Professional Documents
Culture Documents
Design and Fabrication of Engine Powered Two Rows Rice Transplanting Machine
Design and Fabrication of Engine Powered Two Rows Rice Transplanting Machine
Design and Fabrication of Engine Powered Two Rows Rice Transplanting Machine
22
In this formula N is the number of rpm gears and T is the number of teeth of gear.
Two conversion shafts are used for the purpose of speed reduction so the formula
becomes:
135
246
=
6
1
T1 is for engine output shaft and gear box input sahft.
T2 and T3 are on first conversion shaft.
T4 and T5 are on second conversion shaft.
T6 and T7 are on third conversion shaft.
T8 is on wheel shaft
T1, T3 and T5 and T7 are assumed as 12 teeth because to reduce the speed input
gear should have low number of teeth then output gear.
We know the value:
N1 = 2500rpm
N8 = 48.5 rpm
Putting values in the formula
1 3 5 7
2 4 6 8
=
8
1
The output teeth are assumed as equal in numbers i.e T2 = T4 = T6 = T
12 12 12 12
4
=
48.5
2500
T = 32 teeth
Calculating diameter of gears
After evaluating the teeth of sprockets radius is also evaluated to use it in designing
phase and calculating force phase.
23
The formula for the diameter calculation of sprocket is
=
The teeth t1 = T1 = T2 = T3 = 12 and t2 = T2 = T4 = T6 = 32
Using the formula described above to fine out the diameter of all gears.
Pitch of teeth is 0.005meters
For t1: 0.005
=
12
d1 = 0.0191 meters
for t2:
0.005
=
32
d2 = 0.05 m
Transmission of Torque
The engine that is selected have maximum torque of 10.3 Nm at the 2500rpm and
this torque is transmitted to wheels and planting mechanism.
The formula of torque transmission between two gears is:
Calculating torque transmitted from engine to wheel shaft:
8 = 521.06 Nm
4.1.4. Calculating diameter of shafts
The radius of shafts are calculated by using bending moment
diagrams of each shaft.
The formula used for this purpose is:
24
J = /
4
c is radius of shaft
all is the max allowable shear stress of mild steel = 115 MPa
max is calculated by using the force and bending moment diagrams on wheel
shaft.
3
=
Calculating diameter of wheel shaft:
3
=
1394.76
115 10
6
C = 0.0197 m
Diameter = 3.94 cm = 4cm
4.2. Position analysis of planting mechanism
As the planting mechanism is four bar so first of all linkage system is is
designed for the required motion of planting mechanism.
The linkages lengths are taken from the literature review which are then changed
to the required dimentions for our machine using grashof conditions to analyze the
proper motion of four bar mechanism. Which is as follow.
The lengths and known angles are:
a = 7cm
= 0 degrees
b = 19.3cm
= to be calculate
25
c = 12 cm
= to be calculate
d = 17.9cm
= 9 degrees
Applying the Grashoff conditions
The formula is:
S + L Q + P
S = length of shortest link
L = length of longest link
Q and P are lengths of remaining links
Putting lengths in above formula
7 + 19.3 17.4 + 12
26.3 29.4
The above equality is true thus the condition is satisfied which shows that the
shortest link will take full rotation and no toggle will occur.
Now to formulate the equation of relations between the input
2
and the output
3
and
4
.
Equating the vector sum of all linkages in x-axis
= R
= R cos + sin
Replacing the scalar and vector value of all four links using the above formula.
3
= 2tan
1
2
4
2
A= cos
2
+
5
sin
2
+
5
cos
2
+
6
4
B = -2sin
2
+ 2
4
C = cos
2
+
5
sin
2
+
5
cos
2
+
6
4
Now
26
4
=
2.3
2
5
=
2.3
2
6
=
2
2
2
2
4
= 2tan
1
2
4
2
A=cos
2
+
2
sin
2
+
2
cos
2
+
3
+
1
B = 2sin
2
- 2
1
C = cos
2
+
2
sin
2
+
2
cos
2
3
4
Now
1
=
2.3
2
2
=
2.3
2
4
=
2
+
2
2
+
2
2
The above formulation shows that with any input of
2
the values of
3
4
can
be evaluated.
27
CHAPTER 5
Computer Modeling
5.1. Design of frame:
Frame of the machine is the part which will hold all the components of RTP
machine. These components include:
1. Seedlings picking assembly
2. Seedlings planting assembly
3. Tray Assembly
4. Wheel Assembly
5. Engine and engine carrier
6. Floater
7. Handle
8. Conversion shafts with sprockets
5.1.1. CAD Model of Frame:
Initial Design:
Material of frame: Mild Steel
Length of frame: 160 cm
Width of frame: 50 cm
28
Figure 7: Initial design of frame
1. Frame
2. Handle
3. 2x holes for padded wheel shaft, 1 on each side
4. 2x holes for conversion shaft_2, 1 on each side
5. 2x holes for conversion shaft_1, 1 on each side
6. 8x holes for engine carrier, 4 on each sides
7. 4x holes for holding floater, 2 on each sides
8. 2x holes for holding seedling tray support, 1 on each side
2
1
3
4
5
6
7
8
29
Finalized Design:
Figure 8: Final design of frame
Following were the changes that were made later on and was finalized to be
fabricated:
1. Change in length of the frame:
Length of the frame was reduced from 160 cm to 140 cm, due to following
reasons.
1. Removal of conversion shafts due to addition of gear box.
2. To reduce the mass of the machine.
2. Change in Width of the frame:
Width of the machine was changed from 50 cm to 65 cm due to following
reasons:
1. Requirement of bigger engine carrier due to installment of gear box and
clutch assembly to the machine
3. Slots for holding planting arm:
Two slots for holding planting arm were created in the rear end of
the frame that will hold the planting mechanism of the machine, as
shown in figure 8.
30
Figure 9: Highlighted slots for holding planting arm
6.1.Design of planting mechanism:
6.1.1. Initial Design:
The initial design that we picked for the planting mechanism of the machine
comprised of three steps process, which included; Picking of Seedlings from
seedling tray, passing the seedlings o the planting arms via picking assembly and
planting the seedlings in the rice field.
Seedlings picking assembly:
Seedling picking assembly comprises primarily of a simple
cam and follower mechanism. In which a trajectory upon which
gripper will move is used as a cam, while the gripper will function
as a follower. A set of forks will be used with the gripper to hold the
seedlings in place. Function of seedling picking assembly is to pick
the seedlings from the tray and pass them on to the planting arms of
the seedling planting assembly.
Figure 10: Initial design of seedling displacement assembly
31
Planting arm Assembly:
Planting arm assembly is the part of the machine that will plant seedlings in
to the rice field after picking it from the seedlings picking assembly. This assembly
comprises of closed loop four bar mechanism. As our machine is two row planting
machine so there are two planting arms that will plant the seedlings into the field.
Figure 11: Initial design of planting arm assembly
Seedling tray:
Seedlings tray is the part of
the machine that will hold the stack of
seedlings. Picking arm will then pick
the seedlings from the tray and then
will carry it to the planting arm to
plant them to the ground.
Figure 12: Initial design of seedlings tray
32
Seedling tray support:
It is the support that holds the seedling trays and seedling picking
mechanism.
Figure 13: Initial design of seedlings support
6.1.2. Finalized Design:
Planting assembly design was entirely changed from three step planting
method that included picking the seedlings from try, transferring them to the
planting arm via picking arm and planting into the soil via planting arm.
New design is a two-step process that includes picking the seedlings from
seedling box and planting them into the soil via planting arms. It removes the need
of having a picking arm in the whole mechanism.
The reasons for this design change are:
To avoid breakage of seedlings roots which in a three-step planting method
breaks away due to transferring the seedlings from picking to planting arm.
Reduction of weight and complexity of the machine while maintaining the
workability.
The above mentioned design changes necessitated the changes in following parts:
33
Planting arm assembly:
Figure 14: Final design of planting assembly
1. Change in Planting arm:
Change in the planting arms design and thus it was carried out accordingly.
The new planting arm design details are as under.
1x Set of planting arms
Material: Mild Steel
Max vertical length of
arms: 21 cm
Distance between arms:
22.2 cm
Crank hole dia: 1.5 cm
Connecting link hole dia: 1.5 cm
Figure 15: CAD of planting arm
34
2. Change in Planting mechanisms frame:
Design changes in planting mechanisms frame are as under:
1x Planting arm frame
Material: Mild steel
Frame thickness: 0.5
cm
Frame width: 18 cm
Max length: 30.6 cm
Figure 16: CAD of ground support
3. Changes in Seedling carrying assembly:
The seedlings carrying assembly was entirely changed from seedlings
carrying tray to seedlings boxes that are triangular at the bottom to allow the
passage of desired number of seedlings from the box openings.
Figure 17: back and front perspective view of Seedling box assembly
Following are the design specifications for this assembly.
2x Seedling box
Length: 35 cm
Width: 16 cm
Depth: 14.5 cm
35
Inclined angle: 65
2x holes for nuts of 5mm
diameter
Material: iron
Figure 18: Seedling box
1x seedling box assembly support:
4x holes, 2 seedling box for 5 mm dia nuts
Figure 19: Finalized CAD of seedling box support
36
5.2. Engine carrier:
Engine carrier is the part of the machine that will hold the engine in place.
Figure 20: CAD of engine carrier
Material: wood
Max length: 660 cm
Width: 37 cm
Height: 50 cm
5.3. Wheel Assembly:
5.3.1. Initial Design:
Initially the wheel assembly was designed to work only n the rice field with
protruding paddles on the periphery of wheel that will help the machine to move in
the muddy rice field. Two wheels are connected together with the help of shaft,
which have a sprocket on it, that takes power from engine via chain mechanism to
rotate the shaft.
37
Figure 21: Initial design of wheel assembly
5.3.2. Final Design:
Figure 22: Finalized design of wheel assembly
In the final design of the wheel assembly, following changes were made in
the wheel and shaft;
An outer rim was added at the ends of the paddles of the wheel to allow the
machine to move on a smooth surface.
Two sprockets were added instead of one for the purpose of transferring
engine motion to the conversion shaft ahead
38
Details of the design are as follows:
Part name and details Computer model
2x Padded wheels
Material: Mild Steel
Inner rim diameter: 30 cm,
Thickness: 2 cm
Outer rim diameter: 42 cm,
Thickness: 1 cm
Number of paddles on
each wheel: 13
2x sprockets:
Small sprocket:
o Material: Alloy
Steel
o No. of teeth: 57
o Pitch diameter:
272.3
o Pitch: 0.015 m
Large Sprocket
o Material: Alloy
Steel
o No. of teeth:
o Pitch diameter:
272.3
o Pitch: 0.015 m
1x Shaft
Material: Mild Steel
Shaft dia: 3 cm
Shaft length: 80 cm
Table 2
39
5.4. Floater:
Floater is the part of the machine which will help the machine to float
smoothly over the rice filed, as the rice field consists largely of muddy water. It will
help the machine to remain above the water level at all times.
Figure 23: CAD of Floater
1. 4x connecting column with frame
Material : Wood
Maximum Length: 144.6 cm
Width: 65 cm
Thickness: 2.4 cm
1
40
CHAPTER 6
Analysis
6.1.Motion analysis:
The above motion analyses of the bevel gear shaft shows that the shaft rotates with
the constant velocity of 602.5 deg/sec as desired.
6.1.1. Planting arm dynamic:
Figure 24: Planting arm assembly (arrow pointing to shaft)
41
Figure 25: Velocity graph for Planting arm shaft
With the above motion analyses of the planting arm shaft it is confirmed that the
shaft rotates with the desired velocity of 1240.6 deg/sec
The above motion analyses graph shows the to and fro motion of the seedling boxes
with the help of slider joints as the box moves from mean position to the two
extreme positions.
42
6.2. Stress analyses:
The yield strength of low carbon steel is 28.2e+006 N/m
6.2.1. Stress Analyses on Frame:
Figure 26: Stress analyses of frame
Study results:
Minimum Stress: 2.53435 N/m
2
Maximum Stress: 6.3178e+006 N/m
2
Conclusion:
From the CAD results, it is concluded that this part will not fail under the given
stresses as the maximum stress are much lower than the yield strength of the part.
43
6.2.2. Displacement Analysis on frame:
Figure 27: Displacement analyses of frame
Study results:
Minimum Displacement: 0 mm Maximum Displacement: 0.0917051 mm
Conclusion:
From the CAD results, it is concluded that this part will not carry out any
significant deformations according to loading conditions applied.
44
6.2.3. Stress Analyses for Floater:
Model Reference Properties
Name: 1060 Alloy
Model type: Linear Elastic Isotropic
Default failure
criterion:
Max von Mises Stress
Yield strength: 2.75742e+007 N/m^2
Tensile strength: 6.89356e+007 N/m^2
Elastic modulus: 6.9e+010 N/m^2
Poisson's ratio: 0.33
Mass density: 2700 kg/m^3
Shear modulus: 2.7e+010 N/m^2
Thermal expansion
coefficient:
2.4e-005 /Kelvin
Table 3
Figure 28: Stress analyses of floater
Study results:
Minimum Stress: 6.54482e-008 N/m
2
Maximum Stress: 100265 N/m
2
45
Conclusion:
From the CAD results, it is concluded that this part will not fail under the given
stresses as the maximum stress are much lower than the yield strength of the part.
6.2.4. Displacement analyses on Floater:
Figure 29: Displacement analyses on Floater
Study results:
Minimum Displacement: 0 mm Maximum Displacement: 0.00212758 mm
Conclusion:
From the CAD results, it is concluded that this part will not carry out any
significant deformations according to loading conditions applied.
46
6.2.5. Stress Analyses on Wheel Shaft:
Model Reference Properties
Name: 1023 Carbon
Steel Sheet
(SS)
Model type: Linear
Elastic
Isotropic
Default failure criterion: Max von
Mises Stress
Yield strength: 2.82685e+008
N/m^2
Tensile strength: 4.25e+008
N/m^2
Elastic modulus: 2.05e+011
N/m^2
Poisson's ratio: 0.29
Mass density: 7858 kg/m^3
Shear modulus: 8e+010
N/m^2
Thermal expansion coefficient: 1.2e-005
/Kelvin
Table 4
47
Stress analyses:
Figure 30: Stress analyses on wheel assembly
Study results:
Minimum Stress: 1.47848e-008 N/m^2 Maximum Stress: 6.76768e+007 N/m^2
Conclusion:
From the CAD results, it is concluded that this part will not fail under the
given stresses as the maximum stress are much lower than the yield strength of the
part.
48
6.2.6. Displacement analyses on Wheel Assembly:
Figure 31: Displacement analyses on Wheel Assembly
Study results:
Minimum Displacement: 0 mm Maximum Displacement: 0.013722 mm
Conclusion:
From the CAD results, it is concluded that this part will not carry out any
significant deformations according to loading conditions applied.
6.2.7. Stress analyses on rpm conversion shaft:
Model Reference Properties
Name: 1023 Carbon
Steel Sheet (SS)
Model type: Linear Elastic
Isotropic
Default failure criterion: Max von Mises
Stress
Yield strength: 2.82685e+008
N/m^2
49
Tensile strength: 4.25e+008 N/m^2
Elastic modulus: 2.05e+011 N/m^2
Poissons ratio: 0.29
Mass density: 7858 kg/m^3
Shear modulus: 8e+010 N/m^2
Thermal expansion
coefficient:
1.2e-005 /Kelvin
Table 5
Stress analyses:
Figure 32: Stress analyses on rpm conversion shaft
Study results:
Minimum Stress: 6260.85 N/m^2 Maximum Stress: 2.38672e+008 N/m^2
Conclusion:
From the CAD results, it is concluded that this part will not fail under the given
stresses as the maximum stress are much lower than the yield strength of the part.
50
6.2.8. Displacement analyses on rpm conversion shaft:
Figure 33: Displacement analyses on rpm conversion shaft
Study results:
Minimum Displacement: 3.51493e-007 mm Maximum Displacement: 32.229 mm
Conclusion:
From the CAD results, it is concluded that this part will not carry out any
significant deformations according to loading conditions applied.
6.2.9. Stress analyses on planting mechanism ground support:
Model Reference Properties
Name: 1023 Carbon Steel
Sheet (SS)
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises Stress
Yield strength: 2.82685e+008 N/m^2
Tensile strength: 4.25e+008 N/m^2
51
Elastic modulus: 2.05e+011 N/m^2
Poissons ratio: 0.29
Mass density: 7858 kg/m^3
Shear modulus: 8e+010 N/m^2
Thermal expansion
coefficient:
1.2e-005 /Kelvin
Table 6
Stress analyses:
Figure 34: Stress analyses on planting assembly ground support
Study results:
Minimum Stress: 295.475 N/m^2 Maximum Stress: 1.80827e+008 N/m^2
Conclusion:
From the CAD results, it is concluded that this part will not fail under the given
stresses as the maximum stress are much lower than the yield strength of the part.
52
6.2.10. Displacement analyses on planting mechanism ground
support:
Figure 35: Displacement analyses on planting assembly ground support
Study results:
Minimum Displacement: 0 mm Maximum Displacement: 2.11387 mm
Conclusion:
From the CAD results, it is concluded that this part will not carry out any
significant deformations according to loading conditions applied.
6.2.11. Stress analyses on Seedling box assembly support:
Model Reference Properties
Name: 1023 Carbon Steel
Sheet (SS)
Model type: Linear Elastic
Isotropic
Default failure
criterion:
Max von Mises
Stress
Yield strength: 2.82685e+008
N/m^2
Tensile strength: 4.25e+008 N/m^2
Elastic modulus: 2.05e+011 N/m^2
53
Poisson's ratio: 0.29
Mass density: 7858 kg/m^3
Shear modulus: 8e+010 N/m^2
Thermal
expansion
coefficient:
1.2e-005 /Kelvin
Table 7
Stress analyses:
Figure 36: Stress analyses on seedling box support
Study results:
Minimum Stress: 0.359987 N/m^2 Maximum Stress: 3.59578e+007 N/m^2
Conclusion:
From the CAD results, it is concluded that this part will not fail under the given
stresses as the maximum stress are much lower than the yield strength of the part.
54
6.2.12. Displacement analyses on seedling box support:
Figure 37: Displacement analyses on seedling box support
Study results:
Minimum Displacement: 0 mm Maximum Displacement: 0.271909 mm
Conclusion:
From the CAD results, it is concluded that this part will not carry out any
significant deformations according to loading conditions applied.
55
CHAPTER 7
Manufacturing
7.1.Frame
Frame is made by low carbon steel sheet of 2.7mm. Desired shape
of frame is obtained by using press and cutting machine. Sheets are then
drilled using bench drilling machine. Then parts of frame are weld to give
a proper structure to it.
Cutting and bending
Figure 38: Metal sheets for frame fabrication
56
Gas cutting
Figure 39: Gas cutting for frame
Drilling
Figure 40: Drilling for frame
57
Electric Spark welding
Figure 41: Eclectic spark welding for frame manufacturing
7.2.Floater and engine carrier
Floater is made of poplar wood. Saw cutting is done to get desired
shape and white glue and nails are used to join all parts of structure.
Figure 42: Fabricated wooden floater
7.3.Seedling box
Seedling boxes are made of iron. Hand tool is used to cut the
sheet which is the weld by electric welding.
58
7.4.Seedling box support
Seedling box support is made of square pipe of steel. the
thickness of sheet is 2.7mm. angle grinder is used to cut the pipe of
desired dimensions and electric welding is used to weld the parts.
7.5.Machine handle
Machine handle is made of iron circular pipe. Angle grinder
is used to cut the parts and then electric welding is done to weld the
parts together.
Figure 43; Frame handle
59
7.6.Wheels:
Bending, cutting and welding is used in fabricating the wheels.
Figure 44: Rings for fabricating wheels
Bending:
Figure 45: Bending of rings in to circle
60
Welding:
Figure 46: Welding of rings
61
Figure 47: Welding of rings together (top), Welding of bars with wheel rings for support and strengthening
(bottom)
Finished Wheel set:
Figure 48: Finished wheel set
62
7.7.Planting Arm Assembly
Method of sheet metal cutting, welding and drilling is used in fabricating
the whole planting arm assembly.
Figure 49: Fabricated Planting assembly support frame
Figure 50: Fabricated planting arm
63
Figure 51: Fabricated Crank pair for planting arm assembly
Figure 52: Fabrictated link for Planting arm assembly
64
Figure 53: Whole planting arm assembly
7.8.Final Assembly of machine:
65
Figure 54: Final assembly of machine
66
CHAPTER 8
Cost
Sr. No. Product Cost (Rs)
1 Engine 10000
2 Clutch 5500
3 Gear box 7000
4 Frame 1600
5 Seedling box 1000
6 Floater 2300
7 Handle 700
8 Wheels 4000
9 Planting mechanism 1000
10 Engine carrier 600
11 Sprockets 5000
12 Chain 1300
13 Machine Assembly 32000
TOTAL 783000
Table 8
67
CHAPTER 9
Visits
9.1.Daska
In Daska we first searched for already existing machines for rice
transplanting then studied there mechanisms and problems.
Then we searched all the market of sheet metal and sprockets and shafts,
we inquired different prices of process like cutting, welding of sheet and
manufacturing of sprockets.
9.2.Lahore
We went to Lahore to buy engine and clutch for machine, first we
surveyed Bilal Ganj market which is the biggest market for car parts. But
we didnt find our required parts their after doing a lot of survey. Then we
went to Branth road where we found a huge market of new, imported and
locally made engines. We found a shop name SHINGHAI HARDWARES
from where we brought an engine of 5 h.p and a clutch assembly which is
actually used in engine powered lawn mower machines.
9.3.Rawalpindi
In Rawalpindi we first visited National Agricultural Research Center to
know about the current work being done on research and planting methods
on Rice Transplanting. We met Senior Research Engineer at NARC who
gave us valuable information on the subject. He also showed us a Japanese
made rice transplanting machine which was modified by NARC to be
suitable to work on Pakistani soil. We gathered all the valuable stats and
info from this visit.
We needed sheet metals for the planting assembly and material for
fabricating wheels of the machine. For this purpose we visited City Saddar
Road, checked various sheet metal cutting shops and finally ordered the
required material from Shabbir Steels which specializes in cut to size job.
They made us the required material at very economical rates.
68
CHAPTER 10
Conclusion
A rice transplanter is a machine that transplants the seedlings of rice in the
paddy field from seedling box through planting arm using power of engine. This
machine has vast application is Pakistan and Asia. The basic motivation of
selecting this project was to solve the problem of farmers in transplanting rice
seedlings by providing a facility of fast and economical transplantation. A basic
structure was designed using dynamic study, strength of materials, sprocket
chain mechanisms, applied and allowable stress analysis. We have used Creo
pro and Solidworks software applications for modeling, simulation and stress
analysis. Through farms and farm machinery institute visits we were able to
understand the problem and work done so far on this machine more deeply and
also the methods and techniques used to manufacture agriculture machinery.
Fabrication of parts was done using different tools e.g. press machine, grinder,
welding plant, lathe, shaper and gas cutter. Choice of material relayed upon the
strength required and material available. Cost analysis is done on the basis of
CAD model and material selection. Testing will be done in the season of rice
plantation.
Recommendation
Laser leveling of rice field is always recommended before the use of rice
transplanting machine.
There should be two persons all the times with the machine while it is
working in the field, one to operate the machine and other to place seedlings
in machine boxes.
The machine can be further improved by incorporating automated feedback
control systems and actuators to its planting assembly.
By incorporating a seat for worker on top of machine and in turn
incorporating steering to the machine.
Further recommendations will be given after testing of machine.
69
References
H.K.S. MADUSANKA, 2011, DESIGN AND DEVELOPMENT
OF PADDY SEEDLING TRANSPLANTING MECHANISM
University of Peradeniya, Sri Lanka
Md. Syedul islam and Desa Ahmad, 18 May 1998, EFFECTS OF
SEEDLING RAISING METHODS ON THE ECONOMIC
PERFORMANCE OF MANUAL OPERATED PADDY
TANSPLANTER ISSN:0128-7680, University Putra Malaysia
R.N. Pateriya and R.K. Datta, 2012, DESIGN MODIFICATIONS
OF MAT TYPE RICE TRANSPLANTER, International Journal
of Advanced Technology & Engineering Research (IJATER),
Volume 2, Issue 6.
W.P. ENANG, 2010, POWER TRAIN TECHNICAL DESIGN
RICE TRANSPLANTER University of Bath.
Ghafoor, M.A. Ali, R.U. Rehman and A. Razzaq, June 2008,
FACTOR RESPONSIBLE FOR POOR MECHANIZATION OF
RICE TRASNPLANNTING IN PAKISTAN PAKISTAN
JOURNAL OF SCINCE, Volume 60,Number 1-2.