MINI CORN SHELLER MACHINE

OPERATED MANUALLY OR

POWER GENERATED

A RESEARCH PROPOSAL

Presented to the Faculty

of the College of Engineering

Cebu Technological University - Main Campus

M.J. Cuenco Ave., R. Palma St., Cebu City

In Partial Fulfillment

of the Requirements for the

Degree of Bachelor of Science in Mechanical Engineering

By:
Bardoquillo, Ma. Isabel Rose I.
Caraca, Aaron James
Doble, Reynaldo B.
Fortaliza, Janley R.
Inot, Joel Jr. Q.
Labang, Alfred Eve C.
Pino, Raffy Roy B.
Tasong, Jessie G.

October 2016
 APPROVAL SHEET

This THESIS entitled “MINI CORN SHELLER MACHINE OPEARATED MANUALLY OR

POWER GENERATED” prepared and submitted by Ma. Isabel Rose I. Bardoquillo, Aaron James Caraca,
Janley R. Fortaliza, Reynaldo B. Doble, Joel. Q. Inot Jr., Alfred Eve C. Labang, Raffy Roy B. Pino, and
Jessie G. Tasong in partial fulfillment of the requirements for the degree Bachelor of Science in Mechanical
Engineering has been examined and approved for oral defense.

THESIS COMMITTEE

JONATHAN A. MIRABALLES, ME, MSIT

Chairman

JUN-JUN OBISO, ECE EDGAR C. AMBOS, ME, MEng, Ph.D.

Member/R&D Chairman COE Member/Professor

CLARO M. CELERIO, ME, MSME TERESITA CAPIN, IE

Member Member

HERMINIO P. NAVARRO, PME, MSIT

Adviser

THE PANEL OF EXAMINERS

JONATHAN A. MIRABALLES, ME, MSIT

Chairman

JUN-JUN OBISO, ECE EDGAR C. AMBOS, ME, MEng, Ph.D.

Member/R&D Chairman COE Member/Professor

CLARO M. CELERIO, ME, MSME TERESITA CAPIN, IE

Member Member

HERMINIO P. NAVARRO, PME, MSIT

Adviser

Accepted and approved in partial fulfillment of the requirements for the degree BACHELOR
OF SCIENCE IN MECHANICAL ENGINEERING.

NOLASCO K. MALABAGO, ME, Ph.D.

Dean, College of Engineering
 ACKNOWLEDGEMENTS

This success couldn’t be turned to reality without these following persons who help the

researchers and the research in different ways.

First and foremost, our deepest gratitude to the Almighty God who always guide and light

our way as we go along with the research process.

To Hon. Herminio Navarro, as our Research Project Design Adviser, we are very honored

to have you as part of our journey to make this study possible. With your assistance, intelligence,

patience and perseverance, we are very much thankful.

To Dr. Edgar Ambos, as our Project Study 1 & 2, Professor, thank you for the guidance

and moral support. To all your words of wisdom and encouragement to do things as possible as

we can, we thank you.

A wholehearted love and thanks to our family who are always there to support and finance

us in what we need; we very much appreciate your care and concerns. To our friends who serve as

part of the family, thank you too.

Special thanks to the family of Raffy Roy Pino, one of the researchers, for the

accommodation, foods and letting us stay in their house for a night and a day.

And to all who expressed their support, may God Bless You all.
 TABLE OF CONTENTS

Page

APPROVAL SHEET ii

ACKNOWLEDGEMENTS iii

TABLE OF CONTENTS iv

LIST OF FIGURES vi

LIST OF TABLES vi

CHAPTER 1: THE PROBLEM AND ITS SCOPE 1

INTRODUCTION 1

Rationale of the Study 2

Theoretical Background 5

Conceptual Framework 8

THE PROBLEM 9

Statement of the Problem 9

Significance of the Study 10

Scope and Limitations 10

RESEARCH METHODOLOGY 11

Research Design 11

Research Environment 11

Research Respondents 12

Research Instruments 12

Data Gathering Procedure 12

 Treatment of Data 13

Page

Scoring Procedure 14

Definition of Terms 15

CHAPTER 2: REVIEW OF RELATED LITERATURE AND STUDIES 16

CHAPTER 3: PRESENTATION, INTERPRETATION AND DATA ANALYSIS 18

Design Calculations 18

CHAPTER 5: OUTPUT OF THE STUDY 27

Prototype Design 27

Operation and Maintenance Manual 37

REFERENCES 39

APPENDICES 40

Appendix A Bill of Materials 40

Appendix B Gantt Chart 41

Appendix C Survey Questionnaire 42

Appendix D Compliance Checklist 43

CURRICULUM VITAE 44
LIST OF FIGURES

Page

Figure 1: Structure of Corn 3

Figure 2: The rasp-bar cylinder concave sheller 6

Figure 3: Schematic diagram for the cross section of a corn ear,

cylinder and concave showing the forces on the ear 7

at the beginning of the shelling. (Waelti, 1967)

Figure 4: Conceptual Framework of the Study 8

Figure 5: Map of Fortaliza, Tuburan, Cebu 11

Figure 6: Corn Fields of Brgy. Fortaliza 11

LIST OF TABLES

Page
Table 1: Survey Data Evaluation
13
Table 2: Qualitative Interpretation
14
Table 3: Bill of Materials
40
Table 4: Gantt Chart
41
Table 5: Compliance Checklist
43
 CHAPTER 1

THE PROBLEM AND ITS SCOPE

INTRODUCTION

Modern crank-operated corn sheller machine invention is widely attributed to Mr. Lester

E. Denison from Middlesex County, Connecticut. On 12th of August 1839, Denison was issued a

patent for a freestanding, hand-operated machine that removed individual kernels of corn by

pulling the cob through a series of metal-toothed cylinders which stripped the kernels off the cob.

This marks a change for harvesting kernels as dozens of other patents were filed later on that

century.

Since the introduction of the modern corn sheller in the 1800's, the basic design and

function of this machine has remained the same with most modern-day corn shellers bearing a

stronger semblance to the original models designed by inventors like Denison and Briggs.

In today’s industrial world man’s innovative ideas has taken towards all directions

concerning about the production and safety in industrial establishments. Some instruments are of

shear excellence whereas others are the result of long research and persistent work, but it is not the

amount of time and money spent in the invention of device or the sophistication of the operation

is important, but its convenience, utility and operational efficiency that are important in

considering the device. (Wanjala, 2014)

Rationale of the Study

Corn is second to rice as the most important crop in the world, with billions of farmers

depending on corn as their major source of livelihood. It provides nutrients for humans and animals

and serves as a basic raw material for the production of starch, oil and protein, alcoholic beverages,

food sweeteners and, more recently, fuel. It is because of the important place of corn that it’s

handling, processing and preservation within the optimum conditions must be analyzed.

The major steps involved in the processing of corn are harvesting, drying, de-husking,

shelling, storing, and milling. All these processes are costly and for the rural farmers to maximize

profits on their produce, appropriate technology that suites their needs must be used. Corn

processing not only prolongs its useful life but also increases the net profit farmers make from

mechanization technologies. It is in this line that one of the most important processing operations

done to bring out the quality of corn is de-seeding of corn. It is basically the removal of the corn

kernels from the cob. This separation, done by hand or machine, is obtained by shelling, by friction

or by shaking the products; the difficulty of the process depends on the varieties grown, and on the

moisture content as well as the degree of maturity of the grain. (Wanjala, 2014)

According to industries, though corn is the preferred feed-grain by local end-users. Quality

issues are commonly associated with locally produced corn, and most feed-mills prefer imported

corn for its reliability and uniformity in quality. Source: (Grain and Feed Annual Manila

Philippines, 3/15/2016)
 Cob

Figure 1: Structure of Corn

The Municipality of Tuburan is located northwest of Cebu Province. It is a town with

sources of livelihood in both fishery and agriculture. Brgy. Fortaliza is only one of the 54

barangays under the Municipality of Tuburan with planting corn as their livelihood. Upon

observation, the uptake of modern farming machinery in this town is next to nothing. The farmers

prepare their hectares of land by driving carabaos not tractors which is far more suitable and they

also harvest their corn kernels by hand, while others with simple tools like knives resulting to a

very damage product. This is a problem this research aims to resolve.

Besides, the cost of purchasing shellers are high for the rural farmer and therefore call for

the need of a relatively low cost corn shelling mechanism that will be affordable to such farmers
not only to meet their shelling requirement but also to improve the shelling efficiency and reduce

damage to the seed.

With this project of Mini Corn Sheller Machine Operated Manually or Power Generated,

farmers could garner some advantages. The uniqueness of this machine is, it can either be manually

operated or be electrically operated, which is not the case of present corn sheller sold in the market.

Aside that the machine is designed to harvest with higher efficiency in terms of quality kernels

produce, it is also easily transferrable from one place to another. In times of electrical shortage its

dual operation will surely come in hand so not to delay the harvesting therefore avoiding losses.

Also, direct harvest of shelled corn has been accompanied by severe kernel damage that’s

why the economic importance of reducing shelling damage has lead to the objectives of this

research:

1. To design, construct, and test a low-cost corn de-seeding machine,

2. To evaluate the efficiency of the constructed corn de-seeding machine,

3. To use the corn de-seeding machine in establishing an agro-processing center for rural

farmers in Tuburan.

Theoretical Background
 Several theories have been developed for the purpose of explaining the shelling process. In

formulating a theory descriptive of the actual shelling process, a dynamic analysis of the problem

should be implied. However, because of the complicated structure of the ear and the heterogeneous

nature of the corn, most researchers have resorted to a quasi-static approach using an idealized

model. Some experimental work has also been done in an attempt to extend these theories into the

dynamic range by using simple impact loading tests.

Cylinder-concave sheller is a shelling mechanism that consists of a cylinder and a concave.

The corn is shelled by the impact of bars on the periphery of the cylinder as the corn is fed between

the cylinder and the concave bars. The most common type of cylinder bar used is the rasp-bar.

These bars were shown to cause less damage than an angle-bar type cylinder (Pickard, 1955).

The concave assembly nearly conforms to the periphery of the cylinder. It forces the corn

to be in contact with the cylinder through about 90 degrees of cylinder rotation. The concave bars

are channel, rectangular, or half round in shape and are oriented parallel to the cylinder axis. The

severity of the shelling action is controlled by the cylinder speed and the cylinder to concave

clearance. The severity of the shelling action determines the amount of un-shelled corn remaining

on the cob and the level of kernel damage. Cylinder adjustments are a compromise between high

speeds for kernel removal and low speeds for reduced kernel damage. Reducing the concave

clearance also increases the thoroughness of shelling and the level of kernel damage.

Kernel moisture content is another factor that has a great influence on kernel damage

(Hopkins and Pickard, 1953; Barkstrom, 1955; Goss et al., 1955; Pickard, 1955; Fox, 1959; Brass,

1970; Hall and Johnson, 1970; Mahmoud, 1972). These 11 researchers reported that mechanical

kernel damage increased rapidly with increasing moisture content over approximately 20%.
However, corn shelled at moisture contents considerably below 20% moisture also suffered high

levels of damage. Minimum kernel damage was generally found to occur at kernel moisture

contents of 18 to 22%.

CYLINDER FILLER PLATE

CYLINDER RASP BAR

CYLINDER SHELLING BAR

CONCAVE GRATE

Figure 2: The rasp-bar cylinder concave sheller

 Waelti (1967) presented a theoretical analysis of the process of corn shelling in the
conventional combine cylinder. He analyzed the forces applied to the kernels on the kernel as they
are struck by the rasp-bar. The rasp-bar applies a force P (Figure 4) as it strikes the kernel. This
force tends to push the kernels toward the center of the cob and at the same time rotate the kernel
in the clockwise direction, moving it laterally to the right. The moment la and the force Ma oppose
rotational and lateral accelerations, respectively. The concave reaction is believed to be somewhat
smaller than P because part of P is used for accelerating the kernel. Therefore, it can be assumed
that shelling occurs first in the top section of the ear with larger forces on the kernels.

Figure 3: Schematic diagram for the cross section of a corn ear, cylinder and concave showing

the forces on the ear at the beginning of the shelling. (Waelti, 1967)

Another factor in a mechanized system is the size of the corn cob. The mechanical shellers
need to be adjusted to the various sizes of cobs ranging from 50mm to 85mm depending on the
variety. There are also engineering design factors that affect the design of mechanical shellers.
These factors are the design of the power transmission shaft, key, selection of the prime mover,
type of pulley, appropriate chain drive design and selection of appropriate bearings support.

Conceptual Framework
 Manual Operated Power Generated

Corn Sizes
Consideration Effective Manual Dynamic Analysis
and Power
Cylinder Generated Moisture Content
Concave Design Operation

Corn Sheller
Machine

Figure 4: Conceptual Framework of the Study

THE PROBLEM
 Traditional method of corn shelling in the Municipality of Tuburan is by use of hand or

with hand held simple tools which is laborious, time consuming, causes loss of grains and has a

very low output.

Statement of the Problem

The researchers’ will address the following problems:

1. What corn de-seeding method is more convenient to the farmers?

- Manual (by hands)

- Manual (by tools)

- Power Generated

2. What design concepts are necessary for the machine in terms of:

- Corn sheller design

- Electric motor specifications

- Manual operation

3. And how can the researchers create a corn sheller machine with low cost, is very

adaptable in its operation and can answer the rate of production required of the

farmers? While the researchers consider the following:

- Labor Cost

- Operation Cost

- Maintenance Cost

Significance of the Study

 Farming mechanization in Tuburan has been greatly encouraged by the local government

unit. With the application of this research of manual and motorized operated corn de-seeding

machine it can greatly benefit the following people:

Farmers – The machine can lessen work load equals less stress in the body of farmers which is

mostly the case. Compared to hard manual labor, with the help of this new and advance machine

it can greatly lessen time in harvesting therefore lesser money spent.

Students – This research can contribute to the students (researchers) applied knowledge of

mechanical engineering ranging from machine designing to the economic value of the machine at

hand. Aside from improving various skills like welding and designing, through this research it can

further develop attitudes of team work and time management.

Scope and Limitations

The corn de-seeding machine can only be operated manually or by its electric motor.

Operators must follow strictly the guidelines of changing the method of operation otherwise the

machine cannot run as intended. The corn de-seeding machine can only be feed one at a time but

continuously. The size of corn should have a maximum diameter of 2.5 inches and a length of 3 –

7 inches long.

RESEARCH METHODOLOGY
 The study used a descriptive and scientific method of research to give details of the design

concepts and project plans intended to accomplish the research.

Research Design

The design of the machine is similar to a concave cylinder sheller though widely different

in its sheller mechanism and is designed to operate both manually and motorized.

Research Environment

The research is conducted at Brgy. Fortaliza, Tuburan, Cebu. Specifically at corn farms

that uses traditional method of kernel harvesting.

Figure 5: Map of Fortaliza, Tuburan, Cebu Figure 6: Corn Fields of Brgy. Fortaliza

Research Respondents
 The respondents of this research are the farmers of Brgy. Fortaliza. They will evaluate if

the proposed manual and motorized corn de-seeding machine can aid their needs in harvesting the

corn kernels in a way that it is convenient and efficient.

Research Instruments

In finding the information necessary for this research the researchers conducted a few study

sessions in reading study materials like electronic books (e-books), videos and images, and

published patents that are related to this research and made a design in the computer to a software

called auto-cad.

Data Gathering Procedure

In the study, the researchers conducted a survey by asking questions to the farmers.

Through this, the researchers determines the specific machine that is going to be used, the specific

date of harvesting the corn, the specific date or month of planting the corn and other information.

Answers are recorded by the researchers during the said survey. The survey is conducted by the

researchers to know more on how the farmers are going to grow their crops that are subjected to

shelling after harvesting.

After the survey, all data is checked and compiled by the researchers. The gathered data is

used as a guide for improving the machine and also for design considerations.

Treatment of Data
 The gathered data from the questionnaire survey were carefully evaluated and recorded.

These data are essential for the development of manual and motorized operated corn de-seeding

machine.

The acceptability of concept design, function, construction and cost were tabulated using

average weighted mean. Cost and other factors input to the development of this study will be the

main focus of the team.

Table 1: Survey Data Evaluation

Percentage Value Accumulation per

QUESTION NO. Best Possible Answer
QUESTION
1 - -
2 YES -
3 YES -
4 YES -
5 YES -

Total 100%
*Depending on the results of the survey the percentage value accumulation per question can
then be calculated using the formula below.

Average Weighted Mean. This was used to determine the respondent’s perception in the

acceptability and the effectiveness of the design proposed study.

Formula: 𝑥̅ = ∑𝑓𝑤/𝑛

Where:

𝑥̅ = average weighted mean ∑𝑓𝑤 = total weighted mean

𝑛 =Total number of respondents

Table 2: Qualitative Interpretation

 Weighted Mean Range Interpretation
81% - 100% The machine is highly accepted.
61% - 80% The machine is moderately accepted.
41% - 60% The machine is accepted.
21% - 40% The machine is least accepted.
0 – 20% The machine is unaccepted.

A qualitative interpretation then gives meaning to the results gathered from the survey.

Computations of factors both manual and electrical handling are required for further analysis of

the machine’s working operations to achieve high efficiency.

Scoring Procedure

The research applies a scoring approach for reliable application factors. This involved

multiple trials, cumulative observations and data from surveys. The procedure result presents a

qualitative description of the consistency of the process.

Definition of Terms
o Bevel – a slanted surface or edge of a runner that removes kernels from cobs in a manual

sheller.

o De-seeding or Shelling – is the process of removing the corn kernels from the corn cob.

o Efficiency – the effectiveness of operation for both manual and power generated operation.

o Friction – is produce when corn is rub with a tool to remove its kernel from the cob

o Moisture – small amount of liquid inside of corn kernels

o Patent – signifies the ownership of a person to his invention

o Periphery – refers to the outside surface area of the cylinder-concave sheller.

o Quasi-static – is a process that happens slowly enough for the machine to remain in internal

equilibrium.

o Rasp-bar – a metal tool that has sharp points used as the teeth of corn sheller.

o Threshing – (see de-seeding) similar to de-seeding but the term is mostly used in rice

threshing.

CHAPTER 2

REVIEW OF RELATED LITERATURE AND STUDIES

 This chapter presents the related literature and studies as a reference in conducting a

thorough and in-depth research by the researchers to have better comprehension of the machine.

Related Literature

In the patented corn sheller by Frederick W. Kirby, Moline, and Frederick A. Thomann

(July 9, 1946), The present invention relates generally to corn shelling machines, and is more

particularly concerned with hand shellers adapted for manual operation.

The principal object of the present invention is the provision of a hand sheller of sturdy

construction, in which there is little likelihood of any of the operating parts and their bearings

becoming misaligned. Hand corn shellers usually embody a straight runner that moves the ear of

corn into proper position with respect to the bevel runner which removes the kernels of corn from

the cob, and an adjustable rag iron or similar part that retards the ear of corn sufficiently so that all

of the corn is shelled from the cob. The straight and bevel runners are usually mounted on separate

shafts which, in turn, are supported by bearings. Heretofore, the bearings for the shelling

mechanism shafts have been mounted separately on the sheller frame, dependence being placed.

Another patented corn sheller by Harvey Pagkeron (October 16, 1881) in his invention has

reference to that class of corn-shellers having two or more feed-holes. The object of his invention

is to render the feed of such corn-sheller more uniform, and also to provide against the wear and

casual breakage of the parts. Such invention consists, essentially, of, first, an improved sprocket

or cup link in the feed chain; second, a provision in the bottom of the feed-box to prevent wear of

the links of the feed-chain; third, an improved device for tightening and holding taut the feed-

chain; fourth, an improved sprocket-wheel; and, fifth, an improved picker-shaft.

Related Studies

According to Kaul and Egbo (1985), the performance of a thresher depends upon its size,

cylinder speed, cylinder concave clearance, fan speed and the sieve shaker speed. Oni and Ali

(1986) reported that the factors influencing threshability of maize in Nigeria are field drying, maize

varieties, ear size cylinder speed and feed rate. The properties of the crop that affect the thresher

performance are crop variety, shape and size, hardness of the seed, the moisture content of the seed

and the density.

According to Nyongesa Fredrick Wanjala, the traditional method of grain threshing is by

use of hand held simple tools or hitting with stick. For instance, the traditional hand maize shelling

technique can only achieve up to 25 kg/hour of shelled maize. The performance of an improved

pedal maize threshing machine which consists of a single spiked disc in the threshing unit and

whose results show that the machine can shell about 80 kg/hour of maize is not very efficient since

the machine is turned manually and requires very high energy inputs in cycling. Mechanized

shelling techniques such as the motor operated maize sheller as well as the tractor PTO operated

sheller are the most efficient but post a challenge for adoption by the rural farmer because of the

high costs involved in either hiring their services or purchasing the machines.

CHAPTER 3

PRESENTATION, INTERPRETATION AND DATA ANALYSIS

 This chapter incorporates the presentation, analysis and interpretation of the machine’s

design concept in relation to the statement of the problem: What corn de-seeding method is more

convenient to the farmers; What design concepts are necessary for the corn sheller machine; And

how can the researchers create a corn sheller machine with low cost, is very adaptable in its

operation and can answer the rate of production required of the farmers?

Design Calculations

1. Design speed of the Sheller: 200 rpm (3.33rps)

2. Power required to drive the Sheller:

P = FV; F = mw2 r

where: m= total mass of Sheller assembly (slugs)

r = radius of the Sheller
w = angular velocity of the Sheller

*m = (mass of cover plate) + (mass of teeth) + (mass of steel pipe)

m = density x volume; average density of steel is 0.287 lb/ft-in3

0.287 л 3
mp = [4(62 – 1.52)] (8) = 0.0886 slugs
32.2

0.287 3 2 1 2
mt = [ ][ (13.5) + 2(13.5) (1.25- 8)] = 0.0338 slugs
32.2 8 8

0.287 л
msp = (13.5) [4(4.52 – 3.752)] = 0.5847 slugs
32.2

m = mp+mt+ msp = 0.7072 slugs

*Force applied to shell the corn:

 200 2 4.5
F = (0.7072) (2л x ) x = 58.16 lbf = 26.38 kgf
60 2 𝑥 12

*Power applied to shell the corn:

P = F x V; v = лDN
4.5 200
= 58.16 lbf x (л x x )
12 60

lb−ft
= 228.41 = 0.42 Hp
sec

Expectation

Since the design speed is 3.33 rps and the sheller has 12 teeth, the corn is expected to be
hit 39.96 times or 40 per second which is viewed enough to separate the kernels from the cob
effectively.

3. V-belt drive design dimension:

Where: C = center distance

7
C = √(322 + (78)2)
C = 32.95 inches

Type of V-Belt: A

groove angle (2B) :32◦

coefficient of friction: 0.28

Pulley at the motor: 1.5 inches

*Angle of Contact at smaller pulley:

 D−d
Ɵ=∏- c

13−1.5
Ɵ=∏- 32.95

Ɵ = 2.79 rad or 160 degrees

*Belt Length (BL):

л (D−d)^2
BL = 2[ D+d ] + 2c + 4c

BL = 89.67 inches or 2278 mm

* Pulley Diameter:

DN1 = dN2

where: N1 = speed of Sheller

N2 = speed of motor

D (200) = 1.5(1740)

D = 13.05” or 13 inches

4. Shaft size:

Note: All units are in inches (Draw not to scale)

 Ws
where: = 11.5 lb
2

Wp = 18.51 lb

Total length of shaft = 20.75 inches

.Ɵ = 13.8 𝑑𝑒𝑔 * Shaft Material is C 1015, Annealed

Ultimate stress = 56 ksi

Yield stress = 42 ksi

For shaft with key-way:

Allowable shearing stress = 0.3 Sv or = 0.18 Sy (which is minimum)

: 0.3(56) = 16.8 ksi

: 0.18(42) = 7.56 ksi

Therefore, use 7.56 ksi as allowable shearing stress

From ASME Code Equation:

 16√(KmM)2 +(KtT)2
Sa = ∏(d)3

Where:

M = maximum bending moment on the shaft

T = torque acting of the shaft

Km = combined shear and fatigue factor applied to bending moment

Kt = combined shear and fatigue factor applied to torsional moment

Sa= allowable shearing stress

For gradually applied loads:

Km = 1.5 ;kt = 1

Solving for T1 and T2:

P = (T1 - T2) x V

Assuming motor efficiency is 95%,

1.5 1740
0.75 x 0.9 x 550 = (T1 - T2) [14 x x ]
12 60

(T1 - T2) = 34.41 lb

T1 fƟ ∏ 1
= e^ = e0.28 x 160° x x
T2 sinƟ 180 sin16

T1
= 17.06
T2

T1 = 36.55 lb

T2 = 2.14 lb

: T = T1 + T2 = 38.69 lb

MAV = (18.51 +38.69 cos13.8)(13) = 729.08 lb-in

MAH = 38.69sin13.8 x 13 = 119.98 lb-in

MA =√MAV 2 + 𝑀𝐴𝐻^2 = 738.89 lb-in

From: P = 2∏TN
 200
0.75 x 0.95 x 550 = 2∏ x T x 60

T = 18.71 lb-ft = 224.52 lb-in

Using the ASME Code Equation for shafts:

16√(1.5 x 730.89)2 +(1 𝑥 22452)^2

7.56 ksi = ∏d^3

d = 0.91 inch or 1 inch

5. Power loss in bearings:

Type: Self aligning ball bearing

Average coefficient of friction: 0.001

Base on the schematic diagram of forces, the bearing on the left will carry 30.01 lbs while
the second will have 11.50 lbs (considering static loads).

P= 2∏TN , T= Frf

Where:

r= radius of the shaft

f= coefficient of friction

P1= 2∏x(30x0.5/12)x0.001x(200/60x550)

= 4.76x10-5Hp

P2= 1.83x10-5Hp

: Notice that the summation of this power losses is almost negligible, as expected with the
ball bearings.

6. Designed size of the motor to be used:

 Considering 95% of V-belt efficiency based on practice, motor efficiency of 80% with
service factor of 1.25 as recommended for sizes below 1 Hp,

Power required output of motor= 0.42 Hp

0.42 𝐻𝑝
Needed size of motor: = 0.95𝑥0.80

= 0.55 Hp

Considering the service factor:

Actual size needed= 0.55 Hp x 1.25

= 0.688 Hp , use 0.75 Hp (standard)

Bases for the designed power in shelling the corn:

According to Kick’s Relation, the power required to shell the corn,

P= KkxFcxln(L2/L1)

Where:

L1= length of shelled corn= 1.48x10-2 m

L2= length of unshelled corn= 20x20-2 m

Kk= Kick’s constant= 1.2

Fc= Crushing Strength= 1.2 N/m2

P= 1.2x200xln(20x20-2/1.48x10-2)

= 642W or 0.84 Hp

This amount of power is used as a basis in determining the size of electric motors to be
used and is not necessarily the output power of all corn shellers since every unit is designed for a
particular production rate of shelled corn.

7. Chain and Sprocket Drive Design:

 Diameter of Sprocket at the Sheller: 1.5”

Speed of the Sheller: 200rpm

Average speed of manual handling: 50rpm

Center distance: 10 inches

*Diameter of Driver (D1):

D1N1 = D2N2

D1(50) = 1.5 x 200

D1 = 6”

*Chain length (CL):

л (D1+D2)^2
CL = 2(D1+D2) + 2c + 4𝑐

CL = 32.29”

8. Minimum force (kgf) required to drive the Sheller for manual handling:
 *To have the same output with electric handling, this amount of torque must be met with
manual handling:

1.5 𝑖𝑛
T = 58.16lb x = 43.62 lb-in or 4.93 Nm
2

*Amount of force required to be applied at the handle: kgf

T = Total Kinetic Energy

1 1
T = 2mv2+ 2[mr2] x w2

where: v= average velocity (2 лRN)

R = radial length of the arm

R = 8 inches or 0.203m
1 50 1 50
4.93 = 2m [2∏ (0.203) x 60 ]2 + 2m [0.203]2 x [2∏ x 60]2

m= 4.36 kgf

9. Estimated Production Rate of the machine:

This will be complied after the creation of the machine and will undergo testing by trials.

𝑘𝑔
𝑆𝑢𝑚𝑚𝑎𝑡𝑖𝑜𝑛 𝑠ℎ𝑒𝑙𝑙𝑒𝑑 𝑐𝑜𝑟𝑛 𝑝𝑒𝑟 𝑡𝑟𝑖𝑎𝑙 ( )
Estimated Production Rate = ℎ𝑟
𝑇𝑜𝑡𝑎𝑙 𝑛𝑜. 𝑜𝑓 𝑡𝑟𝑖𝑎𝑙𝑠

: Where the trials will be done at least 3 times

The result should be within 300-400 kg/hr for motor sizes between ¼ to 1 Hp considering
continuous operation.

CHAPTER 5
 OUTPUT OF THE STUDY

This chapter presents the proposed design of a Mini Corn Sheller Machine Operated

Manually or Power Generated at Cebu Technological University- Main Campus. This study also

covers the Operation and Maintenance Guidelines that will serve as the basis for operation safety

and proper handling of the machine.

Prototype Design

The corn sheller machine has dual operations, manual and power generated. It is intended

as this for a more advantageous approach in harvesting in case some malfunctions occur in the

operation so not to cause delay. The machines main parts are composed of the casing, frame, and

the sheller. Then its sub main parts which are the sprocket and chain assembly and the motor

mounting assembly on which these two represents the operation that can be executed by the

machine. In its power generated operation, its calculated speed is 200 rpm and the motor having

0.75 Hp connected by pulleys and a v-belt to the corn sheller shaft. Its manual operation, with the

Ø 1.5” of sprocket connected to the shaft with an adjustable chain for easy removal (changing

operations). The machine handle which is connected to the larger sprocket is calculated to have a

force of at least 4.36 kgf to run the machine with an intended speed of 200 rpm.
 OPERATION AND MAINTENANCE MANUAL

User Guidelines (Power Generated Operation)

1. Loosen and disengage the chain from the sprocket to reduce load in the motor.

2. Check the belt pulley system. By adjusting the motor’s position, you can make the belt

not too tight and not too loose.

3. A continuous, uniform and a proper quantity of feeding Crops will be helpful for the

machine good performance.

4. The Corn Sheller machine operator could adjust the feeding quantity flexibly following

the working condition of the machine.

User Guidelines (Manual Operation)

1. Loosen and disengage the belt from the pulley to reduce load in the handle.

2. Check the chain sprocket mechanism. By adjusting the sprocket’s position, you can make

the chain not too tight and not too loose.

3. A continuous, uniform and a proper quantity of feeding Crops will be helpful for the

machine good performance.

4. The Corn Sheller machine operator could adjust the feeding quantity flexibly following

the working condition of the machine.

Maintenance Guidelines

1. To avoid any loose or damaged, check all the fastening parts and belts regularly.

2. To make sure a good performance of the Corn Sheller machine, change damaged

components as soon as possible.

3. All rotating parts should be cleaned and greased every 6 months.

4. Clean the machine every after use by removing dust and impurities and then move the

machine indoor and cover it by plastic fabric (moisture-proof).

5. If the machine is not in use for a very long time; clean and grease the machine and cover

it for storage in dry cool place.

 REFERENCES

o (August 14,2016) Agriculture and Fisheries Market Information System. Corn Commodity

Profile.

o (August 12, 2016) Maize Sheller. www.vidhataindia.com.

o Al-Jalil, Hamid Fadhil (1978). Design and performance of low damage corn shelling machines.

Digital Repository, Iowa State University, Ames, Iowa.

o Das, H. and S. Bhattacharya (1984). Optimum design and location of a hand operated rotary

device. J. Agric .Eng’g. ISAE, Vol. No 21(3): 29-36

o Gonzales, L.A (2003). “PHILIPPINES”, WTO Agreement on Agriculture: The

Implementation Experience. Developing Country Case Studies. Rome: FAO.

o Grain and Feed Annual Manila Philippines. (March 15, 2016)

o Hall, A.S.; Holowenko, A.R.; and Laughlin, H.G (1988). Theory and problems of machine

design. Shaum’s Outline Series, S.I. (metric) ed. McGraw-Hill, New York, NY, USA. pp. 113-

4.

o Pickard, G. E. (1955). Laboratory studies in corn combining. Agr. Eng. 36: 792-794.

o Waelti, H. (1967). Physical properties and morphological characteristics of maize and their

influence on threshing injury of kernels. Unpublished Ph.D. dissertation. Library, Iowa State

University, Ames, Iowa.

o Wanjala, Nyongesa Fredrick (2014). Design of a Modified Hand Operated Maize Sheller.

DEBE, University of Nairobi.

o Wikipedia (August 12, 2016). Corn Sheller. www.wikipedia.org.

 APPENDICES

Appendix A: Bill of Materials

DETAIL SHEET
DESCRIPTION SPECIFICATION QTY. UNIT COST(php)
NO. NO.
0.75Hp, 1740 rpm,
1 2 Electric Motor 1 pc 2500
single phase
2 1 V-belt STRD 1 pc 450
3 3 Pulley(large) Ø 13” 1 pc 400
4 2 Pulley(small) Ø 1.5” 1 pc 250
5 4 Sprocket(small) Ø 1.5” 1 pc 100
6 4 Sprocket(large) Ø 6” 1 pc 500
7 4 Chain STRD 1 pc 320
8 1 Rivets STRD 20 pcs 200
9 2 Bolts and nut Hex bolt, hex nut 20 pcs 400
10 2 Caster wheel STRD 2 pcs 300
11 1 Machine Handle Ø1” x 24" 2 pcs 200
12 2 Motor Support Flat bar 1 pc 300
Tool Steel
13 3 Shaft 1 pc 400
Ø1” x 20.5”
Sprocket drive Round bar
14 4 1 pc 100
Handle Ø3/8”x 8”
15 1 Switch box STRD 1 pc 50
16 7 Kernel outlet Tin plate 1 pc 500
Pillow block and
17 3 Ø1” UCP207 2 pcs 400
Bearing
18 5 Upper Casing Tin plate 1 pc 200
19 6 Lower Casing Tin plate 1 pc 600
20 8 Corn Sheller Steel pipe, Flat bar 1 pc 3500
21 9 Frame Angle bar 1 pc 750
Labor 4750

Total Estimated Amount 17270

Appendix B: Gantt Chart
Appendix C: Survey Questionnaire
A SURVEY OF ALTERNATIVE SHELLING OF CORN
The purpose of this questionnaire is to rate the qualitative approach of alternative shelling
of corn. Please answer the following items below. As a survey, all answers are correct and to be
respected.

I. Area of Corn Field Owned :

Address:

II. Put a check ( ) mark on the box provided for your answers in given choices.
To the questions that need a specific answer, write you answer on the space provided.

1. How many sack of corn every harvest do you get?

2. Do you process your corn on your own?

Yes, I do. No, I sell it directly to the market.
If your answer is YES, how do you de-seed the corn?
I do it manually.
Using simple tools.
Others, specify
3. Have you heard about corn sheller machine?
Yes No
If Yes, What type of corn sheller machine would you prefer?
Manual operated machine
Electric motor operated machine
Others pls. specify:
4. If you have the budget, would you prefer buying this machine?
Yes No, I prefer do it manually (by hands or tools).
If yes, how much money can spare/ budget for buying this machine?
21,000 pesos and up
20,000 pesos and below
Other, pls. specify:
5. Our project is to make use of two operations namely: the manual and power generated, in
a single corn sheller machine. If this is successful, are you interested in purchasing this
Mini Corn Sheller Machine Operated Manually or Power Generated?
Yes No

Thank you and God Bless! 

Appendix D: Compliance Checklist

Compliance
Suggestions/Recommendations/Correction (Indicate Page Remark/s
No.)
1. Change title to “Mini Corn Sheller Machine Operated
i ok
Manually or Power Generated”
2. Follow standard CTU format cover page i ok
3. Do not highlight in bold under List of Figures and
vi ok
Tables
4. Chapter 1 – Rationale of the Study
- Discuss the manual process of separating corn
kernels from cob by using bare hands or by means
2-4 ok
of manual tools such as knives
- Indicate the uniqueness of the machine from other
corn shellers
5. Chapter 1 – Conceptual Framework
8 ok
- Add the moisture content of corn
6. Chapter 1 – Arranged alphabetically Definition of
15 ok
terms
7. Chapter 3 – Provide the following data
- Safety factor for motor power
24 & 26 ok
- Estimated production rate of the machine by the
application of the design considerations (kg/hr)
8. Chapter 5 – Labels of the design should be the same 28-36 ok
9. References should be in APA Style format 39 ok
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Ma. Isabel Rose I. Bardoquillo

Nickname : Mariz

Age : 20 years old

Gender : Female

Birthdate : November 03, 1995

Birthplace : San Marcelino, Zambales

Address : 3 P Del Rosario St., Cebu City

Email Address : marizb1103@gmail.com

Occupation : Student

Father’s Name : Reynato E. Bardoquillo

Mother’s Name : Lilybeth I. Bardoquillo

EDUCATIONAL BACKGROUND

Elementary : Carmelo Elementary School

Secondary : St. Anthony’s Academy of Tuburan

Tertiary : Cebu Technological University – Main Campus

Organizations : DOST SA CTU

DOST SA CEBU
JPSME
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Aaron James Caraca

Nickname : Aaron

Age : 21 years old

Gender : Male

Birthdate : July16, 1995

Birthplace : Sibonga, Cebu

Address : M.J. Cuenco Ave., Cebu City

Email Address : ajay.caraca@gmail.com

Occupation : Student

Father’s Name :

Mother’s Name : Ma. Jessel L. Caraca

EDUCATIONAL BACKGROUND

Elementary : Manatad Elementary School

Secondary : Teodoro dela Vega MNHS
Tertiary : Cebu Technological University – Main Campus

Organizations : DOST SA CTU

DOST SA CEBU
JPSME
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Reynaldo B. Doble

Nickname : Rex

Age : 21 years old

Gender : Male

Birthdate : September 23, 1994

Birthplace : Cebu City

Address : Upper Matumbo, Pusok, Lapu-lapu City

Email Address : rexdoble69@gmail.com

Occupation : Student

Father’s Name : Rolando A. Doble

Mother’s Name : Marites B. Doble

EDUCATIONAL BACKGROUND

Elementary : Pusok Elementary School

Secondary : Pusok National High School

Tertiary : Cebu Technological University – Main Campus

Organizations : DOST SA CTU

DOST SA CEBU
JPSME
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Janley R. Fortaliza

Nickname : Jan

Age : 21 years old

Gender : Male

Birthdate : October 20, 1994

Birthplace : Kang-iras, Hilongos, Leyte

Address : M.J. Cuenco Ave., Cebu City

Email Address : janyell143@gmail.com

Occupation : Student

Father’s Name : Romeo G. Fortaliza

Mother’s Name : Felicidad R. Fortaliza

EDUCATIONAL BACKGROUND

Elementary : Kang-iras Elementary School

Secondary : Hilongos NationalVocational High School

Tertiary : Cebu Technological University – Main Campus

Organizations : JPSME
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Joel Q. Inot Jr.

Nickname : Joel

Age : 21 years old

Gender : Male

Birthdate : September 02, 1995

Birthplace : Cebu City

Address : New Paradise, Pajo, Lapu-lapu City

Email Address : inotjrjoel@gmail.com

Occupation : Student

Father’s Name : Joel Inot Sr.

Mother’s Name : Marilyn Q. Inot

EDUCATIONAL BACKGROUND

Elementary : Curva Elementary School

Secondary : Curva National High School

Tertiary : Cebu Technological University – Main Campus

Organizations : DOST SA CTU

DOST SA CEBU
JPSME
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Alfred Eve C. Labang

Nickname : Fred

Age : 20 years old

Gender : Male

Birthdate : February 29, 2016

Birthplace : Cebu City

Address : Jugan, Consolacion, Cebu

Email Address : ael1431@gmail.com

Occupation : Student

Father’s Name : Alfredo S. Labang Jr.

Mother’s Name : Eva C. Labang

EDUCATIONAL BACKGROUND

Elementary : JuganElementary School

Secondary : La Consolacion College - Liloan

Tertiary : Cebu Technological University – Main Campus

Organizations : JPSME
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Raffy Roy B. Pino

Nickname : Rap-rap

Age : 20 years old

Gender : Male

Birthdate : June 20, 1996

Birthplace : Lapu-lapu City

Address : Relocation Site, Ibo, Lapu-Lapu city

Email Address : raffyroypino@gmail.com

Occupation : Student

Father’s Name : Ruben B. Pino

Mother’s Name : Felipa B. Pino

EDUCATIONAL BACKGROUND

Elementary : Ibo Elementary School

Secondary : Pusok National High School

Tertiary : Cebu Technological University – Main Campus

Organizations : JPSME
 CURRICULUM VITAE

PERSONAL PROFILE

Name : Jessie G.Tasong

Nickname : Jeb

Age : 20 years old

Gender : Male

Birthdate : December 31, 1995

Birthplace : Corella, Bohol

Address : M.J. Cuenco Ave., Cebu City

Email Address : tasong25@gmail.com

Occupation : Student

Father’s Name : Rogelio S. Tasong

Mother’s Name : Romana G. Tasong

EDUCATIONAL BACKGROUND

Elementary : Canangca-an Elementary School

Secondary : Corella High School

Tertiary : Cebu Technological University – Main Campus

Organizations : DOST SA CTU

DOST SA CEBU
JPSME