BMS Institute of Technology Management Avalahalli Doddaballapura Main

BMS Institute of Technology & Management, Avalahalli, Doddaballapura Main Road, Yelahanka, Bangalore -560064 Design and Fabrication of Solar Powered Sugarcane Cutting Machine. Department of Mechanical Engineering. By, A. S. NAVEEN (1 BY 11 ME 001) NAVANEETH. M (1 BY 11 ME 037) PRAJWAL. L (1 BY 11 ME 040) ASHWIN. K (1 BY 11 ME 069) Under the Guidance of, Dr. A. V. SURESH Professor, Dept. of Mechanical Engineering, B. M. S. I. T & M

WHY SOLAR POWERED SUGARCANE HARVESTER ? Solar energy has many advantages like • • • It’s free, clean and infinitely renewable It’s extremely reliable. Reduced Dependence on Fossil Fuels. Environmental Advantages Flexible Locations Government Incentives In today’s competitive world there is a need for faster rate of production of agricultural products. Agriculture is the backbone of India. In India almost all farmers are facing shortage of labour. Labour wages are increasing and demand for the agricultural products is also increasing. The project aims to design and fabricate small scale sugarcane harvesting machine for sugarcane harvesting to reduce farmer’s efforts and to increase production. When compared to manual harvesting by using the machines can be cut at a faster rate and it is economical. India being THE SECOND LARGEST PRODUCER of SUGARCANE it is suitable for both small and big farms.

OBJECTIVES • Usage of solar power. • Can be implemented in the rural and remote areas where electricity is not available continuously. • Faster technique of sugarcane harvesting with minimal labour requirements.

LITERATURE REVIEW. • • In India agriculture has been facing serious challenges like scarcity of agricultural labour, not only in peak working seasons but also in normal time. This is mainly due to increased non-farm job opportunities having higher wage, migration of labour force to cities and low status of agricultural labours in the society. Sugarcane is the world’s largest crop 2010 Food Agricultural Organization (FAO) estimates it was cultivated on about 23. 8 million hectares in more than 90 countries, with a worldwide harvest of 1. 69 billion tons. Brazil was the largest producer of sugarcane in the world and India in second position. Harvesting is a process of cutting and gathering of mature crop from the field. Different types of harvesting machines are available in the market namely paddy harvester, Tea harvester, Potato harvester, Wheat harvester and sugarcane harvester as mentioned above all are available in small scale except sugarcane harvesting machine. Sugarcane harvesting is an agricultural machinery use to harvest sugarcane. Sugarcane can be harvested by hand or mechanically. In world the usage of agriculture equipment is increasing. In the usage of agriculture equipment’s, India contributes only 10% as shown in Figure 1 Conducted survey in year 2012. Figure 1 : World Agricultural Equipment Market Two types of harvesting methods are there : • Manual method • Mechanized type of harvesting In Manual Harvesting to cut one acre of sugarcane 15 -16 labours are required they take 3 days to cut one acre and involves harvesting of 60 -70 tons per acre with labours being paid 500550 Rupees per ton of harvest hence total cost of harvesting per acre comes up to 30, 000 -35, 000 Rupees. Due to mechanization by using large scale harvesting machine it takes about 6 -7 hours for harvesting one acre averaging about 60 -70 tons with labour costing around 3, 500 -4, 000 Rupees per hour hence the total cost of harvesting per acre comes up to 20, 000 -25, 000 Rupees

RESULTS ANALYSIS The Result is analyzed by comparing manual, small scale harvesting machine and large scale harvesting machine. Number of hours required to cut one acre Number of Labours. Total cost of Harvesting/Acre in rupees Wages/Ton/Labour in Rupees. By using this machine the problem of the labour crisis can be reduced. Comparing with the manual harvesting only 18% of labours are required. It makes the process faster hence reduces most of the harvesting time and labour required to operate the machine is also less.

Methodology Concept Design Specifications Part Drawing. Assembly. Testing. Yes. Conclusion No

CAD MODEL . ISOMETRIC VIEW.

PART DESIGN BEARING

CHASSIS

CUTTER

PULLEY

BOLT

NUT

Solar panel Bevel Gear

DESIGN FEATURES Blade cutting speed – 500 RPM DC motor specifications • Power-0. 25 KW • Voltage- 12 volts • Rotation- clockwise • Current- 50 amp • RPM- 600 The minimum requirement of the blade speed for effective cutting of the sugarcane is around 500 rpm based on torque calculations. DC motor with a rated speed of 600 rpm is employed to cut evenly. Battery specifications • Voltage- 12 volts • Current- 55 amps • Dimensions- (W*L*H)= 175*270*190 mm • Weight- 13 KG Battery used is to the nearest standard voltage rating available readily in the market used to collect the solar energy. Solar panel specifications • Peak power- 30 watts • Maximum power voltage- 17. 5 V • Max power current- 0. 57 amps • Open circuit voltage- 21. 6 V • Dimensions-(Lx. Wx. T)=610 x 655 x 34 mm • Weight- 4. 3 kg Minimum wattage required to charge the battery and perform the cutting operation.

Chassis specifications • Dimensions ( L X W X H ) : 105 X 45 X 30 • Material : mild steel rods The chassis specification is designed with respect to the layout of sugarcane farming. The dimensions enable the harvester to move easily through the sugarcane fields. Pulley specifications • Total pulleys used : 1 • Pitch diameter : 10 mm • Outer Diameter : 25 mm • Bore : 17 mm Cutter specifications • No. of teeth : 40 • Diameter : 203. 2 mm • Thickness : 4. 5 mm • Bore : 25. 4 mm For better durability and reliable operation the above specified T. C. T cutters are employed to resist chemical nature of the juices from the canes. Frame specifications • Material used : Mild steel • Length : 760 mm • Height : 310 mm • Width : 465 mm Wheels used • Diameter : 522 mm • No. of wheels : 2

The wheels were selected for a suitable height for easy handling and manoeuvring of the vehicle without much effort. A small wheel placed in the front helps the labour to change directions. Safety measures. For the safety of the workers from the cutters a thick aluminium sheet is added behind the cutters onto the chassis as a safety feature.

Block diagram of the Mechanism Involved. SOLAR ENERGY BATTERY D. C. MOTOR PULLEY (BELT DRIVEN) HORIZONTAL SHAFT BEVEL GEARS VERTICAL SHAFT CUTTING ACTION

RESULTS Test was conducted which got a following result • Time required for completely charging the battery by solar energy is estimated on a normal sunny day is around 18 -20 hours. • The fully charged battery supplies power to motor for nearly 12 hours and with additional simultaneous charging it will nearly work for 13 to 15 hours. • Time required to cut sugarcane is approximately 2 -5 seconds. Thickness or diameter of the stalk is also a factor which directly affects the cutting time. • Time required to cut an acre of sugar cane plot on an average is around 8 -9 hours. • It reduces labour cost and time considerably. The farmer can himself cut the sugarcane without wasting much time and effort. • It is innocuous compared to other present available methods. As the other methods are either costly or complicated or harmful effects on environment. • The stalk of the sugar cane to be cut ranges from 0. 75 to 2 inches in diameter. • An average force of 106. 5 N is sufficient to cut the average sized sugar cane minimal force applied.

Comparison of various parameters for different sugarcane harvesters. [For a Standard One Acre Plot Size] SL PARAMETER NO. S 1 Time for harvesting. (per MANU USING an USING SOLAR AL ENGINE POWER 3 -4 days 10 -12 hours 14 -16 hours. 15 -16 labours 2 to 3 labours. acre) 2 Number of labours. 3 - 30, 000 25, 000 30, 00035, 000 3000 -4000 Nil Low High Comparatively Higher 800 -1200 Cost of Machine 4 Cost of operation. (Rs) 5 Rate of Productivity 6 Maintenance . (Rs) - 1500 -2000

Physical model

SCOPE OF FUTURE WORK • The equipment can be improvised by incorporating a automatic stalk holder during cutting process for effective cutting and collecting process. • Use of solar tracking system for maximum use of available energy and thereby improving the efficiency of the machine. • Use of additional engine or an electric motor to facilitate the mechanized motion of machine during cutting. • Gearbox /stepped cone pulley to achieve variable speeds depending average size of the stalk to be cut in the plot. • Use of pneumatic actuators to vary the height of the cutters depending on the requirements of stalk • Provision for electrical charging along with solar power to charge the batteries can be employed. • The rate of charging and discharging using digital indicators can be installed on the system so that the amount of power consumed can be controlled

REFERENCES. • DESIGN AND FABRICATION OF SMALL SCALE SUGARCANE HARVESTING MACHINE Adarsh J Jain 1, Shashank Karne 1, Srinivas Ratod L 1*, Vinay N 1 Thotad and Kiran ISSN 2278 – 0149 www. ijmerr. com. Vol. 2, No. 3, July 2013© 2013 IJMERR. • Status Paper on Sugarcane DIRECTORATE OF SUGARCANE DEVELOPMENTGOVT. OF INDIA, Ministry of Agriculture, (Department of Agriculture & Cooperation)8 TH FLOOR, KENDRIYA BHAVAN, ALIGANJ, LUCKNOW (UP) • Design of Sugarcane Harvesting Machine IJIRST –International Journal for Innovative Research in Science & Technology| Volume 1 | Issue 11 | April 2015 ISSN (online): 2349 -6010 • REVIEW PAPER ON DIFFERENT ASPECTS OFSUGARCANE HARVESTING METHODS FOROPTIMUM PERFORMANCE International Journal of Research in Engineering and Applied Sciences (IJREAS) SUGARCANE HARVESTER TECHNOLOGY: A CRITICAL OVERVIEW S. Ma, M. Karkee, P. A. Scharf, Q. Zhang • DESIGN DATA HANDBOOK for Mechanical Engineers by K. Balaveera Reddy and K. Mahadevan 4 th edition.

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