CHAPTER ONE

1.0 INTRODUCTION

Melon (Citrullus Lanatus) grown for its seed has probably been domesticated

in the southern Sahel zone or in region surrounding the Kalahari Desert. It is

important also in West Africa. The seeds are increasingly used for their oil in

semi-arid region and also the use of the oil in the cosmetics and pharmaceutical

industry in increasing. There are also prospect for use of the seeds in the

improvement of infant nutrition in view of their high protein and fat content.

Melon popularly known as ‘Egusi’ by ‘Yorubas’ by Hausas and ‘Ogil’

by Igbo people of Nigeria. It is known because of the edible seeds which have

varied uses in preparation of local soup or stew or snacks. The main cultivars

found in Nigeria are Bara (also known as Papa), serewe and sofin. Bara has

large brown seed with thick edges thickened forwards the apex, about 16 x

9.6mm and its common in the Northern and Western part of Nigeria. serewe

seed are smooth, light brown with a light whitish edge that is not thickened

about 15 x 9mm in dimension. They are mainly found in Eastern Nigeria.

Analysis made on melon seed, Ajibola et al (1990) indicate that melon seed

contains about 50% oil by weight, 39.4% of protein, 2.6% fibre, 3.6% ash and

6.4% moisture out of the oil content of the seed, 50% are saturated fatty acid,

which are stearic and Palmitic acid. The presence of unsaturated fatty acids
1
makes melon nutritionally desirable and suggest a possible hypocholesterolic

effect (lowering of blood cholesterol) and also it consumption reduce the

chance of USDA nutrient database shows that melon seed is a rich source of

sodium, iron, manganese, copper, zinc and fat. The nutritional value of melon

per 100g are – carbohydrate – 7.6g, dietary fibre – 0.4g, fat – 0.2g, Protein –

0.6g, and vitamin C – song horsk (1985). The oil extracted from melon seed

can be used in the manufactured of margarine, while the resident cake is a

useful source protein for livestock feed. It is also used for producing melon

snack called ‘robo’. Processing of melon include fermentation, curing,

washing, drying, cleaning, shelling and oil extraction in Nigeria. The

traditional technologies are still employed in the processing of melon. These

include manual depodding of melon fruit and shelling is manually, which is

time consuming, energy sapping, tedious, inefficient and involved drudgery,

thus limiting the availability of the product in the market in order to provide on

easy means of shelling machine which is powered by a prime mover (fuel

Engine) which work on the principle of energy absorbed beyond the elastic

limit of the melon seeds as a result of impact force experienced during

Collision between the seeds and the stationary wall which results in the

cracking and removal of the seeds shells.

2
1.1 BACKGROUND OF THE STUDY

Melon shelling in most part of this world is usually done manually by hand and

like all manual operations, it is time consuming and strenuous. The melon

shelling machine is designed using impact method, is designed, constructed in

order to meet the domestic and commercial demand or melon for soups food

processing and other domestic uses and also to increase its productivity. The

melon shelling machine also create entrepreneurial business for youth, thus

reducing unemployment. The melon shelling machine consist of the frame,

shelling drum. Shelling rotor and a prime mover to facilitate its construction

and uses.

1.2 SCOPE OF STUDY

The scope of this study is to designed, constructed and test a melon shelling

machine that will be used for domestic and commercial users by farmers of

melon seed in order to create a faster means of shelling and also to improve its

productivity.

1.3 STATEMENT OF PROBLEM

It is noted that the present agricultural processing machine or requirements are

expensive and cannot therefore be conveniently afforded by many local

farmers in Nigeria. Invariably, melon cultivation and processing is affected by

3
 the problem of non-availability of cheap processing equipment especially those

for peeling the melon seeds. Although, there are several designs of melon

shelling machine, it is observed that the present designs are relatively more

sophisticated and expensive. The materials used in the construction of this

machines are corrosive and dangerous to human health when such product are

consumed. It is also observed that some of the melon shelling machine designs

are very heavy and cannot be carried about easily. Furthermore, Nigerian’s,

economy has been adversely affected by its over dependence on imported

items. The absence of cheap and portable machine for shelling lemon account

for the persistence use of manual method of shelling melon seed despite its

attendant problem or much time consumption, high energy consumption and

lower rate of productivity. Since the use of locally design and constructed

machine can greatly reduce the hardwork and drudgery associated with farm

work, increase the productivity of agriculture and improve the Nation’s

economy it has become necessary to design, construct a simple, cheap machine

for shelling melon seed.

1.4.1 AIM

The aim of this project is to design, construct and test a melon shelling

machine.

4
1.4.2 OBJECTIVES

The objectives of this project is

a) To offer assistance to the teaming population of local farmers or traders

and medium scale industries involve in melon business in their desire for

an available and easy method of shelling melon.

b) To design a melon shelling machine that eliminate human labour, create

effective shelling.

c) To create an entrepreneurial business for youth

d) To increase population.

5
 CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 A MELON THRESHING MACHINE

In order to address the challenges associated with manual or traditional

methods of shelling melon seeds, S.K Shittu and V.I.O Ndrika (2012) develop

a melon shelling machine which use a rotor that throw the melon seed against a

hard shelling drum by centrifugal force and then converge the seeds onto a

spinning disc with vanes that provide impact force to remove the kernel from

the shell. The feed hopper is a square based frustum with 250mm upper square

and 70mm lower square. It is the structure through which seeds are fed into the

shelling unit. To facilitate the free flow of seeds during the shelling operation,

hopper slant sides are at an inclination of seed’s repose angle to prevent seeds

from piping. Shelling unit consist basically of three parts that include rotor,

spinning disc and shelling drum. The rotor is a trapezoidal hallow box of

180mm long and 55mm high. Inside the rotor, there are two incline planes that

direct seeds to either of its two opening to prevent seed retention. The rotor is

mounted on a vertical shaft directly under the lower opening of the hoper. The

main function of the rotor is to collect seeds from the hopper, to distribute the

seed to the two opening of the rotor and to throw the seeds by centrifugal force

against the hard shelling drum to weaken their shells. The rotor’s opening size
6
is such that substantial seeds can be ejected from the rotor at once. Spinning

disc is a circular plate with a 220mm-diameter having 13strips of vanes welded

to its surface similar to Odigboh (1979) and Oluwole et al, (2004). The disc is

welded to the shaft which is just under the rotor. The seeds flow to the spinning

disc by gravity. The spinning disc provides an impact force needed to further

break and separated the weakened shells from the cotyledons. Delivery chute is

the outlet, through which the mixture of seeds and chaffs are discharged out of

the machine. Similar to the hopper, angle of repose of the shelled seed was

considered in the inclination of the delivery chute to enable free flow of the

shelled seed and chaff out of the machine. All the aforementioned components

were constructed from gauge 20 sheet metal plates, except the shelling drum

that was made from cast iron. The Sheller is powered by a single phase the

2900rpm electric motor through a system of belt and pulley. The frame is

rectangular of size 580mm x 520mm and 700mm high and made from

1.5inches mild steel and iron. It is the main body of the machine that supports

other parts.

To operate the appliance, the mains is switched on to start the electric

motor that runs the shaft on which the rotor and spinning disc in the shelling

unit are arranged when the machine attains its operational speed, seeds are fed

in through the hopper continuously but gradually. The seeds flow through the

lower opening of the hopper onto the inclined planes of the rotor and slide
7
 towards the rotors openings. As a result of the centrifugal force developed by

the rotor, the seeds are thrown against the stationary shelling drum. The impact

force due to seeds collision with shelling drum weakens the shells of the seeds.

The partially shelled seeds flow to the spinning disc that smashes the seeds by

impaction to free their cotyledons finally free from the shells. The mixture of

shelled seeds and chaffs flow out of the machine through the delivery chute.

2.2 A MELON DEPODDING MACHINE

A melon depodding machine was design and construction by (Oloko and

Abgetoye, 2006) of Federal University of Technology Akure, Ondo State. This

machine work on the principle of impact forces adequately depodded two of

the main cultivars found in Nigeria. It operates on the principle from the

fermented pods and discharges pulp end seeds together. This machine consists

of the following components; reciprocating sieve (seed-wash), where seeds

from machine outlets are washed clean of other materials especially, and the

pulp. Another component was a water flow system in the machine cylinder,

which helps to wash-off seeds from the broken pod and pulp, and also to seed

into the reciprocating sieve. A seed guard which assist the seed flow process

from cylinder chamber where pods are crushed before moving to the machine

out let.

8
2.3 MELON PEELING MACHINE

A melon peeling machine was designed and constructed by Mr. Agontu Joshua

Agantu of Mechanical Engineering Department, University of Agriculture

Markudi, 1995. This forms a part of the previous work done on the melon

thresher.

In this design, the machine is composed of several parts which make up

the complete design. The difference between this work and previous works and

the new ones is that the former has several design of shafts, design of square

keys, bearings selection, design of belt drives and design of level gears. In its

design too, the shelling of melon is achieved by the impact of seeds on the

walls of outer, drum on seeds drop from the hopper on the rotating disc at

1800rpm. More so, the rubbing principle adopted is the auxiliary peeling

chamber which is fitted with a cylinder rotating at 1,234rpm and over head

with a special leather material soft enough to remove the shell without crusting

the seeds. The horsepower requirement for the machine is 2hp motor.

2.4 A MELON SHELLING MACHINE USING LOCALLY AVAILABLE

MATERIALS

A melon shelling machine was constructed by Asibeluo Imonifewo Stephen

and Abu Afealiokha Lukman of Delta State Polytechnic Delta State, Nigeria

(2015). The melon shelling machine works on the principle of energy absorbed
9
 beyond the elastic limit of the melon seeds as a result of impact force

experienced during collision between the seeds and the stationary wall which

results in the cracking and removal of the seeds shells. Unshelled melon seeds

are fed into the machine through the hopper which opened directly into the

shelling unit. The shelling vanes are welded at an angle of 45 0 to the shelling

disc in order to increase the speed and rate of Collins of the unshelled seeds

with the rough body of the shelling unit, thereby leading to the breakage and

subsequent removal of the breakage and subsequent removal of the melon

shells from the cotyledons.

2.5 A MELON SEEDS SHELLER

Another melon seeds sheller by Sobowale S.S and Adebiyi J.A and Adebo O.A

of the Department of Biotechnology and food Technology, University of

Johnesburg, South Africa (2015).

The machine consists of the hopper, shelling unit (which consists of

rotating disc and static disc), the frame, the cleaning unit and chute. To

facilitate free flow of seeds into the shelling unit, the conical shaped hopper

was fabricated using mild steel into a height of 200mm, upper radius of 200mm

and lower radius of 50mm and include at an angle of 120 0 . The shelling unit

consists of the rotating and static disc, vanes and shelling drum. The order part

3
of the rotating disc is lined with flat metal blades ( 4 inch) of 50mm length were
10
 welded at an angle of 600 and were arranged side by side with a distance of

10mm between the blades, along the diameter (150mm) of the disc, forming

vane slots at the edges of the rotating disc. The static disc consists of flat metal

rods of 120mm length. Arranged side by side and welded at a distance of

10mm to each other at an angle of 60 0 along the walls of the fixed drum which

formed spikes. The frame which is the support on which the whole unit rests

was made from angle iron into a rectangle of size 920mm x 250mm x 750mm

high. The cleaning unit consists of mild steel folded and welded to form a

dilute of 350mm x 50mm x 40mm, length, width and height respectively.

2.6 A MELON SHELLING MACHINE

Another melon shelling machine was constructed by Adedoyin R.A, Olatunde

O.B of Mechanical Engineering Osun State Polytechnic Iree, Osun State,

Nigeria (2012). The machine consists of a cylinder shaft inserted in a

cylindrical pipe on which the shelling blades (shelling flat ban/flexible rubber)

were welded/attachment round the cylindrical pipe at an angle. The bent

shelling blades creates the slight bending effect on the melon seed required for

shelling action. The pipe rotate via a shaft attached to it which is been driven

by an electric motor via a belt. The shaft consists of helix (forming a

continuous curve around the central point or axis) which serves as a conveyor.

This conveys the shelled melon the discharge after been shelled by the flat bars

11
welded on the pipe. Melon seed is feed into the machine. Through the hopper,

the shelling action is by rotating the flat bar on the pipe against the cylindrical

wall by rubbing action. The melon is shelled and falls through an opening

under the cylinder and a fan is incorporated under to blow off the chaff away

from the seeds melon electric motor of 1.5kw was used to power the melon

shelling machine.

CHAPTER THREE

12
3.0 DESIGN THEORY CONSIDERATION AND CALCULATION

3.2 INTRODUCTION

Before designing and constructing any melon shelling machine, some physical,

gravimetric and frictional properties of melon seeds that are pertinent to the

mechanical processing determined by Davies (2010) were considered by the

design and development of the machine. The properties of melon that was used

are presented.

a. Physical properties of melon seed at 6.25% (d.b)

13
 Properties No of samples mean values

Length (mm) 100 12.81

Width (mm) 100 7.02

Thickness (mm) 100 2.22

One thousand 50 94.0

Unit mass (g)

Arithmetic 100 7.36

Mean diameter (mm)

100 5.84
Geometry

Mean diameter (mm)

100 0.47
Sphericity
50 134.64
Surface area (mm)
100 154.83
volume (mm3)

b. Some gravimetric properties of melon seed at 6.25% (d.b)

14
 properties mean values

bulk density, Kgm-3 405

true density,kgm-3 816.29

porosity, % 53.7

Angle of repose 36

c. Some frictional properties of melon seed at 6.25% (d.b)

Properties Mean values

Coefficient of static

Friction
0.35
Glass
0.51
Plywood
0.43s
Galvanized metal

3.2 MATERIAL SELECTION

S/N COMPONENT MATERIAL REASON

1 Hopper Stainless steel To avoid corrosion since it is used for food

processing and the melon seed is feed into it.

2 Shelling disc Mild steel rod Availability, easy to roll and weld

3 Shelling drum Stainless steel To avoid corrosion and to help support the
15
 shelling disc firmly

4 Shaft Mild steel - Easy machining

- Availability

5 Bearing Mild steel To support the and house the shaft firmly to

the frame.

6 Pulley Mild steel To connect the machine to the fuel engine by

creating a drive system.

7 Belt Rubber Availability, cheap

8 Fuel engine Require no external electrical power,

availability of fuel.

The speed can be control to the shelling of

the melon seed.

9 Frame Mild steel To house the shelling unit and the outlet for

effective shelling

3.3 DESIGN THEORY

3.3.1 Design for the shelling drum and shelling disc.

According to J.E. Shirley (1989), Design for shelling disc was given using the

formula

Shelling disc area Ad = π r 2 - - - -(i)

16
 rd = radius of the disc.

Volume of the shelling disc vd = π r 2 Ld - - -(ii)

Where Ld=length of the shelling disc.

Area of the shelling drum

AD = π r 2 - - - - - -(iii)

Where rD = radius of the shelling drum

LD = length of the shelling drum

Volume of the shelling drum VD = π r D 2 L D - -(iv)

3.3.2 Design for machine power

The design for the machine power was determined using this relationship

2 πNT
P = 60 - - - - - -(v)

Where P = Power require to drive the machine

N = speed of the machine (rpm)

T = Torque transmitted by engine

P x 60
T = 2 πN - - - - - -(vi)

17
3.3.3 Design for the Driven and Driving pulley

The need to regulate or control the speed of the prime moves to certain limited

become necessary because to high speed will crush the melon and too low

speed can over stress the shelling teeth. The formula according to Sharma C.S

and Purchut Kamalesh (2003) is used.

N1D1 = N2D2 - - - - - -(vii)

Where

N1 = revolution per minute of driving pulley

N2 = revolution per minute of driven pulley

D1 = Diameter of Driving Pulley

D2 = Diameter of driven Pulley

The ration of the driven pulley outer diameter to that of the driving pulley outer

diameter is 3.5:1

3.3.4 Design for the Driving and Driven speed of pulley

The speed of the driving and driven pulley can be determined using this

relationship

π N 2 D2
V1 = - - - - - -(viii)
60

18
 π N 2 D2
V2 = - - - - - -(ix)
60

Where

V1 = speed in (m/s) of driving pulley

V2 = speed in (m/s) of driven pulley

3.3.5 Design for shaft

Shaft may be designed on the basis of strength

Rigidity

Design of shaft based on strength

1. Shaft subjected to twisting Moment or Torque.

The diameter of the shaft may be obtained by using the relation:

T Ʈ
=
J r

Where T = Twisting moment or torque acting upon a shaft

J = Polar moment of inertia of the shaft about the axis of rotation

Ʈ = Torsional shear stress

r= distance from neutral axis to the outermost fibre

d
= 2 ; where d is the diameter of shaft

π
For solid shaft, J = 32 x d4 - - - -(x)

19
 The equation ( ) may be written as

T τ
= π 3
π
xd 4 d or T = xτd - - - -(xi)
16
32 2

P x 60
Or T = 2 πN - - - - - -(xii)

2. Shaft subjected to Bending Moment

The maximum stress (tensile or compressive) is given by the bending equation.

We know that

M δb
= - - - - - -(xiii)
I y

Where M = Bending Moment

I = Moment of inertia of cross sectional area of the shaft about the axis of

rotation

δ b = Bending stress and

y = distance from neutral axis to the outermost fibre for solid shaft,

π 4 d
I = 64 x d any y= 2 - - - -(xiv)

WL
For a uniformly distributed load M = 2 -(xv)

Where W = weight of the uniform beam

L = the Length of the beam.

20
 Substituting this value in equation

M δb
= π
π 4 d or M = x δb d 3 - -(xvi)
xd 16
64 2

3. Shaft subjected to combined twisting and bending from maximum shear stress

theory according to Khurmi and Gupta (2005), the maximum shear stress in the

shaft is

1
Ʈ max=
2
√ 2
δ b +4 Ʈ
2

√( ) ( ) = 16
2 2
1 32 M 16 τ
Ʈ max= +4
2 πd 3
πd 3

π x τ max x d3
=√ M 2+T 2 = Ʈe - - -(xvii)
16

Therefore, Ʈe is known as the equivalent twisting moment

Design of shaft based on Rigidity

1) Torsional rigidity

The torsional deflection can be obtained by using the torsional equation

T G .θ T.L
= ∨θ= - - - - -(xviii)
J L J .G

Where, θ = torisional deflection or angle of twist in radians

T = Twisting Moment or Torque on the shaft

J = Polar moment of inertia of the cross-sectional area about the axis of

rotation

G = Modulus of rigidity for shaft material

21
 L = length of shaft

16
Shaft diameter can be determined using d = πδ √(k b mb ) +(k t mt )
3 2 2

2) Lateral Rigidity

The lateral deflection can be determined from the fundamental equation for

d2 y
elastic curve of a beam i.e 2 - - - - (xix)
dx

SHEAR FORCE AND BENDING MOMENT DIAGRAM

11.55N
57.79N
304.8mm

101.6mm 152.4mm

R1

Taking moment about point R2

R1 x 152.4 + 11.55 x 101.6 =57.79 x 254

152.4R1 + 1173.48 =14678.66

152.4R1 = 14678.66 – 1173.48

13505.18
R1 = 152.4 = 88.62N

∑upward forces = ∑downward forces

R1 + R2 = 57.79 + 11.55

88.62N + R2 = 69.34

R2 = 69.34 -88.62
22
R2 = -19.28N

Shear force

X =101.6mm

S.F = -57.79N

X = 254mm

S.F =-57.79 + 88.62 = 30.83N

X = 304.8mm

S.F = -57.79 +88.62 – 19.28 = 11.55N

Bending moment

X = 0mm

B.M = -57.79 x 0 = 0

X = 101.6mm

B.M = -57.79 x 101.6 = -5871.46Nmm

X = 254mm

B.M = -57.79 x254 +88.62 x 152.4 = -1172.97

X = 304.8mm

B.M = -57.79 x 304.8 +88.62 x 152.4 – 19.28 x 101.6 = 0

23
 11.55N
57.79N
304.8mm

101.6mm 152.4mm

R1

30.83

11.55

S.F.D

0 0

- 1172.97

B.M.D
- 5871.46N/mm

24
3.3.6 Bearing Selection

Bearings are manufactured to take pure radial loads, pure thrust loads or a

combination of the two kinds of loads. The bearing has 4 essentials parts. The

outer ring, the inner ring, the balls or rolling elements and the separator.

The bearing life is applied to either two of the common life measures.

Number of revolution of the inner ring (outer ring stationary) until the first

tangible evidence of fatique.

Numbers of hours of use at a standard angular speed until the first tangible

evidence of fatique.

The life of a bearing is the function of the load. If one group of bearing of a

definite type operates under constant load P1 and have a life L1, and another

group in similar condition under the load P 2 has life L2, then loads and lives are

connected by a relation.

( ) for ball bearing -

3
L1 P 2
= - -(xx)
L2 P 1

If L2 = 1 million revolution of inner ring, P 2 can be written equal to C which is

known as basic load rating.

Life of bearing at any load ‘P’ can be written from equation (xx) as

( ) ( )
3
C C 3 6
Rating life L = millions of revolution = x 10 rev - -(xxi)
P P

25
 ()
1
1
P=C 3
- - - - - (xxii)
L

( ) ( )
b 6
C 10
L = P x 60 L where L = in hours, n= rev/min
n

( )
1
106 3
Then P = C 60 L - - - - - (xxiii)
n

The recommended bearing life for various machine is stated in table below

Based on the diameter of the shaft, a bearing of diameter 30mm is chosen

based on ASME.

3.3.7 Design of Key

A key is a piece of mild steel inserted between the shaft and hub or boss

of the pulley to connect these together in order to prevent relation motion

between them.

The Key for the coupling may be designed in the similar from the

determination of the strength of a key from the following relation:-

L 3.5 d
L = 2= 2 - - - -(xxiv)

Where L = length of the key in each shaft

Crushing of key

The tangential crushing force acting at the circumference of the shaft

F = Area resisting crushing x crushing stress

t
F = L x 2 x δc - - - - - (xxv)

26
Torque transmitted by shaft

d t d
T = F x 2 = L x 2 x δc x 2 - - -(xxvi)

Shearing of Key

The tangential shearing force acting at the circumference of the shaft

F = area resisting shearing x shear area

F=Lxwxτ - - - - -(xxvii)

d d
Torque transmitted T = F x 2 = L x w x τ x 2 - - (xxviii)

The key is equally strong in shearing and crushing, if

d t d
L x w x τ x 2 = L x 2 x δc x 2 - - - -(xxiv)

w δc
= - - - - - - -(xxx)
t 2τ

Where T = torque transmitted by shaft

d = diameter of shaft

l = Length of key

w = width of key

t = thickness of key

f = Tangential force and

δ c and τ = shear and crushing stresses for material of key

27
3.3.8 Belt Design

The length of the belt can be obtained from

2
(r −r )
L = π ( r 2 +r 1 ) +2 x 2 1 -(xxxi)
x

Where

L = Length of belt

r1 = radius of driving pulley

r2 = radius of driven pulley

x = centre distance between pulleys

Length of pulley can also by calculated by the formula (Khurmi and Gupta,

2004)

D 2−D1
L = 2c + 1.57 (D2 + D1) +
4C

Where C is the centre distance between pulley

3.3.9 Bolt Design

Bolts are used to fasten various parts of an assembly together, initials tension

in the bolt due to tightening may result from the use of a torque wrench,
28
experimental results indicates that the initial bolt load W(N) in a bolt tightened

by an experienced mechanic may be estimated.

W1 = Kd - - - - (xxxii)

Where d = nominal diameter

k = ranges from 1.075 x 106 to 2.8 x 106 N/m

if a torque wrench is used to tighten the bolt, the value of the initial bolt load w

may be approximately by

τ
W = 2d - - - - (xxxiii)

Where τ = applied torque and

d = nominal diameter of bolt

The diameter of the bolt can be obtained from the following relation.

τ 2
Load on each bolt = 2 d (d 1 ) τ b - - - - (xxxiv)

Total load on all the bolt

τ 2
(d1 ) τ b x n - - - - - - -(xxxv)
4

π d1
And torque transmitted T = (d 1 )2 τ b x n x - -(xxxvi)
4 2

29
 τ b = shear stress of bolt

n = number of bolt

3.3.10 Bearing Housing Bolting

The bearing housing are held firmly in place with the help of the bolts and nuts

so that the bearing is properly enclosed and held in its proper place

The damping force is given by

2τ
Fc = D (4) - - - - - - (xxxvii)

Where T = Shaft torque

D = bearing external diameter

Stresses in the bolt Tb

damping force Fc
Tb = cross sectional area = A - - - - (xxxviii)

30
 Design Calculation

Initial Data Design Calculation Results

P = 4013 W Machine Power Requirement

N = 2500rpm 60 P 60 x 4103 T = 15.7N-m

T = 2 πN = 2 x 3.142 x 2500

Driven Shaft Torque T = 54.85N-m

P= 4103W
60 P 60 x 4103
T = 2 πN = 2 x 3.142 x 714.29
N2 = 714.29rpm

N1 = 2500rpm Driven and Driving Pulley

D1 = 50mm N 1 D 1=N 2 D2

N 1 3.5
=
N2 1
N2 = 714.29rpm
N1 = 3.5N2
D2 = 174.9
N 1 2500
N2 = = = 714.29rpm = 175mm
3.5 3.5

1 1N D
2500 x 50
D2 = N = 714.29
2

V1 = 6.5m/s

31
N1 = 2500rpm Speed of Driven and Driving Pulley V2 = 6.5m/s

D1 = 50mm π N 1 D1 3.142 x 2500 x 175

V1 = =
60 60
N2 = 714.29rpm
π N 1 D1 3.142 x 714.29 x 175
V2 = =
D2 = 175mm 60 60

V1 = V2 there is no slip

P = 4103

N=714.29 Shaft Diameter

Mt = 54.85N/m From table, for gradually applied load Mb was

Mb = 17.19N/m calculated as 17.19Nm by analyzing moments

Mt = 54.85Nm

Kb = 1.5 due to both horizontal and vertical loading in

Kt = 1.0 bending moment diagram of the shaft. Mt was

P x 60
Ss = 40x106N/m2 calculated using Mt = 2 πN (Ryder 1989)

4103 x 60
Mt = 2 x 3.142 x 714.29

The values for Kb and Kt were taken as 1.5 and d = 19.76mm

1.0 respectively for gradually applied load on = 20mm

rotating shaft and allowable shear stress of the

shaft Ss is 40MN/m2 based on ASME code.

16
d3 = πS √(k b m b) +(k t mt )
2 2
r2 = 87.5mm s

32
r1 = 25mm 16
6 √
2 2
d3 = (1.5 x 17.19) +(1.0 x 54.85)
3.142 x 40 x 10
L = 914.36mm ≈
x =273.3mm
considering factor of safety, the diameter of 914.4mm

the shaft is take as 30mm

X= 0.2733m Belt Size

m =0.104328kg (r 2−r 1 )2
L= π ( r 2 +r 1 ) +2 x+
x
Ʈ =40N/mm
( 87.5−25 )2
L = 3.142 (87.5+25)+2(273.3)+
µ = 0.25 273.3

2ᵝ =320 L = 3.142 (112.5) + 546.6 + 14.29

d1 =0.05m Belt tension

d2 = 0.175m O2 M r 2−¿r d 2−¿d 0.175−0.05

sin α = O = 1
¿= 1
¿=
2× 0.2733
1O 2 x 2x

∝ =13.220

angle of lap of smaller pulley

π
θ = 180 -2α =180 -2(13.22) = 153.56 x 360 T1 = 1011.6N

= 1.340rad

centrifugal tension

Tc = mv2 = 0.104328 x (6.5)2 =4.408N

maximum belt tension in the belt

T =Ʈ x a = 4 x 254 =1016N

33
 tension in the tight side
N2 = 714.29 T1 =T –Tc =1016 – 4.408 = 1011.6N T2 = 2.996N

L = 50,00hrs T2 =tension in the slack side

T1
2.3log( T ) = µθ cosecᵦ = 0.25 x 1.304 cosec16 L = 92.857.4rev
2

T1
2.3log T = 1.2154
2

T1 1.2154
log T = 2.3 = 0.5284
2

T1
T2
= 3.376

T1 1011.6
T2 = = 3.376 = 299.6N
3.376

Bearing Life

(a) life in revolution L

L = 60 x 714.29 x 50 x 103

= 92.857.4rev

d = 25mm from manufacturer catalogue

the following parameter are selected for the

diameter of bearing selected.

Ts = 2.57N/M
width = 15mm
D= 8mm
outside diameter = 52mm
L = 43.75mm
if the machine will work for 24hrs, 6days for 4

34
δ s =40MN/m2 weeks in one year then, the total working hours

in a year is (24x6x4x12) = 6912hours.

Fc = 47.98N/M
the assume lifespan in hours according to table

= 50,00hours

the bearing life will last for about

A = 1.19725 x 10-6 m2
50,000
= 7.234 = 7years
6912

d= 8.7298 x 10-4N/m
Key Design

3.5 d 3.5 x 25
L= 2 = 2

L = length of key

Bolt Design

2Ts 2 x 2.57
F= D = 8
x 74.5

Maximum Shear Stress for Bolt

Area of the bolt

Fc 47.98
A= δ = 6 = 1.125x10
-6
s 40 x 10

Diameter of Bolt

√ √
−6
d = 4 A = 4 x 1.19725 x 10
2π 2 x 3.142

35
 CHAPTER FOUR

4.0 ANALYSIS AND DISCUSSION OF RESULT/FABRICATION

PROCEDURES AND TESTING

4.1 FABRICATION PROCEDURES

the melon shelling machine was designed and constructed with a shelling drum

in which the shelling disc was incorporated and a hopper for feeding of the

melon seed into the shelling chamber which has a small opening that is opened

directly to the shelling chamber powered by a prime mover (5.5hp fuel engine)

and supported by a surface frame.

Table 4.1 brief description of the fabrication process of each part

Part No. component Material Fabrication process Equipment/tool

used

1 hopper 1mm - Marking Set square, steel

stainless - Cutting rule scriber,

36
 steel - Welding shearing machine

2 Shelling 10mm - Measuring Rolling machine,

disc rod, flat - Cutting measuring tape,

bar - Rolling of the hacksaw, manual

rod into arc welding

- Welding of 7 machine

inch length

rod to hold the

rod together

- Welding of

flat bar to the

round rod

3 Shelling Stainless - Cutting Rolling m/c,

drum steel - Rolling manual arc

- welding welding machine

4 Frame and 2/2 angle - measuring Measuring tape,

base iron - cutting hacksaw, manual

- setting arc welding

- welding machine.

5 Supporting Mild steel - marking Measuring tape,

37
 frame sheet punch, hammer,

- cutting manual arc

- welding welding m/c.

6 shaft Mild steel - marking Cutting machine,

- cutting lathe machine

- machining

7 pulley The pulley was

purchased from the

market

8 bearing The bearing was

purchased from the

market

4.1.1 Fabrication of the Hopper

The hopper open directly into the shelling unit through a centralized hole are

the hopper is meant to receive the melon seed before they are eventually

moved into the shelling unit the hopper is made up of four welded stainless

steel metal sheet slanting toward the smaller opening. A stainless rule and set

square was use for the marking out the folded four stainless steel and a

38
 shearing machine was used to cut out the metal sheet which was later folded

and welded using the manual are welding machine.

4.1.2 Fabrication of the Shelling Chamber

The shelling chamber consist of the shelling drum, shelling vanes and shelling

disc.

The shelling drum was made from stainless steel of diameter 300mmx 280mm

1
and the inner part of the drum is lined with 4 inch rods the shelling disc was

made from 10mm rod which is folded into two circular rings of ∅ 240mm x

136mm and the shelling vanes which is made up of flat bars of length 136mm

are arranged side by side at an angle of 120o to each other and welded to the

39
 shelling disc at an angle of 45o. The shelling chamber incorporates an opening

at the right hand side part which serves as an outlet for the shelled melon seeds.

4.1.3 Fabrication of the Frame and Base

The frame is the structure that holds all the components together. It was

2
constructed with 2 angle iron of 8mm thickness of length 530mm x 670mm

and mild steel sheet of 520mm x 650mm. The metal plate was welded to the

frame after measurement and cutting it to size. The base is the structure that

support and hold the prime mover (fuel engine). The base was constructed with
2
angle iron 2mm thickness of length.
2

4.1.4 Prime Mover (5.5hp fuel engine)

The prime mover is used to transmit power or rotational motion to the shelling

disc through its protruding shaft with the aid of a drive system. The speed of

the prime mover was 2500rpm with power rating of 5.5hp. The prime mover

was brought already made from the market.

40
4.2 Assembling of Parts

After the components have been fabricated the following steps were taken to

assemble the machine. The shelling drum was welded to the frame in the inner

part with a support from the base. A protruding shaft was insert into the

shelling drum through a centralized hole and pass through into the bearings

fasted on the frame. The shelling disc was inserted into the shelling drum via

the shaft and was held tight to it use a bolt. A mild steel sheet was welded to

two opposite side of the frame. The shelling chamber was cover with a circular

plate. The driving pulley was inserted into the shaft protruding at the other end

and held tight by a bolt and nut. The driven pulley was on the purchased fuel

engine and was connected to the driving pulley on the machine by a V-belt.

The hopper was welded to the shelling pot in a Mannes that permit smooth

flow of unshelled melon seeds into the shelling chamber.

4.3 Finishing Operation

All the parts welded were dislagged and thereafter polished to ensure a smooth

finish. The polishing was done with a hand grinding machine. The outside

body was painted with antirust followed by painting with a green coloured

paint.

4.4 Testing of the Machine

41
 The efficiency of the melon shelling machine was determined by testing the

processed melon seeds, wetted to increase the moisture content and thereby

reduce the brittleness of seed in order to ease the problem of seed breakage.

The test was carried out using moisture content of different quantity and at

different speed. Equally weighed melon seeds were fed into the machine via

the hopper to test for percentage efficiency in both cases.

4.5 Results and Discussions of Results

The table below show the percentage performance of the machine in term of

partially shelled, unshelled, broken shelled, completely shelled and crushed. It

is observed that when the speed was high and with less moisture content the

shelling performance was low compare to when the speed was at critical speed

and with a high moisture content. The table below shows the result of the test.

s/no Test Duration weight of weight of weight of weight of weight of Efficiency

wet completel partially completely crushed (%)

unshelled y shelled shelled unshelled melon

melon melon melon melon seed(kg)

seed(kg) seed(kg) seed(kg) seed(kg)

1 idle run 3min

test

2 first test 2min50sec 1kg 0.7kg 0.18kg 0.1kg 0.02kg 70

3 second 2min 1kg 0.8kg 0.1kg 0.09kg 0.01kg 80

42
test

70+80 150
Average percentage performance = 2
= 2
=¿75%

4.6 Principle of Operation

The melon shelling machine works on the principle of energy absorbed beyond

the elastic limit of the melon seeds as a result of impact force experienced

during collision between the seeds and the stationary wall which results in the

shelling of the melon seed. The melon seed is fed into the machine through the

hopper which open directly into the shelling unit, as the fuel engine is on and

the speed control, the unshelled melon is fed to the hopper and pass into the

shelling unit where it is shelled and blown out of the shelling varies the outlet

chute.

4.7 Precautions

a) For the machine to perform efficiently

b) Ensure that the prime mover is fuel proper and in good condition

c) Ensure that the belt is fit properly on the driven and driving pulley and is

not worn out

d) The machine should be allowed to run for some seconds before feeding the

hopper with the melon seats

43
 e) Feeding of the melon seeds into hopper should be done gradually

f) After operation, the machine should be proper cleaned

g) If frequently used, the machine should be maintain and lubrication of part

should be carried out where necessary. The machine should be switched off

when not in use.

4.8 COST OF MATERIAL

S/ Material Qty Unit cost (n) Total cost (n)
no
1 1mm and 2mm metal sheet(scrap) stainless steel 5500 5500
2 Electrode stainless steel 7pcs 100 700
3 Electrode 12guage 600 600
4 1mm metal sheet mild steel ½ sheet 4000 4000
5 2/2 angle iron 2pcs 4500 9000
6 Flat bar 2pcs 500 1000
7 10mm rod mild steel ½ length 800 800
8 30mm shaft 1000 1000
9 Bearing 2pcs 1800 3600
10 Washers 16pcs 15 240
11 Bolt and nut 10pcs 44 440
12 Pulley 1pcs 1700 1700
13 Cutting disc 1pcs 1000 1000
14 Filing disc 1pcs 700 700
15 Belt 1pcs 300 300
16 Paint 1 tin 600 600
17 Body filler 600 600
18 Fuel engine
19 Workmanship 8700 8700
20 Miscellaneous 40000 40000

CHAPTER FIVE

SUMMARY, RECOMMENDATION AND CONCLUSION

44
5.1 Introduction

These project was carried out with the aim to shell melon seeds to reduce the

stress of shelling melon by local farmers and to increase the availability of if

the market for economic use.

5.2 Summary

In other to achieve this project, research where carried out to source for the

best material and approach to bring it into realization from the information

obtain from the research, we are able to come up with the aim of designing and

constructing a melon sheller powered by a prime mover (fuel engine) and the

use of a stainless steel metal sheet for the shelling chamber which is best use

for food processing machine.

After fabrication of parts and assembling, the picture of the machine we had in

mind was actualized though we encountered some challenges during this

project. The stainless steel metal sheet was hard to obtain in quantity required

for this project which linger the time for the fabrication of some part. The

welding of this metal sheet also is challenging to the workman we are working

with but at last, what was intended was achieved with some perfection

The efficiency of the machine was tested and the machine is suitable for

domestic and small scale industrial use.

45
5.3 Recommendations

I. We recommend that a control valve should be incorporated in the hopper to

control flow of melon seed.

II. We also recommend that a processing chamber should be install to avoid

repetitive shelling of melon

III. We also recommend that the outlet should be at a different point from the

shelling unit.

IV. We also recommend that the pulley should be machined rather than purchasing

it from the market to avoid whorebling.

V. We also recommend that there should be a provision for the adjustment of the

belt.

VI. We also recommend that a blowing unit should be incorporated in the machine

to separate the shelled melon seed and the chaff.

5.4 Conclusion

The melon shelling machine was made from locally available materials which

are easy to operate with little or no technical skill individual can acquire it for

domestic use and melon local farmer. The average performance of the machine

was found to be 75.0% with the average percentage of damage melon seed

25.0%. It can be used to startup a small scale business and means to provide

employment.
46
 REFERENCES

Aaron, D. D (1975), machine design theory and pratices) colliermacmillan publishers.

47
Adekunle, A.S (2009),development and performance manually and motorized melon
shelling machine

Allen, S.H. and Alfred R.H. (1982),theory and problems of machine design McGrew-
hill book co, Singapore pp. 114,138

Fadamoro (1999) design and construction of a manually operated melon sheller,

unpublished B.Sc report, Department of Mechanical Engineering,

University of Lorn.

Fashina A.B (1971), the design and construction of a melon sheller unpublished

B.Sc project report, department of agriculture, University of Nigeria.

Leo Ayodeji Agbetoye, Solomon Ayoola Oloko, design modification and

performance of a melon depoddng machine. Department of Agricultural

Engineering, Federal University of Technology, Akure, Ondo State.

Rta O. Onah, Samuel b. Obetta, design, fabrication and performance of a double-

action melon seed shelling machine.

Sharma, C.S and Purchit Kamalesh (2003),design of machine elements, prentice hill
of Indian, new delhi

Shttu, S.K, Ndrka, V..O (2012) development and performance test of a melon

seed shelling machine. Agrc Eng nt:CGR jounal,14(1)

48
 APPENDIX

Table 1 : Recommended bearing life for various type of machine

49
Types of application life (hrs)

instruments and apparatus for infrequent up to 500

use

aircraft engines 500-2000

machines for short or intermitted service 4000-8000

where service interruption is of minor

important
8000-14000
machine for intermittent service where

reliable operation is of great importance

14000-20000
Machines for 8hrs services which are not

always fully utilized

50000-60000

machine for continuous 24hrs service

100,000 – 200,000
machines for continuous 24hrs service

where reliability is of extreme importance

Table 2 Values for service factor (Ka)

Type of Service Ka

50
 Ball bearing Rover bearing

Uniform Steady Load 1.0 1.0

Light Shock load 1.5 1.0

Moderate Shock Load 2.0 1.3

Heavy Shock Load 2.5 1.7

Extremely Shock Load 3.0 2.0

Table 3 : Value for temperature factor Ke

to c 125 150 175 200 225 250

Kt 1.05 1.10 1.25 1.25 1.35 1.40

DISCUSSION

The machine was started and allowed to run for 3minutes without load before the first

test was carried out.

During the first test at a moderate speed, it was observed that the melon seed are

partially shelled until repeated for 6 to 7 times before it is shelled. This also could be

as a result of the moisture content been less. During the second test, the speed was

brought to average and it was observed that the melon were shelled. When the speed

was too low, the melon seed were unshelled and when the speed was too high, the

51
melon seed were broken rather than shelling it. It is observed that the speed required

to the shelled the melon must be average and there is need for regulate the speed of

machine at regular interval during shelling.

52