DESIGN AND FABRICATION OF

SOLAR GRASS CUTTER

A DESIGN AND FABRICATION PROJECT REPORT

Submitted by

ENIAN C 191002043

ERAI ANBU G J 191002044

GIRISH R 191002045

CHARAN VINAYAK V 191002032

in partial fulfillment for the award of degree of

BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Sri Sivasubramaniya Nadar College of Engineering
(An Autonomous Institution, Affiliated to Anna University)
Rajiv Gandhi Salai (OMR), Kalavakkam – 603 110

MAY 2022

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 Sri Sivasubramaniya Nadar College of Engineering
(An Autonomous Institution, Affiliated to Anna University)

BONAFIDE CERTIFICATE

Certified that this Report titled “DESIGN AND FABRICATION OF SOLAR

GRASS CUTTER” is the bonafide work of ENIAN C (191002043), GIRISH R
(191002045), ERAI ANBU G J(191002044), CHARAN VINAYAK V (191002032)
who carried out the work under my supervision. Certified further that to the best of my
knowledge the work reported herein does not form part of any other thesis or
dissertation on the basis of which a degree or award was conferred on an earlier occasion
on this or any other candidate.

Signature of the HOD Signature of the Supervisor

Dr. K.S. Vijay Sekar Dr. KL. Hari Krishna
Professor and Head Associate Professor
Department of Mechanical Department of Mechanical
Engineering Engineering
SSN College of Engineering SSN College of Engineering
Kalvakkam – 603 110 Kalavakkam – 603 110

24/06/2022
Submitted for project viva-voce examination held on....................

EXTERNAL EXAMINER INTERNAL EXAMINER

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 ACKNOWLEDGEMENT

We are grateful to our Principal Dr. V. E. Annamalai for providing us a

constructive environment for carrying out our project.

We sincerely thank our Head of the Department, Dr. K. S. Vijay Sekar for giving
us permission to carry out our Design and Fabrication Project.

We would like to express our gratitude to our guide Dr. KL. Hari Krishna for
his valuable guidance and support throughout the period of this project work.

We would also like to thank our project coordinator Dr. B. Anand Ronald and
Dr. C. Arun Prakash for his valuable suggestions in carrying out the project
work.

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 TABLE OF CONTENTS
ABSTRACT 6

LIST OF FIGURES 7

LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE 8

CHAPTER 1 8

INTRODUCTION 9

CHAPTER 2 10

SOLAR GRASS CUTTER Error! Bookmark not defined.

2.1 Working of a Solar grass cutter 10

2.2 Parts of Solar grass cutter 11

2.3 Types of Solar grass cutter 12

2.3.1 Cylinder Mower 12

2.3.2 Rotary Mower 12

2.3.3 Pushed Mower 13

2.3.4 Self propelled Mower 13

2.3.5 Hover Mower 14

2.4 Component Specifications Error! Bookmark not defined.

2.4.1 Solar panel Error! Bookmark not defined.

2.4.2 Battery Error! Bookmark not defined.

2.4.3 Solar charger controller 16

2.4.4 DC Motor 16

2.4.5 Frame 17

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 2.4.6 Other components 17

2.4.7 Wheel 17

2.5 Features of Solar grass cutter Error! Bookmark not defined.

2.6 Advantages of solar grass cutter 19

2.7 Limitations of solar grass cutter 19

CHAPTER 3 20

DESIGN CALCULATIONS 20

3.1 Power developed by motor 20

3.2. Torque developed by motor 20

3.3 Battery backup time 21

3.4 Battery charging time 21

CHAPTER 4 22

3D MODEL 22

CHAPTER 5 24

FABRICATION 24

CHAPTER 6 26

RESULTS AND ANALYSIS 26

6.1 COST COMPARISON 27

CONCLUSION 28

REFERENCES 29

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 ABSTRACT

A Solar grass cutter is a machine that uses sliding blades to cut a lawn at an
even length with the help of solar power. Solar grass cutter is a very useful
device which is very simple in construction. It is used to maintain and upkeep
lawns in gardens, schools, college’s etc. We have made some changes in the
existing machine to make its application easier at reduced cost. Our main aim in
pollution control is attained through this. The use of conventional motors is
outdated and it harms our environment, so we planned to make use of Solar
energy which is a renewable energy source. Unskilled operator can operate
easily and maintain the lawn very fine and uniform surface look. A height
adjusting mechanism is also added here to give more options to the user.

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 LIST OF FIGURES

Figure 2.1 Block diagram of solar grass cutter

Figure 2.2 Cylinder Mower

Figure 2.3 Self Propelled Mower

Figure 2.4 Push Mower

Figure 2.5 Hover Mower

Figure 2.6 Rotary Mower

Figure 2.7 Solar panel

Figure 2.8 battery

Figure 2.9 solar charger contoller

Figure 2.10 DC Motor

Figure 2.11 MS sheet

Figure 2.12 M10 Arbor

Figure 2.13 Wheel

Figure 2.14 Height Adjusting mechanism & Solar panel angle adjustor

Figure 4.1 3D model of the assembled setup

Figure 4.2 3D model – Top view

Figure 4.3 3D model – side view

Figure 4.4 3D model – back view

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Figure 5.1 Frame & Height adjustment mechanism

Figure 5.2 after powder coating

Figure 5.3 Solar grass cutter

Figure 5.4 Solar grass cutter – side view

LIST OF SYMBOLS, ABBREVIATIONS AND

NOMENCLATURE

V – Voltage (volts)

P – Power developed by motor (Watts)

N – speed of motor (RPM)

T – Torque developed by motor (N/m)

H – Battery Backup time (hrs)

T – torque required for the barrel (N m)

AH - Ampere hours

Tre – battery charging time(hrs)

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 CHAPTER 1

INTRODUCTION

In the world today, all machines are designed with the aim of reducing or
eliminating greenhouse gas emissions which is the major causes of climate
change. This solar powered lawn cutter will meet the challenge of
environmental production and low cost of operation since there is no cost for
fueling. A solar powered lawn cutter has been developed for the use of
residences and establishments that have lawns where tractor driven mowers
could not be used. The machine’s capacity is adequate for its purpose. The
machine has proved to be a possible replacement for the gasoline powered lawn
cutters.

A polycrystalline solar panel has been used here to absorb the solar energy. The
solar panel has also been made height adjustable to add more options to the
user. We can also select the amount of height a grass can be cut with the help of
a height adjusting mechanism. This grass cutter can be used to cut grasses in
schools, colleges and other domestic applications.

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 CHAPTER 2

SOLAR GRASS CUTTER

The working principle of solar grass cutter is it has panels mounted in a
particular arrangement at an in such a way that it can receive solar radiation
with high intensity easily from the sun. These solar panels convert solar energy
into electrical energy. This electrical energy is stored in batteries by using a
solar charger. This energy is used to drive the motor.

2.1 Working of solar grass cutter

The major parts of solar grass cutter are solar panel, solar charge
controller, battery, DC motor, switch, stainless steel blade. The whole system is
placed on top of four wheels and a metal frame. The solar panel angle is
adjustable. It can be adjusted manually depending on the sun’s position. The
charge controller connects the battery and the panel and protects the battery from
overcharging. The DC motor is connected with the battery and a switch. solar
panels mounted on it in such a way that we can utilize the solar radiation coming
from the sun with high intensity. This solar energy is then converted into electrical
energy which is then stored in rechargeable battery. The battery powers the dc
motor to which the stainless-steel blades are connected, which is used to cut the
grass.

SOLAR PANEL MOTOR

SUN BLADES

SOLAR CHARGER
BATTERY
CONTROLLER

Fig 2.1 Block diagram of solar grass cutter

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2.2 Parts of Solar grass cutter
1. Frame: We used Mild Steel as a frame.MS steel sheet is 2.5mm
thickness. It is bent at two opposite ends into ‘C’ shape.
2. Solar panel: Solar PV panels are comprised of many small photovoltaic
cells – photovoltaic meaning they can convert sunlight into electricity.
These cells are made of semi-conductive materials, most often silicon, a
material that can conduct electricity while maintaining the electrical
imbalance needed to create an electric field.
3. Battery: A rechargeable battery, storage battery, or secondary cell is a
type of electrical battery which can be charged, discharged into a load, and
recharged many times, as opposed to a disposable or primary battery,
which is supplied fully charged and discarded after use. Several different
combinations of electrode materials and electrolytes are used, including
lead–acid, zinc–air, nickel–cadmium (NiCd), nickel–metal hydride
(NiMH), lithium-ion (Li-ion), lithium iron phosphate (LiFePO4), and
lithium-ion polymer (Li-ion polymer).
4. Solar charger controller: Solar charge controllers are an essential
element to any solar electric panel system. A solar charge controller is used
to keep the battery from overcharging by regulating the voltage and current
coming from the solar panel to the battery. The main function of the solar
charger is to increase the current from the panels while batteries are
charging, it also disconnects the solar panels from the batteries when they
are fully charged and also connects to the panels when the charging in
batteries is low.
5. Motor: A DC motor is used for the cutting blade. A DC motor is defined
as a class of electrical motors that convert direct current electrical energy
into mechanical energy. When kept in a magnetic field, a current-carrying

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 conductor gains torque and develops a tendency to move. We used a 775
DC Motor.
6. Blade: Two stainless steel blades are use to cut grass. They are
connected to the motor shaft through M10 arbor.

2.3 Types of Grass cutter (considering only walk mowers):

Walk mowers encompass a range of lawnmowers that the user
walks along behind. They are best suited to smaller lawns, generally anything
up to half an acre in size.

Most walk mowers can be broken down into the following categories.

2.3.1 Cylinder Mower

Cylinder mowers, also known as reel mowers, have vertically rotating

cylindrical blades at the front of the mower, which slices against a fixed blade.
They trap the grass between the blades and slice it off, with action not dissimilar
to scissors. They are designed for use on flat lawns and don’t cope particularly
well with uneven or rough surfaces. They give a neat cut, which works especially
well for creating defined stripes on a lawn if this is a look you would like to
achieve. They also struggle to cut long grass, so if you opt for a cylinder mower,
you will need to keep on top of your mowing and cut your grass regularly, as the
mower won’t perform well on grass that has become overgrown.

2.3.2 Rotary Mower

These are the most common types of walk-along mower you will find.
They have a single blade that rotates at very high speed in a horizontal motion,
cutting grass as it comes into contact with it, a lot like a food processor or
blender. These mowers work best on medium to long grass, meaning you can
leave longer in between mowing sessions without any negative impact. The cut

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you get from a rotary mower is less precise than a cylinder mower. It tends to
bash and thrash the blades of grass around, slicing them on impact due to the
high speed of rotation, which results in a less accurate and more uneven cut than
you would get from a good cylinder mower. The difference of cut, however,
probably wouldn’t be that noticeable to most people.

2.3.3 Push Mower

Push mowers, as the name suggests, requires the user to manually force
the machine across the lawn. The motor turns the blades, but the wheel action is
all you. These mowers are popular because they are usually the most
inexpensive, and they are also lightweight and easy to handle. A push mower
offers good maneuverability, allowing the user to direct exactly where it goes,
steering around obstacles and corners, and even reversing. These mowers take
some physical exertion, which is great if you’re keen to add some extra exercise
into your schedule, but may not be good for people with health complaints or
anyone who doesn’t want to get a sweat on.

2.3.4 Self Propelled Mower

Self-propelled lawnmowers have a transmission that propels the machine

forward, so the user does not need to push it, and instead guides it. These
mowers are generally simple to operate and make mowing a lawn a much easier
and quicker job, even in small yards. The main advantage of a self-propelled
mower is the fact that it doesn’t require any manpower, but there are other
advantages too. These mowers tend to give a more consistent lawn cut
compared to push mowers, as they are able to maintain a constant speed. They
require more maintenance and can be more difficult to fix when things go
wrong. These mowers are typically more expensive to buy than push mowers.

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2.3.5 Hover Mover
These lawnmowers hover a few inches above the ground, sitting on a
cushion of air. Due to their reduced contact with the ground, and therefore
reduced friction, they are very easy to guide around the lawn. They are able to
move in any direction, including sideways, which makes them particularly
useful for yards, which are awkward shapes, or for maneuvering around
obstacles such as planters, trees, and garden features. Hover mowers tend to be
fairly inexpensive, which is another factor that makes them quite popular. The
main problem with hover mowers is that they lack power, presenting an issue
for anyone with a larger sized lawn. They are most often electric-powered, and
they are best suited to small lawns.

Fig 2.2 Cylinder Mower Fig 2.3 Self Propelled Mower

Fig 2.4 Push Mower Fig 2.5 Hover Mower

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 Fig 2.6 Rotary Mower

2.4 Component Specifications

2.4.1 Solar panel

20W Polycrystalline solar panel

• Output Power: 20 Watts

• Operating Voltage: 12 Volt
• Voltage at Max Power: 18.20 volts
• Current at Max Power: 1.10 amps
• Dimensions: 450 x 350 x 22 mm
• Weight: 2.5 Kg

Fig 2.7 Solar panel

2.4.2 Battery
• Rechargeable Lead Acid Battery (sealed)

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 • Nominal Voltage – 12V
• Battery Rating – 7.5AH
• Weight – 2.2kg (approx.)

Fig 2.8 battery

2.4.3 Solar Charger Controller

• Rated Power – 6 Amp
• Voltage – 12 V
• Panel support – up to 125 W

Fig 2.9 solar charger controller

2.4.4 DC Motor
• 775 DC Motor
• Voltage – 12V
• Speed – 5000 RPM

Fig 2.10 DC motor

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2.4.5 Frame
• Mild Steel – 500 × 600 × 2.5 mm

Fig 2.11 MS sheet

2.4.6 Other components

• M10 Arbor
• Stainless steel blades – 2
• Switch

Fig 2.12 M10 Arbor

2.4.7 Wheel

Fig 2.13 wheel

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2.5 Features of Sola Grass Cutter
2.5.1 Height Adjustable blade

• It is based on Lead screw mechanism

• If we rotate the knob in clockwise direction the blade move
upwards, thus height of the grass to be cut will increase. If we
rotate the knob in anticlockwise direction the blade moves
downwards, thus height of the grass to be cut decreases

2.5.2 Solar panel angle can be adjusted

• We can manually adjust the angle of solar panel.

• It can be adjusted by losing the bolt.

Fig 2.14 Height Adjusting mechanism & Solar panel angle adjustor

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2.6 Advantages of Solar grass cutter

• Operating principle is simple.

• Less pollution
• Angle of solar panel can be adjusted depending on suns position to
harvest maximum energy.
• Handle is removable, so it is easy to move from one place to another

2.7 Limitations of a Solar grass cutter

• Manually operated.
• Difficult to operate in rainy seasons.
• High noise is produced.

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 CHAPTER 3

DESIGN CALCULATIONS

3.1 Power developed by the motor:

P = V*I = 24*2.3 = 55.2 watts

3.2 Torque developed by the motor:

P = 2πNT/60

55.2 = 2*π*5000*T/60

So, T = 18.97 N-m.

Assume that the lawnmower takes 1hr for the cutting operation

Whday = Power Required * Working hours

= 55.2 * 1

= 55.2 Wh

Now assume average sunlight hours per day = 6 hours

Power required to be produced by the solar panel = 55.2/6 = 9.2 watts

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3.3 Battery Backup time (hours):

H = Ah/A

I = W/V = 55.2/12 = 4.6

Ah = 7.5

H = 7.5/4.6 = 1.63 hours

But efficiency of the battery is 70%

Hence the corrected Working Life of the battery is

1.63 * (70/100) = 1.14 hours = 1 hour 8 minutes

3.4 Battery Charging time (hours):

Ampere required to charge 10% of the battery = 7.5 * 10/100 = 0.75 amp

Time required to fully charge the 7.5 Ah battery = 7.5/0.75 = 10 hours

But when we consider the 40% battery loss, we need another 7.5*0.4 = 3 Ah of
current to compensate for the battery loss

Time required to fully charge the battery

considering the battery loss Tre = (7.5+3)/0.75 = 14 hours

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CHAPTER 4 - 3D MODEL

FIG4.1 CAD Model of Assembly

Fig 4.2 Top view

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Fig 4.3 Side view

Fig 4.4 Back view

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 CHAPTER 5

FABRICATION

5.1 Frame:

To fabricate the frame, we cut the MS sheet the required dimension

(500*600*2.5 mm) then sides are bent using a bending machine. Next the
wheels are bolted to the frame.

5.2 Height adjustment mechanism:

The workpiece is cut to the required dimension. Then, the process of

drilling, milling is used to create holes and groves for the sliding of the
motor through the groves produced. A lead screw is also attached.

5.3 Motor, Battery, Charger controller, Panel mounting:

• All the components are mounted on the frame.

• The panel is bolted to a stand which is arc welded to the frame.
• The motor is mounted on a plate and bolted to the height
adjustor
• The blades are bolted to the motor shaft through M10 Arbor.

5.4 Powder Coating:

• The parts are disassembled and powder coated.

• Finally, they are assembled after drying.

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Fig 5.1 Frame & Height adjustment mechanism fig 5.2 after powder coating

Fig 5.3 Solar grass cutter

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 Fig5.4 sideview

CHAPTER 6

RESULTS AND ANALYSIS

• The run time of battery is approximately 50 minutes.

• The battery recharge time is approximately 13 hours.

• The area of cut can be increased by increasing the length of blade.

• Should use high torque high speed for smoother cutting.

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6.1 COST COMPARISON

Polycrystalline solar panel ₹ 1400

Nylon trolley wheels (4 pcs) ₹ 450

Battery ₹ 700

Solar charger controller ₹ 700

DC Motor ₹ 400

MS steel ₹750

Motor mount plate ₹150

M10 arbor, blades & other materials ₹ 530

Fasteners ₹ 150

Powder coating ₹ 650

Workshop cost ₹ 1500

Total cost ₹ 7180

Average market cost of a grass cutter varies from ₹10000 to ₹30000. Some are
even more expensive. They are normal grass cutters which causes pollution.

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 CONCLUSION

The solar grass cutter is mainly designed for the campus cleaning in a
sustainable and efficient way. Grass cutting is one of the main operations that is
carried out in the campus for cleanliness. The conventional grass cutter that are
used in the campus is costly. Therefore, the capital investment and operating
cost both is very high. Most of these grass cutters burn fuels which causes air
pollution. So, we designed low-cost solar grass cutter which do not cause air
pollution and uses renewable energy. It also contains features like adjusting the
height of the grass to be trimmed and also the angle of solar panel can be
adjusted. Therefore , it can be concluded that design & fabrication of solar grass
cutter has achieved its main objectives and there is room for further
development.

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 REFERENCES

1. Design of solar grass cutter - International Research Journal of

Engineering and Technology (IRJET).
https://www.irjet.net/archives/V8/i7/IRJET-V8I718.pdf

2. Solar Economical Grass Cutter - International Research Journal of

Engineering and Technology (IRJET).
https://www.irjet.net/archives/V6/i4/IRJET-V6I4520.pdf

3. Design and Fabrication of a Solar Operated Lawnmower - International

Journal of Innovative Science and Research Technology.

https://www.researchgate.net/publication/350038288_Design_and_Fabric
ation_of_a_Solar_Operated_Lawnmower

4. Design of a fully automated solar grass cutter for campus - International

Journal of Creative Research Thoughts (IJCRT)

5. Design and Development of Smart Solar Grass - International Journal of

Engineering and Advanced Technology (IJEAT)

6. Simple Design of Self Powered Lawn Mower”- International Journal of

Engineering and Technology.

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