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TITLE PAGE

DESIGN AND FABRICATION OF A MINI CORN SHELLER MACHINE

BY

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EE/H2013/01430
DEPARTMENT OF ----
SCHOOL OF ---
INSTITUTE OF ---

DECEMBER,2018

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APPROVAL PAGE

This is to certify that the research work, "design and fabrication of a mini corn sheller machine" by ---, Reg. No. EE/H2007/01430 submitted in partial fulfillment of the requirement award of a Higher National Diploma on --- has been approved.

By
---                                                     . ---
Supervisor                                                  Head of Department.
Signature……………….                           Signature……………….        

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External Invigilator

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DEDICATION
This project is dedicated to Almighty God for his protection, kindness, strength over my life throughout the period and also to my --- for his financial support and moral care towards me.Also to my mentor --- for her academic advice she often gives to me. May Almighty God shield them from the peril of this world and bless their entire endeavour Amen.

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ACKNOWLEDGEMENT

The successful completion of this project work could not have been a reality without the encouragement of my --- and other people. My immensely appreciation goes to my humble and able supervisor mr. --- for his kindness in supervising this project.
My warmest gratitude goes to my parents for their moral, spiritual and financial support throughout my study in this institution.
My appreciation goes to some of my lecturers among whom are Mr. ---, and Dr. ---. I also recognize the support of some of the staff of --- among whom are: The General Manager, Deputy General manager, the internal Auditor Mr. --- and the ---. Finally, my appreciation goes to my elder sister ---, my lovely friends mercy ---, ---, --- and many others who were quite helpful.

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Mini Corn Sheller Machine was designed and fabricated at the department of Mechanical Engineering. A dry corn shelling machine presented in this paper helps to separate corn from the cob. The fabricated design consists of a body casing, drum, shelling unit, grain and cob discharge unit, machine frame, hopper (Feeding chute), bearing as some of the major component, It is powered by 2Hp electric motor connected via a belt drive which transmits torque from the electric motor to the shelling unit. A blower powered by a separate electric motor connected to the discharge unit helps to separate the unwanted particles from the shelled corn. The fabricated design was tested and found to be about 79percent efficient with operating capacity of about 63.95kg/hr. The design is relatively cheap, simple and portable when compared to imported product of similar capacity.

TABLE OF CONTENTS
COVER PAGE
TITLE PAGE
APPROVAL PAGE
DEDICATION
ACKNOWELDGEMENT
ABSTRACT
NOMENCLATURES

CHAPTER ONE

•       INTRODUCTION
• BACKGROUND OF THE PROJECT
• PROBLEM STATEMENT
• AIM OF THE PROJECT
• OBJECTIVE OF THE PROJECT
• JUSTIFICATION OF THE PROJECT
• SCOPE OF THE PROJECT
• PURPOSE OF CONSTRUCTION
• IMPORTANCE AND SPECIFICATION OF THE PROJECT
• FUTURE SCOPE OF THE PROJECT
• APPLICATIONS
• ADVANTAGES 0F CORN SHELLING MACHINE
• PROJECT ORGANISATION

CHAPTER TWO
LITERATURE REVIEW

• HISTORICAL BACKGROUND OF CORN SHELLER
• OPERATION OF A CORN SHELLING

CHAPTER THREE
METHODOLOGY

• MATERIALS AND METHODS
• PRINCIPLE OF OPERATION
• DESIGN PRINCIPLES

CHAPTER FOUR

• MATERIAL COST ESTIMATION
• DESIGN AND CAD DRAWINGS
• DESIGN PROCEDURE
• DESIGN CALCULATIONS
• MATERIAL & MANUFACTURING

CHAPTER FIVE

• CONCLUSION
• REFERENCES 

NOMENCLATURES
Quantity                                            Symbol                          Unit
Power of Electric Motor                             P                                    watts
Rotational speed of driver shaft                 Nr                                  rpm            
Rotational speed of driver shaft        Nn                                  rpm
Torsional moment                                      Mt                                  Nm
Bending moment on shaft                 Mb                                  Nm
Combined shock and fatigue
Factor applied to bending  moment  Kb                                      -
Combined shock and fatigue factor
Applied to torsional moment            Ki
Diameter of shaft                              Ds                                   mm
Allowable stress                                Ss                                   N/mm2
Speed of driven pulley                      Sn                                  rad/sec
Speed of driver pulley                       Sr                                   rad/sec
Length of shaft                                  Ls                                   mm
Weight of beater assembly                Wb                                  N

CHAPTER ONE
1.0                                          INTRODUCTION
1.1                                         BACKGROUND OF THE PROJECT
Corn is the most important cereal grain in the world, after wheat and rice, providing nutrients for humans and animals and serving as a basic raw material for the production of starch, oil and protein, alcoholic beverages, food sweeteners and, more recently, fuel. It is because of the important place of maize that it’s handling, processing and preservation within the optimum conditions must be analyzed.
The problem of poverty, hunger and malnutrition would be alleviated if there is adequate production of corn, Corn also called maize plays an important dietary role in most parts of Africa, It is grown virtually everywhere, in tropical, subtropical and temperate regions where rain and irrigation is adequate (Messiaen, 1992), Tindall, 1983).
The major steps involved in the processing of corn are harvesting, drying, de-husking, shelling, storing, and milling. All these processes are costly and for the rural farmers to maximize profits on their produce, appropriate technology that suites their needs must be used. Corn processing not only prolongs its useful life but also increases the net profit farmers (users) make from mechanization technologies. It is in this line that one of the most important processing operations done to bring out the quality of corn is shelling. It is basically the removal of the corn kernels from the cob. This separation, done by hand or machine, is obtained by shelling through friction or by shaking the products; the difficulty of the process depends on the varieties grown, and on the moisture content as well as the degree of maturity of grain.
Corn is considered to be one of the most important staple crops in the world.  People in some parts of the world actually consider corn as their survival food. According to the D-Lab corn Sheller writing at the Massachusetts Institute of Technology (Accessed on Oct 4th 2013), corn accounts for 43% of the Latin American diet. Because of the high need of corn grains, it leads to the invention of a wonderful tool called the corn sheller which helps in shelling the kernels from the cob as well as makes shelling faster and easier. It. The first ever corn sheller was invented by Lester E. Denison at Sayville Middlesex country, connecticus.
Today, corn shellers come in wide variety of sizes and types. From the simplest hand-held device to the more complex bigger self-feeding machines powered by steam, corn kernel separation has been successful since then.

1.2                                   PROBLEM STATEMENT
The factor among others has made the decortications of corn an important process that must be developed to enhance value addition and also remove human efforts and also remove human efforts and associated difficulties when using traditional method of shelling such as losses labour intensity, time consuming and low output capacity.

1.3                                                      AIM
The aim of this work is to design an improved corn shelling machine that operates with high efficiency and flexibility

1.4                                             OBJECTIVES
The specific objectives of the research work are to;

• Design a portable corn shelling machine that will operate with minimum noise.
• Construct a portable corn shelling machine that can effectively separate the corn from the cob.

1.5                         JUSTIFICATION OF THE PROJECT
Our design improves on the prior art because it is inexpensive, small scale, and does not need outside help to build. The materials and tools are readily available and do not require communication with external parties to be built.
Big commercial systems are simply too expensive of our target market. Even the hand cranked machines cost upwards from £130. 
The mini corn Sheller is also a good low cost alternative but it requires the builder to have molds to make the concrete components. If the builder has access to fiberglass materials to make molds out of, it is easy for him to build the device. If he does not have access and buy the molds at through the United States, which may be very expensive. We aim to eliminate the need for molds and the need for outside parties. Our machine requires no foreign assistance at all. It can be built using local materials by the local craftsmen. There is no need for builders to communicate and interact with foreign parties.
Our approach to solving the corn shelling problem is to use the concept of the rubber tire design but make it affordable and easy to build with locally accessible materials. The machine itself is very easy to build, and requires few skills besides basic carpentry. Our concept does away with costs and complexity of is simple; extruded steel and other common components are easy to find. The concept is simple and the design is modular. So it can be expanded of higher through put is desired. Locally accessible materials may differ in different regions. So our design can be adapted to use different materials. The second component of our system is a device that separates the shelled corns from the shells. Prior designs for separation equipment use forced air to carry the shells away from the corns. Since forced air requires complex fan units and extra power. We designed a separation machine that does not depend on air currents. Our design uses the gravity property of the corns to separate them from the cob.

1.6                                  SCOPE OF THE PROJECT
A research-work for design and fabricate of a Corn Sheller consisting of feed hopper, shelling unit, separating unit and power system. The performance of the machine was evaluated in terms of throughput capacity, shelling efficiency, material efficiency and mechanical damage. Regression models that could be used to express the relationship existing between the Sheller performance indices, pod moisture content and feed rate were establish. This paper describes about the design of various components of Corn Sheller machine. Hence in this design of various parts are necessary, and design of various parts due to which the design quality of those parts will be improved. Overall, this project involves processes like design, fabrication and assembling of different components etc.

1.7                                     PURPOSE OF CONSTRUCTION
            This project is meant to achieve the following purposes.
(1)       To design and construct a corn sheller which is easy to operate with high degree of efficiency.
(2)        To save time and cost, with high degree of production volume.
(3)       To design and construct a corn sheller that would not have much breaking effect of grains, leaving the cobs intact during the process.
(4)       To design and construct a corn sheller that is economic and have little or no complication in maintenance
(5)        To design and construct a corn sheller with high percentage of local technology.
(6)         To design and construct a machine that is cost effective manual stress reduction.

1.8                      IMPORTANCE AND SPECIFICATION OF THE PROJECT
The importance attached to this design is the facilitation and the production of voluminous corn shelling without much time and without encountering much breakage of the grains of the corn in shortest possible time.
The specification was obtained considering the items or component used and the hopper and barrel dimensions put into consideration as well. 

   1.9                                                      FUTURE SCOPE OF THE PROJECT
The work has been a real challenge to execute as there were many practical design and fabrication problems along with cost constraints. The machine has a great future scope in any industry and for farmers due to its ease of use, moderate cost and simple design. The main constraint of this device is the slightly higher initial cost but the advantage lies in its low operating costs. Savings resulting from the use of this device will make it pay for itself within the short period of time.

   1.9                                                      APPLICATIONS
The machine can be used to peel the corn grains.

• Used in agriculture industries.
• Used in mills.
• The device can be very helpful to small scale farmers and domestic purpose.

1.10                          ADVANTAGES 0F CORN SHELLING MACHINE

• The power consumption is less.
• Easy in operation.
•  Low cost
• Simple construction.
• Adaptable.
• Performance.
• Easy to setup
• Light weight.
• Easy maintenance.

1.11                                                      PROJECT ORGANISATION
The work is organized as follows: chapter one discuses the introductory part of the work, chapter two presents the literature review of the study,  chapter three describes the methods applied, chapter four discusses the results of the work, chapter five summarizes the research outcomes and the recommendations.

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CHAPTER THREE: The complete chapter three of "design and fabrication of a mini corn sheller machine" is available. Order full work to download. Chapter three of "design and fabrication of a mini corn sheller machine" consists of the methodology. In this chapter all the method used in carrying out this work was discussed.

CHAPTER FOUR: The complete chapter four of "design and fabrication of a mini corn sheller machine" is available. Order full work to download. Chapter four of "design and fabrication of a mini corn sheller machine" consists of all the test conducted during the work and the result gotten after the whole work

CHAPTER FIVE: The complete chapter five of design and construction of a "design and fabrication of a mini corn sheller machine" is available. Order full work to download. Chapter five of "design and fabrication of a mini corn sheller machine" consist of conclusion, recommendation and references.

 

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