Project Report on

SEMI-AUTOMATED PADDY
THRESHER
Submitted in partial fulfilment of
The requirements for the degree of

BACHELOR OF TECHNOLOGY
IN
INSTRUMENTATION AND CONTROL
By

KAMYA SATI (111109031)

SUJEET CHANDORKAR(141209002)
KAILAS DUKALE (141209004)
UNDER THE GUIDANCE OF
PROF. KALYANI BHOLE

Department of Instrumentation and Control

College of Engineering Pune-411005
(2014-15)
ACCEPTANCE CERTIFICATE
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Department of Instrumentation and Control

College of Engineering Pune
(An autonomous Institute of Government of Maharashtra)

The project entitled Semi-Automated Paddy Thresher submitted by

Kamya Sati, Sujeet Chandorkar and Kailas Dukale having MIS No.
111109031, 141209002 and 141209004 accepted for being evaluated.

Prof. Mrs. Kalyani Bhole

Dr.S.L.Patil

Project Guide
Department of Instrumentation

Head
Department of Instrumentation

and Control
Date:-

and Control
Date:-

Abstract
Rice is one of the chief grains in India, and as such, is a major food crop, especially in the
Eastern and Southern regions of India. Rice production accounts for a sizable amount of the
economy. However, farmers that lack resources continue to harvest the same using traditional
methods, which affects their yield, thereby affecting their earnings.
We propose to build a semi-automated paddy thresher that will help farmers improve
efficiency during threshing. It will also lower grain damage and reduce labor needed for
threshing. We also hope to lower power consumption and provide a mechanism for speed
control. We sincerely believe that the improved design can help enrich the lives of farmers
across the nation.

Table of Contents
Abstract
List of Tables
List of Figures
1: Introduction
1.1: Methods of Threshing
1.1.1: Flail
1.1.2: Threshing Floor
1.1.3: Pedal Operated Thresher
1.1.4: Threshing Machine/Combine Harvester
1.2: Classification of threshers
1.2.1: Feed-in type threshers
1.2.2: Hold-on type threshers
1.3: Proposed Paddy Thresher
1.3.1: Automated motor
1.3.2: Vibrating mesh
2: Literature Survey
2.1: Main components of Paddy Thresher
2.1.1: Frame
2.1.2: Threshing Drum
2.1.3: Threshing teeth
2.2: Optimization
2.2.1: Increasing Output Efficiency
2.2.2: Portability and Ease of Use
2.3: Power Source
2.4: Safety and Cost
2.5: Summary of Literature Survey
3: Design
3.1: Machine Dimensions
3.2: Material Selection
3.3: Process of Fabrication

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3.3.1: Building the Frame

3.3.2: Fabricating the Threshing Drum
3.3.3: Attaching the Motor
3.3.4: Vibrating Mesh
3.3.5: Fabricating the Hood
3.4: Mechanism for Vibrating Mesh
4: Automation
4.1: Single Phase Induction Motor
4.1.1: Construction
4.1.2: Working Principle
4.1.3: Comparison between Single and Three phase Induction Motor
4.1.4: Specification and Implentation
4.2: Speed Control
5: Conclusion and Scope for the Future
5.1: Implemented Methods
5.2: Future Scope
5.2.1: Speed Control
5.2.2: Fully automated Paddy Thresher
5.3: Conclusion
6: References
7: Acknowledgements

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List of Tables
1: Optimal Specification
2: Actual Dimensions of Paddy Thresher
3: Specifications for Induction Motor

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List of Figures
1: Pedal operated thresher
2: Feed-in type thresher
3: Slider-crank Mechanism
4: Parts of Induction Motor
5: Pulley system for Speed Reduction
6: Block diagram for Speed Control
7: AC voltage controller circuit
8: Paddy Thresher [Full Body]
9: Paddy Thresher [Threshing Drum]

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Chapter 1

Introduction

There are many steps involved in the process of getting the rice from the fields and into our
homes. First the rice stalks must be harvested from the fields. The next step of the process is
threshing. It is the process of separation of the grain from the stalk. This can be done
manually or by the action of a revolving mechanism. Grain damage is a potential problem
faced during threshing.

1.1 Methods of threshing

Several methods of threshing exist. Some continue to be used today, while others have
evolved with advancements in technology. A brief description of these methods is listed
below.
1.1.1 Flail
It is a hand held agricultural tool which is used to separate grain from the stalk. It is a labor
intensive and time consuming process. The flail is used to beat grains on a threshing floor.
The grains are later collected from the floor.
1.1.2 Threshing Floor
The stalks are spread across the threshing floor and animals like bulls or donkeys walk round
and round dragging a threshing board to separate the grain from the stalk.
1.1.3 Pedal operated paddy thresher
The idea was developed in Japan and is still popular with poor
farmers in many parts of the world. It consists of loop type
threshing drum with a supporting frame. It improves efficiency
and is less labor intensive. However there are instances of injury
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to hands and arm while feeding the stalks into the thresher.
thresher

Fig

1:

Pedal

operated

1.1.4 Threshing Machine/Combine Harvesters

Industrialization helped remove much of the drudgery from the process of farm labor. The
threshing machine uses the same principle as the above. Earlier they were hand-fed and horse
powered but now they can be completely automated. Modern day combine harvesters use the
same basic principles but are much larger in size.

1.2 Classification of threshers

Threshers can be broadly classified into two categories on the basis of method of feeding.
Both categories come with their own set of advantages and disadvantages.
1.2.1 Feed-in type threshers
In these types of threshers, the whole crop is directly fed into the
machine. It provides higher throughput than hold-on type and allows
the farmers freedom to move around. But these types of threshers are
prone to clogging with the straw. It also has higher power requirement
to drive the drum. Sometimes it also results in injuries to hands of the
operator.
1.2.2 Hold-on type threshers
Fig 2: Feed-in type
In these types of threshers only the panicle is fed into the machine. The straw remains intact
and there is lower risk of injuries to the user. However it has lower throughput than feed-in
type thresher.

1.3 Proposed Paddy Thresher

Each of the above mentioned methods has its own set of advantages and disadvantages. The
proposed paddy thresher is designed with the small farmer in mind. We hope to improve
efficiency and yield while reducing labor. This can help small farmers improve their profit
margins. It will also reduce the time spent in threshing which can be utilized elsewhere.
1.3.1 Automated Motor
Non automated threshers require a lot of manual labor which is time consuming and tiring.
We propose to use an induction motor to automate the mechanism of the threshing drum. The
farmer will have ON-OFF control with the help of a single switch.
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1.3.2 Vibrating Mesh

Winnowing is the process of separation of grain from the chaff. We propose to use a vibrating
mesh to separate the paddy grains from the chaff after threshing. This can help reduce time
spend in winnowing and requires no extra effort from the farmers side.

Chapter 2

Literature Survey

There are numerous types of paddy threshers available in the market. Each design has some
advantages and some disadvantages. We have identified the following focus areas for the
literature survey:

Main components of paddy thresher

Optimization of components
Power Source
Safety and Cost

2.1 Main components of paddy thresher

The thresher consists of three main components frame, threshing drum and threshing teeth
2.1.1 Frame
The body frame of the thresher should be made of a durable materials like cast iron or mild
steel to increase life of the machine. The height of the frame should be comfortable for the
user, so that he/she should not have to bend. The recommended height is around 105 cm.
2.1.2 Threshing drum
The drum should be durable enough to take the load of the stalks. It should be constructed out
of slats which are supported at each end by cylinder end discs. The length of the drum should
not exceed 40 cm in case of single user.
2.1.3 Threshing teeth
The slats carry the threshing teeth. They should be arranged in linear manner with a distance
of 4 cm. The height of the teeth should not exceed 6.5 cm. The shape of the teeth affects grain
damage. To minimize damage to paddy grains, wire loop type teeth are preferred.

2.2 Optimization
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Optimization is the methodology of selecting the best element with regard to some criteria.
We wish to optimize the thresher for small farmers.
2.2.1 Increasing output efficiency
Output efficiency of the thresher depends mainly upon the feed rate and the speed of the
drum. The feed rate of the thresher must not be too high so as to prevent overloading the
drum. The speed of the drum should not exceed 850 rpm so as to prevent grain damage.

2.2.2 Portability and Ease of Use

Farmers prefer threshing machines which are portable as they can be used in any part of their
field. The thresher should be easy to operate as most farmers are not well versed with the
usage of highly technical machines.

2.3 Power Source

Pedal powered threshers require a lot of human labor. To automate the threshing mechanism,
one can use an electric motor or a diesel motor. Diesel motors, however, have very high
carbon emission and pose a threat to the environment.
Owing to the rising cost of diesel, electric motors are cheaper to run than diesel motors. Many
farmers have subsidized electricity rates and single phase supplies. An induction motor
requires a single phase supply and does not require much maintenance. An induction motor of
0.5 hp would be sufficient to power the drum.

2.4 Safety and Cost

In agricultural related injuries, accidents due to threshers are the second most common.
Exposed rotating parts result in crushing or amputation of upper limbs. Hence, chute design is
an important parameter to prevent injuries. The chute opening height should be at least 32
cm. Elbows should be kept away to prevent injuries.
Targeting small farmers, the goal of the project is to offer a viably safe thresher at an
affordable price. Also, the thresher should not require much maintenance.

2.5 Summary of Literature Survey

According to the literature survey, the following are the optimal specifications for a semiautomatic paddy thresher:
Parameter
Frame Dimensions

Dimensions
100 x 60 x 105 (in cm)

Drum Length

35-40 cm

Plate Diameter

27 cm

Tooth Spacing

4 cm

Tooth Height

6.5 cm

Power Source

Single Phase Induction Motor

Speed of Drum

600 - 800 rpm

Table 1: Optimal Specifications

Chapter 3

Design

The optimal dimensions have been summarized in the literature survey (in Section 2.5). The
design, however, involves more than a few technical specifications. In this chapter, we will
cover the actual dimensions that were used to build our thresher as well as the materials that
were selected for each component.

3.1 Machine Dimensions

The machine was built according to the following dimensions:
Parameter
Frame Dimensions

Dimensions
90 x 60 x 75 (in cm)

Drum Length

40 cm

Drum Diameter

25 cm

Plate Diameter

18 cm

Tooth Height

6.5 cm

Tooth Spacing

3.9 cm

Chute Opening
35 cm
Table 2: Actual Dimensions of the Paddy Thresher

3.2 Material Selection

According to Indian standards of paddy threshers, cast iron and mild steel are the
recommended materials to build paddy threshers. For our project, we chose cast iron for
many purposes, most important being its competitive price. Cast iron can therefore do the
same job at a lower price. It is also easily available and has high tensile strength.
The only problem with cast iron is that is more prone to corrosion as compared to mild steel,
but this can be rectified with a paint job. For the base of the machine, we have used a 6 cm
thick panel of wood so as to provide cushioning and stability to the machine.
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3.3 Process of Fabrication

The process of fabrication follows the sub-points mentioned below in their exact order:
3.3.1 Building the Frame
This is the first step in the process of fabrication. The frame was built using L-shaped bars
made of cast iron. The dimensions used for the frame are as specified in Section 3.1.
3.3.2 Fabricating the Threshing Drum
The drum was constructed using a series of slats, supported by a cylinder-end plate. Each slat
is 0.5 cm thick and 5 cm wide. The distance between two neighboring slats is maintained at Z
mm.
The cylinder-end plates have a thickness of 0.2 cm and are used to support the slats. The
threshing teeth are welded to the surface of the slat. We have selected Wire Loop type of teeth
which have been welded at a distance of 4 cm to each other.
3.3.3 Attaching the Motor
We have used a Flat Belt type pulley system to attach the motor to the shaft of the drum. This
is the driving force of the machine. The pulley system also helps reduce the speed of the
motor.
3.3.4 Vibrating Mesh
The vibrating mesh is used to separate the grain from the chaff. We have used a linkage
assembly which converts the rotational motion of the drum into linear motion of the mesh.
3.3.5 Fabricating the Hood
This is the final step in the process of fabrication. A metal sheet is bent and welded to the top
of the thresher in order to prevent injury as well as preventing the grains from getting
scattered.

3.4 Mechanism for Vibrating Mesh

We make use of the rotatory motion of the drum for the reciprocating motion of the mesh. A
slider-crank can be used to convert circular motion into reciprocating motion.
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Link AB shown below in Fig is free to rotate 360 around the hinge while link BC oscillates
back and forth because point C is hinged to a roller which restricts it to linear motion. Here
the rotating link AB is the driver.

Fig 3: Slider-crank mechanism

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Chapter 4

Automation

Automation is the process of using control systems to operate equipment, reducing or

removing human intervention. In this chapter, we will discuss the specifications of the
induction motor used, followed by the method used for controlling the speed of the drum.

4.1 Single Phase Induction Motor

The single phase induction motor is the heart of the paddy thresher machine. We have
explained the construction and working of induction motor.
4.1.1 Construction
It has mainly two parts namely rotor and stator.
Stator: As its name indicates stator is a stationary part of induction motor. A single phase ac
supply is given to the stator of single phase induction motor.
Rotor: The rotor is a rotating part of induction motor. The rotor is connected to the
mechanical load through the shaft. The rotor in single phase induction motor is of squirrel
cage rotor type.
The construction of single phase induction
motor is almost similar to the squirrel cage
three phase motor except that in case of
asynchronous motor the stator have two
windings instead of one as compare to the
single

stator winding

in three

phase

induction motor.
Fig 4: Parts of Induction Motor
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4.1.2 Working Principle

When single phase ac supply is given to the stator winding of single phase induction motor,
the alternating current starts flowing through the stator or main winding. This alternating
current produces an alternating flux called main flux. This main flux also links with the rotor
conductors and hence cut the rotor conductors. According to the Faradays law of
electromagnetic induction, EMF gets induced in the rotor. As the rotor circuit is closed one
so, the current starts flowing in the rotor. This current is called the rotor current. This rotor
current produces its own flux called rotor flux. Since this flux is produced due to induction
principle so, the motor working on this principle got its name as induction motor. Now there
are two fluxes one is main flux and another is called rotor flux. These two fluxes produce the
desired torque which is required by the motor to rotate.
4.1.3 Comparison between Single phase and Three phase Induction Motor
1. Single phase induction motors are simple in construction, reliable and economical for
small power rating as compared to three phase induction motors.
2. The electrical power factor of single phase induction motors is low as compared to three
phase induction motors.
3. For same size, the single phase induction motors develop about 50% of the output as that
of three phase induction motors.
4. The starting torque is also low for asynchronous motors.
5. The efficiency of single phase induction motors is less as compare it to the three phase
induction motors.
4.1.4 Specification and Implementation
The specifications of the induction motor used in our project are as follows:

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Parameter

Value

Rotor

Squirrel Cage Type

Output Power

0.5 hp

Supply Voltage

230 V, 50 Hz

Speed

1440 rpm

Current

5A
Table 3: Specifications for Induction Motor

The speed of the motor (1440 rpm) is too high and would certainly have caused significant
grain damage. We have used a pulley arrangement to bring down the speed of the induction
motor. We placed a small pulley on the motor and a larger pulley on the shaft of the threshing
drum. The size of the pulleys was calculated using the following formula:
D1 P1 = D2 P2
where
D1 = driving pulley diameter
P1 = speed of driving pulley
D2 = driven pulley diameter
P2 = speed of driven pulley
Fig 5: Pulley System for Speed Reduction
We require the speed of the drum to be 800 rpm. The plate diameter is 18 cm and the speed of
the motor is 1440 rpm. Placing these values in the formula above, we get:
d1 1440 = 18 800
d1 = 10 cm.
To implement the above, we have used a Flat Belt pulley system.

4.2 Speed Control

We hope to control the speed of the single phase induction motor using triac and a 555 timer.
The control circuitry used depends on one parameter voltage.
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Torque Developed in a Motor Square of Voltage

We control the voltage applied to the stator terminals of the induction motor using gate pulses
from the triac. Delaying of the pulses to the gate reduced the voltage applied to the stator
terminals of the induction motor, and as voltage and torque are proportional to each other, a
decrease in torque simultaneously decreases the speed of the motor.
The control circuit consists of the following:

Triggering Circuit
Triac Circuit
Power Supply Circuit

Power Supply Circuit provides a DC supply of 5 V and 12 V to devices requiring the biasing
voltage. The triggering circuit is used to generate pulses which are then given to the triac as
gate pulses. This acts as the trigger. The triac circuit acts as an intermediate between the
induction motor and the supply.

Fig 6: Block Diagram for Speed Control

Using thyristor, we can control stator voltage by using an AC voltage controller, where
reverse parallel connected thyristors are used in phase between supply and motor. The stator
voltage is reduced from its base value by increasing the firing angle of thyristor from 0 to
180.

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Fig 7: AC Voltage Controller Circuit

For the speed control of single phase induction motor we are using method of stator voltage
supply control. In this method of control we are using an intermediate part called AC
cycloconverter between the AC supply and induction motor. Therefore supply voltage is
controlled by controlling the gate pulses to the cycloconverter. And thereby torque is also
controlled and thus the speed of the induction motor.

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Chapter 5

Conclusion and Scope for the Future

There is scope for improvement in the level of automation of the paddy thresher. Towards
this, in conclusion, we will cover a summary of the methods weve used in our system and
propose a scope for what can be done in the future.

5.1 Implemented Methods

The paddy thresher was built with the aim of helping small farmers increase their output,
reducing labor required and providing a safe and standardized machine at an affordable cost.
The machine is optimized to ensure easy use for the farmer and is built with safe guards to
prevent accidents and injuries in a field with a high risk of amputation. Also, the machine can
be used by a single farmer, as opposed to requiring multiple people operating a single
machine.
Another important aspect we considered was that our machine would test the tides of time
and reduce the cost of maintenance. The machine also combines the process of threshing and
winnowing, thereby reducing the work to be done by the farmer, as it has automatic grain
separation.

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Fig 8: Paddy Thresher [Full Body]

Fig 9: Paddy Thresher [Threshing Drum]

5.2 Future Scope

While we have mentioned that our machine is a semi-automatic one, there is scope for
increasing the level of automation in the thresher. A great way to do this is by implementing
speed control of the threshing drum. We will discuss a few points below:
5.2.1 Speed Control
The speed of the threshing drum should be lowered while changing the bundle of stalks. As
mentioned in Section 4.2, the speed of the threshing drum can be controlled using a triac and
a 555 timer. This can help lower the power consumption as well as the risk of injuries, which
will supplement the goal we had in mind while building this machine. We believe that the
optimum speed we can reach using this method is 600 rpm.
5.2.2 Fully Automatic Paddy Thresher
The current design of the paddy thresher requires the farmer to hold the bundle of stalks over
the threshing drum. We propose to build a mechanism to hold these stalks in place and flip
them over after a certain period of time using a simple flipping mechanism. A microcontroller
can be used to trigger this flipping mechanism after a set period of time, which can be
programmed in the microcontroller.

5.3 Conclusion
What we have built is a product that can be used in the field today. However, while we have
identified the key areas that require change in a paddy thresher, we were unable to implement
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everything that we had hoped to. Nonetheless, what we have built is a step in the right
direction, and a little bit of improvement can render it as a viable solution to an unaddressed
problem faced by farmers for years.

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Chapter 6

References

1. Azouma, Ouezou Yaovi, Makennibe Porosi, and Koji Yamaguchi. "Design of throw-in
type rice thresher for small scale farmers." Indian Journal of Science and
Technology 2.9 (2009): 10-14.
2. Chimchana, D., V. M. Salokhe, and P. Soni. "Development of an Unequal Speed Coaxial Split-Rotor Thresher for Riceit." Agricultural Engineering International: CIGR
Journal (2008).
3. Singh, Gyanendra. "Agricultural Machinery Industry in India (Manufacturing,
marketing and mechanization promotion)." Status of Farm Mechanization in
India (2006).(2)
4. Alizadeh, M. R., and M. Khodabakhshipour. "Effect of threshing drum speed and crop
moisture content on the paddy grain damage in axial-flow thresher."Cercetari
agronomice in Moldova (Romania) (2010).
5. Kumar, Adarsh, et al. "Development of grain threshers based on ergonomic design
criteria." Applied ergonomics 33.5 (2002): 503-508.
6. Singh, K. P., et al. "Optimisation of machine parameters of a pedal-operated paddy
thresher using RSM." Biosystems engineering 100.4 (2008): 591-600.
7. Ukatu, A. C. "A modified threshing unit for soya beans." Biosystems engineering 95.3
(2006): 371-377.
8. Singh, Divya, and Deepa Vinay. "Optimization of machine parameters of Parvatiya
Sugam motorized thresher using response surface methodology."Journal of Applied
and Natural Science 6.1 (2014): 207-213.

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9. Anon. 1982. IS: 3327: Specification for pedal operated paddy thresher. Bureau of
Indian Standards, New Delhi.
10. Kumar, A., Mohan, D., Patel, R., & Varghese, M. (2002). Development of grain
threshers based on ergonomic design criteria. Applied ergonomics, 33(5), 503-508.
11. Agrawal, Kamal Nayan, E. V. Thomas, and K. K. Satapathy. "Effect of thresher drive
linkage design on human physiological workload of a pedal operated thresher."
Agricultural Engineering International: CIGR Journal 15.1 (2012): 78-86.
12. Alizadeh, M. R., and M. Khodabakhshipour. "Effect of threshing drum speed and crop
moisture content on the paddy grain damage in axial-flow thresher."Cercetari
agronomice in Moldova (Romania) (2010).
13. Takahashi, Isao, and Youichi Ohmori. "High-performance direct torque control of an
induction motor." Industry Applications, IEEE Transactions on 25.2 (1989): 257-264.
14. Collins Jr, E. R., H. B. Puttgen, and I. I. Sayle. "Single-phase induction motor
adjustable speed drive: Direct phase angle control of the auxiliary winding supply."
Industry Applications Society Annual Meeting, 1988., Conference Record of the 1988
IEEE. IEEE, 1988.

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Acknowledgements
We would like to take this opportunity to express our deep sense of gratitude and respect to
guide Prof. Mrs. Kalyani Bhole. It was our pleasure to have worked under her valuable
guidance and constant encouragement which inspired us. We thank for the confidence she
showed and developed in us.
We are also thankful to Dr. S.L. Patil, Head of Instrumentation and Control engineering
department and all faculty members who allowed all their facilities and extended their entire
co-operation to us.
Lastly we would like to thank Mr. Sanjay Deskhmuk , the owner of Laxmi Fabricators who
has provided us with invaluable guidance in the process of fabrication.

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