Design optimization of street light hinges

Department of Mechanical Engineering
Universiti Tenaga Nasional
MEMB483 Capstone Design
Final Report
Design Optimization of Hinges for Supporting Long Arm in
Street Lighting
Group Name: Acqintosch (Group AG)

ME090330
ME090250
ME090810
ME088978
ME090223
Tunku Atiqah binti Tengku Hamnet

Thuraiappa A/l Muthurajan
Nurul Amirah Bt Ramizan
Syed Mustakim bin Syed Mukhsin
Prasad a/l Mayilvanan
Acqintosch Sdn. Bhd.
Final Report
Design Optimization of Hinges for Supporting Long Arm in
Street Lighting
ii
1.0 INTRODUCTION
1.1 Background
Streetlight is a raised source of light on the edge of a road or walkway [1]. Street lamp
basically consists of a long pole, which has a long arm coming outwards towards the streets to
light the area. During the Greek and Roman civilizations, oil lamps were used predominantly as
they provided a long-lasting and moderate flame, however, it had to be manually lit every
evening [1]. Nowadays, automated electric lightings are used, as it is more convenient and
efficient. The current technology (LED) Light Emitting Diode is used to replace the normal
fluorescent bulb light to ensure energy efficiency. It also has the capability to adjust its lightings
conditions according to periods with low traffic densities, and to match the current weather
conditions [2].
Based on research conducted street lights can be used to promote security and to increase
the quality of life by artificially extending the hours in which there is light so that activity can
take place [2]. Street lightings help prevent of crime activities from happening at night. This is
because victims can plan their escape route just before they fall prey to criminal activities. Also,
it plays a major role in establishing a safe environment for pedestrians and aids them in avoiding
obstacles at night. As such, it supports nightlife and leisure activities, and is essential for the
freedom to go out at night. Street lightings are also important for creating aesthetically pleasing
urban environment, which in turn affects the pride of many modern cities.
Street lighting systems require on-going maintenance. These maintenances includes
replacing a discharge lamp after it has failed, scheduled replacement of lighting components
when they have reached 85% of their expected life and changing the bolts and nuts that has
rusted from prolonged exposure towards rusting elements such as oxygen and vapour [1]. Long
arm of street lightings give optimum illumination of light to the road. However, problem arises
when safety of officers involved in the maintenance process is affected, as they would have to
perform the task in the middle of the road. This disrupts the traffic and increase potential risk of
road accidents. All of these current problems arise because current design is mainly for normal
road. For further improvement, this new designs will focus on street light with long arm.
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1.2 Project Description
There have been many different types of street lamp arm support system that has already
been introduced and are in use, but these current designs have their flaws and limits that can
further be improved. Our company looks forward to optimize the design of street lightings by
designing a hinge mechanism for supporting the long arm in street lightings. This is so that the
length of the arm can be extended up to 10 meters long to reach closer to the roads to give
optimum illumination of light. Where maintenance of lightings will become an issue as it will
have to be done in the middle of the road, the hinge will create a mechanism the can flip the arm
towards the side of the road for ease of maintenance purpose. Hence, providing a holistic
solution through optimizing the design of hinges for supporting long arm will be aim in this
project.
The first part of the project covers background research on existing designs of streetlights
as well as obtaining the various technical customer requirements in order to select the best and
most suitable design of hinges. Then, the final design will be selected and technical drawing will
be produced and simulated through engineering tool that is CREO. Finally, a prototype of the
finalized design will be fabricated.
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1.3 Project Objectives
General:
1. To solve current industrial problems efficiently.
2. To communicate in an ethical and professional manner.
3. To plan an execute projects effectively.
Specific:
1. To design a hinge mechanism that enables long arm in street lighting to flip towards the
side of the road for ease of maintenance purposes.
2. To design a hinge mechanism that can support 10 meters long arm in street lighting.
3. To develop a working prototype for selected design.
4. To incorporate the use of appropriate engineering tools in optimizing design.
1.4 Original System
Design research of the existing designs of streetlights was done mainly through the web.
Streetlights in different locations in Malaysia and Indonesia were gathered to observe its designs.
These designs were retrieved from the web through news articles, blogs and journals that has
been cited in the Reference section. From the information that has been gathered, the designs of
the streetlights are grouped into 3 categories. For Design 1, it can be observed that only clamping
does the support. Meanwhile, for Design 2, clamps and welded swirl-shaped rod can be observed
for both lamps found. Finally, for Design 3, it is observed that the clamping mechanism is
different from that of Design 1 and Design 2. These existing designs are compiled in Table 1.4
(a).
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Existing Design
Description
Location: Kampung Padang Jawa [3]
Category: Design 1
Sub-system:
Pole, clamping system, straight-arm.
Location: Jalan Daud, Muar, Johor [4]
Category: Design 1
Sub-system:
Location: Felda Sungai Koyan Satu, Kuala Lipis[5]
Category: Design 1
Sub-system:
Location: Kuala Langat, Selangor [6]
Category: Design 2
Sub-system:
Pole, clamping system, straight-arm with additional
support.
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Location: Malaysia [7]
Category: Design 2
Sub-system:
Pole, clamping system, straight-arm with additional
support.
Location: Selindung, Indonesia [8]
Category: Design 3
Sub-system:
Pole, clamping system, curved-arm.
Table 1.4 (a): Type of existing street light design
System
Sub-system
Description
Function: To raise the source of light so that a large area can be
illuminated with light. To contain the cables in it for safety factor.
Design: Straight and hollow cylindrical tube around 8 10 meters
Pole
long built deep into the ground concrete in one end and high into the
air in the other end.
Streetlight
Material: Aluminum/concrete/galvanized metal to sustain longer life
with Short
span from corrosion caused by surroundings.
Arm
Function: Act as a fixed support to hold the arm and pole of the
Clamp
streetlight firm together.

Design: Have two clamps, which are fixed at the pole and at the
upper and lower bracket of the arm.
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Function: To protrude the light bulb closer to the streets so that

streets are well illuminated.
Mast/Arm
Design: Length of arm is short. Fixed support is based on two

clamps only.
Material: Same composites as pole.
Pole
Refer description for short arm.
Clamp

Function: To protrude the light bulb much closer to the streets so
Streetlight
with
that streets are well illuminated.

Mast/Arm
Medium-
Design: Length of arm is moderate. Fixed support consists of two

clamps, as well as a swirl-shaped rod welded at the pole at one end
length Arm
and on the arm at the other end to give additional support.

Streetlight
Pole
Clamp
with Long
Function: To protrude the light bulb closest to the streets to give
Arm
optimum illumination of light to the streets.
(max. 10 m)
Mast/Arm
Design: Length of arm is long. Fixed support consists of two
clamps. The arm is curve-shaped so that the force can be distributed
further to other areas of the arm to withstand the heavy weight of the
long arm.
Table 1.4 (b): System level and sub-system level of existing design
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1.4.1 Original System Operation
Each street light has its own maintenance period based on fixed schedule of performing
maintenance every five years. Maintenance includes servicing at the pole base, the paint of the
pole and changing the light bulb. During this maintenance, the safety of the officer is exposed
because it would require him to do the maintenance job while disrupting the traffic. He indirectly
placed himself in a more harmful situation.
1.4.2 Original System Performance
Streets lights fused in Malaysia so far have operated efficiently, especially in carrying out
its various purposes such as by providing towards a reduction in night time road traffic accidents
and crime, leisure and tourism activities and increase pedestrian movement during hours of
darkness. However, the original street light system is less efficient for maintenance purposes.
Street lighting systems require on-going maintenance, which can be classified as both corrective
and preventative maintenance. Corrective maintenance is a direct response to a lighting failure,
such as replacing a discharge lamp after it has failed, or replacing an entire lighting unit after it
has been hit by vehicle. Preventative maintenance is scheduled replacement of lighting
components, for example changing the lighting component like lamps, pole or mast on the
maintenance so prevents from corrective maintenance [9].
1.4.3 Original System Deficiencies
Whilst such road lights may be proficient in numerous operational circumstances,

including ecologically, they frequently oblige adjusting, for example, light substitution or repair
or substitution of failed control components, the outer casing or the reflector. This is a generally
expensive activity on the grounds that the road lights need to dismantle obliging trucks with no
less than a low voltage protected careful selector to stop under the road light keeping in mind the
end goal to perform these errands. As a feature of the procedure, a few individuals are regularly
Page | 7
needed to control activity around the vehicle on which the careful selector is mounted and
somebody to work the cherry picker and a spotter for instance. This additionally obstructs or
stops activity on slender streets.
The procedure of essentially changing a road light can take of the request of up to an hour
from start to finish. This is a generally long time given the quantity of road lights being used.
Notwithstanding the utilization of the moderately lavish hardware and huge work, there
constantly word related wellbeing and dangers when chipping away at or close streets. Working
nearby high power lines is likewise a critical danger connected with overhauling road lights [10].
In addition, the outline of the first framework is not able to support long arm of roughly 10
meters because of the increment in bending moment that will result at the pole and long arm
connection as required in this design.
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2.0 REQUIREMENTS
2.1 Customer Requirements
The design of lighting pole includes a different type of parameters that comes from
customer requirements. Survey for street light has been conducted to public. The feedback of
survey can be conclude that street light is important in daily life. Majority agreed that it is
important to have street light especially during night. Based on the survey, street light has made
difference to overall safety of the road.
Maintenance is important in order to maintain the life span of a product. Street lighting
systems required on-going maintenance. From the result of survey, public known that
maintenance is important and they willing to spend time on maintenance progress which will
lead to congested road.
The existing street light able to provide enough light due to design but percentage for
new modern technology and design for street light are higher which the new design are being
supported by public. Not only had that, from the survey showed that the weather affected the
durability of the street light. The durability of the material need to be change or choose other
material that has higher durability properties. On the other hand, public agreed to have cost
estimation range from RM200 to RM500 installation cost of street light.
Those requirements are safety, maintenance, design, durability and affordability of the
product from choosing material, manufacture and until installation for full product. Safety and
maintenance will be main priority for the product. For the design, it should be easy for the
customer to install the product. Moreover, by having strong structure where the product can
withstand the long arm of the light with low weight material would be an advantage.
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Requirements
Description
Safety
The location is legal and safe which not harmful to the trees and
environment.
The least impact on residence and facilities
The material and functional system are safe for long term use
The material has ability to undergo permanent deformation without

cracking or fracturing
Durability
Has ability to exist for long period no critical decay by opposing the
impact of heavy use drying, wetting, heating, corrosion, oxidation or
even volatilization.
Long term life span of the light and other component
Maintenance should be conduct after 1 week, one month, 6 months,
Maintenance
Design
Affordability
and annually thereafter after installation
Easy for installation
The component are low weight
Strong structure to withstand weight of long arm
The cost includes the material and design that lead to well-functioned
street light with reasonable cost. Keeping as low cost as possible with
best design, material and function of street light.
Table 2.1: Customer Requirement Descriptions
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2.2 Engineering Requirements
The requirement from engineering perspective that enhance the existing street light
performance and creating new street light according to customer needs.
Specification
Description
Light Weight
Details
Easy to assemble and
All the mechanism and parts should be
disassemble
simple with minimal component where
Low cost but high mechanical
design able to manufactured and assembled
properties
easily
Power Energy
Wattage of each light
The wattage range will be from 50W to
Supply
Voltage drop to last light
400W. Standard voltage is 120V.
Life span of mechanism should
Each material or parts of mechanism are
be the longest period with or
different.
without maintenance.
Having low cost but high properties of
Life Span
material should be the best option.
Mechanical
Able to twist and bend from
The strength of material includes the
stress of load
electrical and mechanical system. The
High tensile strength
material chosen should be designed in
Can bear capacity even after
considering the ability of flex strength and
maintenance
can tolerate the weight of load without
Strength
suffering deformation or breaking.
Thermal
To avoid overheat of
The highest temperature in Malaysia history
mechanism and components
is 40.1C. Material should have thermal

resistance below high temperature in
Resistance
Malaysia
High mechanical strength
Material should not harmful to environment.
Material
Eco-Friendly
It can withstand strong wind and heavy rain.
Quality
High mechanical stability
Need to choose right material which will

reduce the chances of failure
Table 2.2: Engineering Requirement Descriptions
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2.3 Testing Procedures
Based on engineering requirements, the testing procedure for street lighting can be
obtained. Since the street lighting is static object, the structure of it can be obtained by using the
basic knowledge of static mechanism.
From the basic static mechanism, the formula can be verified. Analysis can be carried out
based on formula by using analysis result. Failure analysis will be conduct and get the result of
shearing stress and tensile stress based on the material yield strength.
A software tool was created to simulate the system effect of parts and component lever
failure that can be identified based on the design. The mechanism will be tested using CREO
Simulate. Result from the simulation will show how to enhance the design. All mechanical and
material properties are provided in the software.
This software can also be known as finite element method. The software can help to
optimize the design by compute all component of stress at every element. Moreover, the result
from software to see if it meets the safety factor based on the mechanism. On the other hand, we
can prove that the finite element method considered being safe and almost accurate.
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2.4 House of Quality (HOQ)

G
F
P
+
5- Good 3- Average 1- Poor
Relationships
Strong
Moderate
Weak
+
+
Direction of Improvement
Target
Our Product
Competitor #1 The York Hinge
Competitor #2 Abacus Lighting
Competitor #3 Lightmart Square Base
Customer Competitive
Assesment
Competitor #3 Lightmart Square Base
Competitor #2 Abacus Lighting
Material Type/ Quality
Competitor #1 The York Hinge
Thermal Resistancy

Mechanical Strength
Safety
Durability
Maintenance
Design
Affordability
Life Span
Customer
Requirements
(Explicit and
Implicit)
Power Supply / Energy
Light Weight
Target for Functional

Requirement #1
Requirement #2
Requirement #3
Requirement #4
Requirement #5
Requirement #6
Functional
Requirements
Customer Importance
Column #
Direction of Improvement
Figure 2.4: House of Quality
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Row #
Maximize
Target
Minimize
Our Product
Comparison
Good
Fair
Poor
Correlation (Related)
Based on Figure 2.4, the requirements from customers and engineering were combined
together to see the correlation between customer requirement and the functional requirements.
There are five requirements from customer requirement which is summarization from survey and
six possible functional requirements that will help to gather the quality of the product.
The result of correlation from both requirements can be evaluate that safety is the most
important to create street lighting. The least requirements are maintenance because other
functional requirements are good enough to reduce the cost of maintenance. It helps for a long
term for the product. Choosing the best material might put affordability in high cost but the
outcome and result covers for a longest life span.
The entire requirements are based on the existing design product. Existing design being
put as benchmarking in order to acknowledged the weakest and strongest point to ensure that
own design achieve more than standard specification.
Comparison between own design and other three existing design can be seen in the house
of quality. The comparison is to enhance the requirements and make sure it is practical and
relevant. The idea and concept for the design can be identified and proceed the design to next
level. Information for customer and engineering requirements are based on result from survey
attached in Appendices.
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3.0 EXISTING DESIGNS
Street lights have undergone many stages of improved designs and shapes. This was to
ensure that, the each designed street lights should be able to meet the specific criteria such as the
place requirement and the effects of the light source. The light effect plays a major role by
enabling the road users to utilize the road in a safe manner.
One of the most specific places for the application of the street lights is focused at
housing areas where various necessities correspond. Most of the housing areas have its street
lights joined together in a same pole with the electric and telephone wire just as shown in figure.
Some street lights have attached the normal cable wires to it. It could be seen as three wires and
single wires. The design of the street lights here is based on the purpose of simply using hinges
to provide a fixed support of the arm attached to the pole.
Figure 3.0: Three phase street lights system in Kajang, Selangor [11]
Besides that, there are other street lamps which act according to where they are being
placed, for example, at highways. The design that is considered here is using a single straight
pole with no hinge to attach the arm to the pole at a fixed manner.
Based on the existing designs stated, one of the problems that arise at different types of
existing street lights designs is the maintenance part. The maintenance part includes the changing
of the bulb. We were supposed to install different optimization aspects of the hinges that can
ease the maintenance process.
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3.1 Design Research

3.1.1 XITI 3D Multifunctional hinge
Figure 3.1.1.0: AXITI 3D Multifunctional hinge [12]

The AXITI 3D Multifunctional hinge consists of the 3D technology, self-locking
capability and safety countered. The hinge has the tendency to withstand a weight load of about
150 kg to 550 kg. This design has its multifunctional purpose and can be applied at various
applications that includes concealed installations, architectural installations, architectural
facades, opening systems , glass door hinges , security doors , scissors hinges, huge panel size,
incredible heavy loads, concealed doors , advertising walls hoardings, exhibition showcases,
display cases, museum architecture and showcases [13].
The 3D multifunctional hinge comes with a maintenance free value and comes with an
easy installation with a maximum of load capacity and cost less.
Figure 3.1.1.1:
Figure 3.1.1.2:
Figure 3.1.1.3:
Axiti X100series [13]
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3.2 System Level

3.2.1 Existing Design 1 (Cantilever Mounting Mast Arm)
Figure 3.2.1: Aluminium Model of Lithonia Lightings Cantilever Mounting Mast Arm [14]
The figure shows the aluminium model of the Lithonia Lightings Cantilever Mounting
Mast Arm. This structure has the cantilever mounting arm that consists of brackets which aids in
providing a durable extension onto the street light pole. Moreover, the bracket helps to improve
the effectiveness of the light and the cantilever mounting mast arm is attached to steel,
aluminium, fiberglass, or concrete poles extending area lighting away from the pole by
approximately 4, 6, or 8 m. The cantilever mounting mast type is not suitable for concrete poles
[14].
When consider of making any improvements to this current design, it is not possible to
make any because the design is made to be it its final prepared stage. If further modification is to
be considered, then it would involve the process of welding external arms to the arm. This would
result the top part of the street lamp to be heavier thus ensuring damage done onto the whole
structure.
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3.2.2 Existing Design 2 (Guy Rod Mounting Arm Mast Arm)
Figure 3.2.2: Lithonia Lightings Guy Rod Mounting Arm Mast arm [15]
The figure above describes the Lithonia Lightings Guy Rod Mounting Arm Mast Arm.
This system follows the same criteria of having brackets which aids in the purpose of providing a
durable extension for the light illumination. Besides that, this enables the arm to be situated at an
optimal position for the light source in order to increase the lighting effect.
The Guy Rod Mounting arm Mast arm is suitable to be mounted onto the wood pole type.
The lighting area obtained could be placed approximately 7 metres away. This arm follows the
arm that is mentioned before which is a completed structure. To improve the effectiveness of the
lighting system, additional arm rods should be added by means of welding. Thus, it would put
the system in a situation referring to its benefits and weakness through the selection of materials
[15].
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3.3 Sub-system Level

3.3.1 Sub-system 1: Hinges
Street lights have subsystems that help it to function properly. One of the subsystems that
are presented in the street lights is the hinges. The hinges are an important part of the street light.
Most hinges are present at the base of the street light [16]. There are also some hinges at the top
of the street light connecting the bar with the arm of the street light. These hinges purpose is to
support the arm of the street light. Some hinges are connected in the center of the pole to help
with cleaning and maintain purpose.
Figure 3.3.1 Hinges that are installed at the lower part of pole [16].
3.3.2 Sub-system 2: Locking System
Lock system is also a kind of subsystem for the street lights. There are many kind of lock
system in the market currently. There is the Integrated Slide Lock (ISL), redundant safety lock
system and also the combination of lock and interlock system. These lock system are used to
tighten and secure the connection between the pole and the hinges and also the arms. There is
also another lock system that is mostly used, the screw and bolt system. The screw and bolt
locking system is the most basic yet effective locking system [17].
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Figure 3.3.2 ISL or Locking System [17].
3.3.3 Sub-system 3: Pulley System
Pulley system is where the amount of input effort (force) is multiplied to exert greater
forces on a load. This system typically used to lift the loads which also can apply tension into the
system. Pulley system not only a system that can lift weight safely, but also can move
effectively. Pulley system relies on mechanical advantages (ratio of load of effort). The higher
the mechanical advantage, the easier it is to lift a weight [18]. When the system working, pulley
system reduces the friction of the cable and eases the movement of the load. This system will
work effectively with proper safety of the system.
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4.0 DESIGN CONSIDERED
Based on the sketches drawn, the same qualities that are present include the quick and
ease of performing the maintenance for the street lamp. The first design sketch comes with a
simple working mechanism which uses the hinge, string like and a roller. This helps to prevent
climbing the light pole for maintenance. It can be done at ground itself simply by just using the
handle to bring down the arm of the street light downwards. In addition, time can be safe on
maintenance work, thus preventing public disturbance.
The movement of the arm is controlled by the string. However, the negative qualities are
the cost needed to install this system into the current street light which is expensive. This is due
to the multiple components that are involved in moving the arm in a single direction.
Moving to the second design, these design aids in maintenance of the street light. The
design has two mechanisms which are controlled by two types of hinges welded to the street pole
and the arm, while the other hinge operates on its own purpose. The presence of the slip rings
helps to prevent the non-welded hinge from operating. Each of the hinges has its own locking
mechanism. The disadvantage of the design is that, since it involves welded type structures , thus
the cost of securing this design into every street lights is expensive due to its components which
require more work in order to fixed them into the current system.
The third design also has the simple structure assigned with less mechanical mechanism.
The design includes single motions which in turns save cost of manufacturing. It involves small
number of components. The design of system is not practical, as it has the application of the
hook. There would be a lot of strain concentrated onto the hook, as it is the only structure that
holds and supports the arm.
The final design allows the hinge to be installed easily due to the welding to the arm. The
maintenance work can be carried out easily due to the flipping mechanism of the arm. Besides
that, the bottom hinge was placed to support the weight of the long arm. The disadvantage are,
the arm needs to be cut before installing the hinges and it may not be suitable for all diameters of
the arm.
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4.1 Possible Design 1
Figure 4.1: Possible design 1

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4.5 Advantage and Disadvantages of Possible Designs

The comparisons between the concept designs are tabulated in Table 4.5 below.
Possible
Advantages
Disadvantages
Design
Easy access, not complicated
User-friendly
Design consists of two mechanisms
Expensive
The cost of securing this
which are controlled by two types of
design into every street lights
hinges welded to the street pole and
are expensive due to its
the arm, while the other hinge
components which require
operates on its own purpose.
more work.
The presence of the slip rings helps
The welded section would be
to prevent the non-welded hinge
difficult to be repaired as the
from operating.
damage on that section
Each of the hinge has its own
worsens, it requires to
locking mechanism
change the whole structure
Simple mechanical system
Low torsion resistance
Less mechanical part use
Low safety for arm
Save cost
Just use slide system to do
Arm needs to be cut before
maintenance
Hinge can be installed easily by

welding it to the arm
Light bulb can be reached easily

when arm is flipped for maintenance
installing hinge
May not be suitable for all

diameters of arms
Bottom hinge support the weight of

long arm
Table 4.5: Advantage and disadvantages of design
Page | 26
5.0 FINAL DESIGN SELECTION

5.1 Rationale for Design Selection
Referring to Figure 2.4 which is the result of house of quality (HOQ), there are few
concepts were developed based on relationship between engineering requirements and customer
requirements. Table 3 showed a result of 10 concept which gathered from the possible drawing
system, customer requirement and engineering requirement. All possible data being discussed
and being compared into concept generation.
From Table 5.1.1 where there were 10 concepts being created and it showed few concepts
that has highest total score. Best five concept being chose based on different aspect which
include the material, type of hinge, working mechanism for hinge, the attachment for hinge and
the maintenance based on all aspect stated for a long term.
Based on the Concept Development on Table 5.1.2, the Pugh Matrix was constructed and
the result showed the best five concepts. Datum or Concept 2 is the highest among other concept.
The options for best five concepts were narrow down from concept generation in Table 5.1.1.
Therefore, the design of street light will be created and considered based on the concept 2
with galvanized steel as the material. The hinges working system for the mechanism are pulley
system. Welded joint and bolted joints were chosen as the hinge attachment while the hinge type
will be using stop hinge. The maintenance for long term will include for rotatable arm, height of
the bulb when hinge operated and folded shelf. All specification will be taken in order to
optimize the street light.
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5.1.1 Concept Generation
Specification
Material Strength
Hinge Working
Mechanism
Hinge Attachment
Maintenance
Type of hinge
Type
C1 C2 C3 C4 C5 C6 C7 C8 C9 C10
Steel
1
1
1
Galvanized Steel
1
1
Brass
1
1
1
Stainless Steel
1
1
Friction
1
Locking System
1
1
1
1
1
1
Level System
1
1
1
1
Pulley System
1
1
1
1
1
Welded Joints
1
1
1
1
1
1
1
Bolted Joints
1
1
1
1
1
Glu Type
1
Clamp
1
1
Rotatable Arm
1
1
1
1
1
1
1
Bendable Arm
1
1
1
Height of bulb when hinge operated
1
1
1
Folded Shelf
1
1
1
1
Axity 3D
1
1
Special Purpose
1
1
1
Stop hinge
1 1
1
8
7
7
6
8
7
8
7
5
Total 5
Table 5.1.1: Concept Generation
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5.1.2 Concept Development
Sub-Functions
Material Strength
Sub-sub Functions
Steel
Galvanized Steel
Brass
Stainless Steel
TOTAL SCORE
Hinge Working
Mechanism
Friction
Locking System
Level System
Pulley System
TOTAL SCORE
Hinge Attachment
Welded Joints
Bolted Joints
Glu Type
Clamp
TOTAL SCORE
Maintenance
Type of hinge
Rotatable Arm
Bendable Arm
Height of bulb when hinge operated
TOTAL SCORE
Folded shelf
Axity 3D
Special Purpose
Stop hinge
TOTAL SCORE
OVERALL TOTAL SCORE
Datum/C2
0
1
0
0
0
0
0
0
1
0
1
1
0
0
0
1
0
1
0
1
0
0
0
0
0
C3
0
0
1
0
-1
0
1
0
0
0
1
1
0
0
0
1
0
0
-1
0
1
0
0
0
-2
C4
0
0
0
1
0
0
1
0
0
0
1
1
0
0
0
1
0
0
-1
0
0
1
0
0
-1
C5
1
0
0
0
0
1
1
1
1
-1
1
0
0
0
-1
1
0
0
-1
0
1
0
0
0
-1
C7
0
1
0
0
-1
0
0
1
0
1
1
1
0
1
1
1
1
0
0
1
0
0
0
-1
-1
Table 5.1.2: Pugh Matrix

Page | 29
5.1.2.1 Strong Material
The material used to manufacture the hinges should be solid in specific aspects. This
incorporates the yield quality of the material. The yield quality of a material is the anxiety a
material can withstand without changeless deformation. As the hinge will be subjected to a steady
substantial burden over a drawn out stretch of time such solid materials elements are critical to
avert disappointments. As maintenance job on a road light is normally directed at regular intervals
once, henceforth the objective lifespan of the hinge is situated at five years. The materials likewise
needs to ready to withstand different natural conditions as road lights are open air structures that
are continually subjected to rain, wind and warmth
In consideration of cost and operational functions, two types of materials that fit the criteria
were shortlisted, namely galvanized steel and stainless steel Type 316. In terms of yield strength
and tensile strength, galvanized steel has the higher value at 50,000 psi and 55,000psi followed by
stainless steel at 40,00 psi and 90,000 psi. Raw materials cost of galvanized steel and stainless steel
are typically similar but the cost of machining galvanized steel is much higher compare to stainless
steel.
However, in terms of withstanding environmental factors, each of these materials has its
advantages and disadvantages. Galvanized steel has great strength. It is rust resistant and can be
coated with zinc to prevent from corrosion. Furthermore, for highly corrosion areas, galvanized
steel is recommended, Stainless steel on the other hand in noncorrosive, rust resistant, and very
decorative. However it has less strength than galvanized steel materials. Stainless steel is often
used where appearance is of great concern as it may be polished and plated in various finishes.
Page | 30
5.1.2.2 Controlled Opening Angle
In the street light application, the opening angle of the hinge has to be considered during
maintenance. This is because the supporting arm which is connected to the hinge must have the
capacity to be turned up to a certain angle with the goal that maintenance work can be diverted out
calm from the parkway movement.
One of the approaches to control the opening angle is through the utilization of friction
hinges, detent hinges or through a locking mechanism. A friction hinge is a gadget with torque
between two sections on a typical hub. A friction hinge holds its position anytime in its extent
movement, permitting it to be situated and left in the spot with negligible squirm room. An
exemplary case can be seen on portable PC cases. The case stays until the user opens it, and will
stay in the position the user left it in. these devices are additionally called constant torque hinges.
A comparable configuration has what is known as a decent hinge, where the hinge will stop
at one angle and resume development when pushed. This is not the same as a friction hinge, and
may be utilized as a part of diverse settings. A detent hinge is a device for repeatable "soft stops"
in one or more positions between two sections on a typical hub. Not a genuine friction hinge [18].
Other than that, the opening edge can likewise be controlled by the utilization of a locking
system. Mechanical locks for instance work by method for one or more bits of metal (tumblers,
levers, or hooks) falling into an opening in the bolt, keeping it from being moved. Henceforth,
once the supporting arm is moved to on suitable edge, the locking component can be utilized to
hold the arm in place.
Page | 31
5.1.2.3 Arm to Hinge Attachment
One of the most crucial criteria of attaching the hinge connecting the arm and the light pole
involves the technique of installing the arm together with the hinge. This particular combined
effect should have a good outcome based on the strength to withstand the arm support based on the
hinge. By doing this, it then strengthens the joint attachment and the overall design. There are two
methods proposed, which is through welded and bolted joints.
The bolted joints composed of screw like fasteners which helps to place the combined effect in
a fixed position. The advantages of bolted joints are, they can be easily assembled and
disassembled. Bolted joints are designed to take in tension loads. Besides that, some of the
elements (structural based) are replaceable when its usefulness has worn off. Moreover, when it
comes to attaching two different types of material without rupturing it, only bolted joints are able
to meet the requirements. For example, the bolted joint method can be implemented to joint steel
and aluminium.
Based on the quality, the bolt does not require any kind of heat treatment. Heat treatment can
change the properties of the material significantly, and change the grain structure, which can be
avoided in this case. While applying these fasteners, you do not have to think of the material of the
items that are being fastened. There is absolutely no interference between the fastener material and
parent material. There are situations where you will need a fastener that does not have to travel
through the parent material. Based on the quality, the bolts are manufactured as to meet the types
of industry application subjected to rigorous quality control.
Welding is process where, different materials are joint through fabrication or sculptural process.
The joint is formed when two different work pieces made from metal and plastics materials are
combined together. The advantages of welded joints are, no holes required for the welding process
to take place, hence no reduction of area. So structural members are more effective in taking the
load. Besides that, welded joints are more economical as less labour and less material is required.
In addition, the speed of fabrication is faster in comparison with the riveted joints. The welding
process creates a permanent effect compared to the bolted joint which is made temporary. This can
lead to a disadvantage when one of the members of the welded structure gets damaged, then it
Page | 32
would be difficult to replace the damaged member. This then, cause the whole structure either to
be replaced or repaired.
5.1.2.4 Ease of Maintenance
Street lamps require on-going maintenance either due to damages from environmental
factors or internal wear. Most commonly, maintenance is done at its lighting component after it has
reached its expected service life, damaged, flickering, dimmed or even out-dated. Fixing the
lighting of a long arm streetlight require it to be done on the roadway itself on an elevated height to
reach its lighting component. This poses a serious safety risk to personnel involved in the
maintenance process as they are exposed to possible dangers from the traffic when doing work in
the middle of the roadway. Not only that, it disrupts traffic when maintenance is being performed.
The hinge mechanism designed in this project poses as a function to ease the maintenance
of streetlights by enabling the arm to move in a rotational manner from its initially rigid position.
This way, the arm can be rotated downwards at a 90 angle, resulting the arm of the streetlight to
be closer towards the pole, hence closer to the side of the streets. As a result, the personnel
involved in the maintenance work can do necessary corrective action at the side of the streets,
without having to disrupt the traffic and most importantly endanger life.
Because the height of the streetlight pole is very tall which is 12 meters long, it is not
convenient to do maintenance at a very tall height. With the proposed design, the lighting bulb can
be lowered to the ground. This will further ease the work of the personnel involved in the
maintenance process as they can do work on lower ground. Not only that, it also reduces the cost
of having to use vehicle such as lift truck. After maintenance work is done, the arm can be easily
lifted back by operating the winch that is located at the lower side of the pole. After the arm is
lifted back up, the streetlight can continue its functionality of providing optimum lighting to the
streets.
To improve the maintainability of the hinge itself, the design of hinge is incorporated with
little components, where maximum stress is expected to occur in it. In this design, the use of bolts
and nuts are incorporated at its hinge, pulley and clamp where maximum stress occurs. The bolts
Page | 33
and nuts are expected to wear faster than the larger components. Hence, maintenance requires
replacement of these smaller components, which is more economical and sustainable compared to
having to replace the large components altogether. The number of components are simplified and
reduced to a minimum. However, it is done so without compromising its quality and functionality.
5.1.2.5 Type of Hinges
Hinges commonly used to join a component where the motion occurs around a transverse
axis which based on pivot factor. Hinges will be used at the long arm of street lighting and the type
of the hinges will be explain in order to fulfil the design based on criteria needed.
5.1.2.5.1 Self-Closing Weld-On Hinge

Self-Closing Weld-On Hinge is a high quality and a heavy duty weld-on hinge that selfcloses. It is a self-closing feature which uses a machined surface and gravity to self-close. Pair of
this hinges is rated at 800 lbs. capacity. This hinges is made from mild steel and should be coated
with a finish after installation. This hinge pin are float type which means that this hinges is not
permanently attached to either the top or bottom part of the hinge [20].
Figure 5.1.2.5.1: Self-Closing Weld-On Hinge [20]
Page | 34
5.1.2.5.2 Heavy Duty T-Hinge
Heavy Duty T-Hinge is a stainless steel hinge commonly used for vinyl, redwood cedar and
ACQ (treated) lumber. It is excellent use where corrosion is the main problem occurs. Heavy Duty
T-Hinge is a heavy duty construction which perfectly can be used as long arm hinges. It's made
from solid stainless steel (SS304). The strap length of the hinges is measured from the tip of the
strap to the far end of the hinge pin barrel. The pad width (the widest part of straps) is measured
from the edge of the pad to the inside edge of the hinge pin barrel. The screws inside the hinges are
in the same material which is stainless steel 304 (SS304) [21].
Figure 5.1.2.5.2: Heavy Duty T-Hinge [21]
5.1.2.5.3 Heavy Duty Strap Hinge

Heavy Duty Strap Hinge is made for surface mounted flush installation. It made from 0.197
inches of thickness and material type is stainless steel. The horizontal of the strap measurement are
2.5 inches tall by 7-3/8 inches wide. Meanwhile the vertical dimension measurements are 4-1/8
inches tall by 2-1/4 inches wide. The hinge pin is removal where it held in place by a circlip. Hinge
pin features a zerk fitting to allow lubrication. Each hinge uses 6 each 5/16" lag screws [22].
Page | 35
Figure 5.1.2.5.3: Heavy Duty Strap Hinge [22]
5.1.2.5.4 Heavy Duty Barrel Hinge

Heavy Duty Barrel Hinge is 6 inches tall. It can be used in both weld-on and bolt on
installation. Hinge has a large 1-7/8 inches diameter barrel giving it a very high weight rating
among all. This hinge is capable of opening up to 180 degrees, depending on thickness of
component. This hinge is made from steel and zinc chromate plated. The hardened steel pivot bolts
are in grade 5. A pair of these hinges is rated to hold a 3000 lb. gate or door. The gap can be as
small as inches if welded and If bolted the gap can be a small as approximately 5/8 inches
(depends on the head size of the bolt that you use) [23].
Figure 5.1.2.5.4: Heavy Duty Barrel Hinge [23]
Page | 36
5.2 Design Description
Concept generation was used as the guidelines in filtering the possible design based on
requirement and criteria that had being set up. Among the possible design, the best design was
selected as final design. In the final design, the hinge and pulley was introduced. This design fulfils
our purpose which is to ease the maintenance process of streetlights.
The critical part of the design is the hinge that made of simple bolt and nut. The pole and
arm part will be made of galvanized steel and the clamp material is steel. Meanwhile, all other
parts of the hinge will be made of Stainless Steel Type 316. Major advantages of Stainless steel
have great strength in term of tensile and yield and it is also rust resistant. These requirements is
necessary as the hinge is used to support heavy load and usually used
Pole and arm are designed so that their stresses meet allowable standards for bending and
local buckling over the entire length of the components (not just at the ground line or support. The
poles are also fully accepted and meet the stringent standards set by Tenaga Nasional Berhad and
Telekom Malaysia Berhad in Table 5.2.3 in Appendices [24].
This design incorporates hexagon socket head cap screws and bolt that connects the hinge
with the arm. The bolts and nuts chosen complies with the standards set by American Society of
Mechanical Engineers (ASME) and the bolts and nuts used in the design are available in the
catalogue provided in Appendix section.
The finalized hinge design can be divided into four different subsystems that works
together to hold the supporting long arm as well as enable it to be rotated for maintenance. The
four subsystems included in the finalized design are the butt hinges, arm to hinge attachment,
locking mechanism and hinge attachment during operation. The engineering drawings of each
component as well as the overall system are documented in Appendix.
Page | 37
5.2.1 Sub-System Level
5.2.1.1 Sub-System 1: Long Arm
The long arm is designed to be 10 m in length while still able to minimize bending and
buckling towards it. The long arm is to provide optimum illumination of light towards wide
roadways. The components attached to the long arm are the light casing, hinge and also cable to
support the arm. The casing of the arm is as shown in Figure 5.2.1.1(a) Lamp cover is used to
cover the bulb inside from any insect or temperature. The lamp cover is design to resists the
internal lighting components from any kind of such as insect.
Figure 5.2.1.1(a) Cross-section of light casing and stopper on the long arm.
The stopper is actually a thick rubber material placed below the horizontal arm. If
somehow the steel braided cable fails, a stopper is designed so that is can absorb shock and
prevents the light bulb casing from hitting the pole. The stopper is made of thick rubber material so
that it can longer give impact time to the long arm and light casing in case of failure at the cable.
Meanwhile, at the other end of the long arm attached with hinges as shown in Figure 5.2.1.1(b).
Page | 38
Figure 5.2.1.1(b) Cross-section of long arm with hinge.

5.2.1.2 Sub-System 2: Pole
The pole was design with hollow cylinder to allow the wire pass through. The pole is
design according to standard that was set and being followed by Tenaga nasional Berhad, TNB and
Telekom Malaysia, TM. The pole material is selected to be Galvanized Steel. The Galvanized
Steel of the pole material has higher strength, rust resistance at the same time is being followed as
standard from Table 5.2.3 in Appendices [23].
Figure 5.2.1.2 Cross section of long arm with hollow cylinder and circle hole on surface.
Page | 39
The pole is made of hollow cylinder to contain the lighting cables. It is also design with a
hole just right below the arm. This is to allow the wire inside the hollow pole to exit the pole, and
then enter the interior of the arm to finally reach the light casing. The wire inside the pole and arm
is also made lengthier and flexible to make sure the wires not snap during rotation of the arm.
The base of the pole exerts the most weight as it has to withstand the weight of the whole
system. The diameter of the pole is designed with an outer diameter of 150 mm and inner diameter
of 80 mm, where this can be referred to the component drawing in the Appendix section. This
design meets the safety standards to be used commercially.
5.2.1.3 Sub-System 3: Pulley
Figure 5.2.1.3 Cross-section of pulley attached on top of the pole.
As can be seen from Figure 5.2.1.3, on top of the arm is the attachment of pulley. This is
where maximum force is exerted as the tensions in the cables are very high to support the heavy
weight of long arm. Inside the pulley is the roller, where an allowance of 5 mm is given to
minimize friction between roller and nut. Hence, the cables can pass the pulley smoothly as the
roller aids the movement of cables.
Page | 40
For ease of fabrication, the hollow cylindrical pole is fabricated first, and then the pulley
will be attached by welding. The arm of the pulley is welded at an angle of 30 from its pole,
where it is extruded high into the air. This is to avoid contact between the cable and the hinge box
when lowering the arm. Hence, the frictions between the components are minimized. The pulley is
connected using bolt and nuts to hold the component parts in place, while still allowing movement
of roller. This is because allowances between the dimensions are made.
5.2.1.4 Sub-System 4: Hinge
There is a hinge attached to the horizontal arm. First and foremost, to install the hinge the
arm needs to be cut two. Then, the hinge box will be attached to the elbowed arm by welding,
where attachment is displayed in Figure 5.2.1.3. The hinge box is assembled together with the arm
through bolt and nuts, where the assembly can be seen in the same figure.
Figure 5.2.1.4 Cross-section of hinge that is attached to long arm.

Hinge on the arm allow downwards movement of the arm at an angle of 90. The hinge
also has a hollow circle through it to allow wiring to pass through. The system of the hinge is
completed with cable, pulley and also winch. This will be the connections allowing the lowering
Page | 41
and lifting of the long arm from ground position. The winch operation will be explained in the next
sub-system.
Hinge is one of the points of stresses that are high. Hence, it is made of Stainless Steel to
withstand the high weight load of a long steel arm that is approximately 200kg. The dimensions of
the pin in the hinge connections are also large, which is 25 mm in diameter. The dimensions of
hinge can further be referred to drawing in Sheets 8, 11 and 12 in Appendix. This is to ensure that
the hinge is a safe design.
5.2.1.5 Sub-System 5: Winch
In this design, the winch is outsourced rather than fabricating it. The winch is part of the
system of the pulley to complete its mechanism. It is a mechanical device that is used to wind in or
wind out rope or cable for lifting process [25]. The reason winch is used is so that we could
operate the movement of arm without having to reach high places.
In our design we used a Worm gear winch which will locate at the lower point of pole. This
winch came up with a cordless drill which helps to turn the self-braking worm gear system of the
winch gear box and also 15 metres long steel braided cable [26]. This operates when the cordless
drill place on the shaft of the gearbox and rotate either clockwise or anticlockwise. When it rotates
clockwise the cable from the winch will wind out and wind in when it rotates anticlockwise which
help the streetlight arm to move up and down.
Figure 5.2.1.5 Worm gear winch to be installed at the lower part of pole.
Page | 42
5.3 Implementation
Once the final design dimensions were determined, a failure analysis was conducted on the
design to identify if the proposed design is safe to be used. The design is tested out using simple
stress analysis and simulations to ensure that it meets the safety standards and requirements. There
are two methods of analyses, which is by using manual calculation to identify the tensile and shear
stresses at the hinge. Another method is using Finite Element Analysis in CREO Simulate to
identify the Von Misses stresses at the components of the system.
5.3.1 Failure Analysis
Calculations were performed at the beam and pulley structure, where more stress was
focused on this particular structure. The bulb weighs about 500 N and the weight of the arm is
fixed at about 200 N. Next, the bending stress is obtained and the safety factor was calculated as
1.22, which is lesser than the fixed safety factor value of about 2. Then, the shear stress at the pin
and support arm was calculated, and the safety factor value was a large number. Besides that, the
simulation through the CREO Simulate shows that the considered design is particularly in a safe
position. Full calculation showed in Appendices.
Bending stress,
360.81 Mpa
Safety factor =
Page | 43
Safety factor =
Safety factor = 1.22
Shear stress at arm,

15.95 Mpa
Safety factor =
Safety factor =
Shear stress at pin,

683135.46 pa
Safety factor =
Page | 44
5.3.2 CREO Simulation
The stress analysis of the hinge is further done using CREO Simulate. A weight force of
1962N and 500N is applied downwards on its center of gravity, which is the weight of arm and
weight of light bulb respectively. Meanwhile, a tension force of 24.278 kN from the cable is
applied as the reaction force that is supporting the arm. The materials of the entire design are
assigned as steel with yield strength 442 MPa.
Figure 5.3.2.1: Forces applied on the arm to identify stresses on hinge

From the results of the simulation, the image of the Von Misses stresses is produced as
shown in Figure 5.3.2.1. From the generated image of Von Misses stress, the areas that are prone
to high stresses are identified and analyzed.
Page | 45
Figure 5.3.2.2: Stress Von Misses stresses at hinge

Due to the load applied, it is found that stresses are more prone at the hinge. Meanwhile,
maximum Von Misses stress of 242.6 MPa is at location A, the contact point between the
connections of hinge. This may be due to friction of the edges of the connections with the surface.
Otherwise, the stresses are at a safe range within 185.6 MPa. From the result of the analysis, the
hinge safety factor is 1.8.
From the safety factor calculated, it can be concluded that the design of the hinge is safe to
be used. However, it can further be improved to obtain a safety factor of 2 to 2.5, which is the
range for common applications.
Besides the hinge area, the Von Misses stresses at the clamps are also observed as shown in
Figure 5.3.2.3.
Figure 5.3.2.3: Von Misses stresses at clamp

Page | 46
The clamp area is also the location that is susceptible to failure. However, the maximum
Von Misses stress at the clamp area is found to be 27.1 MPa. The safety factor of the clamp
calculated is 16. The clamp design is safe to support the arm.
The pulley on top of the arm is where the roller exerts most force on it, as it has to support
the large tension force of the cable. The maximum Von Misses stress found in pin is 426.3 MPa.
The pulley has a safety factor of 1.04. Although the design does not fail, however, it can be
improved to achieve a safety factor of at least 2.
Figure 5.3.2.4: Von Misses stresses at pulley.
Finally, the Von Misses stresses along the arm are observed. Long arm are susceptible to
bending making it one of the location of where stresses could be high. Figure 5.3.2.4 shows the
Von Misses stress present along the long arm. The stresses are low, with a maximum of 56.1 MPa.
At the smaller diameter of arm, the color contour shows stresses begin to happen. Also, on the left
end of arm, stresses can also be seen. The middle of the arm has least stress as cable supports it.
The long arm has a safety factor of 7.9 obtained from the analysis.
Page | 47
Figure 5.3.2.5: Von Misses stresses along the long arm.
Page | 48
5.3.3 Dynamic Load
The structure of pole must have adequate quality to resist forces such as wind-induced
forces. The structure must have adequate stiffness to satisfy occupant comfort and serviceability
criteria, and the wind may produce a dynamic response of the pole structure [27]. Wind is dynamic
and random phenomenon in both time and space. The pole is tall and the wind velocity varies
along the height because wind loads change rapidly.
To select a proper pole for street lightning, there are few requirements to be considered.
Based on the nature reaction to the pole, the concept of the pole can be explain using Effective
Projected Area (EPA) whereas EPA is one of the basic principle for the structural engineering
process for street lighting and other mechanical fields as well [28].
Figure 5.3.3.0: Effective Projected Area for Galvanized Steel [28]
Page | 49
Figure 5.3.3.1: Picture of pole based on EPA [30]
Page | 50
Figure 5.3.3.2: Truss Arm EPA [31]
Figure 5.3.3.3: Image of truss arm [31]
Page | 51
Based on the Effective Projected Area (EPA) catalogue in Figure 5.3.3.0 and Figure 5.3.3.1
for galvanized steel with coating, the wind speed (mph) range are between 70mph to 110mph.
Referring to the pole length assumption which is 6.5 inch, 50.2 is the highest and lowest is 19.7 for
maximum EPA (f) reading. For the truss arm, by estimating value for arm length based on the
catalogue, the maximum fixture weight is 20kg while the maximum fixture EPA at 80mph are 2.4.
Other dimension can be referred to Figure 5.3.3.2.The catalogue is intended for general guidelines
only and the value given are suitable for pole and arm applications which both pole and arm can
withstand the dynamic load on specific region.
Page | 52
5.3.4 Prototype Fabrication
The prototype is analysed based on the specifications of making sure that, the model
responsible of withstanding the overall weight. The next requirement includes the function or role
of the hinge to support the arm with the aid of the pulley cable. Besides that, the hinge is required
to prevent the arm from being loosely placed, thus ensuring that the arm is always at a 90 angle.
Moreover, with the instalment of the hinge, it should be able to ease the maintenance process. The
prototype is made up of PVC pipe, PVC connectors (elbow joint), acrylic board, pulley, string,
steel clamp, bolt and nut. In order to attach the PVC components, the PVC glue was used. As for
the hinge and steel clamp attachments, the bolt and nuts were used. Other 2 dimension technical
drawing showed in Appendices.
Figure 5.3.4.1: Dimension of hinge box
Page | 53
Figure 5.3.4.2: Whole prototype

Based on Figure 5.3.4.2, the prototype is constructed. The part does not follow the exact
dimensions as stated. The dimensions stated, is merely for the fabrication of the actual structure.
The hinge attachment to the pole involves the bolt and nut. The arm is locked to the pole based on
the cable pulley system and the system helps positions the arm at an angle of 90. The wiring
system is towards the bottom part of the clamped arm.
Page | 54
Figure 5.3.4.3: Construction of the hinge box

Figure 5.3.4.3 shows the hinge structure, which is made up of the acrylic board and the
bracket which hold the pin that secures the hinge. The next part involves clamping the arm to the 4
feet length PVC pipe with diameter is 3 inch. The arm is clamped using the steel clamp as in the
Figure 5.3.4.4.
Page | 55
Figure 5.3.4.4: Clamped vertical arm

The pulley is attached to the 2 inch diameter PVC pipe to form the pulley system for the
street lamp prototype based on Figure 5.3.4.5.
Figure 5.3.4.5: Pulley structure

Page | 56
A hole was formed at the top part of the 6 inch diameter pipe for the placement of the
pulley system as illustrated in Figure 5.3.4.6. A hook is placed at the bottom part of the 6 inch
diameter pole for the locking management of the pulley. The locking system enables the arm to be
at an angle of 90
Figure 5.3.4.6: Pulley mechanism
Page | 57
5.3.5 Cost Analysis
5.3.5.1 Prototype Fabricating Cost

The cost of fabricating the prototype is tabulated in Table 5.3.5.1
Type of Cost
Description
Quantity
Price (RM)
PVC pipe
RM 14.00
PVC Connector (Elbow joint)
RM 4.00
Acrylic Board
Free
Materials
Bolt and Nut
Tools
RM 5.00
PVC Glue
RM 3.00
Pulley
RM 5.00
Steel Clamp
RM 8.00
String
FREE
RM 39.00
TOTAL
Table 5.3.5.1: Cost for fabrication of hinge, arm and pole.
Page | 58
5.3.5.2 Cost Design for Finalized Design

The cost of the actual design is tabulated in Table 5.3.5.1
Type of Cost
Description
Quantity
Price (RM)
Cable
15 (metre)
RM 75.00
Nut and bolt
5 pair
RM 25.00
Pulley
RM 60.00
Grinding
RM 30.00
Cutting
RM 20.00
Welding
RM 20.00
Labour force
RM 20.00
Materials
Fabricating
Workforce
RM 300
TOTAL
Table 5.3.5.1: Cost for fabrication of finalized design for hinge, arm and pole.
Page | 59
5.4 Testing
The descriptions of how each design requirement was tested according to testing methods are
summarized in Table 5.4.
Testing Method
Identify
Procedure
Free Body Diagram
Resultant force
The weight of the arm, W is

exerted downwards (y-dir.) at
its center of gravity.
Tension
of
cable
act
as
reaction force to support arm.
Tension of cable, T is found by

applying FBD.
Failure Analysis
Shear stress
FR = W T
The force is obtained based on
Tensile stress
Factor of safety
static analysis done on beam.
The bending stress and shear

stress at pin and support arm
was calculated which leads to
the safety factor.
CREO Simulation
Von Misses stress
Final design is created in

CREO.
Materials are assigned as steel

for each component.
Forces are applied at weight of

arm and tension of cable.
Finite Element analysis is run

to generate Von Misses stress.
Table 5.4: Testing procedure of design analysis.
Page | 60
6.0 CONCLUSION
To summarize our project, all the designs are evaluated in accordance to the Customer and
Engineering requirements. Careful consideration has been taken into the selection of the design.
Our finalised design showed the highest potential out of all the other designs. It is simple, and also
contains features that make it easy to maintain. The incorporation of the heavy duty pulley, welded
hinge to arm attachment and the steel braided cable ensured that this design is efficient, reliable
and strong to withstand the 10 metres arm.
Engineering knowledge has been effectively applied throughout the whole designing process
such as calculation of maximum stresses and factor of safety. Technical skills such as using CREO
Simulate for designing and stimulation of the design have also been applied to enhance the
designing process and reduce the risk errors.
The results of both the manual calculation and software stimulation show that the design
chosen is safe and the materials used for the design will not fail. Finally, by combining the
engineering knowledge and relevant principals the design is improved and a successful prototype
is designed and developed for future recommendation.
Page | 61
7.0 GANTT CHART
Capstone Project Gantt chart

Task
Week
10
11
12
13
14
Capstone design briefing

Group and title formation
Meeting with project mentor
Progress report 1
Discussions
Progress report 2
Final design selection
Discussion regarding prototype
Prototype
Oral presentation
Final report, Logbook and peer evaluation
Page | 62
15
8.0 REFERENCES
[1]
Street Light. Wikipedia 2015. Retrieved from https://en.wikipedia.org/wiki/Street_light
[2]
Antal H. & Yvonne A.W. (2012). Light distribution in dynamic street lighting: Two
experimental studies on its effects on perceived safety, prospect, concealment, and escape.
Journal of Environmental Psychology
[3]
Kerja-kerja Membaik pulih Lampu. Mahutolis Magazine 2010. Retrieved from

http://www.jkkkpadangjawaklang.com/?p=2001
[4]
Aduan
Rakyat
(Jalan
Daud).
Blogspot
2010.
Retrieved
from
http://dun-
maharani.blogspot.com/2010/08/aduan-rakyat-jalan-daud-parit-barujalan.html
[5]
60 Lampu jalan di tiga tanah rancangan Felda rosak. Utusan Online 2011. Retrieved from
http://ww1.utusan.com.my
[6]
Terima
Kasih
TNB.
Perjalanan
sebuah
kehidupan
2013.
Retrieved
from
http://www.kembaraminda7.com/2013_02_01_archive.html
[7]
All About Street Lights. Blogtop. Retrieved from

http://blogtop.djmatioca.com/V1/afgerqfqthqoq/5554442346188195934
[8]
Janji Pasang Lampu Jalan di Selindung. Bangka News 2015. Retrieved from
http://bangkanews.com/
[9]
D. Whitfield, Street light. Australia Patent WO 2012167320 A1, 13 December 2012.
[10]
British
Standards,
December
2003.
Retrieved
from
http://persona.uk.com/orga46newark/ha_docs/disposit_docs/dd101-dd200/dd164.pdf.
[11]
Street
Light
Purpose.
Wikipedia,
October
2014.
Retrieved
from
http://en.wikipedia.org/wiki/Street_light#Purpose.
[12]
Axiti 3D hinge,Retrieved from http://www.axiti.eu/axiti-hinge/
[13]
Axiti 3D hinge,Retrieved from http://www.axiti.eu/specifications/
[14]
Cantilever Mounting Arm Mast Arm (Aluminum/Steel). Lithonia Lighting, 2014.

Retrieved from: http://www.lithonia.com/commercial/amac-smac.html#.VG4E1PnugZt.
[15]
Guy Rod Mounting Arm Mast Arm (Aluminum/Steel). Lithonia Lighting, 2014. Retrieved
from: http://www.lithonia.com/commercial/amawg-smawg.html#. VG4E1PnugZt.
Page | 63
[16]
Making changing street light lamps simple. Caravan Park Electrical Services Limited.
2013. Retrieved from: http://www.cpes.co.uk/news/street-light-hinge
[17]
Integrated Slide Lock (ISL) or Locking System. Thomas Regout International BV. 2015.
Retrieved
from
http://www.thomasregout.com/3/229/1369836c-e9c9-4580-a200-
0c4b7c172b81/systemI/integrated-slide-lock-isl-locking-system.aspx
[18]
V.Ryan.Pulley and lifting.A Design and Technology Site.2004-2014.Retrieved from:

http://www.technologystudent.com/gears1/pulley7.htm
[19]
Mc.Mahon. Skola.S. What is Friction Hinge?. Conjecture Corporation. 2003-2015.

Retrieved from:http://www.wisegeek.com/what-is-a-friction-hinge.html
[20]
Self-Closing Weld-On Hinge. Hardware Source. Retrieved August 19, 2015. Retrieved
from:
http://www.hardwaresource.com/hinges/specialty-hinges/weld-on-hinges-welding-
hinges
[21]
Heavy Duty T-Hinge, Stainless Steel. Hardware Source. Retrieved August 19, 2015.
Retrieved
from:
http://www.hardwaresource.com/hinges/specialty-hinges/heavy-duty-
hinges/heavy-duty-gate-hinges-1
[22]
Heavy Duty Strap Hinge. Hardware Source. Retrieved August 19, 2015. Retrieved from:
http://www.hardwaresource.com/hinges/specialty-hinges/heavy-duty-hinges/heavy-dutygate-hinges-1/weld-on-strap-hinge
[23]
Heavy Duty Barrel Hinge. Hardware Source. Retrieved August 19, 2015. Retrieved from:
http://www.hardwaresource.com/hinges/specialty-hinges/heavy-duty-hinges/heavy-dutygate-hinges-1/round-body-barrel-weld-on-hinges
[24]
The American Society of Mechanical Engineers (ASME). Hex and Heavy Hex Bolts.
ASME B18.2.1-2010 (Inch Series). October 2010.
[25]
Winch. Retrieved from: https://en.wikipedia.org/wiki/Winch
[26]
Battery Driven Worm Gear Winch. Hoist UK (HUK). Industrial & Entertainment Lifting
Equipment. Retrieved from:http://hoistuk.com/industrial/industrial-manual-winches/wabattery-driven-worm-gear-winch_263.html
[27]
The American Society of Mechanical Engineers (ASME). Hex Nuts and Jam Nuts and
Heavy Hex Nuts and Jam. ASME B18.2.1-2010 (Inch Series). October 2010.
Page | 64
[28]
Boggs, D., and J. Dragovich. "The Nature of Wind Loads and Dynamic Response." PBD
of Concrete Buildings for Wind Loads SP-2402.
Quintana, Juan. "Philips Lighting." What Is Effective Projected Area (EPA). Philips, 31
[29]
Jan.
2012.
Web.
Sept.
2015.
Retrieved
from:
http://www.lumec.com/blog/index.php/2012/01/31/what-is-effective-projected-area-epa/.
[30]
Lighting Column. Galvanized steel lighting column with powder coating. Ligman
Lighting. February 2014, FM-MA-16/14
[31]
Pole-AMACT-SMACT. Truss Arm; Metal, Fiberglass or Concrete Poles .Lithonia

Lighting. July 2011.
Page | 65
9.0 APPENDICES
9.1 Appendix A - Calculation
9.1.1 Resultant Force
From arm towards beam. Assume downwards positive, a maxed bulb load of about 500 N
is placed. Tension acts on the cable towards the pulley. Must find reaction force at the hinge part.
500 + 200(9.81) 2462 - 0.1222
=0
(1)
Now consider moment about the hinge, point 0.
500(10m) + 200(9.81)(5m) 14810 0.61
=0
(5m) = 0
(2)
24278.68 N
Substitute at equation (1)
Page | 66
9.1.2 Bending stress
360.81 Mpa
Safety factor =
Safety factor =
9.1.3 Shear stress at arm

15.95 Mpa
Safety factor =
Safety factor =
9.1.4 Shear stress at pin

683135.46 pa
Safety factor =
Page | 67
9.1.5 Pulley analysis

There are three forces acting on the pulley due to the tension force
Must obtain
0.9397
+ 0.3420
= -14638.33
(3)
+ 0.9397
= -19269.4
(4)
0.3420
Page | 68
9.2 Survey on Street Light in Malaysia
Page | 69
66.7%
Page | 70
Page | 71
9.3 Standard Bolt and Nut by ANSI/ASME
Table 5.2.1: American National Standard and Unified Standard Hex and
Heavy Bolts (ANSI/ASME B18.2.1-1996) 1 [23]
Page | 72
Table 5.2.2: American National Standard and Unified Standard Hex Nuts and
Jam Nuts and Heavy Hex Nuts and Jam (ANSI/ASME B18.2.1-1996) 1 [23]
Page | 73
9.4 Pole Standard from Tenaga nasional Berhad, TNB and Telekom Malaysia, TM
No.
Pole Type
Loading Class
Pole Length
Planted Length from GL
DSSB-PTP 750L
7.5
1.35
DSSB-PTP 900L
1.5
DSSB-PTP 900M
1.5
DSSB-PTP 900H
1.5
DSSB-PTP 110M
11
1.7
DSSB-PTP 110H
11
1.7
DSSB-PTP 110XH
XH
11
1.7
DSSB-PTP 135M
13.5
1.95
DSSB-PTP 135H
13.5
1.95
10
DSSB-PTP 135XH
XH
13.5
1.95
Table 5.2.3: Pole Type [22]
9.5 Technical Drawing
The technical drawing of the design can be found in the remaining pages of this report.
Page | 74
SEE DETAIL C
ITEM
NO
SEE DETAIL A
SEE DETAIL B
13
PART NUMBER
QTY
ARM1
ARM2
BOLT_M15X1X50MM
BOLT_M25X2X140MM
BOLT_M50X3X160MM
CLAMP
HINGE
LIGHT_CASING
NUT_M15X1X15MM
10
NUT_M25X2X10MM
11
NUT_M50X3X30MM
12
POLE
13
ROLLER
12
SEE DETAIL D
DRAWN BY:
TUNKU ATIQAH BINTI TENGKU HAMNET
ME090330
SECTION:1
DATE:
06/09/2015
UNLESS STATED
OTHERWISE
ALL DIMENSION IN mm
TOLERANCE:
LINEAR:
ANGULAR:
MATERIAL
STEEL
FINISH
AS MACHINE
CHECKED BY:
NURUL AMIRAH BINTI RAMIZAN
ME090810
UNIVERSITI TENAGA NASIONAL
SYSTEM FULL ASSEMBLY

SCALE:NTS
DWG NO.1
SHEET 1 OF 18
FRONT VIEW
50
A
TOP VIEW
150
SECTION A-A
3
SIDE VIEW
ITEM
NO
200
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STEEL
FINISH
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CHECKED BY:
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PART NUMBER
QTY
BOLT_M50X3X160MM
NUT_M50X3X30MM
POLEA
ROLLER
DETAIL A PULLEY
SCALE:NTS
DWG NO.1
SHEET 2 OF 18
100
60
180
5
40
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STAINLESS STEEL
FINISH
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CHECKED BY:
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ROLLER
SCALE:NTS
DWG NO.1
SHEET 4 OF 18
PITCH3
50
50
130
35
DESCRIPTION
30
QUANTITY
DIAMETER
50MM
HEXAGON
50MM
LENGTH
130MM
THREAD
35MM
PITCH
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3.0
BOLT M50X3X130MM
SCALE:NTS
DWG NO.1
SHEET 5 OF 18
50
50
PITCH3
DESCRIPTION
30
QUANTITY
DIAMETER
50MM
HEXAGON
50MM
LENGTH
30MM
PITCH
DRAWN BY:
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SECTION:1
DATE:
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UNLESS STATED
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STAINLESS STEEL
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CHECKED BY:
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3.0
NUT M50X3X30MM
SCALE:NTS
DWG NO.1
SHEET 6 OF 18
BOTTOM VIEW
SECTION C-C
FRONT VIEW
B
30
SECTION B-B
ITEM
NO
25
C
C
SIDE VIEW
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STEEL
FINISH
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CHECKED BY:
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PART NUMBER
QTY
ARM_1
BOLT_M25X2X140MM
ELBOW
HINGE
NUT_M25X2X10MM
DETAIL B HINGE
SCALE:NTS
DWG NO.1
SHEET 7 OF 18
140
5
30
R12
50
30
25
20
90
150
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STAINLESS STEEL
FINISH
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CHECKED BY:
ME090810
HINGE
SCALE:NTS
DWG NO.1
SHEET 8 OF 18
30
80
80
1500
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GALVANIZED STEEL
FINISH
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ARM 2
SCALE:NTS
DWG NO.1
SHEET 10 OF 18
25
22
25
PITCH2
DESCRIPTION
130
QUANTITY
DIAMETER
25MM
HEXAGON
22MM
LENGTH
130MM
THREAD
25MM
PITCH
DRAWN BY:
ME090330
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DATE:
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UNLESS STATED
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ALL DIMENSION IN mm
TOLERANCE:
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ANGULAR:
MATERIAL
STAINLESS STEEL
FINISH
AS MACHINE
CHECKED BY:
ME090810
2.0
BOLT M25X2X130MM
SCALE:NTS
DWG NO.1
SHEET 11 OF 18
22
25
PITCH2
DESCRIPTION
10
QUANTITY
DIAMETER
25MM
HEXAGON
22MM
LENGTH
10MM
PITCH
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STAINLESS STEEL
FINISH
AS MACHINE
CHECKED BY:
ME090810
NUT M25X2X10MM
SCALE:NTS
DWG NO.1
SHEET 12 OF 18
FRONT VIEW
SECTION A-A
R50
30
150
30
A
50
SIDE VIEW
DRAWN BY:
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TOP VIEW
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TOLERANCE:
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STEEL
FINISH
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CHECKED BY:
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ITEM
NO
PART NUMBER
QTY
ARM 1
LIGHT_CASING
DETAIL C CASING
SCALE:NTS
DWG NO.1
SHEET 13 OF 18
50
20
80
R50
10
R100
50
300
R30
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PLASTIC
FINISH
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LIGHT CASING
SCALE:NTS
DWG NO.1
SHEET 14 OF 18
SIDE VIEW
FRONT VIEW
SECTION A-A
15
3
70
80
15
4
150
ITEM
NO
30
5
2
TOP VIEW
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ANGULAR:
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STEEL
FINISH
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CHECKED BY:
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PART NUMBER
QTY
ARM2__
BOLT_M15X1X50MM
CLAMP
NUT_M15X1X15MM
POLE__
DETAIL C CLAMP
SCALE:NTS
DWG NO.1
SHEET 15 OF 18
100
150
15
4.4
17.5
17.5
50
R85
R40
15
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CLAMP
SCALE:NTS
DWG NO.1
SHEET 16 OF 18
15
15
15
PITCH1
DESCRIPTION
50
15
QUANTITY
DIAMETER
15MM
HEXAGON
15MM
LENGTH
35MM
THREAD
15MM
PITCH
DRAWN BY:
ME090330
SECTION:1
DATE:
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STAINLESS STEEL
FINISH
AS MACHINE
CHECKED BY:
ME090810
1.0
BOLT M15X1X50MM
SCALE:NTS
DWG NO.1
SHEET 17 OF 18
15
15
PITCH1
DESCRIPTION
15
QUANTITY
DIAMETER
15MM
HEXAGON
15MM
LENGTH
15MM
PITCH
DRAWN BY:
ME090330
SECTION:1
DATE:
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TOLERANCE:
LINEAR:
ANGULAR:
MATERIAL
STAINLESS STEEL
FINISH
AS MACHINE
CHECKED BY:
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1.0
NUT M15X1X15MM
SCALE:NTS
DWG NO.1
SHEET 18 OF 18

Design optimization of street light hinges

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Design optimization of street light hinges

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Department of Mechanical Engineering

Universiti Tenaga Nasional

MEMB483 Capstone Design

Group Name: Acqintosch (Group AG)

Tunku Atiqah binti Tengku Hamnet

Acqintosch Sdn. Bhd.

1.2 Project Description

1.3 Project Objectives

1.4 Original System

Location: Malaysia [7]

Table 1.4 (a): Type of existing street light design

Material: Aluminum/concrete/galvanized metal to sustain longer life

span from corrosion caused by surroundings.

streetlight firm together.

Function: To protrude the light bulb closer to the streets so that

Design: Length of arm is short. Fixed support is based on two

Refer description for short arm.

Refer description for short arm.

that streets are well illuminated.

Design: Length of arm is moderate. Fixed support consists of two

and on the arm at the other end to give additional support.

Refer description for short arm.

Refer description for short arm.

Function: To protrude the light bulb closest to the streets to give

optimum illumination of light to the streets.

1.4.1 Original System Operation

1.4.2 Original System Performance

Whilst such road lights may be proficient in numerous operational circumstances,

The least impact on residence and facilities

The material has ability to undergo permanent deformation without

Long term life span of the light and other component

Maintenance should be conduct after 1 week, one month, 6 months,

and annually thereafter after installation

Easy for installation

The component are low weight

Strong structure to withstand weight of long arm

Table 2.1: Customer Requirement Descriptions

2.2 Engineering Requirements

Easy to assemble and

All the mechanism and parts should be

simple with minimal component where

Low cost but high mechanical

design able to manufactured and assembled

Wattage of each light

The wattage range will be from 50W to

Voltage drop to last light

400W. Standard voltage is 120V.

Life span of mechanism should

Each material or parts of mechanism are

be the longest period with or

Having low cost but high properties of

material should be the best option.

Able to twist and bend from

The strength of material includes the

electrical and mechanical system. The

High tensile strength

material chosen should be designed in

Can bear capacity even after

considering the ability of flex strength and

can tolerate the weight of load without

suffering deformation or breaking.

The highest temperature in Malaysia history

mechanism and components