BAHIRDAR INSTITUTE OF TCHNOLOGY Design S PDF

Motorized Reaper Machine 2009
BAHIRDAR INSTITUTE OF TCHNOLOGY
FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING

MECHANICAL ENGINEERING DEPARTMENT
Design stream: - group 4 (Barley)
AGRICULTURAL MACHINERY
PROJECT TITLE: - Motorized Reaper Machine
Prepared by ID
1. MULUGETA ESHETU 0502069
2. SAMUEL MELKAMU 0502288
3. ASSEFA ASNAKE 0500415
4. TAMIRAT MELESE 0502516
5. MIHRET BETEMARIAM 0501805
Submitted to MR. Zemenu Tsehaye

Submission Date: - 25/05/2009 E.C
1|Page
ABSTRACT
This project is done on the design of barely reaper machine. Barley have a physical properties cross
sectional area of stalk 6.68 𝑚𝑚2 and a mechanical properties of static ultimate shear strength up to
6.18 MPa. Reaper machine is a harvesting tool which cut crop and windrow it on the field. The main
components of reaper are header, power source and transmission and frame. The header consists of
cutter and conveyor mechanism. The cutting mechanism is reciprocating type; in which one movable
cutter bar reciprocates over a counter shear fixed cutter bar, which form scissor like cutting action.
The crop gathered by the star wheel, and the cut crop can be conveyed to one side through lugged
conveyor belt. Cutting width of the reaper is 1000 mm, conveying speed 0.85 m/s and forward speed
of 0.8 m/s (driven by man). The power source of the reaper is water pump motor having 5hp and
3600 RPM, which is used to drive cutter and conveyor mechanism additionally for pumping water.
The power reaches to the required place through one stage reduction gear box having a speed
reduction of 8:1 The slider crank mechanism converts rotary motion to reciprocating motion for the
cutter bar and cross belt change axis of rotation from horizontal to vertical for the conveyor.
I|Page
ACKNOWLEDGMENT
First of all we would like to thank GOD and our parents because nothing would be done without God‘s.
We have great respect and thanks to our lecture Mr. Zemenu Tsehaye, support and help us with strong
suggestion and comment from the beginning till the end of this project.
II | P a g e
TABLE OF CONTENT
ABSTRACT _____________________________________________________________________ I
ACKNOWLEDGMENT ___________________________________________________________ II
TABLE OF CONTENT ___________________________________________________________ III
CHAPTER ONE _________________________________________________________________ 1
1. INTRODUCTION ____________________________________________________________ 1
1.1 WHAT IS BARLEY? ________________________________________________________ 1
1.2 HARVESTING MACHINE _______________________________________________ 10
1.3 PROBLEM STATEMENT ________________________________________________ 16
1.4 OBJECTIVES __________________________________________________________ 17
1.5 METHDOLOGY ___________________________________________________________ 17
CHAPTER TWO ________________________________________________________________ 19
2. LITERATURE REVIEW _____________________________________________________ 19
CHAPTER THREE ______________________________________________________________ 21
3. DESIGN ANALYSIS ________________________________________________________ 21
3.1 Design of crop cutting unit ________________________________________________ 21
3.2 Design of crop divider and lifter: ____________________________________________ 25
3.3 Design of crop conveyor __________________________________________________ 28
3.4 Cutting force ___________________________________________________________ 30
3.5 Power requirement of VCR:- _______________________________________________ 31
3.6 Height of Cut:- __________________________________________________________ 32
3.7 Gear Design ____________________________________________________________ 32
CHAPTER FOUR _______________________________________________________________ 37
4. COST ANALYISIS __________________________________________________________ 37
CHAPTER FIVE ________________________________________________________________ 38
5. PART DRAWING ___________________________________________________________ 38
5.1 Cutter bar ______________________________________________________________ 38
5.2 Star wheel______________________________________________________________ 38
5.3 Lugged Conveyor________________________________________________________ 39
5.4 Divider ________________________________________________________________ 39
4.5 gear mesh _________________________________________________________________ 40
CHAPTER SIX _________________________________________________________________ 41
6. CONCLUSTION AND RECOMENDATION _____________________________________ 41
III | P a g e
6.1 Conclusion _____________________________________________________________ 41

6.2 Recommendation ________________________________________________________ 41
REFERENCE ___________________________________________________________________ 42
List of figure
Figure ‎1-1 Barley crop _____________________________________________________________ 1
Figure ‎1-2 2 row and 6 row barley____________________________________________________ 2
Figure ‎1-3 land preparation _________________________________________________________ 5
Figure ‎1-4 sickle _________________________________________________________________ 8
Figure ‎1-5 traditional threshing ______________________________________________________ 9
Figure ‎1-6 Combine Harvester Machine______________________________________________ 12
Figure ‎1-7 Reaper Machine ________________________________________________________ 15
Figure ‎3-1 Reciprocating type cutter bar ______________________________________________ 21
Figure ‎3-2 Standard dimension of knives section _______________________________________ 22
Figure ‎3-3 Cutting knife __________________________________________________________ 24
Figure ‎3-4 Crop lifter _____________________________________________________________ 25
Figure ‎3-5 Star wheel With Crop Divider _____________________________________________ 27
Figure ‎3-6 Lunged belt conveyor ____________________________________________________ 28
Figure ‎3-7 Cutting Mechanism _____________________________________________________ 32
Figure ‎5-1 cutter bar______________________________________________________________ 38
Figure ‎5-2 star wheel _____________________________________________________________ 38
Figure ‎5-3 lugged belt ____________________________________________________________ 39
Figure ‎5-4 Divider _______________________________________________________________ 39
Figure ‎5-5 gear mesh _____________________________________________________________ 40
List of table
Table ‎3-1 specification of crop cutting unit of VCR _____________________________________ 24
Table ‎3-2 Standard star wheel specification ___________________________________________ 26
Table ‎4-1 material cost____________________________________________________________ 37
IV | P a g e
CHAPTER ONE
1. INTRODUCTION
1.1 WHAT IS BARLEY?
Barley is a member of the grass family. It is a self-pollinating, diploid species with 14 chromosomes.
The wild ancestor of domesticated barley, Hordeum vulgare, subsp. spontaneous, is abundant in
grasslands and woodlands throughout the Fertile Crescent and is abundant in disturbed habitats,
roadsides and orchards. The wild barley is less commonly occurred and is usually found in disturbed
habitats.
Figure ‎1-1 Barley crop

The mechanical properties of barley in average is [1]
The average of the principal diameters was found to be: - 5.41±0.44 mm,
1000-grain weight was: - 41.9±0.2 g
The grain was narrow and elongated having an average sphericity of: - 47.923±1.8 mm
Shear strength at moisture content 22.5% = 6.18 MPA
Area of straw = 6.68 𝑚𝑚2
1.1.1 Classification of barley
Six row barley can produce 25-60 grains two-row barley produces 25-30 grains. Four-row barley
is actually loose six-row barley. Wild barley is generally two-row, most cultivated barley is of the
six-row type. Two-row barley has lower protein content than six-row barley, thus more fermentable
sugar content. High-protein barley is best suited for animal feed. Malting barley has lower protein,
usually produced without a late fertilizer.
1|Page
Figure ‎1-2 2 row and 6 row barley

1.1.2 Geographical Distribution
Barley suitably grows from 2000m-3500m Suitable Environmental conditions a. s. l. The crop needs
cold weather. The crop may grow at mid altitude at some extent. Barley can grows in areas where
wheat and teff cannot grow due to frost. In moisture stress areas the crop can give better yield than
wheat. Barley requires 700-1000mm of rainfall. However, the crop can grow in areas that receive
400-500mm. Barley produced in such areas are mainly used for food purpose than beer production
because the seeds contains more nitrogen. In general, barley best grows in highlands that receive
enough rainfall and intermediate relative humidity. Barley best grows on soils with loam and
medium clay content and on sandy soils that contains essential nutrients. The soil pH is between 6.5-
7.8. Barley is highly susceptible to waterlogging and care should be taken during site selection.
1.1.3 Seasonal variation of Barley
In the main agricultural regions in Ethiopia there are two rainy seasons, the Meher and the Belg, and
consequently there are two crop seasons. Meher is the main crop season. It encompasses crops
harvested between Meskerem (September) and Yeaktit (February). Crops harvested between
Megabit (March) and Nehase (August) are considered part of the Belg season crop. The Meher
season is overwhelmingly important (96.9 percent of total crop production and 95.5 percent of total
cereal production in 2007/08). Only smallholders cultivate crops during the Belg season and yields
are smaller in the Belg than in the Meher season.
Five traditional barley production systems are recognized within the major barley-growing agro
ecologies (Chilot Yirga, Fekadu Alemayehu and Woldeyesus Sinebo, 1998). These are detailed
below.
2|Page
A. Late barley production system

This is the dominant system, which is important in the high-altitude areas of Ethiopia and is
practiced during Meher, the main rainy season (June to October). This system is characterized by
two distinct planting dates. In South Gonder and North Wollo, the different cultivars are sown in two
separate planting seasons. The first cultivar is planted in May, and the second cultivar is planted
between mid-June and early July. These cultivars require 5–6 months to mature. Grain yields from
this system vary from 0.6 to 2.0 t/ha.
B. Barley production system with guie (soil burning)
This is a system that is practiced during the Meher season. It is important in the highlands of north
and North West Shewa, where waterlogging is a major hindrance to barley production. To alleviate
this problem, farmers use guie (soil burning) and ploughing 3–5 times of fields that have been left
fallow for at least five years. Early-maturing farmer cultivars, such as ‗Demoye‘ and ‗Magie‘, are
used in this system, and the grain yield in the first year is about 2.0 t/ha, but declines dramatically in
subsequent years. Other cultural practices are similar to the late barley production system.
C. Early-barley production system
This is also a system practiced during the Meher season, and is important in both the mid- and high-
altitude areas of Gojam and Gonder (North West Ethiopia) and in some parts of Shewa. Early
cultivars are grown that require 3.5–4 months to mature, such as ‗Semereta‘ in Shewa; Gojam and
Belga in North Gonder; and Tebele in South Gonder. The cultivars are planted from mid-May to
June and harvested in early September to early October. Cultivars ‗Aruso‘ in Arsi and Bale and
‗Saesa‘ in Tigray are early types that are also grown. Cultivars such as ‗Ehilzer‘ and ‗Tebele‘—two
row types—are grown in the early-growing areas of Wollo. The yield of early barley in a normal
year varies from 0.7 to 1.5 t/ha.
D. Belg barley production system
This system is practiced in north and North West Shewa, North Wollo, Bale and a few areas in Arsi.
Belg barley is planted in February to early March and harvested in early July. Early-maturing
cultivars (3–4 month duration) are usually cultivated. In Barley research and development in
Ethiopia this system, farmers do not apply fertilizer. Moisture stress and RWA attack are the major
threats. The yield of Belg barley in a normal year varies from 0.8 to 1.2 t/ha.
E. Residual barley production system
3|Page
This system is important in some parts of Gojam, North and South Gonder, and West Shewa. Early-
maturing cultivars—‗Belga‘ in North Gonder and ‗Semereta‘ in Gojam— are common in this
system. Planting is carried out between September and October, immediately after harvest of the
main-season barley crop. The seed of the main-season barley is re-sown in the same field, in the
main-season fallow field, or in any other field where the main-season crop has failed. Fertilizer is not
generally applied in this system. Harvesting is carried out from December to February. Grain yield
from this system is generally low, less than 1.0 t/ha, and mainly used as seed for the next season.
Water management
Barley is a drought tolerant winter season crop and thus requires less irrigation. Beside a pre-sowing
irrigation for crop establishment, the crop also requires irrigation at 3 stages. Active tillering,flag
1.1.4 Land Preparation and crop management
For good, uniform germination and better control of weed on barley particularly in dryland areas,
well prepared land is essential. Barley needs 2-3 times of ploughing. Any type of Land preparation
and tillage are carried out by oxen, pulling the traditional plough the maresha Again in certain small
pockets of the country, horses and mules are occasionally used to pull the maresha, but generally,
oxen provide the main tractive force.
The traditional plough consists of a metal point or tine, fastened on a wooden arm, to the pole, which
in turn is fastened to a wooden neck yoke. At each side of the metal point are two wooden wings
which push the soil aside. The traditional plough is a light implement ranging from 17 to 26 kg with
the yoke and makes it possible to be transported together to and from the field over different terrain
by one person. Except for the metal tine which the farmer has to buy from the blacksmith, the rest is
home-made.
Each cultivation pass is made perpendicular to the previous one so as to disturb the whole soil. The
depth of the first ploughing ranges from 5 to 8 cm while with the last pass up to 20 cm depth could
be attained. The time required for land preparation also varies from 100 hrs/ha to 150 hrs/ha for
Vertisols and light soils, respectively (Abiye Astatke and Matthews, 1982). The maresha has the
advantage of being handled by a pair of indigenous oxen each weighing not more than 300 kg. The
power developed by a pair of local zebu oxen pulling the maresha ranges between 0.50 to 0.90-kw
(Abiye Astatke and Matthews, 1980).
4|Page
Figure ‎1-3 land preparation

1.1.5 Traditional methods of barley tillage
Throughout most of the Ethiopian highlands the land is tilled using a pair of oxen of one of the
indigenous Zebu breeds which pull the locally-made traditional cultivation tool, the maresha. The
power output of oxen pulling this plough is dependent on their body weight, nutrition and health
status, the terrain and soil condition, depth of ploughing, working speed, pass number, the training of
the animal and the skill of the handler. Depending on the soil type and the crop, the land is cultivated
up to six times before planting. Oxen working condition weighs approximately 250–300 kg. The
maresha is constructed by the farmer from wood and has a metal tip for penetration. This plough
does not turn a furrow like the conventional mould board plough, but disturbs the soil to a depth of
about 15 cm.
Ploughing using the maresha is done perpendicularly and diagonally across plots. Pass numbers refer
to the number of cultivations done in the season. Oxen are commonly worked for 4 to 9 hr/ day,
depending mainly on the time available for soil preparation. Traditionally, animals within the Debre
Zeit area are worked throughout the day with few breaks. In contrast, farmers in the Debre Berhan
areas normally give their oxen a rest period at mid-day during which animals are watered and fed.
1.1.6 Fertilization of barley
Fertilization is the process which is needed to gain more production of crops and it also used to
accelerate the production time of crops.
5|Page
For good yield of barley, enough nutrients and uniform distribution of water is essential. Barley
needs more nutrients during early stage than other stages of planting.
The amount of fertilizer is depending up on crop needed, soil fertility and moisture content of the
soil. In our country Ethiopia traditionally farmers use natural fertilizers for the production of barley,
like 1. Dung/animal wastes
2. Plant humus/ ruin
3. Ashy/cinder
Most of the time the farmers use those natural fertilizers before planting and after planting of the
crop barley to improve the fertility and moisture content of the soil.In addition to those natural
fertilizers the farmers who are lived in low land areas use human made fertilizers to be more
productive and those human made fertilizers are urea and dup.
The rain fed crops are seldom manured directly. It is the preceding crop in the rotation which
receives the manure. In irrigated crop, compost should be applied about a month before sowing. The
application of organic matter to soil besides providing essential nutrients to the crop also helps in
overcoming salt problems of saline and alkali soils and moisture conservation.
1.1.7 Sowing / Seeding
Seeding or sowing is an art of placing seeds in the soil to have good germination in the field. A
perfect seeding gives:
 Correct amount of seed per unit area.
 Correct depth at which seed is placed in the soil.
 Correct spacing between row-to-row and plant-to-plant.
Method of sowing is an important aspect, particularly under rain fed conditions. There should be
adequate moisture in soil for proper germination. There are many more sowing methods for different
seeds, among the following broadcasting seeding operation are adopted in Ethiopia.
A. Broadcasting:- It is the process of random scattering of seed on the surface of seedbeds. It can
be done manually or mechanically both. When broadcasting is done manually, uniformity of
seed depends upon skill of the man. Soon after broadcasting the seeds are covered by planking
or some other devices. Usually higher seed rate is obtained in this system. Mechanical
broadcasters are used for large-scale work. This machine scatters the seeds on the surface of the
seedbed at controlled rates. But Ethiopian farmer uses broadcasting seeding operations for every
type of crops. Seeding operation of barley is carried out still manually by hands in Ethiopia
context.
6|Page
B. Dibbling:- Dibbling is the process of placing and seeds in holes made in seedbed and covering
them. In this method, seeds are placed in holes make at definite depth at fixed spacing. Dibbling
seeding operation is not known in Ethiopia.
C. Drilling: - Drilling consists of dropping the seeds in furrow lines in a continuous flow and
covering them with soil. Even though his operation excellence alternatives, it does not use
Ethiopian farmers for any crops or barley due to the cost of the machine.
D. Seed dropping behind the plough:- it is very common method used in villages. It is used for
seed like maize, gram, peas, wheat and barley. A man drops seeds in the furrow behind the
plough. This is a slow and laborious method. This also is not adapted in Ethiopia.
E. Transplanting: - Transplanting consists of preparing seedlings in nursery and then planting these
seedlings in the prepared field. It does not preferable for barley.
F. Hill dropping: - In this method, seeds are dropped at fixed spacing and not in a continuous
stream. Thus the spacing between plant to plant in a row is constant. Barley sowing is adopted
only by hand due to far from the technology.
Sowing Container Of Barley In Ethiopia When Ethiopian farmers sows different crops , they used
different container or equipment to store the seeds. Most Ethiopian farmer uses traditional
equipment‘s called Kunna. There are other modern machines which are integrated with the
ploughing, but it is not adopted in our country
(i) Seed rate
Seed rate varies according to agro-condition of. In irrigated areas for normal sowing 75-90 kg of
seed/ha is sufficient while in late-sown conditions the seed rate should be increased depending on
90-100 kg/h. Under rain fed conditions, 80-100 kg seed/ha is required depending on soil
availability. For sowing in saline and alkaline soils, use 100-120 kg seed/ha to ensure desired ant
population.
(ii) Spacing
The spacing between rows is usually 22-23 cm under irrigated conditions. In saline and alkaline
soils 20 cm row spacing is recommended. Depth of sowing; the best depth of sowing is 3-5 cm under
irrigated 5-8 cm under the rain fed conditions depending on initial soil condition. In clay soils
shallow planting is preferable.
Research on the agronomics of varied row spacing has shown mixed results. The Agricultural
Technology Centre conducted a row spacing study from 1998 to 2000. An increase in row spacing
resulted in a decrease in yield. The decrease in yield was attributed to the narrow seed bed utilization
of the disk opener. Very little research has been conducted on the effect of row widths on crop
7|Page
yields. Research into the interaction of row width and spacing is required for producers to optimize
yields.A study was started to determine the optimum row width and spacing for seeding barley,
canola and wheat. Major variables in the study were row width, row spacing and the proportion of
nitrogen placed with the seed and banded between rows. The row spacing‘s were 8, 10 and 12 in
(203, 254 and 305 mm). The row widths were 1, 3 and 5 in (25, 75 and 125 mm). The nitrogen
placements were 100% with seed, 50% with seed/50% midrow banded and 100% midrow banded.
Plant counts and crop yields were measured.
Row spacing affected crop yield. An increase in row spacing resulted in a decrease in crop yield.
Row width affected crop yield. The use of the 3 and 5 in (75 and 125 mm) row widths resulted in
higher crop yield than the 1 in (25 mm) row width at 7 of the 11 crop site years. Nitrogen placement
affected crop yield. Placing 100% of the nitrogen with the seed resulted in significantly lower crop
yield at 5 of 6 crop site years.
(iii) Weed control
The crop has early vigorous growth and by active tillage stage, it completely covers the soil resulting
in smothering of weed. Irrigated barley with high fertilization usually suffers from severe weed
competition, the major weeds are Muja, ageratefa, and mesekeleferi and seredo are some of weeds.
Weeds usually pose greater problem in irrigated areas.
The use of weed-free seed and thoroughly prepared seed-bed are essential for controlling the weeds
effectively. One hoeing or hand weeding immediately after first irrigation takes care of weeds in
barley.
1.1.8 Harvesting
Harvesting for silage would begin when the barley heads (grain) are well dried, which is
approximately (of (80 – 90) % of moisture content. The cutting of barley in Ethiopia is done by
simple harvesting tool called sickle.
Figure ‎1-4 sickle

The operation of harvesting is done manually by using sickle. Foe harvesting operation
approximately 25 – 30 persons needed to cut a hectare of barley. During silage some barleys
8|Page
collected and tightened after cutting forming traditional name ―nedo‖. The barleys should cut equally
to form a good tighten and a suitable collection to form a traditional name ―kucho‖.
Cutting of barley in Ethiopia mostly done in the period of September and October, but sometimes it
is done approximately after October 15 for harvesting two times in a year. In this period the silage
done carefully as it is rainy season. During this period the cutting the upper part of the barley to
reduce the spoilage of the grain by some weeds and moisture of the soil. Some farmers splay the
collected barley to dry completely for suitable trashing of the grain
1.1.9 Threshing
Threshing is done after all crops have been gathered from the field. The threshing ground is
prepared first. A threshing ground called Awdemma is made on nearly level or gently sloping
ground by digging out the vegetation inside the soil and smoothing the ground. Note that the
farmers are permanently pushing barley to the center of the threshing ground with forks that have
three or four prongs.
In some parts of the country the ground is made firm by wetting the soil and then driving cattle over
it. Then fresh cattle dung is collected from corrals or fields where cattle have grazed and a mixture
of manure and water is prepared. This mixture is prepared in a shallow hole dug in the ground
called Bola Obid, in earthenware jars, and a wooden container is prepared on the so-called
Awdemma. The loose soil is removed and the bare ground is smeared with this mixture. To some
extent, this reduces the mixing of the grain with soil.
Pulse and other grain crops are threshed first. Barley is then threshed on the firmed Awdemma.
Usually the threshing floor is re-smeared after every threshing, since the same floor is used for
threshing all crops. The size of the threshing ground varies in different localities and dependent in
part on the wealth of the farmer (Taddesse, 1969).Threshing may be a festive occasion.
Figure ‎1-5 traditional threshing
9|Page
1.1.10 Storage of barley

In Ethiopia, like in other developing countries post-harvest losses, including storage losses is
estimated at 5-26%. Damages or loss of barley grains vary generally and are a function of crop
variety, pest and insects, climate, system of harvesting, system of processing, storage, handling and
marketing. Interrelated factors that greatly affect quality of stored grain are grain moisture content,
grain temperature, initial condition of the grain, insects and pest and molds. The main objective of
grain storage is to maintain quality of the produce for a long period of time and the basic
requirements of every grain storage structure or systems are to protect the grains from insects,
rodents and prevent deterioration of the grains by the activities of micro-organisms. Safe storage is
one that minimizes quantity loss and maintains grain quality
Common storage structure used by most of Ethiopian farmers is traditional ones with poor
construction that exposes the stored barley grains to different deterioration agents or conditions and
to which appropriate management and monitoring of all the influencing factors hasn‘t been
considered.
Grain storage is the practice of keeping grain in store houses, heaps, bulks and bags in such a way
that seeds should retain both food and seedling value, provided with certain conditions like
ventilation, fumigation and optimum temperature and humidity. Whereas, the purpose of storing
seeds is to preserve planting stocks from one season until the next. Crop losses occur at all stages of
the post-harvest handling, including pre-processing, transportation, storage, processing and
packaging and marketing. Grain losses could arise either from poor post-harvest handling or from
production over and above the capacity of the available stores.
1.2 HARVESTING MACHINE

A reaper is a farming tool or person that reaps (cuts and gathers) crops at harvest, when they are ripe.
Hand reaper is done by various means, including plucking the ears of grains directly by hand, cutting
the grain stalks with a sickle, cutting them with a scythe, or with a later type of scythe called a
cradle. The reaped grain stalks are gathered into sheaves (bunches), tied with string or with a twist of
straw. Several sheaves (singular sheaf) are then leant against each other with the ears off the ground
to dry out, forming a stool. After drying, the sheaves are gathered from the field and stacked, being
placed with the ears inwards, then covered with hatch or a tarpaulin; this is called a stack or rick.
Ricks are made in an area inaccessible to livestock, called a rick-yard or stack-yard. The corn-rick is
later broken down and the sheaves threshed to separate the grain from the straw. Collecting spilt
grain from the field after reaping is called gleaning, and is traditionally done either by hand, or by
penning animals. [2]
10 | P a g e
Hand reaping is now rarely done in industrialized countries, but is still the normal method where
machines are unavailable or where access for them is limited. A mechanical reaper or reaping
machine is a mechanical, semi-automated device that harvests crops. Mechanical reapers are an
important part of mechanized agriculture and a main feature of agricultural productivity.
Barley reaping can be done either using manually or using machine. In most developing countries,
Barley harvesting is usually done by hand manually. But developed country uses different machine
such as reaper machine and combine machine. The major objectives of using machinery are:
a) To increase labor productivity by substituting mechanization for labor (or by bringing a larger area
of land under cultivation with the same amount of labor),
b) To increase land productivity by removing bottlenecks which hamper higher land productivity,
c) To decrease costs of production by reducing expenditures for labor and draft animals and by more
efficient operations.
1.2.1. Combine Harvester Machine
Combine harvester performs the following basic operations: cutting, conveyor and feeding the cut
material to the threshing mechanism, threshing, separating and cleaning etc. are all completed one
time by the combine in field. The major of the combine are the cutting section, the threshing section,
a separating section, a cleaner and a grain collection system. The cutting section usually consists of
straw lifters for lifting especially lodged crop, a cutter bar for cutting the straw above the ground, a
reel for feeding the cut crop into the conveying system and conveyors for transporting the crop to the
threshing components. The thresher consists of one or more threshing cylinders and a concave. The
threshing unit can be conventional but in most cases rice combines have axial-flow drums, which are
better in handling wet straw and do not require straw walkers for separating the straw. A
conventional combine has a set of straw walkers for separation of the grain from the straw because
the crop passes the concave very quickly and a lot of threshed grains are therefore still contained in
the straw. On the straw walkers the remaining grains are separated from the straw by gravity. All
combines contain a cleaner in which chaff, immature grains and small straw particles are separated
from the grains.
The cleaner consists of a blower and several oscillating sieves. For grain collection the combine
either has a grain tank or is equipped with a grain bagging station. [3]
11 | P a g e
Figure ‎1-6 Combine Harvester Machine

The combine harvesting machine can be classified into wheel combine and claw track combine
according to the moving parts and can be classified into straight-through feed combine and head feed
combine.
A. Straight – through feed combine harvester
The straight-through feed combine is that all the cut crop and stem is fed directly into cylinder for
threshing, separating and cleaning. The straight-through feed combine harvester can be classified
into self-propelled type, trailed-type and mounted type depending on the power supplied.
Self-propelled combine:- the working parts including cutter, conveyor, feeder, threshers, sieve and
the separator, transmission, hydraulic systems and running devices. The crop flow through combine
when the machine moves forward, the divider separates the crop for cutting, the reel picks up the
standing or laid crops and pushes them to the cutting mechanism and then pushes them down to the
platform after cutting and then conveys to the thresher.
Mounted-type combines:- is mounted on a tractor to utilize its power. The platform of crop
combine is in front of the tractor and the thresher is in rear. The conveyor mechanism is positioned
sidewise to connect the platform and thresher. The machine can open cut by itself because the platform
mounted in front of the tractor so it has the advantage as in the self-propelled barley combine.
B. Head feed combine harvester
The head feed barley combine is to hold the cut straws of the crop by clamping chain and let only the
ears contact the thresher mechanism. It feeds only panicle part of reaped paddy into threshing parts
of the machine. Threshed grain is either bagged or poured into a grain tank. The flow of crop in rice
harvesting is as follow: the crop is held by a grain lifter or a reel before cutting; the crop is cut while
its stalk is holding. For horizontal platform, reel slat of pickup reel pushes the crop down onto the
platform. For vertical table, the crop lifter is used to lift the laid crop and then transmits the crop to
star wheel or other kind of reel. The star wheel or reel is holding the crop while the crop is cut. After
12 | P a g e
cutting, the crop is conveyed to aside and clamped by the middle conveyor mechanism and is than
fed to the thresher. Only the upper part of crop heads and ears are fed into the thresher for threshing.
The separated material gets through the concave sieve and down to the cleaning mechanism to be
cleaned. The cleaned grain is conveyed to grain discharge mechanism. The straws stalk after
threshing is discharged by the clamp chain conveyor in windrowing or stacking onto the stubble
land.
1.2.2. Barley Reaper Machine
Barley reaper machine is a machine that cuts and lays stalks of planted rice crop. The cutting tool of
the reaper may apply its cutting action through the rotary motion or reciprocating motion. In
reciprocating action the cutting tool made of several serrated triangular sections that reciprocate
against stationary fingers while in rotary action the cutting element rotate in the horizontal plane.
Reapers are used for harvesting of crops mostly at ground level. It consists of crop-row divider,
cutter bar assembly, feeding and conveying devices.
i. Type of Reaper
Reapers are classified on the basis of conveying of crops as given below:
Vertical conveying Reaper Windrower: It consists of crop row divider, star wheel, cutter bar,
and a pair of lugged canvas conveyor belts. This type of machines cut the crops and conveys
vertically to one end and windrows the crops on the ground uniformly. Collection of crop for making
bundles is easy and it is done manually. Self-propelled walking types, self- propelled riding type and
tractor mounted type reaper-windrowers are available. These types of reapers are suitable for crops
like wheat and rice. The field capacities of these machines vary from 0.20-0.40 ha/h.
Horizontal Conveying Reapers: This type of reapers is provided with crop dividers at the end,
crop gathering reel, cutter bar and horizontal conveyor belt. They cut the crop, convey the crop
horizontally to one end and drop it to the ground in head-tail fashion. Collection of crop for making
bundles is difficult. This type of reapers is tractor mounted and suitable for wheat, rice, soybean, and
gram. Performance of reapers with narrow-pitch cutter bar is better for soybean and gram crops.
Bunch Conveying Reapers: This type of reapers is similar to horizontal conveying reapers
except that the cut crop is collected on a platform and is being released occasionally to the ground in
the form of bunch by actuating a hand lever. Here, collection of crops for making bundles is difficult.
Bullock drawn and tractor-operated models are available and they are suitable for harvesting wheat,
rice and soybean crops.
Reaper Binders: The cutting unit of this type of reapers may be disc type or cutter bar type.
After cutting, the crop is conveyed vertically to the binding mechanism and released to the ground in
13 | P a g e
the form of bundles. Self-propelled walking type models are available but these are not popular due
to high cost of twine. Reaper binders are suitable for rice and wheat.
The reaper machine consists of three main components. These are frame, power source and
transmission and cutting bar.
 Frame – it provide supporting the whole structure or component of the reaper machine.
Frame also provides spacing for the installation of power source and power transmission.
 Power source – it supply energy to the cutting bar.
 Power transmission – it used to transfer power from the source to the user part (ground
wheel if it is power driven, cutting tool, and conveyor). The transmission element consists of
different shaft, gear, belt and pulley and chain and sprocket.
 Cutting bar– it is an assembly of several parts comprising of a cutting tool (knife), conveyor
(chain or belt), star wheel, crop divider, ledger plates, guides and shoes. The knife cuts the
grass or grain crop by its reciprocating action`. It is a metallic rectangular bar, on which
triangular sections are mounted. The knife sections make reciprocating motion inside the
fingers and cuts the plants. There are knife guides with clips to keep the knife sections very
closely on the ledger plates for effective cutting action.
 Knife - It is the reciprocating part of the cutter bar, comprising of knife head, knife back and
knife sections.
 Knife section - It is a steel plate of triangular shape with two cutting edges.
 Knife head - It is the portion of the knife which is connected to the pitman.
 Knife back - It is the strip of steel to which knife sections are riveted and the knife head is
attached.
 Pitman - Pitman is the link between the knife and crank wheel of the mower. It transmits
motion to a knife. Wooden pitman is commonly used for the cutter which acts as safety
device. It breaks and protects the cutter bar from damage whenever the knife is locked by
some obstacle or choked by the crop.
 Connecting rod - It is placed between pitman and crank wheel. It converts rotary motion
of crank wheel in to reciprocating motion of the knife.
 Crop divider (header) – is used to separate crop in relative to their position of growing. It
can have made from metal sheet and attached to the frame in front of the cutting tool.
 Star wheel – freely rotating part which used to grasp the crop to the cutting tool (knife). It
is drive by the conveyor.
14 | P a g e
Figure ‎1-7 Reaper Machine

 Conveyor (belt) – it is a component used to convey the crop to one side of the machine and
windrow the crop on the ground for easy of collecting. The belts have projection allowing it
length where this projection are used hold the crop and convey it.
1.2.3 Operation of Reaper Machine
The power is taken from the engine pulley to the harvester main shaft through compound idlers.
Then the power is transmitted to the cutting tool through connecting rod and pitmen. The connecting
rod converts rotary motion in to reciprocating motion. Knife is connected to pitman hence the knife
reciprocates and performs the cutting job. If the harvested crop is discharged at the right side of the
reaper the machine has to be turned always to the left side.
Working Process of the Machine:-When the machine travels at a given speed, the divider separates
the crop to be guided to the cutter bar with the help of the star wheel, and the crop is cut by the cutter
bar. The cut crop is conveyed to one side by the belt and windrowed with the ears sidewise and the
windrow and the moving direction of the machine forming an angle of 90 degrees for easy collection
and bundling. For this purpose the machine must convey the cut crop bunch on a vertical platform,
continuously and without any blockage (Small Farm Equipment).
During forward motion of the harvester, crop enters in the cutter bar mechanism and gets sheared
and the harvested crop is conveyed to right side of the machine by the conveyor belt. The conveyors
get its power through belt transmission from the main shaft.
15 | P a g e
In the cutting operation of reaper machine there are three processes. These processes are gathering,
cutting and conveying.
 Gathering is the way of attracting the crop to the cutting tool. In the gathering process the
crop divider allows the crops inter to the cutter in separate way with respect to its position
and the star wheel hold and approach them to the cutter.
 Cutting operation is simply cutting of the stalk of the crop by applying significant amount of
force. The oscillating (back and front) motions of the cutting tool cut the crop.
 Conveying is the process of moving the crop (after cutting) to one side of the machine and
the harvested crop are windrowed in the field.
1.3 PROBLEM STATEMENT

Now days, most of our society uses traditional way of cutting and collecting crops. These are mostly
hand tools which are made many years ago or they are made before the centuries or decades of years.
There also exists modern machineries which are able to harvest large farm areas within a short period
of time but they are very costly and most of them need either electric power or fuel for their
operation. This is limited for developed country or farmers with higher income that have large farm
areas due to its high cost. Some of the problems happened in using higher machineries, need high
cost, skilled person and are not applicable for every working area. While cutting cereals by hand
sickle it leads to problems like Back bone pain, tedious process, time consuming, high laborer, high
probability of cutting fingers, the cereals are exposed to unseasonal rain and wind that can decrease
the income of the crops because of their high time consumption.
And also the existing small scale machines have some problems which are:-
 Excessive Vibration
 Clearance between the cutting blade and the base plate
 Noise of the Star wheel
 Power transmission
 Low Forward Speed
 Conveyor problem
 Clogging of the harvested barely with chain
 Twisting of the harvested crop with lug and chain
 Turning Problem
 Damage of crop
16 | P a g e
1.4 OBJECTIVES
1.4.1 General Objectives
The objective of this project is to design and transfer the technology of a reaper machine that use a
power source of water pump for wheat and barley harvesting, which can be easily manufactured in
medium workshops using available materials with in minimum cost and short time.
1.4.2 Specific objective
 To design the components of a reaper machine.
 To analyze the materials used in the machine.
 To modify few component of reaper machine.
 To analyze the cost of the machine.
 To analyze the relationship between the forward speeds of the machine, the cutter speed and conveyor
speed.
 To analyze the cutting mechanism of a reaper machine
 To determine the optimum cutting force that used to cut the rice crop stalk.
 To show the assembly method of the machine and its components using CATIA software, if it‘s
possible.
1.5 METHDOLOGY
With the demand for the grains on barley, the aim was to fabricate affordable reaper collector for
increasing the economy of small scale farmers. For the fulfillment of this aim, it is decided to follow
following steps:
1. Interview the local farmers who have small scale land holding and enquire about the harvesting
practices and the crops produced and emerging trends in crop harvesting.
2. Interview agricultural equipment manufacturers to get information about various equipment‘s that
are available and are in demand.
3. Refer various international papers in small scale harvesters produced earlier.
4. Detain analysis of each component to find the required shape, dimension and material type for each
component.
 Determination of cutting width from normal human walk.
 Study of speed relation such as forward and conveyor belt speed
 Star wheel: its speed, number of wing, position
 Cutter bar : determine length, number of knife, knife (cutting) speed,
17 | P a g e
 Cutting geometry: determine bevel angle formed at the cutting edge, oblique angle formed
between edge and forward direction in order to prevent deflection of crop
 Cutting Power: determination of cutting power requirement from the properties of the crop
 Gear design: find the dimension and check the load it supposed.
 Shaft design: determine the dimension from the power transmitted assuming twisting and
bending moment.
 Tire selection based on load and road condition.
6. Detail part drawing
18 | P a g e
CHAPTER TWO
2. LITERATURE REVIEW
Christopher Molica‘s [4] project was done by the students of Worchester Polytechnic Institute. They
have created a small scale harvester which was combined reaper and binder. This machine was
developed concerned to the small scale grain growers. .
N. S. L. Srivastava [5] checked in the interests of the farmers and the problems they face while
harvesting and maintaining the agriculture field. This paper was an in depth study of the farming
conditions of the farmers and their basic problems.
Indian Government Analysis [6] was the survey done by Indian Government in the fiscal year of
2012-13. This survey was intended to analyze and collect the data related to the problems and
difficulties faced by the Indian farmers. Asia and Pacific Commission on Agricultural Statistics
Twenty-Third Session Siem Reap, Cambodia, 2630 April 2010 [7] was intended to discuss the
characteristics of small scale farmers across Asia. This commission identifies the problems faced, the
average land holdings and the average income of the small scale farmers.
Dr. S.D. Kulkarni Central Institute of Agricultural Engineering (CIAE) Bhopal [8] discusses the
various problems that the farmers face at the peak season of the harvesting. It specifically limits its
results toward the labor scarcity in India, specifically in the peak harvesting season
Pradhan et al. [9] (1998) took some step to evaluate and select an appropriate harvesting method for
rice in Orissa. The sickle manufactured by Gujarat Agro Industries Corporation (G.A.I.C.) was
superior to locally available sickles. Using this improved sickle, local cultivars of lodging 7addy can
be cut efficiently. For high yielding cultivars and local cultivars that stand vertically at the time of
harvesting, power tiller-operated vertical conveyor reapers are preferred to tractor operated vertical
conveyor reapers. sickle, power tiller operated vertical conveyor reaper and tractor-operated vertical
conveyor reaper respectively. Aldas et al. (1998) said that, in 1991, a stripper harvester, model
SG800 and was developed at the International Rice Research Institute (IRRI) in collaboration with
Silsoe Research Institute, UK. The Philippine Rice Research Institute (PhilRice) first collaborated
with IRRI in 1993 to field test the SG800 in a reaper dominated province in Central Luzon.
Collaboration was later expanded to include the adaptation and promotion of the stripper harvester in
selected areas of the country through the IRRI-GTZ Project on Post harvest Technologies for Rice in
the Humid Tropics in 1994-97. Necessary modification for the IRRI designed SG800 strippers were
identified during field test to improve performance and durability. Today, PhilRice and IRRI have 2
upgraded designs for local manufactures to work on the SG800 MK-II model for normal field
19 | P a g e
conditions and LS600 models for soft field conditions. There are 13 known manufactures for stripper
systems in the Philippines and at least 162 units have been disturbed throughout the country.
Increased interests from farmers on the technology have promoted manufacturers to further refine the
machine to suit customer needs and conditions. With increasing needs and field conditions. With
increasing endorsement from the government, more manufacturers are expected to continuously
improve the design and the technology is expected to become even more popular for farmers in the
Philippines.
Datt and Prasad [8] (2000) modified and evaluated a self-propelled reaper for harvesting soybean.
The reaper was modified by reducing the height of cutter bar knife and speed of cross conveyor belt
and evaluated for harvesting soybean. The average grain moisture content ranged between 11.4 to
13.1%. The average field capacity, fuel consumption and stubble height were 0.206 hectare per hour,
0.747 liter per hectare and 8.8 cm respectively. The average stubble loss, shutting loss, header loss
and total machine loss were 0.45, 2.28 and 3.7 respectively of the grain yield.
Rahman [6] (2004) conducted modification of power transmission system of a Chinese reaper and its
performance evaluation. The effective field capacity, field efficiency and fuel consumption were
0.22 ha/hr, 81.58% and 0.47 L/hr respectively. At forward speed of 2 km/hr and the cutting width of
the reaper 1.2 m, the total loss of crop was 3.12%. The requirement for mechanical harvesting was
10 man-hr/ha against for manual harvesting was 200 man-hr/ha. Mechanical harvesting saved 95%
labor requirement of manual harvesting. The reaping cost by reaper was Tk. 286.21/ha. On the other
hand manual harvesting cost was Tk.1980/ha. Harvesting cost of rice with reaper was 88.55% of
manual harvesting. The reaper has a breakeven point 10 ha/yr. Based on the literature reviewed
above it may be inferred that the identification of the problems of the reaper is an important aspect to
popularize it among the farmers level. Previous studies had been gone through only improvement,
development and settings of the machine. None did find out the main functional problems of reaper
and as a result there was very little number of reapers available in the farmer‘s field in working
condition in Bangladesh. So the present study was designed to find out the main functional problems
of the reaper and popularize it among the farmers level.
20 | P a g e
CHAPTER THREE
3. DESIGN ANALYSIS
3.1 Design of crop cutting unit
A. Width of cutting (length of cutter bar) (𝐿𝑐):- based on the standard the row to row spacing of cerial
crops.generally, length of cutter bar is in between 1-3 m. if length of cutter bar is less than 1 m, it
creates problem in collection of cut crop.therefor for
barely row to row spacing :- 20 cm
straw to straw spacing :- 2.5 cm
Therefor the length of cutter bar selected on the base of above condition Lc=1m selected
For this length we cut 40 straw in one row
B. Type of cutter bar: - a reciprocating type cutter bar having 76.2 mm strock length and two cuts per
strock is generally used.
Figure ‎3-1 Reciprocating type cutter bar

𝐿𝑐
Number of knife section :- = 𝑠𝑖𝑧𝑒 𝑜𝑓 𝑘𝑛𝑖𝑓𝑒 − − − − − − − − − − − −Equation ‎3-1
𝑠𝑒𝑐𝑡𝑖𝑜𝑛
1000
= 76.2
= 13.12 ≈ 13
C. Selection of guards: standard size twin guards with lip are used in resprocating knife type cutter bars
for harvesting cereal crops.
D. Size and shape of knife section; the size and shape of knife section of cutter bar is selected on the
base of the following parameters:
 Gripping of stack by cutting pair: the crop is cut by impact and shear action between the knife section
and guard lip. Owing to defilation of the crop, the height of stubble is somewhat greater than the
height of cutter bar above ground surface. For normal cutting action, the stack should be pinched
between cutting edge of knife and guard lip as shown below. this condition is satisfied when
∠𝛼 + ∠𝛽 ≤ ∠𝜑1 + ∠𝜑2 − − − − − − − − − − −Equation ‎3-2
Where, ∠𝛼 =angle between cutting edge and axis of knife section
21 | P a g e
∠𝛽 = angle between cutting edge and axis of twin guard

∠𝜑1 &∠𝜑2 = angle of friction between the crop and cutting edge of knife and guard lip respectively
 Forward speed of machine (𝑉𝑚) : the normal walking speed of human labor is about 0.7-0.8 m/s.
therefore, forward speed of machine is selected as 0.8 m/s.
𝛼 Should range from 25-35 0 for moisture content 14-22% in barley crop. Therefore, for operating
speed of 0.8 m/s of machine, the knife section having an angle 𝛼 of 310 or below is selected.
 Rake angle (𝛽), sharpness and thickness of cutting edge: the smaller rake angle and greater the
sharpness, the greater is cutting ability of the knife. Knives of small rack angle and sharp cutting
edges become blunt more rapidly. The knife with rake angle of 220 are sharp for longer time. So,
a rake angle of 220 with sharp cutting edge is generally selected. Thickness of knife section
should not be exceeding 120-130 mm for most cereals.
 Pitch of serrated knives: in order to avoid slipping off the stacks, the knife section should be serrated.
If the pitch of the serration is equal to stalk diameter, the stack will choke the cutter and result in high
power requirement. To avoid this, pitch of the serrated knives is selected two or three times smaller
than the diameter of barely. The diameter of barely varies between 2-4 mm. Hence, the pitch of
serrated knives is kept in range of 1-1.2 mm.
Figure ‎3-2 Standard dimension of knives section

 Clearance between knife section and twin guard: The quality of cutting is governed by the clearance
between the cutting pair. For serrated cutting knives best result are obtained when clearance between
and ledger plates is maintained at 0.3 mm. so, a clearance of 0.5 to 1 mm is generally kept.
 Velocity of knife sections (𝑅): the velocity of knife section is a function of forward speed of the
machine. The velocity ratio (R) between the two is expressed as
𝑉𝐾 = 𝑅 × 𝑉𝑚 − − − − − − − − − − − − − − − − −Equation ‎3-3
Where, 𝑉𝐾 = average knife velocity, m/s
22 | P a g e
𝑉𝑚 = Machine forward speed, m/s

𝑅 = velocity ratio
For best results, according to Klenin (1985) for 𝛼 of 310 the knife velocity should be 1.5 m/s. the
value of R falls between 1.3 to 1.4 with available cutter knives (Bansal, 1989).
Let take R=1.4 and Forward speed of machine (𝑉𝑚) of 0.8 m/s and putting the value in the above
equation, we get 𝑉𝐾 = 1.4 × 0.8 = 1.12 𝑚/𝑠
Also we know that
𝑁𝐾
𝑉𝐾 = 𝑋 ∗ − − − − − − − − − − − − − − − − − − − −Equation ‎3-4
30
Where, X= stroke length or standard knife section 76.2 mm/7.6.2 cm

𝑁𝐾 = RPM of knife section
Therefore, 𝑁𝐾 = 𝑉𝐾 ∗ 30/𝑋
𝑚 𝑐𝑚 30
= 1.12 × 100 × 7.62 𝑐𝑚 = 440.9 𝑟𝑝𝑚 ≈ 450 𝑟𝑝𝑚.
𝑠 𝑚
For a standard 76.2mm knife section, the above velocity translates into 900 𝑠𝑡𝑟𝑜𝑘𝑒𝑠/𝑚𝑖𝑛 or 450 rpm.
Now, engine 𝑟𝑝𝑚 = 3600,
Assume a speed reduction of 1: 8 from engine to cutter bar shaft, therefore knife rpm (𝑁𝐾 ) is given by
3600
𝑁𝐾 = = 450 𝑟𝑝𝑚
8
90
Assume 10% slippage in belt drives therefore, 𝑁𝐾 = 450 ∗ 100 = 400 𝑟𝑝𝑚
The actual average knife speed of a cutter bar of VCR would be

400
𝑉𝐾 = 7.62 ∗ 30∗100 = 1.03 𝑚/𝑠
On the base of the above discussed design parameters, the dimensions of different components of
crop cutting units selected are furnished in table
23 | P a g e
Table ‎3-1 specification of crop cutting unit of VCR

No Particulars Specifications
1 Type of cutter bar Reciprocating knife sections
2 Length of cutter bar 1000 mm
3 Knife section Standard

3.1 Type Trapezoidal
3.2 Blade Serrated
3.3 Length x Height 76.2 mm, 85 mm
3.4 Angle between cutting edge &axis of knife section (𝛼) 310
3.5 Rake angle (𝛽) 220
3.6 Thickness of knife section 120-130 mm
3.7 Pitch of serrated knives 1 - 1.2 mm
3.8 Clearance between knife section and twin guard 0.5 - 1 mm
3.9 Material High carbon steel
4 Knife section M.S flat 25 x 5 mm
5 Finger guards
5.1 Type Twine guards with lip
5.2 Overall length 162 mm
5.3 Overall Width 33 mm
5.4 lip spacing 30 mm
6 Height of cutter bar above ground level 80-100 mm for 310
Figure ‎3-3 Cutting knife
24 | P a g e
3.2 Design of crop divider and lifter:

The crop divider guides the machine to insert the lifters in the crop smoothly for proper cutting or
harvesting of crop.
Figure ‎3-4 Crop lifter

For lifting and conveying crop cutter bar the size of crop lifter = 30 cm, Therefore
𝑙𝑒𝑛𝑔𝑡 𝑕 𝑜𝑓 𝑐𝑢𝑡𝑡𝑒𝑟 𝑏𝑎𝑟
𝑡𝑕𝑒 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑎𝑟 𝑤𝑕𝑒𝑒𝑙 𝑛 = 𝑠𝑖𝑧𝑒 𝑜𝑓 𝑜𝑛𝑒 𝑐𝑟𝑜𝑝 − − − − − − − − − − − Equation ‎3-5
𝑙𝑖𝑓𝑡𝑒𝑟
100 𝑐𝑚
𝑛= =3
30 𝑐𝑚
Therefore, three number of star wheel type crop divider/lifters will be used in the machine. The
optimum inclination of star wheels should be 200 and for the machine to do job well, the horizontal
component of velocity of star wheel should be greater than or equal to forward speed of machine.
Velocity of star wheel (𝑉𝑠𝑤 ) is given by:-
𝑉𝑚
𝑉𝑠𝑤 > − − − − − − − − − − − − − −Equation ‎3-6
cos 𝛼
Where, 𝑉𝑠𝑤 = Average star wheel velocity, m/s
𝑉𝑚 = Machine forward velocity, m/s
𝛼 = Angle of inclination of star wheel (200 )
Thus, for 200 angle of inclination the eqn. becomes 𝑉𝑠𝑤 > 1.08 𝑉𝑚
𝑉𝑠𝑤 > 1.08 × 0.8
𝑉𝑠𝑤 > 0.864 ≈ 0.85 𝑚/𝑠
To determine the diameter of star wheel using
𝐿𝑐 = 𝑛 × 𝐷𝑠𝑤 + 𝐶 − − − − − − − − − − − − − − − − − − − −Equation ‎3-7
Where: 𝐿𝑐– Width of Cut
25 | P a g e
n – Number of Star Wheel

𝐷𝑠𝑤 – Diameter of Star Wheel
C – Clearance between Star Wheels
1000 = 3 × (𝐷𝑠𝑤 + 50)
𝐷𝑠𝑤 = 1000/3 – 50
𝐷𝑠𝑤 = 283.33 ≈ 300 𝑚𝑚
According to bailing (1985) to insert the lifter smoothly, smaller the angle of cover of lifter
𝛼1 𝑜𝑟 𝛽2 (fig) the better it is. But, it is advisable to have 𝛽2 > 𝛼1 as the star wheel involved with side
of angle 𝛽2 . for better performance of lifters the angles 𝛼1 = 120 𝑎𝑛𝑑 𝛽2 = 160 with deflection of
50 mm should be selected.
Table ‎3-2 Standard star wheel specification
Particular Specification
Outside diameter (Do) 300 mm
Inside diameter (Di) 150 mm
Internal diameter of star wheel (d) 15 mm
Material of star wheel Plastic
The star wheel which is driven by the conveyor belt lug has a linear speed at the tip equal to the conveyor
belt. The star wheel rotate with their own axis and the angular speed of the star wheel can be calculated
as:
𝑉
𝜔𝑠𝑤 = 𝑅𝑠𝑤 − − − − − − − − − −Equation ‎3-8
𝑠𝑤
Where: 𝑅𝑠𝑤 = radius of star wheel and equal to 150mm.

𝑉𝑠𝑤 = linear speed of star wheel and equal to the speed of conveyor belt.
𝜔𝑠𝑤 =Angular speed
𝜔𝑠𝑤 = 0.85/0.15 = 5.76 𝑟𝑎𝑑/𝑠𝑒𝑐 = 55 𝑟𝑒𝑣/𝑚𝑖𝑛
26 | P a g e
Figure ‎3-5 Star wheel With Crop Divider

The anti-wind is used to protect winding of crop around the star wheel. To insert the crop divider
smoothly the angle of the divider 𝛼 𝑎𝑛𝑑 𝛽 is made smaller and experimentation shows that it is
preferable to use 𝛼 = 12° and 𝛽 = 16° with an offset of 50mm.The optimum inclination of the star
wheels, empirically arrived at by the Chinese, is 20° with the horizontal.[11]
The star wheels have outer diameter of (Do) 300 mm and inner (Di) 150 mm. The number star wheel
wing in each star wheel can be calculated from the relation of its forward and rotational speed.
𝑉𝑠𝑤 = 𝑛𝑠 × 𝐿𝑠 × 𝜔𝑠𝑤 − − − − − − − − − − − − −Equation ‎3-9
Where - 𝑛𝑠 = number of star wheel wing
𝐿𝑠 =length of star wheel wing
𝜔𝑠𝑤 = rotational speed of star wheel in rev/s (55 rpm = 0.917 rev/s)
𝐷𝑜 −𝐷𝑖
𝐿𝑠 = − − − − − − − − − − − − − − − − − − − Equation ‎3-10
2
300−150
𝐿𝑠 = = 75 𝑚𝑚
2
0.85 = 𝑛𝑠 × 0.075 × 0.917

𝑛𝑠 = 12.4 ≈ 12
The number of star wheel wing is therefore ns = 12
The angle between stars is 𝜃 which equal to: 𝜃 = 360/12 = 300
Pitch of stars (p) is the gap between consecutive stars at the tip and it is equal to the pitch of the conveyor
𝜋𝐷𝑠𝑤
belt. 𝑃= 𝑛𝑠
𝜋×300
𝑃= = 78.5 𝑚𝑚
12
 Length of crop divider is determined by

27 | P a g e
𝑅𝑠𝑤 −50
𝐿𝑑 = − − − − − − − − − − − −Equation ‎3-11
tan 𝛼
Where, 𝐿𝑑 = length of crop divider

𝑅𝑠𝑤 =Radius of star wheel
𝛼 = Angle of crop divider
150−50
∴ 𝐿𝑑 = tan 12
= 470.46 𝑚𝑚
The horizontal distance from the tip of the crop divider to the contact point of star wheel and lug of belt is
give by:
𝐿1 = 𝐿𝑑 + 𝑅𝑠𝑤 × cos 20 − − − − − − −Equation ‎3-12
Where 𝜃 = angle inclination of star wheel
𝐿1 = Horizontal distance
∴ 𝐿1 = 470.46 + 150 × cos 20 = 583 𝑚𝑚
The vertical height (H1) from the tip of the crop divider to the contact point of star wheel and lug is given
by:
𝐻1 = (𝐿𝑑 + 𝑅𝑠𝑤 ) × sin 20 − − − − − − − −Equation ‎3-13
∴ 𝐻1 = 470.46 + 150 × sin 20 = 212 𝑚𝑚
3.3 Design of crop conveyor

The crop cut by the cutting unit of self-propelled machine is conveyed to one side by the lugged belt
conveyor at an angle of 90 for easy collection and bundling. For this purpose the conveyor of the
machine must convey the bunch of cut crop on a vertical platform continuously without blockage.
Therefore, rate of cut crop conveyed by the conveyor should be greater than the crop cut by the
cutting unit of reaper. The details of conveyor design (Fig) are as follows:
Figure ‎3-6 Lunged belt conveyor

(i) Speed of lugged belt and diameter of pulley: for lugged belt conveyor the belt speed is given by
28 | P a g e
𝜋𝐷𝑝 𝑁𝑝
𝑉𝑏 = − − − − − − − − − − − − − − −Equation ‎3-14
60
Where, 𝐷𝑝 =diameter of lugged belt pulley, m

𝑁𝑝 = Rpm of lugged belt pulley
𝑉𝑏 =Periferial speed of flat belt. (1.33 − 1.5 𝑚/𝑠)
Assume, 𝐷𝑝 = 12.5 𝑐𝑚 𝑎𝑛𝑑 𝑉𝑏 = 1.4 𝑚/𝑠
𝜋×0.125×𝑁𝑝
1.4 = = 214 𝑟𝑝𝑚
60
Since, the driver from the shaft which is used for driving the crank shaft having 400 rpm is used to
drive the conveyor belt through sprocket chain, the speed of pulley shaft would be 𝑁𝑝 = 214 𝑟𝑝𝑚
400
So, the speed ratio would be = 214 = 1.87 ∶ 1
60×1.12
Therefore diameter of pulley on driver is 𝐷𝑑 = = 51.6 𝑚𝑚
𝜋×400
(ii) Length of lugged belt: it is calculated based on length of cutter bar and length of vertical platform
required for supporting the crop.
Length of cut bar (𝐿𝑐) = 100 cm
Length of vertical platform (𝐿𝑝) =100 cm
Now center to center distance (C) between driving and driven pulley is given by
𝐷𝑝 𝐷𝑝
𝐶 = + 𝐿𝑝 + − − − − − − − − − − −Equation ‎3-15
2 2
𝐶 = 6.25 + 100 + 6.25 = 112.5 𝑐𝑚

The length of belt is given by
𝜋 𝐷+𝑑 𝐷−𝑑 2
𝐿 = 2𝐶 + + − − − − − − − − − −Equation ‎3-16
2 4𝐶
𝜋 12.5+12.5 12.5−12.5 2
𝐿 = 2 × 112.5 + +
2 4×112.5
𝐿 = 264.25 𝑐𝑚
The length of flat belt required for lugged belt conveyor would be 264.25 cm
(iii) Pitch of lugs: According to Devnani (1985), the pitch of lugs on flat belt of conveyor is given by
πDs = P × Ns − − − − − − − − − − − − − − − −Equation ‎3-17

Where, Ds = diameter of star wheel, 300 mm
Ns = number of arm of star wheel, 12
P = pitch of lugs on the belt, mm
𝜋×300
Therefore, 𝑃 = = 78.5 𝑚𝑚
12
𝐿 2642 .5
Now, number of lugs on conveyor belt = 𝑃 = = 33.6 ≈ 34
78.5
29 | P a g e
Adjusted length of belt = 𝑃 × 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑢𝑔𝑠 = 78.5 × 34 = 2669 𝑚𝑚 𝑜𝑟 266.9 𝑐𝑚

(iv) Lug height and clearance: The lug height should be such that the branches of cut crop can be
conveyed continuously without any blockage. This is only possible when conveyor output per
unit time is greater than equal to cutter output.
Therefore, 𝑜𝑢𝑡𝑝𝑢𝑡 𝑜𝑓 𝑐𝑜𝑣𝑒𝑦𝑜𝑟(𝑄𝑐𝑜𝑛 ) ≥ 𝑐𝑢𝑡𝑡𝑒𝑟 𝑏𝑎𝑟 𝑜𝑢𝑡𝑝𝑢𝑡(𝑄𝑐𝑢𝑡 )
Vb × h × w × ρ2 ≥ Vm × w 2 × ρ1 − − − − − − − − − − −Equation ‎3-18
Vm × w 2 × ρ1
𝑕≥
Vb × w × ρ2
𝜌2 𝐴1 𝑤 Vm
Take 𝜌1 = 𝑞 = 𝐴2 Then 𝑕 ≥ ×
𝑞 Vc
Where Vm – Traveling speed

Vb – Speed of conveyor belt
W – Cutting width
h – Height of lugs
ρ1 – Density of plant in the field
ρ2 – Density of cut crop on the vertical platform
q- Gathered crop parameter
𝐴1 - 1 𝑚2 area in the field
𝐴2 – Area of a circle bunched cut crop from 1 𝑚2 = 0.06 𝑚2
1
∴q= = 16.67
0.06
100 0.8
𝑕≥ ×
16.67 1.4
h ≥ 3.43 cm
The finger of star wheel should be strike at the center of lug. Therefore, a clearance of 12-15 mm
between flat belt and tip of star wheel should be maintained.
Height of lug = 3.43 + 1.2 = 4.63 cm. hence each lug on both upper and lower conveyor belts may be
kept as 46.3 mm high.
3.4 Cutting force

When cutting the crop the stem may bend. This bending increases in the absence of counter shear. The
counter shear is act as a support. Cutting force increase from zero in initial of cutting and start of contact
between blade and stalk into a maximum value and then become zero again when cutting completed.
Maximum cutting force
𝐹𝑚𝑎𝑥 = 𝜍𝑢𝑙 × 𝐴 − − − − − − − − − − − −Equation ‎3-19
30 | P a g e
Where: - 𝜍𝑢𝑙 = ultimate shear strength

A= cross sectional area barley steam
Where, 𝜍𝑢𝑙 & A given as at moisture content of 22.5% = 6.18 MPA & 6.68 𝑚𝑚2
𝐹𝑚𝑎𝑥 = 6.18 × 6.68 = 41.28 𝑁
The area under the curve of force and the distance that the knife pass over the cross section of the stem is
equal to required cutting energy for cutting of one stalk.
𝐸𝑐𝑢𝑡 /𝑠𝑡𝑒𝑎𝑚 = 𝑐𝑓 × 𝐹𝑚𝑎𝑥 × 𝑋 − − − − − − − − − − −Equation ‎3-20
Where, X - is the knife move to cut and is equal to the diameter of the stalk (d=2.92 mm).
𝐶𝑓 -ratio of average to peak cutting force; value range from 0 to 1; we take 0.925 [1]
𝐸𝑐𝑢𝑡 /𝑠𝑡𝑒𝑎𝑚 - cutting energy for one stalk
𝐸𝑐𝑢𝑡 /𝑠𝑡𝑒𝑎𝑚 = 0.925 × 41.28 × 2.92 = 111.5 𝑁𝑚𝑚 𝑠𝑡𝑒𝑎𝑚
The numbers of stem that may be cut in one frequency of cut depend on the density of crop in the field
and also forward speed of the machine. It is taken as 40 stem in one row.
𝐸𝑐𝑢𝑡 = 40 × 111.5 = 4460 𝑁𝑚𝑚 = 4.46 𝑁𝑚
The power requirement for cutting with a knife and counter shear is the product of energy per cut and
cutting frequency.
𝑃 = (𝐸𝑐𝑢𝑡 × 𝑓𝑐𝑢𝑡 ) 60 − − − − − − − − − − − − − − − Equation ‎3-21

Where, P= power required
𝐸𝑐𝑢𝑡 = energy required to cut steams at once
𝑓𝑐𝑢𝑡 = cutting frequency and it is twice of knife rpm
Therefore power required is determined to be
4.46×800
𝑃= 60
𝑃 = 59.5 𝑊
The total power required for cutting rice crop with a reaper machine of width 1 m and 13 cutting knife is
𝑃𝑡𝑜𝑡𝑎𝑙 = 𝑃 × 13 = 59.5 × 13 = 773.5 𝑤
3.5 Power requirement of VCR:-

Total power required for operation of self-propelled harvesting machine (Wm) is given by the
equation
𝑊𝑚 = 𝑊𝑟 + 𝑊𝑛 + 𝑊𝑤 − − − − − − − − − − − − −Equation ‎3-22
Where, 𝑊𝑟 = power for rolling machine, w
𝑊𝑛 = power for no load working of the machine. w
𝑊𝑤 = power required for full load working of machine, w
31 | P a g e
The power required for cutting crop at knife speed of 1.12 m/s of cutter bar can be taken as 773.5
W/m lengths of cutter bar and power required for conveying cut crop as 50% of the cutting power.
𝑊𝑤 = 773.5 + 0.5 × 773.5
𝑊𝑤 = 1160.25 𝑊
Let us assume the average efficiency as 70%.
1160 .25
Therefore, power requirement for VCR = = 1657.5 𝑊 𝑜𝑟 1.66 𝐾𝑊 = 2.22𝑕𝑝.
0.7
Therefore, 5 hp water pump will be adequate to operate the machine in the actual field conditions
for harvesting of crops and water pumping.
3.6 Height of Cut:-

Height of cut is the length of crop stalk left on the ground when we cut the crop. The stalk left on the
ground is used keep the fertility the soil. It is advisable that 1/3 of the stalk of the crop must left on the
ground. In our country the overall height of barley is not more than 90 cm and from this height around 30
cm is panicle height. The height of the stalk of the crop free from seed is around 60 cm.
The height of cut H= 1/3 x 60 = 20 cm
Where:
L1- The horizontal distance from the tip of the crop divider to the contact point of star wheel
and lug of belt
H2- The vertical height from the tip of the crop divider to the contact point of star wheel and
lug
H1- The distance between the upper and lower conveyor belt.
Figure ‎3-7 Cutting Mechanism
3.7 Gear Design

In put source (Water Pump Motor)
Power = 5hp = 3.73kw
Speed of rotation = 3600rpm
32 | P a g e
 Transmission system
The transmission system of the reaper machine is through the reduction gear box. The required
reduction from the source to the input of the cutter is
𝑁
𝑉𝑅𝐾 = 𝑁 𝐼 − − − − − − − − − − −Equation ‎3-23
𝑂
Where VR -velocity ratio

Ni- Input speed
No- Output speed (No=450rpm)
Velocity ratio can easily determine as
𝑁𝐼 3600
𝑉𝑅𝐾 = = =8
𝑁𝑂 450
8 is Safe velocity ratio so we can use single stage reduction gearbox for our reaper machine
𝑁𝐼 𝑇2
𝑉𝑅𝐾 = = =8
𝑁2 𝑇1
Where vr1 speed reduction ratio
N1 and T1 are speed of input shaft and number of teeth of gear on input shaft
N2 and T2 are speed of output shaft and number of teeth of gear on output shaft respectively.
 Gear Design
Material of gear we used is steel 1144 in the annealed condition. Its property include
Yield strength: ς 𝑦 =358mpa
Ultimate strength: ς 𝑢 =646mpa
Modulus of elasticity: e = 200gpa
Density =7800kg/m3
Gear mesh(Vr1=8)
Let
T1: No of teeth on pinion take minimum 18
T2: Number of teeth on gear
DP1: pitch circle diameter of the pinion, and (mm)
Dg1: Pitch circle diameter (mm)
m: required module of the gear (mm)
Velocity ratio (Vr1) is determined by
𝑁𝐼 𝑇2
𝑉𝑅𝐾 = = =8
𝑁2 𝑇1
𝑇2 = 𝑇1 × 8 = 20 × 8 = 160
Face width of the gear taken from (9.5m to 12.5m, m, module) and we take 12.5m
33 | P a g e
𝜋 × 𝐷𝑃1 × 𝑁1
𝑉=
60
Where V: pitch line velocity
N1 : Input speed
𝜋∗𝐷𝑃 1 ×3600
𝑉= − − − − − − − − − − − −Equation ‎3-24
60
𝜋 × 20𝑚 × 3600
= = 3768𝑚
60
=3.77 𝑚 𝑚/𝑠
Velocity CV= for ordinary cut gear at velocity up to 12m/s
3
𝑐𝑣 = =
3 + 3.77𝑚
Tooth form factor for 200 full depths involutes gears
0.912
𝑦 = 0.154 − For 20o full depth involutes gear
𝑇
0.912
𝑦 = 0.154 − = 0.1084 (T=T1=20 pinion gear)
20
Both the pinion and the gear are made of the same material, so the pinion is the weaker and the
Design based on it.
Torque transmitted by the pinion gear
𝑝 × 60
𝑇=
2𝜋 × 𝑁𝑝
Where T: torque
P: input power
NP: Speed of pinion gear
Torque is determined as
3730 ×60
𝑇= =31.083N-m
2π×3600
Tangential tooth load (WT)
2×𝑇
𝑤𝑇 = − − − − − − − − − − − − − − − − −Equation ‎3-25
𝐷𝑝 1
2×31083 3108 .3
𝑤𝑇 = =
50×𝑚 𝑚
Allowable static stress (𝞂 o): - for steel gear it is approximately taken one-third of ultimate
Tensile strength. (ς 𝑢 =646mpa)
ς𝑜 = ς𝑢 = 646 𝑚𝑝𝑎 =215mpa

3 3
Lewis equation for beam strength of gear tooth
34 | P a g e
𝑤𝑇=ς 𝑜 × c 𝑣 × b × 𝜋m
Where: ς - Allowable static stress
Cv - Velocity factor
b- Face width
= 3108.3 =3
= 215𝑚 × × 12.5 × 𝜋 × 𝑚
𝑚 3 + 3.77
= 25316025𝑚3 = 9324.9 × 11718.3 × m

Solving by hit and trail, we found 𝑚 = 0.98𝑚𝑚 ≈ 1𝑚𝑚
We take the module m as 4mm (standard)
Pitch circle diameter of pinion
𝐷𝑝1 = 20 × 𝑀 = 20 × 4 = 80 𝑚m
Circular pitch pc=𝜋 × 𝑚=𝜋 × 4 = 12.56𝑚𝑚
Face width b= 12.5m=12.5×4=50mm
Pitch circle diameter of the gear 𝐷𝑔 = 𝑇2 ×m=160×4=640mm
Tangential load 𝑤𝑇= 3108.3/m=3108.3/4=777.0N
For 20o full depth involutes system

1. Addendum = 1𝑚 = 1 × 4 = 4 𝑚𝑚
2. Dedendum =1.25𝑚 = 1.25 × 4 = 5 𝑚𝑚
3. Working depth = 2𝑚𝑚 = 2𝑥4 = 8 𝑚𝑚
4. Minimum total depth= 2.25𝑚 = 2.25 × 4 = 9 𝑚𝑚
5. Tooth thickness 1.5708𝑚 = 1.5708 × 4 = 6.28 𝑚𝑚
6. Minimum clearance = 0.25𝑚 = 0.25 × 4 = 1 𝑚𝑚
7. Fillet radius at root = 0.4𝑚 = 0.4 × 4 = 1.6 𝑚𝑚
Checking for gear wear WW
𝑤𝑤=𝐷𝑝 × 𝐵 × 𝑄 × 𝐾 − − − − − − − − − − − − − −Equation ‎3-26
Where WW= Maximum or limiting load for wear in Newton‘s,
DP = Pitch circle diameter of the pinion in mm,
b= Face width of the pinion in mm,
K= Load-stress factor in N/mm2
Q= Ratio factor
2 × 𝑉𝑅 2 × 8
𝑄= = = 1.6
𝑉𝑅 + 1 8 + 1
35 | P a g e
ς𝑠 2 1 1
𝐾= 𝑠𝑖𝑛𝞿 ( + )
1.4 𝐸𝑃 𝐸𝑔
Where ς 𝑠 = Surface endurance limit in MPa =616N/mm2 for steel of 240B.H.N
φ= Pressure angle
EP = Young's modulus for the material of the pinion in N/mm2
Eg =Young's modulus for the material of the gear in N/mm2
Young's modulus for steel is 200GPa = 200000N/mm2
(616)2 sin 20 1 1
𝑘= + ∗
1.4 200 200
= 0.927
𝑤𝑤 = 80 × 25 × 1.6 × 0.927
= 2966.7𝑁
Since the maximum wear load is much more than the tangential load on the tooth, therefore the design is
satisfactory from the standpoint of wear.
36 | P a g e
CHAPTER FOUR
4. COST ANALYISIS
Table ‎4-1 material cost
No Part name Quantity Unit price ETB Total
1 Star wheel 3 150 450
2 Flat belt 2 300 600
3 Gear material 2 - 1000
4 Cutter bar 2 400 800
5 Divider 3 240 720
6 Water pump 1 7500 7500
Total - - 11,070
The above cost is only for material cost without manufacturing.
37 | P a g e
CHAPTER FIVE
5. PART DRAWING
5.1 Cutter bar
Figure ‎5-1 cutter bar
5.2 Star wheel
Figure ‎5-2 star wheel
38 | P a g e
5.3 Lugged Conveyor
Figure ‎5-3 lugged belt
5.4 Divider
Figure ‎5-4 Divider
39 | P a g e
4.5 gear mesh
Figure ‎5-5 gear mesh

40 | P a g e
CHAPTER SIX
6. CONCLUSTION AND RECOMENDATION
6.1 Conclusion
Generally from the above barely reaper machine we conclude that the performance of any
harvesting machines are depend on each type of crop property, whether condition and mechanical
property of crops and the required quality of final product and working environment of machine.
Basically the reaper machines are need a serious design and manufacturing process because the
improper assembling and design cause the cause of crop damage. So in the design process we
must analyses the relationship between each component.
This reaper machine is working by using a water pump for the cutting operation only and it push
by man power,
6.2 Recommendation
The harvesting (reaper) machine we have designed works by water pump. We have only used the motor
for cutting purpose by transferring rotational energy of motor to the cutter and for the purpose of water
pumping from the given height of elevation. However, it is possible to use the motor to drive the wheel
instead pushing behind but it cause effect of turning and need additional power..
41 | P a g e
REFERENCE
[1] Bright, R. E., and R. W. Kleis. 1964. Mass shear strength of haylage. Trans. ASAE 7(2):
100‐101.
[2]Tavakoli, H.Mohtasebi, S.S.Jafari, A.Nazari Galedar, M.(2009).Some Engineering Properties of
Barley Straw ,British
[3] D.N.Sharma,S.Mukesh .(2010) Farm machinery design principle and problems: second revised ,
New Delhi
[4] Design of Small-Scale Grain Harvester: A tool for Urban and Pre-urban Growers; Christopher
Boyle, Ian Jutras, Christopher Molica, Earl Ziegler.
[5] Farm power sources, their availability and future requirements to sustain agricultural production,
by N. S. L. Srivastava.
[6] State of Indian Agriculture 2012-13, Indian Government Analysis.
[7] Asia and Pacific Commission on Agricultural Statistics Twenty-Third Session Siem Reap,
Cambodia, 26-30 April 2010.
[8] Mechanization of Agriculture - Indian Scenario Dr. S.D. Kulkarni, Central Institute of
Agricultural Engineering (CIAE) Bhopal - 462 038, India
[9]. Rahman, Z.U. (1986). The tractor mounted reaper in pakistan. Small farm equipment for developing
countries. Proceedings of the international conference on small farm equipment for developing countries:
past experiences and future priorities, 2-6 September 1985. 1986, 359-370; 12.
[10]. Pradhan, S. C.; Biswajit, Ray; das D. K. And Mahapatra, M. (1998). Evaluation of various paddy
harvesting methods in Orissa, India Agricultural Mechanization Asia, Africa and Latin America. 29; 2,
35-38; 4.
[11]. Datt, P. and Prasad, J. (2000). Modified and Eva luated a Self-propelled Reaper for Harvesting
Soybean. Agricultural Mechanization in Asia, Africa and Latin Ameraca. 31(3): 43-46
42 | P a g e

BAHIRDAR INSTITUTE OF TCHNOLOGY Design S PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BAHIRDAR INSTITUTE OF TCHNOLOGY Design S PDF

Uploaded by

Copyright:

Available Formats

Motorized Reaper Machine 2009

BAHIRDAR INSTITUTE OF TCHNOLOGY

FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING

Submitted to MR. Zemenu Tsehaye

6.1 Conclusion _____________________________________________________________ 41

Figure ‎1-1 Barley crop

Figure ‎1-2 2 row and 6 row barley

A. Late barley production system

Figure ‎1-3 land preparation

Figure ‎1-4 sickle

Figure ‎1-5 traditional threshing

1.1.10 Storage of barley

1.2 HARVESTING MACHINE

Figure ‎1-6 Combine Harvester Machine

Figure ‎1-7 Reaper Machine

1.3 PROBLEM STATEMENT

Figure ‎3-1 Reciprocating type cutter bar

∠𝛽 = angle between cutting edge and axis of twin guard

Figure ‎3-2 Standard dimension of knives section

𝑉𝑚 = Machine forward speed, m/s

Where, X= stroke length or standard knife section 76.2 mm/7.6.2 cm

The actual average knife speed of a cutter bar of VCR would be

Table ‎3-1 specification of crop cutting unit of VCR

1 Type of cutter bar Reciprocating knife sections

2 Length of cutter bar 1000 mm

3 Knife section Standard

4 Knife section M.S flat 25 x 5 mm

6 Height of cutter bar above ground level 80-100 mm for 310

Figure ‎3-3 Cutting knife

3.2 Design of crop divider and lifter:

Figure ‎3-4 Crop lifter

n – Number of Star Wheel

Where: 𝑅𝑠𝑤 = radius of star wheel and equal to 150mm.

Figure ‎3-5 Star wheel With Crop Divider

0.85 = 𝑛𝑠 × 0.075 × 0.917

 Length of crop divider is determined by

Where, 𝐿𝑑 = length of crop divider

3.3 Design of crop conveyor

Figure ‎3-6 Lunged belt conveyor

Where, 𝐷𝑝 =diameter of lugged belt pulley, m

𝐶 = 6.25 + 100 + 6.25 = 112.5 𝑐𝑚

πDs = P × Ns − − − − − − − − − − − − − − − −Equation ‎3-17

Adjusted length of belt = 𝑃 × 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑙𝑢𝑔𝑠 = 78.5 × 34 = 2669 𝑚𝑚 𝑜𝑟 266.9 𝑐𝑚

Where Vm – Traveling speed

3.4 Cutting force

Where: - 𝜍𝑢𝑙 = ultimate shear strength

𝑃 = (𝐸𝑐𝑢𝑡 × 𝑓𝑐𝑢𝑡 ) 60 − − − − − − − − − − − − − − − Equation ‎3-21

3.5 Power requirement of VCR:-

3.6 Height of Cut:-

Figure ‎3-7 Cutting Mechanism

3.7 Gear Design

Where VR -velocity ratio

ς𝑜 = ς𝑢 = 646 𝑚𝑝𝑎 =215mpa

= 25316025𝑚3 = 9324.9 × 11718.3 × m

For 20o full depth involutes system

1 Star wheel 3 150 450

2 Flat belt 2 300 600

3 Gear material 2 - 1000

4 Cutter bar 2 400 800

5 Divider 3 240 720

6 Water pump 1 7500 7500

The above cost is only for material cost without manufacturing.

Figure ‎5-1 cutter bar