Professional Documents
Culture Documents
MASTER OF TECHNOLOGY
in
DESIGN ENGINEERING
Submitted by
Dr. B. P. PATEL
Certificate
This is to certify that the thesis entitled Design, Analysis and Development of
Groundnut
Harvester
being
submitted
by
Mr.
Sangram
Shivajirao
Bhosale
Dr. B.P.Patel
Associate Professor
Department of Applied Mechanics
Indian Institute of Technology Delhi
Hauz-Khas, New Delhi-110016
Acknowledgements
I would like to thank my supervisor, Dr. B.P. Patel, for his valuable guidance, kind help
throughout completion of this project work. I would like to express my deep sense of gratitude
to him for supporting me throughout the year.
I would like to thank all the faculty and staff members of Applied Mechanics
Department who contributed by making provision for necessary arrangements and facilities. I
wish to express my thanks to friends for their heartiest co-operation in every stop of my project
work.
Lastly I would like to express deep gratitude to my father, Shri Shivajirao Bhosale for
his guidance, co-operation, understanding, moral support and constant encouragement which
inspired me to complete this thesis.
II
Abstract
The main objective of the project is to develop groundnut harvester considering needs
of Indian farmers. Among the field operations concerned with groundnut cultivation,
harvesting is the most laborious and costly endeavour. Existing harvesters are too huge to be
useful for small scale farmers and in scenario like multi-cropping. Initially survey of typical
groundnut farm field has been done followed by literature survey, patent study, kinematic
analysis, static analysis, fabrication, testing and design modifications. The developed
groundnut harvester is very cost effective and can also be used as tiller. By replacing the
existing teeth it can be used for harvesting other underground crops as well.
III
Table of Contents
Certificate .................................................................................................................................... I
Acknowledgements ................................................................................................................... II
Abstract ..................................................................................................................................... III
Table of Contents ..................................................................................................................... IV
List of Figures ..........................................................................................................................VII
List of Tables ............................................................................................................................ IX
Chapter 1 Introduction and Literature survey ........................................................................1
1.1 Introduction .........................................................................................................................1
1.1.1 Human uses...................................................................................................................2
1.1.2 Process description .......................................................................................................2
1.1.3 Conventional harvesting technique .............................................................................3
1.2 Literature survey .................................................................................................................3
1.2.1 PATENT US4607703 ...................................................................................................5
1.2.2 PATENT US4687064 ..................................................................................................6
1.3 Need of the product .............................................................................................................7
1.3.1 Land acquired by Indian farmers ..................................................................................7
1.3.2 Mixed / Inter / Multi-cropping......................................................................................7
1.3.3 Labour Cost ..................................................................................................................8
1.3.4 Any delay in harvesting causes huge loss ....................................................................9
1.4 AMP777 course work..........................................................................................................9
1.4.1 Problem statement ......................................................................................................11
Chapter 2 Design Upgradation ................................................................................................12
2.1 Different ways of processing.............................................................................................13
2.2 Updated designs ................................................................................................................14
2.2.1 Groundnut Harvester 1 (GH1) ....................................................................................14
2.2.2 Groundnut Harvester 2 (GH2) ....................................................................................15
IV
VI
List of Figures
Fig. 1 Global Peanut Production Distribution in 2011-2012 [2] ..................................................1
Fig. 2 Groundnut produced (metric tonne) in world verses Year [2] ...........................................2
Fig. 3 Schematic diagram of transmission shaft and fracture point for peanut harvester [6] .......3
Fig. 4 Groundnut digger cum separator [7] ..................................................................................4
Fig. 5 US Patent no. 4,607,703 .....................................................................................................6
Fig. 6 US Patent no. 4,687,064 .....................................................................................................7
Fig. 7 Sole crop yields and actual and expected intercrop yields of groundnut and millet [12]...8
Fig. 8 Primary design of TWGH and developed TWGH ...........................................................10
Fig. 9 Plain Shovel......................................................................................................................12
Fig. 10 Segmented Shovel..........................................................................................................12
Fig. 11 Bucket wheel excavator ..................................................................................................12
Fig. 12 Different possible ways of processing ............................................................................12
Fig. 13 Groundnut harvester 1 ....................................................................................................14
Fig. 14 Groundnut Harvester 2 ...................................................................................................15
Fig. 15 Groundnut Harvester 3 ...................................................................................................16
Fig. 16 Close View of GH3 rotor................................................................................................18
Fig. 17 Model for kinematic analysis in ADAMS ......................................................................20
Fig. 18 'X' coordinate of trajectory versus Time .........................................................................20
Fig. 19 Y coordinate of trajectory versus Time .......................................................................21
Fig. 20 Y coordinate of trajectory versus X coordinate of trajectory ....................................21
Fig. 21 X coordinates of trajectory versus Time ......................................................................22
Fig. 22 Y coordinates of trajectory versus Time ......................................................................22
Fig. 23 Y coordinates of trajectory versus X coordinates of trajectory .................................22
Fig. 24 Loading and boundary conditions on GH3 rotor assembly ............................................23
Fig. 25 Fixed edge boundary condition .....................................................................................24
Fig. 26 von Mises stress distribution in shaft region ..................................................................24
Fig. 27 von Mises stress distribution in the blade region ...........................................................25
Fig. 28 Fixed blade surface boundary condition .........................................................................25
Fig. 29 von Mises stress distribution in sectional view of shaft and ribs ...................................25
Fig. 30 von Mises stress distribution around blade surface ........................................................26
Fig. 31 NGH3 and GH3 rotor assembly .....................................................................................26
Fig. 32 von Mises stress distribution around shaft .....................................................................27
VII
List of Tables
Table 1 Existing patents regarding groundnuts [8] .......................................................................5
Table 2 Various intercropping systems.........................................................................................8
Table 3 Average Daily Wage Rate for Farm Labour (in Rs.)[13] ................................................9
Table 4 Components and their functions of GH1 .......................................................................14
Table 5 Components and their functions of GH2 .......................................................................15
Table 6 Components and their functions of GH3 .......................................................................16
Table 7 Comparative study of proposed designs ........................................................................17
Table 8 Shear strengths of different soil types [15] ....................................................................17
Table 9 Comparison of analytical and ADAMS results .............................................................23
Table 10 No. of elements used in different meshes (NGH3 twist) .............................................28
Table 11 No. of elements used in different meshes (NGH3 Shear)............................................30
Table 12 No. of elements used in different meshes twisting case for GH4 rotor assembly .......41
Table 13 No. of elements for different meshes shear case for GH4 rotor assembly ..................43
Table 14 Cost estimation for GH ................................................................................................48
IX
Chapter 1
Introduction and Literature survey
1.1 Introduction
Peanuts, or "groundnuts" as they are known in some parts of the world, are the edible
seeds and they are high in protein, oil and fibre. Peanuts are mostly used in food and
confection products, but more than 50 per cent of the worldwide production is crushed for its
oil [1].
Worlds total peanut production is approximately 29 million metric tons per year with
India being the worlds largest producer after China. Worldwide peanut exports are
approximately 1.25 million metric tons. The India is one of the worlds leading peanut
exporters, with average annual exports of between 200,000 and 250,000 metric tons.
Argentina and China are other significant exporters. Countries such as India, Vietnam and
several African countries enter the world market depending upon their crop quality and world
market demand [1].
The global peanut production distribution in 2011-2012 is given in Fig. 1 and yearly
production of groundnuts is given in Fig. 2.
temperatures ranging from 18 to 30C. The suitable vegetative growth temperature ranges
from 20 to 35C. However at 33C, this declines to 84%. The temperature favorable for
flowering and pod formation is about 28C. Rainfall of about 500-700 mm per annum will be
satisfactory for good yields of groundnuts. Wider rows are advisable in low rainfall areas
whilst the narrow rows are suitable in higher rainfall area [5].
1.1.3 Conventional harvesting technique:
Harvest is the process of gathering mature crops from the fields. Harvesting usually consists
of a series of operations comprising digging, lifting, windrowing, stocking and threshing.
Among the field operations concerned with groundnut cultivation, harvesting is the most
laborious and costly endeavour.
When the plant has matured and the peanuts are ready to be harvested, the farmer waits
until the soil is neither too wet nor too dry before digging.
The bunch type of groundnut is mostly harvested by pulling out the plants with manual
labour in India. Usually 18 to 20 labours can harvest half-acre area of groundnut crop in
one day.
Fig. 3 Schematic diagram of transmission shaft and fracture point for peanut harvester [6]
The power of peanut harvester was 43 HP and the rotational speed of transmission
shaft ranged from 75 RPM to 228 RPM in service. The diameter of transmission shaft was
40mm. According to the service condition, stress analysis of transmission shaft has been
conducted by analytical approach and finite element simulation using ANSYS. It has been
found that bending stress induced in the transmission shaft was 58 MPa, and shear stress 260
MPa. The shear stress resulted from torsion of transmission shaft. Because shear stress is
much larger than bending stress, the fracture of transmission shaft is in torsion condition. On
the basis of the examination of the fracture surface and stress analysis, they concluded that
the fracture mode of transmission shafts is torsional fatigue [6].
In another case study, Singhal [7] of Grassroots Innovations Augmentation Network
North (GIAN - North), has analysed Groundnut digger cum separator developed by
innovator Khan [7]. Developed digger cum separator is shown in Fig. 4.
The conventional ground nut diggers leave 15-20 % of nut beneath the soil and
additional manpower is required to avoid this loss. They only dig and cut groundnut crops
while the studied innovation digs out remaining 15-20% groundnuts and separates it from the
soil through the vibrating sieve. Khan [7] has developed a machine which is capable of
separating the pods from the soil that comes in the path on which it is moving, moreover it
does digging and filtering of the soil in one go.
Specifications of digger cum separator are
Traction vehicle:- Tractor (35HP or more)
Working width 6 feet
Working Depth 6 inches
Size 4ft x 6ft x 6ft
4
Patent No.
Patent Name
1.
2.
3.
4.
4,000,747
4,136,507
4,142,348
4,166,505
5.
4,188,772
6.
7.
8.
4,227,538
4,607,703
4,687,064
As one can observe from Table 1 that there are only two patents regarding harvesting
of groundnuts. The brief descreption of patent numbers US4607703 and US4687064 is given
in Fig. 5 and Fig. 6 respectively.
1.2.1 PATENT US4607703:
This patent was registered on 26th August 1986 by Wang [8] .This peanut harvester
includes truck body, two pairs of stalk straightners,two peanut diggers, a plant feeder, tilled
conveyor , a horizontal conveyer, a peanut stripper and a peanut collector. By using this
harvester soil can be automatically dug, lifted, stripped, screened and finally picked peanuts
are collected into the bags. Another advantage of this harvester is that it provides a harvesting
method through dividing the rows of peanut plants, straightening of stalks, digging peanuts
under soil, screening and removing dust of the stripped peanuts, finally conveying and
collecting the peanuts into bags for automatic integrated harvesting operation [8].
positioned back-to-back and synchronized with vehicle motion. The plant conveyor belts
carry the harvested plants rearward and upward to cause the roots of the plants containing the
peanuts to pass over a pair of picking elements. A plurality of toothed picking combs is
mounted transversely to the flat belts such that the combs move across the plant for
contacting the roots and stripping the peanuts. In addition to the harvesting and picking
system of this invention, Johnson [8] also provided blowing and shaking provisions for
removing dirt and debris from picked peanuts such that the stored peanuts would be relatively
clean.
the fertility of the soil and increases in crop yield. The products and refuse from one crop
plant help in the growth of the other crop plant and vice-versa. Mixed cropping is an
insurance against crop failure in abnormal weather conditions. It also helps the farmer to
improve its yield and economy and avoid crop failure which was very common in India and
Asian countries [11].
In the developing world, groundnuts are commonly grown in intercropping systems,
especially by small farmers who use traditional combinations often involving up to 5-6 crops
[11]. Moreover intercropping leads to increase in yield. Groundnut is generally intercropped
with sunflower, pigeon pea & millet. Few results of groundnut and millet intercropping are
given in Fig. 7. Various intercropping system are listed in Table 2.
Fig. 7 Sole crop yields and actual and expected intercrop yields of groundnut and millet [12]
has raised cost of production of agri-commodities across the board. No wonder, farmers
organizations have been demanding higher and higher minimum support prices (MSPs) to
cover increased costs of production [13].
Table 3 Average Daily Wage Rate for Farm Labour (in Rs.)[13]
Such high wages not only squeeze farmers margins, but also crimp availability of
labour. Above data shows that there is a need of automated machine which can minimize
labour cost incurred in harvesting.
1.3.4 Any delay in harvesting causes huge loss:
Conventional way of harvesting groundnuts is just holding and pulling the plant so
that we can pick groundnuts. There could be delay in harvesting due to any of following
reasons:
a) Prolonged /Extended / Unexpected raining
b) Unavailability of labour
c) Personal reason of farmer
Due to any of the above reason if harvesting is delayed then plant stem gets weaker
which we cant handle in traditional way & which finally results in huge loss to the farmer.
So, there is a necessity of machine which can dig out groundnuts even though upper plant
weakened.
A survey has been carried out in Satara , Maharashtra by taking into consideration 1
acre of farm field & following observations are made :
Maximum depth: 9 inch.
Max. dia. of spread: 9 inch.
Soil type: Soft soil (easily indented by fingers)
Average nuts: 40-100.
Weight of a plant with nuts: 300-600g.
Usual gap between two plants: 12-15 inch.
Crop period : 90 to 140 days.
10
11
Chapter 2
Design Upgradation
We had with us a Bajaj M80 4.5 bhp engine with gearbox and decided to use this
engine to develop Groundnut Harvester (GH). Based on the literature survey, existing
patent study and field survey the designed product should do following the processes:
a) Digging:
This can be done by various means like using curved blades or using drill.
12
13
This design is combination of A2, B1, B2 (refer Fig. 13). Different components and
their functions are described in Table 4.
Components
Rotor 1
Rotor 2
Chain drive
Engine
Conveyor belt
Box
1. Collecting pods.
2. Separating soil from pod.
Drawbacks:
a) To avoid falling back of groundnuts, segmented belt should be provided which will
increase cost of product.
b) Though in collecting it is more efficient than TWGH, assembly of many parts included
makes design bulky.
14
This design (Fig. 14) is inspired by old watermill (Rahat) which was pulled by bulls.
This design is a combination A2, A3, B2 and B3. Different components and their functions
are given in Table 5.
Components
Box
Bearings
Wheels
Main frame
1. Digging of groundnuts.
2. Transfer groundnuts from ground to box.
3. Separate soil cloud from pod.
1. Collecting pods.
2. Separating soil from pod.
1. To ensure smooth motion of shaft.
2. Support rotating shaft.
1. Provide mobility to design.
2. Support the main frame.
1. Acts as hub for all attachments.
2. Provide rigidity to harvester.
Drawback:
Certainly it is more efficient and reliable in digging/collecting than GH1, but it will
collect plant with soil cloud and would ultimately increase undesirable weight of groundnut
harvester.
15
This design (Fig. 15) is next version of GH without conveyor (GH3). To avoid
carrying undesirable weight of soil, horizontal conveyor belt is incorporated in between
cylindrical rotor and box. Different components and their respective functions are given in
Table 6.
Components
Cylindrical rotor
with blades
Conveyor belt
Bearings
Wheels
Main frame
Box
GH1
Inefficient in separation of
soil
Bulky structure.
GH3
of soil
Simple design
From the comparison given in Table 7, it is concluded that GH3 is most appropriate
solution to the problem.
25-60 MPa
Basalt
20-60 MPa
Slate
15-30 MPa
Quartzite
20-60 MPa
Sandstone
8-40 MPa
Shale
3-30 MPa
Limestone
10-50 MPa
Gravel
200-600 kPa
Sand
100-300 kPa
0-25 kPa
Soft clay
25-50 kPa
Medium clay
50-100 kPa
Stiff clay
100-200 kPa
200-400 kPa
Hard clay
17
Usually groundnut crop is taken in Medium or Soft soil [15], so considering factor of
safety , maximum shear stress () experianced by bucket wheel excavater will be 100 kPa.
From the design GH3 made in Catia V5,
Frontal area of bucket wheel= 0.052 m2refer Fig. 16
Side area= 0.004 m2 .refer Fig. 16
=>
Fmax = 5.2 kN
=>
=>
Nmin= 20 RPM
So the RPM to dig out typical groundnut farm field is 20 and mild steel is opted for
GH3 design because it is easily available and satisfies all desired constraints.
18
Chapter 3
Analysis of GH3
3.1 Kinematic analysis:
The kinematic analysis is carried out to find out the trajectory of the groundnut pod
for different angular velocities of rotor. The analytical calculations are validated using
ADAMS. By using simple formulae of projectile motion based on model designed in Catia
V5, feasible range of rpm is calculated. Using ADAMS software, maximum distance
travelled by groundnut pod is calculated for different speeds and compared with analytical
solution.
3.1.1 Analytical calculations:
Range is calculated by considering the size of conveyor belt. The groundnut pod must
fall on conveyor belt.
From model drawn in Catia V5,
Radius of rotor= 200 mm,
Blade length=100mm,
Pulley radius= 160mm,
Length of rotating platform =290mm.
Distance that should be travelled by groundnut pod 360mm
So the desired minimum velocity can be calculated as follows,
0.36 =
=>
=>
=>
v 2 sin 2
g
v=1.777 m/s
N = 80.56 rpm
v 2 sin 2
g
v= 2.048 m/s
=>
= 11.45 rad/sec
=>
N= 109.39 rpm
19
Weight of box = 0.5 kg(assumed weight of groundnut pod+ soil cloud 500gm )
Coefficient of restitution= 1
Idealized
Groundnut
Pod
Fig. 17 Model for kinematic analysis in ADAMS
Variation of position of pod (X coordinate) with respect to time is shown in Fig 18.
According to simulation done, pod lose contact with rotor after 0.15 sec. One can see from
the graph that after 0.15 sec, pod has travelled substantial distance and has settled down after
0.38 sec.
20
Variation of position of pod (Y coordinate) with respect to time is shown in Fig. 19.
According to simulation done, pod loses contact with rotor after 0.15 sec. One can see from
the graph that at 0.15 sec Y is maximum and it is least settled down after 0.38 sec. in Fig 19.
21
Variation of position of pod (Y coordinate) with respect to time is shown in Fig. 22.
According to simulation done, pod loses contact with rotor after 0.1 sec., one can see from
the graph that at 0.12 sec Y is maximum and it is least settled down after 0.28 sec. in Fig. 22.
3.1.3 Validation:
The maximum distance travelled by the pod, calculated analytically and in ADAMS is
compared in Table 9.
Table 9 Comparison of analytical and ADAMS results
Angular velocity of rotor
8.4rad /sec
11.45 rad/sec
Max. Distance travelled by pod analytically
0.36 m
0.59 m
0.353 m
0.60 m
As it can be seen that the results in both the cases compared in Table 9 are very close.
23
Boundary conditions:
Two separate boundary conditions are considered, in the first case only blade edge is
fixed and in the second case whole blade surface is fixed.
i) Edge of blade fixed:
In this boundary condition, only edge of blade is fixed as shown in Fig. 25.
Sectional view of shaft showing von Mises stress distribution is shown in Fig. 26. The
maximum von Mises stress induced in the shaft region is 977.5MPa.
The induced stresses around blade surface are shown in Fig. 27. The maximum von
Mises stress induced in blade surface is 226 MPa.
24
Sectional view of shaft is shown in Fig. 29. The maximum von Mises stress induced
in shaft is 974MPa.
Fig. 29 von Mises stress distribution in sectional view of shaft and ribs
25
The von Mises stress distribution around the blade is shown in Fig. 30. The maximum
von Mises stress induced in near the blade surface around the ribs is 221MPa.
26
Concentrated force of 48.75 kN is applied at the position shown in Fig. 24. From the
results shown in Fig. 26 and Fig. 29, one can easily conclude that boundary condition blade
edge fixed is more severe (max. von Mises stress = 977 MPa ) than that of blade surface fixed
(max. von Mises stress = 974 MPa). So while analysing NGH3 rotor assembly only blade
edge fixed boundary condition is taken into consideration.
Boundary condition blade edge fixed:
Stress distribution around the shaft is shown in Fig. 32. The maximum von Mises
stress induced in the shaft region is 752 MPa.
27
The von Mises stress distribution around the blade surface is shown in Fig. 33. The
maximum von Mises stress induced in the blade region is 236 MPa.
As average von Mises stresses induced in NGH3 rotor assembly are not that severe
(eqv < 250 MPa), NGH3 rotor assembly is considered for further analysis.
3.2.3 Convergence study for twisting case NGH3 rotor assembly:
The convergence study is carried out by refining the mesh. The stress values are
compared for different meshes at 13 points along a circular path in the shaft from region A
marked in Fig. 32. The number of elements in each mesh is given in Table 10. The stress
values at three different conditions are plotted in Fig. 34.
Table 10 No. of elements used in different meshes (NGH3 twist)
Mesh
No. of elements
Coarse
129170
Fine
233536
Finer
353846
28
3.00E+08
2.50E+08
2.00E+08
Fine mesh
1.00E+08
Finer
5.00E+07
0.00E+00
1
10 11 12 13 14
Point number
Fig. 34 Graph of von Mises stress versus Point number marked in region A (Fig. 32)
Fig. 35 Surface traction applied on blade surface and fixed shaft boundary condition
29
The von Mises stress distribution observed in sectional view of shaft is shown in Fig.
36. The maximum stress induced is 98.77 MPa.
132347
Moderate
226848
Fine
336475
7.00E+07
6.00E+07
5.00E+07
4.00E+07
Coarse mesh
3.00E+07
Moderate mesh
2.00E+07
Finer Mesh
1.00E+07
0.00E+00
1
10
11
12
13
Point number
Fig. 37 Graph of von Mises stress versus Point number marked in region A (Fig. 36)
30
Chapter 4
Fabrication, Assembly and Testing
Out of all parts of the groundnut harvester, rotor was the only part which could not be
fabricated in our workshop because of complexity involved in the fabrication of the proposed
model of rotor.
31
Fig. 40 Total assembled NGH3 rotor design and actual fabricated NGH3 rotor assembly
To minimize the eccentricity introduced due to welding, middle shaft OD has been
reduced to 32 mm from 35 mm using lathe machine and proper rotation of drum has been
ensured. Casted blade-hands are welded to the drum as shown in Fig. 40.
4.2 Trial 1:
Fabricated rotor is designed to fit in the old frame made in the course of AML777. So,
by fitting the rotor in the old frame, testing was carried out. Rotor fitted in frame is shown in
Fig. 41.
32
4.2.1 Observations:
When machine was without load, engine was capable of rotating the rotor. But when
it came in contact with the field soil wooden platform below the engine could not sustain the
thrust produced due to actuation of rotor and cracks on the wooden platform were observed
which made power transmission chain incapable of transmitting power to the rotor.
4.2.2 Causes of failure:
The plywood plate was underdesigned to hold engine while actuating rotor.
Old frame was not able to hold too heavy rotor (80 kg). Large wheels need to be
considered.
Rotor started to rotate at very high RPM and thus sudden acceleration could not be
sustained by plate and engine was also stopping.
Cracked plywood plate is shown in Fig. 42.
33
Chapter 5
Design Modifications, Analysis and Testing
Based on observations made while testing NGH3 rotor assembly following three
major modifications are made:
1. Weight reduction of rotor assembly
2. Static analysis of new rotor assembly
3. Frame analysis
4. RPM reduction
34
The redesigned assembly (refer Fig. 44) is analysed under static twisting case as
explained in section 3.2.1. From the analysis it is observed that the maximum deflection of
the teeth tip after loading is 2 mm. The results are shown in Fig. 45.
Fig. 45 Deflection distribution in rotor teeth without ribs under twisting case
To reduce the deflection, ribs are introduced in the curvature region of teeth. The
maximum deflection is reduced to 0.2 mm after introducing ribs as shown in Fig. 46.
Fig. 46 Deflection distribution in rotor teeth with ribs under twisting case
Step-wise design modifications in the rotor assembly are shown in Fig. 47.
35
Removal of
unnecessary
material
Removal of
unnecessary
material
Without ribs
(deflection 2
mm)
With ribs
(deflection
0.2 mm)
Modified
teeth
Fig. 47 Flow chart for design, modifications done in the rotor assembly
36
While analysing the rotor assembly significantly greater stresses ( 1225 MPa) are also
observed in shaft region as shown in Fig. 48.
From Fig. 49 one can clearly observe that supports provided to the sprockets from rib
region will obstruct the motion of rotor itself. To avoid this problem, the length of rotor is
37
reduced to 300 mm and instead of outside chain drive, it is taken in between the bearings.
The new proposed design (GH4 rotor assembly) is shown in Fig. 50.
Basic difference between GH4 and NGH3 is sprocket position. In the NGH3 design,
sprockets were supposed to fit outside the bearings but in the GH4 they are fitted with drum
ribs with four supports as shown in Fig. 51. Weight of proposed model of rotor assembly is
now reduced to half of the previous i.e. 40 kg.
38
Fmax =3 kN
=>
Tmax =924 Nm
So, for sprocket of 170 mm diameter, equivalent force of 5435 N should be applied on both
sides.
Loading condition:
Concentrated force of 2.718 kN is applied on two nodes of both sides of the sprocket
so as to simulate the induced torque. Loading conditions are shown in Fig. 53.
39
Boundary Conditions:
1. Shaft rotation about X-axis is allowed for the region shown in Fig. 53.
2. Partial blade edge fixed as shown in Fig. 54.
The von Mises stress distribution observed in sectional view of blade-hand is shown
in Fig. 55. The maximum von Mises stress induced is 113.9 MPa.
40
14535
Finer
135318
Finest
1059525
1.00E+08
8.00E+07
Coarse
6.00E+07
Finer
4.00E+07
Finest
2.00E+07
0.00E+00
1
Nodes
Fig. 56 Graph of von Mises stress versus Point number marked in region A (Fig. 55)
41
The von Mises stress distribution observed in sectional view of blade-hand shown is
in Fig. 58. The maximum von Mises stress induced is 296 MPa.
42
No. of elements
Coarse
14535
Finer
135318
Finest
1059525
A
von Mises stress
2.00E+09
1.50E+09
Finest
Finer
1.00E+09
Coarse
5.00E+08
0.00E+00
1
Nodes
Fig. 59 Graph of von Mises stress versus Point number marked in region A (Fig. 58)
43
The deflection distribution is shown in Fig. 61. The maximum deflection of about 7
mm is observed below engine block. This means that after each digging impact, engine block
will get displaced by 7 mm. This excessive deflection lead to the reduction of tension in
power transmitting chains, this was the reason for failure of first trial.
To provide stiff support to the engine block, static analysis is carried out for different
support plate thicknesses. For plate of 10mm thickness, the deflection below engine block is
44
observed to be 0.9 mm as shown in Fig. 62. This support is stiff enough for the engine to
transmit power to the GH4 rotor assembly.
By using sprocket combination as shown in Fig. 63, RPM can be reduced to 15 from 100.
5.5 Trial 2:
All discussed modifications are incorporated in the NGH3 rotor assembly. The
fabrication procedure discussed in Chapter 4 is followed. Only difference is that teeth were
45
welded to the cylindrical rotor in NGH3 whereas in GH4 rotor assembly, the teeth are fitted
to the cylindrical rotor with fasteners. Testing of new rotor assembly (GH4 rotor assembly) is
carried out. Setup for trial is shown in Fig. 64. It has been observed that all previous errors
are minimized. The GH4 rotor assembly is working perfectly fine.
The teeth of GH4 rotor assembly are going 8 cm deep into the soil for digging. The
conveyer belt is shown only for conceptual visualisation of overall working. The GH4 rotor
assembly digs out the groundnut pod from soil and throws it on the conveyer belt. Or
conveyer belt will comb stuck groundnut pod in between teeth and transfer it to the collector
box. Scope for improvement is discussed in the next chapter.
46
Chapter 6
Costing, Features and Scope for Improvement
Final design of groundnut harvesters model (GH4) is shown in Fig. 65 and the
photograph of fabricated prototype is given in Fig. 66.
Collector
Conveyor
Digger
47
2.
4000
3.
1680
4.
2000
5.
Rotor (20kg)
1000
6.
1200
7.
1000
8.
3000
Total
15880/-
2000
While surveying typical groundnut farm fields it was observed that 35-40 labours are
necessary to harvest 1 acre of groundnut farm field in a day which will cost around Rs. 6000
(considering daily wedge rate of Rs.150 per person and 40 labours).
Now, let us see running cost of developed groundnut harvester:
Consumption of fuel (oil mix petrol) = 1 lit. per hour*
Approximately 2 hours* are sufficient for farmer to harvest 1 acre of typical
groundnut farm field. That means only 2 litre of fuel and 2 labours are enough to harvest 1
acre of field in 2 hours. So, it can be seen that the developed groundnut harvester is very
much cost effective.
6.2 Features:
As discussed in section 6.1, developed GH4 is affordable multifunctional tool for farmers.
Few functional features are discussed below.
It can be used to harvest groundnuts as well as for operations like tilling/cultivating.
As teeth of the rotor are detachable, by altering teeth we can use this machine for
harvesting other underground crops like onion, potato etc.
*Judgments are based on Trial 2, vary according to working conditions and skill of farmer.
48
49
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