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Interactive design and structural analysis of pit-opener DAG for airport oil tanks based on user-centered design and finite element analysis

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Abstract

Refuelling is an important activity in the daily routines at airports. Airport oil pits are covered, requiring a special pit-opener to open its lid. After using the pit-opener, there is no designated place to store the pit-opener. Due to the weight of the pit-opener, workers have difficulty in opening, carrying and using the existing pit-opener, which poses risks of musculoskeletal injuries. Often, workers would throw the tool to the ground, causing impact or possible damage. Hence, there is a need for a new pit-opener design to solve this problem, which is lightweight and high-strength. An invention of a new Pit-Opener (DAG) is presented, comprising of a flexible hook at one side and a fixed hook at the adjacent side. In addition, the Pit-Opener (DAG) consists of a handle, stowage bracket and body support. The objective of this paper is to determine the optimal configurations by mass reduction of the DAG prototype. The functionality of DAG has significantly improved the airport worker’s job with regards to ease of use, however, the prototype may still be heavy for long repetitive use. The methodology used in this study consists of using a reverse engineering process to create a CAD model based upon the DAG prototype, conducting stress analysis study and interactive design through a user-centered and systematic design approach. Consequently, the optimization process of the pit-opener design was performed via stress analysis using a Finite-Element Analysis (FEA) tool through iterations with different configurations to obtain the final optimised design. The results permitted an overall further weight reduction of 2 kg of the existing prototype, without sacrificing performance. An evaluation of the model using the Parsimony, Exactness, Precision, Specialization (PEPS) method was used for validation. In conclusion, DAG provides cost-effective, vital, safe and secured storage of efficient pit opening for oil tanker application, and through structural analysis, suitable configurations of the pit-opener were determined.

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Funding

This study [FF-2018-237] was made possible with the funding from Research University Grant GUP-2019-080.

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Authors and Affiliations

  1. Department of Mechanical and Manufacturing Engineering, Faculty of Engineering and Built Environment, Universiti Kebangsaan Malaysia, Bangi, Selangor, Malaysia

    Abdul Hadi Azman & Hawa Hishamuddin

  2. Department of Community Health, Faculty of Medicine, Universiti Kebangsaan Malaysia, Wilayah Persekutuan Kuala Lumpur, Malaysia

    Faiz Daud

  3. Cohu Malaysia Sdn. Bhd., Malacca, Malaysia

    Noorul Adha Baharom

  4. MZTURBO Energy Oil Sdn. Bhd., Wilayah Persekutuan Kuala Lumpur, Malaysia

    Muhammad Amruha Md Zan

Authors
  1. Abdul Hadi Azman
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  2. Hawa Hishamuddin
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  5. Muhammad Amruha Md Zan
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Correspondence to Hawa Hishamuddin.

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Azman, A.H., Hishamuddin, H., Daud, F. et al. Interactive design and structural analysis of pit-opener DAG for airport oil tanks based on user-centered design and finite element analysis. Int J Interact Des Manuf 15, 541–553 (2021). https://doi.org/10.1007/s12008-021-00780-2

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  • DOI: https://doi.org/10.1007/s12008-021-00780-2

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