Final Report

COCONUT DE-HUSKING MACHINE

i
 DECLARATION

We, 2nd year, stage 4 students of Fiji National University do solemnly declare as follows:
1. This project work named as “Coconut De-husking Machine” is truly and entirely
our group work.
2. We assure that no result from this project or any relevant documents will be
submitted to any other Institute or University for their use to obtain the award to
Diploma of Mechanical Engineering or equivalent Certificate.
3. All the additional information source has been duly cited.

ii
 ACKNOWLEDGEMENT

There is a challenge in aspects of the modern world in success and all are eager to step forward
and excel. Project is like a link between practice and theoretical research. We constructed this
specific project with this desire. First of all, we wish to thank the Almighty God, the highest
power, who is there to guide us in any aspect.

We are obliged in taking this opportunity to sincerely thank Mr. Harsh for his valuable
guidance, encouragement and help for completing this work. His suggestions for this whole
work and co-operative behaviour are sincerely acknowledged

We also as a team would like to express our sincere thanks to Mr. Tui Toutou (Lecturer), for
giving us this opportunity to undertake this project. Without his approval and whole hearted
support it wouldn’t have had happened.

We are also grateful to all the Workshop Technicians especially Machine Shop and Welding
Shop for their constant support.

Finally, we would like to express our sincere thanks to our families, friends and relatives who
has helped us in any way or other to complete this project

iii
 TABLE OF CONTENT
Title Page---------------------------------------------------------------------------------------------- i

Declaration-------------------------------------------------------------------------------------------- ii
Acknowledgement---------------------------------------------------------------------------------- iii
List of tables------------------------------------------------------------------------------------------ vi
List of figures----------------------------------------------------------------------------------------- vii
List of Abbreviations------------------------------------------------------------------------------- viii

Abstract----------------------------------------------------------------------------------------------- ix
Chapter 1 Introduction---------------------------------------------------------------------------- 1
1.1- Background--------------------------------------------------------------------------- 2
1.2- Problem Statement----------------------------------------------------------------- 4
1.3- Project Objectives------------------------------------------------------------------- 5

1.4- Project Scope------------------------------------------------------------------------- 6

1.4.1- Gantt Chart--------------------------------------------------------------- 7
1.4.2- Work Plan----------------------------------------------------------------- 8
1.5- Organization of Report------------------------------------------------------------- 9
Chapter 2 Literature Review---------------------------------------------------------------------- 10

2.1- Introduction--------------------------------------------------------------------------- 11
2.2- Methods of Design------------------------------------------------------------------- 13
2.2.1- Machine Description---------------------------------------------------- 13
2.2.2- Motor Requirement Calculation-------------------------------------- 14
2.2.3- Gear Specification------------------------------------------------------- 14
2.2.4- Bearing Specification--------------------------------------------------- 14
2.2.5- Shaft Specification------------------------------------------------------- 15
2.2.6- Gear Specification------------------------------------------------------- 15
2.2.7- Spike Specification------------------------------------------------------- 15
2.3- Methods of Fabrication------------------------------------------------------------- 17

2.4- Types of material used for each material-------------------------------------- 17

2.4.1- Machine Frame----------------------------------------------------------- 17

iv
 2.4.2- Drive Mechanism-------------------------------------------------------- 18
2.4.3- Motor----------------------------------------------------------------------- 18
2.4.4- Reduction Gearbox------------------------------------------------------ 18

2.4.5 Rotating Shaft------------------------------------------------------------- 19

2.4.6 Holding Mechanism------------------------------------------------------ 19
2.4.7 Roller Type Blade Mechanism----------------------------------------- 20
2.4.8 Peeling Spikes------------------------------------------------------------- 20
Chapter 3 Methodology--------------------------------------------------------------------------- 21

3.1 Overview of the practical experiment (Design)------------------------------- 22

3.2 Designs and Sketches---------------------------------------------------------------- 24
3.2.1 Isometric View------------------------------------------------------------ 24
3.2.2 End View------------------------------------------------------------------- 24
3.2.3 Top View------------------------------------------------------------------ 25

3.2.4 Front View----------------------------------------------------------------- 25

3.3 Procedure------------------------------------------------------------------------------ 26
3.4 Materials------------------------------------------------------------------------------- 32
3.5 Components---------------------------------------------------------------------------- 33
3.5.1- Frame-----------------------------------------------------------------------33

3.5.2- Dehusking Unit----------------------------------------------------------- 33

3.5.3- Pillow Block--------------------------------------------------------------- 34
3.5.4- Gear Mechanism-------------------------------------------------------- 35
3.5.5- Motor---------------------------------------------------------------------- 36
3.6 Tests/ Experiments------------------------------------------------------------------- 37

3.6.1- Roller Straightness------------------------------------------------------- 37

3.6.2- De-husking Machine---------------------------------------------------- 37
3.7 Restriction/ Limiting Conditions--------------------------------------------------- 38
Chapter 4 Summary--------------------------------------------------------------------------------- 39
4.1 Conclusion------------------------------------------------------------------------------ 40

4.2 Recommendation--------------------------------------------------------------------- 41

v
4.3 Recommended Design--------------------------------------------------------------- 42
A.1 References------------------------------------------------------------------------------ 43
A.2 Appendices----------------------------------------------------------------------------- 44

vi
 LIST OF TABLES

Table 1.1------Scope Plan-------------------------------- -------- Chapter 1 --------------Page 6

Table 1.2------Gantt Chart---------------------------------------- Chapter 1 --------------Page 7
Table 3.1------Specifications based on Factors-----------------Chapter 3 -------------- Page 22
Table 3.2------ Specific Size of Components------------------ Chapter 3-------------- Page 26
Table 3.3----- Key Way Dimensions--------------------------- Chapter 3-------------- Page 27
Table 3.4----- Key Dimensions--------------------------------- Chapter 3-------------- Page 27
Table 3.5------ Process of Manufacturing & Assembling---- Chapter 3-------------- Page 28
Table 3.6------ Materials Used for Each Components-------- Chapter 3-------------- Page 32
Table 3.7----- P210 Bearing Specifications------------------- Chapter 3-------------- Page 34
Table 3.8----- Motor Specifications---------------------------- Chapter 3-------------- Page 36

vii
 LIST OF FIGURES

Figure 1.1------Structure of a Coconut Fruit--------------------Chapter 1 -------------- Page 2

Figure 1.2------Design of Coconut De-husking Machine-----Chapter 1---------------Page 4
Figure 2.1------Structure of Coconut Fruit----------------------Chapter 2---------------Page 11
Figure 2.2----- 3D View of the De-Husker--------------------- Chapter 2--------------- Page 16
Figure 2.3----- Front View of the De-Husker------------------ Chapter 2--------------- Page 16
Figure 2.4----- Top View of the De-Husker------------------- Chapter 2-------------- Page 16
Figure 2.5----- Design of the Spikes---------------------------- Chapter 2-------------- Page 16
Figure 2.6----- Driving Mechanism of De-husker------------- Chapter 2-------------- Page 18
Figure 2.7----- Shaft Dimensions------------------------------- Chapter 2-------------- Page 19
Figure 2.8----- Pillow Block------------------------------------- Chapter 2-------------- Page 19
Figure 2.9----- Roller Type Blade Mechanism---------------- Chapter 2-------------- Page 20
Figure 2.10--- Roller Spikes------------------------------------ Chapter 2-------------- Page 20
Figure 3.1---- Isometric View of Final Design-------------- Chapter 3-------------- Page 24
Figure 3.2----- End View of Final Design--------------------- Chapter 3-------------- Page 24
Figure 3.3----- Top View of Final Design--------------------- Chapter 3-------------- Page 25
Figure 3.4----- Front View of Final Design-------------------- Chapter 3-------------- Page 25
Figure 3.5----- Frame of the Machine--------------------------- Chapter 3-------------- Page 33
Figure 3.6----- Design of De-husking Unit--------------------- Chapter 3--------------- Page 34
Figure 3.7----- Design of Pillow Block------------------------- Chapter 3--------------- Page 35
Figure 3.8----- Design of the Gears----------------------------- Chapter 3-------------- Page 36
Figure 3.9----- Design of Motor--------------------------------- Chapter 3-------------- Page 37

viii
 LIST OF ABBREVIATIONS

3D Three Dimensional

Mm Millimetres
In (“) Inches
G/B Gearbox
O/D Outside Diameter
I/D Inside Diameter/ Internal Diameter

ix
 ABSTRACT

Coconut husk is utilized in coir industry, shell as a fuel, copra as food, coconut water as a
nutritious fluid. The dehusking of a coconut is viewed as the most tedious, tiring, and
troublesome activity to perform and includes a lot of human drudgery. This paper presents the
innovative design of a coconut de-husking machine based on coconut farming needs.
Dehusking with customary hand devices like blade or a spike relies upon the expertise of
specialist and includes preparing. These days there is lack of such talented specialists. The
motorized or the force worked machines are created to kill the downsides of manual devices.
This current work plans to structure and build up a self-loader coconut dehusking machine with
taking out the previously mentioned disadvantages of the current apparatuses and machines.
The machine considered will have principle parts like dehusking unit mounted on an edge with
electric engine as a force source alongside speed decreasing unit. The dehusking unit will have
a couple of round and hollow rollers with tynes (cutting pins) or blades on its surface. These
rollers will turn inverse way with various speeds so the tynes will enter into the husk and tear
it away from the shell. The best possible tearing of husk from shell happens when the coconut
offers great work with the tynes or blades and it relies upon the profundity or inclusion of nut
into rollers and profile of tynes. Additionally, the reasonable profile of tynes or blades is
required for successful dehusking. These tynes or blades will be connected to the chambers
with clasp so substitution can be handily done.

x
 Chapter 1
Introduction

1.1 Background

1.2 Problem Statement

1.3 Project Objectives

1.4 Project Scope

1.5 Organization of Report

1
 INTRODUCTION

1.1 Background
Indonesia is the largest coconut producer in the world followed by Philippines and India.
Coconut is one of the most important and useful perennial plants in the world. The coconut
husk is additionally potential downstream ventures of the coconut organic product, which can
bolster the network’s financial of coconut ranchers. Usage of coconut husk can be a crude
material in numerous items, for example, sleeping pad, spring bed, mattress, pillow, car seat,
rope, rug, doormat, net, vehicle dashboards, carpet and so on. A coconut fruit shown below is
made up of an outer exocarp, husk known as a thick fibrous coat, hard protective shell is
underneath.

Figure 1.1 Structure of a Coconut Fruit

For soap production Coconut oil is very important. Its shell is utilized for fuel needs. Despite
the fact that coconut is of tremendous financial significance to both the industrialist rural
dwellers, the most challenging, dangerous and difficult operation is to separate the husk from
the nut. The utilization of cutlass which is the well-known conventional strategy for coconut
dehusking presents danger and threat to the life of individuals required, while dehusking, some
cut their hands, and face as the cutlass generally skips back on hitting the husk

The utilization of metal spike was later evolved to beat these negative highlights of dehusking
of the organic product with matchet however this later improvement concentrated distinctly on
extraction of coconut meat despite the fact that mishap, time and vitality utilization was
reduced. The quest for a device that will empower effective recuperation of other products of

2
this fruit such as, shell, milk and fibre proceeded because of the significant importance of these
coconut by-products.

Hence, a coconut dehusking machine was invented in Malaysia in 1986. Although this
invention separated the nut and husk, it facilitated effective recovery of fruits meat, shell and
milk. Breakage of nut, excessive cost of maintenance and production was its major issue and
hindered it popularity. Another machine was developed to overcome this issue which had a
capacity of dehusking 480 coconut per hour. In any case, this later development and other
advancement that followed up till now generally go back and forth with issue of mutilating the
length of the husk (coir fibre) removed. These days, the utilization of natural fibre strengthened
composite is gaining popularity in plastic rubber and cosmetic applications, automotive
industries since if offers environmental and economic advantage over traditional organic fillers
and reinforcements.

Revealed that both fibre orientation and fibre length distribution play a vast role in its
mechanical properties. An increase in the length of coir fibre increases the flexibility of the
composite product like seat cushions for automotive industries. Thus, there is a need for
dehusking machines that can extract coconut fibre/husk without distorting its length.

3
 1.2 Problem Statement
Dehusking with customary or traditional hand apparatuses like blades or a spike relies upon the
ability of specialist and involves training. These days there is lack of such talented laborers
because now we in the modern era even the laborers depend on machines. The motorized or
power operated machines are created to eliminate the hardship of using manual equipment’s
for dehusking.

Following causes were recognized for dehusking of coconut.

• Most time is consumed during the process of dehusking a coconut.
• Difficult and tiring event to perform.
• Includes more drudgery.
• Production is slow.
• Hand tool is used therefore skilled worker is required

The method of coconut dehusking machine can be introduced for continuous improvement for
the above-mentioned problems. These issues are affecting the rate of coconut dehusking hence
affecting the market demand of coconut.

Figure 1.2

Source: Design of Coconut De-husking Machine Using Quality Function Deployment Method

The picture above shows the conventional method for dehusking which is a high risk.

4
 1.3 Project Objectives

The coconut dehusking machine project will undergo different phases of work and it will be a
challenge to fulfil the objectives stated below:
• Prototype a Coconut Dehusking Machine with simple design to de-husk a coconut with
a low cost.
• Understand the working principle, operations of prime movers.
• Practically apply the classroom knowledge attained.
• To design and understand simulation in 3D Solid Works Modelling Software.
• Reduce human effort in dehusking of a coconut
• Reduction of man power
• To improve selection of material and build a better network
• To improve team work skills
• To attain a better knowledge of manufacturing process using various kinds of
equipment’s and machinery.
• To undergo OHS policies and achieve zero injuries during the project timeline.

5
 1.4 Project Scope

The team members used a Gantt chart and scope of works to come up the following due dates:

Table 1.1

6
1.4.1 Gantt Chart

Table 1.2

7
1.4.2 Work Plan

Phase 1

• Project Proposal
• Project Submission
• Reviewing
• Researching
• Working out the material list
• Looking for material supplies
• Quotations

Phase 2

• 3D Solid Works drawing

• Calculations and analysis
• Machining and Fabrication

Phase 3

• Project Assembly
• Overcoming obstacles during assembly
• Test run

Phase 4

• Results and analysis

• Preparing final reports
• Preparing presentation slides

8
1.5 Organization of Report

Chapter 1 Introduction
1.1 Project Background
1.2 Problem Statement
1.3 Objectives
1.4 Project Scope/ Planning- Gantt Chart
1.5 Organization of Report

Chapter 2 Literature Review

2.1 Introduction

2.2 Methods of design

2.3 Methods of fabrication

2.4 Type of materials used for each component

Chapter 3 Methodology
3.1 Overview of the practical experiment
3.2 Designs and Sketches

3.3 Procedure
3.4 Materials

3.5 Components
3.6 Tests/ Experiments

3.7 Restriction/ Limiting Condition

Chapter 4 Summary
4.1 Conclusion
4.2 Recommendation

4.3 Recommended Design

A.1 References

A.2 Appendices

9
 Chapter 2

Literature Review

2.1 Introduction

2.2 Method of Design

2.3 Method of Fabrication

2.4 Discussion of Material

Used in Each

2.5 Summary

10
 LITERATURE REVIEW

2.1 Introduction
India have rated of being the highest producer of coconut in the world with the production
over 16 billion of nuts from acreage under plantation of about 1.89 million hectares. Coconut
is one of the world most useful and important perennial plant. Every part of the coconut has
its own commercial value. The coconut husk can be useful in several items as manufacture of
coir products such as coir carpets, coir geotextile, coir composite, coir safety belt, coir
boards, coir asbestos, coir pith and so on. Coconut milk are most suitable as a refreshing and
nitrous drunk while its oil is use for cooking and making margarine. Coconut oil is also
important in soap production. The shell is use for fuel purpose, shell gasifier as an alternate
source of heat energy. A coconut fruit shown below is made up of an exocarp which is an
outer layer, a mesocarp which is a middle layer containing a thick fibrous coat and a
endocarp (a hard-protective shell) underneath which protect the endosperm from the
surrounding.

Figure 2.1 Structure of Coconut Fruit

Traditional method of dehusking are still very popular at present besides being labour
intensive. It is done either through the use of a sharp machete and spike made of steel and
acquire more human power in order to remove the coconut husk. Despite the fact the coconut
is of a massive financial significant to both the industrialist rural dwellers, the most
challenging, dangerous and tough operation is to separate the husk from the nut. The
utilization of cutlass which is the well-known traditional method for coconut dehusking bear
danger and threat to the life of individual required, while dehusking, some cut their hands,

11
and face as the cutlass generally skips back on hitting the husk. This convectional method of
dehusking takes more time and capacity to complete the dehusking of coconut.

Hence the mechanised coconut de-husking is mostly foreign made that was first developed
since 1930’s in an attempt to initiate the traditional method but have failed due to the
incapability of the machine to compete with manual labour. Such machine was presented as
an operated dehusking machine with a principle of impaling a nut on a pair of spikes initially
together. After impaling the foot pedal separates the spikes to remove the husks radially
outwards. The process is repeated several times until most of the husks are removed. Another
machine was developed with a hard operated dehusking machine with a supporting frame
with hooks that held the coconut while it moves toward a set of knives positioned to slash the
coconut. Later, another dehusking machine was introduced which the coconut was removed
by helical cut of a set of blades while the nut was held between jaws. Finally, a motor
operated coconut de-husker has developed in New South Wales, Australia which has a
principle of feeding the nut on a conveyor belt into a system of contra rotating rollers. The
machine was claimed to have a capacity of about 1000 nuts per hour.

Revealed that the designing of this particular machine with mechanism that can serve
multiple tasks and provide something new in the manufacturing sector such that the
production of goods can be accomplished swiftly and with quality. However, the machine
designs are only focused on improving the efficiency as well as the dehusking time and
capacity.

Coconut is known widely for its culinary and non-culinary uses. According to Dr. Reddy’s
speech on “Whole Nut Processing Training Coconut- Nutrition, Health and Wealth”, Fiji has
an approximation of 10 million coconut trees, of which majority is located in the northern
division. One major product of these coconuts is copra, which remains as the most traded
coconut commodity in Fiji, as per Dr. Reddy. (Reddy, 2019)

Dehusking of a coconut manually is a very labour intensive and painful task. According to
Mohd Taufik, dehusking is usually done manually by individuals with the use of a knife, sharp
blade hardwood. This time-consuming effort needs not only skills but also a lot of strength and
technique. (Taufik, 2014)

According to Jibin Jacob, attempts done to replace the manual method have only been partially
successful but not a complete solution. As per his analysis, power operated machines are
12
usually one phase with 1 HP electrical motor, with major parts consisting of metal frame,
electric motor, dehusking blade and a speed reducer. He also calculated average time of a single
dehusking to be 25 seconds, which calculates to a rate of approximately 140 coconuts. This
can be assumed as a very viable result. (Jacob, 2012)

In another analysis by Alexander M. Pascua, a 7.5hp gasoline motor with major parts such as
frame, dehusking blade, transmission, coconut base alongside control system and speed
reduction unit provided a complimentary output of 240 coconuts in an hour. In his analysis, he
also recommended a movable coconut base to allow for easier dehusking of all sizes of
coconuts. It was also noted, with such advanced units yielded an efficiency of approximately
85.23%. (Pascua, 2018)

As per Stephen Adzimah analysis, change of these processes to electronic systems is much
more efficient and there is more output achieved whilst applying little amount of force as the
input. It was also noted that these machines can be built for portability and yield a minimum
of 70 coconuts per hour. On a downside however, this machinery is not feasible for the common
man and also require regular maintenance for efficient functionality. (Adzimah, 2015)

2.2 Methods of Design

2.2.1 Machine Description

The proposed dehusking machine is driven by motor and it peels the husk from the dry
coconut with the help of systematically arranged spikes on shafts. The dry coconut is placed
in between the two shafts. The shaft has spikes welded on them and rotate in opposite
directions. The rolling motion of the roller shafts allows the spikes to penetrate the husk and
peel them off the nuts. The proposed design consists of a power source to drive the shaft, a
gear box to reduce the speed, chain and gear drive to transmit power, bearing and a frame to
mount and support all the components. A three-phase induction 740 watts motor is used to
drive the mechanism. the drive from the motor is transmitted to the gear box for speed
reduction. The speed of rotation of the output shaft of the motor is 1440rpm. The motor
output shaft is connected directly to the gear box using a love jaw coupling which completely
reduces the transmission losses. The gear box and the motor are mounted on the lower part of
the frame. Care was taken that the motor shaft and the gear box input shaft were in straight
line to minimise the vibration and completely utilise the power of the motor.

13
2.2.2 Motor Requirement Calculation
• 3 phase or single-phase induction motor with 1440rpm
• Shaft radius = 25mm
• Tearing force required = 20kgf
• Power required in tearing: [ (20*9.81) (2*3.14*.025) (100/60)] * 4 = 210w
• Power required for driving the coconut: [ (20*9.81) (3/60)] = 10w
• Total power required= 210+10= 220w The gear box used in this machine has a speed
ratio of 48:1. This reduces the speed from 1440 rpm to 30 rpm. The worm gear
mechanism is used in the designed gear box for reducing the output speed. Reducing
the output speed, increases the torque produced from the motor.

2.2.3 Gear Specification

• Speed ratio is 48:1.
• Speed Reduction: 960rpm to 30rpm.
• Diameter of output shaft =25mm

Belts and ropes drive could slip and strain hence there are not preferred. Chain and gear
drives are preferably used for small distance power transmission. The power from the chain is
transmitted to the shaft by means of sprocket .

• No of teeth in the sprocket attached to the gear box = 18

• No of teeth in the chain pulley attached to the spur gear=40
• Total length of the chain=2400mm

Two 30mm shafts are stepped into 20mm at the both ends of the shaft. This stepped end is
connected to the bearings that are supported by the frame. The bearing to be used should
provide proper balancing of shafts. The 6200 series maintenance free, self-lubricating bearing
suits the requirement well.

2.2.4 Bearing Specification

• Bearing series=6200 series
• Bearing Number= 6202
• Diameter of the bearing=20mm

14
2.2.5 Shaft Specification
• Shaft– Mild steel
• Length of the shaft = 750mm.
• Number of shafts = 2
• Diameter of the shaft =30mm
• Stepped diameter at the both ends of the shaft = 20mm
• Stepped length at the both ends of the shaft =100mm

A Spur gear is attached to the other stepped end of each shaft and they mesh with another to
rotate the shafts in opposite direction.

2.2.6 Gear Specification

• Gear type – Spur gear
• Number of teeth in the driver gear = 40
• No of teeth in the driven gear=40
• Diameter of the gear=60mm
• Centre distance between gears =120mm

Spikes are made from the shaft of 10mm diameter. They are cut into smaller pieces. Sharp
edge is been formed and then the spike has been welded on to the rotating shaft. It is
necessary that the material used has more hardness. The design of the spike is shown in
figure 1. The spikes are sharpened and spaced from one another substantially equal distance
where by the patterned array in which the plurality of spikes is positioned which facilitates
the penetration through the husk and peel them off.

2.2.7 Spike Specification

• Total length of the spike = 30mm
• Sharpened length of the spike at the end of the rod = 5 mm
• Angle of the sharpened edge =135degree

15
Fig 2.2: 3D view of the De-husker Fig 2.3: Front view of the De-husker

Fig 2.4: Top view of the De-husker Fig 2.5: Design of the Spikes

16
2.3 Methods of Fabrication
It is mainly known that the tynes and cylinder are always prepared by the lathe operation such
as turning, facing, drilling, taper turning, cutting etc. different shaft on the lathe is for good
surface finishing and also to smooth it. The type of operation that is mainly used are milling,
drilling and shaping machine. The different types of drilling bits are used to drill holes for the
bolts and buts to seat on. Another main operation of doing this project is welding which
joined tynes and cylinder by the of arc welding and gas welding. The different fabrication are
as follows:

1. The lathe is used for machining the tynes.

2. The cylinders are machined to 163 and 138mm from 170 and 140mm diameter for
larger and small cylinders.
3. 30mm diameter shaft was weld to the cylinder by using the circular plates.
4. The drilling machine is used to make holes over the cylinder for fixing the tynes.
5. Lower portion of tynes is inserted in the holes for the tynes to be weld over the
cylinder.
6. The main load carrying component is the frame constructed by joining angle irons as
in the design.
7. The parts that is welded to the shaft are bearing, bushes, block, etc.
8. Cast iron plate is used for seating for motor made on frame.
9. Transmission of the system is piled with the frame as in the design.

2.4 Types of Material Used for Each Component

2.4.1 Machine Frame
Frame is more important which other component of the DE husking coconut machine is
mounted on it. It is a welded structure constructed from 50x50x50mm mild steel angle iron
with the 933mm dimension in length, width of 515mm and a height of 845.1mm. the steel are
attached to the frame so that vibration and weight are fairly distributed to the frame. Main
frame of geometric structure is designed so that it can produced a good shape and a better
stability to the entire structure.

17
2.4.2 Drive Mechanism
This mechanism plays a vital role is the operation is completely in mechanically oriented.
Shown below are the overall drive mechanism:

➢ Worm reduction gear

➢ Motor
➢ Rotating shaft and chain system

Figure 2.6 Driving Mechanism of De-husker

2.4.3 Motor
An induction single phase motor is used to drive the mechanism. It is commonly used in
various kinds of industrial drives. It’s act as a driving wheel which is connected to the belt
and direct to the gear box. The motor output rotation speed is 1500rpm. The motor’s output
shaft is directly connected to gear box through a belting system that reduce transmission
losses and the motor is fixed on the frame of the machine.

2.4.4 Reduction Gearbox

This mechanism is mainly used for transmitting power of a high velocity ratio. It has a speed
ratio of 70:1 which reduce the speed from 1500rpm to 21rpm. The worm gear mechanism is
used in the gear box and the gear box is partner with the motor by using a pulley that is
connected on the v-belt. The output of the gear box is coupled to a long shaft that protrudes
out from the centre of one of the rollers for the attachment to the holding mechanism. It
consists of the worm and the worm wheel. The worm is, in essence, a cylinder having threads
of the same shape as that of an involute rack. The worm is generally made of mild steel while
the gear or wheel is made of bronze or cast iron for light service.

18
2.4.5 Rotating Shaft (main shaft)
The mechanism the transmits power from places to places is shaft (long rotating cylinder).
Power is delivered to shaft by tangential forces toque on one end is connected to the output
gear box and the other end is connected to the main roller that acts a support to the system
rolling.

Figure 2.7 Shaft Dimensions

2.4.6 Holding Mechanism

The bearing block is for the reducing of vibration or wobbling during the rotation of a long
shaft with a heavy load. To mitigate the vibration of the machine two bearing blocks are used
between the reduction gear box. Bearing block is also known as Plummer blocks and it is
carefully centred so that shaft and bearing block axis is parallel so that it can reduce vibration
and wobbling during the operation.

Figure 2.8 Pillow Block

19
2.4.7 Roller Type Blade Mechanism
The roller type mechanism is such that two rollers, each having an elongated configuration is
disposed and spaced apart, substantially parallel to one another with respect to the base and in
a readily accessible position. A drive means is also provided in support of the base and with
direct driving engagement with the rollers. Interconnection of the rollers to the drive means is
such that the rollers are forced to rotate in an opposite direction relative to the other and in a
preferred embodiment to be described in greater detail hereinafter, at relatively different
speeds. Collectively, the rollers define two outer exposed surfaces, which may be considered
as the upper portions of the roller. In such orientation, the rollers rotate in a direction towards
the centre such that a coconut, placed thereon, will be forced into the spacing between the
rollers.

Figure 2.9 Roller type blade mechanism

2.4.8 Peeling Spikes

These spikes were attached to the shaft which it peels the coconut and it act has a tool in the
machine. This spike is sharpened and its space is equally distance and the array of the spikes
are positioned to grip and tear the coconut husk. Thus, this design arrangement is suitable for
the purpose of de-husking

Figure 2.10 Peeling Spikes

20
 Chapter 3

Methodology

3.1 Introduction/ Overview

3.2 Method of Design

3.3 Procedure

3.4 Materials

3.5 Components

3.6 Tests

21
 METHODOLOGY

3.1 Overview of the practical experiment/Design

Before the designing process of the Coconut de-husking machine, the most important
principles to structure the machine was determined. The following points were considered as
criteria guidance:
• Availability of materials.
• Good performance.
• Economical.
• Cost
The performance of de-husking machine depended on the material selection and function for
each part. Materials and parts were selected based on their availability and easy to use in
repair and maintenance when facing problem. The main principle governing process was the
guide line to achieve our aim for successful project. The most important factor is minimizing
the friction between the mating gears used at both ends of the shaft to change the direction of
the driven shaft. On other hand, material cost played a large factor on de-husking machine
designing. The type and specifications of the designing was based on factors below.

SL NO DESCRIPTION SPECIFICATION
1 Name Coconut dehusking Extraction machine
2 Mechanism Gears mechanism
3 Target customer Farmers, small scale industry and coconut
selling shops.
4 De fibre process Hand operated
5 De fibre function Semi-automatic/rotary handled operated
6 Manufacturing Machining, indexing, bending, welding
and fabrication
7 Safety Avoid sharp corners, safety guards
10 Cost Below 1k
11 Life of the product 4-5 years

Table 3.1 Specifications Based on Factors

22
By applying the previous principles and factors, it was expected to complete a successful
project which would contain the above function.

There is various technique used for dehusking the coconut. These techniques have many
limitations in process. Despite of that these techniques are widely used for dehusking. Those
technique are manual dehusking using machete or spike, using traditional tool, pedal operated
dehusking, hydraulic operated dehusking and pneumatic operated dehusking.

According to our research we are choosing a dehusking machine using an electric motor and
a gear box. We are choosing this method because it is more efficient, low cost, and it reduce
man power. Starting with the motor, previous researches and studies were checked and
researched on and in additional to researches on the dehusking machine based in other
country. A conclusion was reached that all the dehusking machine the selecting of motor with
capacity depends on the size of the roller or the shaft. The higher the output power of the
motor the more the production rate. By using solid works program, the design using real
dimension was applied. That affordable valuable information of how the dehusking machine
will be. Also, it enables the team to correctly create all the necessary piece of so that there
was minimum wastage of material and resources.

On the other hand, from the previous prototype we are able to find out the problem in the
movement that is friction of the components between the shaft or the roller and the bearing.
Moreover, through the team effort we are able machine all the 4 shafts with a transition fit
where the bearing would be a tap fit on the shaft and will be locked with the grab screws.

The innovative design of a coconut dehusking machine can overcome the problems of
manually process of a coconut dehusking. This paper objective is to design a coconut
dehusking machine-based coconut farming community needs. The design used method of the
quality function deployment to develop a machine that suits to coconut farmers

The methodology to design of coconut dehusking based on the Quality function deployment
(GFD) method which the basis of determining the parameter needed to design accordance
with coconut farmer community needs. The methodology flow chart for the intended process
to do survey collection of the data and development of quality for dehusking machine design.

23
3.2 Designs and Sketches
The diagrams shown it this topic is the plan and proposed design for the De-
husking machine done in Solidworks

3.2.1 Isometric View

Figure 3.1 Isometric View of the Final Design

3.2.2 End View

Figure 3.2 End View of the Final Design

24
3.2.3 Top View

Figure 3.3Top View of the Final Design

3.2.4 Front View

Figure 3.4 Front View of the Final Design

25
3.3 Procedure
There are several processes in developing a dehusking coconut machine. After locating of the
materials within the school’s premises and few of the components were bought by the team
members the process of fabricating started. During the process of designing, the safety factors
are the important things should be taken to prevent any accident or damage occurs to a
product, human health and environment. All of the process involved is using by the
mechanical engineering knowledge. Manufacturing process are the steps through which raw
material are transformed into final products. The process begins with the creation of material
which is made in the design. Below are the steps mentioned in designing.

1. Fabricating of the frame but the team managed to located a used frame and it was
modified considering the design of the machine. The frame had an installed motor
which had a built-in speed controller. Since the team could not locate a gearbox with
an output speed of 30 to 60 rpm, it was then decided to use the existing motor.

2. 2 x 90mm galvanised pipe was cut to the length of 530mm each. The pipes I/D was
bored to 80mm and faced down to 520mm.

3. A 100mm O/D shaft was cut into 4 pieces. 2 pieces were 175mm long and 2 were
280mm long. This shaft would be used for bearing seats, pulley and gears. All the
shafts were machined to 80mm to the length of 20mm so it can be pressed on the pipe.
The rest were roughed out 5mm bigger than the required sizes.

4. Both the pipes were bored to 80mm and the shafts were pressed at both ends of the
pipes and tack welded. Then it was machined down to the specific sizes of individual
components. The sizes are mentioned in the Table 3.2 below:

Component Sizes
Bearing Seat 50mm
Gears x 2 (I/D) 46mm
Pulley (I/D) 24mm
Table 3.2 Specific Size of Components

5. The key ways on the shaft was cut on the milling machine to suit the sizes of the gears
and pulley. The sizes of the key ways are mentioned in the Table 3.3 below. All the
key ways were open type.

26
 Component Sizes
Gears x 2 11 x 5 x 43 mm
Pulley 4 x 2.5 x 40mm
Table 3.3 Key Way Dimensions

6. Keys were shaped out on the shaping machine to match the sizes of gears to shaft and
pulley to shaft. All sharp edges were filed. The sizes of the keys are mentioned in the
Table 3.4 below.

Component Sizes
Gear to Shaft x 2 11 x 10 x 43 mm
Pulley to Shaft 4 x 5 x 40mm
Table 3.4 Key Dimensions

7. The bearing was installed on the shaft, then the pulley for the drive end.
8. The gears were installed at both ends of the shaft.
9. 3 numbers 4mm thick and 555mm long plate was sheared on the shearing machine
and welded on the frame according to the bearing housing seat onto the frame.

10. 12 numbers of 25 x 4 x 520mm flat bars was sheared for the blades of the rollers and
6 were welded on each roller accordingly.

11. The rollers were placed on the base and the holes were marked and blown off using a
gas set.

12. A A-groove pulley was machined for the motor and screwed on the motor shaft.
Thread size was M14 x 2

13. Both the rollers were bolted on the base using a M16 x 2” nut and bolts.

27
The Table 3.5 shows the process of making and assembling the major parts of Coconut de-
husking machine.

Images showing the process Manufacturing Process

Modifying a current frame to suit the design

of de-husking machine.

Cutting of 90mm galvanized pipe using a

drop saw.

Cutting of 100mm round shaft using an

automatic drop saw at machine shop.

28
Facing of the pipe on a lathe machine with
steady rack.

Boring process of the pipe with a boring

bar.

Machining process of the shaft on the lathe.

29
Machined shaft showing diameters of
pulley, bearing seat, shoulder and diameter
of the bore of pipe that will be pressed

Final sizing of the shaft after it has been

pressed on the pipe.

Process of cutting key way on a milling

machine. 3 keyways were milled. 2 for
gears and 1 for pulley.

30
Shaping of key on shaping machine.
3 keys were shaped out, 2 for gears and 1
for pulley

Installation of bearings, gears and keys.

Also checking of gear meshing.

Shearing of 1” flat bars for the purpose of

using it as blades for dehusking.

Process showing the marking of equal

distance for 6 blades on each roller. An
engineering divider and straight edge is
being used.

31
 Mig welding being carried out to join the
blades on the rollers.

De-husking blades welded on the rollers.

Blades used was 1” and 790mm long

Table 3.5 Process of Manufacturing & Assembling of Components

3.4 Materials
Parts Materials
Motor -
Shaft (2) Mild Steel
Gears High Carbon Steel
Pulley Mild Steel
Frame 1” galvanized square tubing
Pillow block bearing Cast iron
V-Belt (A37) Chloroprene rubber
Roller blade Mild steel
Bolt and nut 16mm, 12mm Mild steel
Covers 6mm ply wood
Pipe (2) Galvanized steel
Table 3.6 Material for Each Components

32
3.5 Components
The major components of the developed coconut dehusking machine are:
1. Frame
2. Dehusking Unit
3. Pillow block bearing
4. Gear Mechanism
5. Motor

3.5.1 Frame
The frame is the main supporting structure upon which other components of this
machine are mounted. The frame is a welded structure constructed from 30 x 30 mm
square tubing with the dimension of 1510mm in length, 555mm wide and 520mm
high.

Figure 3.5 Design of the Frame

3.5.2 Dehusking Unit

The dehusking unit comprises of two rollers, 4 shaft, 2 pressed and welded on
each end of the roller. Each roller was formed by welding 6 1” x 4mm flat bars on a
90mm diameter and 520mm long galvanised steel pipe. The shafts are supported on
bearing at both ends on a P210 pillow block with the spur gears mounted right at the

33
 end of each shaft. Also mounted at the end of one shaft is the pulley which is driven
by a V-belt connecting with the motor.

Figure 3.6 Design of De-husking Unit. 2 rollers with blades

3.5.3 Pillow Block

A total of 4 pillow block bearings are installed. 1 each at both ends of the rollers. The
pillow block used is P210. The details of it are in the Table 3.7 below.

Specifications
Dynamic Load Rating 35,099 N
Static Load Rating 23,235 N
Shaft Diameter 50.00 mm
Shaft Height 57.20 mm
Housing Width 60.00 mm
Mounting Hole Center-to-Center 159.00 mm
Housing Length 206.00 mm
Mounting Slot Length 22.00 mm
Mounting Slot Width 20.00 mm
Bearing Inner Race Width 51.60 mm
Bearing Inner Race Width (Short Side) 19.00 mm
Bearing Inner Race Width (Extended Side) 32.60 mm
Mounting Bolt Size 16.00 mm
Bearing Number UCP 210
Housing Number P210
Bearing Type Extended Inner Race with Grab
Screw
Table 3.7 P210 Bearing Specifications

34
 Figure 3.7 Design of the Pillow Block

3.4.4 Gear Mechanism

There are 2 spur gears installed at both rollers end. The spur gears I/D is 46mm. The
shaft size machined to cater for the gear is 46.025mm giving it an interference fit and
it is located by means of a key to avoid slipping on the shaft seat. Both the gears are
of different diameters. One with 154mm with 35 gear teeth’s and the other is 180mm
diameter with 40 gear teeth’s

Input teeth number: 35

Output teeth number: 40
Gear Ration: 0.9: 1
Mechanical Advantage: 1.14
Input Rotational Speed: 112.5rpm
Output Rotational Speed: 98.44rpm
Therefore, it can be said that the driven shaft from the prime mover is has an rpm of
112.5 and it has 35 gear teeth installed on it which now becomes the driver and
drives the other roller in the opposite direction which has 40 gear teeth at an rpm of
98.44.

35
 Figure 3.8 Design of the Gears

3.5.5 Motor
The prime mover used in this machine is a motor. Specifications are listed in the
Table 3.8 below:

Specifications
Type DC Motor MD-803
Make Brother
Phase Single Phase
Voltage 240
Speed VSD
Table 3.8 Motor Specifications

The O/D of the pulley installed in the motor is 67mm and the one installed on the
roller is 100mm with the motor rpm at 150. The reduction of the output at the rollers
are as follows:
Belt Length 37" Ratio 1: 1.33
RPM Small Pulley 150 RPM Large Pulley 112.5
Belt Speed 117.8 ft / min Pulley Gap 9~1/2"

36
 Figure 3.9 Design of the Motor

3.6 Tests /Experiments

3.6.1 Roller Straightness
After the shafts were pressed on the pipe, it was mounted on a lathe machine
to check for its straightness. It was found that the pipe was not 100% straight
or circular. It was then machined taking out 1.5mm of the material and getting
it around 85% true. We couldn’t get it 100% straight or else the pipe would
become very thin and weak which is not recommended.

3.6.2 De-husking Machine

After assembling all the components, the machine was ready to be tested.
Upon running the motor both the rollers ran fine but when the coconut was
place on the rollers the motor stopped. It was found that the motor was too
weak for the load. The initial motor ordered by the group was a 2hp which was
the recommended motor but the failure of its arrival resulted in the group
using the available motor that was found by the group. Due to this further test
we’re not carried out.

3.7 Restriction/limiting Condition

37
 The dehusking coconut machine is a machine that is used de-husk the coconut. The
most important for the dehusking coconut machine is to have a successful result. The
solid works drawing needs to be applied to help the dehusking coconut machine
structure. Some of the limitation factors that the group faced during manufacturing of
the de-husking machine were:

➢ Delay in work, the construction work was started in week 13 due to no

material available but the group requested authorities to use the materials
available with them.
➢ The group could not locate a gearbox with 30 to 60 rpm but a VSD sewing
machine motor was found outside Welding and Fabrication workshop.
➢ Unavailability of the workshops delayed the work progress as workshops
were only available when it was not in use.
➢ The group members contributed towards the purchase of 2 pillow blocks
and 2 others were used from previous projects.
➢ No special project rooms allocated for project purpose; hence possibility of
loosing components and parts are high.

These are some of the important factors which needs to be considered in the successful
construction of the prototype. Material selection is very important. The tolerance, fits and
measurements are very essential for machining and fabrication purpose. Also, the measuring
tools and equipment’s plays a vital role for the prototype.

Safety is also a very important factor in the successful construction. All the team members
were briefed about being safe and SOP of all machines.

38
 Chapter 4

Summary

4.1 Conclusion

4.2 Recommendation

4.3 Recommended Design

A.1 References

B.1 Appendices

39
4.1 Conclusion
In conclusion, the team was able to Prototype a Coconut De-husking Machine with a simple
design but could not fully achieve the goals and required function of the machine. The
concept of the De-husking machine was found to be simple whereby it started with a square
tubing frame that has the property to withstand the loads attached to it. During the test it was
found that the motor rating was too low to accommodate the load of tearing the coconut husk.
The required motor for tearing is at least 1.5hp motor.

The team members also understood the total concept of machining all the individual
components of the machine such as, shafts, threading, using of milling machine to mill the
keyways, shaping out the key, giving the type of fits of each component. Also, during the
process, the group applied basic engineering principles learnt as a mechanical engineering
student and improved professional and teamwork skills. The construction phase provided as
opportunity to get hands on experience with various manufacturing methods and to use
various engineering tools. The team also came to know the techniques of welding process.

It can be said that good project planning and time management are essential and are highly
recommended to accomplish a successful project. Due to lack of time and compromising of
components the group could not achieve the full objectives of the project but were on a verge
of breakthrough had be there more time for testing or availability correct prime mover and
reduction gearbox. Also, it was a good learning curve and experience for the group.

40
4.2 Recommendation
After the completion of this project and analysing the tests and results, the group has come up
with the future recommendations that can be done to improve the design, operations and
manufacturing the De-husking machine by:

• Using of the recommended motor.

• Installation on a reduction gearbox to have to output speed of 30 to 60 rpm.
• Making proper guards for the machine for safety purpose.
• The rollers can be designed with spikes instead of flat bars.
• The school to provide materials as soon as possible after starting the semester so there ais
enough time to complete, test and modify it required.
• A proper workshop should be allocated for students to do the Prototype.
• Use of direct coupling system from the output of the prime mover instead of using V-
belt.
• Using of same size gears to change the motion of driven roller.

41
4.3 Recommended Design

42
A.1 References
• Nusbir, Yohanes & Candra, Helmi & Satriardi, & Susilawati, Anita & Arief,
Dodi. (2016). Design of Coconut De-husking Machine Using Quality Function
Deployment Method.

• ARTICLE, M., Development of a Coconut Dehusking Machine for Rural

Small-Scale Farm Holders.

• JACOB, J. and RAJESH KUMAR, S., Dec 2012. Design and fabrication of
coconut dehusking machine, Dec 2012, IEEE, pp. 155-159.

• CONFERENCE PAPER, N., Design of Coconut De-husking Machine Using

Quality Function Deployment Method

• Adzimah, S. K. (2015). Conceptual Design of Coconut Dehusking Machine.

Conceptual Design of Coconut Dehusking Machine, 4.

• Jacob, J. (2012). Design and fabrication of coconut dehusking machine. 2012

International Conference on Green Technologies (ICGT), 2.

• Pascua, A. M. (2018). Performance Characteristics of a. International Journal

of Advances in Agricultural Science and Technology, 1.

• Reddy, M. (2019). Minister Reddy's Speech for The Whole Nut Processing
Training Coconut- Nutrition, Health and Wealth. The Fijian Government, 1.

• Taufik, M. (2014). Performance evaluation of coconut dehusking machine.

Journal of tropical agriculture and food science, 183.

• https://www.blocklayer.com/pulley-belteng.aspx

• https://www.omnicalculator.com/physics/gear-ratio

43
A.2 Appendices

Standard operational Procedure (SOP)

Operation of the De-husking Machine:

1. Before starting the machine check out the surroundings. It should be used at a safe place
2. Check the general condition of the machine (tearing blade, bearing conditions and gear
meshing)
3. Use the safety googles for protection.
4. Apply grease on the gears to reduce friction, wear and tear.
5. Check the tension for the V-belt
6. Check the holding down bolts for the bearings. Should not be loose.
7. Do not wear loose clothing while operating the machine.
8. After using, turn of the power source and then clean the machine.

44
 7 4
6
3

2
5

10

10

45