Chapter One: Introduction

1.1 Background
Maize is one of the most important staple crops in the world. Corn is cultivated globally, being
one of the most important cereal crops worldwide. It is, after wheat and rice, the most important
cereal grain in the world, providing nutrients for humans and animals and serving as a basic raw
material for the production of starch, oil and protein, alcoholic beverages, food sweeteners and
more recently, fuel. In ancient days, people processed maize by hand to tear the skins of corn and
take off the kernel by simple tools even by hand. Many farmers grow maize but could not afford
the cost of acquiring some of the imported threshing machines because of their cost. Such people
resort to manual means of threshing which results into low efficiency, high level of wastage and
exerting of much labor. Corn threshing machine was constructed to shell maize and separate the
cob from the grains. Large scale shelling for commercial purposes is not possible due to fatigue.
Traditional shelling methods do not support large-scale shelling of maize. There are hand
operated maize Sheller’s which are cumbersome to use. Hand shelling takes a lot of time, even
with some hand operated simple tools. There are, of course, machines which can shell maize, but
these are usually unaffordable for rural farmers. There is a need for a cost effective, eco-friendly
solution for shelling maize. The cost of purchasing such Sheller’s is high for the poor rural
farmer, and therefore necessitates the design of low-cost system that is affordable and also
increases threshing efficiency. Electricity plays a key role in keeping homes and businesses to
run smoothly, power transportation that takes people to work, school and other places, and
supplies electricity to appliances in all sectors. But due to the steadily increasing demand of
electricity and other energy, some places in the world are experiencing energy crisis. Throughout
the world, greater demand for energy in developing nations has been putting pressure on the
availability and cost of all natural resources. These pressures are reflected in electricity cost
because of rising prices for fuels used to generate power, as well as transportation cost for
delivering fuel. In this case, the use of alternative energy source is needed. Alternative energy
encompasses all those things that do not consume fossil fuels. They are widely available and
environment friendly. They cause little or almost no pollution. One of the ecofriendly alternative
energy resources is using solar energy. It is the energy from the sun that is converted into
electrical or mechanical energy. Solar energy is harnessed using a range of technologies such as
photovoltaic, solar panels, solar thermal energy, solar architecture and artificial photosynthesis.
In order to lessen the problem in energy shortage, the researchers aimed to design and develop a
project using solar panel as the source of power in harnessing the solar energy. The project solar
powered corn threshing machine uses solar panel to harness the energy from the sun. It could be
a very useful machine especially to the farmers engaged in small scale industry. The main
purpose of this study was to design and develop a solar powered corn threshing machine for
efficient deseeding of corn in small scale production using solar energy.

1.2 Statement of the Problem

Creating a linkage between ruler area with different governmental institutes helps to solve
different problem that arise from society. lack of moderate and efficient trashing is one among
the different problems of society. the trashing machine that uses for trashing of crops helps to the
society in terms of the following advantages.
 Efficient in time and money consumption
 Reduce labor force
 Produce an efficient crop

1.3. Significance of the study

The following are some of the significance of the study.

 To reduce the problem cultural harvesting methods in our country

 To improve the living standard of society by using modern corn trashing methods
 It used to increase the ability of investigating problem in similar for project
 To reduce the cost man power using traditional wheat trashing methods

1.4 Objectives of the Study

1.4.1 General Objective
The general objective of this project is to design solar powered maize Sheller/threshing
machine.

1.4.2 Specific Objective

To meet the general objectives of the study the project is intended to achieve the following
specific objectives.

 To identifies working principles of wheat trashing machine

 To identifies the advantages and disadvantages of modern wheat trashing machines.
 To study the participation (use age) of the society in the modern wheat trashing machines
 To develop, fabricate and describe this wheat trashing machine for the society on the
market To introduce, modern wheat trashing machines with their relative advantages

1.4-Scope of the Project

The scope of this project is to design solar powered maize threshing machine which solve the
problem of that detaching of the maize or grains from its cobs in rural and urban area of our
country also saves electric bills, time consumes and energy/man power .This project is starts with
literature review and design specification in order to satisfy the project objective. The design
includes material selection, working principle, dimension analysis, power and force requirement
for threshing of the maize, part design, component selection, cost analysis and modeling of each
parts by using 3D cad design.

1.5 Design Methodology

1.6- Organization of the Project/ Work

 This work generally will contains 5 chapters and the reference part.
 Chapter one (introduction) this chapter contains the background, statements of
the problem, the objectives of the work, scope of the project, design methodology,
and working principle generally this chapter contains the overall introduction of
the project.
 Chapter two (literature review) this chapter describes or reviews previously
written documents related to the design.
 Chapter three (detail design) this chapter contains the geometric analysis,
design specification design considerations, the strength analysis of all components
 of the machine, the assembling drawing of the machine to be designed and finally
cost analysis of the machine.
 Chapter four (result and discussion) this topic briefly explain the results and
provides clear and neat discussion about the result that we got from detail design.
 Chapter five (conclusion and recommendation) in this chapter we conclude for
what we done in the design and finally recommend for whom it concern related to
the design or the machine.
 Chapter Two: Literature Review

2.1 Definition of Maize Sheller’s

Maize shelling is a post-harvest operation that is the removal of maize seeds from the cob. This
operation can be carried out in the field or at the storage environment. Maize shelling is an
important step towards the processing of maize to its various finished products like flour. The
different methods of maize shelling can be categorized based on various mechanization
technology used. These includes: hand-tool-technology, animal technology, and engine power
technology. Hand technology involves the use of hand tools in shelling, while as observed
animals were used in threshing on the field by marching on the maize. Engine powered
technology involves the use of mechanical assistance in threshing or shelling the maize. To
facilitate speedy shelling of maize in order to reduce post-harvest deterioration, mechanical
Sheller’s are recommended, because hand shelling methods cannot support commercialized
shelling. An average moisture content of 15% to 18% must be necessary for maize that was to be
threshed. Moisture content seriously affects the thresh ability of maize. Another factor that affect
the thresh ability of maize in a mechanized system is the size of the maize cob. The mechanical
Sheller was needed to be adjusted in the various sizes of cobs. According to the various sizes of
maize cob range from 50mm to 85mm depending on variety. There are also engineering design
factor that affect the design of mechanical Sheller’s. These factors are the design of the power
transmission shaft, selection of the prime mover, type of pulley, appropriate belt design, key and
selection of appropriate bearings support. Threshing or shelling operations of maize follow the
harvest and whatever pre drying of the crop is undertaken. This operation can be carried out in
the filled or at the storage environment.
 Figure 1: Different sizes of maize

2.2 Maize Shelling Techniques

Depending on the influence of agronomic, economic and social factors threshing or shelling is
done in different ways.

 Threshing or shelling by hand, with simple tools.

 Mechanical threshing or shelling, with simple machines operated manually.
 Mechanical threshing or shelling with motorized equipment.
 Different components of a combine harvester

2.2.1 Hand Shelling

Maize is shelled traditionally by hand (Figure 2). Here, the grains are detached from the cob by
pressing them with the thumb. The technique produces unbroken kernels but the process is
tedious. A few kilograms can be shelled in an hour, with damages left on Sheller’s’ fingers.
Another simple and common method of traditional maize shelling is to rub two maize cobs
against each other in order to detach the maize kernels. However, these traditional methods of shelling
are, not efficient, consume a lot of time, and require a lot of energy with very low productivity since
farmers can shell only a few kilograms/hour.
 Figure 2: Maize shelling by hand

2.2.2 Manual Maize Shelling

This method is almost similar to the traditional method of shelling except that it requires more
energy compared to traditional methods to run manual maize Sheller (Figure 3). For some
manual Sheller’s, two people are required during shelling, one person constantly feeds the maize
cobs and the other operates the equipment by rotating the handle while other manual Sheller’s
require one person. Hand operated Sheller’s, requires less time to shell the maize compared to
the traditional methods. These come in several models, and they are usually driven by rotating
the handle or a pedal. With the output capacity of 14–100 kg/min, they are more suitable for
small-scale maize production. Hand-operated maize Sheller’s are also suitable for shelling maize
for seed purpose since damaged maize kernels are fewer compared to motorized maize Sheller’s
 Figure 3: Manual maize Sheller

2.2.3 Motorized Maize Sheller’s

This method uses the same concept as hand-operated maize Sheller’s except that the Sheller’s are
powered using a motor or an engine (Figure 4). The Sheller’s under this method can be
categorized into immobile and mobile maize Sheller’s. These Sheller’s save time and they reduce
on the drudgery during maize shelling. However, the challenges with some of these Sheller’s is
that they are heavy, do not clean the maize kernels and are characterized with a broken
percentage of 8.4 which is above the recommended 2%. Motorized maize Sheller’s use
mechanically generated power to shell the maize. To facilitate speedy shelling of maize in large
scale maize production, motorized maize Sheller’s are recommended compared to hand-operated
maize Sheller. The output of motorized maize Sheller’s range between 500 and 2000 kg/hour and
they can be operated by tractor power take off (PTO) or engines with power varying from 5 to
15hp depending on the equipment used.
 Figure 4: Motorized maize shelling

2.2.4 Different Components of a Combine Harvester

In developed countries like Europe, North America, and China, maize shelling operation is done
using combine harvesters. Combine harvesters (Figure 5) simultaneously perform operations of
ear picking, threshing, separation, and cleaning on the mature maize plants in the field. The
purpose of this mechanized maize harvesting technology is to replace manual labor to harvest
maize from fields in time with minimum loss while maintain high quality standards. Some of the
advantages of mechanized maize shelling include: reduced drudgery, enhanced productivity,
time consciousness of agricultural operation, and availing labor footer agricultural operations.
Combine harvester designers are working towards the quality of the process automatic controls
and protecting the environment.
 Figure 5: Different components of a combine harvester

Chapter Three: Detailed Design Analysis

3.1-Geometric Analysis
Required parameters and assumptions taken for this project:

 Overall machine dimension (l x w x h) 1200mm x 800mm x 1500mm, by considering of

the cost of the machine.
 Shaft of at least 1000mm in length by considering the length of the machine and the
components that hinged or fixed on it.
 Hopper of Overall Height 500mm inlet allowance of 500mm by 50mm by considering
the portability in operation time.
 Steel bars of 1.5” 1.5” and 2mm thickness for frame by considering easily available, less
in cost and better strength.
 Total mass of machine= mass of motor + thresher mass + instant mass of maize
3.2-Design Specification
Selection of motor: A 1 Hp single phase induction motor was used to drive the corn threshing
machine. Induction motor was chosen for the reason that it is maintenance free motors due to
absence of slip rings and brushes unlike synchronous motors.

Solar panel sizing: To calculate the rating of solar panels needed by the system, the total load
demand was computed by determining the number of individual loads multiplied by its usage
time.

AC Motor = 1 hp = 746 Wn =1740 rpm

Torque =

Torque =

Torque = 2.9167 lb.ft

Formula: Total load = Load x hour

Total load = 746 W (1hr) Total load = 746 Wh

The computed total load of 746Wh was used to compute the power needed from the pane To

compute for the total power needed per day which must be provided by the panels, multiply it by
1.3 which is the energy lost in the system. Power needed from panel = Total load x 1.3 Power
needed from panel = 746 Wh x 1.3 Power needed from panel = 969.8 W Divide the total power
generated per day from the solar panels by 4.7675 which is the panel generation factor of the
solar panel if it is located in Batangas and the solar panels face directly south, to get the total
Watt-peak rating needed for the PV panels needed to operate the machine. Size of the panel = Size
of the panel = Size of the panel = 203.4189 W Size of the panel = 300 W

Inverter sizing. To calculate the rating of the inverter, it must have the same nominal voltage as
your battery. For stand-alone systems, the inverter must be large enough to handle the total
amount of watts to be used. The inverter size should be 25-30 percent bigger than total watts of
the equipment. Size of the inverter = 746 W (1.25) (2) Size of the inverter = 1865 W Size of the
inverter = 2 kW
Battery sizing. The battery type recommended for use in solar PV system is deep cycle battery.
Deep cycle battery is specifically designed for to be discharged to low energy level and rapid
recharged or cycle charged and discharged day after day for years. The battery should be large
enough to store sufficient energy to operate the appliances at night and cloudy days. To find out
the size of the battery, calculate as follows:

Battery Capacity (Ah) Battery Capacity (Ah) = Battery Capacity (Ah) = 243.7908 Ah

Therefore, the researchers used 2 x 150 Ah deep cycle batteries for the system because these are
designed for solar applications and the rating should be more than the computed rating. Solar
charge controller sizing. Once you have sized your battery bank and solar panel array,
determining which charge controller to use is comparatively straight forward. Find the current
through the controller by using Power = Voltage x Current. Take the power rating of the solar
panels and divide by the voltage of the batteries. Then multiply by the safety factor of 1.25. Size of
the charge controller = Size of the charge controller = Size of the charge controller = 31.25 A
the researchers used 40 Ampere rating of charge controller

3.3-Design Consideration
The considerations that are that are taking in account for designing the machine are:

a) Crop factors, profile (shape, size, and length) and moisture content,
b) Mechanical properties like reliability, rigidity, bend ability, weld-ability, buckling, wear
corrosion, lubrication system vibration and stability.
c) The machine will be manufactured from locally available materials. To insure that
maintainability is secure, assembling and disassembling process must not complex and
easy operation process.

3.4-Detail Design
3.4.1 Design of Hopper
The hopper is design to be fed in a horizontal position .The materials used for the construction is
mild steel sheet metal which is readily available in the market and relatively affordable. The
hopper has the shape of upper and lower rectangular. The upper rectangular is greater than the
lower rectangular.
 Figure 6: Hopper
Assumed that the dimension of the hopper by the following consideration.

 Safe in operation.
 Safe holding capacity of maize.

By considering the upper rectangular dimensions

 Upper length= UL= 600mm= 0.6m

 Upper width= UW= 300mm= 0.3m.

By considering the lower rectangular dimension Lower Length= LL=300mm= 0.3m Lower
width=LW= 100mm= 0.1m.

The height of the hopper= H= 500mm= 0.5m.

The volume of the hopper is calculated as follows.

V = (1/3) * h * ((UL) ^2 * (UW) - ((LL) ^2 * (LW))/ (UL-LL)………………………Equation 1

V = (1/3) * 0.5 * ((0.6) ^2 * (0.3) - ((0.3) ^2 * (0.1))/ (0.6-0.3)
V =O.2178 m^3

3.4.2 Selection of Flywheel

A fly wheel used in machines serves as a reservoir which stores energy during the period y is
more than the requirement and releases it during requirement of energy is more than supply. One
of the biggest issues with regard to flywheels is balancing. Because they are, by intention,
devices with large inertias, balancing them to remove eccentric loading and thus lower the
loading on bearings and other components is very important. ls develop large stresses at their
inter hub connection due to dynamic forces caused by the spinning. These stresses can lead to
failure. Careful design is required to avoid catastrophic failure. In general, the flywheel disc is fit
to provide continuous energy source is discontinuous in such cases the flywheel stores energy
when torque is applied by the energy source stored energy when the energy source is not
applying torque to it.

Figure 7: flywheel
Determination of Flywheel Dimensions

m = b × t × π ×di × ρ……………………..…………………….Equation 2

Where;
m= mass of the flywheel

Di=internal diameter of the fly wheel

t1=Thickness of the flywheel rim

b = Breadth of the flywheel rim=2t

Do=mean or outer diameter of the fly wheel

The internal diameter of fly wheel is greater by the clearance of 2mm that of shaft diameter so
Di=25mm +2mm=27mm and Do=200mm.
10=2t²×π×(0.027)
 2t²=117.89
t²=58.9
t=7.67 say 10mm or safe design. So the breadth of the flywheel
b=2t
=2×10=20mm

The weight of the fly wheel: The material for pulley is cast iron of density 7800 kg/m3 because
of cast iron have the following properties.

 High Tensile strength

 High Compressive strength
 Better Shear strength

To find the weight of the fly wheel

Wf = mf * g, where: mf =mass of fly wheel, g=gravity

But, mf= volume*density=2*ᴨ.A* ρ

A = 2t × t, from the selection of the fly wheel the thickness of the rim is t=10mm so the mass of
the fly wheel
A= 2 ∗ 0.01 ∗ 0.01 = 2 ∗ 10^ − 4
mf= v∗ ρ;
= 2ᴨ ∗ 2 ∗ 10^ − 4 ∗ 7800
= 9.8kg

By approximates to 10 kg it will be designed because it used as a factor of safety. So the weight

of the fly wheel Wf=10*9.81=98.1N

3.4.3 Design of Pulley

The pulley are used to transmit power from one shaft to another by means of flat belt ,v belt,
ropes, the velocity ratio is the inverse ratio of the diameter of driving and drive pulley ,
 Therefore the pulley diameter should be carefully selected in order to have designed velocity

Figure 8: pulley
The best material for pulley is steel because of steel pulley is the following good properties.
 Have good friction
 Good wear resistance
 Have great strength
 High durability
Determination of the Dimension of Pulley : 1. The diameter of the pulley will be obtained from
velocity ratio considerations or centrifugal stress induced in the rim of the pulley
δᵼ=ρν² ……………………….. Equation 3
where ρ= Density of the rim material
= 7200 kg/m3 for cast iron
ν = Velocity of the rim = πdn / 60.................................................. Equation 4
D being the diameter of pulley and N is speed of the pulley.
So to determine the diameter of the pulley given parameters from pedal threshing unit
V1= 68.32 m/s

N1=1740 rpm
D1=750mm
Assume the speed of the motor1:4 (N1:N2) to the speed of the pulley
so:- N1/N2=1/4
1740/N2=1/4
N2=1740×4=6960 rpm
so, D 2=60×V2/π×N2
 So substituting to the above equation
D2=60×68.32/π×6960
D2=0.187m
D2=187mm
From the standard pulley diameter
D2=180mm is appropriate diameter of pulley

2. If the width of the belt is known, then the width of the pulley is taken 25% greater than width
of the belt. B=1.5b Belt width in belt design has gained 40mm. so width of pulley is
WP=40mm+13mm=53mm

3. The thickness of the pulley rim (t) various from

D/200+2mm to d/200+3mm for single belt so, 200/200+2mm to 200/200+3mm=3 to 4mm, so
the maximum thickness of pulley t=40mm.
The weight of the pulley the material for pulley is cast iron of grade 7200 kg/m3 because of cast
iron have the following
properties.
 High Tensile strength = 100 to 200 MPa
 High Compressive strength = 400 to 1000 MPa
 Better Shear strength = 120 MPa
To find the mass of the pulley
M=ρ×ν ………………………………………………….Equation 5
Given parameters from pulley design
D=180mm
WP=53mm, But to find the volume
ν=A×wp, Where V=volume of the pulley A=area of the pulley Wp=weight of the pulley
ν=π×d²/4×wp ν=π×(0.18) ²/4×0.053 ν=1.017×10-3 m3=0.001148m3
So substituting to in equation 3.3 Mp=7200kg/m3×0.001148m3 Mp=8.26kg
So in the manufacturing process by turning method it will be reduced to 8kg by considering safe
operation of the machine.
WP=mp *g, Where mp=mass of pulley G=gravity so the weight of the pulley is
WP = 8*9.81=78.48 N
3.4.4 Design of Threshing Unit
The threshing unit for this design consists of the threshing disc (drum) and the threshing bar or
concave. The discs are connected facing each other and rotate as a block and their surface is to
be grooved and rasp bars so as to provide a rough contact on the maize cob against the spiked
rigid metallic surface .Hence this forced friction results to the threshing of maize kernels from
the cob. Below the threshing unit a collector and spot metallic member is to be fitted and is
designed to incline towards its central longitudinal axis where an opening is allowed for grain
collection as the cobs pass over the member surface towards the exit where they are collected
below the machine.

Figure 9: threshing unit

The threshing disc with the vibrating concave component could increase the shelling e grain
damage and the threshing disc is also made were not made so sharp to avoid the damage of the
maize grain The threshing disc with the vibrating concave component could increase the shelling
made with the edge of the sharp to avoid the damage of the maize grain

This was due to low impact on maize being shelled by using the vibrating concave component
that was attached with a carbon steel spring .in addition ,the viscous elastic properties of the
carbon steel used for hanging the vibrating concave component resulted in more evenly
distributed friction on maize cobs during the shelling process
Determination of the threshing teeth or wire dimension most adapted maize grain sizes in mm

Measured no Grain size in

mm
1 3
2 3.5
3 4
4 4.5
5 5
Table 1: most adopted maize grain size
The diameter of threshing teeth So by considering the above maize sizes the diameter of
threshing wire is D=5 mm
The diameter of threshing teeth So by considering the above maize sizes the diameter of
threshing wire is
Determination of length of threshing wire, Dt=400 mm for large scale of operation system
L=diameter of threshing disc-diameter of shaft/2

L=400-mm-25mm/2=187.5mm

The threshing disc also contains a number of wires teeth arranged by considering the dimension
of the maize. So it is the best that the wire is arranged with a 5mm gap

Figure 10: Threshing disc and bolt (wire)

 Figure 11: Threshing Disc
The weight of the threshing disc The proper material for threshing disc is mild steel with
density of 7860 kg/m3.Because of mild steel have the following properties.

 High tensile strength

 High strength
 Best toughness , So the weight of the threshing disc calculated as follows

Wtd=Vtd*ῥ*g , Where Vtd=volume of the threshing discῥ=density of the threshing disc

material g=gravity

Vtd= π∗ d²*L Where d=diameter of the threshing disc L=length of the threshing disc From the
design analysis of threshing disc the diameter of the threshing disc is 400mm by considering the
manufacturing and operation condition.
v = π ∗ (0.4)² ∗ 0.5

= 2.51 ∗ 10 − ³ m³

And the weight of the threshing disc also

Wtd = 0.00251*7860*9.81
= 193.79 N
 The mass of the threshing disc
m=pv
= 7860N*0.00251m = 20kg

Determination of the Dimension of Concave Bar The concave is designed with 25mm by
15mm hole and 10mm gap holes to deliver the maize grain and to the concave bar it will be
consider the length of threshing wire, the maximum maze grain size and the clearance between
the bar and concave metal. That is

Concaved bar dimension= length of threshing wire+ maximum maze grain size+ clearance

=187.5+80+20 =287.5mm, so the concave bar is concaved by the radius of 287.5mm.

3.4.5 Shaft Design

The shafts which supports the threshing drum and transmit power to it is a back bone having
multiple purpose .It also transmit power to the clearance system that is to the fan and cylinder
crank brush through belt and to the sieve through its cam by pushing the push during cycling
motion .so to select proper material for this component ought to consider the following
properties:

 Should have good machine-ability

 High strength
 Good wear resistance
 Low notch sensitivity factor

This shaft is subjected to bending stress due to the drum load and the tension or reaction at both
end, further it is subjected to shear due to the transmission of torque or torsion load .The load of
the shaft itself is also taken in consideration for the bending stress evaluation .so that shaft is
subjected to combined twisting and bending load.
 Figure 12: pulley, threshing disc and flywheel on the shaft

Figure 13: all loads on the shaft

All loads act on the shaft
Wtd = weight of the threshing disc
Wp = weight of the pulley
Wf = weight of the flywheel
F= t1-t2 = the difference in tension on the tight side and slack side of the belt

The material used for shaft should have the following properties.
 It should have high strength.
 It should have good Mach inability.
 It should have low notch sensitivity
 It should have high wear resistance.
The material used for ordinary shaft is carbon steel grade 40c8, 45c8, 50c4 and 50c18.
The mechanical properties of those grades of carbon steel are given in the appendix A2
The material selected is carbon steel 40c8 and with yield strength of 320Mpa and σu=5609 Mpa
Indian standard Ultimate tensile strength, Yield strength, Mpa
destination Mpa
40c8 560-670 320
45c8 610-700 350
50c4 640-760 370
50c12 700MIN 390

Now to calculate the diameter of the shaft the following parameters and calculated values are set
first.
Length of shaft, L=950mm (from geometry)
Power=2.5Kw at 1740rpm
So torque, T= P/w, where w= angular velocity & Where, N=speed in rpm and P=power
w=2*П*N/60
w=2*П*1740rpm/60
w=182.2rpm
Then, T=2.5Kw/182.2
T=13.72Nm
The maximum shear stress on the shaft

Given values from material selection

By Substitute the value in eqn………………………………………

So it can be find the distribution force acted on the shaft as follows

Wtd=193.7
L=550mm
Distribution load=193.79N/550mm=0.352n/mm

So the reaction forces calculated as follows

Total up ward force=Total down ward force

RA+RB=278.48+352.2+98.1
=
And taking moment about B

RA*0.55+98.1*0.2-478.48*0.75-352.3*0.75=0
RA=1097N

3.4.6Design of Mainframe
The metal frames used are angle iron bars. This type of frame is used for various purposes in
Engineering industry; it is also known as L-shaped frame. The material used for the frame is
mild Steel. It has carbon ranging from 0.10-0.20%, Tensile strength is 420 N/mm2. The frame is
used as the main structure, which supports the magnetic assembly. It also supports the collector
and the shaft having pulley, fly wheel and threshing disc. The metal plate-carrying shaft is
welded to the frame. The metal frame is cut as per the requirements and then they are welded.
The two design factors will be considered in determining the material required for the frame is
weight and strength.
Design of Angles: - Due to the load of plate, job and filing force, the angle-link may buckle in
two planes at right angle to each other. For buckling in the vertical plane (i.e.in the plane of the
Links), the links are considered as hinged at the middles and for buckling in a plane
Perpendicular to the vertical plane, it is considered as fixed at the middle and the both the ends.
Here, The maximum load due to above factors = 81kg (including friction) F= 81x 9.81 = 794.61
N. We know that the load on each link, F1 = 794.61/4 = 198.652N. Assuming a factor of safety
As 4, the links must be designed for Crippling load of Wcr = 199x 4 = 796N Let t1=
Thickness of the link b1= width of the link so, cross sectional area of the link = A = t1x b1
Assuming the width of the link is three times the thickness of the link, i.e.b1= 3 x t1 Therefore
A= t1x 3 t1 = 3 t1² and moment of inertia of the cross section of the link, I = 1/12 t1b1³ =
1000/12t1× (3t1)³=3.08t1⁴
We know that I = AK², where k = radius of gyration.
K² = I/A = 3.08t1⁴ / 3 t1² = 1.02t1²Since for the buckling of the link in the vertical plane and the
ends are considered as hinged.
Therefore, the equivalent length of the link L = l = 1000 mm. And Rankin’s constant, a = 1/ 7500
Now using the relation, F and A
Wcr = 1 + a (L / K) ²
Where;
Wcr = Crippling load
L=length of bar
K=radius of gyration
a=rankine constant
By substituting from the above equation
796= 1 + (1 /7500) (800/1.02t1)²
796=1+46.13t1²
796=46.13t1²
t1²=17.225
t1=4.153
So
b1=3×t1=3×4.153=12.461.But the standard angle available of 35x 35 x 5 mm. Hence
considering the safety aspect it has been selected. This can bear the impact loading. Hence the
design is safe.

Figure 14: Main Frame

3.4.7 Selection of Bearing

A bearing is a machine element which supports another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while
carrying the load. To select the bearing for this design that is considered the diameter of shaft.
All the dimensions have been standard on an international basis. Radial ball bearing has been
selected because by considering the following advantages.
 Accuracy of shaft alignment.
 Easy to mount and erect.
 Reliability of in service.
 Cleanliness.
 Small in overall dimensions.
  Low cost of maintenance
 No lubrication is required while in service
 Ability to with stand momentarily shock loads

Figure 15: Roller (Radial) ball bearing

The following table shows the principle dimensions of radial ball bearing number
From the table A5 the dimensions of the bearing selected by considering the diameter of shaft is
as follows
Bearing number: 205
Bore diameter (mm):26mm because by considering shaft diameter
Outside diameter: 52mm
Width (mm):15mm
Determination of static load and dynamic load on the bearing
The static load is calculated in the design of shaft that is
Ra=297.02N=0.297KN
Rb=268.18=0.268KN
The Dynamic Loads

Fcp = mprpwp
Fcd=mdrdwd² and
Fcf=mfrfwf
Where Fcp= Centrifugal force on the pulley
Fcd= Centrifugal force on the disc
Fcf= Centrifugal force on the flywheel
mp =mass of the pulley
md= mass of the threshing disc
mf= mass of the flywheel
r=radius
w=angular velocity in rpm which is N2=464rpm
So
Fcp=8×0.09×464²=155013.12N=155.013KN
Fcd=20×0.2×464²=861184N=861.184KN
Fcf=10×0.1×464²=215306.1N=215.306KN
The dynamic reaction is
Ra¹+Rb¹= Fcp + Fcd + Fcf =155.013+861.18+215.306
Ra¹+Rb¹=1231.503 KN ………………………..equation a
+ve ƩM B=0
Fcp×0.75+Fcd×0.275-Ra×0.55-Fcf×0.2=0
155.01×0.75+861.184×0.275-Ra×0.55-215.306×0.2=0
-0.55Ra=-310.021
 Ra=563.676KN so by substituting in to equation a
-563.676+Rb¹=114.8KN
Rb=678.476KN
Therefore the dynamic loads are
RA¹=563.676KN
RB¹=678.476KN
The maximum and minimum loads on the bearing; And will be determined when the line of
action of the dynamic load coincides with that of the static loads.

The maximum load on bearing A: = Ra + Ra¹=0.37+563.67=564.01KN

The minimum load on bearing A: =Ra-Ra¹=0.37-563.67=-563.30KN
The maximum load on bearing B=Rb+Rb¹=0.14+678.47=678.616KN
The minimum load on bearing B=Rb-Rb¹=0.14-678.47=-678.336KN

3.4.8 Selection of Belt Drive

The belt is used to transmit power from one shaft to ano another or one pulley to another pulley
by means of pulleys which rotates at the same speed or at different speed we have select the belt
drive according to the following importance factors :
1. Speed of driving and driven shaft
2. Power to be transmitted by
3. Center distance between the shaft
4. Positive drive requirement
5. Shafts layout
6. Service condition
 We have select a flat belt because flat belt has a moderate amount of to be transmitted from
one pulley to another when the two pulley are not more than 8 meters apart
.1), p, 678

The material used for flat is leather .the flat belt has two sides the hair side and the flesh side, the
hair side of the leather is smoother and harder than the flesh
The dimension of the belt is calculated as follows:

 The length of the belt

 And the width of the belt

The standard flat belt thickness is 5, 6.5,8, 10 and 12mm.the preferred values of thickness are as
follows.
A, 5 mm for nominal belt width of 35 to 63mm
B, 6.5mm for nominal belt width of 50 to 140mm
So we have select 5mm thickness and width of 40mm by considering the cost and safe in
operation. [1]

3.4.9Proportion of Key
For a good design result the width of the key is made one-quarter of the diameter of the shaft and
the length of the shaft is made half of the diameter of the shaft .The thickness of the a key for
equal strength of the key in failure by shearing of the key and compression on the key may
shearing is determined by the corresponding allowable stresses in shear and compressions.[1]
The length of the key can be calculated as
L=E2
=1.57d………………………………………equation 3.23
Where, d =diameter of the shaft
The forces on the top and bottom of the key resist tipping of the key, and the force F between the
side of the key and the key way in the hub is due to the resisting torque.
T’=FE2
………………………………………………….equation 3.24
Where T’=resisting of torque
F=resisting force
d=diameter of shaft
L=length of key
We have select rectangular sunk key for safe in operation. The sunk key are provided half in the
key way of the shaft and half in the hub or boss of the pulley.
Usual proportion of the sunk key
1 .The width of the sunk key
The dimensions are calculated as follows
 The length of the sunk key

3.4.10 Design of Collector

A collector or a spot is made with available material within the environment like sheet metal by
welding process. The main purpose of this collector is to collect all the grains that deliver in to
collector chamber and out with a small hole for safe operation. The determination of the
dimension is based on the frame dimension.
 Figure 16: Collector
For safe operation the dimension will give as follows by considering the dimension of the
machine.
θ=45◦
W=800mm
L= 1200mm
H=600mm
t=3mm
3.4.11Analysis and Selection of Fan
A fan consisting of a rotating impeller, blade and energy transfer in to the grain and straw or dust
mixture fall dawn perpendicular to the axis of fan shaft. The feed into the grain trough the un-
wanted particles called forced draft. So based on the arrangement of threshing shaft and fan
shaft, the fan type should axial having the following merits over centrifugal fan have presser
rating of 4:1, for simple machine unless multi stage is used at an efficiency of (70_80)%.
As khoshtaghaza and Mehdizadeh (2006) excrementally determined. the velocity of air flow to
separate grain and straw should be less than 7.04m/s and more than 4.85m/s. here it is better the
speed to be 6m/se , to prevent weak grains flow with straw and some heavy straws may fall with
grain, there for, moderate speed of air is recommended. At the exit end the speed of impeller
speed to be found 40 or 36m/s. take 40m/s(see in the design of fan, shaft, and polar in section
3.4.2 in detail)
Specific the gravity of maize=780_800kg/m3/ ρwater=280/1000-800/100, specific gravity
S.G=0.78_0.8 (see geometric analysis)
Density of cracked maize=673kg/m3 so specific gravity=0.673

Density flow maize =590kg/m3 and S.G=0.59

We have length of the grain = (4 up to 10mm)

Width of grain=2.5 up to 4.5mm
Unit grain mass=30 up to50miligram.
Now, ρ=m/v, v=ρ/m where v=volume the grain of straw
Ρ=density

M=mass of unit grain

For the average mass of unit grain

M=30+50/2=40miligram, ρ mean=780+800/2=790kg/m3
And v=40miligram *10-6/790kg/m3=5*10-8m3=50.25mm3
The inner velocity of straw chat as well as fan
U1= r1w
U2at blade =r2w
Straw exit out let area = 620.7x300 = 186000mm2, we go the value from sieve width or cylinder
outer diameter and fan diameter respectively air velocity exit =40m/s
Therefore the volume flow rate (Q) = A*V=15.4m3/s the area of suction end is given by
Q=AXV, A=0.38m3, V=6m/s therefore air volume flow rate at suction QS=AXV= 6m/sx0.38=
2.3m3 pressure head Ph =V*ϒ where ϒ=specific weight=head through the suction=volume
W = weight, ρ= density of straw, ϒ= ρ*g=9.83x590kg/m3 =5793.8kg/m3 the head (H) =drum
length +cam and frame thickness clearance between cam and frame and the diameter drum
=800mm+20mm+26mm+5mm+5mm=856mm
Therefore: PH=5793.8X0.856=4959kpa
The 101.325kpa atmospheric pressure is now increase to 4959kpa at exit of straw

3.4.11Design of Wheel
The wheel is used in this design project to move all the body of the machine one place to another
Place .The wheel must be designed or select by considering the following parameter:-
  It must be resist total load of the machine
 It must have high strength
 It must have low friction

Fig 3.22 Wheel

3.4.14.1 Determination of Wheel Dimension

The dimension of the wheel is determined by considering the diameter of shaft and by
considering the height of the machine that means the height of the machine is not greater than
1500 mm and by considering appropriate or safe transportation of the machine. So by
considering those:
Where
d=internal diameter
D=outer diameter
Internal diameter
The internal diameter is determined by the diameter of the shaft. So it is only greater than by
Minimum clearance of 1mm both sides.
So
di=30+2=32mm
Outer diameter
Let assume the outer diameter is five times the inner diameter.
So
Dout=5di
=5×30
=150 mm

3.5 Determination of Threshing Force

To aid the rotary motion the better disc or threshing unit the force to be applied to move the
pedal tangentially is calculated while putting in to consideration the mass of the fly wheel (mf)
mass of pulley (mp), mass of threshing disc (mtd), and mass of the shaft and other consideration
of mass (mo).
For our design those components of mass are estimated as follows:
Mf=10kg, Mp=8kg, mtd =20kg, Ms=5kg, Mo=2kg so that the total mass act on threshing unit is
Mt=10+8+20+5+2=40kg
The threshing force is calculated as follows:-

3.7 Cost Estimation

Cost estimation may be defined as the process of forecasting the expenses that must be incurred
to manufacture a product. These expenses take into a consideration all expenditure involved in a
design & manufacturing with all related service facilities such as pattern making, tool, making as
well as a portion of the General Administrative & selling costs.
The following table shows the name of component, quantity, unit cost in birr and total cost in
Birr of the machine
 no Name of component Quantity Unit cost in Total cost in
(birr) (birr)
1 Hopper
2 Main frame
3 Shaft
4 Pulley
5 Flywheel
6 Bearing
7 Belt
8 Threshing unit
9 Collector
10 Wheel
11 Solar panel
12 Rechargeable battery
13 Charge controller
14 Solar inverter
sum

Table 2

Chapter Four: Result and Discussion

The major results of each component that was obtained from the detailed analysis are listed in
the following table.

Part nane Dimension in(mm)

length Diameter width Speed Thickness in mass Force or
in rpm (mm) power

Main frame
belt
Thrashing
shaft
collector
drum
sieve
hopper
 Pulley
bearing

Table 3

 In addition to these we have

 An motor in put power of 2.5 kw
 Total height of the machine 1500mm and total width of the machine
 Size of the panel =300w
 Size of the inverter=2.5kw
 Motor speed= 1740rpm

Discussion
The values set in the above table are the basic parameters which are used to assemble the machine and to
manufacture it. The motor power is safe to thresh the maize, since it requires less power than this input
power. The component dimensions are expressed based on the values that we got from the calculation and
from standard specification of elements from tables, the speed rate fan is safe because it is selected based
on the mass, density of the slug and corn.