Mechanism Testing and Modeling of Teff Harvesting Machine 0

Mechanism Testing and Modeling of Teff Harvesting Machine

Researchers:-

1. Mesay Alemu (MSc)

2. Getachew Shunk (MSc)

MECHANICAL ENGINEERING DEPARTMENT INSTITUTE OF TECHNOLOGY JIMMA UNIVERSITY

July, 2013

Principal Writer Institute coordinator for Research, P, GS&C

Mechanism Testing and Modeling of Teff Harvesting Machine 1

Contents 1. Executive summary of the project ........................................................................................................ 2

2. Background and Justification ................................................................................................................ 2

3. Objectives of the project ....................................................................................................................... 4

4. Review of literature ............................................................................................................................... 4

5. Materials and Methods .......................................................................................................................... 7

6. Expected output/outcome ...................................................................................................................... 8

7. Time schedule ....................................................................................................................................... 8

8. Duration ................................................................................................................................................ 9

9. Facilities and funding ............................................................................................................................ 9

10. Budget ............................................................................................................................................... 9

11. References ....................................................................................................................................... 11

Mechanism Testing and Modeling of Teff Harvesting Machine 2

1. Executive summary of the project

Teff is the principal food source of the majority of the Ethiopian population. This makes Teff to be one of the important cereals at global level presently and for the future. Despite these facts, the production of Teff in Ethiopia has been in an extremely traditional way for centuries. This research project focuses on designing and manufacturing of a portable and small scale (that can replace 120 persons) Teff harvesting machine that is cost-wise affordable by the local community. The main objective of the project is improving the traditional Teff harvesting process by making our farmers beneficiary of a harvesting machine that saves energy, time and money and helps them in increasing the harvesting efficiency.

2. Background and Justification

Ethiopia is one of the countries with agriculture as a backbone of their economy. The majority of the export products come from agriculture. It accounts for about 80% employment of the population.

Figure 1 Teff Plant

Teff is among the plenty crops grown in the country and it has been the principal ingredient in the diet of the population. It accounts for about two-third of the daily protein intake in the diet of the Ethiopian population (Ethiopian Nutrition Survey, 1959). A number of wheat and barley harvesting machines have been existed for quite a long time but they have not been suitable for teff harvesting . The progress in improvement work on teff has not been developed as on other major cereals consumed in the worldwide.This is mainly due to the fact that teff is originated and mostly consumed only in Ethiopia. Even also in Ethiopia researches are not done on the teff harvesting yet. Despite being more important cereal in Ethiopia, teff harvesting is highly traditional. Farming is based on small scale fragmented pieces

Mechanism Testing and Modeling of Teff Harvesting Machine 3

of land. It is oriented to satisfy family level needs due to lack of farm machinery that fit with framers economy.

Like for any other crop, the production processes, Figure 2, of Teff in Ethiopia are extremely traditional and, hence, very tedious, time consuming and less efficient. Among these tiresome production processes is the harvesting.

Figure 2 Main Teff Production Processes Traditional harvesting is carried out by grasping the Teff plants in one hand and cutting them with the sickle near the base of the plant, Figure 3.

Researches indicate that eight to twelve people can harvest Teff on land of about 2000-2500 m2 in one working day (Alemayehu Refera, 2001). This is extremely small area and makes the farmers to waste long time for harvesting. The long harvesting time, in turn, makes the Teff production susceptible to wastage aggravating the low life standard of our farmers.

In general, the traditional production process has lots of drawback.

Production is very tedious and it makes the lives of our farmers extremely boring. It takes long time to work on a very small land area. There are lots of loss through each process which results in less efficient production.

Consequently, farmers produce less product enough only for their anual consumption and there will be scarecity of cereals in market. This in turn makes the cereals to be expensive. To overcome these problems, the majority of the population will be forced to remain farmers. This has a nagative impact on the new generation also as children are supposed to help their farmer families and will be obliged no to go to school. The collective effect of this is that the transition from agriculture driven economy to industry based economy of the country will be delayed.

Figure 3 Traditional Teff Harvesting in Ethiopia

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Then as citizens of the country and specifically as machanical engineers, we planned to contribute towards the activities of improving the life standards of our farmers through research and development. Our present research project focuses on aiding Teff harvesting process of our farmers by a machine that can replace about 120 persons. The main task is to design, test, manufacture and communicate to stake holders a small scale and less costly Teff harvesting machine.

3. Objectives of the project

The main objective of this research is to design and manufacture a small scale and less costly Teff harvesting machine in order to improve the traditional harvesting process. Specific objectives of the project:

Improve the boring life of our farmers that is brought about by the time and energy intensive Teff harvesting process.

Improve the efficiency of Teff production (increase productivity). To overcome the traditional methods of teff mowing for long years lied in our

country.

To incorporate teff harvesting machine in agricultural sector with aim of increasing

agricultural industry in Ethiopia.

Reduce cost of teff for society by reducing the effort and loss during teff harvesting

Developing new mechanism especial for teff harvesting that easy manufactured in

local industry

Testing the mechanism of new machine that will be produced from exist materials

Modeling and simulation of the analysis.

4. Review of literature

Ethiopia, a landlocked country in the Horn of Africa, is located at 8.0 N and 38.0 E (The World Fact Book 2002). The altitude of Ethiopia on average is about 2000 m above sea level. This is a more appropriate environment for maximum Teff production. The total land area of the country is 1.1 million km2 and m o r e than 80% of the Ethiopian population is dependent on agriculture where c r o p production plays a significant role (Bureau of African Affairs, 2006). Agriculture contributes to 47% of the countrys GDP and contribution of teff products to the agricultural economy is increasing from time to time. The country has long-standing history with traditional agricultural and a reasonably good resource potential for development of agro-industries. Teff is a very important crop in Ethiopia. Its production exceeds that of most other cereals. Each year, Ethiopian farmers plant almost 1.4 million hectares of Teff and they produce 0.9 million tons of grain or about a quarter of the country's total cereals (Lost Crops of Africa: Volume I: Grains, 1996). Researches indicate that Teff has long been produced for food in other countries like Yemen, Kenya, Malawi, and India. Also, the plant is widely grown as forage for grazing animals in South Africa and Australia.

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Commercial production of Teff has begun in both the United States and South Africa, and international markets are opening up. There are different types of mechanical harvesting tools, suitable for crops harvesting with

their limitations as mentioned below.

A. Serrated blade sickle

It has a serrated curved blade and a wooden handle. The handle of improved sickle has a bend at

the rear for better grip and to avoid hand injury during operation. Serrated blade

Figure 3 Serrated blade sickle B. Reapers

Reapers are used for harvesting of crops mostly at ground level. It consists of crop-row-divider,

cutter bar assembly, feeding and conveying devices.

Reapers are classified on the basis of conveying of crops as given below:

1. Vertical conveying reaper windrower

It consists of crop row divider, star wheel, cutter bar, and a pair of lugged canvas conveyor belts.

This type of machines cut the crops and conveys vertically to one end and windrows the crops on

the ground uniformly. Collection of crop for making bundles is easy and it is done manually.

Self-propelled walking type, self-propelled riding type and tractor mounted type reaper

windrowers are available. These types of reapers are suitable for crops like wheat and rice.

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Figure 4 Vertical conveying reaper windrower 2. Horizontal conveying reapers

This type of reapers are provided with crop dividers at the end cutter bar (crop gathering reel)

and horizontal conveyor belt.

They cut the crop, convey the crop horizontally to one end and drop it to the ground in head-tail

fashion. Collection of crop for making bundles is difficult. This type of reapers is tractor

mounted and suitable for wheat, rice, soybean, and gram.

3. Bunch conveying reapers

This type of reapers are similar to horizontal conveying reapers except that the cut crop is

collected on a platform and is being released occasionally to the ground in the form of a bunch

by actuating a hand lever. Here, collection of crops for making bundles is difficult. The cutting

unit of this type of reapers may be disc type or cutter bar type. After cutting, the crop is

conveyed vertically to the binding mechanism and released to the ground in the form of bundles.

Reaper binders are suitable for rice and wheat.

Figure 5 Bunch type Reaper

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4.Combines

Various designs of combine harvester having 2 to 6m long cutter bar are commercially available.

The function of a combine harvester is to cut, thresh, winnow and clean grain/seed. It consists of header unit, threshing unit, separation unit, cleaning unit and grain collection unit. The function of the header is to cut and gather the crop and deliver it to the threshing cylinder. The reel pushes the straw back on to the platform while the cutter bar cuts it. The crops are threshed between cylinder and concave due to impact and rubbing action. The threshed material is shaken and tossed back by the straw rack so that the grain moves and falls through the openings in the rack onto the cleaning shoe while the straw is discharged at the rear. The cleaning mechanism consists of two sieves and a fan. The grain is conveyed with a conveyor and collected in a grain tank.

Figure 6 Combined Harvester

The biggest problem with Teff harvesting is related to the fact that it lies on the ground after getting ripe. Therefore, the market available reaping machines are not suitable for harvesting Teff. They are suitable only for standing crops like Barley, Wheat and others. To the best of our knowledge (as has been tried to scan literatures), the presence of any Teff harvesting machines in Ethiopia (either manufactured or imported) has not been reported to the date. Even those Teff harvesting machines available abroad are used to harvest teff while it is standing (before the crop gets ripe). The Teff obtained here is used for forage. Therefore, this project aims at designing and manufacturing a Teff harvesting machine suitable for reaping the lying crop and put it in an orderly manner so that the crop will dry properly.

5. Materials and Methods

To achieve the objectives mentioned, the following methodologies will be followed. 1. Collecting data necessary for the design analysis from field.

2. Conceptual design of different alternative mechanisms will be made.

3. Detail design of components will be made.

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4. Elements outline design will be made; the best elements and the best mechanism will be

chosen

5. Animation and simulation of static and dynamic analysis to validate the components by

using soldwork and ANSYS software.

6. Material is selection based on analysis result.

7. Calculating the power that required for the machine.

8. Performing Engineering judgment on the size obtained.

9. Purchasing the equipments as per the specification

10. Once the required components purchased and then manufactured at mechanical

engineering workshop at Jimma University, disseminate to the community.

6. Expected output/outcome

The following outputs/outcomes are anticipated after completion of the project.

Saving in the time and energy of farmers during harvesting. Increased productivity. Comfortable harvesting. Reduced number of persons involved in harvesting. Reduced loss of grain due to fast harvesting during bad season. Reduced gap in the area of locally manufacturing machineries.

According to the information from agricultural office and experience we have, it requires 50 laborers to reap 1 hectare of land covered by a teff per day (8hrs). It is anticipated that the teff harvesting machine travels 3km per hour. The blade of the teff cutter is 1m wide. Therefore, it can be collected 3000mX1m = 3000m2 area of land covered by teff per her. The teff can reap for about 8hrs per day. i.e. 3000m2x8 = 24000m2. Therefore, the teff harvesting machine can cover an area of farm land equivalent to 120 laborers per day. The minimum payments for one labour 50 birr per day then 120 labours 50x120=6000 birr per day have to pay 24000 areas of land to cover but harvesting machine for fuel expenditure maximum 43.20 birr per day to cover 24000m2 areas.

7. Time schedule

S.No Activity Month 1 2 3 4 5 6 7 8 9

1 Detailed Design and Simulation 2 Material Procurement 3 Fabrication and Assembly 4 Testing and Correcting Shortcomings 5 Communicating to the Community 6 Preparing Report

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8. Duration

The project duration is nine months beginning in October.

9. Facilities and funding

Jimma University with its unique community based education viewpoint encourages research activities. As a pioneer research oriented department of our institute, the mechanical engineering department will hopefully allow us to use all the machineries available to undertake the research, especially in manufacturing the necessary components. Most of the components of the machines can be manufactured in the workshop of our department; generator and few components will be purchased.

10. Budget

TRAVEL COSTS (Data collection, purchase the equipments, per-diem and load/unload)

Number of persons

Distance Type of transport

Total cost of Transportation (Birr)

Five A.A & Jimma Land 4000

Personnel costs

Task Qualification Number of Personnel

Payment/day (Birr)

No of days Total (Birr)

Designers MSc 2 210 20 8400 Manufacturer Technical 2 100 25 5000

Total 13400

Stationary

S.No Items Total (Birr) 1 Stationary Cost Paper, Pen,

Pencil, Photocopy , flash Disk, and etc.

1200

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Cost Analysis of Materials, Equipment and Supplies

S.No Material type Estimated Size Quantity Unit Cost (birr)

Cost(birr)

1 Sheet metal 2000*1000*4 3 800 2400 2 Sheet metal ----------- 1 600 600 3 Angle iron ------------- 2 350 700 4 shaft 2 1250 2500 5 Electrode ------------ 2 200 400 6 Metal plate ---------------- 3 1350 4050 7 Pulley ------------ 8 500 4000 8 Bevel gear ------------ 3 900 2700 9 Tube ------------ 1 400 400

10 Paint and rust resistance paint 2 150 300 11 Epoxy ---------- 1 80 80 12 Rivets Do=4 1 packet 200 200 13 Metal Spring ----------- 4 300 1200 14 Belt ----------- 10 180 1800 15 Tyre/ Wheell ----------- 4 3000 16 Conveyor Fiber material 1 1200 1200 17 Cast iron ----------- 1 1500 1500 18 Bolt and nut ----------- ---- 800 800 19 Ball Bearings ------------- 4 250 1000

Total 28,830

Personnel and miscellaneous Cost + traveling cost +Fabrication Cost (materials, equipment,

supplies) cost = 13400.00 + 1200.00 +4000.00 + 28830.00 =47430.00 Birr

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11. References

1. Anon. 1894. Tropical fodder grasses. Kew Bul. 95:378-380. 2. Anon. 1887. Teff (Eragrostis abyssinica). Kew Bul. 1:2-6. 3. Bekele, E. and R.N. Lester. 1981. Biochemical assessment of the relationship

of Eragrostis tef (Zucc) Trotter with some wild Eragrostis species (Gramineae). Ann. Bot. 48:717-725.

4. Bekele, E. 1985. A review of research on diseases of barley, tef, and wheat in Ethiopia, p. 79-108. In: T. Abate (ed.). A review of crop protection research in Ethiopia. Proc. First Ethiopian Crop Prod. Symp. Dept. Crop Protection, Inst. Agr. Res., Addis Ababa, Ethiopia.

5. Berhe, T. and D.G. Miller. 1976. Sensitivity of tef [Eragrostis tef (Zucc.) Trotter] to removal of floral parts. Crop Sci. 16:307-308

6. carts, Zimbabwe, 1992. John Palmer, Welding, Brazing, and Soldering; Arc Welding of Stainless Steels, American Society for Metals, Metals Park,

7. Kurt M.Marshek /Robert C.Juvinal, Fundamental of Machine Component Design. USA,1995, 3rd edition.

8. R.S.khurmi and J.K.Gupta, A text Book of machine design, India

Executive summary of the projectBackground and JustificationObjectives of the projectReview of literatureMaterials and MethodsExpected output/outcomeTime scheduleDurationFacilities and fundingBudgetReferences