch time is dictated by the compressor used in the system with a more powerful compressor yielding a lower batch time. The client has requested for a batch time of 30-40 minutes, as such it is given a high importance rating of 5.

DESIGN EVOLUTION (GENERATION AND SELECTION)

MORPHOLOGY CHART

To begin the designing process, a morphology chart is created with 5 varying mechanism in mind, which are as follows; A. B. C. D. E. Pre-mix chamber Cooling method Churning chamber Dispenser type Power Source

Then, a concept is design by mitch-matching options from each of the five mechanism. Although not all of the options are used and some design would incorporate more than 1 option from the same mechanism (i.e. Power source).

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INITIAL CONCEPT GENERATION

The first concept generation was accomplished combining the option BO2, D03, E01 and E03. B02: Compressor D03: Manual dispenser E01: Type G Electrical outlet E03: Li-ion battery Pre-mixture & Churning design: For mechanism (A) and (B) a custom designed dasher is used. The design of the dasher allows the pre-mixture to combine well and is able to churn the mixture afterwards. This allows both mechanism to take place in a single chamber, minimizing the overall size of the machine. Cooling method design: A compressor due to its reliability over that of dry ice and liquid nitrogen, it is also more convenient than the freezer bowl as it does not require the mixing bowl to be pre-freeze prior to making the ice-cream. Dispenser design: A manual lever is used in the design to dispense the ice-cream. It uses gravitational force and weight and low density of the ice-cream to dispense it through an open slot. This option was chosen to reduce overall build cost as an automatic option would require multiple circuit boards within the dispenser. Power Source: To allow portability, the machine is fitter with a light weight high efficiency lithium ion cell that would allow it to make between 2-3 batches before needing to recharge. It is also fitted with a Type G electrical outlet (which is the prominent socket power outlet in Malaysia) to recharge the battery. The Type G electrical outlet has a secondary function, which is to allow the device to be used at home in the kitchen should the end user choose to do so without having to fully charge the battery. The design is inspired by the Cuisineart ICE-45 with some subtle differences. The height of the machine allows the ice-cream to be dispense into a cone or cup with enough moving to avoid spilling and uncomfortable usage. The ventilation on the side ensure optimum efficiency of the compressor system within the machine. The compartment in the back allows the electrical cord to be stored and hidden during outdoor uses or when storing the device when its not being used. The mixing bowl has a multi-level hole in the middle where the icecream will be dispensed, the spiral design of the dasher will draw the ice-cream to the middle of the bowl and pushes it downwards. When the lever is pulled, the roller connected to the level will rotate 90 degrees and hole of the bowl and the star shaped hole in the roller will align to allow the ice-cream to flow through them, thus dispensing it.

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Figure 7 : Sketch 1 of the Initial Concept Detailing the Mechanism and Parts

Figure 8 : Sketch 2 of the Initial Concept Illustrating and Detailing the Mechanism of the Custom Dasher.

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SECONDARY CONCEPT GENERATION

With the secondary design, we have opted for the energy efficient route and went with a design incorporating the following elements from the morphology chart; A04, B04, C04, D03, E01 and E03. A04: Standard commercial dashers B04: Dry Ice (Solid CO2) C03: Standard commercial dasher D03: Manual Dispenser E03: Li-ion Battery Pre-mixture and Churning design: With this design we have opted for the more commercially common dashers in the hope of reducing the overall cost of manufacturing the device as a custom designed dasher would cost more to produce. It is also the same dasher used in most professional grade ice-cream maker. Cooling method design: For this design, dry ice is used as the main cooling method due to its low temperature of -78C and availability in the consumer market. Recently dry ice has become a very popular method in making ice-cream due to its low cost and quick batch time. The ice-cream is made instantly once the dry ice is introduced into the cream mixture, and due to the rapid cooling, the ice crystals formed are small in size creating a smooth texture. With the integration of dry ice the design would use substantially less power than the initial design (an estimated power rating of 70W). Dispenser Design: For the dispenser mechanism we have chosen a more simplistic design, a standard valve release system. The body of the device is place on the edge of a picnic table or anything of the like and this would allow the device to dispense the ice-cream into a cone or cup. Power Source: The main power source for this design will be lithium ion cells. The only motor used for this design is for the dasher and with its low power rating (50-70W) the device will be able to last between 2 to 3 hours of continues use. The main appeal of this design is in its simplicity and eco-friendly nature. The device uses parts readily available in the market and would thus cost significantly less to produce than the initial design. Also, the parts that has worn down or is broken can be easily replaced and the use of dry ice means the device will not consume a lot of electricity, reducing its carbon footprint.

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Figure 9 : Sketch of the Secondary Concept with Labelled Parts

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TERTIARY CONCEPT GENERATION

The tertiary borrows concept from both the initial and secondary concept. Like the secondary concept itll use dry ice as the main cooling method to make the ice-cream and it is similarly fashioned like the initial concept with more a profound oval shaped to invoke a more modern look. The design incorporates the following aspects; B04, D02 and E04. B04: Dry Ice (Solid CO2) D02: Automated Dispenser w/o Timer E04: Solar Panel Pre-mixture and Churning Design: The design like the previous 2 will share the pre-mixing and churning mechanism in one chamber with the aid of a custom dasher. The dasher is design in such a way that it is able to incorporate liquid ingredients well and at the same time churns the mixtures well enough to incorporate air. Cooling Method Design: The cooling method for this concept is similar in regards to the previous concept. Dispenser Design: For a more modern take on the device, we have opted for an automatic dispenser without the inclusion of a timer. The exclusion of the timer allows the user freedom to determine the size of his/her portion with just the push of a button. The dispenser is in the form of a controlled valve that is operated by means of a circuit board. When the dispense button is pushed, it sends a signal to the circuit board which then opens the valve allowing the ice-cream to pass through. Power Source: The device uses solar panel located within the removable cap of the device to power the motor of the dasher. This is made possible by using a low power motor for the dasher (around 30-50W) that will be running at around 29rpm. The basis for this design eco meets modern technology. For this design we wanted to completely the reliance of external power source and make the device as self-sustaining as possible. This would allow the device to operate for an extended period of time, ideal for long camping trip or to just reduce your electric bill (marginally of-course).

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Figure 10: Sketch of Tertiary Concept with Specified Parts

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DESIGN MATRIX (PUGH CONCEPT SELECTION)

Criterias
(Score of 1-3, higher is better)

Weight 2 3 1 3 2 3 1 3 1 1 2 3 N/A

Convenience of design (Simplicity of usage.) Efficiency (Time taken to produce a single batch) Capacity of ice-cream made per batch Cost of manufacturing Manufacturing Difficulty Safety Easy to clean Appearance Eco-friendly/Carbon footprint Cost of usage Few moving parts to increase lifespan Portability/Mass Total Score

Initial Concept 0 + 0 0 0 0 + + 0 0 0 + 4

Secondary Concept ++ 0 ---+ + + + + ++ 2

Tertiary Concept ++ 0 ---+ ++ + + + ++ 3

Table 4: Pughs Decision Matrix for the Ice-cream Maker

THE DATUM FOR THIS CHART WILL BE THE NEWAIR AIC-210 (PG.06)

ANALYSIS OF DESIGN MATRIX AND CONCEPT SE LECTION

Initial Concept: Scored quite well in safety and manufacturing cost and difficulty. With many similar products within the market, the device would be easy to manufacture. With that said, there are profound improvements within the concept of this device that makes it a better choice than the competitors, mainly the cost, weight, and efficiency. Secondary Concept: Scored well in criterias that initial concept did not. However, it has a low safety rating due to the use of dry ice. Dry ice when not handled properly can lead to injuries similar to a burn, there is also the threat of pressure build up by the dry ice if its too tightly insulated which may lead to a violent explosion (NASA ASRS : Report ACN 346002). This significantly cripples the safety factor of the device. The manufacturing cost scored quite poorly as well due mainly in part to the complexity of the container needed to hold the dry ice. Proper insulation for the dry ice is needed as dry ice tends to sublimate at a rapid speed, especially in a tropical climate. This proves as an engineering hassle for us since the cost to research and manufacture the housing for the dry ice might significantly increase its production value. Tertiary Concept: Scored similarly to the secondary concept in all aspect save for a better appearance. We have decided to proceed with the initial concept since it is the most practical of the 3 concepts and scored well against the other 2 concepts in the Pugh analysis.

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FINAL DESIGN

This section explains in details the components and alterations in the final design of the concept with CAD; it also explains how those component relate to engineering specifications and client requirement.

Figure 11: Isometric view of the final design of the portable ice-cream machine

Pre-mixing and Churning Chamber: One of the main changes to this mechanism in the final design is the inclusion of a hole at the top right lid. This allow air to be incorporated in the ice-cream, which is critical in the ice-cream making process as mentioned before. Based on research, the dasher for the chamber will be powered by a dual speed motor. The mixing process will require a higher speed than the churning process, 56RPM for the mixing process and 23RPM for the churning process. This will be controlled by a circuit board that will have predetermined time for each process and change speed accordingly. The motor will is rated at 100W at 56RPM and 50W at 23RPM. This is determined using the following formula; Equation 2 When the force and radius of the system is kept constant the power and angular velocity directly proportional. Cooling Method: As shown in Figure 11 the cooling mechanism is made up of 4 main components; a gas compressor, a condenser coil and an evaporator coil. After much research, some theoretical calculations and a discussion with the lecturer we have decided to use a 200W compressor. This is will be enough the cool the ice-cream mixture from liquid to solid within 20-40 minutes depending on the initial temperature of the mixture (this estimation is

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taken from the fact that the NewAir AIC-210 uses a 100W compressor and has a batch time of roughly 40 minutes). The mechanism of this system in elaborated more in Design Analysis. Dispenser mechanism: Similar to the initial concept with no alterations made. Power Source: The device will be powered by 4kg lithium ion cell that is able run the device for 2 hours of continues use when not connected to a power socket. With a minimum batch time of 20 minute we expect the device to be able to make 3-4 batches of ice-cream before requiring it to recharge.
PARTS OF THE DEVICE

Figure 12: Isometric view of the top right case lid with dimensions (mm)

The inside of the lid will house the necessary components to provide power and control the time and speed of the motor which is located in the right lid. There are latches on the bottom of the lid which allows it to snap on to the chassis snug and tight while still being capable of easy removable.

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Figure 13: Isometric view of the top right lid with dimensions (mm)

Houses the motor and has a funnel like hole which allows the raw ingredients to be channeled directly into the mixing bowl.

Figure 14: Top view of the chassis showing the hollow innards which will house the cooling mechanism and the hole where the ice-cream will be dispensed with dimensions (mm).

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The chassis is fitted with carrying handles on the both side to allow the device to be carried properly. A sizable dimple on the left corner arm on the device is included to allow the placement of ice-cream waffles or cornet.

Figure 15: Isometric view of the chassis with dimensions (mm).

Ventilation is shifted to the back to better allow the placement of the condenser coil. The lower slot allows the user to store their power outlet cable, will include a flap (not shown).

Figure 16: Back view of the chassis with dimensions (mm).

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Figure 17: Isometric view of the dispenser device with dimensions (mm).

The dispenser is based on a simple mechanism similar to that of a valve. When the handle of the device rotated the cylinder in the dispenser device will rotate accordingly. This will align the hole in the cylinder and with the corresponding hole in the mixing bowl, thus allowing the ice-cream in the mixing bowl to flow through and out of the dispenser mechanism.

Figure 18: Dimetric view of the dispenser handle with dimension (mm).

Figure 19: Right side and Top side view of the mixing bowl with dimensions (mm)

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Figure 20: Isometric view of the helical dasher with dimensions (mm).

The helical dasher has wide arm to better combine the raw ingredients and at the same time churns the mixture to better incorporate air. The helix in the middle assists in the dispenser mechanism, it directs the flow of ice-cream to the bottom of the bowl where the dispensing hole is located.

Figure 21: Isometric view of the washable spill tray with dimensions (mm).

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INNER MECHANISM OF THE DEVICE

Figure 22: Isometric exploded view of the assembled device.

Some parts seen on the images here were not covered in the previous section as they were parts that our team are supposed to design but were created to have a better idea of the orientation of all the parts within the device. These parts include the condenser coil, the evaporator coil and gas compressor, the lithium ion cell battery and exhaust fan. The expansion valve and copper piping connecting the condenser coil, evaporator coil and gas compressor were not shown

Figure 23: Right side cross-section view of the device.

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DESIGN ANALYSIS
MATERIAL SELECTION

An analysis was performed on the major component of the final design, which is the chassis of the device itself. ICE-CREAM MAKER CHASSIS Function: To house the working components and act as the main visual representative of the finish product. Objective: Minimize both cost and weight of the chassis. Constraints: The chassis must not fail when subjected to a minor impact force and should be able to withstand changing weather conditions in Malaysia (i.e. heat and rain). A material index was derived to rank the vast material option returned by the CES 2011 Edupack software. The index compares the strength of the material to its respective density; Equation (1)

This is a measure of strength to weight ratio. The main goal is to maximize the strength of the housing while maintaining its light weight to enable mobility. The following limits and constraints were added to the software to narrow down the material selection, also a constraint was inserted to bring results from the polymer material tree only. Categories Durability: Water and Aqueous Solutions Criteria Water (Fresh) Water (Salt) Soils, acidic (Peat) Soils, alkaline (Clay) Industrial Atmosphere Rural Atmosphere Limit Excellent Excellent Excellent Excellent Excellent Excellent

Durability: Built Environments

Table 5: Table of Limits Imposed on the CES 2011 Edupack Software to Yield Material Result

The above constraints mimics the environment of the real world application of the device, when subjected to rain and other outdoor conditions analogues to tropical climate. A second graph was created pairing the price of the materials in USD against CO2 emission to allow us to narrow down the material selection even further with basis on price and environmental sustainability. This allowed us to find the most cost efficient material with the least impact to the environment and is both light weight and sturdy. Ultimately the software returned five possible material choices, the following printouts acts as supporting document to our final material selection for the chassis of the device, Polypropylene (PP).

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CES Graph 1

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CES Graph 2

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ICE-CREAM MAKER RIGHT AND LEFT TOP LID Function: To house the motor and the wiring for the motor to run the dasher. Objective: Similar to that of the chassis. Constraints: Similar to that of the chassis. To minimize manufacturing cost and time the same material for the chassis is chosen, Polypropylene (PP). The material serves the same purpose for the lid as it does for the chassis.

HELICAL DASHER Function: To mix the raw ingredients and churn the ice-cream. Objective: Strong enough to churn the ice-cream mixture without breaking while still be light and cost effective. Constraints:

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CES Graph 3

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CES Graph 4

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MANUFACTURING PROCESS

The manufacturing process for all of the complex plastics parts which includes the following; (a) (b) (c) (d) (e) (f) Chassis Top Right Lid Top Left Lid Helical Dasher Dispenser Mechanism Dispenser Handle

will all be done by using injection molding, a process where hot resin or any polymer of the kind will be injected into a mold which is then cooled. Injection molding allows us to create parts with the notches and latches easily like case lid and the case itself, as well as complex shapes like the helical dasher. The mixing bowl can be fabricated using a similar process known as injection blow molding (IBM), a process common to creating large quantity of hollow plastic or glass part like the mixing bowl in our device.
ENGINEERING SPECIFICATIONS AND ANALYSIS

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Thermo TAble

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Figure 24: Calculation for price and weight of the chassis with C++

The final price for the device and its mass are RM20.82 and 11.57kg respectively. Estimated mass values: Mass of cooling system: 5kg (this includes the gas compressor, piping, condenser coil, exhaust fan and evaporator coil.) Mass of li-ion battery: 4kg (obtained using the known rating of 150W.hr/kg) Given that the final estimated mass is 11.57 kg, which is 4 kg below the critical specification, there is a lot of flexibility in case the true mass of the cooling system is above the estimated 5 kg. Estimated pricing: Component Gas compressor Piping, Condenser coil, Exhaust Fan Manufacturing cost of ABS parts Manufacturing cost of PP parts Total
Table 6: Estimated pricing table for the device.

Price RM300 RM 70 RM100 RM30 RM500

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CONCLUSION
The aim of this project was to develop a design for an ice-cream maker that is portable, fast and convenient. The device was design for use among the consumer market of Malaysia, the target audience was the middle to high income family or couple, especially those that engages in outdoor activities such as camping and picnicking. The device would be a more appealing alternative to the other devices within the market due in part to its speed, portability, visual appeal, and mid-end price range. The final design specification was based on the result of the survey and research on the available products within the market. The most important specification with the device concerns speed, mass, price and safety. Powered by a 200W compressor the batch time for the device is reduced to 20 minutes, this meets with the requirement of the client of 30-40 minute batch time. The final weight of the devices comes to below 12 kilograms, with a manufacturing cost of roughly RM500 (estimated). All the specification for the design was met with the clients demand. We believe the device will cater well to Malaysia market, however we fell that various specification within the device can be further improved or be analyzed better if were able to come up with a prototype and put it to field test. As it stands, we believe the final design made sufficient progress to be competitive within the consumer grade ice-cream maker market.

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REFERENCES
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Ice Cream Science. (2012). Ice Crystals in Ice Cream. Available: http://icecreamscience.com/2012/01/25/formation-of-ice-crystals/. Last accessed 15th Apr 2013. Cuisinart. (2013). Products - Ice Cream/Yogurt Makers. Available: http://www.cuisinart.com/products/ice_cream.html. Last accessed 15th Apr 2013. Hamilton Beach. (2013). Half Pint Soft-Serve Ice Cream Maker. Available: http://www.hamiltonbeach.com/ice-cream-makers-half-pint-soft-serve-ice-creammaker-green-68551e.html. Last accessed 15th Apr 2013. RepairClinic 2012, How It Works: Refrigerators, online video, accessed 15 April 2013, <http://www.youtube.com/watch?v=5vA8Ksv5kVY> Antons Ricalovskis 2012, How Refrigerator Works, online video, accessed 15 April 2013, < http://www.youtube.com/watch?v=BFt-Q7XvAxc> KitchenwareDirect 2008, Cuisinart Soft Serve Ice Cream Maker Demonstration from Kitchenware Direct, online video, accessed 15 April 2013, <http://www.youtube.com/watch?v=AGCabu8qjRc> BeanMeister22 2012, Ice Cream Machine Review: Make Soft Serve Ice Cream At Home, online video, accessed 15 April 2013, < http://www.youtube.com/watch?v=ScinRmJY9WI> Wdnot40 2011, Instant Ice Cream Dry Ice, online video, accessed 15 April 2013, <http://www.youtube.com/watch?v=XNrb1Kwqd9s>

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INDEX
In this section, all the available information we have gathered and were not able to display in the main body of the report. This includes but is not limited to the survey, the other initial concept drawings, and picture taken to help in the development of the concept design. The materials shown in this section will not be in any particular order.

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