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ABSTRACT
This report deals with the brief design analysis, design concept, design matrix,
performance, literature review, manufacturing process, assembling process,
detailed drawing and assembly drawing of the mechanical driven reciprocating
reaper which reaps or harvests 1.8 hectare per day on doing 8 hours
The structure or body which carries or holds all the parts of the machine
Cutter blade is the main part that attains its name to be the harvester or reaper.
Wheel or axel with its shaft to create the motion or rotation to drive all
mechanisms.
The upper shaft is an intermediate shaft to transmit power and motion from the
wheel or axel shaft to the recovery reel and cutter blade.
Belts are used to transmit power from the axel to the intermediate shaft (V-
belts) and from the intermediate shaft to the recovery reel (flat belt) and to drive
the canvas or the conveyor (timing belt).
Canvas is used to transmit or convey the harvested or cut grain to the free
space side.
Revolving reel swept the harvested grain to the face of the conveyor by
revolving on its axis.
Inclined shaft carries and drives the canvas and transmit power from the
intermediate shaft to the cutter blades using bevel gears.
2. INTRODUCTION
2.1 Farm mechanization
2.2.1 Sickle
A sickle is a curved, hand-held agricultural tool typically used for harvesting
grain crops before the advent of modern harvesting machinery. It consists of a
curved blade with a short, one-hand handle attached. The inside of the curve is
sharp, so that the user can swing the blade against the base of the crop, catching
it in the curve and slicing it at the same time. It is sometimes referred to as a
'grass hook'.
2.2.2 Scythe
Scythe is a similar tool with the sickle used to harvest grain crops. The most
noticeable difference between a sickle and the scythe is the shape of the blade of
which the Scythe blade is more linear whereas a sickle blade is more in the shape
of a C with a point at the top.
2.2.3 Cradle
Cradle is a more developed tool for reaping and harvesting. It consists of an
arrangement of fingers attached by a light frame work to the snatch of a scythe.
Its purpose is to gather the straw as it is cut and deposit it in a swath. At the end
of the cutting stroke, the cradle is tilted to drop the straw in a pile. Also,
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Design of mechanical driven reaper Farm technology
substantially more grain can be cut in a day with the cradle. However, loss due to
shattering (grain dislodged from heads due to shock) is greater with the cradle
which makes to continue using the sickle to harvest grain.
2.2.4 Mowers
An agricultural mower having a crop cutting rotor that is rotatable about an
upright axis and cuts a strip of crop along a cut edge of the crop so as to emerge
laterally from side cut edge, and a crop guide that is located adjacent the
periphery of the rotor where it emerges from side cut edge of the crop so as to
support the crop upright at side edge while it is cut. The guide thereby avoids
leaving any uncut lines of crop caused by the rotor pushing crop aside at a cut
edge in the crop where it is unsupported by adjacent standing crop. The
invention is particularly applicable to a mower with two or more cutting rotors
that are rotatable in the same sense about respective upright axes alongside one
another with one rotor offset rearwards relative to the other so as to cut crop
adjacent a cut edge left by said other rotor, the crop guide being located adjacent
the periphery of said one rotor to support the crop along said edge.
2.2.5 Reapers
Reapers are harvesting-machines used for cutting grain-crops. They either
deliver the grain to one side in gavels ready to bind into sheaves, or elevate the
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Design of mechanical driven reaper Farm technology
gavels upon a platform where two operators bind them into sheaves by hand. An
attachment is often provided whereby the machine successfully performs the
binding of the sheaves automatically with wire before delivering them
The essential parts of a reaper are: the cutting arrangement, similar in design to
that of mowing-machines (except that in many cases sickle-knives in place of
plain knives are used); sweep or table rakes to convey the grain to and from the
machine; and mechanical means to regulate the delivery of the gavels, so that the
size of the same shall be sufficient for binding even in spots or places upon the
land where the crop is very light. Many of these machines are constructed so that
the various devices for raking, sweeping, gathering, or delivering, may be
detached, leaving the machine a simple mower
4. LITERATURE REVIEW
Agricultural machinery is designed to till the soil and render it more suitable
for crop growth, to sow seeds, to apply agricultural chemicals for improved
plant growth and control of pests and diseases, and to harvest and store the
mature crops. There is an extremely wide variety of agricultural machines, but
all are essentially a combination of gears, shafts, chains, belts, knives, shakers
and so on, assembled to perform a certain task. These parts are usually
suspended in a frame which may be either stationary or, as is more often the
case, mobile and designed to perform the desired operation while moving
across a field. The major groups of agricultural machines are: soil tillage
machines; planting machines; cultivating machines; forage harvesting
machines; grain, fiber, vegetable, and fruit and nut harvesting machines;
agricultural chemical applicators; transport and elevating machines; and sorting
and packaging machines.
One of the stands out benefits of walking tractors is their use as secondary tillage
machines. Their low weight minimizes compaction while their maneuverability
encourages their frequent use to keep weed competition down from early crop
emergence or soon after transplanting. The addition of an inter row tiller
attachment speeds up your field, breaks up encrusted and incorporate
amendments.
Combine a accurate metering grain drill with your walking tractor and place your
grain seed or cover crop where it will flourish, do away with the hit or miss
results of broadcast seeding. Choose disc openers for heavier ground and areas
less well prepared. Or choose shoe type openers in lighter soils and those that
have been well tilled.
This planting machine is made for use in small and medium-sized tractors;
available from 1 to 7[8] lines; hydraulic planting machine, articulated, with
pantograph system for direct planting; the lightest planting machine in the
market; seed container capacity: 18 Kg; fertilizer container capacity: 60Kg;
estimated weight (empty) 110 KG per line[8].
Individual articulated system, to the right or to the left, to make planting in
curves and slopes easier for planting soy beans, black beans, corn, sunflower
seeds, and other grains.
They also improve the soil tillage so as to make it more absorptive of rain.
Fig.6 A farmer tilling around a plum tree with a cultivating machine [10]
This machine is for weeding and aerating the soil. We suggested weeding near
the trees by hand to avoid harming the tree's roots. The trees further toward the
rear are peach trees.
Rakes with short, stiff spikes are normally used for raking hay, fallen branches,
seaweed and paper-waste. The functionally designed Universal Rake with wings
can also be used for cultivating. The wings support the spikes and keep them
from digging into the ground. The wings are removable. The open structure
allows soil to flow through the rake's head, which also makes cultivating work
easier.
vehicle, which may be a towed wagon. Crimpers, which crush or break the stems
of plants, are often used to expedite the field-drying process of fodder crops to
prevent spoilage, especially of legumes that will be placed in dry storage or
baled. Pelleting machines are used to compress fodder crops into compact cubes
for mechanical feeding of livestock. Balers are used to compress fodder into
square or round bales to facilitate storage and handling. Some bales are small
enough to handle manually, while others may be so large as to require
mechanical handling systems [12].
and stacking transport unit. Inclined chain, flight or belt conveyors or other
mechanical handling devices are used to move bulky material (hay, straw, ear
corn and so on) from wagon to storage or from one location in a building to
another. Screw conveyors are used to move granular material and grain from
one level to another, and blowers or pneumatic conveyors are used to move
light materials horizontally or vertically.
Reaper is any farm machine that cuts grain. Early reapers simply cut the crop
and dropped it unbound, but modern machines include harvesters, combines, and
binders, which also perform other harvesting operations.
With the sickle or reaping hook one man could cut from one-half to one acre in a
hard day's work. The cut grain was later bound by hand.
4.2.2 Cradle
The cradle was the most efficient means of cutting grain before McCormick's
invention of the reaper. The cradle consisted of a broad scythe with a light frame
of four wood fingers attached to it. The advantage of the cradle was that by a
turn to the left the operator could throw the grain into a swath, ready to be raked
and bound into sheaves. This improvement was introduced in America about
1776[15], according to Professor Brewer of Yale, and was the common
instrument of grain harvesting as late as 1840. For cradling grain, two acres was
considered a day's work.
4.2.3 Scythe
The scythe was the companion tool to the reaping hook or sickle. It was always
used for mowing grass but sometimes oats and barley were cut with it. It was not
generally used for cutting wheat. With the scythe a man could cut up to three
acres a day.
While this first machine required only 2 people for operation (a person to ride
the horse and a man to rake the cut grain from the platform), it cut as much grain
in one day as 4-5 men with cradles or 12-16 men with reaping hooks.
The McCormick Patent Reaping Machine of 1857 [15] combined machinery for
reaping and mowing, and was built from 1852-1865[15]. Its chief improvements
over the 1831 reaper were seats for driver and raker, a cutting knife fabricated in
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Design of mechanical driven reaper Farm technology
sections rather than one piece, and an all-metal main wheel. This machine also
cut a wider swath than the first reaper and was pulled by two horses.
The McCormick Patent Reaping and Mowing Machine were manufactured from
1852-1865, with various improvements being incorporated from time to time.
This specific machine includes seats for raker and driver and cut a wider swath
than McCormick's reaper of 1831.
swept cut grain off the platform, depositing the grain in neat gavels on the
ground, ready to be bound into bundles by the hand binders.
Here an "Old Reliable" of 1864[15] deposits neat gavels of grain on the ground
to be bound by a crew of 4-5 men.
An "Old Reliable" of 1867[15] with its automatic sweep arm removed cut grain
from the reaper platform. This arm released one more man for other farm jobs.
The McCormick "Advance" Combination Reaper and Mower. This machine was
manufactured and sold by McCormick from 1869-1879 [15]. The "Advance," a
combined mower and reaper, had an automatic rake as part of the reel. Platform
and reel were removable so that the machine could be used as a straight hay
mower. This illustration shows the machine for use as a reaper.
The McCormick Marsh Type Harvester, built from 1875-1883, consisted of the
same cutting mechanism as McCormick's earlier reapers, with an elevator and
binding platform added. Two men rode on the platform, binding grain by hand as
it was delivered to the by the elevator. This machine was patented as early as
1858 but was not put into general use until 1875. With the Marsh type harvester,
2 men bound the grain while earlier harvesters had required 4-5 men for binding.
McCormick Harvester and Binder of 1876 at work in the field was the first
practical self-binder ever built. People traveled miles to see the first machine
controlled by one man, which cut and bound grain in a single operation.
McCormick built and sold 50,000 of these binders between 1877 and 1885.
The McCormick Light Steel Binder built in 1888[15]. This was an improvement
over the first steel binder of 1885[15]. The knotter was improved for the first
time since the binder came into existence. Improvements in the reel construction
were made and an adjustable canvas grain shield was added on the rear of the
platform.
Concept 3: design of mechanical reaper the same as that of concept 2 but with
out any additional component to drive the plat form or the canvas drives directly
by the inclined shafts.
Concept 4: design of mechanical reaper with V-belt for power transmission from
the carriage shaft to intermediate and timing belt to drive the canvas plat form.
Material 6 9 9.5 8
availability(10)
Strength(10) 9 8 5 9
Manufacturability(10) 5 6 8 7
Weight(5) 3 3 4.5 4
Maintainability(5) 4 3 3 4.5
Effectiveness(10) 9.5 9 5 9
As you see in the above table the fourth one or design concept 1 is better than the
others and it is selected to be designed.
5.4.1 Determining the relation ship of wheel and the overall speed ratio
Determining the radius of the wheel R and the overall speed multiply ratio X, the
distance traveled L, and the time require cutting L[cm] distance traveled by the
wheel t in order to operate the machine smoothly.
w * X
L w * R * t[cm]and L * l[cm]* 2t Where l is the length of the cutter
2
blade and the number 2 describes double bladed. Assuming the length of the
cutter to be 10cm
10* w * X 10* X
L = w *R *t = t R=
Comparing the values as in the table below to determine the preferred one:
12.73 4 25.46
19.1 6 38.2
25.5 8 52
31.83 10 63.66
38.2 12 76.4
From the above table I was selected the values with R=25.5 cm and X=8 in order
to have enough space for the driving V-belt pulley.
F = 824.98
C =1100MPa
A = r2
C =F/ r2
r = 1.545mm
F = 825/2cos300 = 476
This is less than the reaction force when the rib is at horizontal position.
For the manufacturing simplicity and strength take diameter of the rib to be d =
10 mm
Fig.25 wheel
Belt drives are being most widely used in industries for transmission of power
from one shaft to another over considerable distances. It is successfully
competing with individual drives in which the machine is directly couple to the
shaft of his own motor. The flexibility of the belt helps in arranging the shafts of
the driving and the driven pulleys in any manner and in using as many pulleys as
possible. The materials of the belts to be used for transmission must be strong in
tension, flexible and pliable, durable, relatively light in weight, and have good
frictional surfaces. The most commonly used materials are:
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Design of mechanical driven reaper Farm technology
1. Leather
3. Rubber belts
Unless the belts are endless, some type of fastener is required to join the two
ends of the belt length. And the efficiency of the belt depends on the type and the
place of joining or fastening the ends of the belt. For example cemented by belt
maker and cemented by other persons have the efficiencies of 1 and 0.98
respectively.
Working stress
Factor of safety for leather belt may be taken equal to 8 to 10. Factor of safety
for rubber and balata may be taken from 6 to 8. The working stress so obtained
must be multiplied by the efficiency of the joint to find the allowable stress.
Belt speed
The belt speed should not be very high since as the belt speed increases,
centrifugal force begins to pull the belt away from the pulley thus reducing the
efficiency.
Some amount of slip is always present between the belt and pulley surfaces
when power is being transmitted. Amount of slip increases if the belt is over
loaded. It has been found that a slip of up to 3% increases the coefficient of
friction. Under normal condition a slip of about 1.5% to 2% is present. Due to
slip the speed of the belt and is less than the peripheral speed of the driving
pulley. Creep is also the phenomenon caused by the elasticity of the material.
The belt is stretched more on the tight side than on the slack side.
Coefficient of friction
The coefficient of friction between the belt and the pulley surface depends up on
the belt material, material of the pulley surface, the belt speed and pulley speed.
Center distance
The life of the belt is a function of the center distance between the driver and
driven shaft. The shorter the belt the more often it will be subjected to additional
bending stresses while turning around the pulley at a given speed and quicker it
will be destroyed due to fatigue so the center distance is chosen so as to increase
the life of the belt.
A-section
2 2 2
1 2
2 2 2
2 2
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Design of mechanical driven reaper Farm technology
D<C<3(D+d) 250<C<975
Taking C=600mm.
Dd
L D d 2C sin cos Where sin
2 2C
D d 175 175 2
sin sin 1 cos 1
175
2C 1200 1200
1200
L=1750 mm.
2
2
C 0.25 L D d L D d 2 D d
2 2
C 613.5mm
D d 175 175
sin 1
2C 1227 1227
DN1
V 0.3m / s Where D=250mm and N1 =22.93 rpm.
60
belt/pulley interfaces can support with out gross slip. The V 2 term often
Fmax V2 e f min
Fmin V2
Where f min min f1, f2 f2
From standard table the power rate per belt having belt properties
The correction factor of the power rating per belt with speed ratios greater than 2
is 0,009Kw/belt
Pr/z =101.5w.
Fmax Fmin V Pa / z Where V speed of the belt is, P is actual given power
a
Pr
Also V 2 Fmax where k is the drive property of the belt?
zk V
f P 2
k 1 e min 0.768 Thus, Fmax r V Will be
zk V
The overall severity of belt loading on each of the two pulleys may thus be
expressed as an equivalent damaging force F*.
M
F* Fmax and
1 D
M
F2* Fmax
d
F* 536.267NandF* 919.147N
1 2
m
F
N* Where N * life cycle of the belt, F is the reference load and m is
F*
the index. F and m are constant properties of the belt with values 3216N and
11.11 respectively.
m m
F F
N* 4.394*108 cycle And N* 1.104*107 cycle
1 * 2 *
F F
1 2
Miners rule states that failure occurs when the cumulative damage via both
mechanisms reaches 100% [16]
N N
1 2 1
I.e. * where N1 = N 2 = N c where N c is the combined life of the
N N*
1 2
belt.
Nc Nc N* * N*
Hence * * 1 Nc *1 2 1.0772*107 cycle
N
1
N
2 N N*
1 2
T
Nc L 7
6.2836*10 sec
6.2836*107
5.9year Where L is length of
V 365*8*60*60
the belt, V is speed of the belt and N c is the combined life of the belt
Pa Actual given power, Pr rated power, z number of belt, S f service factor, and
P
Pa 63.64w , r 101.5w / belt Sf 1.3 assuming medium shock and K L 1
z
for length L=1750 from table
S * Pa
z f 0.815
Pr Taking the nearest whole number
KL *
z
z 1belt
Given power p=58.867 assuming the efficiency of the first belt to be 92.5%,
Angular speed N1=76.4 rpm
2
D d
L 2C
4C
2
D d
L 1482.933 Approximating to the next standard
L 1509mm
2 2
C 0.25
L 0.5 D d L 0.5 D d
2 D d
C 613mm
Vb 1 s V 0.98V Where s=0.02 is the slip and V is the speed of the driver
dN1
V 0.32m / sec Where N1 and d are the speed and diameter of the first
60
pulley
Vb 0.3136 Since this speed is too small the effect of centrifugal force will
be neglected.
F1 F2 V T 260P
N
7.33Nm
1
F1 F2 23.384N .. [1]
F
1
F
2.3log 2 0.25*3.1183
min
F
1 2.178
F
2
F 2.178F ......................... 2
1 2
F
b*t 1
Where f t is the allowable tensile stress of the belt material and C1
f t *C1
43.2346
b 3.2mm But taking the smallest belt width from standard
2.7 *5
b 25mm
From the structure the center distance c of the pulley is given of fixed as 980mm
and from table of American standard timing belts with XL cross-section, above
10 numbers of grooves Pb the pitch length or distance is 0.2 inch = 5.08 mm
Power transmitted to the upper shaft will be 0.925P, p = actual given power
and 0.925 is the efficiency of the belt. The new power will be p = 0.925*63.64 =
58.867W
The input speed for this gear is the output speed of the belt
N1 D 250 22.92
N2 d 75 N2
Gear ratio=2.4
Material selection:
Through hardened steel of type Grade 1 for both gear & piston HB =250
Assumption:
Module m=5 mm
And an assumed life of 8 hrs per day, 200 days per year for 15 years.
Determining number of teeth and the pitch angles of the pinion and gear
ZG 12 * 2.4 28.8 ; 29
p1 tan
1
1
V.R
o o
22.62 And p2 90 p1 67.38 where V.R is the
speed ratio of the gears and p1 , p2 are the pitch angles of the pinion and gear
respectively.
respectively.
Z Ep Z p1 sec p1 13
Z EG Z p2 sec p2 76
0.686
y p1 0.124 0.0668
Zp1
0.686
y p2 0.124 0.1
Z p1
60P
Torque on the pinion is given by T 2N 3066Nmm
p1
2T
Wt 102.192N
mZp
dp
Cone length l 80mm
2sin p1
For successful operation of the bevel gear the recommended face width is
6.3m f 9.5m
31.5 f 47.5
Take f 40mm
Addendum a m 5mm
1000Wt K A K v K HB Z x Z xc
c Z E Where
f * d p * Z1
Wt =tangential force
f =face width
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Z Z
cp clim NT w Where
Sfc*K *Zz
Z w = hardness factor
K = temperature factor
Z z =reliability factor
K v = Dynamic factor
Dynamic factor K v
B 2
Kv A
Where A 50 56 1 B , B 0.25 12 Q 3 and Q v 6
v
A 200V
K v 1.148
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Design of mechanical driven reaper Farm technology
6 2
K HB K mb 5.6 *10 *f Where f is face width and K mb 1 for both
members straddle.
K HB 1.009
Zx 0.6343
Z NT 1.0836
HB1
Zw 1 1 Where HB1 and HB 2 are the hardness of pinion and gear
HB2
Zw 1
Z Z
cp clim NT w
Sfc*K *Zz
cp 325.25 Mpa
1000Wt K A K v K HB Z x Z xc
c Z E
f * d p * Z1
c 118.4 Mpa since this value is less than the permissible contact stresses
1000 * Wt * K A * K V YX K H
b And
f * d * m * YB * J
blim * YNT
bp Where
Sfb * K A * YZ
=1.148
m =Module
Size factor YX
0.323 For 6 10
YNT 1.683N 3 *10 N 10 where N is the life cycle
YNT 0.8996
1000 * Wt * K A * K V YX K H
b
f * d * m * YB * J
b 18.90785Mpa And
blim * YNT
bp Where blim 0.3HB 14.48 89.48
Sfb * K * YZ
Since the pinion and gear are made of the same material. Having the same stress
and strength as the pinion with small dimensions is safe it is true that the design
of the gear with larger dimensions is safe.
DG
Cone length of the gear L G 2sin 79 where p2 =67.38 pitch angle of
p2
the gear
Addendum a=m=5mm
Dedendum d=1.2m=6mm
Clearance c=0.2m=1mm
A shaft design really begins after much preliminary work, the design of the
machine it self will dictate that certain gears, pulley, bearings, & other element
will have at least been partially analyzed and their size and spacing tentatively
determined. At this stage the design must be studied from the following points of
view
A. bending deflection
B. torsional deflection
A. stating strength
B. fatigue
C. reliability
=440.457+228.413
=668.96N
W= mg =100*9.81 = 981N
w F1 981 668.98
F2 2
2
824.98N
From American standard tubes and pipes select the internal diameter and
calculate the outside diameter to get the safe dimension or select from the
standard i.e.
Take d=23.5mm
p=63.64
The figure below shows or indicates the overall shaft geometry, free body
diagram of the reaction forces, the shear force diagram and the bending moment
diagram of the shafts.
Note: A and B are the reaction forces right and left side of the bearings
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Design of mechanical driven reaper Farm technology
Taking moment at A
R B 490.5N
Fx 0 R A 490.5
T Fmax Fmin * R P , where R P = pulley radius
= 53011N.mm
From the concept of shafts subjected to combined twisting moment and bending
moment.
Te
2 2
Tmax M max & M e 0.5 M max 2
Tmax M max
2
3
Te * D * 1 K
16
4
Me
32
3 4
* b * D 1 K Where d = internal diameter,
d
D = external diameter & K
D
3 ult
Te 117.35 *10 Nmm And F 136.4N / mm
2
s
D
3
1 K 4 4381.63466mm2
Now lets calculate and analyze d & D and compare with the standards Using
equation of twisting & bending moments.
Me
32
3
* b * D 1 K
4
2
= 104753.2268, b 220N / mm
D 4 4850.63D d 4
The minimum outer diameter D will be 25mm for more safe and comfortable
lets take D=30mm & d=23.5mm by using these values. Lets check the strength
32Me 2
b 63.384N / mm
D3 1 K 4
=63.384 N / mm 2 which is less than the yield strength i.e. 220 N / mm 2
Tangential load of the bevel gear Wt 102.192N angular speed of the shaft is
N 76.4rpm , power is P=58,867W tensions on the first or V-belt pulleys
Wa 14.306N
Wr Wt tan sin G
Wr 33.252N
Components of the force due to tensions of the second pulley which is inclined at
an angle of 200 from the horizontal
F1x F1 cos 20 40.627N And F2x F2 cos 20 18.653N and the y component
force will be: F1y F1 sin 20 14.787N and F2y F2 sin 20 6.789N
Since the power transmission between the gears is at 45 0 from the horizontal the
moment reactions are also at 450.
Fig: that shows free body diagram, shear force and the bending moment diagram
of the shaft along X-axis and Y-axis.
F y 0 R Ay 305.5045N
F y 0 R Ax 8.64N
Taking the local extreme points to find the maximum bending moment
2125
2
M2 1348592 134876.341Nmm
60P 60*58.867
T 7357.833Nmm
2N 2* *76.4
From shafts subjected to combined twisting moment and bending moment design
Te M 2 T 2 135076.8858Nmm
M e 0.5 M M 2 T 2 134976.6134Nmm
16Te
d3 17198.53mm 3
all
d 17.5mm 18mm
32M e
d3 6249.366
b
d 18.42mm 20mm
Taking the big and material availability the diameter will be d=20mm
From design analysis of the upper shaft or the second shaft the reaction forces on
the upper parts of the structure are:
R Ax 36.957N R Bx 76.48N
And
R Ay 305.5045N R By 351.5545N
32M d
pipes and tubes: D 1 K where K
3 4
and d=internal diameter and
D
D=outer diameter of the structure material.
32M
D4 d 4 D 4 2758.2276D d 4
* b
D=21.336mm d=19.626 but the standard internal diameter of the pipe for the
given outer diameter D is d=15.8mm.which describes using the design is safe.
For the vertical structure take the maximum force from the above analysis of the
Now checking the compression strength of the vertical member of the structure
By taking the material as that of before the cross sectional area of the member
D2 d 2 F
will be A 205.584896mm 2 and the compression stress c =
4 A
4F
= 4.14Mpa
D d2
2
Assuming the size weld to be 5mm and the weight of the revolving reel to be 16
KG which accounts the weight carried by each structure will be 8KG.
shear stress all 27.5Mpa , safety factor SF 2.5 , length of weld l * D , Area
of weld A * D * t , thickness of the weld t=0.707s, and size of the weld
s=5mm.
F 78.48N
0.33Mpa Which is much less than the allowable given
A 236.95mm 2
stress that indicates the revolving reel is safe under shear.
M
b Where b is the bending stress, M is bending moment and Z is section
Z
modulus.
* t * D3
M F*e 78.48*380 29822.4Nmm And Z 107864.44mm3
4
M 29822.4Nmm
b 0.2765Mpa Which is much less than the
Z 107864.44mm 3
allowable bending stress of the given material. The taking the same material as
before is safe.
D=21.336mm and d=15.8mm are the internal and external diameters of the
member.
F
Area of shear A s l* t , where l=21.336mm is length of the member and t
A
is the thickness.
F F F
t 0.026mm
A l* t *l
F F F
all t 0.076mm But for safety and easiness take t=4mm
A c l* t all *l
F 76
A=2tl=2*0.707*5*21.336=15.8455mm2 and 0.5Mpa
A 15.8455
Since this is less than the allowable stress the structure is safe.
Fig
Assuming that half of the weight at a 280mm distance from the bearing to be
40*9.81* 4
1.0975Mpa which less than the allowable stresses.
* 21.336*5*0.707
Material:
Density =7200KG/m3
1. Driver pulley:
Diameter of hub d1
* D * N * 250* 22.92
Velocity of the rim V 0.3m / sec where N is the
60 60
angular speed of the pulley
d1 2d =60mm
L 0.5d 48mm
D D
2mm t 3mm
300 200
2.833mm t 4.25mm
Take t 4mm
It is usually elliptical with major axis ( a1 ) and minor axis ( b1 ) which is equal to
half of the major axis.
2T 2* 26.515
Wt 106.059N Where: T is the torque R is the pitch radius
R * n 0.125* 4
of pulley and assuming the number of arms n=4
The maximum bending moment on the arm is developed on root of the hub and
is given by:
* b1 a1 But b1 0.5a1
2
Z
32
* a1
3
Z
64
Since the driven pulleys diameter is less than 200mm a solid pulley is used.
From the driver pulley a=3.3mm, c=8.7mm, w=11mm and f=10mm, and shaft
diameter d=12mm, pitch diameter of the pulley dp=100mm
5.4.7.2 Design of pulleys for the second transmission or flat belt pulleys
Material:
Cast iron
Power P=58.867W
Driver pulley
w=b+13mm=28mm
Driven pulley
N 76.4rpm
1
The speed of the inclined shaft that drive the reciprocating mechanism
N 2 183.6rpm
Since the cutters have double blade during one revolution of the reciprocating
mechanism the cutter bade cutes on each forward and backward motion.
During one stroke of the blade leftward or rightward of the cutter the revolving
pass through one of the revolving reel linkage.
367.2
N
6
61.2
Revolution ratio from the intermediate shaft to the revolving reels shaft will be
N 61.2
N 76.4
1
R 0.8
d 80mm
1
d 100mm
2
The internal length of the revolving reel equal to the length of total cutter blades
Fig.37 key
Since the shaft is hollow or it is made of steel pipe it better to make the key
integrated by welding over it with a great care to avoid the damage of the shaft
and the key needs some preparation by grinding for welding.
To check the strength of the key as it is welded through out its circumference the
side to be welded, taking some arbitrary dimensions of the key and assuming
size of weld S=5mm to check the shear stress.
F
Where F is the tangent force developed at a distance r from the center of
A
60P 60*63.64
the shaft and is given by F 1767.65N P is the
2 * N * r 2 * 22.92*0.015
power, N the angular speed of the shaft and r is the radius of the shaft.
F 1767.65N
11.906Mpa all 27.5Mpa
A 148.47mm 2
2. Design of key for the second V-belt pulley, the Gear & pulley of the flat
belt on the upper shaft
Material:
Power P=58.867W
From table the recommended value of W and H for diameter of shaft d=20mm
W=H=6mm
Taking the length of the key l=16mm check for shear of the key
A s l* W 16*6 96mm 2
And the tangential force F on shaft at the distance of its diameter is give by:
60P
F =735.783N
2 * N * r
By Alemu Yamane Mechanical engg dept. 67
alemuyem2007@yahoo.com
Design of mechanical driven reaper Farm technology
F
The shear stress =7.664Mpa which is less than the allowable stress.
A
3. Design of key for the pulley of the flat belt on the revolving reel shaft
Power P=58.867W
From table the recommended value of W and H for diameter of shaft d=12mm
60P
F =1532.882N
2 * N * r
F
15.33Mpa This is less than the allowable stress.
A
4. Design of key for the pinion and timing belt gears on the inclined shaft
Material:
Power P=58.867W
60P
F =436.5N
2 * N * r
F
4.365Mpa This is less than the allowable stress.
A
The dimension of the key in table form is as shown below (table summary of
keys).
Key No. 1 2 3 4
Width w 5 6 5 5
Height H 5 6 5 5
Length l 16 16 20 20
Fig.38 bearing
s D t G w d
If R is radius of the big circle, r is radius of the rod inserted to the big circular
with 5mm thickness and e is the eccentricity distance or the distance to be
offseted
2e 50, r 4mm
e 25mm
Considering the thickness of circular member after the rod and the eccentric
distance
Take R=25+4+5=34mm
1. The overall structure or the body is made up of from steel pipes and angle
iron (for the placement of the cutters) and manufactured by welding given the
overall dimensions and the parts in the analysis part.
2. The carriage shaft is made of hollow shaft steel pipe and is manufactured by
cutting the shaft for the required length, weld the key for the pulley, and drilled
for the bolts.
3. The cutters are hardened steels with double blades and are manufactured by
cutting, forging and grinding to attain the required shape and profile.
4. The upper shaft is a solid shaft and is manufactured by selecting with the
given diameter steel, cut in to the required length, machined for the key seats,
and drill for the thin holders.
6. Canvas or the conveyor the timing belt, V-belt and the flat belts are buying
from market using the standard dimensions and specification in the analysis part.
7. The pulleys are manufactured by casting and some machining operation for
finishing.
9. The wheel is made of steel plates by selecting the material with the required
thickness and width cut in to the required perimeter of the wheel, rolled with
rolling machine to the approximate circle, and then welds the two ends of the
plate. Similarly the collar or small circular plate is prepared, mark the two
circular plates at every 600 s and finally cut steel rods taken as ribs and weld or
connect the two marks at the smaller and bigger wheel steel plates.
10. To increase friction between the wheel and the land, weld a 5 or 6mm
thickness steel with the same lengths as the width of the wheel at every 180.
11. The revolving reel shaft select the material with the given dimension, cut to
the required length, preparing the seat for the keys through machining and drilled
for the revolving reel to avoid relative motion.
12. The revolving reel is manufactured by preparing two circular steel pipes, 12
small steel plates to be welded at the circular pipes every 600 6 0f each, 6 long
steel plates with the dimensions given in the analysis part to connect the two
circular pipes by welding at the tip of each small steel plates.
Cutters 50 12 600
As you see in the table the total cost for manufacturing of this reaping machine
is 1897.70 with no need of operational cost like fuels. When this reaper harvests
for 20 days continuously it harvest about 40 hectares but using the manual sickle
it needs 200 labors with a total price of 20*200=4000.00 ETB which is more
than the cost of the reaper makes its cost low and reasonable to farmers.
2. Insert one washer of the pulley into the carriage shaft and pass through one
of the holes(from left side) of the structure or the body, insert the pulley, the
By Alemu Yamane Mechanical engg dept. 74
alemuyem2007@yahoo.com
Design of mechanical driven reaper Farm technology
second washer, the wheel, the spacer, washer and passes through the second
hole(right side) of the structure. And moving the shaft to the other side (right
side) of the structure and insert the wheel, the spacer the washer, the V-belt and
returning to the correct positioning, insert the bearing and the washer.
3. Tighten the wheels with the carriage shaft and lock parts which require a
locker.
4. Insert the upper shaft through one of the upper stand holes(left side) pass the
shaft through retaining ring V-belt pulley retaining ring, V-belt, and through the
second hole(right side) the assemble the gear and the flat belt pulley according
their sides.
5. Arranging and ordering the lower cutters and placed on the angle iron tighten
with small flat bolts (the bolts are totally immersed in the cutter. Then the top
cutter will also be placed above the lower cutter and pinned using adjustable
pines.
6. carrying or holding the revolving reel between the two carriages insert the
revolving reel shaft through either side and pass through the retaining ring, the
pulley, retaining ring, the flat belt and revolving reel.
The source of power for all components of the reaper comes from the person
who drives it by rotating the wheels and the carriage shaft (That are connected
by bolts), transmits to the upper or intermediate shaft through V- belts, the
intermediate shaft drive the canvas and the reciprocating mechanism through the
bevel gear and the revolving reel through the flat belt drives.
7 REFERENCES
1. http://www.countrystudies.us/ethiopia
2. http://www.nationsencyclopedia.com/economies/Africa/Ethiopia-AGRICULTURE.html
3. http://www.americanartifacts.com/smma/grain/cradle.htm
4. CADU 1969 Progress Report No. 1. Implement Research Section. CADU Publication No. 32).
5. Henock Kifle. 1972. Investigations on Mechanized Farming and its Effect on Peasant
Agriculture. CADU Publication No. 74.
6. http://www.ferrari-tractors.com/walking.htm
7. http://www.ferrari-tractors.com/walking.htm
8. http://www.alibaba.com/catalog/11222559/Direct_Planting_Machine.html
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13. http://www.ilo.org/encyclopedia/?print&nd=857200015
14. http://www.ferrari-tractors.com/walking.htm
15. http://www.vaes.vt.edu/steeles/mccormick/harvest.
16. http://www.mech.uwa.edu.au/DANotes/V-belts/miscellany/miscellany.html
17. http://www.sdp-si.com/D790/PDF/D790C02006.pdf
18. Cecil Jensen & Jay D.Helsel, Engineering drawing and design, 5 th edition, Mc Graw-Hill,
1996, New York.
19. Joseph Edward Shigley & Charles R.Mische, Mechanical Engineering design, 5 th edition, Mc
Graw Hill, 1989, New York.
20. Robert C.Juvinal & Kurt M.Marshek, Fundamentals of machine components design, 3 rd
edition, John wiley, 1999, New York.
21. R.S. Khurmi & J K Gupta, A Text book of machine design, Eurasia, 2002, New Delhi.
22. http://www.engineeringtoolbox.com/ansi-stainless-steel-pipes-d_247.htm
APPENDIX