Ohio University Mechanical Engineering Senior Design Capstone
Contents
1. Cn mu 950 m VE Ea OEE EE 5 2 2125 v E 2 m LEE Lu 3 FL LEEN Figure G 11 Angle Iron Mounting Rail 1 Engineering Drawing e Dn a LII UU KN Figure G 12 Angle Iron Mounting Rail 2 Engineering Drawing e e BED 000 ET maa TERT u TT Solid Edge emer I Spe Get PLE ARE Reie Gen am LN 5777 ET EE TU Eh FIELA m 2000 2 Sheetmetal Thickness is 1 8 thick kar Solt Ede TELS AS E 1 Figure G 13 Seed Funnel Engineering Drawing Appendix H Design Evaluation The original customer specifications with the results of the prototype analysis are shown in Table H 1 below The main specifications which were not met were 1 having interchangeable screens for the screener 2 having the rotating parts guarded 3 OSHA compatibility and 4 having pedal power with backup Due to time and funding constraints the screener was not manufactured this led to the complete screener missing the customer specification For safety consideration machine guarding is preferred for any machine with rotating parts But because the design only uses pedal power it is not as important as if a motor was used OSHA specifications are listed in Appendix A more research would need to be done to fully understand if the system meets OSHA requirements Lastly pedal power 1s the sole method of p2. Table 2 Customer Needs Ability to run as stand alone machine Compatible with Team 2 s design Able to be put on trailer or built on trailer Size and weight road ready Stationary when operating Able to de hull various seeds Maintained from spare equipment Cleaner screens interchangeable OSHA compatible Appropriately sized Pedal power with backup Figure 3 Dehuller on Bed of Trailer DESIGN The final dehuller concept was chosen to be the roller on roller mechanism Each of these methods was chosen after careful consideration for how well the concept would function maintenance ease of use simplicity and manufacturability were also taken into consideration One of the rollers would be driven using a power source however it would be stationary and its mount would be bolted in that position on the frame The other roller would not be driven however it would be able to move on the frame to variable distances from the other roller to allow for different sized seed crops to be passed through The power source was determined to be a human pedaling a stationary bicycle Figure 4 which has a chain that connects the bicycle s gears to the shaft of a separate transmission that was geared to accept the belt that connects a gear already mounted on the driven roller The rest of the design was then built around those key concepts The two rollers used for the prototype were realized through a purchase solution that
3. se os 5s om 1 4 4 Ae Ae Ae Ae La Zeie A7 een AM AA 1E Figure 3 3 Now attach the belt from the roller gear to the other side of the motor Pinch point Keep hands clear af rollers Follow lockt procedure servicing WARNING Beware of pinch points between the gears and rollers Make sure all parts are not moving 4 Line up the subassembly of the hopper to the top of the frame Follow the procedure on figure 4 below to line up the holes in the angle iron on the hopper to the angle iron of the frame The frame will be labeled with letters A D as will the hopper Line up the similar letters onto the frame Use the bolts washers and screws provided to secure the hopper in place Figure 4 Figure 4 5 Install the Slide Gate Take the slide gate in hands with the black side closest to your body then insert the slide gate into the slit on the side of the frame Insure that the slide gate 1s facing up the lip of the angle iron should be facing upwards Be sure to slide it onto the angles supports underneath the hopper as shown below Figure 6 2 3 ASSEMBLY SAFETY TEST PROCEDURE a Make sure the chain cannot come off There should be between 1 4 1 2 6 12 mm total vertical movement of the chain Figure 7 In order to verify this distance use a ruler and orient the 0 line in the middle of the chain and push upwards with your finger as far as possible If
4. mem 2 JE E Table C 3 Average Amplitude of Accelerometer as a Function of Voltage Average Amplitude mm Sie EE EE EE VEN EN 5s ams am no L9 MR xm No nh 205 356 432 NO 055 164 129 NO ME SE ME N 1 1 135 46 521 NO 14 53 44 1046 YES 5 T s as No i 10 224 236 514 YES u 223 295 516 YES 14 428 66 979 YES Appendix D Final Design for Production During the construction and testing of the prototype certain design features were realized to be undesirable For this reason the following changes are proposed if a production model was to be created e Add More Guards e Add 10 to Leg Height Replaced Slide with Funnel e Replaced Bolts with Welds e Add Bracing on Corners e Remove Diagonal Bracing e Decrease Angle Iron Thickness Manufacture Rollers from Pipe Bearings and Shaft The reasons for making these changes include increasing safety usability function or decreasing materials or production costs A CAD model of the revised system for production is shown in Figure D 1 below This model features minimal material and maximum safety The main system components include a hopper assembly frame assembly roller and mounts assembly and lastly a funnel and guard assembly Figure D 1 Production Model The hopper assembly includes the hopper a slide gate and the mou
5. Figure B 1 Risk Priority Numbers for Potential Failure Modes Table B 3 Main Failure Modes Using Pareto Analysis Mode of Operation Failure Mode safety Motor shaft pinch points Agitator parts crack off Gears Pulleys Belts In Use eed All gears pulleys have pinch Belt comes loose from pulley slippage Safety Pinch point between rollers Table B 4 Action Items Problem Action Item Motor Supports Fail Huller Housing Supports Fail If the motor supports fail the motor could A static load analysis will be done to determine potentially fall while running With pulleys proper materials and geometries for both coming off the motor this could cause serious support structures harm to anyone near it at time of failure If the Problem Action Item huller housing fails the roller tolerances could 7 be unobtainable and unsafe for use Vibrations from the motor cause parts to Look into dampers for motor to sit on loosen parts to be out of tolerance or damage equipment over time If rocks or other unwanted debris falls 1nto Put a screen on the top of the huller hopper to rollers the flow rate will be decreased and will prevent large pieces of debris to fall 1n Create require the machine to shut down Also could a squeegee like cleaner for the huller cause potential failure of rollers and stress on bearings Belt comes loose from pulley slippage While in use belts and pulleys can slip causing Pro
6. 15 2 512 c 30 00 1 1 f 1 1 5 05 05 05 05 0175905 6 Time to Complete Operation hr 2 1 2 2 2 0 25 1 1 0 5 0 4 Basic Overhead Factor T e Equipment Factor 05 05 05 f Special Operation Factor 0 0 Total Labor Overhead Equipment Cost c 1 d e f 36 00 27 00 18 00 45 00 36 00 36 00 4 50 h Purcased Material Cost 2744 5492 429 Figure E 2 Production Hopper System with Parts Labeled for Purchasing Table E 3 Hopper Assembly Purchasing Costs From Design ToPurchase Purchase Length gra in Unit Material Size Area in Quantity Price Price 1 h a d mr Iron EFT 375 2 30 75 4 64 4 64 24 36 25 7 EN SECH sex ETES 10 x Sheet Metal 20 gauge 20 x 60 4 12 x 36 10 67 21 34 Table E 4 Hopper Assembly Production Costs Drill holes Cut Cut in angle slide Cut Layout angle iron cate holes cuts on Cut and iron to support handle and rivet Explanation of sheetmeta bend support and to handle to Operation sheetmetal slide gate weld hopper hopper lengt up Oemin as s us us os i os Operation hr 3 1 5 2 1 0 25 12 12 12 eth 5 Labor Rate per hour 12 12 12 0 5 1 1 5 S 1 1 1 1 5 05 05 05 05 05 f Special Operation Factor 0 o 0 o o o In Total Labor Overhead Equipment Cost c 1 d e f 27 0
7. assembly Figure D 4 shows the mounts attached to the roller shafts while Figure D 5 illustrates a top view of the rollers highlighting the spacing between the two rollers D 4 Roller Subassembly D 5 Roller spacing The last sub assembly of the system is the most important safety aspect and that s the funnel and guard system This system is what protects the user from the many dangerous moving parts and pinch points that are created by the moving rollers these specific danger points are included in the user s manual The funnel s main purpose is to funnel the seeds and chaff into the collection unit placed directly underneath the system The secondary purpose of the funnel is to eliminate the possibility of the user getting their hand caught in the rollers The shields located on all four sides of the rollers also eliminate this possibility by completely encasing the rollers Figure D 6 shown below highlights the funnel and protective guards Please refer to the user s manual for all safety precautions Safety Shield Safety Shield Funnel Figure D 6 Funnel and protective guards highlighted Combining the subassemblies results in a buckwheat and spelt huller that 1s safe and dependable The system works by depositing the raw seeds into the hopper and regulating the flow rate into the spinning rollers by using the slide gate The seeds then fall into the spinning rollers where they are forced through the space betw
8. in jig and Explanation of Operation sheetmetal sheetmetal weld H Time Complete Operation 3 1 0 25 5 c 1 2 e Special Operation Factor 0 0 Total Labor Overhead Equipment Cost c 1 d e f 36 00 54 00 18 00 4 50 112 50 h Purcased Material Cost 2668 J d Basic Overhead Factor Table E 9 System Assembly Overall Costs Subsystem Frame 36 65 202 50 239 15 Hopper Slide Gate 85 18 202 50 287 68 Rollers Mounting Structure 119 32 274 50 393 82 Funnel 26 68 112 50 139 18 267 83 792 00 1059 83 Appendix G Engineering Drawings RE eg 52 gt 2 LER MEE 1 EB FP Lll ET A horizontally knurled finish is applied to the outer surface roller GS r EET Sr E nuna 224 2 TH nano Lu FLL 1 e HEEN Figure G 1 Adjustable Roller Engineering Drawing ET Rma TERT INN AE HEP 2 Ju SEP 2 L IF ATE E ud d uu F 1 DO i The Timing Gear is A horizontally Knurled finish is applied to the outer surface roller GH 4 FEL N xw e F M MI y E ud al add Ak EE TEE EFFE MEE 2 Figure G 2 Stationary Roller Engineering Drawing SI 3 mem Lessel NE EO d EN N Bal UE Rl ENT uu a GU EDD ME UU a Sold Edge Figure G 3 Angle Bracing Enginee
9. the chain has moved upwards at least 4 but not exceeding 72 then your chain has sufficient tension for use Figure 7 b The belt should also contain sufficient tension so that the belt can remain on the gears Also double check to make sure that belt is between the guide pins on the frame to make sure the belt does not travel off the gear on the roller c Check the attachments of the bike supports and screws Tighten any screws that are loose NOTE The bike has a operator weight limit of 300 Ibs DO NOT EXCEED 300 LBS d Double check all the screws on the frame sub assembly and the hopper subassembly Tighten any loose screws WARNING IF A PART A PART OR SUBASSEMBLY IS BROKEN AND CANNOT BE FIXED DO NOT USE MACHINE AND CONTACT SUPPLIER FOR MAINTENANCE ISSUES Chapter 3 Operation Guide Operating Instructions Perform above safety instructions and inspection WARNING THIS HULLER IS MEANT TO BE USED WITH AT LEAST TWO OPERATORS BE SURE TO HAVE ANOTHER PERSON WITH YOU AT ALL TIMES 3 1 How the System Functions 1 The system uses human pedal power to apply power to the sprockets which turn the gears to rotate the rollers Have one operator get on the bike and begin to pedal the rollers at a constant comfortable speed 2 Before putting unhulled crop in the hopper make Bicycles DF heir parts can be sure that the slide gate is completely pushed into the broken or damaged by riding in a side of the
10. 0 54 00 27 00 27 00 36 00 9 00 18 00 4 50 h Purcased Material Cost 7472 5 464 dse n 0 18 00 3 1 0 Figure E 3 Production Roller System with Parts Labeled for Purchasing Table E 5 Roller Assembly Purchasing Costs From Design Unit Quantity Quantity o ap saal sa o ap sna sus 1 1 41 823 3292 1 1 1 1 2 x1 4508 4 Round 5 OD 2785 2 56 2 49 5 509 24625 2 49 1 5863 m Table E 6 Roller Assembly Production Costs into stock to bottom block and clean Total 1 3 12 12 12 c 18 18 d Basic Overhead Factor 1 1 1 1 1 05 0 5 f Special Operation Factor 0 0 0 0 0 0 Total Labor Overhead Equipment Cost c 1 d e f 36 00 27 00 36 00 54 00 54 00 27 00 36 00 4 50 Drill Cut Cut Cut 3 8 roller roller Press fit mounting j holes Weld pipes shafts bearings block in mounting Inspect a b 5 Time to Complete Operation 2 15 2 3 102 2 82 1 Explanation of Operation 5 g pipe length mount together up 5 0 5 0 5 1 274 50 119 32 393 82 Figure E 4 Production Funnel with Parts Labeled for Purchasing Table E 7 Seed Funnel Purchasing Costs From Design ix Unit Material Size In 1 Quantity Price Price 23 Table E 8 Seed Funnel Production Costs Place Inspect sheetmetal and
11. 8 Bearings designed insufficiently 8 1 17 6 Bearing insufficiently supported 8 12 Shaft sized incorrectly Roller surface manufactured unevenly EN Manufacturing tolerances cutouts plum square backlash Rollers not square with each other adjustment maa P 22 6 Roller surface cracks 60 2 l Texture on rollers vvear ng dovvn Debris stones stuck betvveen rollers Wear on the adjustment mechanism Rollers become eccentric uneven LEN 6 2 2 12 8 a s 4 o amp 1 8 8 3 36 3 2 6 Rollesconacteachother 13 4 4 E 6 6 LEE Risk Priority Failure Mode 7 aaa 777 o Motor insufficient Supports fal fail Motor vibrations break other things Inability to reduce speed to desired RPMs 2 Incorrect air fuelratio 17 Injectors clog from bad fuel 5 5 Run out of fuel Pistons seizing Pistons seizing 5 2 Safety Noise level too loud 6 6 15 Safety gears pulleys have pinch points 7 Belissnap pn Ip 4 44 Shear pin shaft connection point fal 5 5 J6 1150 Belt comes loose from pulley slippage 4 J7 8 22 Tiresdry rot 76 5 13 0 Brake lights fail 6 Ip ODA 0 Too heavy for 8 2 033 8 Unsfeforrad 960 3 133 8l 300 250 200 150 100 50 UI 10 15 20 25 30 35 40 45
12. HINE AND GET OFF THE BIKE WAIT UNTIL ALL MOVING PARTS STOP BEFORE ATTEMPTING ANY MAINTENANCE 3 2 Adjusting the Roller Gap Distance Before attempting to adjust the rollers make sure that all moving parts are stopped Only one operator is necessary for gap adjustment 1 Remove the hopper assembly from the frame 2 Unlock movable roller s mount by using a 9 16 inch socket to loosen its four bolts 3 Usea combination of feeler s gages 0 118 gap for buckwheat 0 080 for spelt to measure the distance between the two rollers 4 Measure the gap at each end of the roller and in the middle The gage should barely be able to move within that gap See Figure 9 5 Lock textured rollers into place by using a 9 16 inch socket to tightening each of the four bolts of the moveable roller mount to the frame One turn past finger tight should be sufficient 6 Replace the hopper onto the frame Figure 9 Chapter 4 Disassembly and Storage 4 1 Disassembly A Removing Chain from Bicycle Make sure all moving parts have stopped e Unscrew the front bike mount from the motor base e Push bike forward so that the chain releases tension Take the chain off of the gears and sprockets B Removing the Belt from the Motor and Roller Make sure chain is removed from assembly first e motor should not be attached to anything Therefore move the motor towards the frame to release tension Now that there 1s slack remove the belt fro
13. Ohio University Mechanical Engineering Senior Design Capstone Project Staple Food Seed Crop Dehuller The Plainsmen Jon Doucet Kevin Drummond Seth Gale Matt Mooney Mike Totterdale ABSTRACT The objective of the Senior Design Capstone Experience at Ohio University 1s to select an engineering project that will make a difference in the life of someone or a group of people in the community or region The customer chosen by The Plainsmen was the Appalachian Staple Foods Collaborative ASFC The mission of the ASFC is to grow and process staple food crops locally these crops include buckwheat spelt amaranth and beans Available farming equipment is expensive and mostly used for large acre plots and can process a single crop The ASFC currently farming plots ranging in size from one quarter acre to two acres have asked the eroup to design and manufacture a small scale system to remove the outer shell from the seeds of buckwheat and spelt The result is a pedal powered machine that utilizes two textured rollers to break and peel the outer shell from the seed The machine will ultimately be mounted on a trailer with threshing and cleaning equipment so that the overall system can be transported from site to site while being able process a range of crops BACKGROUND The Ohio University senior design experience is set up to combine a group of five senior level Mechanical Engineering students with a real world customer The objective is t
14. ards created by moving machinery parts as follows 1928 57 a 7 i Through the installation and use of a guard or shield or guarding by location 1928 57 a 7 il Whenever a guard or shield or guarding by location is infeasible by using a guardrail or fence 1928 57 a 8 Strength and design of guards 1928 57 a 8 i Where guards are used to provide the protection required by this section they shall be designed and located to protect against inadvertent contact with the hazard being guarded 1928 57 a 8 il Unless otherwise specified each guard and its supports shall be capable of withstanding the force that a 250 pound individual leaning on or falling against the guard would exert upon that guard 1928 57 a 8 ili Guards shall be free from burrs sharp edges and sharp corners and shall be securely fastened to the equipment or building 1928 57 a 9 Guarding by location A component is guarded by location during operation maintenance or servicing when because of its location no employee can inadvertently come in contact with the hazard during such operation maintenance or servicing Where the employer can show that any exposure to hazards results from employee conduct which constitutes an isolated and unforeseeable event the component shall also be considered guarded by location 1928 57 c Farmstead equipment 1928 57 c 1 Power take off guarding 1928 57 c 1 1 All power take off shafts including r
15. arts 1928 57 c 4 1 Guards shields and access doors shall be in place when the equipment is in operation Appendix B FMEA Table B 1 List of Potential Failure Modes System Hopper Hopper Hopper Hopper Huller Mode of Operation Transporting In Use R Failure Mode VValls bending Agitator fails to agitate Improper gear ratio to agitator insufficient torque rotate too fast Slide gate not effective Stands come loose from fasteners Hopper structure insufficient Agitator parts crack off Slide gate sticks open closed Ergonomically inefficient to lift seeds high Sharp edges Paint flaking Holes in sheet metal from rusting Agitator rusting Legs rusting Hoppers too top heavy Bearings designed insufficiently Bearing insufficiently supported Shaft sized incorrectly Roller surface manufactured unevenly Manufacturing tolerances cutouts plum square backlash Rollers not square with each other uneven adjustment Adjustment screw theads too coarse Shaft breaks Gear comes off shaft Shaft roller connection breaks Safety Pinch point between rollers Adjustable mechanism locks up Roller surface cracks Texture on rollers wearing down Debris stones stuck between rollers Wear on the adjustment mechanism Rollers become eccentric uneven Mode of System Operation Failure Mode Huller Transporting Rollers contact each other Motor pow
16. d work well After the manufacturing phase the dehuller was able to be powered and tested using both buckwheat and spelt the result was a success for buckwheat but the spelt seed was not properly removed from the hull The buckwheat hulls were being cracked and some of the seeds were actually able escape from their hulls with a very small number of seeds breaking altogether The spelt a completely different type of seed had moderate results The hull of the seeds were being massaged just enough that with very little effort the user 15 able to extract an unbroken seed from the many layers of the hull With some vibration from the cleaner or transfer system the seed should come out of the hull but the dehulling process could be more efficient using more shear force rather than compressive force A detailed evaluation of the prototype including specific results can be found in Appendix DISCUSSION The fully manufactured prototype will now be handed off along with user s manual and CAD drawings to a Graduate Student who will make some of the changes mentioned in the Development section as well as add his own modifications that he feels will benefit the concept as well He 1s also given the task of combining the dehuller with the thresher concept onto one trailer and being powered by a single power source This is so that the customer may be able to take one trailer to a farm with the system able to thresh dehull and clean various crops Because som
17. e concave wall Appendix I User s Manual 5 A US WA 3 0 Hee adiis jon Dot n Jmimmonda 0 LOucet f lel Matt ma Za less T WS wl 1 att Mooney ilk slotterdai Ki lt d Ze gem A N 1 SE 4 E ES Ewe IS Table of Contents Ch 1 26 5 25 Chapter 1 o Ch 1 2 ANSI Safety symbols Safety TENZI Checklist of Pants En 22 Assembly ofikl ller 2 3 Assembly 9316 5 Procedures Ch 3 1 How SystemaWonks Chapter 2 Assembly Chapter3 ZER PS TIVE gt ROLF Gel DRAMAS Operation Guide 9 GI d c Disassen AN Chapter 4 5 7 9 9194 2 3 Ch3 c 21 5 1 Maintenance CiS 2 Replacement Parts p 4 mets jo 0 fo didici en 112 Replacement aa Parts Chapter Safe Operation Procedures Warning This symbol represents a hazardous situation or area of the machine that if not avoided could result in death or serious injury This unit contains many moving parts and sharp edges All users must ALWAYS wear personal protective equipment including Eye protection e Hand protection In order to decrease the risk of death or serious injury please follow all precautions and warnings while working with or around this piece of equipment SAFETY HAZARD SYMBOLS USED IN THIS MANUEL 5 e Rollers contain pinch points bet
18. e crops only require threshing the threshing process will continue to be powered by a separate source than the dehuller Appendix A System Regulations A 1 Trailer Regulations Dimensions Total length 65 feet trailer length 40 feet width 102 inches height 13 6 feet Hitch When 1 vehicle is towing another vehicle the drawbar or other connection may not exceed 15 feet from 1 vehicle to the other e When the connection consists only of a chain rope or cable there shall be displayed upon such connection a white flag or cloth not less than 12 inches square e In addition to a drawbar or other connection each trailer and each semitrailer which is not connected to a commercial tractor by means of a 5th wheel shall be coupled with stay chains or cables to the vehicle by which it is being drawn Every trailer or semitrailer shall be equipped with a coupling device which shall be so designed and constructed that the trailer will follow substantially in the path of the vehicle drawing it without whipping or swerving from side to side Lighting Trailers must carry either as part of the tail lamps or separately 2 red reflectors Trailers must be equipped with at least 1 red tail lamp visible from 500 feet to the rear and a white light to illuminate the license plate and render it visible from at least 50 feet from the rear e Trailers must be equipped with at least 2 stoplights visible from 500 feet to the rear Speed Limits 55 mp
19. e in house using existing equipment which would have saved 375 Reducing the size of the roller mounts according to its position on the machine 1s another way to reduce the cost of the machine The mounts were originally made all the same size for manufacturing purposes but costs could be cut by making this change In order to make the machine easier to use the mounts could be slightly modified by developing a mechanism that would attach to the mounts of the movable rollers so that the distance between the two rollers could be set easily and uniformly on both sides It was idealized that a screw mechanism like that of a larger scale micrometer to vary the distance between the rollers however the concept could be built upon Figure 11 Optimized Design for Production EVALUATION Overall the outcome of the project was a success The machine does in fact crack most of the buckwheat seeds put through it and some of the seeds are actually extracted from their hulls The customer was able to have their desire of a human powered machine and it 1s also quite portable with a simplistic design so it can be taken apart and reassembled with ease With respect to the prototype a tensioning mechanism needs to be designed for the belt between the rollers and the transmission The gears on the bike as well as the transmission also need to be adjusted and made true so that the chain is not as likely to come off With that said the design of the machine shoul
20. ear mid or side mounted shafts shall be guarded either by a master shield as provided in paragraph b 1 11 of this section or other protective guarding 1928 57 c 1 ii Power take off driven equipment shall be guarded to protect against employee contact with positively driven rotating members of the power drive system Where power take off driven equipment is of a design requiring removal of the tractor master shield the equipment shall also include protection from that portion of the tractor power take off shaft which protrudes from the tractor 1928 57 c 1 it Signs shall be placed at prominent locations on power take off driven equipment specifying that power drive system safety shields must be kept in place 1928 57 c 2 Other power transmission components 1928 57 c 2 1 The mesh or nip points of all power driven gears belts chains sheaves pulleys sprockets and idlers shall be guarded 1928 57 c 2 ii All revolving shafts including projections such as bolts keys or set screws shall be guarded with the exception of 1928 57 2 smooth shafts and shaft ends without any projecting bolts keys or set screws revolving at less than 10 rpm on feed handling equipment used on the top surface of materials in bulk storage facilities and 1928 57 2 Smooth shaft ends protruding less than one half the outside diameter of shaft and its locking means 1928 57 c 3 Functional compone
21. een the two rollers resulting in the shell cracking and in some cases the shell and seed being separated Once the seeds fall through the rollers they are funneled into a collection unit via the funnel With the outer shells cracked the seed within 1s free to fall out and separate itself from the shell during the collection process The complete operating instructions as well as safety maintenance and service information can be found in the user s manual included in the appendix Appendix E Materials Costs This section outlines the materials costs and cost to manufacture the production model The individual subsystems are outlined separately to shown the cost breakdown throughout the system The overall system cost 1s shown in Table E 9 below Figure E 1 Production Frame with Parts Labeled for Purchasing Table E 1 Frame Assembly Purchasing 7 i Length Total Length Unit Material Size 7 Quantity Length in Quantity Price Price 1 Angle Iron 1 1 x 1 8 2 gl 1 8 12 8 12 Er xn i 429 3 Angemon 1 xt mxs 30 af mo e 21 9 66 s1932 5 FaStck wew 523 8 4528 Table E 2 Frame Assembly Production Costs Drill Cut legs holes and and top Cut angle Cut slots in Place Inspect angle iron brackets mounting mounting frame in and to length tolength brackets bracket various jigs Weld Explanation of Operation 8 for welding frame p 5 1 5 12 12 12
22. eep angle will increase the overall height of the system causing difficulty accessing the hopper located above rollers and a higher center of eravity while transporting To test this a flat piece of sheet metal was held at an angle Figure C 5 and the seeds were dropped from the minimum height that they would fall in the system 37 This experiment was conducted with two sets of conditions 1 seeds at rest no motor vibrations and 2 dropping seeds with motor vibrations varying applied voltage for different intensities A visual observation was then used to decide if the angle was sufficient to transport the seeds and hulls down the slide Figure C 5 Seed Slide Test Apparatus The results from each case can be found in Table C 2 and C 3 respectively For static loading the average angle that made all seeds move was approximately 20 degrees for both spelt and buckwheat With motor vibrations the angle decreases to 15 degrees for most cases but not for low applied voltages at 20 degrees all seeds fell for all applied voltages This shows if the motor did not provide considerable vibrations the seeds would not adequately slide at angles less than 20 degrees for this reason the slide angle was chosen to be 20 degrees Table C 2 Slide Angle Experiment Results Spit Buckwheat Angle a 2 20 3 18 3 o l 4 21 51 D 6 20 Lo 7 19 Ma 6 E
23. er insufficient Motor Motor In Use Supports fail Motor vibrations break other things Inability to reduce speed to desired RPMs Decreased efficiency through use Safety Motor shaft pinch points Insufficient lubrication Drive shaft fails Incorrect air fuel ratio Injectors clog from bad fuel Run out of fuel l Pistons seizing Maintenance l Motor Safety Noise level too loud Transporting Safety All gears pulleys have pinch points In Use Belts snap Gears Shear pin shaft connection point fail Pulleys Belt comes loose from pulley slippage Belts Storage Maintenance _ Transporting hee Brake lights fail Too heavy for trailer sigo Unsafe for road Misc Table B 2 Risk Rankings for Potential Failure Modes Risk Priority ELI Mode Severity Likelihood Dectectability Number Walls bending 2 10 020 Agitator fails to agite 4 1120 4138 2024 mueren s uu OU rotate too fast 5 Slide gate not effective 2 P OB 2 Stands come loose from fasteners 6 3 D 136 Hopper structure insufficient 6001300202 136 Agitator parts crack off 8 15 8 1320 Slide gate sticks open closed 3 4 04 8 Ergonomically inefficient to lift seeds high e e Paint flaking Il 2 18 Holes in sheet metal from rusting 3 J6 bBo 54 Agitator rusting 02 6 4 48 Legs rusting Ip 6 3 010
24. etal slide was also created to be put underneath the rollers to catch the separated seeds and hulls and funnel them into transportable container Figure 10 Seed DEVELOPMENT After initially assembling the prototype various components of the design were determined that they could be revised in order to make a better product The primary way to reduce time and cost is to weld the angle iron together as opposed to drilling holes and bolting it all together since thirty four holes were drilled in all It would save the cost of drill bits bolts and nuts as well A simple way to reduce the cost of the product would be to reduce the angle iron thickness from 1 4 and 3 16 to 3 16 and 1 8 This would also dramatically reduce the weight of the machine Another aspect is to eliminate the two longer diagonal frame supports on the side of the angle iron supports to give rigidity to the design and instead weld smaller bracing to the angle iron in order to create triangles making the frame a rigid body By accomplishing this change it would allow for the collection container after the dehulling process to be placed directly beneath the rollers rather than in front of the machine The rollers would have to be raised ten inches vertically but 11 this is done then a seed funnel can be utilized rather than a seed slide After the rollers were out sourced to a sub contractor it was determined that they could have been don
25. frame rendering it closed ensuring that no manner more stressful than the intended use of the bike If the bike is damaged you could lose control and fall Do not ride beyond the design limits of the bike If you are unsure of the limits of the bike consult your dealer crop will enter the rollers See Figure 8 Slide Gate is 1 7 1 Fully os ned i s y ope Slide Gate is N Fully closed Figure 8 3 Supply the hopper with the intended crop to be dehulled The hopper can be filled as much as desired though make sure the hopper does not overflow 4 Slowly open the slide gate in order to allow the seeds to enter the rollers by pulling on the slide gate handles the black angle iron Remember the rollers should already be spinning WARNING BE SURE TO WEAR SAFETY GLASSES WHEN SUPPLYING ROLLERS WITH SEEDS TO DECREASES RISK OF INJURY TO EYES BEFORE opening the slide gate MAKE SURE THAT THE OPERATOR DOES NOT PUT HANDS INSIDE HOPPER OR NEAR MOVING PARTS 5 When finished dehulling seeds close the slide gate Continue to spin rollers until all seeds have gone through DO NOT ABRUPTLY STOP PEDALING THE ROLLERS Instead slowly decrease pedaling speed until the rollers come to a slow steady stop Immediately stopping the pedaling will result in the chain coming off the motor or bike and busting the chain itself WARNING IF AT ANY POINT THE DEHULLER BREAKS DURING USE IMMEDIATELY STOP USING THE MAC
26. h is the maximum speed for any vehicle or vehicle combination that weighs over 8 000 Ibs A 2 Farm Equipment Regulations 1928 57 a 6 Operating instructions At the time of initial assignment and at least annually thereafter the employer shall instruct every employee in the safe operation and servicing of all covered equipment with which he is or will be involved including at least the following safe operating practices 1928 57 a 6 1 Keep all guards in place when the machine 1s in operation 1928 57 a 6 ii Permit no riders on farm field equipment other than persons required for instruction or assistance in machine operation 1928 57 a 6 iii Stop engine disconnect the power source and wait for all machine movement to stop before servicing adjusting cleaning or unclogging the equipment except where the machine must be running to be properly serviced or maintained in which case the employer shall instruct employees as to all steps and procedures which are necessary to safely service or maintain the equipment 1928 57 a 6 iv Make sure everyone is clear of machinery before starting the engine engaging power or operating the machine 1928 57 a 6 v Lock out electrical power before performing maintenance or service on farmstead equipment A 3 Machine Guarding 1928 57 a 7 Methods of guarding Except as otherwise provided in this subpart each employer shall protect employees from coming into contact with haz
27. his aspect of the design worked very well The project should continue but the prototype is not ready for production This is the first prototype of this project The minimal testing of the target crops buckwheat and spelt that has been completed has shown the huller is capable of removing the hull from samples of buckwheat Regarding spelt more of a shearing motion would benefit the removal of the layered hull This could possibly be achieved by designing the rotation of the two rollers at different speeds This will require more testing of the two different roller speeds working in parallel with varied roller spacing to determine the maximum efficiency that can be achieved There 1s the possibility to incorporate the team s previous concept designs with the prototype frame To do this the adjustable roller could be removed and replace with a concave wall or a flat Figure H 1 shows an example of the concave wall Flanges can be added to the ends of this wall to align with the adjustable slots Small ribs could be applied to the inner surface to create edges for gripping the hulls as they are force between the roller and the wall Table H 2 Design Specifications Specification Ideal Value Actual Value Specification Met Pending Speed of Process Bushels Hour 225 Unknown Testing gt 1000 1 000 Maximum Power Im 1032 os Ye o Pendi meh EN Testing Pendi Testing f Peopl Operate Figure H 1 Exampl
28. layers and 1s fibrous which resembles that of a grain which makes impact dehulling impossible The hull must be almost peeled off of the seed The fields being farmed range in size from quarter acre to two acre size plots This leads to a desired customer throughput of a quarter acre of crop seed per hour or twenty five bushels per hour The machine must be small and light enough to be constructed deconstructed easily enough so as to be taken from farm to farm across Athens County The customers would like the design to be capable of being pedal powered via a human They are in contact with Job S Ebenezer Ph D president of Technology for the Poor who has developed a device which can be attached to a standard bicycle allowing normal mechanical machines to be operated by human power 3 a 232 x Un hulled buckwheat Hulled buckwheat Figure 1 Buckwheat with and without its hull Spelt Figure 2 Spelt on and off of its stalk The importance of focusing on small plot farms 1s that in the United States food travels on average 1500 miles from seed to plate This means the crops grown are raised for resilience not for taste and nutrition 4 Food bought from local sustainable farms is often fresher better tasting and more nutritious compared to mass produced crops Buying locally grown crops also supports the local economy and is better for the environment overall RATIONALE The crops currently being grown include mille
29. m the motor For ease of re assembly the belt can remain on the roller for storage However if the belt needs to be replaced remove it from the roller e First unbolt the roller from the frame closest to the gear and belt Once unbolted lift the end of the roller and slowly take the belt off the roller Tighten the roller back onto the frame when finished 4 2 Storage A Bike and Bike Mounts e The bike and bike mounts should be stored indoors at room temperature NOTE The chain may rust if not lubricated before and after use Be sure to apply lubricant to avoid rust B Frame And Hopper Assembly e The frame and hopper assemblies should be stored indoors to avoid contact with weather conditions when not in use This will avoid any type of rust to accumulate on the huller Warning The frame and hopper assemblies are over 100 lbs and HEAVY OBJECT operators should use precaution when 57 muscle strain or lifting and moving the huller ack injury Use lifting aids amp proper lifting assemblies techniques when removing ar replacing C Motor and Belt e The motor and belt should also be stored indoors and away from weather conditions The sprocket on the motor should also be lubricated frequently to defer the spread of rust D Transportation e The frame bike and motor should all be securely attached to the trailer used for transportation This can be done by bolting down the feet of the frame to the
30. nded to be less than 400 pounds while the total footprint of the machine was not allowed to exceed a 5 x4 x4 cube This ensured that the machine is portable and capable of being placed on a trailer to be relocated to the plot site The number of people required to operate the system determines how much time and effort will be spent on the processing of the crops For this reason the target number of people required to operate the system was determined to be 1 2 people Once the crop 1s loaded into the hopper and the slide gate 1s set to the desired flow rate this machine can be operated by one person alone but should be supervised for safety reasons The maximum amount of power this machine was designed for was from one half to two horse power while this 1s a large amount of power and could potentially be dangerous the seeds require a large amount of force to crack the hull The last metric to be set was the overall cost of the system After researching existing equipment the total cost goal was set at less than 1000 This puts this machine in the range of affordable farm equipment and allows for users from all backgrounds to benefit from the versatility and portability of this system Table 1 Target Design Specifications Speed of Process Bushels Hour Weight of Machine Width of Machine Length of Machine salesPre uss 1990 T Maximum Power HP s lt 9 Efficiency ull breakage
31. ng between huller rollers 2 force required to break buckwheat and spelt seeds and 3 required angle for the seed slide coming off of rollers The purpose of the first experiment was to determine the gap size for each type of seed buckwheat and spelt where the hull is broken while the inner seed remains intact this is important because some of the customer s products require a whole seed rather than allowing broken seeds The design chosen uses two rotating rollers to crack the seeds between them A small scale replica of our system was built to test different gaps between the rollers scaled down from 5 to 172 shown in Figure C 1 The texture of the rollers also plays a large role in the ability to pull the crops into the spacing of the rollers Horizontal knurls were spaced so that crops could not get stuck between the spacing and would have enough grip to force the seeds through The rollers were spaced at 0 08 0 085 0 087 0 09 and 0 1 Adjustable Roller i Driven Roll Clamping Sarf 0 1 Plastic Spacers Shaft for attachment for power drill Figure C 1 Roller Spacing Experiment Apparatus The optimum spacing between the rollers for processing buckwheat was found to be 0 0935 4 0 0065 This experiment required qualitative and quantitative methods to interpret the results As seen in Figure C 2 the seeds were in different conditions The various conditions of the seeds after the
32. nting hardware to attach the hopper to the frame assembly The hopper serves the purpose of containing the raw crop and feeding it into the moving roller assembly The slide gate is used to regulate the flow rate of the raw crop from the hopper into the rollers The mounting hardware includes two sets of bolts nuts and washers to attach the hopper to the frame assembly via two welded pieces of angle iron as shown in Figure D 2 below Slide Gate Mounting 9 Safety Shield Hardware Figure D 2 Hopper Subassembly The frame assembly is comprised of 17 feet of 3 16 angle iron and 3 5 feet of 4 flat bar for bracing purposes The structure of the assembly has been minimized to ensure that the least amount of material is required while still ensuring the structural integrity of the design Figure D 3 illustrates the frame assembly used for the final production design Figure D 3 Frame Subassembly The most complex assembly 1s the roller and mounts assembly The mounts themselves consist of two separate pieces the base plate and block The mounts have been designed in two separate pieces and assembled last to allow for the tightest of tolerances to be achieved The rollers are manufactured with bearings between the shaft and the end caps so that the roller is free to spin independently of the shaft The shaft of the rollers are placed into the block of the mounts and attached via bolts to the frame
33. nts 1928 57 c 3 1 Functional components such as choppers rotary beaters mixing augers feed rolls conveying augers grain spreaders stirring augers sweep augers and feed augers which must be exposed for proper function shall be guarded to the fullest extent which will not substantially interfere with the normal functioning of the component 1928 57 3 Sweep arm material gathering mechanisms used on the top surface of materials within silo structures shall be guarded The lower or leading edge of the guard shall be located no more than 12 inches above the material surface and no less than 6 inches in front of the leading edge of the rotating member of the gathering mechanism The guard shall be parallel to and extend the fullest practical length of the material gathering mechanism 1928 57 c 3 iii Exposed auger flighting on portable grain augers shall be guarded with either grating type guards or solid baffle style covers as follows 1928 57 c 3 i1 A The largest dimensions or openings in grating type guards through which materials are required to flow shall be 4 3 4 inches The area of each opening shall be no larger than 10 square inches The opening shall be located no closer to the rotating flighting than 2 1 2 inches 1928 57 c 3 iii B Slotted openings in solid baffle style covers shall be no wider than 1 1 2 inches or closer than 3 1 2 inches to the exposed flighting 1928 57 c 4 Access to moving p
34. o select an engineering project that will make a difference in the life of someone or a group of people in the community or region Throughout this project the group will perform analytical techniques of design design construction and evaluation of the performance of an engineering system The project focuses on the voice of the customer through dialogue observations surveys etc Once the problem of the customer was clear the needs of the customer were transformed into specifications and then conceptual design generation and selection began background and benchmarking research were also utilized The group chose the Appalachian Staple Foods Collaborative ASFC as the customers for the project The ASFC was started two years ago by Michelle Ajamian and Brandon Jaeger they are the primary customer contacts for the duration of the project The ASFC mission is to build a regional bean grain and seed staple food system which is focused on growing and processing high nutrition crops while working toward zero dependency on chemical inputs in staple food agriculture and the development of appropriate scale farming and processing equipment 111 The ASFC is in its second year of operation and is currently using land plots donated by local farmers to test 1f various crops grow well in the Appalachian area The crops currently being farmed are millet meal corn amaranth spelt beans and buckwheat The ASFC is farming plots ranging in size from a q
35. only buckwheat was tested The buckwheat was cracked one seed per test and was repeated 60 times Figure C 3 Force Test Apparatus The results of the single seed force test can be found in Table C 1 The data illustrates the wide range of forces required to break a single seed because of the wide range of results 1 8 62 5 N a more definitive graph was made to help illustrate the important force results Figure C 4 shows the number of seeds that were broken in a 5 Newton range Table C 1 Force to Break Hulls Average 20 2 N N o o o N o 2 E 3 2 5 10 10 15 15 20 20 25 25 30 30 35 35 40 40 45 45 50 50 55 Newtons Figure C 4 Number of Seeds Broken in 5 Newton Force Range It can be seen that the bulk of the forces are between 15 and 30 Newtons For this reason it can be assumed the average of 20 2 Newtons is reliable Using this information along with the calculating the maximum number of seeds along the rollers is 200 using seed size and roller length the maximum force on the rollers 1s approximately 4000N 900 pounds Using these forces along with tension on the gear and a factor of safety of 2 the necessary shaft size 1s approximately 1 The third experiment was to determine the minimal angle needed to have all the seeds and hulls move down the slide At low angles the coefficient of friction will not allow the hulls and seeds from sliding down but an unnecessarily st
36. owering the system the main reason for this 1s the final layout of the systems on the trailer is not known so the power source might need to be changed or moved Table H 1 Customer Specifications Customer Specifications Did the Design Comments Meet the Ability to run as stand alone machine Compatible with Team 2 s design Able to be put on trailer or built on trailer Stationary when operating Able to de hull various seeds Maintained from spare equipment Cleaner screens interchangeable The cleaner was not manufactured Easy to change huller settings between crops safe Limbs guarded from rotating machinery 2 5 Not all moving parts have guards OSHA compatible Ld Not all moving parts have guards 5 270 Pedal povver vvith backup No backup As seen by Table H 2 the prototype meets the majority of the specifications set at the beginning stage of the project The weight and the dimensions are well within the set specifications More testing 1s required to fully assess the performance of the prototype Once the testing of the prototype is complete the speed of the process the noise level and the efficiency can be determined At this stage of the project the only specification not met by the prototype 1s the sales price A unique feature of the prototype 1s the texture of the rollers There are horizontal knurls along the length of the rollers This allows the seeds to be gripped and pulled down between the rollers T
37. perly design belts Have tensioners on all decreased efficiency and power to the desired 1 pulleys mechanism This could cause variability in the speed of the winnowing fan or speed of the rollers variability in these speeds would be detrimental to the machine If either of the roller shafts break the entire Properly design shaft accurately measure huller would be out of service Also 11 the forces on shaft manufacture correctly etc shaft broke there would be a safety issue with the heavy rollers rotating unevenly If the welds fail on the hopper agitator parts Design the agitator to try and decrease the could potentially come off If they then fit possibility of welds failing and pieces falling through the opening in the slide gate they off could fall into the rollers and cause serious damage and a safety hazard Safety Pinch Point Between Rollers All gears and pulleys Motor shaft Pinch points with all rotating equipment is a Whenever possible guards will be installed to serious hazard Clothing getting pulled prevent accidental contact with rotating through or fingers getting stuck could result in equipment serious injury Signs stickers will be put near rotating parts warning of the danger Appendix C Mock Up Testing for Design Validation Three experiments were conducted to verify the designs chosen all relating to the huller portion of the system The experiments were done to determine 1 optimal spaci
38. ring Drawing 5 000 All thickness is 16 gauge 500 900 sheet metal 12 000 Figure G 4 Guard 1 Engineering Drawing Figure G 5 Guard 2 Engineering Drawing 30195 Sheet Metal thickness is Gauge TT ggg H N a Sheet Metal Thickness is 6 Gauge Figure G 6 Guard 3 Engineering Drawing REVISION HISTORY DESCRIPTION DATE APPROVED DRAWN Kmurrnordi 0 solid Edge CHECKED nuru APPR o 77 SIE DWG NO REV UNLESS OTHERWISE SPECIFIED A DIMENSIONS ARE IN INCHES FILE NAME Hopper Housing Fing Rollers df 0 011 9 SCALE WEIGHT SHEET OF Figure G 7 Seed Hopper Engineering Drawing REVISION H STORY DESCRIPTION DATE APPROVED 4 000 NAME DATE CHECKED Solid Edge Hopper Mounting Angle Iron TITLE ENG APPR MGRAPPR SUE DWG NO REV UNLESS OTHERWISE SFECIFIED A FILE NAME Hopper Angle Iron Shortart SCALE WEIGHT SHEET OF I DIMENSIONS ARE IN INCHES 0 0I Figure G 8 Hopper Mounting Bracket Engineering Drawing cn GI RW 1 1 500 11 50 Figure G 9 Long Frame Angle Iron Engineering Drawing 4 590 All Tolerances are DOOS unless otherwise specified fel IET Solid Edge Figure G 10 Mounting Block Engineering Drawing AD 3 50 35 2000 d A FR
39. sted in Appendix A 3 These standards will limit our design in that we will have to ensure that our machine has the proper guards on all moving pieces Also all safety instructions and training must be provided to each individual that plans to operate the machine To consider this machine a success specific goals were specified for the performance and usability of the machine Table 1 displays the target design specifications for the project Table 2 shows the needs of the customers These specifications were chosen based on various levels of reasoning including the most important reason of the capability of the machine to efficiently and effectively dehull the crop To achieve this a goal of greater than 90 percent efficiency was determined With a machine operating at an efficiency of this level the customer would not be required to run the seeds through multiple times saving time and energy The speed at which the crop 1s capable of being processed is also another crucial metric of the system Greater than 25 bushels per hour was chosen as the target process speed this 1s roughly the equivalent of a quarter acre of crop With the intended application of this product being small plots of land the 25 bushels per hour target 1s significant enough to save time and energy by processing the crops at the plot location Also included in the target of processing the crops on location goals for the weight and size of the machine were set The weight was inte
40. t meal corn amaranth spelt beans and buckwheat With regards to appropriate sizing the plots of land range in size from quarter acre to two acres presently but could increase to ten acres within a few years Since the land plots are not side by side the desired machine must be portable able to be transported on roads but also stationary while operating Almost all of the machinery available on the market 15 stationary and not portable and includes both the dehulling and cleaning processes The dehulling machines available are in general made to process a specific crop Crop specific seed dehullers researched were for oats sunflower seeds buckwheat and peanuts Research was also done on other methods of breaking or crushing objects such as rocks The three most feasible alternatives for the dehulling operation involved using two rollers one roller on a concave wall or one roller on a vertically flat wall In order to identify the applicable standards the design and components of the machine were evaluated so that they met the standards and regulations of other farming applications The main components found to be standardized were 1 the necessities of a road safe trailer BMV 2 general safety for agricultural equipment OSHA and 3 machine guarding OSHA OSHA also provides standards for applications and methods of guarding or protecting the user from the rotating parts in machinery Those that apply to farmstead equipment are li
41. t any hardware store Belt The belt used was a timing belt purchased from McMaster Carr HTD Series PowerGrip GT Series Specifications Material Neoprene Number of teeth 160 Belt Width 20 mm Pitch 8 mm Trade Size 1280 8M REFERENCES 1 Appalachian Staple Foods Collaborative ASFC Appalachian Staple Foods Collaborative Web 2 Jun 2010 http localfoodsystems org appalachian staple foods collaborative asfc Combines and Headers John Deere Web 2 Jun 2010 lt http www deere com en_US ProductCatalog FR category FR_COMBINES html gt Project Reports Sustainable Agriculture Research and Education Web 5 Apr 2010 lt http www sare org reporting report_viewer asp pn FNCO07 663 amp ry 2008 amp rf 0 gt Appalachian Sustainable Agriculture Project ASAPconnections Web 2 Jun 2010 http www asapconnections org
42. trailer and the base of the bike can also be bolted down to the floor of the trailer Make sure all parts are unable to move on the trailer during the transportation WARNING KEEP ALL MOVING PARTS AND OPERATION OF MACHINERY OUT OF REACH FROM CHILDREN AND ALL TIMES INCLUDING STORAGE DUE TO SHARP CORNERS AND PINCH POINTS Chapter 5 Maintenance and Replacement Parts 5 1 Maintenance Below is a table of the frequency of maintenance for the different parts of Huller Following this table should deter any unwanted problems and maintenance issues with the device Table 1 Frequency of Maintenance FREQUENCY AREAS OF MAINTENANCE Lubrication of chain Wipe Down Slide Brush off Rollers Remove unwanted debris from Daily h opper Check all bolt connections Wipe down inside of hopper Check chain and belt for any BE Disassemble huller and clean all parts Check roller mount connections and bearings inside mony rollers 5 2 Replacement Parts e Bike Chain The bike chain is a standard bike chain that can be purchased at any store i e Wal Mart K Mart cyclist stores The bike chain currently used for the huller is shown below Akiki 6 Customer Reviews 9 97 Read reviews or write a review Bell Sports Multi Speed Bike Chain Product Details Questions amp Answers Add to My List Add to Registry Age Range Adult to Adult Bolts 3 8 bolts 1 1 5 long standard coarse threads Purchased a
43. uarter acre to two acres and are planning on expanding to plots of approximately ten acres in the coming years According to USDA research in 2007 61 6 of all farms in Ohio ranged from 1 to 99 acres 2 The designing and manufacturing of smaller scaled farming equipment has the possibility to be very beneficial not only for the ASFC but also throughout the Appalachian region of the country STATEMENT OF THE PROBLEM The ASFC is in need of a machine to refine the staple seed crops being farmed after being cut in the field The entire process includes 1 threshing 2 cleaning 3 de shelling dehulling and 4 cleaning The goal of this project was to crack the shell of the seed and 1f possible separate the shell from the unbroken seed in the process This process 1s known as dehulling as the outer shell is also known as a hull A variety of seeds from staple crops are grown by the ASFC but the focus of the project is buckwheat and spelt Buckwheat has been a major issue for the customer because the outer shell is hard to crack because it is thin Figure 1 yet tough Other impact dehullers have proven to be inefficient because once the machine was able to crack the hull the seed which 1s soft and crumbles easily the seed breaks up and 1s rendered useless The spelt when separated from its stalk 1s coupled into pairs Figure 2 which makes the dehulling process difficult The hull is different from that of buckwheat because it has
44. ween the rollers and cop ande zimmer d rollers the belts attached to the gears Keep all hands away Follow lackout procedure before servicing from parts when moving Object contains sharp edges Keep hands and fingers away e Machinery contains moving parts Keep all extremities away Use Eye protection when utilizing machinery HEAVY OBJECT Can cause muscle strain or Warning Object may be heavy and could back injury Use lifting aida amp proper lifting lechniques when removing or replacing cause injury to back or muscles Use caution when lifting Chapter 2 Assembly The subassemblies of the bike frame and hopper should come pre assembled Figure 1 below shows what the sub assemblies should look like Figure 1 2 1 Checklist of Parts Before proceeding any further please use the checklist below to determine whether all the necessary components are supplied CHECKLIST 2 2 ASSEMBLING THE HULLER Step by Step 1 Begin by screwing the front bike support to the wooden motor base 5 shown below Figure 2 Insert the screws as shown by the green arrows Figure 2 2 Attach chain from bike to the sprocket attached to the end of the motor The attachment should look similar to Figure 3 below Make sure the chain lines up perfectly and is not angled or offset Attached to the largest Attach to the largest sprocket ee ee VEE DR Oe AF HEL et tei ETE 2 1 L
45. were taken from a treadmill The rollers are especially unique because they not only had a true central shaft but bearings were also pressed into the inner diameter of the rollers This made a great deal of difference because it not only cut cost but also significantly reduced manufacturing time By utilizing the pressed bearings it eliminated the need for bulky pillow bearings and allowed for cheaper custom steel mounts to be made in house to connect the rollers onto the frame It was decided that some kind of texture Figure 7 would need to be put onto the rollers to ensure that the seeds would be pulled through The rollers were sent to an outside source to be trued and to have a horizontal knurl texture be put onto them Drive Belts Rollers T ud gt Figure 4 Overall Dehulling Machine LI S Figure 5 Rollers bolted to roller mounts and mounting rails SS 7 Figure 8 Mounting Rails Sheet metal was used to encase the rollers for the purposes of the user s safety and to contain the seeds within the machine Angle iron was used as the frame for the machine and the steel roller mounts Figure 6 were connected to it and provided the rollers with support Figure 5 Sheet metal was also used to create a hopper Figure 10 that would be able to hold the amount of twenty five gallons of seed A slide gate was created to control the flow of the seeds eoing into the rollers from the hopper A steel m
46. y were fed through the rollers were the hull not cracked hull cracked and seed remaining in the hull seed not crushed and removed from the hull seed removed from the hull and crushed These conditions were the criteria used for the qualitative analyses of the results The seeds were successfully hulled if the seed was 1 whole and 2 was removed from hull or on the verge of being removed At distances of 0 08 and 0 085 almost all of the seeds were cracked so they were obviously not the optimal distances At the distances of 0 087 0 09 and 0 1 the successful hull breaking percentage was 81 86 and 71 percent respectively These results provided an acceptable gap clearance of 0 0935 4 0 0065 Figure C 2 Results of 0 09 Spacing The second experiment was to crack the hulls of the seeds between two plates while measuring the force applied with a force transducer as seen in Figure C 3 The objective of this experiment was to find the hardness of each of the seeds this is important because the force from the seeds will be the main forces on the roller shafts which will dramatically affect the shaft size Also the force to break the seeds affects the required roller thickness to get the necessary rigidity so as not to deflect out of tolerance Since spelt has a fibrous hull which is not brittle breaking the hull requires more of a shear force to remove the hull not a compressive force simulated by this experiment For this reason
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