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With the increasing levels of technology, the efforts being put to produce any kind of
work has been continuously decreasing. The efforts required in achieving the desired
output can be effectively and economically be decreased by the implementation of better
designs. Conveyor systems are one of the most commonly used equipment in almost
every industry. They help in achieving different kinds of functions and by automating
them you can get the added advantages of flexibility and safe practices. Besides, they also
help in enhancing the performance and cost-effectiveness of your processes. This
conveyor system we can modify according to application and also can be develop as per
height and width of job/ application.
In this project, we have tried to develop a new mechanism for sugarcane lifter
for tractor trolley loading and unloading purpose. Here we have used the chain/ belt
conveyor concept to manufacture the proposed mechanism.
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“ Design & development of sugarcane lifter. ”
CHAPTER 1
INTRODUCTION
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“ Design & development of sugarcane lifter. ”
CHAPTER 1
Introduction
• India is one of the largest consumers and producers of sugar in the world and is the
world’s second largest producer next to Brazil of the sugarcane.
The excess of bagasse is stored in open area.so the lot of human health hazards is
taking place due to loading of bagasse . Now a days industries are using the crane to
lift the sugarcanes which is very slow working.
A conveyor system is a common piece of mechanical handling equipment that
moves materials from one location to another. Conveyors are especially useful in
applications involving the transportation of heavy or bulky materials.
The belt conveyors are used for transporting light and medium weight loads between
operations, departments, levels and buildings , providing considerable control over
the orientation and placement of the load.
Overview of that introduction we done our project to reduce the human efforts.
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“ Design & development of sugarcane lifter. ”
CHAPTER 2
LITERATURE
SURVEY
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“ Design & development of sugarcane lifter. ”
CHAPTER 2
Literature Survey
India is one of the largest consumers and producers of sugar in the world and is the
world’s second largest producer next to Brazil of the sugarcane. Sugar production is an
energy intensive industry and requires both steam as well as electricity. Bagasse is the
leftover of the sugarcane after crushing and is burnt as a fuel in the boiler of sugar mill.
Bagasse cogeneration has been practiced in sugar mills since long to meet sugar mills
own energy needs. However, supplying excess electricity to the grid has gained
momentum worldwide in last one decade. It offers several advantages such as near – zero
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“ Design & development of sugarcane lifter. ”
fuel cost, increased viability of sugar mills, energy security, fuel diversity, reduced
transmission and distribution losses and carbon emission reduction. In view of this, GOI
has launched a programmed to enhance surplus electricity generation from bagasse
cogeneration. Bagasse cogeneration is renewable energy and comes under Ministry for
New and Renewable Sources of Energy of Govt of India.
Remark:Cogeneration potential will increase in near future. Sugar sector in India is very
complex. GOI has taken several initiatives to enhance bagasse cogeneration, which
received positive response from sugar sector. However, this article has indentified the
barriers which need to be overcome to continue the growth story.
In all sugar industries the cane after processing is left with the waste product called
“Bagasse”. The Bagasse produced in the mills is used as a fuel to boilers and the
generation of steam. The steam thus produced is expanded in turbines and the power is
generated. The excess bagasse is then stored in an open area. Lot of human health hazards
is taking place due to loading of bagasse. Nowadays, the industries are using the crane
systems to load the bagasse into the tippers, which is a very slow task and causing more
dust. The bucket conveyors are used to move bulk materials in a vertical or inclined path.
Buckets are attached to a cable, chain, or belt. Buckets are automatically unloaded at the
end of the conveyor run. The belt conveyor is used for transporting light- and medium-
weight loads between operations, departments, levels, and buildings, providing
considerable control over the orientation and placement of the load. The belt is roller or
slider bed supported; the slider bed is used for small and irregularly shaped items.
Concluding Remarks:-
From literature survey it is seen that this mechanism is required as per market
demand and problem exist in the farming area. In this survey it is seen that very few
research is present and we have to do more research and development activity.
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“ Design & development of sugarcane lifter. ”
CHAPTER 3
PROBLEM
STATEMENT
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“ Design & development of sugarcane lifter. ”
CHAPTER3
Problem Statement
3. Problem Defination:-
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“ Design & development of sugarcane lifter. ”
To avoid or to eliminate these problems we have tried to develop a new mechanism for
sugarcane lifting for loading a tractor trolley.
4. Project scope::-
This project will help to labour a lot due to reduced their manual effort required to load
sugarcane in the trolley / in truck. This will give one standard system to agricultural field so
that human accident and stress will get reduce.
5. Objectives of project:-
a) Fabricate a new preposed conveyor system for human easy purpose.
b) Understanding the existing problems and finding out the proper and best
solution.
c) Understand project planning and execution.
d) Understand the fabrication techniques in a mechanical workshop.
e) Understand the usage of various mechanical machine tools and also measuring
tools.
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“ Design & development of sugarcane lifter. ”
CHAPTER 4
THEORY
CHAPTER 4.
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“ Design & development of sugarcane lifter. ”
Theory
Sugarcane, or sugar cane, are several species of tall perennial true grasses of the
genus Saccharum, tribe Andropogoneae, native to the warm temperate to tropical regions
of South Asia and Melanesia, and used for sugar production. It has stout, jointed, fibrous
stalks that are rich in the sugar sucrose, which accumulates in the stalk internodes. The plant
is two to six meters (six to twenty feet) tall. All sugar cane species interbreed and the major
commercial cultivars are complex hybrids[1]. Sugarcane belongs to the grass family Poaceae,
an economically important seed plant family that includes maize, wheat, rice, and sorghum,
and many forage crops.
Sucrose, extracted and purified in specialized mill factories, is used as raw material
in the food industry or is fermented to produce ethanol. Ethanol is produced on a large scale
by the Brazilian sugarcane industry. Sugarcane is the world's largest crop by production
quantity.[2] In 2012, The Food and Agriculture Organization estimates it was cultivated on
about 26×106 hectares (6.4×107 acres), in more than 90 countries, with a worldwide harvest
of 1.83×109 tonnes (1.80×109 long tons; 2.02×109 short tons). Brazil was the largest
producer of sugar cane in the world. The next five major producers, in decreasing amounts
of production, were India, China, Thailand, Pakistan, and Mexico.
The global demand for sugar is the primary driver of sugarcane agriculture. Cane
accounts for 80% of sugar produced; most of the rest is made from sugar beets. Sugarcane
predominantly grows in the tropical and subtropical regions (sugar beets grow in colder
temperate regions). Other than sugar, products derived from sugarcane
include falernum, molasses, rum, cachaça (a traditional spirit from Brazil), bagasse, and
ethanol. In some regions, people use sugarcane reeds to make pens, mats, screens, and
thatch. The young, unexpanded inflorescence of tebu telor is eaten raw, steamed, or toasted,
and prepared in various ways in certain island communities of Indonesia.[3]
The Persians, followed by the Greeks, encountered the famous "reeds that produce
honey without bees" in India between the 6th and 4th centuries BC. They adopted and then
spread sugarcane agriculture.[4] Merchants began to trade in sugar from India, which was
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“ Design & development of sugarcane lifter. ”
considered a luxury and an expensive spice. In the 18th century AD, sugarcane plantations
began in Caribbean, South American, Indian Ocean and Pacific island nations and the need
for laborers became a major driver of large human migrations, including slave
labor and indentured servants
Global sugar production exceeded 170 million tons (MT) a year in 2011-12.
Approximately 80% of the output was sourced from sugar cane, which is largely grown in
tropical countries. The remaining 20% is produced from sugar beet, which is grown mostly
in the temperate zones of the northern hemisphere. The 10 largest sugar producing nations
represent roughly 75% of world sugar production. Brazil alone accounts for almost 25% of
world production. Though the industry was characterized by production deficits in 2008-9
and 2009-10, surplus output was seen in 2010-11 and 2011-12 as sugar crop areas expanded
on the back of higher prices. World consumption of sugar has also grown at an average
annual rate of 2.7% over the past 50 years, driven mostly by rising incomes, population
growth and changes in diet in the developing economies
Facts about Global Sugar Industry
More than 123 countries produce sugar worldwide, with 70% of the world’s sugar
consumed in producer countries and only 30% traded on the international market.
About 80% of global production comes from sugar cane (which is grown in the
tropics) and 20% comes from sugar beet (grown in temperate climates, including
Europe).
Around 170 MT of sugar are produced every year. The largest producers are Brazil
(22%), India (15%) and the European Union (10%).
About 20 % of global sugarcane production was used for ethanol production in 2012.
The top five consumers of sugar use 51% of the world’s sugar. They include India,
the EU-27, China, Brazil and the US.
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“ Design & development of sugarcane lifter. ”
the global sugar production. The country consumes approximately 22 MT of sugar annually,
with Maharashtra contributing over 60% of it while the rest of the output come from states
like Tamil Nadu, Karnataka, Uttar Pradesh and Madhya Pradesh. The sufficient and well
distributed monsoon rains, rapid population growth and substantial increases in sugar
production capacity have made India the largest consumer and second largest producer of
sugar in the world. Highly fragmented with organized and unorganized players, the sector
supports over 50 million farmers and their families, making significant contribution towards
socio-economic development in the rural areas of the India.
Facts about Indian Sugar Industry
2nd largest producer of sugar in the world
5 million hectares & 60 million cane farmers and dependents
Industry valued at `800 billion
Large number of sugar mills – 527 operated in 2011-12
Estimated cane price payment for 2011-12 is `550 billion (Paid to farmers directly
without involvement of any middlemen)
Located in rural heartland, directly contributes to rural economic development and
employment.
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“ Design & development of sugarcane lifter. ”
Around 460 million tonnes of sugar is produced every year. The largest producers are Brazil
(72%), India (15%) and the European Union (10%). Altogether, there are more than 123
sugar-producing countries, but only 30% of the produce is traded on the international
market. In 2011 global sugar export trade was worth $47bn with $33.5bn of sugar exports
are from developing countries and $12.2bn from developed countries.
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“ Design & development of sugarcane lifter. ”
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“ Design & development of sugarcane lifter. ”
CHAPTER 5
DEVELOPMENT OF
SYSTEM
CHAPTER 5.
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“ Design & development of sugarcane lifter. ”
Development of system
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“ Design & development of sugarcane lifter. ”
CHAPTER 6
PROBLEM
STATEMENT
CHAPTER 6
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“ Design & development of sugarcane lifter. ”
Specification of proposed
1. Function : for grinding the jobs.
2. Specification :
i. Type : abrasive belt type
ii. Power:- 0.5 hp.
iii. Overall dimensions(Tentative): 3feet x 3feet x 4feet height. approx
v. Job capacity- up to 300 mm
vi. General Information :
The machine consists of a mechanism for adjustable belt tension also its orientation. We
will give facility of digital display to visualize speed easily so that we can adjust the
speed quickly.
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“ Design & development of sugarcane lifter. ”
the schematic drawing on the basis of problem statement and feedback and suggestion
received from end customer and vendors.
Phase V : Fabrication
(01) Manufacturing of various components and subassemblies will be carried out by using
suitable manufacturing processes.
(02) The components will be assembled per the drawing.
(03) Working trials of the project will be conducted to confirm and testing parameters
(Time and speed) we will decide for to get best quality of product.
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“ Design & development of sugarcane lifter. ”
P = 23.56 watt
By considering application and extra jerk and safe design prime mover power
considered = 360 watt
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“ Design & development of sugarcane lifter. ”
From below table we have determined which chain type is applicable for drive
From above table asper application and speed we have selected the service factor = 1.3
Design power required = 23.56 x 1.3
= 30.62 watt
By considering application and extra jerk and safe design prime mover power
considered = 360 watt
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“ Design & development of sugarcane lifter. ”
From chart 10B 5/8” chain drive is selected. Here in our project the speed reduction
is not involved due to conveyor type application. The 30 rp is considered.
The chain selected Simplex, 19 teeth, 15.87 mm pitch is selected.
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“ Design & development of sugarcane lifter. ”
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“ Design & development of sugarcane lifter. ”
From above table we have to select factor but there is no speed reduction so K = 1 assumed.
P = Load of sugarcane
T = Max Torque generated due to sprocket wheel. = 7500 N-mm
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“ Design & development of sugarcane lifter. ”
RA = Support reactions.
Motor speed N =30 rpm
For speed reduction the pulley and v belt is used.
As per Design data book shaft material is selected Carbon steel C40
σ = 145 N/mm2
We know that,
Max bending moment equation is given by
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“ Design & development of sugarcane lifter. ”
P = 150 N
The sprocket dia D = 150mm
F Y 0
RA + RB = P
As per load condition and farm condition the total load on wheel is considered
RA =150 …………………………………………………I
The distance we have considered as per component fitment
L = 100 mm
Calculation of bending moment at loading point P,
BM at M = 150 x 100 = 15000 N-mm
From equation A and B we have selected the diameter of shaft = 20mm considering
extra jerk and for safe design.
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“ Design & development of sugarcane lifter. ”
Te = 16770 N-mm
Me = 23385N-mm
By using above equation we have checked the allowable shear stress and allowable bending
stress and it is seen that the both values are within limit hence design is safe.
Selection of bearing :-
P = RB = 150 N
Life in hrs = 10000 hrs
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“ Design & development of sugarcane lifter. ”
L = 36 millions of rev
From SKF bearing catalogue we have selected the bearing static capacity for shaft dia
20mm = Co = 2.32 KN
From above equation = C = 201 N
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“ Design & development of sugarcane lifter. ”
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“ Design & development of sugarcane lifter. ”
CHAPTER 7
TESTING OF
MACHINE
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“ Design & development of sugarcane lifter. ”
CHAPTER 7.
Testing of Machine
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“ Design & development of sugarcane lifter. ”
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“ Design & development of sugarcane lifter. ”
Calculated as:
Payback Period = Cost of Project / Annual Cash Inflows
Advantages and disadvantages of payback method:
Advantages:
1. An investment project with a short payback period promises the quick inflow of
cash. It is therefore, a useful capital budgeting method for cash poor firms.
2. A project with short payback period can improve the liquidity position of the
business quickly. The payback period is important for the firms for which liquidity is
very important.
3. An investment with short payback period makes the funds available soon to invest in
another project.
4. A short payback period reduces the risk of loss caused by changing economic
conditions and other unavoidable reasons.
5. Payback period is very easy to compute.
Disadvantages:
1. The payback method does not take into account the time value of money.
2. It does not consider the useful life of the assets and inflow of cash after payback
period.
Initial cost :- 80000 /- with fabrication material and labor cost.
Maintenance cost :- 10 % of initial cost = 80000 x .10 %= 8000 /- Per year
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“ Design & development of sugarcane lifter. ”
Rs per year
Total cost = 6 x 15 = 90/- Working days considered
100
Per day charges = 80Rs
Total cost = 3 x 15 = 45 Rs
03 Storage cost Neglected Neglected
05 Electricity charges NA For one hour it will be
To load one trolley 150Rs
04 Labour charges To 1890/- To load one trolley 1175 To load one trolley
load one trolley
Payback Period
= 71500/ 80000
= 0.893 year
So from above analysis it is seen that the pay back period for developed mechanism is 10
months
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“ Design & development of sugarcane lifter. ”
CHAPTER 8
PROJECT COST OF
BILL MATERIAL
CHAPTER 8
Project cost and Bill of material
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“ Design & development of sugarcane lifter. ”
Unit in Rs.
Rs.
1 Steel material (angle, C channel, 70 kg 2000
plate, strips)
2 Chain sprocket and chain 02 2500
3 Bottom plate for foundation 2 250/- 2500
4 Supporting frame stand 02 2000 500
5 Motor 1 3500 1500
6 Pulley and belt drive with 3500
machining
Pillow block bearing 4 500 3000
6 Fabrication (labour charges) - 3000/- 2000
Total 18000
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“ Design & development of sugarcane lifter. ”
CHAPTER 9
CONCLUSION
CHAPTER 9
Conclusion
In this project we have conclude that the human can face to more problems in
industry, specially in sugar industry. They have many hazards to lift the sugarcane , it fill in
tractor trolley like that so we have tried to develop a new mechanism for humans in sugar
industry, to lift the sugarcanes in tractor trolley.
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“ Design & development of sugarcane lifter. ”
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“ Design & development of sugarcane lifter. ”
CHAPTER 10
REFERENCES
CHAPTER 10
References
1 Mr. R. S. Khurmi & J. K. Gupta Machine Design Pub.: Eurasia Publishing House
Pvt. Limited.
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“ Design & development of sugarcane lifter. ”
5 Fabrication of wet grinding machine and measure the metal removal rate using
different grades emery paper Author :- Bhaskar Chandra Kandpal, Rajesh Kumar
Verma.
PHOTOGRAPHS
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