DESIGN AND MANUFACTURE
OF MULTI-PURPOSE CORN
THRESHER AND COFFEE
PULPIER MACHINE
Advisor Mr. Fetene
CONTENTS
Introduction
Statement of problem
Objective
Methodology
Benefits and beneficiaries
Scope of the project
Literature review
Working principle
Design analysis
INTRODUCTION
Multi-purpose corn thresher and coffee pulpier machine is a
combination of two mechanisms.
It separates the kernels from the cob of the corn and also it
can be used to separate the pulp (outer layer of coffee) from
coffee beans.
This equipment uses one electric motor to perform both
operations.
Before this there were different types of threshers but this
threshers were not affordable for the farmers.
STATEMENT OF PROBLEM
Traditional threshing methods do not support large-scale
threshing of corn, especially for commercial purposes.
Locally in Ethiopia it was observed that most threshing of corn
was done by hand. Hand threshing take a lot of time and
energy
Most mechanical threshers causes great damage to the corn
seeds besides breaking the cob to pieces.
In coffee pulping process there are a lot of problems in
obtaining 100% pulped coffee.
Farmers who grow both corn and coffee has two buy two
machines which is costly.
CONT.
Unpulped
Cherries
Naked beans
Skins
Broken immature
Cherries
OBJECTIVES
Specific objectives
General objective
Asses and identify the different
The main objective of this project types of corn and coffee in
Ethiopia
is to design, simulate,
Asses and Identify the size of corn
manufacture and test an and coffee
appropriate multipurpose corn Simulating using on CATIA
threshing and coffee pulpier. workbench
Determine the geometry of the
machine based on the design
parameters
Manufacture the product
BENEFITS AND
BENEFICIARIES
Some of the benefits of the machine are
Combine the separate corn thresher and coffee pulpier
Reduce the cost of buying the machines
Reduce the time for threshing and pulping
Increase the production efficiency of the products
The beneficiaries
Farmers
Agriculture machinery producers
METHODOLOGY
Planning:
Data collection:
Concept development:
System-level design:
Detail design:
Testing and refinement:
Production ramp-up:
SCOPE OF THE PROJECT
The scope of the project includes the design and manufacture of a
multi-purpose corn thresher and coffee pulpier machine.
The design includes material selection, working principle, dimension
analysis, power and force requirement for threshing of the corn, part
design, component selection and modeling of each parts by using 3-
d cad design.
LITERATURE REVIEW
Corn thresher was invented by Mr. Lester E. Denison from Middlesex
After Denison a lot of different kinds of corn threshers were build
Corn threshing techniques
Threshing by hand, with simple tools.
Mechanical threshing, with simple machines operated manually.
Mechanical threshing with motorized equipment.
Methods of coffee processing in Ethiopia
Wet processing
Dry processing
WORKING
PRINCIPLE OF
THE CORN
THRESHER
corn will enter the
machine from the top,
when the disks rotates
counterclockwise the
corn will descended
while the kernels are
threshed and drop at
the bottom and the
striped cob released at
the side
WORKING
PRINCIPLE OF
THE COFFEE
PULPIER
Dry coffee is feed into
the machine pass
through small opening
and falls to the coffee
pulpier section. The
rotating blades hit the
falling cherries and
smash them to the
sides of the chamber.
WORKING
PRINCIPLE
The corn thresher and
the coffee pulping
sections use one same
electric motor.
The speed needed for
coffee pulping is very
high. Therefore the
speed from the motor is
directly transferred to
the pulping blades. But
for the corn the speed is
reduced by the pulley
DESIGN ANALYSIS
Designed components
Pulleys
Belt
Spring
Threshing disk
housing
Shaft
Bearing
DESIGN OF DRIVING PULLEY
Using centrifugal stress consideration we have found the diameter of the
pulley
D=70mm
Width of the pulley B=25mm
Cross sectional area of the belt: b*t
Mass of the belt per meter length: A*L*density
Centrifugal tension:
Maximum tension in the belt:
Tension in the tight side: T1 = T-Tc
Thickness of pulley rim single belt:3.35mm
CONT.
Then we designed shaft for the driving pulley
Using the torque transmitted and shear stress formulas
and
Then we have found the diameter of the shaft to be
d=11.9mm
This diameter is the minimum safe diameter
since it is safe to take the electric motor shaft diameter which
is 20mm.
DESIGN OF DRIVEN PULLEY
We know that =1440rpm is the speed from the motor, but this speed
harmful to the corn kernels. Therefore we take the velocity ratio of .
Therefore diameter of the driven pulley must be
Diameter of hub = 2d=30
Length of hub, L=2/3*B = 33.33mm
Tangential load per arm, t = T/ R* n/2=27.6 N
DESIGN OF BELT
step-1 material selection: cotton fabric (rubber)
2 driver pulley d1 = 70mm,
driven pulley d2 = 280mm,
Motor rpmN1 = 1440rpm
Using velocity ratio N1/N2 = d2/d1, N2 = 360rpm
3 Peripheral velocity of the belt on the driving pulley, V 1 = *d2*N1/60=9.04m/s
4 Total length of the belt, L = *(r 1 - r2) +2*(r1 - r2)2/x + 2*x - (r1 - r2)2/x = 1071.6mm
5 Angle of contact, = (180 - 2) */180rad = 3.05rad
6 maximum tension on the belt, T = A = 4982.9N
7 centrifugal tension, = 2 = 0.076N
8 tension in the tight side, T1 = T-Tc = 4982.9N - 0.076N = 4982.8N
9 tension in the slag side, 1516N
DESIGN OF SPRING
Selected material = carbon steel:
Allowable shear stress =336Mpa
And modulus of rigidity G=80KN/mm2
Data: maximum load (W) =200N (assumed)
Deflection=40mm
Spring index (c) =D/d=5
Whales stress factor 1
Using Maximum shear stress wire diameter=d=10.17mm
CONT.
Mean diameter of the spring coil = = c = 50.8 7
Outer diameter of the spring coil = = + = 61.0 4
Inner diameter of the spring coil = = = 40. 7
Number of turns of the spring coil
Then n= 16
For squared and ground ends, the total number of turns
= + 2=18
Free length of the spring
= + + 0.15 = 193.06
Pitch of the coil =11.35
DESIGN OF SHAFT
We
designed the shaft that will used in the coffee pulping
section that transmits the power from the motor to pulping
blades.
Selected material of shaft is steel (40 C 8)
Calculate torque
Calculate diameters from
Te= and
Me=1/2(m) compare the diameters and then take the larger
one.
SELECTION OF BEARING
first of all the basic dynamic load is calculated(c).
The life of bearing in revolution
= 60 = 36 106 rev
The basic dynamic equivalent radial load
= + =592.8
Depending on the value of C bearing no 200 is selected having
Co = 2.24 KN and C = 4KN
the outer diameter of 52mm and 14mm width.
DESIGN OF THRESHING
DISK
The threshing disk is used to remove
the kernels of the corn from the cob. It
has a number of teeth arranged in an
irregular pattern in order to get all the
surfaces of the corn
Selected material for the threshing disk
is cast iron.
The threshing disk is manufactured by
sand mold.
We have found a standard disk or our
project.
DESIGN OF
THE
HOUSING
The dimensions of the
housing is shown in the
Catia drawing at the
back of the document.
The selected material
for the housing is cast
iron because of its low
cost and high
availability.
THE END
