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Design and Development of Variable Rate Metering System for Fertilizer

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Journal of Agricultural Engineering

ISAE Vol. 54 (3): July-September, 2017

Design and Development of Variable Rate Metering System for Fertilizer

Application
Bholuram Gurjar1, P. K. Sahoo2 and Adarsh Kumar3
1
Ph.D. Scholar, 2,3Principal Scientist, Division of Agricultural Engineering, ICAR-IARI, New Delhi. Corresponding author
email address: gurjar.bholuram@gmail.com

Article Info ABSTRACT

Received : September, 2016
Revised
accepted : July, 2017
Key words:
Feed shaft fluted roller, variable
rate technology, PWM motor
A variable rate fertilizer metering mechanism was designed by changing the speed of the
feed shaft for use in variable rate fertilizer applicator. A micro-controller unit programmed
with a Pulse Width Modulation (PWM) motor driver was used to run the feed shaft for
varying speeds. Two types of fluted rollers (straight and helical flute) were used with
varying number of flutes having same volume for each fluted roller. No significant
difference in discharge rate between helical and straight fluted roller was observed with
varying number of flutes (6, 8, 10, and 12). However the discharge rate of SSP fertilizer
was significantly higher than that for DAP. Also, significant difference was observed in
applied torque and power requirement for straight and helical flute.

India is the third largest producer (16.36 Mt) and
consumer (27.40 Mt) of fertilizer in the world with an
average consumption of 129.8 kg.ha-1 (Anon., 2013).
Conventional application of chemical fertilizer to the
crops often results in very low yield at low fertility
sites, whereas lodging of plants with increased biomass
at high fertility sites is undesirable due to difficulty
in harvesting. Constant rate of fertilizers application,
therefore, can result in under-fertilization of some
parts of a field, and over-fertilization in other parts.
Under-fertilization may result in yield loss, and over-
fertilization generally increases the crop yield up to
an optimum level. Excess fertilizer is less utilized or
mobilized, and is also harmful to the environment (Tola
et al.,2008).
Existing seed-cum-fertilizer drills are not capable
of efficient metering and placement of fertilizers as
recommended for variable application. Existing seed-
cum-fertilizer drills draw power from spiked ground
wheel, which many times slip. This variation of speed
is in the range of 15 to 20 per cent. Even after fixing
seed and fertilizer application rate, uniform application
rate throughout the field may not be achieved because
of skidding of ground drive wheel and inefficient seed/
fertilizer metering mechanism. Seed rate variability has
been reported to the tune of 10-20 %, which requires
higher seed rate (Singh et al., 2012).Thinning operation
at densely sown locations is additionally done for
achieving the desired plant population. The variability
in fertilizer application is even more dependent upon
its flow ability.
Precision farming using variable rate technology based
upon crop condition has been used to reduce fertilizer
consumption and increase both the productivity and
quality of agricultural products. With intervention
of Variable Rate Technology (VRT), it is possible
to manage soil nutrient variations throughout a field
with prescribed dose of fertilizer application. Fulton
et al. (2000) studied the limitations of VRT equipment
that can create application errors where the actual
application rate might differ from desired rate, causing
inaccuracy. The design parameters limitations of the
spreader and the actuators affected the dosing accuracy.
On the commercially available spinner disc fertilizer
applicator, the flow control by actuators and rate
changes are executed by controlling the gate opening
or metering device such as apron chain (conveyor belt).
A variable rate fertilizer metering system may either
be achieved by either changing the active feed-roll
length, or varying the speed of feed shaft. By changing
Bholuram Gurjar, P. K. Sahoo and Adarsh Kumar JAE : 54 (3)

the active feed-roll length, application rate is adjusted,
whereas in variable rate metering system fertilizer rate
can be changed by varying the speed of feed shaft. An
existing seed-cum-fertilizer drill can be converted into
a variable rate seed-cum-fertilizer drill by using micro-
controller and DC motor. Ning et al. (2015) developed
a variable rate fertilizer system by changing active feed
roller length.
The present study was undertaken to develop a variable
rate fertilizer metering system using micro-controlled
variable speed feed shaft.
MATERIALS AND METHODS
Fertilizer Types
Two types of granular fertilizers, di-ammonium
phosphate (DAP) and single-superphosphate (SSP)
were used for this study. A total of 10 kg of each of the
fertilizer was used for the study. Moisture content (wet
basis) of DAP and SSP fertilizers were in the range of
1.63 % to 2.4 % and 2 % to 4.7 %, respectively.
As per the BIS (IS 4813: 2000), standard roller
diameter of 48 mm as roller diameter, and the length
of roller as 54 mm were considered. Accordingly,
helical and straight types of fluted roller with different
numbers of flutes (6, 8, 10, and 12) were tested (Table
1). Considering constant volume (19.79 cm3 as per
standard) of roller in each revolution for a particular
number of flutes, as recommended for use in seed-
cum-fertilizer drill, laboratory investigations were
conducted. Eight fluted rollers comprising of four
helical (Fig. 1) and four straight (Fig. 2) with flute
diameter of 20 mm, 15 mm, 12 mm and 10 mm were
fabricated. Fluted rollers were made of high density
polyethylene (HDPE). Fluted rollers were made of
high density polyethylene (HDPE) of density in the
range from 0.93 g.cm-3 to 0.97 g.cm-3. HDPE is little
branched to give it stronger intermolecular forces and
tensile strength than low density polyethylene (LDPE),
and can withstand higher temperatures (120 °C for short
periods). This facilitated the fabrication, and ensured
longer life of the fluted rollers.

Fertilizer size and shape

Relevant physical properties (size and shape) of the
fertilizers were determined (Mohsenin, 1986). Size of
the fertilizer in terms of major, minor and intermediate
diameters was measured using digital vernier calliper
(Mitutoya make). The dimensions of 50 randomly
selected fertilizers for each variety were measured,
and their geometric mean diameter (GMD) determined.

Variable Rate Metering Mechanism

Most commonly fluted roller types metering mechanism
having flutes of different sizes and shape were
considered for metering of fertilizer. The design of
roller diameter, exposure length, flute diameter and
number of flutes depend on the required application Fig. 1: Helical fluted roller with different number
rate. flute: (a) 6, (b) 8, (c) 10, (d) 12

Table 1. Design specifications of fluted rollers

Type Roller Roller Internal Flute Roller Roller No. Flute Flute vol- Spacing
of roller diameter, length, diameter, length, helical volume, of diameter, ume, between
mm mm mm mm angle, mm3 flute mm mm3/flute two flute,
degree mm

Helical 6 20 6597 8
roller / 48 54 16 42 15° 19792
Straight 8 15 3711 4
roller
10 12 2375 3

12 10 1649 2

13
July-September, 2017 Design and Development of Variable Rate Metering System for Fertilizer Application
Fig. 2: Straight fluted roller with different number of
flutes: (a) 6, (b) 8, (c) 10, (d) 12
Electronic control system
A micro-controller (model ATmega8Aa, 8-bit high
performance micro-controller of Atmel’s Mega AVR
family) with low power consumption was used for
automation system. It worked on maximum frequency
of 16 MHz. ATmega8A a 32 pin micro-controller had
8 KB programmable flash memory, static RAM of 1
KB and EEPROM of 512 bytes. It was programmed
in C language for desirable speed control of the
fertilizer metering system. This micro-controller acted
independently in controlling the rotational speed of
the steeper motor. Direction and rpm of the motor was
controlled through a PWM motor (1.57 N.m capacity)
driver “MD2U-MD20”. This driver was directly
connected with a micro-controller (ATmega8A), and
the micro-controller controlled the motor rotational
speed corresponding to the given pulse in the range
of 0-24 V. Pulse was given manually via an input
button; while rotational direction was changed with
selective buttons. The output of metering mechanism
was changed in terms of seeds/ fertilizers varying
according to the input change in the speed of the feed
shaft. The system was pre-calibrated to deliver a certain
output for a given input rpm value of the feed shaft.
The controller had no lag time between a given input
rpm by the micro-controller and the output rpm of the
motor. The electronic control system could mount a
LCD monitor for display of all system data. The main
controller and the steeper motor driving circuit board
are shown in Fig. 3.
Measuring system
An electronic measurement system was developed and
used to determine the relationship between the PWM
14
Fig. 3: Main controller and steeper motor driving
circuit board
motor output torque and discharged fertilizer. The
measuring system measured PWM motor rotational
speed (N), roller shaft torque (τ), and fertilizer discharge
rate. Motor rotational speed was observed by using a
non-contact type tachometer. It could measure from
2 rpm to 1000 rpm with resolution of 0.1 rpm/1 rpm.
Roller shaft torque (τ) was measured by a torque
transducer (Kyowa Electronic Instruments Co., Ltd.,
TP-1 KCB; maximum 500 N.m; accuracy 0.2 N.m)
installed between the roller shaft and the motor to detect
the strain corresponding to the torque developed by the
roller shaft. The torque transducer had strain amplifier
to convert the strain to electric signal and subsequently
to digital signal for display.
Fertilizer metered by the fluted roller feeder was
received in a cup on an electronic balance with least
count of 0.01g (Jafari et al., 2010).
In order to measure the power consumption for driving
the fluted roller for fertilizer metering, an electronic
measurement system coupled with the torque sensor
was deployed at the feed shaft of the unit. On left
corner of the metering mechanism, the PWM motor
was installed to power the fluted rollers (Fig. 4).
Experimental Procedure
The system was operated under two conditions of no-
load and full-load. The torque at no-load was in the
range of 0.57 N.m to 1.82 N.m. Torque was calculated
by subtracting the values obtained at no-load from that
at full-load. The procedure was adopted for DAP and
SSP fertilizers in order to measure the extent of torque
variation. The experiment was conducted for both types
of fluted rollers with different number of flutes and at
different exposure lengths. The length of the exposed
flutes was maintained at 50 %, 75 % and 100 percent.
Bholuram Gurjar, P. K. Sahoo and Adarsh Kumar JAE : 54 (3)

Fig. 4: Schematic diagram variable rate fertilizer metering mechanism

The roller rotational speed varied within the range of
10-100 rpm (Jia1 et al., 2014).
In the first phase, the unit was operated at 100 %
exposed length of the straight-shaped flutes having 6
flutes with 10 kg of each fertilizer placed inside the
hopper. The rotational speed of the feed shaft was
changed by the micro-controller, and the initial speed
was kept at 10 rpm. The torque required by the feed
shaft and discharge rate of the fertilizers was measured
with the torque sensor and the weighing balance,
respectively. In next phase, the exposed length was
decreased to 75 % of the total length of flute, and the
discharge rate and torque was measured. Similarly,
the exposure length was further reduced to 50 % to
determine the variation of discharge rate and power
required in comparison to 100 % and 75 % of the total
length of flute.
roller shaving 8, 10 and 12 numbers of flutes with
rotational speed varying from 10-100 rpm in increments
of 10 rpm; and the flute exposed lengths of 100 %,
75 % and 50 percent.
The above set of experiment was conducted with the
helical-shaped flutes for measurement of torque and
discharge rate of the fertilizer.
The independent and dependent variables of the
experiment are given in Table 2.
Statistical Analysis
The experimental data were analysed using randomized
complete block design (RCBD). The statistical package
SAS was used to analyse the experiment data for
analysis of variance of the mean and interaction of the
selected variables under no-load and load condition.

In the second stage of experiment, the rotational speed
of the fluted roller was increased to 20 rpm under
similar conditions to measure the power and discharge
rate of the fertilizer. The rotational speed was increased
up to 100 rpm in increments of 10 rpm.
Similarly, the experiment was conducted with different
Table 2. Experimental procedure
RESULTS AND DISCUSSION
Physical Properties of Fertilizer
Relevant physical properties (size and shape) of
the granular fertilizers were determined as given in
Table 3. Average values were used for computing the
dimensions of the fluted roller.

Sl. No. Independent variable Level Dependable variable

1. Flute shape 2 ( Straight, Helical) Discharge rate, torque,
2. No. of Flute 4 (6, 8, 10, 12) power requirement
3. Flute exposure length, % 3 (50, 75, 100)
4. Flute rpm 10-100(increments of 10)

15
July-September, 2017 Design and Development of Variable Rate Metering System for Fertilizer Application

Table 3. Sizes and shapes of fertilizer granule

Sl. No. Property Fertilizer

DAP SSP
1. Average diameter, mm 4.48 ± 0.28 3.76 ± 0.33
2. Range of diameter, mm 3.92 - 6.72 2.88 - 4.15
3. Shape, fraction 0.94 ±0.02 0.93±0.053

Effect of Granules Size on Discharge Rate
The rate of application for different fertilizer was
dependent on the granule size of the fertilizer used.
As the granule size increased, the discharge rate
decreased. For bigger size of fertilizer granules,
flow ability was affected due to higher inter-
granular space. It was observed that fertilizer having
average granule size of 3 mm to 4 mm had greater
flow ability, and the distribution was found to be
more uniform. The bigger granules having sizes of
more than 6 mm were found to clog the flutes of
Discharge rate, kg.min-1
metering rollers. The average particle size of DAP
and SSP was 4.48 ± 0.28 mm and 3.76 ± 0.33 mm,
respectively, and were well within the range of
3 mm to 5 mm. Hence, the designed fluted rollers
could ensure smooth flow of fertilizer granules.
Discharge Rate for Different Rollers
Variations in SSP fertilizer flow rates at different feed
shaft rotational speeds for different exposed flute
lengths are shown in Fig. 5-7, and that of DAP fertilizer
are shown in Fig. 8-10.

Rotor rotational speed, rpm

Fig. 5: Variation in SSP fertilizer flow rates with fluted roller

rotational speed at 100 % exposed length
Discharge rate, kg.min-1

Rotor rotational speed, rpm

Fig. 6: Variation in SSP fertilizer flow rates with fluted roller

rotational speed at 75 % exposed length

16
Bholuram Gurjar, P. K. Sahoo and Adarsh Kumar JAE : 54 (3)

Discharge rate, kg.min-1

Rotor rotational speed, rpm

Fig. 7: Variation in SSP fertilizer flow rates with fluted roller rotational
speed at 50 % exposed length
Discharge rate, kg.min-1

Rotor rotational speed, rpm

Fig. 8: Variation in DAP fertilizer flow rates with fluted roller

rotational speed at 100% exposed length

Discharge rates at 100 % exposed flute length of
straight and helical fluted roller with 6, 8, 10 and 12
number of flutes are shown in Fig. 5 and 8. Changes in
rotational speed of the feed shaft from 10 to 100 rpm did
not have significant difference(5 % level) in discharge
rate with different types of fluted rollers with varying
number of flutes as well as their exposure lengths.
Fertilizer discharge rate, however, varied significantly
with the type of fertilizer (DAP and SSP) at different
rotational speeds. Discharge rate of DAP and SSP
increased from 0.18 kg.min-1 to 1.94 kg.min-1, and
0.29 kg.min-1 to 3.02 kg min-1, respectively, when the
rotational speed of the feed shaft increased from 10 to
100 rpm for 6 flutes (straight). Similar trends for helical
and straight type fluted rollers were also observed for
8, 10, and 12 flutes.
At 75 % exposure length of flutes, the minimum
discharge rate of DAP fertilizer with helical fluted roller
with ten flutes was found to be 0.12 kg.min-1 at 10 rpm
and 1.32 kg.min-1 at 100 rpm (Fig. 9). Similarly, the
maximum discharge rate with straight fluted roller with
twelve flutes was 0.19 kg.min-1 at 10 rpm of rotational
speed and 2.05 kg.min-1 at 100 rpm. Minimum discharge
rate of SSP fertilizer with straight fluted roller with six
flutes was 0.195 kg.min-1 at 10 rpm and 1.99 kg.min-1
at 100 rpm (Fig. 6). But maximum discharge rate with
helical fluted roller with ten flutes was 0.212 kg.min-1
at 10 rpm and 2.17 kg.min-1 at 100 rpm.
With 50 % exposure length, minimum discharge rate
of DAP fertilizer with helical fluted roller with ten
flutes was 0.116 kg.min-1 at 10 rpm and 1.21 kg.min-1

17
July-September, 2017 Design and Development of Variable Rate Metering System for Fertilizer Application

Discharge rate, kg.min-1

Rotor rotational speed, rpm

Fig. 9: Variation in DAP fertilizer flow rates with fluted roller rotational
speed at 75 % exposed length

Table 4. Power requirements of helical vs straight 6-flute roller

Sl. Power, SSP DAP % Reduction in power

No. W Helical roller Straight Helical Straight SSP DAP
roller roller roller
1. Minimum 0.38 0.58 0.48 0.43 34 10
2. Maximum 2.18 3.45 3.62 3.52 37 3

at 100 rpm. Similarly, the maximum discharge rate with twelve flutes was 0.155 kg.min-1 at 10 rpm and
with straight fluted roller with twelve flutes was 0.124 1.58 kg.min-1 at 100 rpm (Fig.7).
kg.min-1 at 10 rpm and 1.28 kg.min-1 at 100 rpm (Fig.
10). Minimum discharge rate of SSP fertilizer with With flute exposed length decreasing to 75 % and
straight fluted roller with six flutes was 0.117 kg.min-1 50 % of the total flute length, fertilizer discharge rates
at 10 rpm and 1.22 kg.min-1 at 100 rpm. However, followed similar trend as for 100 % exposed length of
maximum discharge rate with straight fluted roller the straight and helical fluted roller.
Discharge rate, kg.min-1

Rotor rotational speed, rpm

Fig. 10: Variation in DAP fertilizer flow rates with fluted roller rotational speed at
50 % exposed length

18
Bholuram Gurjar, P. K. Sahoo and Adarsh Kumar JAE : 54 (3)

Power Requirement Power requirement increased with increasing speed of

Power requirement at the feed shaft at different
rotational speeds of straight type metering fluted rollers
with different exposed lengths of 100 %, 75 % and
50 % of total flute length are shown in Fig. 11 and 12,
while that of helical-shaped rollers are shown in Fig.
13 and 14.
Power, W
the feed shaft. There was significant difference in power
requirements between the straight and helical fluted roller
with different number of flutes (Table 5). SSP granules
was found to flow better than that of DAP, because small
portion of DAP granules had maximum granule size larger
than 6 mm (Table 3), resulting in clogging of fertilizer in

Rotor rotational speed, rpm

Fig. 11: Power requirement of straight fluted roller with varying number of flutes
at 100% exposed length for DAP fertilizer discharge
Power, W

Rotor rotational speed, rpm

Fig. 12: Power requirement of straight fluted roller with varying number of flutes
at 100% exposed length for SSP fertilizer discharge

19
July-September, 2017 Design and Development of Variable Rate Metering System for Fertilizer Application

Power, W

Rotor rotational speed, rpm

Fig. 13: Power requirement of helical fluted roller with varying number of flutes at
100 % exposed length (DAP)
Power, W

Rotor rotational speed, rpm

Fig. 14: Power requirement of helical fluted roller with varying number of flutes at
100 % exposed length for SSP discharge

Table 5. Power requirement (F value) at difference exposure lengths of fluted roller

Source DF F Value Pr > F

100% 75% 50% 100% 75% 50%
EP 1 15.25 0.04 11.31 0.0001 0.8354 0.7523
Fertilizer 1 11.15 29.88 12.43 0.0009 <.0001* <.0007
Flute 7 6.77 2.12 7.51 <.0001* 0.0409 <.0001*

20
 Bholuram Gurjar, P. K. Sahoo and Adarsh Kumar JAE : 54 (3)
the flutes and consequent increase in power requirement.
Helical fluted roller with different number of flutes
required less power than that of straight fluted ones. It was
found that minimum and maximum power requirement
for helical fluted roller with 6 flutes was 0.38 W and
2.18 W, respectively, for SSP fertilizer; whereas for straight
fluted roller with 6 flutes the minimum and maximum
power requirement was 0.58 W and 3.45 W, respectively.
Minimum and maximum power required for metering DAP
fertilizer by helical 6-flute fluted roller was 0.48 W and
3.62 W, respectively, and for straight fluted roller was
0.43 W and 3.52 W, respectively (Table 4). Therefore,
helical 6-flute roller was found to be more suitable for
metering DAP and SSP fertilizer. It was observed that
power requirement decreased with decreasing exposure
length.
CONCLUSIONS
A metering system with different shapes and sizes
of fluted rollers with different number of flutes was
developed for variable rate fertilizer application. Power
requirement for helical fluted roller with different
number of flutes were lower than that of straight fluted
rollers. Power requirement for metering of SSP and DAP
fertilizer by 6-flute helical roller were 34 % and 10 %,
respectively, lesser as compared to metering by straight
fluted roller. Helical shaped roller with 6 flutes was
found to be more suitable for metering SSP fertilizer,
but no significant difference in power requirement was
observed for DAP fertilizer due to larger flute diameter
and minimum number of flutes preventing clogging.
The electronic control system needs to be programmed
for the total run of a drill in the field depending upon
the fertility distribution across the field. The designed
metering system can be used to develop an applicator,
which can also be used as a retrofit on existing machines
for variable rate fertilizer application.
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