This document describes the design and fabrication of a semi-automatic sugarcane bud chipping machine. It aims to reduce labor requirements and increase efficiency in the sugarcane planting process. The key components of the machine include an electric motor, gearbox, shaft, cutter, and supporting frame. It works by reducing the motor speed through pulleys and a worm gear setup, converting the rotational motion into reciprocating motion of the cutter to chip sugarcane buds. The design calculations show the machine can chip buds at a rate of 23 buds per minute. An analysis indicates it will save farmers costs and provide an additional source of income by allowing the use of just buds for planting versus full sugarcane pieces currently used.

1. DESIGN AND FABRICATION OF SEMI AUTOMATIC SUGARCANE
BUD CHIPPING MACHINE
HARCOURT BUTLER TECHNICAL UNIVERSITY,
KANPUR
PRESENTED BY:-
Shivanand
Shubham gangwar
Rohit jaiswal
Amit verma
UNDER THE GUIDANCE OF:-
Prof.(Dr.) Rajive Gupta
A PRESENTATION ON

2. OBJECTIVE
•To design and fabricate semi-automatic sugarcane bud
chipping machine.

3. NEED OF EQUIPMENT
•The need for sugarcane bud chipper is only for the farmers, where
they are using full size of sugarcanes in the field for plantation
purpose.
•With the use of sugarcane bud chipper we can reduce the wastage
of sugarcane by cutting it into small buds.

4. EXISTING DESIGN
Spring
Handle
Frame
Cutter
Fig 1. Existing design of sugarcane bud chipper

5. LIMITATION OF EXISTING DESIGN
1. Requirement of large human labour.
2. More time taking process.

6. REQUIRED COMPONENTS
• Power source (Motor)
• Gear box
1.Worm and worm wheel
• Shaft
• Cutter
• Belt drive
• Supporting frame
• Cam

7. Fig. Electric motor Fig. Gear box
Fig. Working model(top view) Fig. Working model(front view)

8. WORKING
• When the Single phase Ac induction motor is switched on, it
starts to run at 1400 rpm.
• Speed is reduced by the belt and pulley drive to 700 rpm.
• This speed is transmitted to the gear box which contains worm and
worm wheel drive which has gear ratio of 1:30.
• Now speed is reduced to 23 rpm. A cam is connected to gear box
which convert rotary motion into reciprocating motion of cutter.
• When cutter moves in forward direction it cuts the sugarcane bud
which is manually feeded.
• When cutter moves in backward direction it release sugarcane bud
and these buds are collected in collector.
• By this method, rotary motion of the motor is converted and
delivered as reciprocating motion at the cutter end and eventually
the removal of bud is also achieved.

9. DESIGN CALCULATIONS:-
Known data:
Force required to cut the bud of sugarcane F= 400N
Bud cutting frequency = 23/ min
Leather Belt specification:
ρ = 0.95 g/cm3
µ = 0.35
t = 5 mm
Permissible stress:
σ = 2.45 N/mm2
Centre distance of pulley = 25 cm
width of belt = 13 mm
thickness = 5 mm

10. Worm gear specification:
Speed ratio N2 /N1= 30:1
So N2=N1 ×30
So N2=23 ×30
So N2=690
Pully: D2=10 cm
V=πD2N2/1000*60
V=(π×10×100×690)/1000*60
V= 3.611m/s
Length of belt :
L=2C+ (π(D1+D2))/2+ (D2-D1)2/4C
L=2×250+ (π(64.28+100))/2+ (100-64.28)2/(4×250)
L=759.1955mm
α=180-2 sin-1(D2-D1)/2C
α=180-2 sin-1(100-64.28)/(2×250)
α=171.8060
α=171.806/180×π
α=2.997 rad

11. Volume of belt:
V=L×B×T
V=100×13/10×5/10
V=65 cm3/m
Mass of belt:
m=0.95×65 gm
m=0.95×65/1000 kg
m=0.06175kg
mv2=0.06175 × 3.6112
mv2=0.80522
e(µ×α )= e(0.35×2.997 )=2.854
(T1-mv2)/(T2-mv2 )= e(µ×α )=2.854
(T1-0.80522)/(T2-0.80522)= e(µ×α )=2.854

12. Max permissible stress in the belt:
σ= T1/A
T1= σ ×A
T1= 2.45 ×5×13
T1= 159.25N
So , T2= 55.798N
P=(T1-T2)×V
P=373.5 W
• Torque Calculation
Torque formula:
P = (2*3.14*N*T)/60
where, P stands for Power, N stands for Speed, T stands for Torque.
Torque in the motor before speed reduction,
P = (2*3.14*N3*T3)/60
373 = (2*3.14*1400* T1)/60
Hence, T3 = 2.54 (Nm)

13. We know that,
T3x N3 = T2x N2
Hence, T2 = (T3 x N3)/N2
thus, T2 = (2.54 x 30) T2 =5.08 (Nm)
Assuming the transmission efficiency is 82% hence, T2=5.08x 0.82
Hence, T2 = 4.16 (Nm)
For gear box :
T2x N2= T1x N1
4.16x 700= T1x 23
T1= 126.6 (Nm)
Design of shaft:-
Total vertical load acting on the pulley:
Wt = T1 + T2 +W
= 159.25 + 55.798 + 2
= 217.048 N
Bending moment acting on the shaft:
M = Wt × L
= 217.048 × 50
= 10852.4 N-mm

14. Twisting moment acting on the shaft:
T = 4160 N-mm
Equivalent twisting moment:
Te =
2
(𝑀2 + 𝑇2)
=
2
(10852.42 + 41602)
= 11622.40 N-mm
σyt = 250 N/mm2
fos = 4
τyt = 0.5 × σyt
= 125 N/mm2
τw =125/4
= 31.25 N/mm2
τw = 16 Te /π d3
d = (16 × 11622.40)/𝜋 × 31.25
= 12.37 mm
= 13 mm

15. As we are using 25mm dia. Shaft. So our design is safe.
Cutter Design:
τyt = 125 N/mm2
F= the average force for punching from the literature and the experiment is
400 N.
τyt = F/A
= 400/2 × (π D2 /4)
= 400/2 × (π 252 /4)
= 0.4076 N/mm2
Since, τ << τ y
Hence design is safe under shear.

16. Fabrication aspects of the prototype
1. Arc Welding
a. Manual arc welding
2. Machining
a. Turning
b. Grinding
c. Boring

17. Components Material used Specification Unit price(in
RS)
Total price(in
RS)
Motor .5 HP, 1400rpm 3200 3200
Gear box Gear ratio 1:30 2150 2150
Pulley (2) Cast iron D1=50mm
D2= 100mm
150 300
Flat belt Leather L=760 mm
b= 13mm
t=5mm
200 200
Shaft Mild steel Dia =25mm 100 100
Cutter High carbon
steel
Gap = 30mm 250 250
Supporting frame Mild steel L= 1000mm
B=400mm
H=450mm
600 600
Cam Mild steel Dia=10mm 200 200
Total 7000 /-
PROTOTYPE DEVELOPMENT COSTING

18. ADVANTAGES
• Human effort is reduced.
• Wastage of sugarcane is reduced.
• These bud chips are less bulky so transportation of chips is
easy.
• Less time is used as compared to conventional process.
• Easy to operate.
• Labor cost is reduced.
• High cutting speed and more number of buds can be cut.
• Reduces the plantation cost.
• Noiseless.
• Only about 240kg of seeds are required per acre against of 2-
4 tons of sugar cane in normal planting.
• The sugarcane after taking buds can be sent for milling or to
juice center.
• Injuries caused during normal operation is eliminated.

19. LIMITATION
•Automatic feeding of sugarcane is difficult.

20. Income For Farmers Through Our
Machine
In conventional method about 36000 whole sugarcane pieces are
required to be planted for cultivating sugarcane in one acre of
land. However in our method only 36000 sugarcane buds are
required for the same purpose and not whole piece of sugarcane.
Therefore the saved parts of sugarcane can be sold to vendors in
market which acts as an added source of income for the farmer. It
is estimated that the profit that can be earned through this way is
about Rs 11,433.

21. Continue…..
Conventional method:
36,000 pieces of sugarcane is required for cultivation (One acre).
1 Ton=6,750 pieces
Hence, 5.2 ton of Sugarcane pieces used (One acre).
Our method:
36,000 buds used for cultivation (One acre).
36,000 buds= 1.5 ton
Left out sugarcane pieces weight = 3.7 Tons
1 Ton sugarcane= Rs 3,090
Hence, 3.7x3090= Rs 11,433
This is the Profit that can be earned by the farmer.

22. Cost Comparison:
The following are the data associated with conventional and our
method of sugarcane cultivation.
Conventional method:
Amount to be invested to buy sugarcane = Rs 14,820 per acre
Amount collected as Revenue = Rs 1.42L per acre
Our method:
Based on our estimation, our machine will cost about Rs 7000.
Amount to be invested =Rs 14820(per acre) + Rs 7000(first year
only) = Rs 20820.
Amount collected as Revenue = Rs 1.53L per acre
Therefore based on the above data it can be seen that a profit of
Rs 4,433 can be earned by the farmer in the first year, and in the
successive years a profit of Rs 11,433 can be obtained per year.

23. CONCLUSION
By providing high profits at low investment and also by
simplifying bud removal process along with minimizing
labour requirement, our machine proves to be a highly
profitable investment for farmers and breakthrough in
farming technology.

24. REFERENCES
1. 1. R.S. Khurmi & J.K Gupta, “A textbook of machine
design”, 2003.
2. V B Bhandari, “Design Of Machine Elements”, 2013.
3. International Journal of Advance Engineering and Research
Development (IJAERD) Volume 5, Issue 03, March-2018, e-
ISSN: 2348 - 4470, print-ISSN: 2348-6406.
4. H.Bakker , “Sugarcane Cultivation and Management”, 1999.

25. THANK YOU