Project Title

Design and Fabrication of a Hand Operated Beans

Shelling Machine

By

Group 5

Research Project Report

Submitted to

The Department of Design and Technology

At The

Technical and Vocational Teachers College

Luanshya
In Partial Fulfilment of the Requirements for the Award of

BSc DTTE

31st March, 2021

 Technical and Vocational Teachers College

Project Title

Design and Fabrication of a Hand Operated Beans

Shelling Machine
By

Name Student no Signature

Kauzeni Kapila 18259

Masumba Kutemba 18550

Mubanga Isaac 18643

Muuka Muuka 18778

Mwanza Boyce 18255

Department approval Name Signature

Lecture Approval Name Signature

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ABSTRACT
Threshing of beans is an after-harvest activity used by farmers to depod the beans from the
husks. This report set out to investigate the challenges faced by small scale farmers when
threshing/depodding their produce with the sole purpose of developing a machine that would
make the farming process much less stressing.
In collecting data for the research both qualitative and quantitative methods of research were
implored. These involved carrying out surveys in Mpongwe, carrying out structured
interviews with farmers and questionnaires to help in determine the troubles and give the
researchers an insight of the product that would be relevant to the needs of the society in
terms of ergonomics, economics and durability.
It was discovered that an average farmer was willing to spend money on a machine that
would cost K4,000.00 and below, most farmers also preferred a machine that would be
operated by a single individual.
A machine was developed and fabricated considering in mind the requirements of the target
group even though initial performance did not yield 100% threshing efficiency the required
machine met a lot of expectations in terms of pricing, ergonomics and durability.

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DEDICATION

This research study is wholeheartedly dedicated to our parents, who have been our source of
inspiration and gave us strength during our academic life and have continued to provide their
financial, moral, spiritual and emotional support.

We further extend our dedication to all our Course lecturers who impacted the knowledge in
us and encouraged us especially when we felt discouraged. We also acknowledge our
brothers/ sisters, relatives, mentors, friends and classmates who shared their words of advice
and encouragement to finish this study.

Lastly, we dedicate this Thesis booklet to all group five members for working in one accord
throughout the project itself and to see to it that the research study become a success.

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ACKNOWLEDMENTS
We sincerely thank the almighty God for seeing us through the years in which we have been
at Technical and Vocational Teachers’ College (TVTC), for the good health mentally and
physically and for the strength to endure everything that came our way. We hereby wish to
thank our families for their never-ending support and for never giving up on us when we
needed them the most, our supervisors Mr. Chisalu and Mr. Mulubwa for their expert input
and for always being there whenever we called upon them for their guidance and we cannot
forget the immeasurable support we received from the members of staff in the department of
Design and Technology at the Institution. Last but not least, our gratitude also goes to the
TVTC Workshop machinist Mr Kawana for the Technical support rendered.

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Table of Contents
CHAPTER 1: INTRODUCTION .............................................................................................. 1

1.1 Introduction ...................................................................................................................... 1

1.2 Problem Statement ........................................................................................................... 3

1.2.1 Significance of the Problem ....................................................................................... 4

1.2.2 Aims ........................................................................................................................... 4

1.2.3 Research Questions/ Hypothesis ............................................................................... 5

1.2.4 Objectives of the Project............................................................................................ 5

1.2.5 Justification ............................................................................................................... 5

1.3 Scope of the Project.......................................................................................................... 5

CHAPTER 2: LITERATURE REVIEW .................................................................................. 7

2.1 Historical Background of beans shelling machine ........................................................... 7

2.2 Available types of threshing machines............................................................................. 9

2.2.1 Roller Method ............................................................................................................ 9

2.2.2 Tumbler Method ...................................................................................................... 11

2.2.3 Shearing Method...................................................................................................... 12

2.3 Theoretical Foundations of Manually Operated Beans Shelling Machine .................... 14

CHAPTER 3: METHODOLOGY ........................................................................................... 18

3.1 Research Design ............................................................................................................. 18

3.2 Components specification .............................................................................................. 19

3.3 Modelling & Fabrication ................................................................................................ 22

3.4 Assembly Drawings. ...................................................................................................... 28

3.5 Equations ........................................................................................................................ 32

3.6 Data analysis .................................................................................................................. 33

CHAPTER 4: RESULTS ......................................................................................................... 41

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 4.1 Overview ........................................................................................................................ 41

4.2 Descriptive results .......................................................................................................... 41

4.3 Empirical results ............................................................................................................. 42

4.3.1 Determination of the rate of beans shelling ............................................................ 42

4.3.2 Determination of technical efficiency ...................................................................... 46

CHAPTER 5: DISCUSSION ................................................................................................... 49

5.1 Conclusions .................................................................................................................... 50

5.2 Limitations ..................................................................................................................... 51

5.3 Recommendations for Future Research ......................................................................... 52

CHAPTER 6: REFERENCES .................................................................................................. A

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List of figures

Figure 2.1 Example of a table top roller operated pea sheller ................................................. 9
Figure 2.2 Roller method as patented by G.B Price (1864) .................................................... 10
Figure 2.3 Double Roller Mechanism Patent .......................................................................... 10
Figure 2.4 (a) and (b) Front and Side view of the 1977 tumbler method shelling machine by
W. Woodrow ............................................................................................................................. 11
Figure 2.5 1977 tumbler method shelling machine patent by Taylor ...................................... 12
Figure 2.6 Images of rice Huller as adapted from Hirtz et-al ................................................. 13
Figure 2.7 representation of shearing method patent as extracted from Hirtz et-al ............... 14
Figure 2.8 side view of the 1977 tumbler shelling machine by Taylor.G ................................ 15
Figure 2.9 Pea sheller patent by George and Brett Taylor (2010) ......................................... 16
Figure 2.10 representation of the blower in the 2010 pea sheller by George and Brett Taylor
patent........................................................................................................................................ 17
Figure 3.1 schematic drawings of the Frame .......................................................................... 23
Figure 3.2 schematic drawings of the feed hopper .................................................................. 24
Figure 3.3 (a) and (b) shows images of a crank sprocket and freewheel sprocket for a bicycle
used for the drive mechanism of the machine .......................................................................... 24
Figure 3.4 simulation of shaft with stepped diameters in mm ................................................. 25
Figure 3.5 simulated representative of the shelling drum ....................................................... 26
Figure 3.6 picture of the actual shelling drum after fabrication ............................................. 26
Figure 3.7 shows an image of the UCP P205 Plummer block bearings used ......................... 26
Figure 3.8 (a) and (b) show the lower part of the mechanism during the fabrication process
.................................................................................................................................................. 27
Figure 3.9 shows the complete assembly in 3-D...................................................................... 29
Figure 3.10 shows the wireframe drawings of the machine .................................................... 29
Figure 3.11 images of the machine after fabrication .............................................................. 30
Figure 3.12 images of the fabricated machine in readiness for trial testing ........................... 31

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List of Figures

Table 3.1 table of materials used and their costs ..................................................................... 21

Table 4.1 Table of times taken to shell 5kg of beans at varying speeds .................................. 42
Table 4.2 data collected of beans processing at different operating speeds ............................ 43
Table 4.3 summary of data analysis at different speeds .......................................................... 47

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CHAPTER 1: INTRODUCTION

1.1 Introduction
Beans is a common household food in Zambia and is among the most farmed crops in the
country “Beans were probably introduced to the eastern Africa coast by Portuguese traders
in the sixteenth. These traders settled at Sofala in Mozambique, Zanzibar and Mombasa in
Tanzania and Kenya respectively. Their goods, including various new food plants, were
carried to the interior by Arab slave traders and by Swahili merchants.’’ (Sibiko, 2012)
‘’Beans became established as a food crop in Africa before the colonial era, but there is little
clear indication of the status the crop attained. The wealth of local names given to
distinctive genetic varieties, are together evidence of the long establishment of beans as a
crop” (Charles S Wortmann, 1998).
In todays’ times beans remains a major crop in many parts of Africa, especially in eastern,
central and southern parts of Africa. It is an important food to people of all income
categories; it is especially important to people in rural communities and is often the principal
source of dietary protein for the urban poor. Its production is agronomically diverse, being
grown in many different crop associations.
According to (Graham & Ranalli, 1997) “there has been an increase in beans production
following the governments repeated call for crop diversification from maize farming to other
cash crops, which has led to an increase in beans production. Unfortunately, the rate of
increase in beans production has been exceeded by the rate of population growth in the last
ten years. With the number of beans famers remaining constant while demand for the crop
booming”. A number of researchers in Central and Southern Africa alike recognizes
research on beans as being of high importance.
Farming of beans involves three distinct phases namely; planting, harvesting and processing.
In agricultural processing relevant activities include unit operations such as shelling,
threshing, de-hulling and decortications. The major objective of shelling, threshing, de-
hulling or decorticating of most farm products is to improve their value by detaching or
dissociating their kernels or seeds from their enclosure.
Mostly, shelling machines are used for processing ‘’the principle of operation of a shelling
machine usually involves application of impact force with partial shear force depending on
the hardness of the shell of the seed. Threshers on the other hand involves application of
impact force only. Decorticators apply combination of impact with compressive force.’’
(Kabir A & Fedele O, 2018) While de-hullers apply abrasive force to operate in most cases.

1
Shelling, threshing, de-hulling and decorticating operations were done using manual
methods like the use of sticks in hitting sacks loaded with cob of corn or the use of mortar
and pestle before the advent of agricultural machines. (Prem, Ranjan, Pragi, Dabhi, & Baria,
2017).
Manual processing of agricultural produce is time consuming and tedious; the conditions
prevalent at this level of operation is generally unsanitary and inherently unhygienic, with
little attention being paid to quality control, making the wholesomeness and quality of the
products, below standard. The need to reduce the stress and time associated with the manual
method of processing beans, gave rise to the conceptual design and construction of beans
shelling machine which eliminates a number of problems associated with the manual
processing of beans.
A labour force survey conducted by the ministry of labour and social security (Labour &
Security, 2013) showed that informal employment in the agriculture sector as at 2012 stood
at 52% whereas formal employment in the agricultural sector stood at only 28%. This
disparity in labour force trends can be a reason for the low supply of beans on the market.
This is because majority of the beans that ends up on the market is mainly produced by
farmers in the informal agricultural sector who lack automated machinery to help improve
production.
According to government reports (Zambia, 2015) a total of 260,030 households grew mixed
beans during the 2014-2015 farming season. Northern Province recorded the largest
percentage of households that grew mixed beans accounting for 32.9 percent followed by
Muchinga and North Western provinces which accounted for 18.4 and 11.5 percent,
respectively. Luapula Province accounted for 11.1 percent while the rest of the provinces
accounted for less than 10 percent of the total production of mixed beans each. Further
government records show that a total of 52,379.0 metric tonnes of mixed beans were
produced during the season.
Out of the total quantity of mixed beans produced, 28,005.8 metric tonnes were sold in 2015
agricultural season. Northern Province sold the largest quantity of mixed beans at 54.8
percent. North Western and Muchinga provinces accounted for 10.5 percent and 9.8 percent
of the total sold, respectively.
Small scale farmers are faced with many challenges which limit their production capacity
most notable is that equipment manufacturers tend to lean towards producing machinery for
high value operations, ensuring that they make good money sales on their products. This

2
disadvantages the small-scale farmers who are in need of mechanical solutions that are not
meant for large operations.
Also, the time required to process any deliverable quantity of produce makes beans farming
very costly for small scale farmers. Due to the fact that there are few beans contained in
each bean pod. While shelling machines are available commercially, the capacities of these
systems only cover very small or very large operations with no alternatives available for
mid-sized operations. Using a machine intended for small operations is hardly more efficient
than shelling the beans by hand and using an industrial machine intended for large
operations is not financially feasible (Allen, Hritz, & Janosik, 2012)
Owing to the huge numbers of beans being produced by small scale farmers it is therefore
required to design, and develop a technical product that will enhance productivity of these
small-scale farmers. The main goal is to create a machine that combines the financial
feasibility of a small-scale application with the automation of a large-scale application. This
machine will accept dried bean pods as input and produce shelled beans as output, requiring
the operator to simply load the bean pods and remove the shelled beans.
1.2 Problem Statement
The labour force survey of 2012 indicates that only 28% of the Zambian population are
involved in the formal agricultural sector while another 52% of the population is involved in
the informal agricultural sector. Farmers in the formal sector are mainly involved in
commercial farming of maize and vegetables, leaving the informal sector (52%) to be the
main supplier of beans on the Zambian market. The informal sector is comprised of small-
scale farmers who usually farm around five hectares of mixed crops mainly for
consumption, with only a few of their produce occasionally entering the market.
This low turnout is due to the labour-intensive nature of agriculture, depodding of beans for
small scale farmers is a tedious process which is also time consuming.
Most agricultural equipment manufacturers target the commercial farmers, and as such most
beans shelling machines on the market are available for large scale operations leaving the
small-scale farmers who are the major supplier of beans on the market to use the traditional
ways of depodding beans.
There are so many problems associated with the traditional ways of processing beans, like
the unsanitary conditions associated to depodding of the beans, the lack of quality control,
failure to scientifically quantify processing rate which makes it an unattractive venture for

3
 people who would like to enter the market. Also, the physiological demands associated with
manual handling of beans processing.
These problems have consequently led to the need for the design and development of a
machine that will reduce the labour demands, increase the rate of processing and improve
the quality of the beans collected.
Manually operated machines are available on the market and these machines are by far,
much faster as compared to the hand method of depodding beans. Most machines are
designed to only depod the beans and have no means of separating the husks from the beans
which leads to more work for the labourers who have to separate the beans from the husks,
this is probably one of the reasons why the manually operated beans shelling machine is not
so popular.
1.2.1 Significance of the Problem
Looking at the time it takes and all the inherent physiological problems attached to the
primitive ways of processing beans by small scale farmers it is imperative that an
economically viable product is developed for the existing market. The problem presents a
gap in the agriculture machinery market and if successfully developed the significance of
developing a manually operated machine are that;
i. It will reduce the labour involved in processing of beans
ii. The machine will be manufactured using locally available materials
iii. Reduce the time taken to process beans whilst consequently improving returns for
the farmers
The research project is of great significance to the body of knowledge as it will lead to
further research in the production of such farm machinery. The main aims of the study were
to build a cheaper affordable machine using materials and labour that are locally available
and the use of durable materials. The project is another among the many projects that have
been undertaken locally with similar aims. It incorporates theories of mechanisms that have
been overlooked by other researchers in the same vain. The starting point of importance to
consider in developing the machine is the rate of processing, which alone will determine the
attractiveness of the machine once completed and before other aspects can be examined.
1.2.2 Aims
To review the existing methods of beans shelling used by small scale farmers, how are the
current beans Sheller’s operated? And develop an efficient cheaper beans shelling machine
for the local farmer.

4
1.2.3 Research Questions/ Hypothesis
Design and manufacturing Bean Sheller, that would make the depodding of beans less stress
and affordable to buy.

1.2.4 Objectives of the Project

The specific objectives are as follows;
i. To evaluate the efficiency and effectiveness of already existing methods of beans
shelling
ii. To incorporate already existing theories in building a cheaper more efficient beans
shelling machine
iii. To design a technical product that will have a larger output by increasing the
input/output feed per minute by means of continuous feeding
iv. To incorporate a separation mechanism at the output which will separate the beans
from the husks

1.2.5 Justification
Small scale farmers produce a sizeable amount of beans which require the use of a machine
to shell the beans in good time and reduce on the labour required to shell the beans. The
development of a hand operated machine that will shell the beans will in the long run reduce
on the time spent shelling the beans using traditional methods. Among the other significances
such a machine would bring are
i. Reduce on the labour required to shell the beans instead of having a lot of people
shelling the beans one or two people must be able to operate the machine
ii. Industrial beans shelling machine available are too expensive for the small-scale
farmers with respect to the amount of produce they process a cheaper machine for the
small-scale farmers is necessary
iii. Separation of the husks from the beans at the output is a step forward as most existing
manually operated machines can’t achieve this

1.3 Scope of the Project

The main areas of concern for the development of the machine include the time taken to
depod the beans and energy consideration which arise from among other factors, the
physiological responses of the farmers during operation of the beans Sheller and easy
accessibility of the serviceable parts in order to carry out design modifications in the work
system so as to have higher machine system efficiency. The velocity ratios and rotational

5
speed of the drive shaft will be analysed to determine the amount of torque that will be
produced as well as the power transmitted to the shelling unit in order to successfully depod
the beans without breaking it. The target population for carrying out the research were the
locally based small-scale farmers around the Copperbelt in Luanshya, Chililabombwe,
Kalulushi and rural parts of Mufulira. The shelling mechanisms is to be operated by manual
means without the use of an electric motor and the machine to be developed should not
exceed a market value of K4,000.00.
In order to achieve the research objectives, the project will follow the laid down procedure as
prescribed for carrying out academic research. The research team will first embark on
literature review to familiarise with the available information on shelling processes and
machinery. From there a conceptual framework will be drawn appropriate tools for purposes
of data collection and analysis will be developed. From the knowledge of engineering
mechanisms and material properties the research will design and develop an appropriate
machine for the purpose of shelling beans effectively whose efficiencies will be assessed and
conclusions drawn. Recommendations for further research of the chosen topic will also be
made at the end of the project report.

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CHAPTER 2: LITERATURE REVIEW

2.1 Historical Background of beans shelling machine

A beans sheller is an apparatus designed to take out the beans from their pods. Early models
were powered by hand by the use of a crank; most of later models are powered by electricity.
The mechanically operated sheller was invented in the 17th century, as patented in (Eskin,
1989) by Scotsman Andrew Meikle. Typically, Beans shellers press the beans or peas
between two rollers, which squeeze the grain out of the pods; some machines are designed
with rollers that have ridges that slice the pods open. Beans shellers have different types of
mechanisms to separate the shells from the pods and other debris. (Allen, Hritz, & Janosik,
2012)
As indicated by (Clark, 2007) “the invention of the Shelling machine by Scotsman Andrew
Meikle in 1786 took place at a time when there was a surge in industrial innovation due to the
industrial revolution. Socially the innovations of industrial revolution had far reaching
consequences and in 1830 sparked protests by farm labourers”.
These farm labourers had faced unemployment for a number of years due to the widespread
introduction of the Shelling machine and the policy of enclosing fields. Farm owners no
longer needed thousands of men to tend crops, a few would suffice with the use of machines,
the labourers felt disadvantaged by the use of more efficient mechanized methods of farming
and in retaliation the rioters smashed shelling machines and threatened farmers who had
them. (Clark, 2007)
The subsequent adoption of such machines was one of the earliest examples of the
mechanization of agriculture during the industrial revolution. During the 19th century,
shellers and mechanical reapers and reaper-binders gradually became widespread and made
grain production much less laborious.
However, reaper-binders and shellers have largely been replaced by machines that combine
all of their functions, these machines are called combine harvesters. Today, in developed
areas, most farming operations are done by machine, harvesting is usually done by a combine
harvester, which harvests, shells, and winnows the grain while it is still in the field. Despite
these developments, the simpler machines remain important as an appropriate technology in
low-capital farming operations, both in developing countries and in developed countries.
(wikipedia, 2021)

7
2.2 Later adoption
In 1834, John Avery and Hiram Abial Pitts devised significant improvements to a machine
that automatically shelled and separated grain from chaff, freeing farmers from a slow and
laborious process. (wikipedia, 2021)
Since the invention of this machine, other inventors have progressively introduced a variety
of improvements, most notable among these are the modern day combine harvester which
binds and threshes wheat in the case of wheat processing, such machine exist for corn, beans
and other crops. With such machines the aim is to simplify the labour involved in operating
the processing of produce (wikipedia, 2021).
Modern developments
Modern day combine harvesters operate on the same principles and use the same components
as the original shelling machines built in the 19th century, they also perform the reaping
operation at the same time. The name combine is derived from the fact that the two steps are
combined in a single machine.
Today, the operation of a typical threshing machine is similar as to processes used in the 19th
century, the shelling begins with a cylinder and concave. The cylinder has sharp serrated bars
and rotates at high speed (about 500 RPM), so that the bars beat against the grain. The
concave is curved to match the curve of the cylinder and serves to hold the grain as it is
beaten. The beating releases the grain from the straw and chaff.
Whilst the majority of the grain falls through the concave, the straw is carried by a set of
"walkers" to the rear of the machine, allowing any grain and chaff still in the straw to fall
below. Below the straw walkers, a fan blows a stream of air across the grain, removing dust
and fines and blowing them away.
The grain, either coming through the concave or the walkers, meets a set of sieves mounted
on an assembly called a shoe, which is shaken mechanically. The top sieve has larger
openings and serves to remove large pieces of chaff from the grain. The lower sieve separates
clean grain, which falls through, from incompletely shelled pieces. The incompletely threshed
grain is returned to the cylinder by means of a system of conveyors, where the process
repeats.
The beans and corn sheller use similar design of combine harvesters, only slight
modifications are added to ensure that the grain being harvested will be collected. Modern-
day combines can be easily dismantled and assembled to add the required mechanism for
processing a required crop. Despite the rapid developments of combine harvesters a shelling
machine that meets the production capacity of small-scale farmers remains an important
8
machine especially in Zambia where majority of the beans that ends up on the market is
supplied by small scale farmers who cannot afford a combine harvester.

2.3 Available types of threshing machines

Through team research, several existing methods to depod beans have been discovered. Most
commercially available machinery are either too large or too small, or are designed to process
the wrong type of pods. The research yielded three different mechanized methods used for
shelling beans. These methods use either a roller method, a tumbling method, or a shearing
method.

2.3.1 Roller Method

The roller method of bean shelling can be found in several readily available hand crank or
table top models. These machines are in essence a kitchen tool which are mainly used for
fresh beans or peas. The beans pods are fed into two very closely spaced rotating rollers
which squeeze the beans out of the pod and then pull the empty pods through the roller
mechanism to be collected and discarded. These devices were designed to be used in the
kitchen and for the purposes of depodding fresh beans only.

Figure 2.1 Example of a table top roller operated pea sheller

These machines were the pioneers to later developments in the field of beans shelling
machines. Figure 2.2 shows a patented roller method “pea sheller.” This is an example of the
earliest record of patents to exist on beans and pea shelling machines

9
 Figure 2.2 Roller method as patented by G.B Price (1864)

The concept shown above is from 1864. It uses a hand crank to drive the main two rollers as
well as a conveyor feed system. The conveyor is driven by a pulley system. The gap
between the two rollers can be easily adjusted with a screw mechanism at the top of the
machine. The beans are separated from their pods after they move through the rollers. This
method of separation is different from most of the other roller method designs. The most
typical method of separation is to have the peas stay on the feed side of the rollers while the
pods move to the other side. An additional patent is shown below in Figures 2.3

Figure 2.3 Double Roller Mechanism Patent

In Figure 2.3 two sets of rollers are used to de-shell the beans. When the beans go through the
first set of rollers, they are sliced open by the bottom roller. The top roller has ridges on it to

10
help pull the beans through. This process is shown in Figure 2.3. The next set of rollers are
placed close together so that the pods get pulled through but the beans are left behind.

2.3.2 Tumbler Method

Shelling machines that use the tumbler method consist of a slowly rotating inner mesh
cylinder which contains a quickly rotating shaft with mounted beaters, and a stationary
external wall. The pods are loaded into the inner cylinder which rotates and directs the pods
to fall into the spinning shaft which breaks up the pods through contact with the rotating
beaters. The shelled beans then fall through the inner cylinder mesh and are collected from
the external wall, while the empty pods remain within the inner cylinder to be later collected
and discarded. The only commercially available tumbler style machines are designed for an
industrial scale operation and therefore are both too large and expensive. A tumbling shelling
machine with an appropriate capacity for the small-scale farmer needs, costs around K20
000.00, which is too expensive for small scale farm operations.
Tumbler style machines can typically handle a much higher load capacity than that of the
roller method machines. A 1977 design for a tumbler shelling machine by (Woodrow W.
Welborn, 1977) is shown in Figures 2.4 below;

Figure 2.4 (a) Figure 2.4 (b)

Figure 2.4 (a) and (b) Front and Side view of the 1977 tumbler method shelling machine by W.
Woodrow

This machine, as well as most tumbler method machines, uses a screen with properly sized
holes for shelled beans to fall through which leaves the pod remnants inside the chamber.
After all the beans are shelled, the pods are then removed from the device and a new batch of
beans can be loaded for the next run. Tumbler method machines can become increasingly
complex and efficient.

11
A patented design using the tumbler method is shown in Figure 2.5 below, it includes several
different features from the one developed by Woodrow.W

Figure 2.5 1977 tumbler method shelling machine patent by Taylor

The first unique feature in this design is that the cylindrical drum turns as rows of beaters
turn. The patent calls out a beater to drum rotational speed ratio of 5:1. The drum spins in the
opposite direction as the beaters. Another different feature of this design is that the beaters
have free spinning forks at the ends. The patent calls out several different types of
interchangeable tips that can be used at the ends of the beaters for different applications. This
design also includes a method for further sorting beans from hull debris after the screen of the
main drum. The design uses offset shafts on pulleys, to make two sets of screens vibrate.
The vibration motion moves the beans over the screens and sorts them accordingly into
collection buckets. (George, 1977)

2.3.3 Shearing Method

As discovered by (Allen, Hritz, & Janosik, 2012) “The only device in production that
employs the shearing method found on the market is a rice huller. In this method the rice is
fed onto a stationary table with an oscillating or reciprocating surface just above the table.
The friction and shearing forces applied by the table split the rice hulls open and then

12
separate the chaff and grains of rice. The chaff and rice grains are then separated using an
additional device or process. Alternate Rice huller designs employ a rotating drum that shears
the rice against a curved surface.” Figure 2.6 presents an example of a rice huller.

Figure 2.6 Images of rice Huller as adapted from Hirtz et-al

In early stages of development of the beans shelling machines, machines with a similar
concept as that of a rice huller were made as can be seen by the existing patents found.
However their complexity in operation and manufacture made it a costly endeavour which
led to a natural death off the market effectively putting an end to any further improvements
and production of such machines (Ashwin Kumar & Begum, 2014).
A few adjustments can however be made to the existing rice hullers to make them suitable for
the purpose of depodding beans but it would be an expense of energy and resources because
such machines lack the versatility of the tumbler machines and would require more complex
design in order to achieve what can be easily achieved by the tumbler method shelling
machines. This method of shelling beans is not as prominent as the roller or tumbler methods.
Only one patent by W.E Moulsdale and Co Ltd was found for a machine of this type.
(Westminister, United Kingdom Patent No. 9857[ Class 58 ], 1935) The design is shown in
Figure 2.7

13
 Figure 2.7 representation of shearing method patent as extracted from Hirtz et-al

This device uses a hopper to feed the beans down. Once at the bottom of the hopper, the
beans are grabbed by teeth from a spinning disc. The beans are then dragged across a
stationary set of teeth and are torn open. As the beans are freed from their pods, they fall
down out of the mechanism. The ground up pods also fall into the same area. (Allen, Hritz,
& Janosik, 2012)

2.4 Theoretical Foundations of Manually Operated Beans Shelling Machine

Having carried out extensive review of existing beans shelling machines for both large scale
and small-scale farm operations. Most literature showed that the tumbler method of beans
shelling forms the basis for the manufacture of medium to large scale beans shelling
machines.
From the reviewed patents, in the earlier stages of beans shelling machines a variety of
patents were found which include a tumbler operated beans shelling machine by W.J
Stevenson in 1858. A few years later an improved machine patent of the earlier tumbler
machine was filed by E.C Morton. Around the same time a pea shelling machine which uses
a shearing mechanism was also patented by (Empson, 1894).

14
However an earlier 1891 tumbler method model by (Edward.C.Morton, 1891)which
incorporated beaters mounted on a drum had already taken a lead in the field of beans
shelling machines. Most beans shelling machines that followed thereafter follow the general
basics implored in the design of this machine by Edward C Morton.
After many years of continuous improvement, two machines in 1977 by (George, 1977)
shelling machine and another by (Woodrow W. Welborn, 1977) Vegetables Peas and
Separating The Hulls Therefrom had made too much advances in the field and tumbler
methods had established themselves as the basis of manufacture for farm operated shelling
machinery. The machines were far much more efficient and effective in depodding beans.
George Taylor continued to work on the improvement of the efficiency of the machine and
by 2007 the 1977 invention was an improved by a newer version of the “legume sheller”
Below is a side view of the 1977 shelling machine by George Taylor

Figure 2.8 side view of the 1977 tumbler shelling machine by Taylor.G

The later version of the tumbler method Legume Sheller by (George.F.Taylor & Taylor,
2010) is a beans Sheller having both an air separator and a sieve separator for removal of
chaff or trash. Airflow through a screen carries legumes and trash upward wherein most of
the lighter trash is carried further up the separator and over into the trash retainer. The
legumes and some residual larger pieces of trash, fall over a weir onto a sieve this machine is
rather too complex for small scale farm operations and rather too expensive. The inclusion of

15
an electric motor and a gyrating sieve mechanism make it quite costly. Figure below shows
the 2010 “Pea Sheller” by George and Brett Taylor

Figure 2.9 Pea sheller patent by George and Brett Taylor (2010)

Instead of the shelled beans falling straight into a bin after falling through the screen, the
beans fall onto a conveyor. The conveyor moves the beans to an air blower contraption that
further sorts the beans from any small, unwanted debris that may have fallen through the
screen. The lighter debris are then blown up and captured in a separate container. This
process is shown in Figure below

16
 Figure 2.10 representation of the blower in the 2010 pea sheller by George and Brett Taylor patent

In order to produce a beans shelling machine that will be affordable and at the same time
achieve the breaking of pods and separation of the beans, the project will adopt the basic
concepts used by George. F and Brett Taylor. The beans Sheller is to have a feeding hopper
as a means of the feeding the beans into the cylindrical chamber, a cylindrical drum with
beaters mounted on it will be coupled to a drive mechanism. The tolerance between the drum
beaters and the casing will be kept at a minimal in order to achieve complete impact action by
the beaters enough to make the beans fall off. The lower part of the depodding chamber will
be perforated with holes big enough to allow only beans grains to fall through. In order to
separate the tiny particle that fall through the holes with the beans another sheet of metal
concave shaped will be perforated with holes so as to allow the particles to fall through and
for the collection of pure beans at a lower end of the concaved sheet.
The decision to use the 2010 model was arrived at because of all the existing machinery it
would be easier to borrow concepts from.

17
CHAPTER 3: METHODOLOGY
This chapter describes the methods and procedures that are required to follow for the
successful completion of the design and manufacture of the beans Shelling machine. In order
to have a systematic and empirical approach to the development of the beans shelling
machine, participants for purposes of data collection and analysis were identified and a
research carried out, the data collected from participants was later analyzed and used in the
design of the beans shelling machine.

3.1 Research Design

The research makes use of a qualitative research strategy. A qualitative research strategy is
particularly applicable for the purpose of this research, where the connection between several
different variables had to be established through interpretation. It gives opportunity to
approach the research objectives from different viewpoints. This is a way of assuring the
validity of research through the use of a variety of methods to collect data on the same topic,
when involving different types of samples as well as methods of data collection. For the
purpose of this research, we decided to use questionnaires and interviewing the participants.
Instruments used in the research include questionnaires, open and close ended interviews for
purposes of collecting primary data. As for secondary data, extensive review of literature was
undertaken which mostly involved the review of publications on shelling machines and alike.
Participants
Participants in this research project were picked from a range of people which included city
based small scale farmers, small scale farmers in rural settings and agricultural machinery
sellers. The small-scale farmers were from Luanshya town, Chembe west in the outskirts of
kalulushi. Kambilombilo farming block in Mufulira and farmers from Chililabombwe town.
For the agriculture machinery traders Lumo Agro Dealers and Vika Agro Solutions were
involved. The research aimed to gather data from farmers who were still using manual
process of removing beans from the pods.
In arriving at the selected participant groups in the research project a number of factors
influenced the picking of participants. Firstly, the group of researchers was comprised of five
members who reside from different parts altogether, as such each member of the research
group did collect primary data from selected participants in their locality which was later
grouped together for analysis purposes. For the small-scale farmers in Luanshya, the school
under which the researchers carried out the research is based in Luanshya which was the
starting point for the research. Traders of agricultural equipment were picked based on their

18
availability, other agricultural equipment suppliers were unreachable and others were not
willing to participate in the research, this is why only the available and willing suppliers were
used for the research. Participants provided enough data that is useful to the whole research.
Data collection
This is the information gathered from different sources concerned with the project which is of
more importance in developing the project. The main three methods of collecting data used
was by; interview, observation and questionnaires.
Data collection was split in two phases, in phase one a fact finding Inquiry was set up to have
insights on how beans farming by small scale farmers in Zambia is done, the target group
were the small scale farmers based in Luanshya, open ended interviews were used for data
collection at this stage.
Phase two of the research was further subdivided into two parts, this was done so that the
researchers can be able to draw comparison between what the farmers were looking for and
what the agriculture machinery market was offering. Developed instruments for this purpose
therefore were questionnaires, to be used for the farmers and structured interviews to be used
for the equipment suppliers.

3.2 Components specification

Materials for the manufacture of the machine were all sourced locally mostly from local
suppliers within Luanshya, Ndola and Kitwe in Copperbelt Province of Zambia. The
selection of these materials was based on availability, cost, durability, strength and weight.
Various components were put together in the fabrication of this machine however the major
components of the design are the Frame, Upper Casing which forms part of the shelling
chamber and has a hopper for feeding, the Drive mechanism which consists of a chain and
sprocket mechanism for the creation of a rotary motion and finally the Lower casing which
forms the lower part of the Shelling chamber, it has a sieve which allows for the beans to fall
through onto a lower sieve which separates the beans from the finer particles that goes
through the first sieve in the lower casing. A drum with beaters mounted on it in a helical
pattern forming a paddle screw conveyer completes the shelling chamber.
Frame
This holds all the components together. Its main purpose is to support other components of
the machine, for this reason it must be able to withstand the forces imposed when the
machine is in operation or when it is stationary. Another purpose is that it must have good
welding properties, hence, 40mm x 40mm x 6meters mild steel angle bar were used and

19
joined together by means of arc welding. The frame was also designed in such a way that the
machine could easily be assembled and serviced.
Feed Hopper
The feed hopper is designed such that at the point of entry, the machine should allow free fall
of raw beans acted upon by a gravitational pull. It is designed based on a criterion called ‘the
angle of repose’ which is defined as the steepest angle at which a sloping surface formed of
loose material is stable. For agricultural materials, at least 8° more than the angle of repose is
recommended for inclination. (www.jstor.org, 2021) The angle of repose for beans is 25°.
The hopper was designed to discharge raw beans using gravity. After designing the hopper
with this angle of 25° it was discovered that raw beans when fed in the hopper wasn’t
obeying the angle of repose, however the hopper was modified, in order to be able to achieve
this. The angle of repose was adjusted to 75° so that only gravitational force is required to
feed raw beans in the machine. The Hopper need to have good strength as one is loading and
it must be able to withstand the vibration loads and stresses and good corrosion resistance. In
order to achieve this, 1.2mm Sheet metal mild steel was used.
Drive Mechanism
The drive mechanism for the Beans Sheller machine consists of a Bicycle Crank and
Freewheel, Sprockets and Chain. The Crank is the source of power and it is manually
propelled by hand. The crank has sprockets around it that are coupled to the Chain drive that
transmits power to the freewheel sprocket. The freewheel sprocket drives the main shaft that
spins the shelling drum with beaters mounted on it at the same time the main shaft drives the
link mechanism that is connected on the opposite side of the freewheel side. The main shaft
rests on P205 Plummer block bearing that enables it to rotate freely with less friction. The
link mechanism is then connected to one end of the Lower sieve to oscillate the sieve. The
sprocket ratios define the required speeds for the processes.
Shelling Chamber
The upper sieve and the upper housing form the shelling chamber. This houses the shelling
drum with beaters mounted to it and it is where the shelling operation is done inside it
therefore; it must be able to withstand load and stresses, good weldability and corrosion
resistance. So, mild steel of 2mm thickness was selected for the upper casing and 1.2mm
thickness was selected for the upper sieve.

20
Shelling Drum
It is a round drum that has flat beaters welded in six (6) spirals. The diameter of the shelling
drum is 240mm.The active length of the drum is 866mm. It is made up of sheet metal of 2mm
thick.
Upper Sieve
This part is semi-circular in shape and has some 12mm holes punched on the bottom. It must
have good strength and high resistance to impact loads therefore; Sheet metal 1.2mm
thickness was used to make this.
Husks Outlet
On the upper housing, one lower side with truncated Cover was used. The truncated cover
must have good strength and high resistance to impact loads, therefore 1.2mm thickness of
sheet metal was used.
Lower Sieve/ Output
The sieve is semi-circular in form and has 7mm holes punches on it. One end is closed while
the other end is open. It also has a hole centred from each side and one hole off centred on the
closed side. Mild steel sheet metal of 1.2mm thickness was used.
Material list
Table 3.1 table of materials used and their costs

Serial Description Details Quantity Price(K)

1 Sheet metal (Mild steel) 2 mm thick Half Sheet 860

2 Sheet metal (Mild steel) 1.2 mm thick 1 Sheet 1080
3 Bicycle Crank Single 1 55
4 Free wheel Single 1 20
5 Plummer Block Bearing P205 2 600
6 Bicycle Chain 1 30
7 Bicycle Hub Rear Hub 1 30
8 Round Bar (mild steel) 1100 x 35 mm diameter 1 220
9 Flat bar (mild steel) 2m x 2mm thick 1 200
10 Angle bars (Mild steel) 40mm x 40mm x 6m 1 445
11 Bolts and nuts (mild steel) M10 10 200
M12 4 88
TOTAL 3,828

21
3.3 Modelling & Fabrication
The Construction of the beans shelling machine begins with the manual propelled by hand. It
is designed in such a way that it should be able to withstand different conditions of the
atmosphere. In order to achieve this mild steel becomes the main constituent material for the
artefact. Other considerations which were put in place are things like ergonomics, which is
mainly the relationship between the average user and the machine itself. This is intended to
maximize productivity by minimizing operator fatigue and discomfort. The machine is about
1360mm in height and 920mm in length while 420mm width. An average adult is able to load
the raw beans in the machine at that height with less difficulties.
Part drawings with details
Frame
The frame is made using 40mm x 40mm angle bars. It stands at a height of 800mm. The top
on which the upper casing is to rest is 400mm in width and 900mm in length.
Two (2) T-shaped members made from mild steel flat bars are wedded to make the T- shapes
which hold the lower sieve. Both members have a width of 400mm while the lengths are
different with one having a length 220mm being the longer one while the shorter one has a
length 160mm making it the shorter one. Both were welded at exactly 200mm from the base
on top to the bottom.
To improve the stability for the frame, two members of length 900mm from the 40mm x
40mm angle were cut and welded on the longer sides for the frame and 200mm from the
bottom.
A rectangular shaped extension was also welded. This is the part that will hold the crank
sprocket. The members are made up of 40mm x 40mm mild steel angle bars to give it more
strength as the crank is being hand propelled. The figure below illustrates the full design
specifications for the frame.

22
 Figure 3.1 schematic drawings of the Frame

Feed Hopper/ Upper Casing

The Feed Hopper and the Upper Casing are fabricated as one unit. The upper case was
fabricated using a 2mm thick mild steel sheet metal which was cut in size of 628.5mm x
900mm. From the 628.5mm side, 80mm was for making collars for the upper case which was
further divided in 2 to make each collar have a width of 40mm and length of 900mm. The
remaining 548.5mm makes half of the circumference for the sieve with the length 900mm at
a radius 200mm. The sheet metal was rolled to come with the semicircle shape and later the
collars made.
As for the Feed Hopper, it is made from 1.2mm mild steel. Two pairs of A shaped, were cut
with the following dimensions; the first pair has 400mm x 150mm while the other pair has
300mm x 150. They were welded together to make the top opening 400mm x 300mm while
making the bottom 150mm x 150mm. Once the feed hopper was done, it was attached to the
top housing to make it more stable as shown in the figure below;

23
 Figure 3.2 schematic drawings of the feed hopper

The drive mechanism consists of various components such as the Bicycle drive mechanism
(Crank and Freewheel sprockets and Bicycle Chain). The other components are the main
shaft, shelling drum with beaters mounted on it, link mechanism, Plummer block bearing.
The figures below illustrate the parts of the drive mechanism.

Crank

Figure 3.3 (a) Figure 3.3 (b)

Figure 3.3 (a) and (b) shows images of a crank sprocket and freewheel sprocket for a bicycle used for
the drive mechanism of the machine

24
Main Shaft
A solid bar 33mm in diameter was chosen for machining it to a shaft. This chosen shaft was
cut to 1100mm and machined to 29mm diameter on both ends to make shoulders for the
Plummer blocks on both ends. The 33mm and 29mm diameters makes shoulders for the
shelling drum. The bearing which were chosen had 25mm inner diameter therefore the shaft
was further machined to 25mm on both ends to enable the bearings to be slotted. A transition
fit was used in order to allow the shaft to be fitted in. This prevents the shaft from slipping
through the bearing which could result in damaging the bearing. The shaft was machined to
23mm diameter at both far ends in order to enable the free wheel sprocket and the crank shaft
on the opposite side to be fitted to the shaft. The area differences between 23mm and 25mm
diameters enables both the free wheel sprocket and the crankshaft bearing to be locked in
place as these areas act as shoulders. These are illustrated in the figure below;

Figure 3.4 simulation of shaft with stepped diameters in mm

Shelling Drum
The shelling Drum is made from the mild steel sheet metal 2mm in thickness. Sheet metal of
size 754mm in width and 866mm in length was cut. The width side was then rolled to make a
circular shape which was later welded throughout the whole length to make a drum that is
open on both sides.
Two covers of diameter 240mm mild steel sheet metal 2mm thick are used to cover the ends
of the drum. These circular covers have 29mm holes drilled on them, which to allow the shaft
to go through and settle on the 29mm shaft diameter shoulders.
The beaters made from flat bar mild steel 40mm in length and 15mm in width were later
welded to the shelling drum in six (6) spirals as illustrated in the figure below;

25
 Beaters

Figure 3.5 simulated representative of the shelling drum

Figure 3.6 picture of the actual shelling drum after fabrication

Figure 3.7 shows an image of the UCP P205 Plummer block bearings used

26
Upper Sieve
The upper sieve was fabricated using a 1.2mm thick mild steel sheet metal which was cut in
size of 628.5mm x 900mm. From the 628.5mm side, 80mm was for making collars for the
sieve which was further divided in 2 to make each collar have a width of 40mm and length of
900mm. The remaining 548.5mm makes half of the circumference for the sieve with the
length 900mm at a radius 200mm.
First the sheet metal was rolled to come with the semicircle shape and later the collars made.
12mm Holes were punched on the base for the semicircle to make a sieve.
When the sieve is fitted in the machine, one side is closed while the other side is open. This
will be illustrated the full assembly 3D drawing and it acts as the first upper output.
Lower Casing
The Lower casing is made from the mild steel sheet metal 1.2mm in thickness which was cut
in size of 490mm x 900mm. From the 490mm, the sheet metal was bend 40mm at an angle of
90° to create a collar for the casing. The sheet metal was further bend 200mm from the
previous bend at an angle of 30° to create an angle of repose. The angle of repose for beans is
25°hence 30° was chosen in this case. Another 200mm allowance was given and at this
200mm allowance the sheet metal was further bend at an angle of 60° to allow the remaining
50mm to become vertical. An identical member was also fabricated for the opposite side. The
side covers were also fabricated in such a way that they follow the side profiles for the two
(2) front and back covers. The four members were then riveted to make one component called
the lower casing. The figure below shows one side of the lower casing front and back cover.

Figure 3.7 (a) Figure 3.7 (b)

Figure 3.8 (a) and (b) show the lower part of the mechanism during the fabrication process

27
Lower Sieve
The Lower sieve was fabricated using mild steel sheet metal 1.2mm in thickness. It has a
radius 150mm. With this radius 150mm radius, the circumference 942.5mm was calculated.
The sheet metal was cut with a size of 942.5 in width and a length of 900mm. The width side
was later rolled to make a semicircular shape as illustrated in the figure below. Holes of 7mm
diameter were punched through in order to make it a sieve.
A 2mm thick x 25mm in width was bend to come up with a rectangular shape of size 300mm
x 900mm and later riveted on the edge to give support to the sieve and holes in the sides were
drilled on both centers for both shorter sides on the rectangle for allowing the sieve to be
fitted loosely on the frame. One side was covered while the other side was left open. The
open side had a hole 10mm drilled on the side about 10mm from the edge so that the link
mechanism could be fitted loosely.
The sieve is inclined at an angle where the closed side is on the upper part and open side is
lower and makes the second lower outlet.

3.4 Assembly Drawings.

This part looks at the complete assembly drawings and the principle operation of the beans
Sheller machine. The figures below show the complete 3D assembly for the beans Sheller
machine.

28
 Upper Casing

Upper Casing

Freewheel
Sprocket Plummer
block bearing

Husks
outlet
Chain
link
Link
mechanism

Lower
Sieve Lower
Beans outlet casing
Crank Frame
sprocket
Figure 3.9 shows the complete assembly in 3-D

Figure 3.10 shows the wireframe drawings of the machine

29
 Figure 3.11 images of the machine after fabrication

Principle of operation
The apparatus developed is aimed at achieving both the breaking of pods containing beans
and also separating the husks from the beans. The machine has a typical drum and beater
configuration that breaks the beans from the pods and dispenses the beans with residual husks
onto a sieve with 12mm hole perforated on it.
The machine is designed to be operated by two (2) persons. Thus; one on the power input
mechanism and the other one on the feed hopper. All the components for the fabricated beans
shelling machine rest, or are attached to the frame. Making the frame the main skeletal
component of the machine, however the operation of this manually operated beans shelling
machine starts from the crank sprocket mechanism which is particularly the main torque
generator component. It has a hand held handle, which drives all mechanisms of the machine
when cranked or rotated. The crank can rotate in both directions however, it can only do work
in the clockwise direction. This is achieved by the chain link that links the crank sprocket and
freewheel sprocket that only does work in the clockwise direction.

30
 Figure 3.12 images of the fabricated machine in readiness for trial testing

When the crank sprocket is being hand propelled in the clockwise direction, the torque is
generated and power is transferred to the free wheel by means of the chain link. During this
power transfer, the speed increases since the driver sprocket’s diameter (crank sprocket) is
larger than the driven sprocket (Freewheel sprocket). These two sprockets have the ration 3:1.
The Freewheel sprocket is mounted on the main shaft that sits on two Plummer block
bearings. As the free wheel rotates, it also rotates the main shaft with it which also rotates the
shelling drum that rotates at an average speed of 156 rpm. The shelling drum has beaters
mounted around it and arranged in 6 spirals. From the literature review, beans pods can be
crushed open at an average speed of 300rpm.
Once the speed has reached the average speed, the machine is ready to begin the process of
shelling beans from the pods. Raw beans with pods is fed through the feed hopper that is
inclined at a repose angle 75°. This repose angle enables raw beans to fall easily in the
shelling chamber were the beaters crack the pods open. The beaters perform two functions as
they continue to spin, by virtual of them being flat and arranged in spiral, they first crush the
pods open and the husks are then pushed out of the shelling chamber through the husks outlet
which is the open side of the lower casing. This is achieved by virtual of beaters forming a
paddle screw conveyer.
The beans is heavier than the husks therefore, during the shelling process, beans fall on the
upper sieve and penetrate through the 12mm diameter holes into the lower casing which is
inclined at a repose angle 30°. This repose angle enables the beans to fall free with gravity
into the lower sieve.
The opposite end of the main shaft (opposite to the free wheel side) has a small crankshaft
fitted and locked with a key and keyway. A rod is attached to it to create a link mechanism.

31
As the crankshaft rotates, the rod moves in a reciprocating motion and the other lower end of
the rod is linked to one side of the lower sieve’s semicircular side which is closed.
Semicircular sides are linked to the frame in their centers on both sides. Since the
reciprocating rod is off centered, this makes the sieve to oscillate and it’s this oscillation that
enables the smaller pieces of husks to penetrate through the 6mm holes of the lower sieve as
beans from the upper sieve falls on the lower sieve. This lower sieve is further inclined at 15°
less than the repose angle to enable the clean beans roll to the open side (beans outlet) as the
sieve oscillates. The shelled beans can be collected a small bucket or and similar media that is
not higher than the beans output.
3.5 Equations
In order to assess the effectiveness and safety of the machine the following equations were
used for theoretical modelling.
1 Velocity Ratio
Do determine the velocity ratio created by the crank and sprocket mechanism the
following is used
Velocity Ratio (VR) = Number of teeth on the driver Crank/ Number of teeth on the
driven Crank

2 Efficiency of the machine

To determine the efficiency of the machine two very important factors are considered
these are: the total mass of beans at the output and the total mass of beans at the input
Therefore: Efficiency = (total beans at output / total beans at the input) x 100%

3 The combined Force (in Newton) exerted by the shaft and the drum
Force= mg (N) Where : m= mass of the shaft and drum (kg)
g= gravitational force acting on the mass (ms-2)

4 Maximum bending Moment to which the shaft is subjected

Mb = Wl/4 where : W= weight acting on the shaft (N)
l = length of the shaft that is supporting the load (mm)
5 Torque developed under cyclic loading is given by
T= Iα Where : I= Inertia given by
I= mr2

32
 m = mass of the body in motion
r = radius of the shaft supporting the body in motion
Also: α = Acceleration of rotating body
α = (ω1-ω0)/ t
ω1 = rotational speed of the body in rads/sec
t = time taken in sec

6 Power developed by the rotational action is given by

Prot = T ω Where: T= Torque
ω = Rotational speed
7 Combined stress is given by
q = √ (δ/2)2 + τ2
8 The equivalent torque is given by
Te = √ Mb2 + T2
9 In order to determine the shaft diameter
Te/ J = τ/ r where : Te = Torque (Nmm)
τ = Shear stress
r = Shaft radius
J = Polar 2nd moment of area
J = πD4/32
10 Dwell time

td = the time taken between the feeding of the beans at the hopper and the time
the beans is ejected at the output
11 Separation efficiency

η = the amount of clean beans collected without husks in them and vice versa
12 Safety factor

3.6 Data analysis

Data analysis was carried out in two phases which involved interpretation of findings of the
research first and then the use of scientific and engineering principle to deduce accurate
dimensions that would lead the successful fabrication of a beans shelling machine for the
targeted group of small-scale farmers.

33
1. Velocity Ratio
VR= number of teeth on the drive Crank/number of teeth on the driven Crank

By inspection: number of teeth on drive crank = 48 teeth

number of teeth on driven crank = 16 teeth

VR= 48/16
VR= 3/1
VR= 3

2. The combined force as exerted by the shaft and the drum

We know that
F = mg but m = mass of the shaft + mass of the drum
From inspection and weighing the masses
m = 32.78 kg + 3.65 kg
m = 36.43 kg
Therefore F= mg
F = 36.43 kg x 9.81ms-2
F = 357.3783
F =357.38 N

3. Maximum bending moment ( resolving the force acting on the shaft into a point load
and from (Kurhmi, 2000) for an overhang beam )
Mb = Wl/ 4
We know that W=Force = 357.38N
L = 1100mm

Mb = Wl/ 4
Mb = (357.38 x 1100)/ 4
Mb = 393118/ 4
Mb = 98279.5 Nmm

34
4. The rotational speed as taken from experimental observation
At an average speed the machine was effectively depoding the beans and the drive
crank make 156 revs/ min

Therefore ω = 156 revs/ min

Using the velocity ratio VR to determine the speed at which the shaft and drum is
rotating
ω1 = VR x ω
ω1 = 3 x 156 revs/ min
ω1 = 468 revs/ min

converting ω1 from revs/min to rads/sec

ω1 = 2 πN/ 60
ω1 = (2 x 3.1415925654 x 468) / 60
ω1 = 2940.53 / 60
ω1 = 49.00 rads/sec
5. The toque under cyclic loading is given by
T = Iα
But it is required that for such operations as the shelling of beans and other agriculture
produce the shaft diameter ranges between 18mm – 30mm (Igbinoba J, Unuigbe A,
Akhere F, Ibhahe G, & V, 2019) and (Kurhmi R, 2000). To determine the Torque
produced we assume a Diameter of 30mm to help us determine the torque.
We know that
I = mr2
I = 357.38 kg x 152
I = 357.38 x 225
I = 80410.5 kg mm2
Also

α = (ω1 – ω0) / t
α = (49 rads/sec – 0)/ 60 sec
α = 49 rads/sec / 60 sec
α = 0.817 rads/ sec2

35
 replacing the values of I and α into the equation
T=Iα
T = 80410.5 kgmm2 x 0.817 rads/sec2
T = 65668.575 Nmm
6. Shaft Diameter
The shaft is to be machined from a metal bar of 070M20 (EN3) steel, this steel is used
because the shaft will be subjected to light duty operations and the EN3 steel is
suitable for this purpose
The following Data will be used for the design
From the table
Tensile strength of 070M20(EN3) = 460 N/mm2
Shear strength of 070M20(EN3) = 270N/mm2
Maximum bending moment Mb = 98279.5 Nmm
Torque under cyclic loading T = 65668.575 Nmm
Safety factor S.F = 2
The shaft is to have shoulders on which the bearings will rest , as such it is required
that the fatigue failure due to shoulder will be reduced by the incorporation of fillets
on the shaft shoulders and as such the allowable stress will be computed as follows
Allowable stress = Fatigue limit / Safety factor x stress concentration factor

For steel it is generally assumed that the fatigue limit is at least 40% of the static
strength quoted
Hence for steels
Bending Fatigue limit = 0.4 x tensile strength
Torsional fatigue limit = 0.4 x shear strength

i. The combined stress q = √ (δ/2)2 + τ2

Tensile strength of steel used (EN3) = 460 N/mm2

Bending Fatigue limit = 0.4 x tensile strength
= 0.4 x 460
= 184 N/mm2

36
 From petersons table of approximate stress concentration factors Kt (bending) =1.5

Allowable bending stress σ = Fatigue limit / Safety factor x Kt

σ = 184 / 2 x1.5
σ = 61.33 N/mm2

Shear strength of steel used (EN3) = 270 N/mm2

Torsional fatigue limit = 0.4 x tensile strength
= 0.4 x 270
= 108 N/mm2
From petersons table of approximate stress concentration factors Kt (torsion) =2

Allowable torsional stress τ = Fatigue limit / Safety factor x Kt

τ = 108 / 2 x 2
τ = 27 N/mm2
Therefore q = √ (δ/2)2 + τ2
q = √ (61.33/2)2 + 272
q = √ (30.67)2 + (27)2
q = √940.34 + 729
q = √1669.34
q = 40.86 N/mm2
ii. The equivalent torque Te = √ Mb2 + T2
Te = √ Mb2 + T2
Te = √ 98297.502 + 65668.582

Te = √ 9658860120 + 4312362399

Te = √ 1.397122 x1010

Te = 118199.93 Nmm
iii. The diameter of the shaft to be designed is given by; Te/ J = τ/ r

We know that; but r = d/2

and J = πD4/32

37
 re-arranging the equation above

d = 3√ (32 x Te x 0.5) / π x q

d = 3√ (32 x 118199.93 x 0.5) / π x 40.86

d = 3√ 1891198.88 / 128.36

d = 3√14733.80

d = 24.5

say d = 25 mm
The calculated value of diameter will be used to select a suitable bearing from the catalogue
available and it follows that the design of the shaft in which the bearing is going to fit will
use the system of fits and limits to achieve a transition fit. In order to reduce the stress
concentration at the shoulders the desired fillets will be made as follows

D = 1.1 x d
D =1.1 x 25
D = 27.5 mm
Fillet radius = 0.001 x 27.5
= 0.275 mm
= say 0.5 mm
7. Using limits and Fits to determine the tolerances on the shaft when machining
The fit to be used is a transition fit, from the unilateral system of fits

Hole – H7
Shaft – n6

By inspection using values from the table of limits and fits

i. Shaft diameter = 18mm – 30mm
ii. Upper limit = +28
iii. Lower limit = +15

38
 Tolerances
Upper limit = 28 x 0.001mm
= 0.028 mm
Therefore; Ul = 25mm + 0.028mm
= 25.028mm

Lower limit = 15 x 0.001mm

= 0.015mm
Therefore; Ll = 25mm + 0.015
= 25.015mm
The tolerance of the shaft therefore is to lie between 25.015mm -25.028mm
8. The power generated in driving the shaft and breaking the beans can be found by

Prot = T ω
Prot = 118199.93Nmm x 49.00 rads/sec
Prot = 118.20 Nm x 49.00 rads/sec
Prot = 5791.8 joules

9. Dwell time
This is the time that the raw beans spends in the shelling chamber before the shelled
beans and husks transition to the collection point (outlets)
In order to determine the Dwell time td
The time taken from the first batch to start exiting the shelling chamber
Was observed
td = time taken for first batch to start leaving the shelling
chamber
td = 16 sec
10. Overall Machine Efficiency
This is the ratio of the mass of the beans and by products at the output to the mass of
the beans at the input

11. Shelling Efficiency ηs

39
 To measure the shelling efficiency, a sample of beans was collected at the outlet. The
beans seeds were separated from the residual husks and unshelled beans that found
their way into the collecting chamber. The beans was weighed separately as well as
the by-products separately.

12. Separation efficiency

ηse = the amount of clean beans collected without husks in them and vice versa
Similarly the separation efficiency is determined by collecting separating and
weighing the amount of husks and beans at output 2

40
CHAPTER 4: RESULTS
4.1 Overview
This chapter is divided into two major sections. The first section discusses the descriptive
results comprising the data collected from participants that justified the need for the
development of a beans shelling machine.

In the second section of the chapter empirical results as obtained from the trial runs of the
machine at varying speeds are analysed. The data was collected by running the machine in a
controlled environment and using such instruments as stop watch and a beam balance for
measuring the mass of the end products. Data was collected, grouped, analysed and tabulated
for easier interpretation for later discussion. In the discussions, comparisons are drawn
between the results obtained and factors affecting differences are outlined.

4.2 Descriptive results

Small scale farmers involved in the farming of beans were involved during the research, these
participants were drawn from a range of farming areas on the Copperbelt Province. A total of
50 participants were targeted for the purpose of data collection, however data was only
successfully collected from 36 participants.

Of the 36 participants that took part in the research, most expressed displeasure with the
tedious processes involved in the shelling of beans. When asked if they would like to use an
improved alternative method of depodding the beans? Only 30 of the participants responded
affirmative the remaining 4 were not so sure and the other 2 were just okay with the status
quo citing the financial costs of such a machine as a reason for their resistance to new
technology.

In the second part of data collection/analysis agricultural equipment suppliers were

interviewed. The agricultural suppliers reported that beans shelling machines were not on
high demand as compared to the maize shelling machine which was more on demand and that
they struggled to make sales of the beans shellers.

When participants were asked if they would buy such a machine if it were made available to
them, 25 of the participants were willing to buy a beans shelling machine costing less than
K5000.00, six (6) of the respondents agreed to buying a machine less than K4,000.00 the
other four (4) were willing to buy a machine as long as it was below K10,000.00.

41
When asked on the expectations, participants stressed on the efficiency of the machine if it
were to be made available. Most of the respondents were concerned on how the separation of
beans from husks would be would be achieved.

The survey provided clear direction on the market expectations of the farmers; these findings
played a role in the formulating of a conceptual framework as the data created an empirical
foundation for the research.

4.3 Empirical results

4.3.1 Determination of the rate of beans shelling
After the assembling was completed, the machine was properly lubricated at the shelling hub
end and bearing for smooth running. It was then observed for any noise or vibration, which is
normal to all sprocket and chain drive machine. The weight of the beans shelling machine is
75kg (as obtained after measurement).

A specific quantity of beans pods was fed into the fabricated design one after the other, the
tabulated observations were made. Shelling was carried out for approximately equal size of
beans and ten sets of test data were recorded. The speed of the rotating member was varied at
intervals of 100 rpm, 150 rpm and 200 rpm. At different shaft speeds, the following results
were collected and are tabulated in the table below

Table 4.1 Table of times taken to shell 5kg of beans at varying speeds

LOW SPEED MODERATE SPEED HIGH SPEED

(100rpm) (150rpm) (200rpm)
Interval of Amount of Interval of Amount of Interval of Amount of
feed (sec) raw beans feed (sec) raw beans feed (sec) raw beans
(kg) (kg) (kg)
15 0.5 15 0.5 15 0.5
45 1.0 30 1.0 30 1.0
90 1.5 90 1.5 50 1.5
135 2.0 120 2.0 70 2.0
180 2.5 150 2.5 90 2.5
225 3.0 180 3.0 110 3.0
270 3.5 210 3.5 130 3.5
315 4.0 240 4.0 150 4.0

42
 360 4.5 270 4.5 170 4.5
405 5.0 300 5.0 190 5.0
Total time taken = 405 sec Total time taken = 300sec Total time taken = 190 sec
After running the machine for a mass of 5.0 kg each the produce at both the beans output
(lower sieve) and the husks output (upper beans sieve) was collected and the masses of the
mixture weighed for purposes of analysing the efficiency of the machine, the table below
gives the masses of the collected output

Table 4.2 data collected of beans processing at different operating speeds

1000rpm 150 rpm 200 rpm

At beans At husks At beans At husks At beans At husks
output output output output output output

Weight of beans; Ws 1.9 kg 0.3 kg 2.6 kg 0.5 kg 2.1 kg 0.4 kg

Weight of husks; Wh 0.7 kg 1.2 kg 0.3 kg 1.1 kg 0.7 kg 1.0 kg
Weight of pods; Wp 0.4 kg 0.5 kg 0.3 kg 0.2 kg 0.3kg 0.5 kg

Combined weight; Wc 3.0 kg 2.0 kg 3.2 kg 1.8 kg 3.1 kg 1.9 kg

Weight at feed; Wf 5.0 kg 5.0 kg 5.0 kg

Operating time (min) 6.7 min 5.0 min 3.17 min

The following parameters were calculated using the standard formulae as given below, basic
ratios are used to compare the output and inputs so as to determine the operational
efficiencies of such agricultural machinery, as adapted from (Hoque, Hossain, & Hossain,
2018) , (Igbinoba J, Unuigbe A, Akhere F, Ibhahe G, & V, 2019) and (Kabir A & Fedele O,
2018)

i. Shelling capacity, Sc =60Ws/T

Where,
Sc = Shelling capacity, kg/h
Ws = Combined weight of shelled grain at beans and husks output in kg
T = Operating time, minutes
Therefore at:

43
100 rpm: Shelling capacity (beans fed in) Sc = 60Ws/T

= (60 x 5.0)/ 6.75

= 44.44 kg/hr

Shelling capacity (beans produced)

Sc = 60Ws/T

Sc = 60( 1.9 +0.3)/6.75

Sc = 19.56 kg/hr

150 rpm: Shelling capacity (beans fed in), Sc = 60Ws/T

= (60x5.0)/ 5

= 60 kg/hr

Shelling capacity (beans produced)

Sc = 60Ws/T

Sc = 60(2.6 + 0.5) / 5

Sc = 37.2 kg/ hr

200 rpm: Shelling capacity (beans fed in), Sc = 60Ws/T

= (60x5.0)/ 3.17

= 94.64 kg/hr

Shelling capacity (beans produced)

Sc = 60Ws/T

Sc = 60(2.1 + 0.4)/3.17

Sc = 47 kg/hr

ii. Breakage percentage, Br = (Ws + Wh /Wf) x100

Where; Br = Breakage percentage
For 100 rpm

Br = (Ws + Wh /Wf) x100

44
 Br = [(1.9 +0.3) + (0.7+ 1.2)]/5

Br = 0.82 x 100

Br = 82%

For 150 rpm

Br = (Ws + Wh /Wf) x100

Br = [(2.6 +0.5) + (1.1 + 0.2)]/ 5.0

Br = 0.9 x 100

Br = 90%

For 200 rpm

Br = (Ws + Wh /Wf) x100

Br = [(2.1 +0.7) + (0.4 + 1)]/ 5

Br = 0.84 x100

Br = 84%

iii. Unshelled grain, Un = (Wp/Wf) x 100

Where; Un = Unshelled grain, %
For 100 rpm

Un = (Wp/Wf) x 100

Un = (0.4 +0.5)/ 5 x 100

Un = 0.18 x 100

Un = 18%

For 150 rpm

Un = (Wp/Wf) x 100

Un = (0.3 +0.2) x 100

Un = 0.1 x 100

Un = 10%

45
 For rpm 200

Un = (Wp/Wf) x 100

Un = (0.3 +0.5) x 100

Un = 0.16 x 100

Un = 16%

4.3.2 Determination of technical efficiency

iv. Shelling efficiency, Ws = Br - Un

For rpm 100
ηs = Br - Un
ηs = 82 – 18
ηs = 64 %

For rpm 150

ηs = Br - Un
ηs = 90 – 10
ηs = 80 %
For rpm 200
ηs = Br - Un
ηs = 84 – 16
ηs = 68 %

v. Separation efficiency, ηsep = Ws / (Ws + Wh)

This is the ratio of the beans recovered at the beans output against the mass of
husks collected at the husks output form the mass of the beans collected.

Where; Wh = Weight husks in kg

For 100 rpm

ηsep = Ws / (Ws + Wh)

ηsep = 1.9 / (1.9 + 1.2 )

ηsep = 0.6129 x 100

46
 ηsep = 61.3 %

For 150 rpm

ηsep = Ws / (Ws + Wh )

ηsep = 2.6 / (2.6 + 1.1)

ηsep = 0.7027 x 100

ηsep = 70.3 %

For 200 rpm

ηsep = Ws / (Ws + Wh)

ηsep = 2.1 / (2.1 +1 )

ηsep = 0.6774 x 100

ηsep = 67.7 %

The results as collected and analysed after running the machine in trial can be tabulated as
follows for ease of interpretation

Table 4.3 summary of data analysis at different speeds

100 150 200

rpm rpm rpm
Shelling capacity (beans pods); Sc 44.44 kg/hr 60 kg/hr 94.64 kg/hr
Shelling capacity (shelled beans); Sc 19.65 kg/hr 37.6 kg/hr 47.0 kg/hr
Breakage percentage; Br 82 % 90 % 84 %
Percentage of unshelled beans; Un 18 % 10 % 16 %
Shelling efficiency; ηs 64 % 80 % 68 %
Separation efficiency; ηsep 61.3 % 70.3 % 67.7 %

The results in Table 4.3 show the results of the effects of running the machine at three
different speeds. In the first instance the machine is rotated at an average speed of 100 rpm
and from the results it was deduced that the shelling efficiency was found to be 64% while
the separation efficiency was at 61.3 %.

47
When the speed of rotation is increased to an average of 150 rpm the results yielded a
shelling efficiency of 80 % and a separation efficiency of 70.3%, the results were obtained
with an estimated rate of processing 60 kg/hr of unshelled beans which produces a return of
37.6 kg/hr of shelled beans.

In the third stage of testing the results yielded were a shelling capacity (beans pods) of 94.64
kg/hr to produce 47 kg/hr of shelled beans. However the machine produced a rather higher
capacity of unshelled beans of 16 % resulting to a low shelling efficiency of 68%. The
separation efficiency also went low to 67.7 %.

48
CHAPTER 5: DISCUSSION

The project had set out to investigate the challenges faced in the processing of beans by small
scale farmers, with an inherent aim of devising easier, safer and cheaper ways of processing
the beans.
Through a systematic approach reasonable cause was for the design and development of
manually operated beans shelling machine was determined. The intended machine was to
meet a processing rate of at least100kg/hr of beans among other technical efficiencies.
By the use of scientific and engineering principles a manually operated beans shelling
machine was successfully designed and fabricated by the researchers. This machine was
designed as much that it would meet the cost expectations of the target group. Locally
sourced materials were mainly used for its manufacture.
Upon the completion of fabrication of the machine, the researchers subjected the machine to
testing under a controlled environment in order to determine its effectiveness and efficiencies
in operation.
Preliminary results were overwhelming as the machine was able to successfully break the
beans off its pods and drive the husks out of the shelling chamber. However, this being an
initial design all parameters did not perform at 100% efficiency as shown in the data analysis,
the discussion that follows interprets the implications of the results from the data analysis and
brings out suggestions of how the machine can be improved.
5.1 Summary
The rate at which unshelled beans is fed into the hopper and quantity of shelled beans at the
outlet entirely depends on the shelling speed at which the machine is operated. In this case a
moderate speed of 150 rpm is suitable as it increases the shelling efficiency, separation
efficiency and the grain recovery efficiency. A speed below or above 150 rpm decreases the
operational efficiencies of the machine. At 150 rpm the machine is able to process60 kg of
beans pods at an interval of one hour , while producing shelled beans grain of at a rate of 37.6
kg/hr.
The efficiency and effectiveness of the manually operated beans shelling machine was partly
achieved by the decreasing the cylinder-concave clearance. Operating clearance is another
operational factor that affects the performance of shelling or decorticating machines.
Operating clearance can be described as the gap or spacing between two different
mechanisms which bring about a process. The shelling efficiency of beans is also seen to

49
increase with a decrease in the cylinder concave clearance while the percentage whole seed
recovered generally increased then decreased with the cylinder-concave clearance.

5.2 Conclusions
It can be well concluded that the research project achieved its intended purposes as stated in
the hypothesis. The researchers successfully used the primary data collected to design and
develop a technical product to be used in the shelling of beans. During the designing many
different factors such as compatibility of materials used, machine portability, complexity of
the mechanisms, efficiency and the cost of manufacturing the machine were analysed form
which the optimum design was selected. Different part of the design were arrived at by the
use of calculations to determine the suitable dimensioning, other parts were designed based
on the shape and function the researchers wished to attain so as to have optimal use of
resources and optimal performance of the machine. Other components such as bearings,
sprocket and chain were selected as per table of standards available to the researchers, as such
these parts’ working efficiencies were determined using engineering specifications.
The design, fabrication and evaluation of the beans shelling machine by use of scientific and
engineering relationships, tables and standards of machine components design were presented
and its performance was evaluated in terms of efficiency, separation and total loss due to
unshelled pods.
The results of the practical tests and qualitative observations showed that the device has
enough strength against the maximum torque produced by the crop. The results of the
scientific tests from the variance showed that the effect of rotating speed and distance
between beaters on the efficiency , separation and total grain recovery were significant at 150
rpm.

To further analyse the efficiencies of the developed machine the following key features of the
machine are discussed below.
Shelling capacity
The shelling capacity at the feed for 150 rpm was found to be 60kg/hr, for a rotational speed
of 100 rpm the capacity was at 44.46 kg/hr and at 200 rpm the capacity was found to be at
94.65 kg/hr.
Shelling capacity

50
The shelling capacity of shelled beans which represents the actual return of beans collected at
the output after processing was found to be at 37.8 kg/hr for 150rpm. This return of beans
compared favorably to the other returns of 19 kg/hr at 100 rpm and 47 kg/hr for 200 rpm.
Breakage percentage Br
The rate of breakage of beans from the pods was 90% at 150 rpm, 82 at 100 rpm and 84 at
200 rpm. These percentages represent the rate at which the beans was successfully broken
loose from the pods. It can be seen that at low speed the rate is low as the speed is increased
so does the breaking rate. However extreme speeds show a low return in the breakage
percentage.
Shelling Efficiency
From the data analysis, the shelling efficiency of the machine was found to increase as the
speed of shelling increases (i.e. from 64% to 80.08%). However, at an even higher speed the
efficiency starts falling down (i.e. from 80% to 66%). In order to maintain a good shelling
efficiency, the machine should be operated at an average speed of 150 rpm.
Separation Efficiency
The separation efficiency represents the amount of beans collected at the beans outlet, this
was found to increase at increasing speed from 100 rpm through to 200 rpm. The separation
efficiency heavily depends on the ability of the paddle screw conveyer to drive out the lighter
husks from the shelling chamber. At higher speeds the conveyer is able to achieve this.
Grain Recovery Efficiency
Grain Recovery Efficiency depends on the performance of the shelling drum and hopper.
Grain Recovery Efficiency reduces as the moisture content of beans increases.
From the results obtained it can be clearly seen that the machine operates well at moderate
speed. It is therefore the recommendation of the researchers that the machine should be
operated at an average speed of 150 rpm.
5.3 Limitations
Limitations to the research project encompassed a variety of factors ranging from technical
challenges to data collection challenges. The main challenges that had a direct effect on the
research project are listed below

 Sources of data – it was hard to find locally published research on beans shelling
machine or agricultural machinery as such the research had to rely on published
sources of data from other countries like the United states of America and India.

51
  It was observed that even though the research project had not set out to investigate the
effect of moisture content in the beans to be shelled the moisture content factor had a
huge impact on the operational efficiency of the machine. At a higher moisture
content percentage, the breakage efficiency reduced and the number of unshelled pods
increased and at lower moisture content percentages the shelling efficiency of beans
was higher and unshelled pods decreased.
 The dwell time which is the time the beans spent in the shelling chamber had a high
impact on the shelling efficiency of the beans. It was observed that the longer the
beans stayed in the shelling chamber the more it repeatedly got impacts and the higher
the shelling efficiency of the machine. A lower dwell time though led to quick
transition of the beans and pods to the outlet leading to a higher percentage of
unshelled beans and poor separation efficiency.
 Increasing the feed rate was observed to increase the shelling capacity while
providing cushioning effect that may reduce grain damage however it has a
decreasing effect on the separation efficiency.
 Operating clearance is another operation factor that affects the performance of
shelling or decorticating machines. Operating clearance can be described as the gap or
spacing between two different mechanisms which bring about a process. Other
researchers have established that the shelling efficiency of agricultural increase with
decrease in the cylinder-concave clearance while the percentage whole seed recovered
generally increased then decreased with the cylinder-concave clearance.

5.4 Recommendations for Future Research

The time frame in which the research project was carried out would not allow for further
innovations by the researchers to the work, however for purposes of future research and
innovations to make the machine more worthwhile the following are recommendations by the
researchers:
 Future work on the machine should work to increase the dwell time from 16 seconds
to a longer dwell time as can be seen from (George.F.Taylor & Taylor, 2010) and as
experimentation had shown. Empirical evidence from (George.F.Taylor & Taylor,
2010) shows that an increase in the dwell time td, increased the rate of collision on the
beans pods. This consequently ensures that the beans is fully broken and broken lose
before it transitions into the lower chamber.

52
  The feed rate can be adjusted by fitting the adjusting component on the hopper in
order to enhance the efficiency of the machine.
 In order to improve the separation of husks from the beans, a fan propelled by a motor
rotating just at an appropriate speed enough to blow away the husks can be fitted in
the machine.
 Even though the incorporation of an electric motor would almost double the cost of
the machine, the motor can be incorporated so as to automate the machine and reduce
on human resource required to operate the machine. This can also help to achieve a
constant speed. With this fact, the machine can be operated by one person.
 For improved safety, a guard bar or cage may be inserted over the Chain and
sprockets.
The beans Sheller machine is affordable by most scale farmers. Investing in this machine can
save the famer in terms of monitory, time and labor costs involved. This machine can be
operated by two people only instead of the traditional methods used that require a lot of
human labor, time and money. Money invested to buy this machine can be recovered in a
shortest possible time and the machine is durable as it can go a long way before requiring any
form of maintenance. On the aspect of maintenance, the machine can easily be de-assembled
and assembled without requiring much technical knowledge. All parts can easily be
fabricated and replaced as the materials can easily be sourced from any ordinary hardware.

53
CHAPTER 6: REFERENCES & APPENDICES

References
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University.
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Performance Evaluation of a Motorized Maize Shelling Machine. Journal of Biology,
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Ashwin Kumar, B., & Begum, S. H. (2014). Design, development and performance
evaluation of a hand operated maize sheller. International Journal of Agricultural
Engineering, 194–197.
Brown, R. H., & Ltd, M. &. (1935). Westminister, United Kingdom Patent No. 9857[ Class
58 ].
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Edidition .ed.,. Oxford : Princeton University Press .
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Hoque, M. A., Hossain, M. Z., & Hossain, M. A. (2018). Design And Development Of a
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Kabir A, A., & Fedele O, K. (2018, January 17). A Review of Shelling, Threshing,De-
Hulling and Decorticating Machines. Open Access Journal of Agricultural Research.
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A
Labour, M. o., & Security, S. (2013). Zambia Labour Force Survey Report. Lusaka: Central
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(http://www.krishisanskriti.org/Publication.html).
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SHELLING MACHINES - A REVIEW. International Journal of Agricultural
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 APPENDICES A

Questionnaire:

THE COPPERBELT UNIVERSITY

IN ASSOCIATION WITH

TECHNICAL AND VOCATIONAL TEACHERS COLLEGE

Declaration

Dear sir/madam

Dear respondents we are a group of students from the Technical and Vocational Teachers
College pursuing a Bachelor of Science degree in Design and technology Teacher Education.
As part of our curriculum, we are required to carry out a problem research project and
develop a technical product. All responses given by you will be strictly kept confidential and
used for academic purposes only.

1. How much beans do you harvest every season

…………………………………………………………………………………………
2. What methods do you use for depodding the beans
…………………………………………………………………………………………
…………………………………………………………………………………………
…………………………………………………………………………………………
…………………………………………………………………………….
3. What challenges do you face when depodding the beans?
…………………………………………………………………………………………
…………………………………………………………………………………………
…………………………………………………………………………………………
……………………………………………………………………………….
4. How long does it take you to depod the beans
…………………………………………………………………………………………
…………………………………………………………………………………………

C
 …………………………………………………………………………………………
……………………………………………………………………………….
5. Would you like to improve the current methods of depodding the beans and
how……………………………………………………………………………………
…………………………………………………………………………………………
…………………………………………………………………………………………
……………………………………………………………………….
6. Can an improvement on the depodding methods available add any significance to
your farming and how?
…………………………………………………………………………………………
…………………………………………………………………………………………
…………………………………………………………………………………………
……………………………………………………………………………
7. Have you ever used any beans depodding machine for you depodding?
..........................................................................................................................................
..................................................................................................................................
8. If you have used any machine what are the positives and negative experiences you
have had with the machine?
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9. What innovation would you like to see in the sector that will improve your farming
experience
?........................................................................................................................................
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10. Any thoughts of innovations that can improve the farming and processing of beans?
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D
INTERVIEW QUESTION ITEMS
To assess the marketability of a beans shelling machine
1. Would you buy a beans shelling machine if it was made available to you?
2. How much is your expected market price for a beans shelling machine?
3. Would you prefer a manually operated or electrically operated beans shelling
machine?
4. Would you prefer a stationary machine or a mobile machine?

E
 Glossary

Automation: the technique, method, or system of operating or controlling a process by

highly automatic means, as by electronic devices, reducing human intervention to a
minimum.

Bean pod: a seed case that splits along two seams to release its seeds when partial
pressure is applied.

Beans: an edible seed, typically kidney-shaped, growing in long pods on certain leguminous
plants.

Booming: Having a period of great prosperity or rapid economic growth.

Compressive force: a force that squeezes an object's surfaces together and causes its
mass to bulge.

Conceptual: something having to do with the mind, or with mental concepts or

philosophical or imaginary ideas.

Decortications: the act or process of removing the outer coverings (such as bark or husks)
from something (such as fiber or seed)

De-hulling: Product obtained by steaming and rolling dehulled seeds of peas.

Depodding: to remove the pod or shell from (peas, beans, etc)

Diversification: the process of a business enlarging or varying its range of products or field
of operation.

Enhance: to improve its value, quality, or attractiveness.

Feasible: Possible to do easily or conveniently.

Impact force: a high force or shock applied over a short period when two or more bodies
collide.

Rotational speed: of an object rotating around an axis is the number of turns of the object
divided by time, specified as revolutions per minute, cycles per second, and radians per
second.

Shear force: are unaligned forces pushing one part of a body in one specific direction and
another part of the body in the opposite direction.

F
Tedious: too long, slow, or dull, tiresome or monotonous.

Threshing: separating grain from (corn or other crops), typically with a flail or by the action
of a revolving mechanism.

Velocity ratio: the ratio of a distance through which any part of a machine moves to that
which the driving part moves during the same time.

G
 The Engineering Design Process

Chart 1
Grey cast Copper Brass Aluminium Aluminium alloys
Iron (60/40) LM14 LM6 Duralumin
(grade 14/17)
Tensile stregnth 200 150 220 100 280 180 400
(N/mm²)
Compressive stregnth 650 220 80 100 200 100 350
(N/mm²)
Shear strength 110 180 110 60 200 120 250
(N/mm²)
Density 7200 8900 8300 2700 2800 2600 2800
(Kg/m³)
Brinell No. 150 50 65 40 110 70 150
Thermal conductivity 13 92 24 35 30 30 30
(% silver)
Electrical conductivity 15 94 25 57 30 30 30
(% silver)
Melting point 1200 1080 900 660 540 560 540
(°C)
Coefficient of
expansion 11 17 20 24 24 24 24
(/°C)x10-6

Chart 2
Carbon steels
045 080 220
070 A72 M10 M40 070 M20 M07 Phosphor S.G.
EN 42 EN 32A EN 8 EN 3 EN 1A bronze Iron
Tensile stregnth 600 500 620 460 420 350 650
(N/mm²)
Compressive stregnth 600 500 620 460 420 650
(N/mm²)
Shear strength 360 300 370 270 250 200 120
(N/mm²)
Density 7800 7800 7800 7800 7800 8600 7700
(Kg/m³)
Brinell No. 200 140 200 120 110 150 200
Thermal conductivity 14 14 14 14 14 40 13
(% silver)
Electrical conductivity 10 10 10 10 10 25 15
(% silver)
Melting point 1400 1500 1450 1500 1500 900 1100
(°C)
Coefficient of
expansion 12 12 12 12 12 17 11
(/°C)x10-6

H
 ISO System of Limits and Fits (BS 4500 : 1969)

Hole and shaft relationships for selected fits. (Hole basis.)

(Tolerance scale applies to the diameter range, 18mm to 30mm)

I
Tolerance Limits for selected shafts

J
ISO system of Limits and Fits. (BS 4500 : 1969)

Tolerance limits for selected holes. (Hole basis)

K
L