3.

DESIGN CALCULATIONS

3.1Power of electric motor

Pi=(V×I×P.F×√3)/1000

Where,

Pi=single phase power, Kw

V=Voltage, volts

I=Current, amp

P.F=Power factor

Pi=(240×2.4×0.76×√3)/1000

Pi=0.75Kw Or 1.0053≈1hp

ii) Input Power at full load

Pir=H.P×(0.7457/ɳm)

Where,

Pir=input power at full load,kw

H.P=Horse power
ɳm=efficency of motor
Pir=1×(0.7457/58)

Pir=0.01928kw

Design Of Spur Gear

In the present case,

Rated power = 1hp

Speed of the gear (pinion), = 1440 rpm

Teeth of gear, = 68

V.R. = 1.02, V.R. = ,1.02 =

=189.21,Approx 190 rpm

= 85

3.1.1. Design power (Pd):

Pd = PR * KL ……………………… k = 1.80

= 0.50*180=1h
p=746watt
Toothload,
= 1.432m m/s

3.1.2. Bending strength

……………………… = 70 cast iron medium grade

 =0.4……………………………… …………… B=10m assume

Y for full depth

Y = 0.485 -

= 70*0.421 = 29.47

Select the maximum value

=476 N

Now find module

4760 = m = 1.88

Calculate actual value

= 1300 N
PCD of pinion

= 2 * 19 = 38 mm

= 2* 68 = 136 mm

= 0.278 * 2 = 0.574 m/s

Calculate the face of width b minimum

………..Assume class 1

= 0.5454

N=49* N

Equating

49* =894

mm

= 18.24*3=54.7mm

Dynamic load,
C = 11400e ( full depth)

…………….Hence design is safe.

Limiting wear strength

Q=[ ]=1.56

= 1185*k N

1185*k=3760

K= 3.17

Std=0.42

(BHN)p =150

(BHN)g = 180

= 4950*0.4255

=2106.225
Hence design is safe.

3.3 Design Of Antifriction Bearing

There are two antifriction bearings B1 and B2 used in the experimental setup. The maximum
reaction developed at

bearing B2 i.e. = 667.33 N is considered for designing the bearing.

1. Equivalent load coming on

bearing,Fe, N Fe = (XFr+
YFa) KsKoKpKr

Fr= 750
N Fa= 0
N e =
Fa/ Fr e
=0

Selecting self aligning ball

bearing X=1,Y=2.3

Kp = 1 (no preloaded bearing)

Kr = 1(outer race fixed inner race Rotating).

Ks = 2 (moderate shock load)

Fe = (XFr+ YFa) KsKoKpKr
= (1x 750 + 0) x 1 x 1 x 1 x 2

= 1334.66 N

2. Life of bearing, L (million

n
revolution) L = (C/Fe)
Kret.

L = 500 (demonstration model)

n = 3 for ball bearing

 Kret = 1 (reliability = 90%)

C =(500)(1/3) x
Fe C =
10818.138 N
Selecting series 02xx ( C = 11000)

Dimension d = 25 mm,

D = 52 mm,

B = 15 mm

3.4 Design of Handle

A square steel pipe used as a handle which is folded to a length of 2.74 m and 0.76 m orientation
toward the machine frame at an angle of 45 degree which is welded for the operator’s Convenience.
The handle is subjected to both axial and bending forces due to the inclined position.

4 Construction And Working

Construction and fabrication of multi crop cutter machine

The fabrication of any machine demands adequate planning and selection of systematic process.
Basically, the fabrication is carried out after the design process. Once the required dimension
obtained then the only work remains and that is to convert the drawing dimensions into real physical
model. The forth coming article focuses on how the design is obtained in previous chapter being
converted in real physical model.

4.1 Mechanical Parts Of The Machine

1. Electricmotor , 2. Pulley, 3.Bearing b1, b2, 4 v-belt,flat belt 5.Spur gear , 6. Shaft
s1 .7 scotch yoke mechanism.

8 collecting mechanism. 9 body , 10. Process unit.

4.2 Designed Model Of multicrop cutter by using electric motor

As per the designed and analytical calculations made in the previous chapter following CAD model
is developed by using different commands of Pro E software. This CAD software provides the tools
needed to perform modeling of different parts of the proposed machine efficiently and free from
tedious and time consuming task. The front view and side view of the model is shown below

Volume 6, Issue 5, May 2017 Page

108
International Journal of Application or Innovation in Engineering & Management (IJAIEM)

Web Site: www.ijaiem.org Email: editor@ijaiem.org

Volume 6, Issue 5, May 2017 ISSN 2319 - 4847

Fig 4.2.1 .front view of multicrop cutter

4.3 Fabrication

The manufacturing process used in the fabrication of multicrop cutter machine is such that the total
cost of fabrication is low and also one that can make use of the available materials. The
manufacturing process involved in this work includes, joining of metal parts by welding, cutting
using hacksaw and hand cutting machine. Each component of the machine is fabricated separately
before they are joined or welded together as the case may be.

4.4 WORKING

It is a walk behind type of harvester which is powered by the 1 HP, 1440 rpm electric motor. With
the help of V-belt, drive power is transmitted to gearbox. As the required rpm at cutter is as less as
200 rpm, a spur gearbox used. Here high torque Johnson type motor is used to collecting the crop cut
by cutter blade . One end of this output shaft is connected to slider crank mechanism which converts
rotary motion of shaft into reciprocating motion of cutter blade. Reciprocating cutter blade slides
over fixed blade and creates scissoring action responsible for cutting the crops. Collecting
mechanism consist of flat belt with collecting plates bolted on it.

Fig.4.4.1. actual model of crop cutter

Wegive input electric supply to the Electric motor when electric motor start it transmit the power to
the gear box with the help of V belt drive through pulley arrangement the Spur gearbox change the
direction of power direction at 90o through shaft . theed of shaft is connected to the scotch yoke
Mechanism.Skotch yoke mechanism which converts rotary motion of shaft into reciprocating motion
of cutter blade. The another high torque Johnson motor used for the collecting belt. Collecting
mechanism consist of flat belt with collecting plates bolted on it.the collecting Mechanism rotate
through pulley Arrangement. Collecting mechanism collect the crop cut by the cutter Blade

Volume 6, Issue 5, May 2017 Page 109

 Actual cost of crop cutter
5 .COST ESTIMATION
Machine

Sr. Part Quantity Price/part Total

Require cost
No d (Rs.) (Rs.)
1 Electric motor 1 2000 2000
2 Spur gear box 1 2000 2000
3 6” pulley x2 1 542 542
4 Bearing 2 192 500
5 Shaft 1 500 400
Wheel
6 assembly 1 750 750
52" V
7 belt 1 400 400
32" V
8 belt 1 250 250
9 Frame Angle 37 kg 54/kg 1500
40x40x5 mm
10 MS plate 13 kg 58/kg 750
16mm,10mm
11 1"dia -Pipe 2 325 650
G.I.
12 Sheet 1 250 250
13 Collecting belt 1 300 300
14 Bearing circles 10 20 200
15 Cutter blade 18 40 720
16 Nut bolts etc 113
Labour
17 charge 1000
18 Electricity
VAT
19 charges 2000
Total cost (Rs) 14600

6. Testing And Results

After fabrication of machine we did experimental analysis, we conduct the four

major tests they are

1. Grass cutting test

3. Testing of wheat cutting

6.1 Test results on Grass Cutting

This design was tested against standard manual cutting on a farm. Tests wer performed cutting a 10
m long sugarcane row. With each test,

(1)The time taken to cut the row,

(2)The amount of cane left behind (butt height) and

(3) The stalk damage at the impact zone were recorded.Stalk damage was subjectively assessed
using a damage classification developed. This classification scores a zero for a very clean cut and an
eight for an extensivelydamaged stalk. Each test was repeated at least eight times, allowing for
thecalculation of means and standard deviations. It should also be noted that manual cane cutting
was performed by inexperienced persons, and improved performances may be expected among
experienced labourers. The brush-cutter was found to be easy to use, even with no previous
experience in cane cutting, andalthough not tested, it is believed that itcould be used on steep slopes.
Varioussafety measures, such as protective clothing,glasses, ear covers and a blade cover
wererequired to safeguard the brush-cutteroperator.

6.2Test results for the wheat Harvesting

A. Comparison of Harvesting Cost by Traditional Method and Our Harvester:

1) Harvesting done by manual process:

Amount paid to the labour for one day = Rs. 250 per labour

Total number of labour required in general to harvest the 1 acre farm of

wheat in a day = 6 Total amount paid to the labour = 6 x 250

= Rs. 1500 per acre in one day

Therefore, total expenditure in one day is = Rs. 1500

2) Harvesting done by machine:

Quantity of electricity for 0.25 to 0.5 acre
=Required 2 hours = 746*2/1000

=1.5unit electricity required

1 unit= 7 Rs

Hence 1.5 unit =1.5*7=11 Rs

Quantity of Electricity require for 1 to 1.2 acre = Required 4-5 hours

= 746*5/1000

=3.73unit electricity required

1 unit= 7 Rs

Hence 1.5 unit =3.73*7=26.11 Rs

Cost of Electricity per unit = 7 Rs.

Design, Development and Fabrication of a Compact Harvester

Total cost of Electricity for 1 acre farm for a day = 27 Rs

Amount paid to the labour = 250 Rs

Total expenditure = Total cost of electricity + Amount paid to the labour + Maintenance

= 27+250+
50 =327
Rs

Amount saved by using the harvester =1500 – 327 = 1173 Rs. per day per acre.

7. CONCLUSION

Based on the present works the following are some important conclusions have been done.
 1.From this work the followingconclusions were drawn For the work to be accomplished in 1acer
area without amachine (crop cutter) or manually, it costsRs:4200/- by a minimum of Rs:350/-
pereachlabour in a day. Whereas, by using an, Multi crop cutter wee can accomplish the same
work in the same area (1acer) withonly one labour (skilled labour), it takes 5-6 hours at a cost of
only Rs:650/- (i.e., fuel Rs:300/- & labour cost 350/-). So byusing an ultraportable crop cutter we
can reduce the cost up to 80% . The performance through manual cutting cannot be. The same
through out the day, as man get strained,whereas a machine cannot Therefore , 80% of the time
can also be saved by using the Multi crop cutter.It is concluded that the device is most
economical.

2.The Combined reaper and colleting machine is built to be compact and efficient to cut the crops.
The machine was tested on a field to check its cutting capability and efficiency.

3.The harvesters available in market are suitable for large farms, so this can be the best machine
for the farmers with small land. The success of this machine depends on how the farmers receive
this machine as their ally.

4.There are some changes that need to be done on the machine and a final product is to be taken
out for sell.

5..From this work the following conclusions were drawn for the work to be in lacer area without a
multi crop cutter or manually, whereas by using a multi crop cutter we can complete the same
work in the same area (1acer) with only one labor. The samethroughout the day, as man get
strained, whereas a machine cannot.

REFERENCES:

[1] Praveen Kiran Mali, Dr. C. N. Sakhale, S. D. Shelare. “A Literature Review on Design and
Development of Maize Thresher” Ijpret, 2015; Volume 3 (9): 9-14Issn: 2319-507

[2] “Fabrication and performance test of an Ultraportable Crop cutter” Mr. G Maruthi Prasad Yadav,
GMD JaveedBasha IJRSET Volume 2
[3] Relationship between Stalk Shear Strength and Morphological Traits of Stalk Crops, by Li Liang
and YumingGuo.

[4] Farm power sources, their availability and future requirements to sustain agricultural production,
by N. S. L. Srivastava.
[5] State of Indian Agriculture 2012-13, Indian Government Analysis.
[6] “Design and fabrication of small scale Sugarcane Harvesting Machine” Adarsh J Jain,
ShashankKarne, SrinivasRatod, Vinay N1 Toted and Karan ISSN 2278 – 0149 .ijmerr Vol. 2,
No. 3, July 2013
[7] State of Indian Agriculture 2012-13, Indian Government Analysis.2. “Design and Development
of manually Operated Reaper” Mr. P. B. Chavan, Mr. D. K. Patil, Mr. D. S. Dhondg, Volume 12,
Issue 3 Ver. I (May. - Jun. 2015), PP 15-22.

[8] http://india.gov.in/topics/agriculture

[9] http:en.wikipedia.org/wiki/Agriculture_in_India

[10] Pressure on farmland The Hindu. 4 February 2014. Retrieved 4 February 2014.

Volume 6, Issue 5, May 2017 Page

111
International Journal of Application or Innovation in Engineering & Management (IJAIEM)

Web Site: www.ijaiem.org Email: editor@ijaiem.org

Volume 6, Issue 5, May 2017 ISSN 2319 - 4847

BIOGRAPHIES

“Vilas S. Gadhave studying in B.E.

Mechanical, G.H
RaisoniCOEM,chas,Ahmednagar,Maharashtr
a,India”

“PravinP. Gadsing studying in B.E. Mechanical, G.H

RaisoniCOEM,chas,Ahmednagar,Maharashtra,India”

“Y.K.DIKE studying in B.E. Mechanical, G.H

RaisoniCOEM,chas,Ahmednagar,Maharashtra,India”

“A.S.JAYBHAYE studying in B.E.

Mechanical, G.H
RaisoniCOEM,chas,Ahmednagar,Maharashtr
a,India”
“P.A.LONDHE studying in B.E. Mechanical, G.H
RaisoniCOEM,chas,Ahmednagar,Maharashtra,India”

Prof. Praveen Kiran Mali Is workingin GHRCOEM Savitribaiphulepune university. He

has completed Mtech in Mechanical Design .He has published 14 research papers in
various international journals and also published the book “Design of machine elements
by using maize thresher” in Lambert academic publishing Germany recently.He is
memeber of professional bodieslike ISTE,IAENGetc.He has also work experience in
automobile industry about instrument cluster,Fuel level sensor etc. and design fixture

for mahindramahindra cluster.

Volume 6, Issue 5, May 2017 Page
112