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Chapter: - 1
INTRODUCTION
1.1 Introduction :
Mechanized agriculture is the process of using agricultural machinery to mechanize
the work of agriculture, greatly increasing farm worker productivity. In modern times,
powered machinery has replaced many jobs formerly carried out by manual labour or by
working animals such as oxen, horses and mules. The history of agriculture contains
many examples of tool use, such as the plough. Mechanization involves the use of an
intermediate device between the power source and the work.
Rice is one of the most important crop and staple food of millions of people which is
grown in many countries of the world. The total area planted under rice crop in India is
42.20 million hectares.
Improved weeper reduces weeding cost by 79-90%. Walking type vertical conveyer
reaper, power tiller and tractor front mounted reaper save 50-60% labour and harvesting
cost by 60-70% as compared to manual harvesting. Combine harvesting save 40-50%
cost as compared to manual harvesting and threshing by power thresher. Use of pedal
operated thresher, motorized hold on thresher reduce time, labour, cost of threshing to a
great extent.
Reapers are used for harvesting of crops mostly at ground level. Reapers are
classified on the basis of conveying of crops. It avoids fuel consumption, labour
requirement. As the population of India increases day by day, there is increment of food,
vegetables so need of farm mechanization also increases, machineries provides more
operations in less time, but the machineries are very costly for the common man, it is not
affordable for them ,so manually and power operated machineries, equipment’s are also
the most important factor.
Reaper harvesters on the other hand are other alternative harvesting equipment,
provided straw is considered as economic by-product for animal feed and/or industrial
applications. Keeping these in view, a feasibility study was undertaken to reduce the cost
of harvesting in paddy crop through mechanization of harvesting and manually and power
operated reaper is more important for it, this type of reaper can easily be operated by
single person, only the pushing efforts are required in less economy, easily affordable for
farmers for keeping the better farming.
Wheat is preferred food amongst all the cereals in the world. Concerted efforts are
needed to enhance food grain production in the world and to investigate problems that
stand in the way of meeting food needs of humanity so as to avoid peace upsetting and
famine occurrence in the world.
Wheat is the leading food grain of Pakistan, and being the staple diet of the people,
it occupies a central position on agricultural policies. It is the largest grown crop over an
area of 8666 thousand hectares in 2011-12, showing a decrease of 2.6 percent over last
year’s area of 8901 thousand hectares.
Wheat contributes 12.5 percent to the value added in agriculture and 2.6 percent to
GDP (Anonymous 2011-12). Despite the introduction of improved varieties of wheat,
better chemical and hydrological inputs, the production is still not enough to feed the
present population. Pakistan’s present problem is the augmentation of food supplies to
masses in order to meet the country’s needs. It could be accomplished either by bringing
more area under wheat cultivation or by increasing yield per unit area. Acreage increase
has limitations like scarcity of water and precariously established balance in land
allocation between equally important cash crops.
Any disturbance in this balance may cause another crisis, more or less of equal
severity. Hence, productivity enhancement along with pre and post harvest losses
management are the only alternative because of the existing differences between the
national average and the potential.
The wheat grain losses are classified as i) pre-harvest grain loss due to the birds,
rodents and environmental; ii) harvest grain loss during harvesting of the crop; and iii)
postharvest grain loss due to bundling, transporting, threshing and winnowing.
These harvesters are available for purchase but because of their high costs, they
are not affordable. However, agriculture groups make these available for rent on an hourly
basis. But the small holding farm owners generally do not require the full featured combine
harvesters. Also, these combine harvesters are not available in all parts of rural area due
to financial or transportation reasons. Thus, there is a need for a smaller and efficient
combine harvester which would be more accessible and also considerably cheaper.
For purchase
Areas with no access to renting full featured harvesters and where manual labor is
not easily available.
For renting
Small farms that do not need the complete harvest their crops. These would rent
our product on per hour basis.
Hadidi et.al (1984) stated that, the height of crop stubbles increasing as stalks
moisture content increased and decreased with increasing of knife velocity. He added that
the percentage of wheat and rice grain losses increasing as the machine forward speed
increased. Increasing cutter bar speed leads to decrease the percentage of grain losses.
Also, increasing forward speed leads to increase the number of uncut stalks.
Sahar (1988), reported that, the use of a large scale machine is inappropriate for
the following reasons:- it needs high technical experience for operation and maintenance,
high capital requirements. Low field efficiency is in small holding and losses of straw are
high on irregular furrowed soils. The use of small machines is appropriate for small
holdings, low capital requirements and low technical operations and maintenance
experience.
El-Sahrigi et.al. (1992) developed a front mounted repear. The design features
included a flat belt mechanism conveying the crop to the side of machine, improve cutter
bar star wheel assembly to minimize clogging, a bevel gear drive for power transmission,
a robust frame, a header provide design that will not dig in to the soil and provision to
covert the flat belt conveyor drivers to chain without frame modification.
Habib et.al (2002) stated that the parameters affecting cutting process are related
to the cutting tool, machine specifications and plant materials properties. They added that,
the cutting energy consumed in harvesting process.
4GL-120A power reaper was described to save time constraints and reduce the
cost of harvesting operation of rice by mechanization. This reaper was studied to
recommend the appropriate system for rice harvesting. The system was evaluated
according to the technical parameters: knife speed, operating speed, actual field capacity,
and theoretical field capacity, field efficiency, cutting efficiency, cost economics and
percentage of grain losses. The actual cutting width of the reaper was 1.2 m. In this study,
performance of power reaper used for rice harvesting was assessed and compared with
manual harvesting using sickle. The results showed that the actual field capacity of the
reaper was 0.24 ha/h compared to 0.05 ha/h for manual harvesting. Labor requirements
for reaper and manual harvesting were 4 and 28 man/ha, respectively. The fuel
consumption, knife speed, field efficiency and cutting efficiency were 1.89 l/h, 1.223 m/s,
92% and 98% respectively. The cutting cost of power reaper was 67% less as compared
with manual harvesting. The grain loss was less than 0.5% and was admissible. The
overall performance of power reaper for rice harvesting was found satisfactory.
Chapter: - 2
Construction and working of reaper machine parts
Frame:- The frame is use for supporting the part member use in this project.
Frame’s specification is in above the table.
Ground Wheel:- Ground wheel is use for the travelling like one field to another
field. Specification of ground wheel is in above the table.
Sprocket: - A wheel that has row teeth around their edges which fit into the holes
of something and cause it to turn when the wheel turns also any one of the teeth on
such a wheel.
Belt: - A belt is a looped strip of flexible material used to mechanically link two or
more rotating shafts. A belt drive offers smooth transmission of power between
shafts at a considerable distance.
Chain: - Chain drive is way of transmitting mechanical power from one place to
another. It is often use to convey power to the wheels of a vehicle, particularly
bicycles and motorcycles. It is also used in a wide variety of machines besides
vehicle.
Cutter Bar: - Made up of the knife sections and hold-down clips. The cutter bar
is positioned along the front part of the reaper. It will cut the crop by shearing
action.
Chapter: - 3
Reaper Selection
Reaper is generally selected on the land holding of the farmer, greater the land
holding, tractor operated vertical conveyer reaper is choose, for medium land holding
power tiller mounted vertical conveyer reapers are preferred. When we started with the
project manually operated reaper, we came across some problems. Due to those
problems the machine was not working properly. The design of the machine was
technically perfect, but due to some fabrication, material used and conveying mechanism
problem, it was not giving satisfactory results. We observed and came to the conclusion
that there are major problem of clogging and power requirement. We solved the problem
and got satisfactory result. We hope harvesting practices made easy by our some
developments provide in this machine. There are some different parameters which decide
the selection and performance of reaper, they are as follows;
Objectives
Chapter: - 4
Flow process chart of manually and power operated reaper machine
Sr. Description Dist- Time Qty Remarks
No. ance
1 Material lifted to shop . 5 labour
2 Welding of frame . 1 labour
3 Inspection of welding frame .
4 A wait for the next operation .
5 Sprockets mount on the shafts .
6 Bearing mount on frame and .
shaft fitted on the shaft
7 Inspection of all .
8 Ground wheel fitted on the .
shaft
9 Inspection of ground wheel . 1 labour
10 Connect chain on sprocket 1 to . 1 labour
2 and 3 to 4
11 Motor fitted on the shaft . 3 labour
12 Inspection of motor joint on the .
frame completely fitted or not
13 Motor pulley connected with .
second shaft
14 Disc connected on third shaft . 1 labour
15 Disc connected to connecting .
rod
16 Connecting rod connecting . 1 labour
with iron strip
17 Strip connected to cutter . 1 labour
18 Inspection of disc, connecting .
rod and iron strip joint
19 Cross belt drive mounted on .
vertical shaft
20 Strip connected to frame in . 2 labour
front side star wheel & crop
divider mount on
21 One strip mount on frame just .
front of second shaft and iron
wheel. Join the use of bolt
22 The handle joint on the frame .
at besides with the use of nut &
bolt
23 Inspection of reaper machine .
24 Reaper machine store in store . 2 labour
room
Total 15 6 1 1 1
Chapter: - 5
Manually and Power Operated Reaper
The frame is use for supporting the part member use in this project. Frame’s
specification is in above the table.
Ground wheel is use for the travelling like one field to another field. Specification of
ground wheel is in above the table.
5.3.5 Sprockets:
A wheel that has a row teeth around its edge which fit into the holes of something
and cause it to turn when the wheel turns also any one of the teeth on such a wheel.
A cylinder with teeth around the circumference at either ends that project through
perforations in something to move it through a mechanism.
5.3.6 Pulley:
A pulley may also be called a sheave or drum and may have a groove or grooves
between two flanges around its circumference. The drive element of a pulley system can
be a rope, cable, belt or chain that runs over the pulley inside the groove or grooves.
Hero of Alexandria identified the pulleys as one of six simple machines used to lift
weights.
Pulleys are assembling to form a block and tackle in order to provide mechanical
advantage to apply large forces. Pulleys are also assembled as part of belt and chain
drives in order to transmit power from one rotating shaft to another.
A belt drive is analogous to that of a chain drive, however a belt sheave may be
smooth so that the mechanical advantage is approximately given by the ratio of the pitch
diameter of the sheaves only, not fixed exactly by the ratio of teeth as with gears and
sprockets.
In the case of drum-style pulley, without a groove or flanges, the pulley often is
slightly convex to keep the flat belt centre. It is sometimes referred to as a crowned pulley.
Agriculture tractors built up to the early 1950s generally had a belt pulley for a flat belt. It
has been replaced by other mechanisms with more flexibility in methods of use such as
power take-off and hydraulics.
5.3.7 Bearing:
A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of bearing may, for
example, provides for free linear movement of the moving part or for free rotating around a
fixed axis or, it may prevent motion by controlling the vectors of normal forces that bear on
the moving parts.
Many bearings also facilitate the desired motion as much as possible, such as by
minimizing friction. Bearings are classified broadly according to the type of operation, the
motion allowed, or to the directions of the loads applied to the parts.
Plain bearing, also known by the specific styles: bushing, journal bearing, sleeve
bearing, rifle bearing, composite bearing.
Jewel bearing, in which the load is carried by rolling the axle slightly off-centre.
Flexure bearing, in which the motion is supported by a load element which bends.
In simple terms, roller bearings locate rotating components such as shafts or axles
within mechanical systems, and transfer axial and radial loads from the source of the load
to the structure supporting it.
To minimize friction, heat, power loss and wear, rolling elements such known as
rollers or balls with a circular cross-section are located between the races or journals of
the bearing assembly.
A wide variety of bearing designs exits to allow the demands of the application to be
correctly met for maximum efficiency, reliability, durability and performance.
The term “bearing” is derived from the verb “to bear”, a bearing being a machine
elements that allows one part to bear another. The simplest bearing are bearing surfaces,
cut or formed into a part, with varying degrees of control over the form, size, roughness
and location of the surface.
Other bearings are separate devices installed into a machine or machine part. The
most sophisticated bearings for the most demanding applications are very precise
devices; their manufacture requires some of the highest standards of current technology.
History:-
The invention of the rolling bearing, in the form of wooden rollers supporting, or
bearing, an object being moved is of great antiquity, and may predate the invention of the
wheel.
Though it is often claimed that the Egyptians used roller bearing in the form of tree
trunks under sleds, this is modern speculation. They are depicted in their own drawings in
the tomb of as moving massive stone blocks on sledges with liquid-lubricated runners
which would constitute a plain bearing.
There are also Egyptian drawings of bearings used with hand drills.
5.3.8 Disk:
Rotating disk is use to covert rotary motion of ground wheel to the reciprocating
motion of cutter blade.
Chain drive is way of transmitting mechanical power from one place to another. It is
often use to convey power to the wheels of a vehicle, particularly bicycles and
motorcycles. It is also used in a wide variety of machines besides vehicle.
Most often, the power is conveyed by a roller chain, known as the driver chain or
transmission chain, passing over a sprocket gear, with the teeth of the gear meshing with
the holes in the links of the chain. The gear is turned, and this pulls the chain putting
mechanical force into the system. Another type of drive chain is the Morse chain, invented
by the Morse chain company of Ithaca, New York, United States. This has inverted teeth.
Sometimes the power is output by simply rotating the chain, which can be used to
lift or drag objects. In other situations, a second gear is placed and the power is recovered
by attaching shafts or hubs to this gear. Through drive chains are often simple oval loops,
they can also go around corners by placing more than two gears along the chain; gears
that do not put power into the system or and transmit it out are generally known as idler-
wheels.
By varying the diameter of the input and output gears with respect to each other, the
gear ratio can be altered. For example, when the bicycle pedals gear rotate once, it
causes the gear that drives the wheels to rotate more than one revolution.
Advantages:-
As no slip takes place during chain drive, hence perfect velocity ratio is obtained.
Since the chains are made of metal, therefore they occupy less space in width than
a belt or rope drive.
It has the ability to transmit motion to several shafts by one chain only.
Dis-advantages:-
The production cost of chains is relatively high.
The chain drive has velocity fluctuations especially when unduly stretched.
5.3.15 Belt:
A belt is a looped strip of flexible material used to mechanically link two or more
rotating shafts. A belt drive offers smooth transmission of power between shafts at a
considerable distance.
Belt drives are used as the source of motion to transfer to efficiently transmit power
or to track relative movement.
An open belt drive is used to rotate the driven pulley in the same direction of driving
pulley. In the motion of belt drive, power transmission results make one side of pulley
more tightened compare to the other side.
In horizontal drives, tightened side is always kept on the lower side of two pulleys
because the sag of the upper side slightly increases the angle of folding of the belt on the
two pulleys.
A crossed belt drive is used to rotate driven pulley in the opposite direction of
driving pulley. Higher the value of wrap enables more power can be transmitted than an
open belt drive.
Advantages:-
Belt drives are simple are economical.
They are very economical when the distance between shafts is very large.
Dis-advantages:-
In belt drives, angular velocity ratio is not necessarily constant or equal to the ratio
The torque can produced mechanical rotation. Motors are classified as Series
Wound and Shunt Wound Motors.
Chapter: - 6
Specification of Manually and Power Operated
Reaper
Chapter: - 7
Prototype Design of Manually and Power
Operated Reaper Machine
(A) Isometric View:
Chapter: - 8
Modifications
The available speed of cutter bar is 8 reciprocating movement with one complete
rotation of rear wheel. It works successfully but there was clogging due to less number of
blades in pre design of reaper. Now, the clogging is not occurring as of a new blade is
reciprocating at clogging area where, one guard is already available. Before adding one
blade the extra guard is not included in working.
The replacement of damaged cutting blades are also done for proper functioning of
cutting of crops without any trouble in movement of cutting bar and it helps to reduce
clogging and cutting losses.
Angle of approach of divider is important as very high result in dozing of crop and
flatter position of divider is not suitable for a lifting of even partially lodged crop. Thi s angle
has been optimizing at 22o. During pre-design of manually operated reaper, the crop
divider was having some errors. The crop was not divided properly. The crop was striking
to side cutting mechanism. So the position of the crop divider is shifted little towards left
side. Now crops are successfully divided without any damage to it.
In new design of reaper, for reducing these losses the flat belt conveying
mechanism is mounted as shown in plate no.3.15. Using rear wheel power, conveyor
works successfully. Four pulleys are used for completing conveying mechanism and
rubber belt is used for transferring the power from one pulley to second pulley. Third
pulley attached to a same shaft of second pulley. The conveying belt is placed on third
pulley and fourth as shown in plate no.3.15. The sheet metal is used for carrying blade as
shown in plate no.3.15.
The minimum required speed of star wheel based on simple geometry is expressed as
Vs = Vm cosα
Where,
Vs = average speed of star wheel, kmph
Vm= machine working speed, kmph
α = angle of inclination of star wheel.
Optimum value of to give inclination of star wheel to give angle of approach suitable
for lifting of the crop is about 22o for this value above equation can be simplified as
Vs = 1.08 × Vm
= 1.08 × 1.8 = 1.94 kmph
This optimize between shattering at higher speed and choking at lower speed. On
the basis of this, we have design star wheel.
Chapter: - 9
Field Performance
Sr. No.
1 Time of start 11:00 am
2 Time of finish 11.15 am
3 Actual field operation 15 min.
4 Time lost owing to a. Turning b. Clearing 1 min. 4 min.
and clogging
5 Actual area covered 100 sq. m
6 Effective working width 300 mm
7 Effective field capacity 0.055 ha/hr
8 Field efficiency 66.13 %
9 Speed of machine 0.5 m/s
10 Height of cut 75 mm
11 Labour required 2
12 Length 10 m
13 Width 10 m
14 Area 100 m2
15 Type of soil Black cotton soil
Chapter: - 10
Pre-testing Observation
Field selection:
The harvesting is done in well matured crop with maintained row to row distance.
That is at least fine textured, smooth, relatively leveled soil.
For the cutting purpose, the height of crop plant must be more than 10-15cm.
Inclined angle of crop plant shows inclined angle from vertical line.
Chapter: - 11
Advantages
11.1 Advantages:
Eco- friendly.
Less cost.
Less maintenance.
Chapter: - 12
Limitations & Application
12.1 Limitation:
Not suitable for large farm.
12.2 Application:
It is use for rice cutting.
Wheat cutting.
Grass cutting.
Chapter: - 13
Cost Estimating
Chapter: - 14
Importance
This project is to help small-scale farmers to meet an increased demand for local
grains, by designing a reaper machine to harvest grains more efficiently. Our research
work will focusing on ease of harvesting operation to the small land holders for harvesting
varieties of crop in less time and at low cost by considering different factors as power
requirement , cost of equipment , ease of operation , field condition , time of operation and
climatologically conditions. The operating, adjusting and maintaining principle are made
Chapter: - 15
Future Scope
This is a manually and power operated reaper. It works on Work energy and
Electrical energy. In this manually and power operated reaper when, electric motor is
failed to start so, we can operated it manually and we use chain drive in this reaper.
Chapter: - 16
Conclusion
After modification of manually and power operated reaper it work continuously and
gives more efficiency than the machine before modify. Conveying mechanism now helps
to stop clogging and decreases the cutting losses. Continuous working leads to harvest
crop in less time with minimum man power. Based on analysis of results following
conclusion are drawn: The Manually and power operated reaper is high labour saving
equipment requiring only 20 man-hr/ha. The cost of harvesting with this manually and
power operated reaper is 1250.4 Rs/ha and that with traditional method is 2000 Rs/ha.
The cost of reaper is low so it is affordable to small farmers. The field efficiency is
satisfactory which more than 66%, it increases from 59% due to its modifications.
axial-flow threshers, vertical conveyor reapers and corn sellers. The study and
manufacturing of rice combine harvester with one-step harvesting technology has been
Models like GLH – 0.2 and GLH – 0.3A finished with relatively perfectiveness, but
haven't been mass-produced. Harvesting mechanization for main crops is a large and
Chapter: - 17
References
www.google.co.in
www.wikipedia.org
www.youtube.com
www.harvester.com