Final Makka Cutter.docx

MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

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.

This intermediate device usually transforms motion, such as rotary to linear, or provides some sort of mechanical advantage, such as speed increase or decrease or leverage. Current mechanized agriculture includes the use of tractors, trucks, combine harvesters, airplanes (crop dusters), helicopters, and other vehicles. Modern farms even sometimes use computers in conjunction with satellite imagery and GPS guidance to increase yields.

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 MAKKA CUTTER, power tiller and tractor front mounted MAKKA CUTTER 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.

MAKKA CUTTERs are used for harvesting of crops mostly at ground level. MAKKA CUTTERs 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.

MAKKA CUTTER 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 MAKKA CUTTER is more important for it, this type of MAKKA CUTTER 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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Mechanization refers to interjection of machinery between men and materials handled by them. In agriculture materials are soil, water, environment, seed, fertilizer, pesticides, growth regulators, irrigation, agricultural produce and by-products such as food grains, oilseeds, fruits and vegetables, cotton, sugarcane, jute & kenaf and other cash crops, milk, meat, eggs and fish etc. There is scope of mechanization in every unit operation of production agriculture, post-harvest and agro-processing, and rural living.

Mechanization has varied connotations. While in the developed world it tends to be synonymous to automation but in developing countries, like India, mechanization means any improved tool, implement, machinery or structure that assists in enhancement of workers’ output, multiplies the human effort, supplements or substitutes human labour that is enabling and removing, avoids drudgery or stresses that adversely affect human mental faculties leading to errors, imprecision and hazards and eventually loss of efficiency. It also means automation and controls that assure quality, hygiene. Agricultural mechanization in a limited sense relates to production agriculture.

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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

1.2 Problem Statement :

The intricate steps involved in planting, cultivating, harvesting, and preparing rice requires an immense labor force. However, recently farmers have seen a shortage of skilled labour available for agriculture. Due to high literacy rate and an urbanized life style, a majority of the younger generation villagers have migrated to urban & other countries in search of better jobs. The laborious nature of work, low-wage structure, low self-esteem and lack of social status are some of the other reasons that lead to occupational mobility of the paddy field laborers to other lucrative fields. Because of this shortage the farmers have transitioned to using combine harvesters.

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.

1.3 Target Market: Our target market includes both male and female small rice paddy cultivators with land holdings of one or less acres, to about ten acres, in the states of India. Our manual and power operated MAKKA CUTTER would be available for both purchasing and renting.

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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

1.4 Review of Literature: This chapter deals with research work done in past by various investigation on the performance,

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.

Badr (2005) compared the performance of three different combines in terms of harvesting time, grain losses, fuel consumption, energy required and total cost. He found that the highest field capacity of 3.02 acre/h and the lowest field efficiency of 70.5 % were obtained at forward speed about 4.0 km/h and grain moisture content of 22 %. D. N. Sharma and S. Mukesh, they studied on the designing of handle and in that study approximate 100 cm height is sufficient for pushing of any machinery. Er. Prabhakar Dutt, Principal Scientist, studied star wheel, crop divider and conveyor design of MAKKA CUTTER. Er. Beds Prasad A., Er. Dalvi Devdatta N., Er. Virkar Amol D. (2013) developed manually operated MAKKA CUTTER and evaluated performance as well as its uses and drawbacks.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

1.5 Present Design of Power MAKKA CUTTER:

4GL-120A power MAKKA CUTTER was described to save time constraints and reduce the cost of harvesting operation of rice by mechanization. This MAKKA CUTTER 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 MAKKA CUTTER was 1.2 m. In this study, performance of power MAKKA CUTTER used for rice harvesting was assessed and compared with manual harvesting using sickle. The results showed that the actual field capacity of the MAKKA CUTTER was 0.24 ha/h compared to 0.05 ha/h for manual harvesting. Labor requirements for MAKKA CUTTER 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 MAKKA CUTTER was 67% less as compared with manual harvesting. The grain loss was less than 0.5% and was admissible. The overall performance of power MAKKA CUTTER for rice harvesting was found satisfactory.

Figure No.1 Present Design of MAKKA CUTTER

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 2 Construction and working of MAKKA CUTTER machine parts

Figure No. 2 Construction and working 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.





Bearing: - A bearing is a machine element that constrainsrelative motion to only the desired motion, and reduces friction between moving parts.





Pulley: - A pulley is a wheel on an axle or shaft that is design to support movement andchange of direction of a taught cable, rope or belt along its circumference.

 

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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

 

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 MAKKA CUTTER. It will cut the crop by shearing action.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 3 MAKKA CUTTER Selection MAKKA CUTTER is generally selected on the land holding of the farmer, greater the land holding, tractor operated vertical conveyer MAKKA CUTTER is choose, for medium land holding power tiller mounted vertical conveyer MAKKA CUTTERs are preferred. When we started with the project manually operated MAKKA CUTTER, 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 MAKKA CUTTER, they are as follows;

i. Should have the proper cutting speed of cutter bar. ii. Should require proper crop spacing. iii. Should require proper power. iv. Continuous power transmission. v. Proper registration and alignment of cutter bar. vi. Should require less effort.

Objectives

1. To modify the manually and power operated MAKKA CUTTER.

2. To evaluate the performance of modified manually and power operated MAKKA CUTTER.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 4 Flow process chart of manually and power operated MAKKA CUTTER machine Sr.

Description

Dist-

No.

Time Qty

Remarks

ance

.

1

Material lifted to shop

2

Welding of frame

3

Inspection of welding frame

4

A wait for the next operation

5

Sprockets mount on the shafts

.

6

Bearing mount on frame and

.

5 labour

.

1 labour

. .

shaft fitted on the shaft

.

7

Inspection of all

8

Ground wheel fitted on the

.

shaft 9

Inspection of ground wheel

10

Connect chain on sprocket 1 to

.

1 labour

.

1 labour

.

3 labour

2 and 3 to 4 11

Motor fitted on the shaft

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

.

15

Disc connected to connecting

.

1 labour

rod 16

Connecting with iron strip

rod

connecting

.

1 labour

17

Strip connected to cutter

18

Inspection of disc, connecting

.

1 labour

.

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 MAKKA CUTTER machine

24

MAKKA CUTTER machine store in store

. . 2 labour

room Total

15

6

1

1

1

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 5 Manually and Power Operated MAKKA CUTTER

5.1 Working Principle:

When machine is push by the operator at the designed speed in the field, rear wheel rotation leads to reciprocate cutter bar with the help of sprocket and chain. The crop lifter guides the crop to the cutter bar and the crop is cut by the cutter. The cut crop is conveyed with the help of star wheel at one side by the lugged belt conveyer for easy collection and bundling.

5.2 Parts used in manually and Power Operated MAKKA CUTTER:

Sr. No.

Component

Material Used

1

Frame

Mild Steel

2

Ground Wheel

Mild Steel

3

Rotating Disk

Mild Steel

Shafts : 1.Ground wheel shaft 4

2.Idle shaft (v-belt pulley) 3.Rotating disc shaft

High Carbon Steel

4.Rotating pulley shafts 5

Crop Divider

G. I. Sheet

6

Star Wheel

Wood

7

Cutter Bar

High carbon steel

8

Handles

Mild Steel

9

Chain

High carbon steel

10

Belt

Rubber

11

Shaft Pulley

Cast iron & Alluminium

12

Sprockets

Gun metal & Mild steel

Table No. 1 Part Used

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3 Specifications of Each Part:

5.3.1 Specifications of Frame: 1

Number of Square Pipes

4

2

Number of Bearing

8 (Dia. 20)

3

Length

1200mm

4

Width

550mm

5

Height

50mm

Table No. 2 Specification of Frame

The frame is use for supporting the part member use in this project. Frame’s specification is in above the table.

Figure No. 3 Frame

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3.2 Specifications of Ground wheel: Sr. No.

Details

Size

1

Diameter

500mm

2

Width

40mm

3

Thickness

3mm

4

Shaft diameter

20mm

5

Length of shaft

700mm

6

Distance between two

650mm

wheel

Table No. 3 Specification of Ground Wheel

Ground wheel is use for the travelling like one field to another field. Specification of ground wheel is in above the table.

Figure No. 4 Ground Wheel Page 12

MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3.3 Specifications of Idler shaft, Sprockets, Pulley, Bearing &disk: 1

Diameter of shaft

20mm

2

Number of sprocket

4

3

Number of pulley

2

4

Number of teeth on two

42

larger sprockets 5

Number of teeth on smaller

14

sprockets 6

Diameter of pulley

7

Number of bearing

8

Diameter of disc

90mm 8 90mm

Table No. 4 Specification of Idler shaft, Sprocket, Pulley, Bearing& Disc 5.3.4 Shaft:

Figure No. 5 Shaft

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3.5 Sprockets:

Figure No. 6 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.

Sprocket is fitted on shaft and rotate to chain for cutting operation.

A chain drive is also rotated with the help of Sprockets.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3.6 Pulley:

Figure No. 7 Pulley

A pulley is a wheel on an axle or shaft that is design to support movement and change of direction of a taught cable, rope or belt along its circumference. Pulleys are used in a variety of ways to lift loads, apply forces, and to transmit power. In nautical contexts, the assembly of wheel, axle, and supporting shell is referred to as a “block.”

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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

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.

Figure No. 8 Flat belt on Pulley

A belt and pulley system is characterized by two or more pulleys in common to a belt. This allows for mechanical power, torque and speed to be transmitted across axle. If the pulleys are of differing diameters, a mechanical advantage is realized.

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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3.7 Bearing:

Figure No. 9 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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

     

    

Plain bearing, also known by the specific styles: bushing, journal bearing, sleeve bearing, rifle bearing, composite bearing.

Rolling element bearing such as ball bearings and roller bearings.

 

Jewel bearing, in which the load is carried by rolling the axle slightly off-centre.

Fluid bearing, in which the load is carried by a gas or liquid.



Magnetic bearing, in which the load is carried by a magnetic field.



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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

History:-

Figure No. 10 Tapered Roller Bearing

Figure No. 11 Drawing of Leonardo da Vinci

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

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.

Figure No. 12 Rotating Disk

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3.9 Specifications of Handle: 1

Shape

Hollow pipe

2

Diameter of Pipe

15mm

3

Length

900mm

4

Width

550mm

Table No. 5 Specification of Handle

5.3.10 Crop divider:

Figure No. 13 Crop Divider 

 

It’s also used for divide crops into two parts.



Crop divider fitted in front of manually and power operated MAKKA CUTTER machine.



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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

5.3.11 Star wheel: Conveys the cut grain from the cutter bar to the feeder belt drive. This is located past the cutter bar.

Figure No. 14 Star Wheel

5.3.12 Specification of Star wheel:

Sr. no.

Particulars

Specifications

1

Outside diameter(Do)

200 mm

2

Inside diameter(Di)

152 mm

3

Internal diameter of star wheel(d) 25 mm

4

Material of star wheel

Wood

Table No. 6 Specification of Star Wheel

5.3.13 Cutter bar: Made up of the knife sections and hold-down clips. The cutter bar is positioned along the front part of the MAKKA CUTTER. It will cut the crop by shearing action.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Figure No. 15 Cutter Blade 5.3.14 Chain: Chain & belt are used for the Power transmission.

Figure No. 16 Chain

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

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 idlerwheels.

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 may be used for both long as well as short distance. It gives high transmission efficiency. It gives fewer loads on the shaft.







It has the ability to transmit motion to several shafts by one chain only.



 

  

It transmits more power than belts.



It permits high speed ratio of 8 to 10 in one step.



It can be operated under adverse temperature and atmospheric conditions.



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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Dis-advantages:  

   

The production cost of chains is relatively high.



The chain drive needs accurate mounting and careful maintenance.

Particularly lubrication and slack adjustment.





The chain drive has velocity fluctuations especially when unduly stretched.

5.3.15 Belt:



Fig No. 17 Conveyor 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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Types of belt drives:In a two pulley system, depending upon the direction the belt drives the pulley, the belt drives are divided into two types. They are open belt drive and crossed belt drive. The two types of belt drives are discussed below in brief.

Open Belt Drives:-

Fig No. 18 Open Belt Drive

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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Crossed Belt Drives:-

Fig No. 19 Crossed Belt Drive

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.

However, bending and wear of the belt are important concerns.

Advantages:



Belt drives are simple are economical.



 

    

 

    



They don’t require parallel shafts.



Belt drives are provided with overload and jam protection.





Noise and vibration are damped out.



Machinery life is increased because load fluctuations are shock-absorbed.



They are lubrication-free.

They require less maintenance cost. Belt drives are highly efficient in use.







They are very economical when the distance between shafts is very large.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Dis-advantages:    



  

 

In belt drives, angular velocity ratio is not necessarily constant or equal to the ratio  of pulley diameters, because of slipping and stretching.



Heat buildup occurs.



Speed is limited to usually 35 meters per second.



Power transmission is limited to 370 kilowatts.



Operating temperatures are usually restricted to 35 to 850C.

Some adjustment of center distance or use of an idler pulley is necessary for  wearing and stretching of belt drive compensation.

5.3.16 Electric Motor:

Fig. 20 Electric Motor It is used for transmit the power on shaft.

The electrical motor is an instrument, which converts electrical energy into mechanical energy. According to faradays laws of electromagnetic induction, when a current carrying conductor is placed in a magnetic field, I experience a mechanical force whose direction is given by Fleming’s left hand rule.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Construction of DC Generator and DC motor are identical. The same DC machine can be used as a generator or as a motor. When a generator is in operation, it is driven mechanically and develops a voltage. The voltage is capable of sending current through the load resistance. While motor action a torque is developed.

The torque can produced mechanical rotation. Motors are classified as Series Wound and Shunt Wound Motors.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 6 Specification of Manually and Power Operated MAKKA CUTTER

1

Type

Manually and Power Operated

2

Source of power

One person and Electric Motor

3

Machine suitability

To harvest cereal crop

4

Machine dimensions a. Length

1700 mm

b. Width

450 mm

c. Height

900 mm

5

Crop cutting unit A

Type of cutter bar

Reciprocating knife section

B

Length of cutter bar

300 mm

C

Knife section

Standard

D

Type

Trapezoidal

E

Blade

Serrated

F

Length × height

76.2mm×85mm

G

Angle between cutting edge

31º

and axis of knife section(α) H

Rake angle

22º

I

Thickness of cutting edge

5-3 mm

J Pitch of serration K

1-1.2 mm

Clearance between knife and 0.5-1 mm twine guard

L

Material

high carbon steel

6

Finger guard A

Type

twine guard with lip

B

Overall length

110mm

C

Overall width

35mm

D

Lip spacing

50mm

E

Height of cutter bar above

75 mm

ground level

Table No. 7 Specification of MAKKA CUTTER

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 7 Prototype Design of Manually and Power Operated MAKKA CUTTER Machine (A) Isometric View:

Fig. 21 Isometric View of manually and power operated MAKKA CUTTER (B) Front view:

There are two wheels used to maintain the balance, connected to the frame by the shaft. Bearings are used for rotation of the shaft on which rotating discs are mounted in fig.

Fig. 22 Front view of Manually and Power Operated MAKKA CUTTER

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

(C) Side view: The shafts are containing larger and smaller sprocket connected with two end bearing at upper side and lower side respectively. Power is transmitted with the help of chains. A rotating disc is provided at lower shaft for giving power and speed to the cutter bar. The main shaft provides the whole power to the cutter bar as shown in fig.

Fig. 23 Side view of Manually and Power Operated MAKKA CUTTER

(D) Top view: With the help of the two idler shafts whole transmission of power carried out with help of chain sprockets= mechanism of ratio of 1:9. The upper idler shaft contains the conveyer belt mechanism for conveying of crop.

Fig. 24 Top view of Manually and Power Operated MAKKA CUTTER Page 32

MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 8 Modifications 1. Adding a blade on cutter bar: 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 MAKKA CUTTER. 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.

Fig. 25 Modification of Cutter Bar 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.

2. Change in position of crop divider: 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 MAKKA CUTTER, 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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Fig. 26 Modification of Crop Divider

3. Add conveyor mechanism to conveying the crop to the side of machine: For every harvesting machine, conveying mechanism is necessary for reducing losses during harvesting. In pre-design of machine, there was absence of conveying mechanism and due to this there was maximum harvesting losses occurred.

In new design of MAKKA CUTTER, 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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Fig. 27 Modification of Conveyor

4. Star wheel speed and inclination: 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.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

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

Table No. 8 Field Performance

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

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.

Height of crop plant: For the cutting purpose, the height of crop plant must be more than 10-15cm.

Inclined angle of crop plant: Inclined angle of crop plant shows inclined angle from vertical line.

i.

Moisture content of steam and grain at the time of harvesting Moisture content of steam and grain at the time of harvesting must

be measured. ii.

Area and shape of test field

iii.

Soil moisture

iv.

Condition of machine and operator - Adjustment of working part of machine. - Operating speed. - Skill of operator

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 11 Advantages

11.1 Advantages:         

        

Eco- friendly.



No need of any power source at manually operated.



Less cost.

No labour required for cutting.



Mostly suitable for small farm owner.

Easy to handle & operate.

Less maintenance.





Less time required compare to sickle.

Also use for grass cutting.



  Easy to afford for poor farmer.  



Good field performance.







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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 12 Limitations & Application

12.1 Limitation:  

  

Not suitable for large farm.

The force requirement is high due to its weight. It’s more costly because of electric motor.

12.2 Application:  

  



It is use for rice cutting.



Wheat cutting.



Grass cutting.







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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 13 Cost Estimating

Sr No.

Component

No. of Component

Price

1

Frame

1

550

2

Shaft

3

Disk

4

Sprockets

5

Chain

2

80

6

Pulley

4

220

7

Belt

2

200

8

Star Wheel

2

100

9

Crop Divider

2

80

10

Bearing

8

650

11

Handle

1

180

12

Ground Wheel

3

250

4 1 4

350 80 150

13

Electric Motor

1

1500

14

Fabrication Work

-

2000

15

Total Cost

-

6390

Table No. 9 Cost Estimating

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 14 Importance

This project is to help small-scale farmers to meet an increased demand for local grains, by designing a MAKKA CUTTER 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 simple for effective handling by unskilled operators.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 15 Future Scope

This is a manually and power operated MAKKA CUTTER. It works on Work energy and Electrical energy. In this manually and power operated MAKKA CUTTER when, electric motor is failed to start so, we can operated it manually and we use chain drive in this MAKKA CUTTER.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 16 Conclusion

After modification of manually and power operated MAKKA CUTTER 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 MAKKA CUTTER is high labour saving equipment requiring only 20 man-hr/ha. The cost of harvesting with this manually and power operated MAKKA CUTTER is 1250.4 Rs/ha and that with traditional method is 2000 Rs/ha. The cost of MAKKA CUTTER 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.

Harvesting mechanization for main crops-an urgent demand of agricultural goods production. Main achievements: research, design, manufacturing and wide application of axial-flow threshers, vertical conveyor MAKKA CUTTERs and corn sellers. The study and manufacturing of rice combine harvester with one-step harvesting technology has been carried out by many individuals, mechanical firms as well as scientific institutes.

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

complex field of science and technology, the international cooperation is essential to satisfy the increasing demand of production.

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MANUALLY AND POWER OPERATED MAKKA CUTTER MACHINE

Chapter: - 17 References   

   

www.google.co.in





www.wikipedia.org



www.youtube.com

 www.harvester.com

Pa ge 44