FABRICATION OF SOLAR

POWER OPERATED PADDY

CLEANING MACHINE

1
SYNOPSIS

2
 SYNOPSIS
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.

3
 CHAPTER – I

INTRODUCTION

4
 1. INTRODUCTION
In today’s industrial world man’s 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.

5
 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 can’t 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.

6
 CHAPTER – II

OBJECTIVES OF THE PROJECT

7
 2. OBJECTIVES 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.

8
 CHAPTER – III

LITERATURE SURVEY

9
 3. LITERATURE 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.

10
Fig. (1.1)

Fig. (1.2)

11
 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
12
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-seeding

De-seeding of corn is the process of removal of its inner layers,

leaving only the cob or seed rack of the corn.

13
 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 huller
This type of the machine gets the brown rice in good quality by a
cylindrical sieve set inside the body.

 Swimming huller
14
 By swimming a set of sieves, it separates the brown rice.

 Mangoku-shiki huller
“Mangoku” , 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.

Cornhusker

A 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.

15
 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 Operations

In 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

16
which separates the brown corn, husk and immature grains. The separated
grains are then separately discharged by the screw conveyors.

CHAPTER - IV

WORKING PRINCIPAL

17
 4. WORKING PRINCIPAL
The device is simple in operation consisting of following parts

 Drum
 Spikes
 Casing
 Stand
 Motor
 Belt
 Shaft
 Pulleys

The 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

18
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.

19
 CHAPTER – V

SELECTION & DESIGN CRITERIA

20
 5. SELECTION & 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

21
 CHAPTER – VI

DESIGN PROCEDURE

22
 6. DESIGN 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:
 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.
 Make selection of the possible mechanism which will give the desire
motion.
 Determine the forces acting on it and energy transmitted by each
element of the Machine.
 Select the material best suited for each element of the Machine.
 Determine the allowable or design stress considering all the factors
that affect the Strength of the Machine part.
 Identify the importance and necessary and application of the machine.
 Problems with existing requirement of the machine productivity and
demand.
 Determine the size of each element with a view to prevent undue
distortion or breakage under the applied load.
 Modify the machine element or parts to agree with the past experience
and judgment and to facilitate manufacture.
23
 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.

24
 II. DRUM

Fig. (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.

25
 III. Single Phase AC Motor

Fig. (7.3)

SPECIFICATION

 Capacity of the Motor = 1 HP

= 0.748 KW

 Speed of the Motor = 1750 rpm

26
Assembly:

Fig. (7.4)

27
Drafting:

Fig. (7.5)

28
CHAPTER – VII

CALCULATION

29
 7. CALCULATION

DESIGN OF SHAFT

A 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,

πD1N1 = πD2N2 …….(8.1)

D1/D2 = N2/N1

1.5/6 = N2/1750

N2 = 437.5rpm

Now to find torque we have,

P = 2πN2T/60 …….(8.2)

0.746 = 2*3.142*437.5*T/60

T = 0.01628 KN-m

Now force acting on drum,

30
 F = T/r …….(8.3)

F = 0.01628/0.1524

F = 0.1068 KN

Bending Moment,

BM = WL/4 …….(8.4)

BM = 0.1068*406.4/4

BM = 10.85 KN-mm

From the general Bending equation we have,

M/I = σ/y …….(8.5)

M*64/π*d4 = F*d*4/π*2*d2

d3 = 32*M/F

d3 = 32*10.85/0.1068

d = 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-Belt

Centre Distance,

C = d1/2+d2/2+l …….(8.6)

= 1.5’’/2+6’’/2+14.5’’

C = 18.25 inches

C = 463.55 mm
31
𝜃L = 𝜋+{2sin−1 (𝐷 − 𝑑)/2𝐶}*𝜋/ 𝜃S = 𝜋-{2sin−1 (𝐷 − 𝑑)/2𝐶}*𝜋/
180 180

4.5∗25.4 4.5∗25.4
𝜃L = 𝜋+{2sin−1 }*𝜋/180 𝜃S = 𝜋-{2sin−1 }*𝜋/180
2∗463.55 2∗463.55

𝜃L = 3.3887 radians. 𝜃S = 2.8943 radians

Length of Belt,

L = {4C2-(D2-D1)2}1/2+(D2θL+ D1θS)/2 …….(8.7)

L = {4*463.552-(152.4-38.1)2}1/2+(152.4*3.385+ 38.1*2.897)/2

L = 920.027+313.1248

L = 1233.152 mm

L = 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 = 686.7N

Where, the load acting on each link,

32
 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 be

Crippling load = Wcr =4π2EI/L2 …….(8.8)

Where,

Wcr = crippling load.

E = Young’s 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
33
 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 = (4π2*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.

34
CHAPTER – VIII

FABRICATION

35
 1. FABRICATION
1. L Angle (42 inch x 17.5 inch x 24 inch)
Material: Mild Steel
Operation: Cutting, Welding, Grinding & Drilling.
2. Shaft (1 inch dia. x 22 inch long)
Material: Mild Steel
Operation: Facing, Counter Boring & Step turning.
3. Drum (6.5 inch dia. x 12 inch long)
Material: Mild Steel
Operation: 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 Foundation
Material: 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 Casing
Material: Mild steel.
Operation: Cutting, Grinding, Bending & Welding.
9. Sheet Metal
Material: Galvanised Steel.
Operation: Marking, Punching, Cutting, Bending,
Drilling & Welding.
36
 CHAPTER – IX

ADVANTAGES &
DISADVANTAGES

37
 9. ADVANTAGES
 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.

DISADVANTAGES
 Only dry corn can be de-seeded.
 Continuous power supply.

38
CHAPTER – X

APPLICATIONS

39
 10. APPLICATIONS
 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.

40
 CHAPTER – XI

COST ESTIMATION

41
 11.COST 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 estimating

 To determine the selling price of product for a quotation or contract
so as to ensure a reasonable profit to the company.
 Check the Quotation supplied by vendors.
 Determine the most economical process or material to manufacture
the product.
 To determine standards of production performance that may be
used to control the cost.

Basically the overall cost estimation involves

 Material cost.
 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 categories

1) Material for fabrication

In this material is obtained in raw condition and is manufactured or

processed to finished size for proper functioning of the component.

42
 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;

 After designing a project, a bill of material is prepared which is

divided into two categories
o Fabricated components
o Standard purchased components
 The rates of all standard items are taken and added up.
 Cost of raw material purchased taken and added up

43
 CONCLUSION
 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.

44
 REFERENCE
All the design formulae and other essentials are extracted from the
following books.

Theory of
machine……………………………………………………....By R.
S. Khurmi & B. C. Gupta

Machine Design data hand

book…………………………………..By H. G. Patil & Dr. K.
Lingaiah

Workshop
Technology………………………………………………….By
Hazara Choudhri

Production
technology………………………………………………….By R.
K. Jain

Machine Design elements 1 &

2……………………………………By Bandari

45
PHOTO GRAPHY

46
PHOTO GRAPHY

47