DESIGNANDDEVELOPMENTOFTEFGRAINANDCHAFF

SEPARATINGANDCLEANINGMACHINE

MSc.Thesis

AbayinehAwgichewNadew

January,
2015
Haramaya
University

DESIGNANDDEVELOPMENTOFTEFGRAINANDCHAFF
SEPARATINGANDCLEANINGMACHINE

AThesisSubmittedtotheSchoolofGraduateStudiesthrough
theSchoolofNaturalResourceandEnvironmentalEngineering
HARAMAYAUNIVERSITY

InPartialFulfillmentoftheRequirementfortheDegreeof
MASTEROFSCIENCEINAGRICULTURAL
MACHINERYENGINEERING

By
AbayinehAwgichewNadew

January,
2015
Haramaya
University

SCHOOLOFGRADUATESTUDIES
HARAMAYAUNIVERSITY
AsThesisResearchAdvisor,herebycertifythatIhavereadandevaluatedthisthesis
prepared,undermyguidance,byAbayinehAwgichewentitledDesignandDevelopmentof
Tef Grain and Chaff Separating and Cleaning Machine. I recommend that it be
submittedasfulfillingthethesisrequirement.
Dr.AbebeFanta
NameofMajorAdvisor

______________

________________

Signature

Date

AsmemberoftheExaminingBoardoftheFinalMSc.OpenDefense,wecertifythatwehave
readandevaluatedthethesispreparedbyAbayinehAwgichewandexaminedthecandidate.
WerecommendedthattheThesisbeacceptedasfulfillingtheThesisrequirementforthe
DegreeofMasterofScienceinAgriculturalMachineryEngineering.
Dr.SimieTola
NameofChairman

___________

____________

Signature

Date

Dr.SolomonAberra

___________

NameofInternalExaminer

Signature

Dr.FisihaGetachew

___________

NameofExternalExaminer

Signature

____________
Date
____________
Date

ii

DEDICATION
IdedicatethisthesismanuscripttomyfatherAwgichewNadewandmymotherMestewat
Zewdewhomeducatedmewithoutthemselvesbeingeducated.

iii

STATEMENTOFAUTHOR
First,Ideclarethatthisthesisismysolelyworkandthatallsourcesofmaterialsusedforthis
thesishavebeendulyacknowledged.Thisthesishasbeensubmittedinpartialfulfillmentof
the requirements for MSc degree at the Haramaya University and is deposited at the
UniversityLibrarytobeavailabletoborrowersunderrulesofthelibrary.Isolemnlydeclare
that this thesis is not submitted to any other institution anywhere for the award of any
academicdegree,diploma,orcertificate.
Brief quotations from this thesis are allowable without special permission provided that
accurateacknowledgementofsourceismade.Requestsforpermissionforextendedquotation
fromorreproductionofthismanuscriptinwholeorinpartmaybegrantedbytheheadofthe
majordepartmentortheDeanoftheSchoolofGraduateStudieswheninhisorherjudgment
the proposed use of the material is in the interests of scholarship. Inall other instances,
however,permissionmustbeobtainedfromtheauthor.
Name:AbayinehAwgichew Signature:_____________
Place:HaramayaUniversity,Haramaya
Date:January,2015

i
v

BIOGRAPHICALSKETCH

TheauthorwasbornonFebruary19,1987inOromiaRegionalState,ArsiZone,Aseko
DistrictfromhisfatherAwgichewNadewandhismotherMestewatZewde.Heattendedhis
elementaryeducationatJisoandIresaPrimarySchool,hissecondaryeducationatAdama
Comprehensive High School and his preparatory education at Hawas Preparatory School
(Adama). He joined Hawassa University in 2005 and graduated with BSc degree in
Agricultural Engineering and Mechanization in July 2009. Soon after graduation, he was
employedbyOromiaAgriculturalResearchInstituteasresearcher.Theauthorafterserving
threeyears,hejoinedtheSchoolofGraduateStudiesatHaramayaUniversityinOctober,
2012topursuehisstudiesinAgriculturalMachineryEngineeringatgraduatelevel(MSc
Program).

ACKNOWLEDGMENTS
Above all, I would like to thank the Almighty God for providing me the patience and
endurancetocompletethestudy.
IwouldliketoexpressmydeepestandheartfeltthankstomythesisresearchadvisorDr.
AbebeFantaforhisconsistentguidance,criticalreviewandsupportthroughoutthecourseof
thisresearchworkandpreparationofthethesis;hisreadinesstoprovideassistance,advice
andguidancegreatlyhelpedmetocompletemystudies.
Mydeepest gratitudeandacknowledgementgoto OromiaAgricultural ResearchInstitute
(OARI)andAsellaAgriculturalMechanizationResearchCenter(AAMRC)forprovidingme
the opportunity to read for my MSc degree in Agricultural Machinery Engineering and
provisionoffundstocovercostsassociatedwithresearchwork.
IamgreatlyindebtedtothetechniciansofAAMRCworkshopwhosharedwithmetheir
wisdom,skillandexperience.Myspecialappreciationandacknowledgmentarealsoextended
tostaffmembersofAAMRC,andtoAtoGetachewDameandAtoBelaynehTafarrawho
helpedmeintheproductionoftheprototypefromtheverybeginninguptotheend.
Finally,heartfeltanddeepestappreciationgotomybelovedparents,sisters,brothersand
friendswhosestaunchsupport,unreservedloveandpersistentencouragementandallrounded
assistanceweresubstantialinputstomyinspirationanddevotionthroughoutthecourseofthe
researchwork.

v
i

LISTOFACRONYMSANDABBREVIATIONS
AAMRC

AsellaAgriculturalMechanizationResearchCenter

ANOVA

AnalysisofVariance

ASME AmericanSocietyofMechanicalEngineers
CBA ConveyerBeltingAustralia
EATA EthiopianAgriculturalTransformationAgency
FR

FeedRate

IMP

IranianMinistryofPetroleum

LCC

LorenCookCompany

LSDT LeastSignificantDifferenceTest
MOG MaterialsOtherthanGrain
OARI OromiaAgriculturalResearchInstitute
RPPC RajendraPulleyPedestalCentre
SGA2000

SasakawaGlobalAfrica2000

SO

SieveOscillation

SS

SieveSlope

TGM ThousandGrainMass
USDA UnitedStateDepartmentofAgriculture
wb

wetbasis

vi
i

TABLEOFCONTENTS
STATEMENTOFAUTHOR

iv

BIOGRAPHICALSKETCH

ACKNOWLEDGMENTS

vi

LISTOFACRONYMSANDABBREVIATIONS

vii

LISTOFFIGURES

xii

LISTOFTABLESINTHEAPPENDIX

xiii

LISTOFFIGURESINTHEAPPENDIX

xiv

ABSTRACT

xv

1.INTRODUCTION

2.LITERATUREREIVEW

2.1.FunctionofGrainSeparationandCleaning

2.2.SeparatingandCleaningDevices

2.2.1.AerodynamicSeparatorandCleaner

2.2.2.Mechanicalseparation

2.2.3.Combinationofaerodynamicandmechanical

2.3.FactorsAffectingSeparatingandCleaningEfficiency

2.3.1.MachineFactors

2.3.1.1.Effectofsieveoscillationandsieveslope

2.3.1.2.Effectoffeedingrate

2.3.2.Cropfactors

2.3.2.1.Physicalpropertiesoftefgrainandstraw

2.3.2.2.Aerodynamicpropertiesoftefgrainandstraw

10

2.4.ScreeningSurfaceandRecommendedSieveSizesforDifferentGrains

11

2.5.DesignConsideration

12
vii
i

2.5.1.Designofpowertransmission

12

2.5.2.Designoffan

13

2.5.3.Designofshaft

15

3.MATERIALSANDMETHOD

18

3.1.ExperimentalSiteDescription

18

3.2.DesignConsiderations

18

3.3.DescriptionoftheMachine

19

3.4.WorkingPrinciplesoftheMachine

20

3.5.MeasuringDevicesandInstruments

21

3.6.PreparationofSamples

21

3.7.DesignAnalysis

22

3.7.1.Determinationofsieveslope

23

3.7.2.Determinationofsieveoscillation

23

3.7.3.Constructionofbeltconveyor

23

3.7.4.Designandfabricationoftheprototypeseparatingandcleaningunit

24

3.7.5.Sieveslopeadjustment

26

3.7.6.Designandconstructionoffanandhousing

27

3.7.7.Selectionofpulleysandbelts

29

3.7.8.Determinationofshaftdiameter

31

3.7.9.Determinationofpower

39

3.8.PerformanceEvaluation

40

3.9.ExperimentalDesignandTreatment

41

3.10.StatisticalAnalysis

41

4.RESULTANDDISCUSSION

42

4.1.EffectSieveSlope,SieveOscillationandFeedRateonSeparationEfficiencyand
SeparationLoss

42

4.1.1.Effectofsieveslopeonseparationefficiencyandseparationloss

42

4.1.2.Effectofsieveoscillationonseparationefficiencyandseparationloss

43

4.1.3.Effectoffeedrateonseparationefficiencyandseparationloss

43
i
x

4.1.4.CombinedEffectSieveSlope,SieveOscillationandFeedRateonSeparation
EfficiencyandSeparationLoss

44

4.2.EffectofSieveslope,SieveoscillationandFeedrateonCleaningEfficiencyand
CleaningLoss

47

4.2.1.EffectofSieveslopeonCleaningEfficiencyandCleaningLoss

47

4.2.2.EffectofSieveoscillationoncleaningefficiencyandcleaningloss

47

4.2.3.Effectoffeedrateoncleaningefficiencyandcleaningloss

49

4.2.4.CombinedEffectofSieveslope,SieveoscillationandFeedrateonCleaning
EfficiencyandCleaningLoss

49

4.3.TheMultipleRegressionAnalysis

51

4.4.CostAnalysisoftheSeparatingandCleaningMachine

51

5.SUMMARY,CONCLUSIONSANDRECOMMENDATION

52

5.1.Summary

52

5.2.Conclusion

53

5.3.Recommendation

54

6.REFERENCE

56

7.APPENDICES

60

7.1.Appendixtables

60

7.2.Appendixfigure

66

LISTOFTABLES

Table1.PhysicalPropertiesofTefGrainatVariousMoistureContents

Table2.MeasuredandCalculatedMeanDimensionsofTefGrainatDifferentMoisture
Content

Table3.SpecificationofTefChaffSamples

10

Table4.RecommendedSieveOpeningsSizesforDifferentGrains.

12

Table5.SomeBasicSpecificationofVBeltSections

13

Table6. PertinentDimensionsofComponentPartsandPowerSourceanditsRatedPower 20
Table7. AdjustedInletAreaatDifferentrpminordertoKeepConstant3.2m/satFanExit29
Table8. AnalysisofVarianceoftheResultofthePerformanceoftheMachine

44

Table9. SeparationEfficiencyandSeparationLossasAffectedbytheInteractionBetween
Sieveslope,SieveoscillationsandFeedrate

45

Table10.CleaningEfficiencyandCleaningLossasAffectedbytheInteractionbetween
Sieveslope,SieveoscillationsandFeedrate.

50

Table11.MultipleRegressionEquationofParametersStudied

51

Table12.TheSummarizedCostofSeparatingandCleaningMachine

51

x
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LISTOFFIGURES
Figure 1.DetailsoftheExperimentalTefChaffSeparatingandGrainCleaningMachine

19

Figure 2.ThroughPutMaterials(Grain&Chaff)UsedintheExperimentalInvestigation

22

Figure 3.InclinationofSievewithTheHorizontal

23

Figure4.MaterialConveyingDriveSystem

24

figure5.Schematicpresentationofsievesarrangementandmotiongenerationsystem

25

Figure6.SieveSlopeAdjustmentMechanism

26

Figure7.FanHousingandFanBlade

27

Figure8.ForcesActingonFanShaftandtheirLocations

31

Figure9.ForcesActingonEccentricDriveWheelandtheirLocations

31

Figure10.DirectionBeltPullsontheFanShaft

32

Figure11.FreeBodyDiagramoftheFanShaftonVertical(YZ)Plane

34

Figure12.FreeBodyDiagramofFanShaftonHorizontal(XZ)Plane

35

Figure13.ShearForceAndBendingMomentDiagramsforFanShaft

36

Figure14. FreeBodyDiagramOfTheEccentricWheelShaftOnVertical(Yz)Plane

36

Figure15. FreeBodyDiagramoftheEccentricWheelShaftonHorizontal(Xz)Plane

37

Figure16. ShearForceandBendingMomentDiagramforEccentricDriveWheelShaft

38

Figure17. EffectofSieveSlope,SieveOscillationandFeedrateOnSeparationEfficiency
andSeparationLoss

46

Figure18.TheEffectofSieveSlope,SieveOscillationandFeedrateonCleaningEfficiency
andCleaningLoss

48

xi
i

LISTOFTABLESINTHEAPPENDIX
Appendixtable1.Effectofinteractionofsieveslope,sieveoscillationandfeedrateon
cleaningandseparationefficienciesandassociatedlosses

60

Appendixtable2.Analysisofvarianceofseparationefficiency

61

Appendixtable3.Analysisofvarianceofseparationloss

61

Appendixtable4.Analysisofvarianceofcleaningefficiency

62

Appendixtable5. Analysisofvarianceofcleaningloss

62

Appendixtable6.Tablesofmeansofefficienciesandlossesateachleveloffactors

63

Appendixtable7. Somespecificationofatypevbelt

63

Appendixtable8. Coefficientoffrictionbetweenbeltandpulley

64

Appendixtable9. Rawmaterialscost

64

Appendixtable10.Productioncost

65

Appendixtable11.Costsummary

65

xiii

LISTOFFIGURESINTHEAPPENDIX
Appendixfigure1.Viewoftheseparatingandcleaningmachine

66

Appendixfigure2.Forcesactingonmaterialsandtheirdirectionoverthesievesurface

67

Appendixfigure3.Photoofmachineduringconstruction,testinganddatacollection

68

xi
v

DESIGNANDDEVELOPMENTOFTEFGRAINANDCHAFF
SEPARATINGANDCLEANINGMACHINE
ABSTRACT
Availableevidencesuggeststhattefgrainseparationandcleaning,intheruralareaofEthiopia,is
verymuchtraditionalandmakesuseofwindaswinnowertoeffectseparationmanuallyoperatedset
offlatsievetoaccomplishthecleaning.Thismethodistimeandlabourconsuming,andoftenleadto
contaminationofthetefgrainwithdust,dirt,smallsandsorsiltonthethreshingground.Inaneffort
to alleviate the above stated problems, a small engine driven tef grain and chaff separator and
cleaningmachinewasdesigned,manufacturedandtestedtoevaluateitsperformanceintermsof
separationandcleaningefficiencies,andseparationandcleaninglossesatdifferentfeedrate,sieves
oscillationsandsievesinclinations;threelevelsofsieveslopes(0,5and10degrees),fourlevelsof
sieveoscillation(5,10,15and20Hz)andfourlevelsoffeedrates(3,6,9and12kg/min)wereused.
The experimental design was factorial in splitsplit plot. The prototype tef grain separating and
cleaningmachinehadtheabilitytowinnowtheprematuregrains,chaffandleaves,whicharelighter
than grains. It was also capable of reducing time wastage, grains loss, labour requirement and
contamination. The performance evaluated in terms of separating efficiency, cleaning efficiency,
separationlossandcleaninglossatdifferentsieveslopes,sieveoscillationsandfeedratesindicated
thattheseparationandcleaninglossesincreasedwithincreasingsieveoscillationandfeedratefor
all sieve slopes. But the separation and cleaning efficiencies decreased with increasing sieve
oscillationsandfeedratesatallsieveslopes.Theminimumlossesandthemaximumefficiencywere
achievedat5osieveslopeforallsieveoscillationsandfeedrates.Theseparationefficiency,cleaning
efficiency,separationlossandcleaninglosswere97.94,98.58,0.71and0.7%,respectivelyatsieve
oscillationof5Hz,feedrateof3kg/minandsieveslopeof5degrees.Theseparationefficiency,
cleaningefficiency,separationlossandcleaninglosswere52.71,39.88,25.62and34.5
%,respectively,atsieveoscillationof20Hz,atfeedrate12kg/minandatsieveslopeof5degree .
Nonetheless, themachineneeds tobereevaluatedusingmechanicalfeedingdevice andvariable
speedelectricmotortodrivethemovingpartsatdesiredlinearorangularspeeds.

Key words: Tefseparationandcleaning, design, sieve slope,Sieve oscillation,feedrate,

efficiencies,andlosses.
x

1.INTRODUCTION
OneoftheeconomicalcerealcropsinEthiopiaistef.Itisindigenoustothecountry,andisa
fundamentalpartoftheculture,tradition,andfoodsecurityofthepeople.Thiscropisgaining
international recognition and acceptance, and is a means of foreign currency earning in
addition to its value as food and industrial crop at home. Currently, tef is grown on
approximately 2.80 million hectares of land which is 27% of the land area under cereal
production. Tef accounts for about a quarter of the total cereal production and is highly
economicalfoodgraininEthiopia.Approximately,6millionhouseholdsgrowtefanditisthe
dominant cereal crop in 30 of the 83 highpotential agricultural woredas (Bekabil et al.,
2011).Thegrain,aftergrindingandfermentationofthedough,isusedtomakeathinflatpan
cakecalledinjera (Eleni, 2001).
Thepotentialoftefasrawmaterialfornewfoodproductsdevelopmentishighduetoits
proteincomposition;itisglutenfreeandhasaveryhighqualityaminoacidcomposition.Tef
proteiniscomparablewiththatofegg,anidealproteinforchildrenbetweentwoandfive
yearsofage.Ithasbeendemonstratedthattefstarchhasalowglycemicacid,andhasa
mineralcompositionbetterthanothercereals(GamboaandEkris,2008).
Thetraditionalmethodsofharvesting,threshingandpostharvesthandlingoftefusuallylead
intocontaminationoftheproductwithstones,sticks,chaff,dirtanddust.Materialsobtained
after threshing include long straws, chaff, small fragments of spikes, leaves and grains.
Thereforetefgrain,afterthreshingcannotbestoredorusedforconsumptionorasplanting
materialduetotheveryfactthatthepresenceoflongstraws,chaff,smallfragmentsofspikes,
leaves,dust,dirtandotherforeignmaterialsinthegrainwillacceleratedeterioration,thus
lead to poor physical condition and quality of grain becomes eminent. Grain primary
processing usually improves grain condition and quality and the process is a vital and
necessary link between production, storage and distribution. As a result, farmers are
compelledtodoadditionalworkofseparatingandcleaninggrainsfromundesirablematerials
thatwillotherwisereducethequalityandthevalueoftheproductpriortostorage,marketing,
distributionandsubsequentprocessing.

Tef winnowing, separation and cleaning i.e. removal of undesirable materials, is

accomplishedmanuallybytossingthegrainintoairandlettingthewinddotheseparationand
cleaning, removal of lightest impurities, leaves and large amount of debris with certain
amountofgrainsorgrains.Forfurthercleaningisusuallydoneusingsievestoremovethe
heavyparticlesanddirtlargerthanthatoftefgrainorgrain.Thetraditionalmethods of
separatingandcleaningarelaborintensiveandtimeconsuming.Incertaincircumstances,the
velocityofthewindmaybetoolowsothatheavierimpurities(gravel,ear,chaff,etc.)remain
mixedwiththegrains.
Againstalltheodds,theEthiopianfarmersprefertogrowtefbecauseittolerancetolow
moisture stress, waterlogged and anoxic conditions being better than maize, wheat, and
sorghum.Cattleprefertofeedontefstrawratherthananyothercerealstraws.Moreover,tef
asgrainhashighestmarketpricesthantheothercereals;thisincludesbothgrainandstraw,
andthegrainisnotattackedbyweevilsduringstorage(Seyfu,1993).Doublingboththegrain
and the straw yield of tef would significantly contribute to Ethiopias economy and food
security.Techniquesbeingexploredtoachievetheseincludenotonlyincreasingareaunder
tefcultivationbutalsousingappropriatemechanizationtechnologies.
Agricultural production, productivity and its sustained development depend on the
advancementofscienceandtechnologythatwillenhanceproduction,processing,handling,
transportation,distributionandmarketingprocessesofstrategicallyimportantcrops.Inthis
regard,concertedeffortsareunderwaytomodernizetheproductionandprocessingoftef.
Nonetheless, the development and demonstration of threshing, separating and cleaning
machinery,destinedtoalleviatethepressingproblemoffarmers,weredoneontrialanderror
basis or were simple reproductions of crude machines developed elsewhere without
appropriateperformanceevaluationandrealitiesonground.Almostallofgovernmentaland
nongovernmentalorganizationsinvolvedinresearch,development,testingandimprovement
ofmechanicalthreshersarenotfarfromthefactstatedabove.
The AAMRC and Sasakawa Global Africa 2000 (SGA2000) are currently involved in
modifyingtefthresher,demonstrationandintroductionofthesametothefarmers.Despite

havingafan,themodifiedtefthresherhadfailedtomakeproperandacceptablelevelof
separationandcleaningoftefgrainfromundesiredmaterials.Asaresult,famerswereforced
toredoseparationandcleaningofgrainfromstraw,chaff,dirtanddustusingsievesmanually
inordertomaintainhighquality,securereasonablemarketvalueandminimizedeterioration.
Toalleviateproblemsassociatedwithchaff,straw,dirtanddustseparationandcleaningtef
grainitwasfeltappropriatetodevelopamachinethatcanseparateundesiredmaterialsand
cleantefgrainafterthreshingusingeithermanual,animalormechanicalmeans.Althoughthis
researchendeavorismainlyconcernedwithtefgrains,thetechniquesandtheequipmentwill
applicabletoalltypesofgrainsbyonlyreplacingthesieve.
Thegeneralobjectiveofthestudywas:
1

Todesignandfabricateaprototypemachineforseparationtefchafffromgrain

andtodocleaning.
Specificobjective
1

Toevaluatetheeffectivenessofthemachineonseparatingandcleaningin

termsofseparationefficiency,separationloss,cleaningefficiencyandcleaningloss
basedonsieveslope,sieveoscillationandfeedrate.

2. LITERATUREREIVEW
2.1. FunctionofGrainSeparationandCleaning
Itiswellrecognizedthatgrainsarethemostimportantinputforagriculturalproductionand
theycarryimportantgeneticinformationofwhichthedesirabletypescanbeexpressedunder
wellorganizedproductionknowhow.However,thebenefitsofgoodcropvarietiescannotbe
realized without the availability of clean seeds to farmers. Furthermore, clean seeds of
improvedvarietiesneedtobemaintainedunderspecificconditionstoproducequalitygrains
byfarmer.
Thefunctionofgrainseparationistoremove/separategrainfromunwantedmaterialssuchas
brokenandyetshortstraw,piecesofbrokenears(cobs)andchaff.Thefunctionofgrain
cleaningistoeliminateforeignorundesirablematerialsuchastwigs,leafandsoilparticles,
emptyandweedseeds,dust,chaffandtheliketoreducebulk,improvestorabilityandmake
grainseasiertohandleduringsubsequentprocesses.Theidealcleanedgrainisfreefromany
othermaterials.Thedegreetowhichthisisachievediscalledthepurity(cleaningefficiency),
usually measured in percentage (Schmidt, 2000). Cleaning refers to separation of
contaminantsfromproduceandcompleteremovalofthecontaminantssothatthecleaned
produceisfreefromrecontamination(Kajuna,2001).
Separatingprocessfractionthegrainlotintotwocategories,onecategorycontainingthegrain
andtheothercontaininginertmatterlikestem,leaves,dust,dirt,chaff,etc.tobedischarged.
Therearemethodsthatmayseparatethegrainlotintoseveralfractionswithvariouspurities.
Intermediate fractions typically contain both grains and inert matter and must be further
cleaned(Schmidt,2000).
Basically,undesirablematerialcanbeseparatedfromthegrainifitdiffersinitsphysical
characteristicssuchassize,shape,weight/massanddensityorspecificweight.Andthemore
similar the impurities are to the grains, the more difficult they are to remove/separate.
Variationingrainsizeandmorphologyofthegrainaddsanotherconstrainttograincleaning:

thelargerthevariationinthegrainlot,themoredifficultitistoclean.Eliminating/takingout
inert matter without eliminating grains with different sizes is difficult for many species
(Schmidt,2000).
2.2.SeparatingandCleaningDevices
Theobjectiveofusingaseparatingandcleaningdeviceistoseparategrainfrommaterials
otherthangrain(MOG).Suchdevicesmaymakeuseofdifferencesinsurfacecharacteristics
ofthegrains.Therearemanytypesofseparatingandcleaningdevicenamely:aerodynamic,
mechanical,combinationofaerodynamicandmechanical,specificgravitytablemethodetc.
(Arfia, 2006). Many commercial cleaners incorporate more than one of these cleaning
methods(Hauhouotetal.,2000).
2.2.1.AerodynamicSeparatorandCleaner
NageshandLakshminarasimhan(2014),pointedoutthatthreshedgrainsrequireconsiderable
additional cleaning before it can be used as food, whole or ground and even as grain.
Pneumatic(aerodynamic)cleaningistheprocessofusingairtoliftlight,chaffyanddusty
materialsoutofthegrainswhileheaviermaterialsmovedownward.
Foraerodynamicseparationtooccur,theparticlesinamixturemustbeacceleratedasfree
dispersedbodiesandnotasamat.Aerodynamicseparationdependsupontheexistenceofa
differential between suspension velocities (terminal velocity) of the components to be
separated.Aerodynamicseparatorandcleaneruseairasamediumtoliftlightmaterialssuch
aschaffanddustoutofmixtureofgrainandundesirablematerials;i.e.heaviermaterials
moving downward while light materials are blown away. Air current, either to blow or
suspendlightermaterials,isgeneratedbynaturalormechanicalfan.However,thelimitation
ofnaturalaircurrentasameansofseparationistheunpredictabilityindirection,speedand
continuity of the air current (wind), and the high labor requirement and rather imprecise
degreeofseparation(AguirreandGarray,1999).

Aerodynamicseparatorsandcleanerarebasicallyoftwotypes,namelytheverticalairstream
andhorizontalairstreamseparators(GorialandCallagham,1990).Intheverticalairstream
separator,airstreamisflowingverticallyagainsttheinjectedmixedproductsuchthatheavy
particlesdropthroughtheair(countercurrentflow)whilethelightmaterialsmoveupward
andarecarriedalongbytheair(concurrentflow).Inthehorizontalairstreamseparator,airis
blownhorizontallyorataninclinedangletothehorizontalagainstmixedproductinjected
along the vertical plane. The mixed products are displaced along the horizontal plane at
variousdistancesbasedontheiraerodynamicproperties(GorialandCallagham,1990).

2.2.2.Mechanicalseparation
Inmechanicalseparationmixedmaterialsaremovedoveraperforatedandoscillatingsurface
with openings of specified shape and size. Mechanical or sieve separation is a process
separatingthedesiredmaterial/grainfromundesiredmaterialsonthebasisofdifferencesin
sizes and shapes. Multi sieve separators are used for classifying grains to size grades.
Nonetheless, presence of short straws creates problems by blocking sieve openings and
therebyreducesthequalityoffinalproduct.Segregationandseparationtakeplacealongthe
sieve length as grain and MOG are being transported over the sieve. The thickness and
looseness of the grain and MOG layer on the sieve influences separation (Gorial and
Callagham,1990).Theprocessofseparationisensuredbytherelativemovementoflayersof
grainandundesiredmaterialscausedbytheoscillationofplainsieves(Wangetal,1994).
2.2.3.Combinationofaerodynamicandmechanical
Combinedairandsievesystem,usedtoseparategrainfromundesiredmaterials,employs
terminalvelocity,size,shape,anddensityas ameanstosegregationandseparation.The
methodisadvantageousandeffectivethantheothersmethodsofseparation.Theprimary
methodofgrainseparatingandcleaning,atthemoment,istheairsieveseparator(OARI,
2006/7).AccordingtoSimonyanetal.(2006)thephysicalparametersaffectingtheseparating
andcleaningprocessaregroupedintotwo:(i)cropfactorsthatincludecropvariety,maturity

stage,grainmoisturecontent,strawmoisturecontent,bulkdensityofgrain,bulkdensityof
6

straw,stalklength,terminalvelocitiesofparticles(bothgrainandothermaterials),grainsize
and(ii)machinefactorssuchasfrequencyofsieveoscillations,amplitudeofoscillation,sieve
slope,lengthofsieve,widthofsieve,sieveholediameter,fanspeed,angle/directionofair
flowfromthefan.
2.3.FactorsAffectingSeparatingandCleaningEfficiency
Separationandcleaningmachinehasbeenevaluatedusingparameterssuchasseparatingand
cleaningefficienciesandlossesassociatedwithseparationandcleaningloss.Machinebased
factorsuchassieveoscillation,sieveslopeandfeedingrate,andcropbasedfactorsuchas
physicalpropertiesandaerodynamicpropertieswereconsideredtoaffecttheperformanceof
themachine
2.3.1.MachineFactors
2.3.1.1.Effectofsieveoscillationandsieveslope
Ebaid(2005)indictedthatsieveslope,sieveoscillationandairspeedswerethemainfactors
thataffectseparating,cleaningandtotallosses.Bothseparatingandleaningefficiencyand
totallossincreasedwithincreasingairspeed,sievetiltangleandsieveoscillation.According
toAwady etal. (2003) cleaningefficiencyandtotallosseswereseriouslyaffectedbyair
speed,andsievetiltangle.Abdel etal.(2007) reportedthattheslopeofthesievewasthe
main factor that had a great effect on separation efficiency. The separation efficiency
increasedsignificantlywithincreaseinsieveslopeatsmallstrokelengthanddecreasedat
highstrokelengths.Ingeneral,therewasdecreaseincleaningefficiencywithincreasingsieve
oscillation frequency along the sieve length. The decrease in cleaning efficiency with
increasingsieveoscillationsmaybeduetolessresidenttimeofmaterialstobeseparatedon
thesieve.
HarrisonandBlecha(1983)describedthatthetransportofparticlesalongoscillatingsieves,
whichisafunctionofsieveoscillationfrequency,affectstheefficiencyoftheprocessand

affectsmeteringofparticulatesubstancesalongthesieve.FellerandFoux(1975)indicated
thatthefrequencyaffectsthepassageofparticlesthroughthesieves.Therewasanincreasein
cleaninglosswithincreasingsieveoscillationfrequency.AccordingtoSalwa etal. (2010)
increasingthesieveoscillationfrom26Hzto34Hzconsiderablydecreasedthecleaning
efficiencyoffennelgrain.Inthecleaningsystemofcerealharvesterhavingoscillatorysieves
andalsoinvacuumseparatorsfrequencyofoscillationswerefoundtobethemainfactorthat
canappreciatetheoptimalefficiencyofseparation(Voicuetal,2007).
2.3.1.2.Effectoffeedingrate
Inverserelationshipshadbeenreportedbetweenseparatingandcleaningefficienciesandfeed
rate.Declineinefficiencyhasbeenacommonphenomenonwithincreasingfeedingrate.The
inverserelationshipbetweencleaningefficiencyandfeedratewasindicatedbeduetothe
increasingloadonthesievethatrestrictedfreemovementofgrainsandundesiredmaterials
(Abduljelil,2010).Abduljelil(2010)notedacleaningefficiencyof40.13%atthefeedrateof
120 kg/hr while the same efficiency declined to 36.83 % at the feed rate of 600 kg/hr.
According to Awady et al (2003) cleaning efficiency and total losses were affected by
increasingfeedratewhencleaningrice(athigherfeedrate,itrequiredgreatersievelength
andtooklongertimeforthegraintobeseparatefromMOG.Thiswasconsideredtobedueto
thedensenessoftheMOG,whichmakesdiffusionofthegrainthroughitverydifficult.The
increaseincleaninglosswithincreasingfeedratewasindicatedtobeduetohighintensityof
loadwithMOGonthesievethathadmattingeffectonthesieveandpossiblyblockedsieve
holes(Awadyetal.,2003).Awadyetal(2003)furtherindicatedthatiffeedrateisincreased
(higher),thematerialsarenolongersupportedaerodynamically,andformamatonthesieve,
increasinggrainlosses.Abduljelil(2010)indicatedthattherecouldbeanincreaseingrain
loss with increasing throughput of MOG. Faran and Macmillan (1979) confirmed that
increasingmaterialfeedratealsoincreasedthetotalheadonthefanleadingtoareductionin
airvelocityfromthenominalvalue.AccordingtoKepneretal.(1972)separation,atlowfeed
rateswithcerealgrainsandlargegrains,isprimarilyaerodynamic,andlossesareusually
small.

2.3.2.Cropfactors
2.3.2.1.Physicalpropertiesoftefgrainandstraw
GumbleandMaina(1990)indicatedthatphysicalandmechanicalpropertiesofgrainssuchas
size,shape,density,reposeangle,coefficientoffriction,tensileandcompressivestrengthsare
importantparametersandbemeasuredorestimatedinordertodesignseparating,cleaning,
sizingandgradingmachines.Abdulejelil(2010)measuredand/orcalculatedaveragediameter
(based on major and minor axis diameters), arithmetic and geometric mean diameters,
equivalent diameter, thousand grain weight (TGM), coefficient of friction on different
materials,anddensityoftefgrains(VarietyDzCr196)withinthemoisturerangeof11.94
to27.10%(wb)(Table1and2).
Table1.Physicalpropertiesoftefgrainatvariousmoisturecontents
Moisturecontent
(%,wb)

TGM(gr)

Coef. of friction,
(onmildsteel)

particleDensity
3)
(kg/m

11.94
15.10
21.10
24.20
27.10
Source:Abduljelil,2010

0.2920
0.3201
0.3609
0.3918
0.4207

0.41
0.50
0.66
0.58
0.52

1361.82
1358.22
1314.85
1283.67
1252.91

Table2.Measuredandcalculatedmeandimensionsoftefgrainatdifferentmoisturecontent.
Moisture
content
(%,wb)
11.94

Major

Minor

Averagedia.

Geo.Mean

Equivalent

(mm)

(mm)

(mm)

L22)1/3

(mm)

dia.L1

dia.L2

(L1+2L2)/3

dia.(L1x

.dia.De

1.14

0.54

0.74

(mm)
0,69

15.10

1.15

0.56

0.76

0.71

0.77

21.10

1.36

0.61

0.86

0.80

0.87

24.20

1.38

0.62

0.87

0.81

0.84

27.10
1.40
Source:Abduljelil,2010

0.62

0.88

0.81

0.86

0.74

Abduljelil(2010)alsoestimatedthediameterandmassofnodefree,middlenodedandend
nodedstrawswithdifferentlengths(Table3).
Table3.Specificationoftefchaffsamples
Strawlength
(cm)

Nodefree

Middlenode

Endnode

Mass(g)
0.008

Dia.(mm)
2.250

Mass(g)
0.021

Dia.(mm)
1.220

Mass(g)
0.014

Dia.(mm)
1.590

0.014

2.260

0.023

1.520

0.016

1.770

0.025

1.610

0.028

1.830

0.026

1.650

0.029

1.630

0.032

1.760

0.032

1.810

0.034

1.870

0.060

1.712

0.061

1.720

10

0.058

1.670

0.640

1.880

0.063

1.830

Source:Abduljelil,2010
ZewduandSolomon(2006)indicatedthatlength,width,equivalentspherediameter,and
TGWoftefincreasedfrom1.01to1.27mm,0.59to0.68mm,0.71to0.87mmand0.257to
0.421g,respectively, withincreasein moisture content from5.6%to29.60%(wb).The
sphericitydecreasedfrom0.70to0.63withincreaseinthemoisturecontentfrom5.60%to
21.43%andincreasedto0.69withfurtherincreaseinmoisturecontentto29.60%.Thebulk
3

andtruedensitiesdecreasedfrom840to696andfrom1361to1207kg/m ,respectivelywith
increaseinmoisturecontentfrom5.60%to29.60%(wb).Theporosityandangleofrepose
increased, respectively, from 38.31%to 42.32% and23.741 to 51.161with increase in
moisturecontentfrom5.60%to29.60%(wb).Thecoefficientofstaticfrictionincreasedfrom
0.29to0.50,0.36to0.51,and0.18to0.48onmildsteel,plywoodandglass,respectively,
withincreaseinmoisturecontentfrom5.60%to29.60%(wb).
2.3.2.2.Aerodynamicpropertiesoftefgrainandstraw
Mohsenin(1978)indicatethatseparationofaproductfromitsassociatedandyetundesirable
materials, such as straw and chaff, in air stream, require knowledge of aerodynamic
characteristicsofalltheparticlesinvolved.Furthermore,itwasnotedthatarangeofair

10

velocities,foreffectiveseparationofthegrainfromMOGneedtobeestimated.Assuch,the
terminal velocity (Vt) be used as an important aerodynamic characteristic of materials in
pneumaticconveyingandseparation.
Wuetal.(1999)andZewdu(2007)notedthatbydefiningtheterminalvelocityofdifferent
threshedmaterials,itwaspossibletodetermineandsetthemaximumpossibleairvelocityin
whichMOGcanberemovedwithoutlosses.Abduljelil(2010)foundtheterminalvelocityof
tefgraintoincreasingfrom3.24m/sto4.04m/swithincreasingmoisturecontentfrom11.94
%to27.10%(wb).Onthecontrary,henotedthatthedragcoefficientwasdecreasingfrom
0.76to0.66withincreasinginmoisturecontentfrom11.94%to27.10%.Similarly,Zewdu
(2007)foundthattheterminalvelocityoftefgrainwasincreasinglinearlyfrom3.08to3.96
m/swithincreasinginmoisturecontentfrom6.50%to30.10%(wb)whilethedragcoefficient
oftefgraindecreasedfrom0.83to0.65withincreasinginmoisturecontentfrom6.5to30.1
%wetbasis(wb).
Short straws are the major contaminant of threshed materials; they are very difficult to
separatefromthegrain.Strawsareneithersymmetricalnoruniform,indensity,andtheirlack
ofsymmetrycauses aerodynamic instability. Theterminalvelocity ofbothnodefree and
middlenodedstrawsoftefdecreasedfrom3.69m/sto2.13m/sand3.08m/sto1.70m/s,
whiletheterminalvelocityofendnodedstrawincreasingfrom3.32m/sto5.40m/swith
strawlengthincreasingfrom1to10cm(Zewdu,2007).Completetheoreticalseparationoftef
grainfromstrawusingaircurrentonlyisnotpossibleparticularlywhenendnodedstraws
have terminal velocities close to or even greater than that of tef grains (Zewdu, 2007;
Abduljelil,2010)
2.4.ScreeningSurfaceandRecommendedSieveSizesforDifferentGrains
Thebasicsieveforcleaningelongatedgrainisaslottedtopsieveandaslottedbottomsieve.
Inspecialseparationsitmaybenecessarytopasssuchgrainthroughroundholetopsieveor
oversomesieveotherthanaslottedbottomsieve,butgenerally,slottedtopandbottomsieves

11

areused(USDA,1968).AAMRC(2012)recommends differentsievesfordifferentcrops
(Table4).
Table4.Recommendedsieveopeningssizesfordifferentgrains.
No.

Crop

Screenopeninginmm
TopScreen

MiddleScreen

BottomScreen

1.

Wheat

10r,9r,
8r,6.5r

4s,4.5s,6.35r

2s,2.25s

2.

Barley

14r,10r

4.5s,3.5s

1.7s,1.4s

Soybean

12r

8r

2.5s

Sorghum

6r,7r

4.25s,4.5s

1.7s,2s

Haricotbean

10r

6.5s

2.75s

Tef

2r

1s

0.56s,0.5s

Maize

14r

12r,10r

8r,6r

Rapegrain

4r

2.5s

1s

Source:AAMRC,2012;whererstandsforround,sstandsforslotted
Materialscreeningonsieveswithoscillatorymotionisacomplexprocess,influencedbya
widerangeoffactors,relatedbothtothephysicalpropertiesofthematerialsubjectedto
screening,aswellastothegeometryoftheseparationsystemanditskinematicandfunctional
parameters.Thus,theunderstandingoftheangleofinternalandexternalfrictionofgrainson
the separation surface, their density, shape of material particles (of grains), grains size,
contentofimpuritiesingrainmixture,etcareimportant(Yanet.al,2010).
2.5.DesignConsideration
2.5.1.Designofpowertransmission
Thepowertransmissionsystemsusedinthedesignofmachinearebeltandpulleys,sprocket
wheels and chain, shaft, gears, universal joints and clutches. Among flexible machine
elements,perhapsVbeltdriveshavethewidestindustrialapplication.Hence,oneormoreV

12

beltsmaybeusedonadrive,asrequired,totransmitpowerbecauseoftheirsimplicityand
easeofdesign,selection,installation,maintenanceandrepairandtheirlowcost.Thestandard
VbeltsectionsareA,B,C,DandE.TheTable5containsdesignparametersforallsections
ofVbelt.ThekWratinggivenforaparticularsectionindicatesthatbeltsectionselection
dependssolelyonthepowertobetransmitted,irrespectiveofnumberofbeltsused.Ifthe
requiredpowertransmissionfallsintheoverlappingzone,thenonehastojustifytheselection
fromtheeconomicviewpointalso(RPPC,undated).
Table5.SomebasicspecificationofVbeltsections
Section

KWRange

MinimumPulleyPitchDia.(mm)

A
B
C
D
E

0.44
1.515
1070
35150
70260

125
200
300
500
630

Width(mm) Thickness(mm)
13
17
22
32
38

8
11
14
19
23

Source:RPPC,undated.
2.5.2.Designoffan
Fansaremachineswithrelativelylowpressurerisesthatmoveairorgasesorvaporsbymeansof
rotatingbladesorimpellersandchangetherotatingmechanicalenergyintopressureorworkon
thegasorvapor.Theresultofthisworkonthefluidwillbeintheformofpressureenergyor
velocity energy, or some combination of both (IMP, 1993). Loren Cook Company (1999)
classifiesfanintocentrifugalandaxialfans.Centrifugalfansdischargeairperpendiculartothe
axisofanimpellerrotation.Itwasindicatedthataprecisedeterminationofairflowvelocityand
outletpressurearethemostimportantparametersinthedesignand/orselectionofafan.The
choiceoffantypeforagivenapplicationdependsonthemagnitudesofrequiredairflow.Fora
givenfantype,theselectionoftheappropriateimpellerdependsonrotationalspeed.Speedof
operationvarieswiththeapplication.Foragriculturalapplications,fanspeedsarerecommended
tobebetween450and1000rpm(Adane,2004).AscitedbyAdane(2004),Bosoietal(1991)
indicatedthattheinitialdatarequiredforthedesignofafanarethemeanvelocityofairstream
flow at its exit (Cmean ), the volume flow rate (V). The flow rate of desired air stream is
determinedformtheconcentrationofthematerialentrainedbythe

13

air, givenasratioof Gm toGa andhasavaluebetweenorequalto0.20and0.30.The

volume flow rate of air required to make separation between grains and MOG can be
estimatedfromtheequationgivenbelow.
22

G G
a m

(1)

1 ()

Where:
3

V=volumeflowrate(m /s),
Ga=themassflowrateofair(kg/s)
Gm=thequantityofmaterialremoved
bytheairstreamperunittime(kg/s);

=coefficientofconcentration(unit
less),
3

= densityofair(kg/m ).
2
Thedynamicheadh C mean
d
2

(2)

below.
Thestatichead,dependsonthe
resistanceoftheaircurrent,is
estimatedtheequationgiven

hs

(1k2)h

where:

Where:
A=theareaofcross
sectionalattheexitof
2

thefandischarge(m )

Aeq=anequivalentareawhichallowsthesamequantityofairflowsatentrance(m )
Theoverallpressureheadcanbecalculatedas:

Hhshd
2.5.3.Designofshaft
A shaft is a rotating machine element that transmits power (Khurmi and Gupta, 2005;
Nwaigweetal,2012).Thedesignofshaftincludesthedeterminationofthecorrectshaft
diametertoensuresatisfactorystrengthandrigiditywhiletransmittingpowerundervarious
operating and loading conditions. Design of shaft is based on the maximum shear stress
theory.Shaftsareusuallysubjectedtotorsion,bending,andaxialloads.Forasolidshaft
havinglittleornoaxialloading,thediameteroftheshaftcanbecalculatedusingtheequation
givenbyASMEcode(ASME,1995)as:

d3

16

(kbMb)2(ktMt)2

(5)

max

where:
d=diameteroftheshaft(m),
Mt=torsionalmoment(Nm),

Mb=bendingmoment(Nm),
Kb and Kt = combined shock and fatigue factor applied to bending and torsional
momentrespectively.Kb=1.2to2.0;Kt=1.0to1.5.

max=allowablestress(55MPaforshaftwithoutkeywayand40MPaforshaftwith
key).Forrotatingshafts,whenloadissuddenlyapplied(minorshock):Itmustbe
notedthatfactorofsafetyneedtobeconsideredinactualdesignwork.

AccordingtoKhurmiandGupta(2005)torsionalmoment(Mt)canbecalculatedas;

15

Mt(TiTj)

D2
2

(6)

Where:
Ti=tensionontightsideofabelt(N)
Tj=tensiononslacksideofabelt(N),
D2isthediameterofdrivenpulley(mm).
Todeterminetensionsonthetightandslacksidesofabeltthefollowingequationscanbe
used(KhurmiandGupta,2005).

max
Ti
Tmaxa

(7)
(8)

(9)

T c mv2

Where:
TcandTmax=thecentrifugalandmaximumtensionofabelts(N),

=maximumsafenormalstress(N/mm2),aiscrosssectionalarea(mm2),
m=massperunitlength(kg/m)ofbeltsandvisspeedofbelt(m/s).
Theslacksidetensionofbeltscanbedeterminedfromthefollowingrelation;

Ti Tc
e
Tj Tc

cosec

(10)

Where:
=coefficientoffrictionbetweenabeltandapulley

=grooveangle

=angleofwrap
1
6

AccordingtoRyder(1989)Mtcanbecalculatedas:

Mt

P60

2N
(11)

where:
P=powerrequiredtodrivethemachine(W)
N=speedoftheshaft,rpm
Themaximumbendingmomentshallbecalculatedasfollows(Ryder,1989);
Mb(Mv2Mh2)1/2

(12)

where:
Mv=bendingmomentonverticalplane(Nm)
Mh=bendingmomentonhorizontal(Nm)

1
7

3. MATERIALSANDMETHOD
3.1. ExperimentalSiteDescription
The experiment was conducted at Asella Agricultural Mechanization Research Center
(AAMRC),OromiaAgriculturalResearchInstitute(OARI).Asellaislocatedat659'to8
49'Nlatitudesand3841'to4044'Elongitudes,havinganelevationof2430metersabove
sealevel(masl).
3.2.DesignConsiderations
Thetefseparatingandcleaningmachinewasdesignedanddevelopedbasedonthefollowing
considerations.
9.

Theavailabilityofmaterialslocallytoreducecostofproductionandmaintenance;
thematerialsfortheconstructionofthevariouscomponentpartswereselectedon
thebasisoftheforcethatwouldbeactingonthem,theworktheyareexpectedto
performandtheenvironmentalconditioninwhichtheywouldfunction;

35.

Duetosmallsizeoftefgrainsandtheirlowterminalvelocity,separationofgrains
from chaff and straw and complete cleaning was thought to be practically
impossible. Hence, it was decided to use combination of fan (pneumatic) and
mechanical(sieves)methodstoeffecttheseparationandcleaning.Asaresult,the
designincludedselectionofsievesandidentificationoptimumoscillationlevel;
and

61.

Toavoidcloggingofthemachineduringtheexperiment,manualoperatedconstant
anduniformfeedingmechanism,foreachfeedingrate,wasdesignedandused.

1
8

3.3.DescriptionoftheMachine
Themajorcomponentsofthetefandchaffseparatingandcleaningmachinearetheframe,
belt conveyor, pulleys and Vbelts, separating and cleaning unit, diesel engine, eccentric
wheel,fanandfanhousing.Figure1givesdetailsofmachinedesigned,constructedandused
intheexperiment.(Photographoftheprototypeduringconstruction,materialdistributionover
theconveyor,testinganddatacollectionwasgiveninAppendixFigure3.)

(A)

(B)
Figure1.DetailsoftheExperimentalTefChaffSeparatingandGrainCleaningMachine(A=
isometricview,B=sectionview;alldimensionsareincm)

19

Amanualdrivenbeltconveyorwasusedtocontrolfeedrate(bothrateanduniformity
distribution)ofchaffandtefgrainintotheseparatingandcleaningunit.Thebeltconveyor
washorizontalandhadbeenprovidedwithrectangularguards(262x50cm)onitsbothsides
foreasyflowandzerolossofweighedtestmaterials,tefchaffandgrain,intotheentranceof
separatingandcleaningunitofthemachine.Thefanhousewasmadefrom1.50mmthick
sheetmetalandmeanttoaccommodatethefanbladeandshaft.Theseparatingandcleaning
unithadthreesieves,sieveframe,rockerarmandchaffandgrainoutletpan.A5hpHONDA
dieselenginewasusedassourceofpower.Driveanddrivenassemblyconsistedofashafts,
beltsandpulleys.Theframeoftheexperimentalmachinewasmadefrom40x40mmangle
iron.Table6givespertinentdimensionandpowersourceanditsratedpower.
Table6.Pertinentdimensionsofcomponentpartsandpowersourceanditsratedpower
Component
Overallsize(lengthwidthheight)
Sieve(widthlength)
PowerSource,HONDAengine
Maximumfanspeed
Perpendicularloadareaofbeltconveyor
Beltconveyorcylinderdiameter
Beltconveyorcylinderlength
Diameterofeccentricwheel
Rockerarm(Lengthxwidthxthickness)
Pulleydiameterofengine
Pulleydiameteroffanshaft
Pulleydiameterofeccentricwheelshaft
Fanoutletarea
and
clean
3.4.WorkingPrinciplesofthe thetef
grains.
Machine
A
mixtur
Themachinewasdesignedto etef
employacombinationof
grains
mechanicalandaerodynamic and
principlestoseparatetefchaff chaff

Dimensions/Po
wer
(316x50x148)
cm
(40x60)cm
5Hp
1000rpm
(36x200)
2
cm
32cm
36cm
10cm
(50x4x0.4)
cm
120mm

1
6
5

m
m
1
3
8

m
m
2
4
0

c
m
2

w
lyspreadonthebeltconveyer
aalongitsentirelengthandfed
sintotheseparatingand
ucleanunitatpredeterminedrate
noffeeding.Asthematerials,tef
igrainsandchaffwereontheir
f
wayintotheseparatingunit,
o
theyweresubjectedtoair
r
currentgeneratedbythefan.As
m
a
20

result, light chaffs with low terminal velocities were blown away before they reached
separatingandcleaningunits.Heaviermaterials,withhigherterminalvelocity,managedto
landonthetopsievethatpermittedpassageoftefgrainsandretainedchaffswithsizesgreater
thanthegrains.Thefinalseparationandcleaningwaseffectedbysievesoscillatedatdifferent
cyclespersecond.Thetopsievewasdesignedandselectedtoretainverycoarsematerialsand
toconveythemtotheMOGoutlet.Themiddlesievewasselectedinsuchwaythatitcould
scalpallmaterialslargerandheavierthangrainspassedthroughthetopsieve.Thepurposeof
thebottomsievewastocarryoutfurthercleaningoftefgrainfromtrash,sand,dust,dirtand
brokengrains.A5hpHONDAdieselengineprovidedthepowerrequiredtooperatethe
machineduringtheentireworkoftheexperimentalinvestigation.
3.5.MeasuringDevicesandInstruments
AnExtechInstruments (Model 451126),VaneThermoanemometerdata logger,madein
Taiwanwasusedformeasuringtheairspeedatfanoutlet.ColeParmer8204tachometer,
with measuringrange of62to19999rpm andhavinga resolution of1rpmwas usedto
measurethespeedsofshafts.ModelCTdigitalbalance,madeinJapan,wasusedtomeasure
weightsofsamplesbeforeandafterseparatingandcleaningexperiments.Thebalancehad
o

accuracy0.02g.Anelectricaloven,madeinUSA(CarboliteDryovenmax400C )wasused
formeasuringthemoisturecontentofsample.
3.6.PreparationofSamples
Samples for the experimental investigations were prepared from materials obtained after
threshingtefasshowninFigure2.Fivekgofsampleswiththreereplicationsweretaken,
siftedmanuallyandweighedtodeterminetheamountofcleangrainsandinasamplebefore
commencingontheexperiment.Theamountofcleangrainsandimpuritieswereusedto
knowthemassofgrainsandimpuritiesbeforeandafterseparationandcleaningusingthe
prototypemachineunderinvestigation.Themoisturecontentsofthesampleswerefoundtobe
o

10.20%(wb)usingaconvectiveairovenmethodadjustedat105 .

21

Figure2.Throughputmaterials(grain&chaff)usedintheexperimentalinvestigation.
Thesamplespreparedwerefedattherateof3,6,9and12kg/minatpredeterminedsieve
slope(degrees)andsieveoscillation(cycle/sorHertz).
3.7.DesignAnalysis
Theseparatingandcleaningmachinewasdesignedforseparatingtefchaffandcleaningtef
grain.Inordertomeettheseparatingandcleaningrequirements,differentparameterssuchas
determinationsieveslope,determinationofsieveoscillation,pulleydiameters,shaftdiameter,
belt length, center distance between pulleys etc. were decided based on work done by
different researchers on different crops earlier and by applying theories, principles and
practices of machine design particularly grain separators and cleaners. Accordingly, the
followingdimensionshavebeenselected;Maximumfanspeed1000rpm(Adane,2004),Air
speed at fan exit 3.2 m/s by considering terminal velocity of tef grain (Zewdu, 2007;
Abduljelil,2010).

2
2

3.7.1.Determinationofsieveslope
Thesieveslopesusedintheexperimentweredeterminedinthebasisoftheconditionthatthe
angle be angle (Fouda,2009).Where is theinclinationofthesievewiththehorizontal
whileisthefrictionanglebetweenthemixturegrainandchaffandthesievesurface.Asper
theconditionstatedabove,theentirematerialonthesievewouldnotslidewhenthesieve
wasatrest(stationary),i.e.whenthevelocityofthesieveequaledtozeroattheendofthe
strokes. According to Zewdu and Solomon (2006), the mean value (angle of inter nal

resistance)oftefgrainonmildsteelis20 .Hence,0 ,5 and10 sieveslopes(Figure3)were

selectedtoinvestigatetheireffectsofseparationandcleaningoftefgrainandchaff.

Figure3.Inclinationofsievewiththehorizontal.
3.7.2.Determinationofsieveoscillation
Thedataonoptimumsieveoscillationfrequencyofsievestomakeseparationbetweentefgrain
andchaffandtoeffectcleaningwasnotavailable.However,Voicuet,al.(2011)studiedthe
influenceofsieveoscillationfrequencyusingdifferentgrainsatoscillationfrequenciesof6,9
and13Hz.Tabatabaeefaretal(2003)foundthatsieveoscillationfrequencyof200Hztobethe
optimumtogradechickpea.Khawaja(2009)recommendedsieveoscillationfrequenciesbetween
6and20Hztobeusedincleaningcerealgrains.Accordingly,sieveoscillationfrequenciesof5,
10,15and20Hzwereusedinthisstudytodeterminetheoptimumoscillationfrequencyof
sievestoseparatetefchaffandcleantefgrain.

3.7.3.Constructionofbeltconveyor
Theconveyor,meanttofeedtheprototypemachineatuniformandcontinuousfeedingrate
andavoidoverloadingofthesievesand/orintermittentflowofmaterialsintotheseparation
andcleaningunit,wasdesignedandmadefromcloth(abujedi).Theconveyorwasmadeto

2
3

runovertwocylindersmadeoutofsheetmetal,placedatcenterdistanceof2mandhaving
diameterandwidthof32cmand36cm,respectively.Conveyingofmaterialswasmade
possiblebyturningtheconveyorrotatingarmatconstantandpredeterminedspeedtoachieve
andmaintainthedesiredfeedrate(Fig.4,andFig.1).Beforetheactualexperimentwas
commenced, operators were trained to turn rotating arm at a constant speed so that the
conveyorcoveredadistanceof2minoneminutetherebyitslinearspeedwas0.033m/s.
AccordingtoConveyorBeltingAustralia(CBA)(2009),thecapacityofbeltC(Eq.13)was
determinedtobeas32.34kg/s.Thewidthoftheconveyorcylindersandtheclothused(36
cm) were 4 cm narrower than the sieve width in order to make sure that all conveyed
materialslandonthesievewithoutspillingoverandoutofsievearea.

CAV

(13)

Where:
A=loadcrosssectionareaperpendiculartothebeltcomputedasWidthxlength=
2

0.36 mx2m=0.72m
2

=densityofmaterial(1361kg/m )

V=velocityofconveyor(0.033m/s)

Figure4.Materialconveyingdrivesystem.
3.7.4.Designandfabricationoftheprototypeseparatingandcleaningunit
Themajorcomponentsofseparatingandcleaningunitincludedsieves,sieveframeandrocker
arm.Thesievingunitconsistedofthreesievesforseparatingandcleaning

2
4

simultaneously.Thethreesieveshadlengthof60cmandwidthof40cm.Thetopsievehad
roundholes,3mmindiameter,themiddlesievehadroundholes2mmindiameterwhilethe
bottomsievehad1mmslottedholes.Theverticalintervalsbetweensieveswere10cm(Fig.
5).Theframethatsupportedthesieveswasconstructedfromsheetmetalof1.5mmthickness.
Thesieveframehadfouroscillatingorrockinglegs,atthefrontandrear.Theoscillatingor
therockinglegsweremadefromsheetmetalhavingathicknessof4mm,awidthof4cmand
heightof50cm.AscanbeseenfromFigure5,thebottomsideofseparatingandcleaningunit
wasconnectedtoconnectingrod.Theotherendoftheconnectingrodwasconnectedtoa
wristpineccentrictothewheelcentrethatproducedareciprocatingmotionontheseparating
andcleaningunit.

Figure5.Schematicpresentationofsievesarrangementandoscillatorymotiongeneration
system(alldimensionsareincm)
2
5

Onawheelmadeoutofmildsteelroundbarwithadiameterof10cm,aholewithdiameter
of25mmwasdrilledataradialdistanceof10mmfromthecenterofthewheelandwasused
aslocationofwristpinateccentricdistanceof10mmfromthecentre.Theeccentricitywas
responsibletocauseoscillationsonthesieves.Wheneverthewheelwasrotated,thesieves
weredisplacedproportionallytotheirpositionfromcentreofrotationofthelegs(Fig.5).A
ballbearing25mminternaldiameterwasfittedonthewristpin.Theshaft,onwhichthe
wheelwithwristpinwasfitted,hadaVpulleywithdiameterof138mmatitsoneend.The
assembledshaftwithapairofbearingswasmountedontheframeoftheseparatingand
cleaningmachine.
3.7.5.Sieveslopeadjustment
Since three different sieve slopes (zero, five and ten degree) were tested, to adjust the
inclinationtorequiredslope,threeholeswhichhavediameterof3cmmadeonthefront
rockerarmwereused(Fig.6).Thenholesareconnectedtosieveframewithbolt.Theseholes
weremadebytakingthelengthofsieveashypotenusewiththefollowingcalculation;

Figure6.Sieveslopeadjustmentmechanism

sin
60c
m
Hencelengthofsieveis60cmthen;

At=zerodegree,x=0

2
6

At=fivedegree,x=5.23cm
At=tendegree,x=10.42cm
Basedonvalueobtained,theholesweremadeonrockerarmin10,15.23and20.42cmfrom
thetopendtobottom.
3.7.6.Designandconstructionoffanandhousing
Acentrifugalfanwasconstructedfromasheetmetalof1.50mmthickness.Itwasmounted
on a shaft with a diameter of 25 mm and supported on roller bearings below the feed
conveyor.Thefanassemblyhadfourradialblades.Thefanbladeswere38cminlengthand8
cminwidth.Thefanwasoperatedatthreedifferentangularvelocitieswherethemaximum
being1000rpm.Thefanspeedswereadjustedandsetatdesiredlevelbyadjustingengine
speedratherthanemployingpulleysorgears.A5hpHONDAdieselenginewithVbeltand
pulleyarrangementswasusedaspowersource.
Thefanhousingwasprovidedwitheightrectangularinletholes,fouroneachside.Thesizes
2

oftheholeswerefour6x5cm andfour8x5cm inordertocontroltheairflowrateininto

2

thefanhousing.Onerectangularholewithsizeof6x40cm ,asanoutletoftheairfromthe
fanhouse,wasprovided.Thisholedirectedairatrecommendedvelocitytowardsmaterials
fallingfromtheconveyorintotheseparatingandcleaningunit(Fig.7).

Figure 7. Fan housing and fan blade; A is outlet opening and B is inlet opening (all
dimensionsareincm).
2

Theairentranceintothefanhousingwasat90totheairoutletopening.Theairentersthe
fanhousingparalleltothefanshaftandthenrotatedthrough 90 bythefanbladebefore
discharged.Thefandischargedairblastunderthefeedingconveyorwithconstantvelocityof
3.2m/s(theminimumterminalvelocityoftef)throughtheexit.Thisconstantairspeedwas
adjusted using a digital anemometer and either by decreasing or increasing the air inlet
openingsonthesidesofthefanhousing.Theinletopeningscouldbeclosedandopenedusing
theshuttersprovidedtomaintainthedesiredairvelocity.
3

Thevolumeflowrateofair(V)atfanexitwascalculatedtobe0.077m /s(velocityofexit
2

(3.2m/s)xcrosssectionalareaatexit(0.024m )=0.077m /s).Usingtheequationgiven

below, quantity of material removed ( Gm ) by the air stream per unit time (kg/s) was
determinedtobe0.023kg/s.

G G
a m

22

Where:
3

22

=volumeairflowm /s,

=densityofair(1.2kg/m ),

Ga=themassflowrateofairatexitwhichequalstotheflowratefanexitmultiplied
bythedensityofair(VX=0.077x1.2=0.092kg/s),and
=acoefficient0.25.
Thedynamichead(hd)ofthefanwascalculatedusingEq.(2)andassumingCmean=terminal
3

velocityoftefgrain=3.20m/sanddensityofair1.2kg/m wasfoundtobe6.14Pa
2

hdC mean
2
Theinletarea(Aeq),coefficient(k),statichead(hs)andoverallpressurehead(H)were
computedfordifferentfanrpmandgiveninTable7.

2
8

Table7.Adjustedinletareaatdifferentrpmtokeepconstant3.2m/satfanexit.
Fanspeed
(rpm)

InletArea

500
740
1000

210
200
160

Aeq(cm)

eq

0.88
0.83
0.67

(1k2)h
d
hs
k 2
(Pa)
1.79
2.77
7.54

cmean(m/s)
(anemometer
readingat
fanexit)
3.2
3.2
3.2

Overall
pressure
head
(H=hs+hd)

7.93
8.91
13.68

3.7.7.Selectionofpulleysandbelts
Themachinerequiredthreepulleys;onepulleymountedonthecrankshaftofthediesel
engineasmaindrive,andonfanshaftandtheeccentricwheelshaftoneeach.Twobeltswere
usedtotransmitpowerfromenginetothefanshaftandeccentricwheelshaft.Thedriving
pulleywasmountedonthecrankshaftoftheengineandthedrivenpulleysweremountedon
fanshaftandeccentricitywheelshafts.Duetoitsavailability,lowcostandhighperformance
castironpulleyswereselected.Thedrivingpulleywasmountedonthecrankshaftofthe
enginewhilethedrivenpulleysweremountedonfanshaftandeccentricwheelshafts.The
diameterofthepulleyusedonthecrankshaftoftheenginewas120mm.Thepower,fromthe
engineshafttothefanshaftandeccentricwheelshaft,runningatdifferentangularspeeds,
wastransmittedthroughVbelts.Sincetheselectedenginewas5hp,slightlylessthan4kw,
typeAVbeltwasselectedandused.
AccordingtoSharmaandAggarwal(2006)thediameterofdrivenpulleys,centerdistance,
beltlengthandbeltspeedswerecalculatedasfollows:

D1N1D2N2

(14)

C D1D2 D
1
2

(15)

L2C1.57(DD
1

D2
1

4C

(16)
2
9

N D
2

60000

(17)

Where:
D1andD2=diametersofdrivinganddrivenpulleys(mm),
N1andN2=rpmofdrivinganddrivenpulleys,
C=centerdistancebetweentwoadjacentpulleys(mm),
L=lengthofbelt(mm)
V=speedofbelts(m/s)
Thediameterofdrivenpulleyswasarrivedbasedonthefollowingvalues;
1

Thespeedofdieselengineshaftis1375rpm

Diameteroftheengineshaftpulleyis120mm

Maximumfanspeedis1000rpm(Adane,2004)

Maximum speed of eccentric wheel is 1200 rpm, since the maximum

oscillationis20Hz.
Therefore,thediametersofpulleysusedonthefanshaftandeccentricdrivewheelshaftwere
calculatedusingEq.(14)andwerefoundtobe165mmand138mmrespectively.Thecentre
distancesbetweenthedivingpulleyanddrivenpulleysweredeterminedusingEq.(15),and
foundtobe263mmand249mmtheengineandfanandengineandeccentricwheelshafts,
respectively. However, to maintain stability and to minimize vibration 500 mm center
distancebetweenfanshaftandenginecrankshaftpulleyswasusedsinceitliesbetween

(D1 D2 )

D1C2(D1D2)asrecommendedbyMaciejczykandZbigniew(2000).The

2
lengthsofbeltswerecalculatedusingEq.(16)andfoundtobe1448mmand903mmto
connectpulleysonenginecrankshaftandfanshaftandenginecrankshaftandeccentricdrive
wheelshaft,respectively.BasedonthecalculationsmadeA57andA36beltswereselected
toconnectpulleysfanshaftandenginecrankshaftandeccentricdrivewheelshaftandengine
crankshaft,respectively.Thelinearspeedofthebeltconnectingthefanpulleytotheengine
pulleywas8.64m/swhilethelinearspeedbeltconnectingeccentricdrivewheelpulleytothe

enginepulleywas8.67m/satmaximumoperatingwithEq.(17).
30

3.7.8.Determinationofshaftdiameter
The diameters of the fan shaft and eccentric drive wheel shaft were determined using
maximumshearstresstheory.Figure8and9showforcesactingonfanshaftandeccentric
drivewheelshaft,respectively.

Figure8.Forcesactingonfanshaftandtheirlocations.
Where:
RAH=horizontalbearingreactionforceatA
RAV=verticalbearingreactionforceatA
WFB=weightoffanblade
RCH=horizontalbearingreactionforceatC
RCV=verticalbearingreactionforceatC
TB=totalbelttension(Ti+Tj)atD
Wp=weightoffanpulley

Figure9.Forcesactingoneccentricdrivewheelandtheirlocations.

31

Where:
RAH=horizontalbearingreactionforceatA
RAV=verticalbearingreactionforceatA
Wes=weightofeccentricity
RCR=horizontalforceduetoconnectingrodatB
RCH=horizontalbearingreactionforceatC
RCV=verticalbearingreactionforceatC
TBH=horizontaltensionduetobeltatD(Ti+Tj)
Step1:Determiningthedirectionbeltpullsonthefanshaft(Fig.10)

sin opposite 26 0.433,then31.33

hyphotness 50

Figure10.Directionbeltpullsonthefanshaft.
Step2:Determinationofbelttensions(TiandTj)andtorsionalmoment(Mt)

UsingEq.(8):

Tmaxa=170.1N
3
2

Where;

anda=2.1N/mm2and81mm2respectively(AppendixTable7)
UsingEq.(9):
TcmV2=8.06N,forbothbeltssincetheyhavealmostsimilarvelocity.

Where;
m=0.108kg/m(Appendixtable7),
V=8.64m/s
ThenusingEq.(7)thetightsidetension(Ti)ofbothbeltswascalculatedtobe;

TiTmaxTc=162.04N
SlacksidetensionTjwasdeterminedas19.12Nand18.17Nforfan/engineandeccentric
wheel/enginebelts;usingEq.(10):

Ti Tc
e
Tj Tc

cosec

Where:
1

=coefficientoffrictionbetweenbeltandpulley=0.3(AppendixTable8)

=grooveangle=40(AppendixTable7)

2 =angleofwrap=3.05and3.07radforfanengineandeccentricwheelengine
beltsrespectivelyandweredeterminedusingEq.(18)(KhurmiandGupta,2005)

1802sin

D
1

2C

Where:
D1=120mmforengineshaftpulley,
D2=165mmforfanshaftpulleyand138mmforeccentricdrivewheelpulley,

(18)

33

C=500mmforbetweenshaftandenginepulleyand249mmforbetweeneccentric
drivewheelshaftandenginepulley.
Torsionalmoments(Mt)werecalculatedusingEq.(6).

Mt(TiTj)

D2

2
Andfoundtobe11791Nmmand9927Nmmforfanandeccentricwheelshaftrespectively.
Where:
Ti=162.04Nforbothfan/engineandeccentricdrivewheel/enginebelts
Tj=19.12Nforfanand18.17Nforeccentric
D2=165mmforfan138mmforeccentric.
Step3:Analysishorizontalandverticalforcesonfanshafts
Tocalculatebendingmomentsonshaftsitwasnecessarytoknowthehorizontalandvertical
forcesactingonshafts.
Forcesactingonfandrivingshaftvertical(YZ)plane)

Figure11.Freebodydiagramofthefanshaftonvertical(YZ)plane.
TBTiTj=162.04+19.12=181.16N
o

WFB=11N,Wp=15N,=31.33 ,(TBcosWP)=170N
InordertocalculatereactionforcesRAVandRCV,itwasconsideredthat

BMA0

3
4

50*RCV=25*WFB+70(TBcos

WP)RCV=243.50N

Fv0
RAV+WFB+RCV+(TBcosWP)=0
RAV=62.50Ndownward
Forcesactingonfandrivingshaftonhorizontal(XZ)plane

Figure12.Freebodydiagramoffanshaftonhorizontal(XZ)plane.

TBsin=181.16xsin31.33=94.2N

BMA0
50*RCH=70TBsin
aRCH=132N

Fh0
RAH+RCH+TBsina=0
RAH=37.8Ndownward.
Basedonthemagnitudeandlocationofallforcesactingonthefanshaftshearforceand
bendingmomentonthehorizontalandverticalplanscontainingthefanshaftwerecomputed
andplottedasfollows:

3
5

a)Vertical(YZ)plane

b)Horizontal(XZ)plane

Figure13.Shearforceandbendingmomentdiagramsforfanshaft
Step4:Determinationofthemaximumbendingmomentforfanshaft
ThemaximumbendingmomentwasfoundtobeatpointCofthefanshaft.

12=(18.42+18.92)1/2=26.38Nm

Mmax M2VM2H

Followingthesameprocedure,horizontalandverticalforcesactingoneccentricwheel
drivingshaftwereanalyzedasfollows:
Verticalforcesactingoneccentricwheeldrivingshaft(XZplane)

Figure14.Freebodydiagramoftheeccentricwheelshaftonvertical(YZ)plane
WP=5N,Wes=10N

3
6

BMA0
50*RCV=25Wes+65WP
RCV=11.5N

Fv0
RAV+RCV+Wes+WP=0
RAV=3.5N
Horizontalforcesactingoneccentricwheeldrivingshaft(XZplane)

Figure15.Freebodydiagramoftheeccentricdrivewheelshaftonhorizontal(XZ)plane.
WhereTB=Ti+Tj=162.04+18.17=180.21N
RCR=20N

BMA0
25RCR+50RCH+65TB=0
RCH=244.6N

Fh0
RAH+RCR+RCH+WP=0
RAH=44.13Ndownward
Basedonthemagnitudeandlocationofallforcesactingonthefanshaftshearforceand
bendingmomentonthehorizontalandverticalplanscontainingtheeccentricdrivewheel
werecomputedandplottedasfollows:

37

a)YZplane(vertical

b)XZplane(horizontal)

Figure16.Shearforceandbendingmomentdiagramforeccentricdrivewheelshaft.
FromthediagramthemaximumbendingmomentfoundatC

12=(3.382+272)1/2=27.2Nm

Mmax M2VM2H

Thediametersofthefanshaftandeccentricdrivewheelshaftsweredeterminedasfollows
d3

16
max

1
fs

(kbMb)2 (ktMt)2

ForfanshaftMt=11.79Nm,Mb=26.38Nm,kt=kb=1.5andmax=55Mpathend=15.89
mm.Assumingasafetyfactorof3,d=15.87x3 3=22.89mm

d=25mm
ForeccentricdrivewheelshaftMt=9.93Nm,Mb=27.20Nm,kt=kb=1.5,max=55MPa
thend=15.9mm.Assumingasafetyfactorof3,d=15.9x3 3=22.93mm

d=25mm

3
8

3.7.9.Determinationofpower
Thepowerrequiredtooperatingtheseparatingandcleaningmachinewasconsideredtobethesumof
powersrequiredtodrivethefanassembly,theeccentricdriveassemble,thesievingsystemincludingthe
grainandchaffonthesieves,powerrequiredtooscillatethesievesand P theloadsonthemandpower
required to overcome frictional resistance. The total power ( required for the cleaning and separating
processeswasdeterminedbyusingtheEquationgivenbyNdukaetal,(2012).

PtP10%P(10%ispossiblepowerlossduetofrictiondrive)

(19)

Where:

Pt=totalpowerrequiredtodrivethemachine,
P=thesumof(TiTj)Vforfanandsieveoscillation,
Ti=tightsidetensionofbelt,162.04Nforbothfanandeccentricdrivewheelbelts
and
Tj=slacksidetensionofbelts=19.12and18.17Nforfanandeccentricdrivewheel
belts,respectively,and
V=speedofbelts=8.64m/sforbothfanandeccentricdrivewheelbelt.
Onthebasisoftheabove,powerrequiredtodrivethefanassembly,Pf=(162.04N19.12
N)8.64m/s=1234.83W
Accordingly,thepowerrequiredtodriveeccentricdrivewheelassembly,Pe=(162.04N
18.17N)8.64m/s=1243.04W
ThetotalpowertooperatefanandeccentricdriveassemblyP=Pf+Pw=1234.43W+
1243.04W=2477.87W.

OveralltotalpowerPt=P+10%ofP=2725.66W=3.63hp.
3
9

3.8.PerformanceEvaluation
SeparationandcleaningprocesstakeplacealongthesievelengthasgrainandMOGwere
transportedoverthesieve.DuringeachtestrunmaterialsleavingthroughMOGoutletand
thoseleavingthroughgrainoutletwereweightedusingdigitalbalanceinordertodetermine
the separation efficiency, cleaning efficiency, separation loss and cleaning loss. The
performanceevaluationoftheseparatingandcleaningmachinewasmadeonthebasisofthe
followingparameters;separatingefficiency,cleaningefficiency,grainlossandcleaningloss.
AsperAmer(2009)separationefficiencyandgrainlosseswerecalculatedusingEq.(20and
21).

SE M1 X100%
M2

(20)

SL M4M3 X100%

(21)

Where:
themassofimpuritiesafterseparationandcleaning(kg),
M

themassofimpuritiesbeforeseparationandcleaning(kg),
themassofgrainsafterseparationandcleaning(kg),
themassofgrainsbeforeseparationandcleaning(kg),

SE=separationefficiency(%)andSL=separationloss(%)
ThecleaningefficiencyandcleaninglosswerecalculatedusingtheequationsgivenbyWerby
(2010);Eq.(22and23).

CE cssx100%CL

(22)

sbc

Where:
Mcss=massofcleangrainsample(themassofgrainsafterseparationandcleaning)(kg),

40

Msbc=massofsamplebeforecleaning(kg)andCLiscleaningloss(%);
CL Sl x100%
So

(23)

Where:
CL=cleaningloss,
Sl=grainlostbehindmachine(M4M3)inkg,
So=grainoutput(M3)inkg.
3.9.ExperimentalDesignandTreatment
Toevaluatetheseparatingandcleaningperformanceoftheprototypemachine,threelevelsof
o

sieveslopes(0,5and10 ),fourlevelsofsieveoscillation(5,10,15and20Hz)andfour
levelsoffeedrates(3,6,9and12kg/min)wereused.Theexperimentaldesignwasfactorial
insplitsplitplot,3x4x4having48experimentalunits.Eachcombinationofanexperiment
(slopexoscillationxfeedrate)wasreplicatedthreetimesthetotalnumbersoftestrunswere
144.Thesieveslopewastakenasmainplotwhilesieveoscillationandfeedrateweretakeas
subplot and as subsub plot, respectively. The air velocity at fan outlet throughout the
experiment was kept constant at 3.2 m/s which were considered to be equivalent to the
minimumterminalvelocityoftefgrains.
3.10.

StatisticalAnalysis

Dataweresubjectedtoanalysisofvariancefollowingaprocedureappropriatetothedesignof
theexperimentasrecommendedbyGomezandGomez(1984).AnalysiswasmadeusingGen
th

Stat15 editionstatisticalsoftware.Thetreatmentmeansthatweredifferentat5%and1%
levelsofsignificancewereseparatedusingLSDT.Levelofsignificance(P)fortheserelations
wasobtainedbyFtestbasedonanalysisofvariance.

4
1

4.RESULTANDDISCUSSION
TheprototypemachinewasdesignedandfabricatedatAAMRConthebasisofthephysical
andaerodynamicpropertiesofthegraintobeseparatedandcleaned.Thephysicalattributes
andaerodynamicpropertiesoftefgrainandtheterminalvelocityofthesamewereobtained
fromthedatageneratedbyZewdu(2007)andAbduljelil(2010).Knowingthethicknessand
widthoftefgrainhelpedtheselectionofsieveopeningsizesrequiredtoeffecttheseparation
andcleaningofthegrain.Theairvelocityoverthesieveunitwaskeptclosetotheterminal
velocity of tef grain. Oscillations of the sieves were made by using a fourbar linkage
mechanismwherethelegsofthesieveholdingframewerepinnedandoscillatedabouta
verticalplane.Itmustbenotedthatduetothestackedarrangementofsievesandthedrive
mechanismemployedthehorizontaldisplacementsofthesieveswerenotthesameorequal.
Thismighthavecausedorleadaresultthatmightnotbecompatiblewiththefindingsofother
researchers.
4.1.EffectSieveSlope,SieveOscillation andFeed Rateon Separation Efficiencyand
SeparationLoss
4.1.1.Effectofsieveslopeonseparationefficiencyandseparationloss
AscanbeseenfromFigure17(a)andAppendixTable6,increaseinsieveslopefrom0to5
degreesincreasedseparationefficiencyfrom64.72to73.37%;furtherincreaseinsieveslope,
to10degrees,resultedindecreasingseparationefficiencyto61.39%.Thiswasduetothevery
factthatthegrainsmovedoutoftheseparationunitwiththeMOGbecausethegreaterforce
(mgsin)actingontheentirematerial,grainandchaff,downtheslopeandthedifference
2

betweengravitycomponentandinertiacomponentofforces(mgcos <m r) thatleadto

slidingratherthantossingandflailingthegrainandchaff(AppendixFigure2).Thisimplies

thatat10 sieveslope,thesievetendedtoconveythegrainandstrawmixturebeforebeing
sievedandsiftingthoroughly.Consequently,grainswentoutwithchaffthroughMOGoutlet.
Theseparationlossdecreasedfrom12.95to10.20%assieveslopeincreasefromzero
4
2

to5degree.Nonetheless,theseparationlossincreased18.08%assieveslopeincreasedfrom5
to10degrees(Fig.17(a)andAppendixTable6).
4.1.2.Effectofsieveoscillationonseparationefficiencyandseparationloss
Separationefficiencytendedtodecreasewithincreasingsieveoscillationwhileseparation
loss increased with increasing sieve oscillation (Figure 17(b), Appendix Table 6). The
increaseintheseparationlosswasfrom4.93to22.64%assieveoscillationincreasedfrom5
to20Hz.Thedecreaseinseparationefficiencyandincreaseofseparationlosswithincreasing
sieveoscillationsmaybeduetolessresidenttimeofmaterialstobeseparatedonthesieve.
Highersieveoscillations,forcedgrainsandchafftobouncewithoutadequatetimetoreside
on the sieve so that the separation and cleaning to take place, hence poor or low level
separationbecameeminentleadingintolowseparationefficiencyandhighseparationloss.
Voicu et al, (2011), concluded that high oscillation frequency lead, in general, to faster
movementofgrainsonthesieve,hencelesstimewasavailableforthegrainstopassthrough
materialsonthesieveandsieveholes.Theyalsoindicatedthatathighsieveoscillation,grains
andchaffbedischargedwithoutpassingthroughthesievesperforations.Furthermore,itwas
learntthatsievesathighoscillationfrequencycouldserveasconveyorratherthanameansto
sieveandsiftthroughtoeffectseparation.
4.1.3.Effectoffeedrateonseparationefficiencyandseparationloss
Figure 17(c) and Appendix Table 6 indicate that separation efficiency decreased with
increasingfeedratewhiletheseparationlossincreasedwithincreasingfeedrate.Increasing
feedingratefrom6to12kg/mindecreasedtheseparationefficiencyfrom72.69to55.98%
whileseparationlossincreasedfrom10.6to20.66%andeffectwashighlysignificantat(P<
1%)(Table8).Thelowseparationefficiencyandthehighseparationlosswiththeincreasing
feedratecouldbeduetothethicklayerofmaterial(mattingofgrainsandchaff)formedon
thesievesthatconstrainedpenetrationofgrainthroughthematofmaterialsonthesieves.
Hence,effectofthefeedingratecouldbeseenasincreasingofthethicknessofmixtureof
grainandchafflayeronsieve.Aboveall,athigherfeedrate,ittakesalongdurationoftime

4
3

forthegraintobeseparatedfromtheMOGduetothedensenessoftheMOGthatmade
diffusionofthegrainthroughtheMOGsluggish.
4.1.4. Combined Effect Sieve Slope, Sieve Oscillation and Feed Rate on Separation
EfficiencyandSeparationLoss
AnalysisofvariancemadeinTable8andAppendixTable2and3indicatesthattheeffectof
sieveslope,sieveoscillationandfeedratewerehighlysignificant (P<0.01)onbothseparation
efficiencyandseparationloss.Sieveslopeandsieveoscillation(SSxSO),sieveslopeand
feedrate(SSxFR)andsieveoscillationandfeedrate(SOxFR)combinationshadhighly
significant (P<0.01)effectonbothseparationefficiencyandseparationlossexceptthatSSx
FRcombinationhadsignificanteffectatP<0.05onseparationloss.Separationefficiencyand
separationlossweredominantlyaffectedbysieveslopeandsieveoscillationandfollowedby
sieveslopeandfeedrateandsieveoscillationandfeedrate.Table9showstheeffectofthe
interactionbetweensieveslopes,sieveoscillationandfeedrateatLSD5%.Thehigh
o

separationefficiencyandlowseparationlosswereobtainedat3kg/minfeedrate,5 sieve
slopeand5Hzofsieveoscillation(AppendixTable1).
Table8.Analysisofvarianceoftheresultoftheperformanceofthemachine
Separation
Efficiency

Fvalue
Separation
Loss

Cleaning
Efficiency

Cleaning
Loss

Sourceofvariation
D.F
Replication
2
SS
2
1684.4**
220.76**
179.4**
156.14**
SO
3
26058.02**
450.03**
433.42**
407.98**
FR
3
1960.44**
260.47**
217.73**
189.98**
SSxSO
6
2076.2**
19.49**
20.86**
21.27**
SSxFR
6
41.69**
2.55*
3.25*
3.73*
SOxFR
9
33.43**
7.52**
9.36**
10.5**
SSxSOxFR
18
39.14**
3.7**
3.19**
2.92**
Error
72
*,**;significantat5%and1%probabilitylevel,respectively;D.Fdegreeoffreedom
4
4

Thecombinedeffectofsieveslope,sieveoscillationandfeedrate(SSxSOxFR)wasalso
highlysignificant (p<0.01) on separationefficiencyandseparationloss.Ingenerally,
separationefficiencydecreasedwithincreasingsieveoscillationandfeedratewhile
separationlosswasincreasedwithincreasingfeedrateandsieveoscillation(AppendixTable
1and6)
Table9.Separationefficiencyandseparationlossasaffectedbytheinteractionbetweensieve
slope,sieveoscillationsandfeedrate.
Parameter

Separation
Efficiency
(%)

Separation
Loss(%)

andLoss(%)

tionEfficiency

Sourceofvariation
LSD
SE(M)
Sieveslope
SSxSO
(5%)
SO1
SO2
SSO3
SO4
aA
aB
aC
aD
SS1
88.58
81.74
61.92
26.63
aA
aB
aC
bD
SS2
91.29
83.94
60.82
57.44
5.982 1.970
bA
bB
bC
cD
SS3
81.04
75
54.13
34.74
Sieveslope
SSxFR
FR1
FR2
FR3
FR4
aA
aA
aB
aC
5.631 1.840
SS1
73.79
68.77
61.85
54.46
bA
bA
bB
bC
SS2
83.02
80.31
69.66
60.51
cA
cA
cB
cB
SS3
70.32
68.98
53.32
52.95
Sieve
SOxFR
FR1
FR2
FR3
FR4
oscillation
aA
aA
aB
aC
4.817 1.713
SO1
96.01
93
82.23
76.64
a
aA
aB
bB
SO2
86.34 A
97.08
86.88
86.59
bA
bB
bC
cD
SO3
79.25
88.77
70.53
69.79
cA
cA
aC
bD
SO4
49.79
46.35
35.88
26.35
Sieveslope
SSxSO
SO1
SO2
SSO3
SO4
1.747 0.596
aA
aB
aC
aD
SS1
4.13
8.07
14.40
25.19
aA
aB
aC
bD
SS2
3.41
6.96
13.87
16.54
bA
bB
bC
cD
SS3
7.26
18.55
20.32
26.19
Sieveslope
SSxFR
FR1
FR2
FR3
FR4
aA
aB
aC
aD
1.678 0.591
SS1
7.13
10.82
15.35
18.50
bA
bB
bC
aD
SS2
4.81
6.76
11.96
17.26
cA
cB
cC
bD
SS3
11.75
14.22
20.14
26.22
Sieve
SOxFR
FR1
FR2
FR3
FR4
oscillation
aA
aA
aB
aC
1.976 0.703
SO1
1.40
2.28
5.18
10.89
bA
bB
bC
bD
SO2
5.81
9.40
12.16
17.42
cA
cB
cC
cD
SO3
9.23
13.25
18.04
24.26
dA
dB
dC
SO4
15.15
17.48
27.88
ThesamesmallletterssuperscriptincolumnindicatesnosignificantdifferentatLSD5%
(neglectingcapitalcaseletters)andthesamecapitalletterssuperscriptinrowindicatesno
significantdifferentatLSD5%(neglectingsmallcaseletters)
45

30

80

60
40
20
0
0
5
1
0

SieveSlope(degrees)

..

20
0
3

.
(c)

80
Figure17.Effectofsieveslope,sieveoscillationandfeedrateon
60

separationefficiencyandseparationloss.

46

FeedRate(kg/min)

100

Los

Separat and
ion

120

40

s(%)

Efficiency

(a)

12

4.2.EffectofSieveslope,SieveoscillationandFeedrateonCleaningEfficiencyand
CleaningLoss
4.2.1.EffectofSieveslopeonCleaningEfficiencyandCleaningLoss
AsshowninFigure18(a)increasingthesieveslopefrom0to5degreesleadtoslightly
increasecleaningefficiencyanddecreasedcleaningloss.Increasingthisslopeto10degrees
resulted in declining cleaning efficiency and increasing of cleaning loss. As shown in
Appendix Table 6, increasing the sieve slope from 0 to 5 degrees increased cleaning
efficiencyfrom70.68to77.63%anddecreasedcleaningloss16.37to12.17%butfurther
increaseinthesieveslopeto10degreesresultedindecreasingcleaningefficiencyto58.17%
andincreasingcleaninglossto23.75%.Thephenomenonwascommontoalllevelsofsieve
oscillationsandfeedratesandatsieveslopeof10degreesgrainswerelostwithchaffthrough
MOGoutlet.
4.2.2.EffectofSieveoscillationoncleaningefficiencyandcleaningloss
Increaseinsieveoscillation,ingeneral,leadtodecreasedcleaningefficiencyandincreased
cleaninglossatdifferentsieveslopesasshowninFigure18(b).Themeanvaluesofthe
cleaningefficiencywasdecreasedfrom89.65to46.55%andcleaninglosswasincreased
from5.41to30.81%assieveoscillationincreasefrom5to20Hz,respectively(Appendix
Table6).Thiswasduetothefactthatathighersieveoscillationssomegrainsandchaffcould
beforcedtoleavethecleaningunitwiththechaffbecauseofhighinertiaforceactingon
them,hencegoingthroughthesieveperforations wouldnotbepossibleandthesituation
becomesworstwhensieveslopeincreased.

ngEfficiencyand

4
7

CE

CL

100

Loss ) (%

80
60
40
20
0
0

10

Rate(kg/min)

(c)
Figure18.TheEffectofSieveslope,SieveoscillationandFeedrateon
CleaningEfficiencyandCleaningLoss.

SieveOscillation(Hz)
48

andLoss(%)

CleaningEfficiency

F
e
e
d

4.2.3.Effectoffeedrateoncleaningefficiencyandcleaningloss
AscanbeseenfromAppendixTable6,whenthefeedratewasincreasedfrom3to12kg/min
cleaning efficiency decreased from 82.97 to 51.71%. At the time, the cleaning loss was
increased from 9.13 to 27.63%. Figure 18(c) shows the relationship between cleaning
efficiency, cleaning loss and feed rate. The declining cleaning efficiency and increasing
cleaninglosswithincreasingrateoffeedingwasduetotheformationofathicklayerof
materialonsievesthatconsiderablyhinderedorlimitedpassageofgrainsthroughthesieve
perforations. The increasing in cleaning loss and decreasing of cleaning efficiency with
increasingfeedratecouldbeattributedtheloadintensityonthesievethatcouldresultin
matting of the sieve with material other than grain blocking sieve holes. Furthermore,
whenevertherearehighfeedrate,thecurrentsuppliedwillnotbecapableofsuspendingand
blowingthematerialsaerodynamicallyasmultipleparticlesactasobstructiontoairflow.For
aerodynamic separation to occur, the particles in a mixture must be accelerated as free
dispersedbodiesandnotasamat,hencefeedratemustbelimitedto6kg/miniftheprototype
machinehastobeused.
4.2.4. CombinedEffectofSieveslope,SieveoscillationandFeedrateonCleaning
EfficiencyandCleaningLoss
The calculated values and figures plotted clearly indicated that the cleaning efficiency
decreased with increasing sieve oscillation and feed rate while the cleaning loss was
increasingwithincreasingsieveoscillationandfeedrate(Figures18andAppendixTable1
and6).
AnalysisofvariancepresentedinTable8andAppendixTable4and5indicatesthattheeffect
ofsieveslope,sieveoscillationandfeedratewerehighlysignificant(P<0.01)onboth
cleaningefficiencyandcleaningloss.Thecombinedeffectofsieveslopeandsieveoscillation
(SSxSO),oscillationandfeedrate(SOxFR)werehighlysignificant (P<0.01)onboth
cleaningefficiencyandcleaningloss.Thecombinedeffectofsieveslopeandfeedrate(SSx
FR)wassignificant(P<0.05)oncleaningefficiencyandcleaningloss.Thesecondorder
4

interactionsbetweensieveslope,sieveoscillationandfeedrate(SSxSOxFR)washighly
significant (P<0.01)onbothcleaningefficiencyandcleaningloss.Table10presentsthe
effectoftheinteractionbetweensieveslopes,sieveoscillationandfeedrateatLSD5%.
Table10.Cleaningefficiencyandcleaninglossasaffectedbytheinteractionbetween
sieveslope,sieveoscillationsandfeedrate.
Parameter
Sieveslope
SS1
SS2
SS3

Cleaning
Efficiency
(%)

Sieveslope
SS1
SS2
SS3
Sieveoscillation
SO1
SO2
SO3
SO4
Sieveslope
SS1
SS2
SS3

Cleaning
Loss(%)

Sieveslope
SS1

Sourceofvariation
SSxSO
SO1
SO2
SO3
aA
aB
aC
91.44
83.01
68.23
aA
aB
aC
92.94
85.40
69.40
bA
bB
bC
84.58
57.74
53.49
SSxFR
FR1
FR2
FR3
aA
aB
aC
84.74
76.07
64.66
bA
bA
bB
90.03
85.73
73.80
74.15 cA 68.54cB 53.03 cC
SOxFR
FR1
FR2
FR3
aA
aA
aB
97.18
95.38
89.26
bA
bB
bC
87.90
79.73
73.60
bA
cB
cC
80.44
71.12
59.86
cA
dB
dC
66.38
60.89
32.60
SSxSO
SO1
SO2
SO3
aA
aB
aC
4.43
8.92
17.36
aA
aB
aC
3.66
7.63
16.73
bA
bB
bC
8.15
23.70
26.19
SSxFR
FR1
FR2
FR3
8.13

aA

13.11

aC

20

SE(M)

4.426

1.507

4.531

1.595

5.209

1.854

SO4
aD
34.78
bD
20.67
cD
36.96

2.721

0.926

FR4

2.880

1.014

SO4
aD
40.03
bD
62.78
cD
36.85
FR4
aD
57.25
aC
60.95
36.94 bD
FR4
aC
76.80
bD
60.32
cD
43.40
dD
26.34

24.25

aD

7.50bA 14.24 bB 21.79 aC

B
cC
bD
17.24
26.82
36.84
SOxFR
3.277 1.166
FR2
FR3
FR4
Sieveoscillation FR1
aA
aAB
aBC
aD
SO1
1.43
2.35
5.56
12.32
bA
bB
bC
bD
SO2
6.30
10.87
14.24
22.26
cA
cB
cC
cD
SO3
10.32
15.62
22.10
32.33
dA
dA
dB
dC
SO4
18.47
21.64
39.51
43.60
ThesamesmallletterssuperscriptincolumnindicatesnosignificantdifferentatLSD5%
(neglectingcapitalcaseletters)andthesamecapitalletterssuperscriptinrowindicatesno
significantdifferentatLSD5%(neglectingsmallcaseletters).
5
SS2
SS3

5.16 bA
cA
14.09

aB

LSD
(5%)

4.3.TheMultipleRegressionAnalysis
Themultipleregressionanalysismadethelevelcorrelationcoefficientswereusedtoidentify
parametersthathadadominanteffectonseparationandcleaningefficienciesandassociated
losses.FromtheequationgiveninTable11onecannotethatthedominanteffectoffeedrate
exceptonseparationefficiency.
Table11.Multipleregressionequationofparametersstudied.
Regression
SEVsSS,SOandFR
SLVsSS,SOandFR
CEVsSS,SOandFR
CLVsSS,SOandFR

R
0.834
0.824
0.802
0.783

Equation
SE=128.0440.52xSS3.21xSO2.593xFR
SL=14.231+0.513xSS+1.163xSO+1.45xFR
CE=137.0081.251xSS2.82xSO3.558xFR
CL=22.78+0.738xSS+1.657xSO+2.108xFR

4.4.CostAnalysisoftheSeparatingandCleaningMachine
Thecostinvolvedintheseparatingandcleaningmachinehadbeenevaluatedintermsofraw
materialcostandproduction(machineandlabor)costonly.Materialswastageandoverhead
costsareestimatedfromrawmaterialandproductioncost.TheTable12showscostof
machinewithoutengineandthedetailprocedureisgiveninAppendixTable9,10and11.
Table12.Thesummarizedcostofseparatingandcleaningmachine

No.
1
2
3
4
5
6
7

Variable
Rawmaterial
MaterialsWastage
Production(machine+labor)
Overheadcost
Profitcost
Selltaxcost
Sellingcost

Cost(ETB)
4865.63
121.64
894.33
44.72
592.63
977.84
7496.79

5
1

5. SUMMARY,CONCLUSIONSANDRECOMMENDATION
5.1. Summary
Traditionalmethodoftefgrainsseparationfromchaffandcleaningfromforeignmaterials
thatemploywindaswinnowerandsievesascleaneristhemosttimeconsuming,laborious
anduneconomical.Aboveall,themethodisinadequateandinefficienttoenablefarmerto
deliverhighoutputandoftenresultinlowqualityproduct.
Inanefforttoalleviatetheabovestatedproblems,asmallenginedriventefgrainandchaff
separator and cleaning machine was designed, manufactured and tested to evaluate its
performanceinterms ofseparationandcleaningefficiencies,andseparationandcleaning
lossesatdifferentfeedrate,sievesoscillationsandsievesinclinations;threelevelsofsieve
slopes(0,5and10degrees),fourlevelsofsieveoscillation(5,10,15and20Hz)andfour
levelsoffeedrates(3,6,9and12kg/min)wereused.Theexperimentaldesignwasfactorial
insplitsplitplot.
The prototype machine was fabricated at AAMRC on the basis of the physical and
aerodynamicpropertiesoftefgrainandchafftobeseparatedandcleanedfromundesirable
material(s).Thephysicalattributesandaerodynamicpropertiesoftefgrainsandtheterminal
velocityofthesamewereobtainedfromthedatageneratedbytheearlierresearchendeavors.
Amongrangeofsievesloped,sieveoscillationsandfeedratesrecommendedbydifferent
researchers,suitablerangesbasedonthesizeofthemachinethatwouldbedesignedand
fabricatedwereselected.
Oscillationsofthesievesweremadebyusingafourbarlinkagemechanismwherethelegsof
thesieveholdingframewerepinnedandoscillatedonaverticalplane.Itmustbenotedthat
duetothestackedarrangementofsievesandthedrivemechanismemployedthehorizontal
displacementsofthesieveswerenotthesameorequal.Thismighthavecausedorleadtoa
resultthatmightnotbecompatiblewiththefindingsofotherresearchers.
5
2

The prototype tef grain separating and cleaning machine had the ability to winnow the
premature grains, chaff and leaves, which are lighter than grains. It was also capable of
reducingtimewastage,grainsloss,labourrequirementandcontamination.Theperformance
evaluatedintermsofseparatingefficiency,cleaningefficiency,separationlossandcleaning
lossatdifferentsieveslopes,sieveoscillationsandfeedratesindicatedthattheseparationand
cleaninglossesincreasedwithincreasingsieveoscillationandfeedrateforallsieveslopes.
Buttheseparationandcleaningefficienciesdecreasedwithincreasingsieveoscillationsand
feedratesatallsieveslopes.Theminimumlossesandthemaximumefficiencywereachieved
o

at5 sieveslopeforallsieveoscillationsandfeedrates.Theseparationefficiency,cleaning
efficiency,separationlossandcleaninglosswere97.94,98.58,0.71and0.7%,respectivelyat
sieveoscillationof5Hz,feedrateof3kg/minandsieveslopeof5degrees.Theseparation
efficiency,cleaningefficiency,separationlossandcleaninglosswere52.71,39.88,2
5.62and34.5%,respectively,atsieveoscillationof20Hz,atfeedrate12kg/minandat
sieveslopeof5degree.
5.2.Conclusion
Performanceevaluationtoquantifytheeffectsofthesieveslopes,sieveoscillationsandfeed
ratesonseparationandcleaningefficienciesandassociatedlosseswhenseparatingchaffand
cleaningtefgrainsandchaffwasmade.Threelevelsofsieveslopes,fourlevelsofsieve
oscillations and four levels of feed rates were investigated to identify the optimum
combinationofthevariablesinquestion.Basedontheperformanceevaluationmadeand
resultsobtained,thefollowingconclusionscanbedrawn:
1

The performance of the machine was significantly affected by feed rate, sieve

oscillationandsieveslopeinthatorderofdominancy;
2

Separationandcleaningefficienciesingeneraldecreasedwiththeincreasingsieve

oscillation and feed rate, while separation and cleaning losses increased with the
increasingsieveoscillationandfeedrate;
5

Theseparationefficiencyslightlyincreaseassieveslopeincreasefrom0to5degrees

butfurtherincreaseofsieveslopesupto10degreeskeptonreducingtheefficienciesof
separationandcleaning;
2 Theseparationandcleaninglossesweredecreasedassieveslopeincreasedfrom0to5
degreesandincreasedassieveslopeincreasedto10degrees;
3

Highlevelsoffeedrateandsieveoscillationisconsideredareinefficientandcannot

obtainsatisfactoryoracceptableefficienciesandlosses;
4

Thestudyclearlyindicatedtheoptimumcombinationofsieveslope,sieveoscillation

andfeedratetobe5degree,5Hzand3kg/min,respectivelyfortheprototypemachine
developed;and
5

Themultipleregressionanalysesmadeandtheequationsdevelopedcanbeusedas

cornerstonesandspringboardstoselectoptimumcombinationofthevariableparameters
tofurtherdevelopand/orimproveseedsandgrainsseparatingandcleaningmachine.
5.3. Recommendation
Basedonthefindingsobtained,thefollowingrecommendationsaremade:
Sincethebeltconveyorwasoperatedmanually,theuniformityoffeedmaterialsintothe
cleaningunitwasnotconsistent;henceanautomaticfeedingmustbedevelopedand
used;

Oscillationsonthesievesweredevelopedusingafourbarlinkagemechanismthatmake
thedisplacementofthestackedsievesdifferent,theefficienciesandlossesmighthavebe
affectedbythevariationinthedisplacementsofsieves;hence,slidercrankmechanismbe
consideredasanappropriateoptionforequaldisplacementofstackedsieves;

5
4

Lackofavariableelectricorhydraulicmotormadetheuseofdieselengineamustand
controlofspeedsatdifferentlocationwasthroughreductionofenginespeed,whichwas
feltinappropriate;hence,furthertest,usingpowersourceswithvariablespeeds,bemade;
and

Theprototypemachine,ingeneral,needsfurthertestsandreevaluatedusingmechanical
variable speed electric motor to drive the moving parts at desired linear or angular
speeds. Furthermore, the sieve system must be redesigned to give all sieves equal
displacement.

5
5

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onAgriculturalEngineering,Croatia
Wang,Y.S., D.S.Chung, C.K.Spillman, S.R.Eckhoff, C.Rhee and H.H.Converse, 1994.
EvaluationofLaboratoryGrainCleaningandSeparatingEquipment.AmericanSocietyof
AgriculturalEngineers,TransactionsoftheASAE,37(2),507513;
Werby,R.A.,2010.PerformanceCleaningUnitforCloverGrainsAffectingSomePhysical
andMechanicalProperties.MisrJ.Ag.Eng.,27(1):266283
Wu, S., S.Sokhansanj, R.Fang and A.Opoku, 1999. Influence of Physical Properties and
Operating Conditions on Particle Segregation on Gravity Table. Journal of Applied
EngineeringinAgriculture,15(5),495499
Yan, J., C.Liu and L.Zhao, 2010. Dynamic Characteristics of Vibrating Screen with
Determinate Structure and Statistically Indeterminate Structure. Applied Mechanics and
Materials,34(35):18501854.
Zewdu Abdi, 2007. Aerodynamic properties of tef grain and straw material. Journal of
BiosystemsEngineering,98(2007):304309.
ZewduAbdiandSolomon.W.,2006.MoistureDependentPhysicalPropertiesofTefGrain.
JournalofBiosystemsEngineering96(1):5763.

5
9

7.APPENDICES
7.1.Appendixtables
AppendixTable1.Effectofinteractionofsieveslope,sieveoscillationandfeedrateon
cleaningandseparationefficienciesandassociatedlosses
CleaningEfficiency
SS

SO
5
10

10

3
97.841.01
91.050.1

15
0

FR

83.960.78

20

66.092.76

98.580.14

10

93.080.19

15

86.080.52

20

82.390.27

95.10.22

10

79.571.25

15

71.290.68

20

50.661.01

CleaningLoss

12
80.50.1
6
9
93.830.48 93.590.21
73.570.73
87.010.59 80.431.24
52.870.37
77.62.38 58.490.17
22.061.99
45.840.22 26.120.26
81.45.17
98.460.24 93.250.26
75.410.25
90.761
82.360.6
47.070.41
78.430.84 66.010.18
39.880.53
75.270.43 53.590.46
68.440.28
93.840.19 80.950.13
31.980.35
61.421
58.010.7
30.261.08
57.340.5 55.081.21
17.081.58
61.560.67 18.092.14

SeparationEfficiency
0

10

95.422.5

90.282

88.510.6

10

90.120.03 84.770.7

78.410.9

15

73.210.9

68.930.2

54.930.3

20

46.410.7

31.100.2

25.540.1

97.940.5

96.110.7

89.460.6

10

90.630.8

89.040.2

81.031.3

15

73.641.3

69.480.1

55.450.1

20

69.861.0

66.620.3

52.712.0

79.670.5

73.610.6

56.710.1

10

60.032

79.491

54.982

15

40.483

62.121

31.171

20

41.111

37.693

29.400.2

3
1.090.3

3.140.14

4.580.03

6.710.18

8.360.23

11.90.71

18.510.82

30.680.06

0.710.04

0.770.07

3.520.06

4.740.3

7.210.16

11.370.25

9.190.08

13.130.13

2.480.07

3.130.06

10.790.37

21.170.3

15.40.2

23.590.15

27.70.3

21.090.2

S
ep
ar
at
io
n
L
os
s

80.090.46

1.070.56

3.031.31

3.150.8

9.270.42

73.662.96

4.380.21

6.271.56

9.272.85

12.341.7

50.631.18

7.682

10.54.32

18.620.5

20.811.1

13.480.19

15.45.53

23.480.5

30.333.6

31.56056

81.650.77

0.70.28

0.770.31

3.320.55

8.850.73

75.081.13

3.41.93

4.51.94

8.420.78

11.541.84

44.721.48

6.71.57

10.20.43

15.560.7

23.020.56

40.582.48

8.421

11.61.4

20.541.8

25.620.76

37.190.41

2.420.7

3.030.31

9.070.78

14.543.62

34.901

9.642.5

17.422.6

18.781.2

28.371.94

30.741

13.311.5

19.072.9

19.931

28.962.5

24.980.4

21.642.7

17.364

32.785.4

335.5

60

AppendixTable2.Analysisofvarianceofseparationefficiency
Sourceofvariation
df
ss
REP
2
1.30
SS
2
3673.52
Residual
4
4.36
SO
3
50119.58
SS.SO
6
3993.30
Residual
18
7.69
FR
3
9279.54
SS.FR
6
394.67
SO.FR
9
474.67
SS.SO.FR
18
555.80
Residual
72
85.20
Total
143
50215.17
CoefficientofVariation=1.9%
Standarderror
=0.96

ms
0.65
1836.77
1.10
16706.50
665.55
0.42
3093.18
65.78
52.70
30.88
1.18

Fvalue
0.59
1684.40
1.70
26058.02
2076.20
0.41
1960.44
41.69
33.43
39.14

Fpr.
<.001
<.001
<.001
<.001
<.001
<.001
<.001

AppendixTable3.Analysisofvarianceofseparationloss
Sourceofvariation
df
REP
2
SS
2
Error
4
SO
3
SS.SO
6
Error
18
FR
3
SS.FR
6
SO.FR
9
SS.SO.FR
18
Error
72
Total
143
CoefficientofVariation=15.3%
Standarderror
=2.104

ss
5.980
1538.037
13.934
6095.146
527.960
81.264
3460.632
67.867
299.882
294.564
318.872
12704.138

ms
2.990
769.018
3.483
2031.715
87.993
4.515
1153.544
11.311
33.320
16.365
4.429

Fvalue
0.86
220.76
0.77
450.03
19.49
1.02
260.47
2.55
7.52
3.70

Fpr.
<.001
<.001
<.001
<.001
0.027
<.001
<.001

6
1

AppendixTable4.Analysisofvarianceofcleaningefficiency
Sourceofvariation
df
REP
2
SS
2
Error
4
SO
3
SS.SO
6
Error
18
FR
3
SS.FR
6
SO.FR
9
SS.SO.FR
18
Error
72
Total
143
CoefficientofVariation=8.2%
Standarderror
=5.659

ss
40.70
9339.68
104.12
35970.05
3462.12
497.94
20921.88
623.88
2696.97
1839.00
2306.14
77802.48

ms Fvalue
20.35
0.78
4669.84 179.40
26.03
0.94
11990.02 433.42
577.02
20.86
27.66
0.86
6973.96 217.73
103.98
3.25
299.66
9.36
102.17
3.19
32.03

Fpr.
<.001
<.001
<.001
<.001
0.007
<.001
<.001

AppendixTable5.Analysisofvarianceofcleaningloss
Sourceofvariation
df
REP
2
SS
2
Error
4
SO
3
SS.SO
6
Error
18
FR
3
SS.FR
6
SO.FR
9
SS.SO.FR
18
Error
72
Total
143
CoefficientofVariation=20.6%
Standarderror
=3.595

ss
16.34
3297.86
42.24
12475.17
1301.16
183.51
7366.37
289.53
1222.11
680.30
930.71
27805.30

ms Fvalue
8.17
0.77
1648.93 156.14
10.56
1.04
4158.39 407.89
216.86
21.27
10.19
0.79
2455.46 189.95
48.26
3.73
135.79
10.50
37.79
2.92
12.93

Fpr.
<.001
<.001
<.001
<.001
0.003
<.001
<.001

6
2

AppendixTable6.Tablesofmeansofefficienciesandlossesateachleveloffactors

Separationefficiency
0
5
10
64.72
73.37
61.39
5
10
15
86.97
80.43
58.96
3
6
9
75.71
72.69
61.61

SS
SO
FR

SS
SO
FR

SS
SO
FR
SS
SO
FR

0
12.95
5
4.93
3
7.90
0
70.68
5
89.65
3
82.97
0
16.37
5
5.41
3
9.13

Separationloss
5
10
10.20
18.08
10
15
11.19
16.20
6
9
10.60
15.81
Cleaningefficiency
5
10
77.63
58.17
10
15
75.39
63.71
6
9
76.78
63.83
Cleaningloss
5
10
12.17
23.75
10
15
13.42
20.10
6
9
12.62
20.35

20
39.62
12
55.98

20
22.64
12
20.66

20
46.55
12
51.71

20
30.81
12
27.63

AppendixTable7.SomespecificationofAtypevbelt
Parameters
Value
2
Crosssectionalarea(a)
81mm
2
Maximumsafestress()
2.1N/mm
Massperunitlength(m)
0.108kg/m
o
Grooveangle
40
Source:KhurmiandGupta(2005)SharmaandAggarwal(2006
6
3

AppendixTable8.Coefficientoffrictionbetweenbeltandpulley
Beltmaterial

Pulleymaterials
Castiron,steel
Wet
Greasy
0.2
0.15
0.32
0.22

Dry
Leatheroaktanned
0.25
Leather
chrome
0.35
tanned
Convassstitched
0.20
0.15
Rubber
0.30
0.18
Balata
0.32
0.20
Source:KhurmiandGupta(2005)SharmaandAggarwal(2006)

wood

0.12

AppendixTable9.Rawmaterialscost
No Itemsdescription

Unit

Quantity

U.Price

Meter.sq
Meter

3.2
0.08
3

93.99
185
85

300.77
14.8
255

Meter
No
No

0.04
17
6
1

916.97
63.33
200
680

36.67
1076
1200
600

1
0.24
0.24
0.24

500
400
500
560

580
96
120
134.4

1
1
12
12
1
4

60
47
4
3.5
154.99
25

Sheetmetal1.5mmthickness
3mmthickness
Roundbar25mm

3
4
5

100mm
Angleiron(4x40)mm
Bearing6204
OnelinePulley20x165mm

7
8
9
10

20x138mm
Sieve3mmroundhole
2mmroundhole
1mmslottedhole
VBeltA56
A36
BoltandNutM10x50mm
M8x50mm
Electrode2.5mm
Cloth(abujedi)
Subtotal

Meter.sq

No
No
packet
Meter

Total
price

60
47
48
42
154.99
100
4865.63
6
4

Leather

0.3
0.4

0.38
0.48

0.23
0.32
0.35

0.27
0.40
0.40

AppendixTable10.Productioncost

N
o.

Typeofmachine

Machin Worki Cost

Labor
Workin Cost
ecost/ ng
(ETB) cost/hr ghour
(ETB)
hr
hour
1 Universalmetalcutting
10.00
8
80
8
8
64
2 Weldingmachine
5.10
13
66.3
8
13
104
3 Powerhacksaw
3.67
4
14.68
8
4
32
4 Lathmachine
14.94
16 239.04
8
16
128
5 Rollingmachinemanual
2.87
0.5
1.44
8
0.5
4
6 Radialdrillmachine
2.57
8
20.56
8
8
64
7 Grindingmachine
0.74
5
3.7
8
5
40
8 Bendingmachine
2.87
3
8.61
8
3
24
Sub total
434.33
460
N.B.Thelaborcostisdependentonthesalarypermonthofthemachinist
AppendixTable11.Costsummary
No.
1
2
3
4
5
6
7

Variable
Rawmaterial
MaterialsWastage=2.5%of1
Production(machine+labor)
Overhead=5%of3
Profit=10%of(1+2+3+4)
Selltax=15%of(1+2+3+4+5)
Sellingprice=(1+2+3+4+5+6)

Cost(ETB)
4865.63
121.64
894.33
44.72
592.63
977.84
7496.79

6
5

7.2.Appendixfigure

(A)

(B)

(C)
AppendixFigure1.Viewoftheseparatingandcleaningmachine(A=Front,B=Rightsideand
C=Top;alldimensionareincm)

66

AppendixFigure2.Forcesactingonmaterialsandtheirdirectionoverthesievesurface(Fi=
inertiaforceandFf=frictionforce)

6
7

Duringconstructionoftheprototype

Duringmaterialsdistributionovertheconveyor

Photooftheprototypeandduringtesting

Duringdatacollection
AppendixFigure3.Photoofmachineduringconstruction,testinganddatacollection.

6
8