ABSTRACT
India is presently is in need of technology in the agricultural
field. The farmers face a lot of problem in extracting the grains
(seeds) from the crops (harvest) i.e., the huge yield. The farmers
need to do all the segregating processes manually which is a
cumbersome task for them and also this increases the cost of the
final products. The low quality in the products can be attributed
the impediment in the use of technology for the agricultural
purposes. Taking the example of separating the corn grains as known
is a very cumbersome and time taking process when to be done on a
large scale. This consuming of time can be reduced to a
considerably large extent by the use of a corn de-seeding machine.
This machine de-seeds the corn in a mechanical way thereby reducing
the time required.The productivity of the single machine is
increased than the existing machine. If we try to manufacture this
machine in mass production the cost of the machine could be reduced
optimally. In this Compact High Production Corn De-Seeding Machine,
the de-seeding of corn takes place by shearing action between
Casing and Spikes welded to the Drum, the clearance maintained
between the Spikes and Casing is in such a way that increases
initially from the hopper end and it gradually decreases to the of
casing.
CONTENTS
Sl. NoTITLEPage
Chapter 1Introduction
Chapter 2Objective
Chapter 3Literature Survey
Chapter 4Presently used Machine
Chapter 5Machine
Chapter 6Selection of Design Criteria
Chapter 7Design Procedure
Chapter 8Design Calculation
Chapter 9Fabrication
Chapter 10Advantages
Chapter 11Disadvantages
Chapter 12Applications
Chapter 13Cost Estimation
Chapter 14Expenditure
Chapter 15Conclusion
Chapter 16Reference
Chapter - 1INTRODUCTION In todays industrial world mans
innovative ideas has taken him towards all directions concerning
about the production and safety in industrial establishments. Some
instruments are of shear excellence where as others are the result
of long research and persistent work, but it is not the amount of
time and money spends in the invention of device or the
sophistication of it operation is important, but its convenience,
utility and operational efficiency that are important in
considering the device.
India is presently is in need of technology in the agricultural
field. The farmers need to do all the segregating processes
manually which is a cumbersome task for them and also this
increases the cost of the final products.
Here is a device which is based on scientific principles of
machines. It is simple, cheap and maintenance free that is produced
as result of this project work. The corn de-seeding machine can use
in areas like mills etc. This device can cut the grains and
separates the cub.
The existing methods of corn husking in agriculture industry
consists of breaking the grains by hand the pieces, both of which
are not effective and time consuming expose. Safety being a prime
consideration, an innovative idea such as this would go long way in
solving this simple but serious problem.
As for as cost aspects is concerned it works much cheaper as
compared to human labor, since the major component is rotating drum
and casing arrangement. The size of machine is important feature in
considering the capacity of the device.
The operating cost of the device is low as it requires only a
single person to operate as compared to manual method. Its
maintenance cost is almost negligible as it requires only periodic
lubrication.
Basically there are machines for De-seeding the corns but they
are costlier enough so that small scale farmers cant afford it. To
overcome this, we thought of developing a machine for the same
purpose with minimum cost as far as possible.
And later we got the idea of making it automatic using the
Robotic Arm. This Machine with the cylindrical rotating drum with
spikes welded to it, removes the corn through the shearing action
between the Maize & spikes and Maize & casing. Robotic arm,
which is automatically controlled through microcontroller, is used
to feed the corn to the De-seeding machine at regular intervals of
time.
Chapter - 2OBJECTIVES OF THE PROJECT
To manufacture a machine which helps the Indian farmers who are
the backbone of national economy. To make a complete device which
reduce the human effort and cost of the machine. To make a device
this is suitable for small scale industries. Simple machine
construction and better features. Developing a machine which cuts
grains of the corn in less time. To make it affordable to the
common farmer. To make it compact in size. To make it portable.
Chapter 3LITERATURE SURVEY
Maize, known in many English-speaking countries as corn, is a
grain domesticated by indigenous peoples in Mesoamerica in
prehistoric times.
The Aztecs and Mayans cultivated in numerous varieties
throughout central and southern Mexico, to cook or grind in a
process called nixtamalization. Later, the crop spread through much
of the Americas. Between 170 and 1250 BC, the crop spread to all
corners of the region. Any significant or dense populations in the
region developed a great trade network based on surplus and
varieties of maize crops. After European contact with the Americas
in the late 15th and 16th centuries, explorers and traders carried
maize back to Europe and introduced it to other countries through
trade. Maize spread to the rest of the world due to its popularity
and ability to grow in diverse climates.
Maize is the most widely grown crops in the Americas with 332
million metric tons grow annually in the United States alone (40%
of the crop 130 million tons used for corn ethanol. Transgenic
maize made up 85% of the maize planted in United States in 2009.
While some maize varieties grow to 12 meters (39ft) tall, most
commercially grown maize has been bred for a standardized height of
2.5 meters (8.2 ft). Sweet corn has shorter than field-corn
varieties.
Fig. (1.1)
Fig. (1.2)
Maize stems superficially resemble bamboo canes and internodes
can reach 44.5 centimeters. Maize has a distinct growth from; the
lower leaves being like broad flags, generally 50-100 centimeters
long and 5-10 centimeters wide (2-4 ft by2-4 in); the stems are
erect , conventionally 2-3 meters (7-10 ft) In height, with many
nodes, casting off flag-leaves at every node. Under these leaves
and close to the stem grow the ears. They grow about 3 millimeters
a day.
The ears are female inflorescence, tightly covered over by
several layers of leaves, and so closed- in by them to the stem
that they do not show themselves easily until the emergence of the
pale yellow silks from the leaf whorl at the end of the ear. The
silks are elongated stigma as that look like tuffs of hair, at
first green and later red or yellow. Plantings for silage are even
denser, and achieve a lower percentage of ears and more plant
matter. Certain varieties of been bred to produce many additional
developed ears. These are the source of baby corn used as
vegetables in Asian cuisine.
Maize is facultative long-night plant and flowers in a certain
number of growing degree days>500 F (100 C) in the environment
to which it is adapted. The magnitude of the influence that long
nights have on the number of days that must pass before maize
flower is genetically prescribed and regulated by the phyto chrome
system. Photoperiodicity can be eccentric in tropical cultivars,
while the long-days characteristics of higher latitude allow the
plants to grow tall that do not have enough time to produce seed
before being killed by frost. These attributes, however, may prove
useful in using tropical maize for bio fuels.
The apex of the stem ends in the tassel, an inflorescence of
male flowers. When the tassel is mature and suitably warm and dry,
anthers on the tassel dehisce and release pollen. Maize pollen is
anemophilous (dispersed by wind) and because of its large settling
velocity most pollen falls within a few meters of the tassel. Each
silk may become pollinated to produce one karnel of maize. Young
ears can be consumed raw, with the cob and silk, but as the plant
matures (usually during the summer months) the cob becomes tougher
and the dries to inedibility. By the end the growing season, the
karnels dry out and become difficult to chew without cooking them
tender first in boiling water. Modern farming techniques in
developed countries usually rely on dense planting, which produce
one large ear per stalk.
Husk (or hull) in botany is the outer shell or coating of a
seeding. It often refers to the leafy outer covering of an ear of
maize as it grows on the plant. Literally a husk or hull includes
the protective outer covering of a seed, fruit or vegetable. It can
also refer to the exuvia of bugs or small animals left behind after
moulting.
De-seedingDe-seeding of corn is the process of removal of its
inner layers, leaving only the cob or seed rack of the corn.
Fig. (1.3)
De-seeding is the process of removing the hulls (or chaff) from
beans and other seed. This is sometimes done using a machine known
as a huller. To prepare the seeds to have oils extracted from them,
they are cleaned to remove any foreign objects. Next, the seed have
their hulls, or outer coverings or husk, removed. There are three
different types of de-seeding systems that can be used to process
soybeans: Hot De-seeding, Warm De-seeding and Cold De-seeding. Hot
De-seeding is the system offered in areas where beans are processed
directly from the field. Warm De-seeding is often used by
processors who import their soybeans. Cold De-seeding is offered to
plants that have existing drying and conditioning equipment, but
need to add De-seeding equipment to produce high protein meal. The
different De-seeding temperature options are different types of
production, beans and preparation equipment.
A huller or husker is an agricultural machine used to automate
the process of removing the chaffs and the outer husks of grain.
Throughout history, there have been numerous techniques to hull
rice, in more recent times the processes are mechanized, and the
machine is called a huller or rice huller. These machines are most
widely developed and used throughout Asia. The common idea is to
shake and have them collide and scratch each other and
container-walls, thereby loosening the outer husk and then blowing
the lighter husk away. Other methods pass the grains between rubber
rolls or other soft material, this is often less damaging to the
grains.
Types of Huller Rotary hullerThis type of the machine gets the
brown rice in good quality by a cylindrical sieve set inside the
body. Swimming hullerBy swimming a set of sieves, it separates the
brown rice. Mangoku-shiki hullerMangoku , sometimes called
Elec-Huller, was first developed during the Edo period of Japan and
is still the most efficient way of grading harvested rice.Most
modern hullers are driven by a motor, usually gasoline or electric,
and are fully automated, computer controlled food processing
systems.
CornhuskerA cornhusker strips the husks from the ears of corn.
In the USSR, the OPP-5 semi mounted machine is used. The husking
device consists of eight pairs of rollers: each member of each pair
turns toward the other. The pickup unit picks up the ears, and a
conveyer drops them into the husking device. The cleaned ears go
onto a sorting conveyer, where unhusked ears are removed manually
and put on the rollers for a second husking. Diseased and
underdeveloped ears are thrown out. An elevator drops the cleaned
ears unto a wagon or arranges them in a pile. The working parts of
are driven by the power takeoff of then tractor. The husker has a
productivity of 4-5 tons/hr. the husking device of corn-harvesting
combine has the same design. The cornhusker used outside the USSR
function similarly.Hold the stem at end of the husked ear of corn
and rest the tip of the ear on the bottom of a very large bowl.
Using a sharp paring knife to cut off corn karnels and let them
fall into the bowl. Be careful to cut just the karnels and not
include any of the tough, inedible cub. (Better, on fact, to leave
some karnel behind than to include some cob). Continue cutting
around the ear to remove all karnels.Cutting the karnels into a
bowl makes much less mess and makes it easier to hold the ear at an
angle that allows you to cut down around the ear safely.Seed Corn
is brought in from the field where the Hughes Husker performs the
task of anciently removing the husk from around the ear as well as
any filed trash. The husk free ear is then discharged from the
husking bed for further processing. Corn is fed into the in feed
hopper through the use of a metering tilt belt. The hoppers convey
the corn to the vibratory feed plan which creates an evenly
distributed flow of corn onto the husking bd. The husking bed is
comprised of a specific number of lanes that consist of two centred
shafts rotating against each other. Attached to these shafts are a
variety of different possible roll combinations that grab the husk
and remove it from around the ear. The husk free ear travels to the
end of the bed where it is conveyed away for further
processing.
Features It is easy to operate machine. Due to its large size,
output of the operation is high. It consists of rollers, separator,
weight pressing rollers etc. Speed of the roller is adjustable.
Normally the corn husker has air cooling system.
Mechanical OperationsIn the husking machine the paddy or rice is
fed into a husking chamber. The rollers present in the chamber
moves in opposite direction with different speeds. The corn is
husked when it is passed between the rollers. The pneumatic control
system in some of the husker machine ensures a uniform husking
ratio. The corn so husked is discharged into the aspirator which
separates the brown corn, husk and immature grains. The separated
grains are then separately discharged by the screw conveyors.
Chapter 4PRESENTLY USED MACHINEFig. (4.1)
Fig. (4.2)
Chapter 5THE MACHINE
Fig. (5.1)
WORKINGThe device is simple in operation consisting of following
parts Drum Spikes Casing Stand Motor Belt Shaft PulleysThe compact
high production corn deseeding machine is a simple in design and in
construction. In this machine the corn is deseeded from the cub by
shearing action between the drum spikes and casing.The power from
the motor which is been placed at the base of the machine is
transmitted to the Drum through V-Belt drive. The Speed ratio
between the Drum and the Motor is 1/4 using pulleys.The corn is
sent through the hopper provided on the top of the Compact High
Production Corn De-Seeding Machine. Then the corn descends through
the clearance which is been provided between the Drum spikes and
spiral casing up to the point of contact that takes between corn
cub and Drum spikes. Due to the high rotational force provided by
the Drum the corn shears between Drum spikes and Spiral casing
which has been fixed into the housing. The clearance which has been
provided between the Drum spikes and Spiral casing goes on
decreasing gradually from the top of the hopper to the end of the
Casing. Since clearance goes on decreasing from the hopper, the
different sizes of corn grains can be the De-seeded from the
cub.
Till the complete removal of the corn grains from the cub, the
Corn cub revolves around the Drum. After the complete removal
process, the cub is been ejected outside through the casing
end.This De-seeded cub and grains are been collected in the tray
which is been provided in front of the machine and there after the
corns and grains can be separated.
Chapter - 6SELECTION & DESIGN CRITERIA
General requirements of machine design High productivity
Ability to produce and provide required accuracy of safe and
size and also necessary surface finish
Simplicity of design
Safety and easy to control
Low cost
Design and process are simple
Good appearance
Light weight
Compact in size
Chapter 7DESIGN PROCEDURE
Before we proceed to the process of manufacturing, it is
necessary to have some knowledge about the project design. It is
essential to design the project before starting the manufacturing
without side effects, the product consists of
Functional design Product design Engineering design
Design procedure for a product:When a new product or their
elements are to be designed, a designer may proceed as follows:
1. Make a detailed statement of the problem completely; it
should be as clear as possible and also of the purpose for which
the machine is to be designed.
2. Make selection of the possible mechanism which will give the
desire motion.
3. Determine the forces acting on it and energy transmitted by
each element of the Machine.
4. Select the material best suited for each element of the
Machine.
5. Determine the allowable or design stress considering all the
factors that affect the Strength of the Machine part.
6. Identify the importance and necessary and application of the
machine.
7. Problems with existing requirement of the machine
productivity and demand.
8. Determine the size of each element with a view to prevent
undue distortion or breakage under the applied load.
9. Modify the machine element or parts to agree with the past
experience and judgment and to facilitate manufacture.
10. Make assembly and detail drawings of the machine with
complete specification for the materials and manufacturing method
i.e. accuracy, Surface finish etc.
COMPONENTS:
I. Mechanical frame and casing:
Fig. (7.1)
CONSTRUCTION: The dimensions of L-angle frame is 42x18x24 inches
(L x B x H). The curvature of casing is 12 inches, along the
circumference of the drum. Each rod of 14 inches are arranged
parallel. Two plane angles of 14.8 inches are been welded at the
bottom of the frame for motor position.
II. DRUMFig. (7.2)
CONSTRUCTION Diameter of the drum is 6.5 inch. Dimension of the
shaft Length 21 inch. Diameter 20 mm. Spikes length 1.5 inch. Are
arranged in zigzag fashion Pulley of diameter 6 inch is fixed at
the one end of the shaft. Side plates of diameter 7.5 inch and
thickness of 3mm are welded on both sides of drum.
III. Single Phase AC MotorFig. (7.3)
SPECIFICATION Capacity of the Motor = 1 HP= 0.748 KW Speed of
the Motor = 1750 rpm
Assembly:Fig. (7.4)
Drafting:Fig. (7.5)
Chapter - 8CALCULATION
Design of shaftA solid shaft rotating at 1450rpm is made of mild
steel. The shaft here is subjected to both bending moment and
torsional stresses. The ultimate shear stress of a mild steel shaft
from design data is 210Mpa. The safe load is 300N (30Kg). the shaft
length 560mm is subjected to bending moment and torsional
stresses.
Known data: Diameter of Drum = 6.5inch = 165mm Diameter of
Larger pulley, D2 = 6inch = 152mm Diameter of Smaller pulley =
1.5inch = 38.16mm Power of the motor = 1HP = 0.746KW Speed of the
Motor, N1 = 1750rpm
From speed ratio we have, D1N1 = D2N2.(8.1)D1/D2 = N2/N11.5/6 =
N2/1750N2 = 437.5rpm
Now to find torque we have,P = 2N2T/60.(8.2)0.746 =
2*3.142*437.5*T/60T = 0.01628 KN-m
Now force acting on drum, F = T/r.(8.3)F = 0.01628/0.1524F =
0.1068 KN
Bending Moment,BM = WL/4 .(8.4)BM = 0.1068*406.4/4BM = 10.85
KN-mm
From the general Bending equation we have,M/I = /y.(8.5)M*64/*d4
= F*d*4/*2*d2d3 = 32*M/Fd3 = 32*10.85/0.1068d = 14.814 mm.
Since we have chosen the diameter of shaft 25 mm, according to
calculation minimum diameter of shaft is 14.8 mm. Hence Design of
shaft is safe.
Design of open V-BeltCentre Distance, C = d1/2+d2/2+l.(8.6) =
1.5/2+6/2+14.5C = 18.25 inches C = 463.55 mm COMPACT HIGH
PRODUCTION CORN DE-SEEDING MACHINE
DEPT. OF MECHANICAL ENGINEERINGL = +{2}* L = +{2}*L = 3.3887
radians.
S = -{2}*S = -{2}*S = 2.8943 radians
Length of Belt,L = {4C2-(D2-D1)2}1/2+(D2L+ D1S)/2.(8.7) L =
{4*463.552-(152.4-38.1)2}1/2+(152.4*3.385+ 38.1*2.897)/2L =
920.027+313.1248L = 1233.152 mmL = 48.55 inches
Since we have the V-Belt of size 47-B. According to the design
of Belt calculation L=48.55 inches. To get the tension, the Belt
selected should be less than the Design value. Hence the design of
belt is safe.
Design of Angle:Due to the load of drum, casing, sheet metal and
self weight of angle, the angle may buckle in two planes at right
angles to each other and also the force acting on the frame due to
shearing action. For buckling of the vertical plane, the link
considered as hinged at the mid point and for buckling in a plane
perpendicular to the vertical plane, it is considered as fixed at
the middle and at both the ends.Here, the maximum load acting on
four links is equal to around 70Kg.F = 70Kg = 70*9.81 =
686.7NWhere, the load acting on each link, F1 = F/4 F1 = 686.7/4 =
171.67N
Assuming a Factor of Safety as 3 (Because as the angle is made
up of mild steel, which is a ductile material)The links must be
designed for buckling load
Buckling load = load acting on each link* factor of safety =
171.67*3 = 515.02N
Crippling load:As here both the links are fixed so crippling
load would beCrippling load = Wcr =42EI/L2.(8.8)
Where, Wcr = crippling load. E = Youngs Modulus of mild steel =
210Mpa I = Moment of Inertia L = Length of the link = 610.56mm
Moment of Inertia, I = (A1y1 + A2y2)/ (A1 + A2) .(8.9) A1 = b1t1
= 38.16*5 = 190.8mm2 A2 = b2t2 = 33.16*5 = 165.8mm2
Where, b1= 38.16mm, b2=33.16mm t1 = t2 = 5mm y1 = 2.5mm, y2 =
21.58mm I = ((190.8*2.5) + (165.8*21.58)) / (190.8+165.8) I = 11.37
mm4
Cross sectional area of the link, = t1* 2b1 .(8.10) = 5*2*38.16
= 381.6mm2
Crippling Load = (42*210*11.37)/(610.56)2 Wcr = 0.2528N
Design of Bearing:Bearings are used in this machine as a
supporting device of shaft and drum arrangement, which takes the
overall load acting on drum and other components and transmits to
angles. These bearings are made up of Babbitt material such as
lead-tin Babbitt, which have the good properties like
Conformability, Embedabilty.
Chapter - 9FABRICATION
1. L Angle (42 inch x 17.5 inch x 24 inch)Material: Mild
SteelOperation: Cutting, Welding, Grinding & Drilling.
2. Shaft (1 inch dia. x 22 inch long)Material: Mild
SteelOperation: Facing, Counter Boring & Step turning.
3. Drum (6.5 inch dia. x 12 inch long)Material: Mild
SteelOperation: Facing, Counter Boring & Turning.
4. Side Plate (8 inch dia. x 0.12 inch thick)Material: Polished
Steel.Operation: Marking, Grooving, Cutting & Welding.
5. Motor FoundationMaterial: Mild Steel.Operation: Marking,
Cutting, Welding & Drilling.
6. Pulleys (6 inch larger dia. & 1.5 inch smaller
dia.)Material: Cast Iron.Operation: Boring & Fitting.
7. Bearing (1 inch inside dia.)Material: Babbitt.Operation:
Fitting.
8. Spiral CasingMaterial: Mild steel.Operation: Cutting,
Grinding, Bending & Welding.
9. Sheet MetalMaterial: Galvanised Steel.Operation: Marking,
Punching, Cutting, Bending, Drilling & Welding.
Chapter - 10Advantages
The machine is in compact size. The power consumption is low.
Reliable to operate. Less time consuming. Maintenance cost is less.
High Production in less time (Capacity 100 to 150 kg per Hr) Any
size of corn can be De-seeded. Simple in Design and Fabrication. No
need of any safety device. Benefit for small and medium scale
farmers. The machine is also used as Mould Breaking Machine. There
is no damage of the corn grains.
Chapter - 11Disadvantages
Only dry corn can be de-seeded.
Continuous power supply.
Chapter - 12Applications
Used in agricultural field.
Used in mills.
The device can be very helpful to small scale farmers and
domestic purpose.
This machine can also be used as Mould breaking machine.
Chapter - 13COST ESTIMATION
Cost estimation may be defined has process of forecasting the
expenses that must be incurred to manufacture a product this
expenses take into consideration of all expenses involved in a
design and manufacturing with all related service facilities such
as pattern making ,tool making has well as a portion of the General
Administrative and selling cost .
Purpose of cost estimating1. To determine the selling price of
product for a quotation or contract so as to ensure a reasonable
profit to the company.2. Check the Quotation supplied by vendors.3.
Determine the most economical process or material to manufacture
the product.4. To determine standards of production performance
that may be used to control the cost.
Basically the overall cost estimation involves 1. Material
cost.2. Machining cost.
Material cost estimation Material cost estimation gives the
total amount required to collect the raw material which has to be
processed or fabricated to design size and functioning of the
components. This material are divided into two categories1)
Material for fabricationIn this material is obtained in raw
condition and is manufactured or processed to finished size for
proper functioning of the component.2) Standard purchased parts
These include the parts which are readily available in the market
like Allen screws etc. a list in for chard for estimation stating
the Quality, size and standard parts, the weight raw material and
cost per kg for fabricated parts.Machining cost estimation This
cost estimation is an attempt to forecast the total expenses that
may include manufacturing apart from material cost. Cost estimation
of manufactured parts can be considered is judgement on and after
careful consideration, which includes labours, material and factory
services required to produce the required part.Procedure for
calculation of material cost.The general procedure for calculation
of material cost estimation is;1. After designing a project, a bill
of material is prepared which is divided into two categoriesa.
Fabricated componentsb. Standard purchased components2. The rates
of all standard items are taken and added up.3. Cost of raw
material purchased taken and added up
Chapter - 14EXPENDITUREMaterial Cost
Sl NoParticularsMaterialQuantityCost in Rs
1Single phase Motor-1 Nos2500
2L-Angles(30 kg)MS2 Nos1200
3DrumMS1 Nos1000
4SpikesMS114 Nos200
5Big PulleyCI1 Nos350
6Small PulleyCI1 Nos80
7BeltLeather1 Nos250
8Plumber BlockHSS2 Nos800
9Rod and Metal PlateMS1 and 2 Nos 350
10Nut and BoltsMS75 Nos120
11AxelsPolished Bar2 Nos180
12WheelsRubber4 Nos600
13Sheet MetalGalvanized steel2 Nos1500
14Electrical--100
Process Cost
1Machining--500
2Drilling--200
3Welding--1000
4Painting--300
5Sheet Metal Work--500
6Casing Arrangement--200
7Miscellaneous--2000
Total13,930 /-
Chapter - 15CONCLUSION
Huge weighted bulky construction is reduced to cost effective
and innovative alteration which gives sufficient output. Which
intern helps the farmers by minimum use of resources. The
automation makes the device quite simpler for handling as well as
for working. Design and fabricated seed removal mechanism from
Maize is easier.
Chapter - 16REFERENCEAll the design formulae and other
essentials are extracted from the following books.
Theory of machine....By R. S. Khurmi & B. C. GuptaMachine
Design data hand book..By H. G. Patil & Dr. K. LingaiahWorkshop
Technology.By Hazara ChoudhriProduction technology.By R. K.
JainMachine Design elements 1 & 2By Bandari
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