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Design And Development Of Manually Operated Reaper Machine

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 International Journal of Advanced Research and Publications
ISSN: 2456-9992

Design And Development Of Manually Operated

Reaper Machine
Tesfaye Olana Terefe
Faculty of Mechanical Engineering
Assistant Lecturer, Post Graduate Student (Mechanical System Design)
Jimma University, Jimma Institute of Technology, Jimma, Ethiopia, 2017.
tesfitti2016@gmail, [email protected]

Abstract: Grain harvesting is the important part in agricultural mechanization. The use of reaper technology in developing countries to
minimize the product cost which will be result in economic development of agricultural production. This paper tends to provide the design
and development of manually or mechanically operated reaper machine. The current situation in our country the traditional use of harvesting
mechanism is more tedious, time consuming and not able to develop the agricultural sector of the low farmers in economic. Depending on
the problem stated through abstraction of literature and the existing reapers, to satisfy the customer needs the gathered data has been
interpreted to meet the requirement of the objective of the problem. The mission of this project through which the product is developed to
spread out the appropriate technology to the countries primary and the secondary market are identified with the stakeholders. The general
procedure of conceptual design used; concept generation by decomposing into main and sub function, product ideas from internal and
external search, generating alternative solution by setting criteria’s and Digital Logical Approach has been used for concept evaluation and
selection. The product architecture and configuration finally introduced in the embodiment design after the selection of final concept.
Design and development of mechanically or manually operated reaper for grain harvesting machine which is evaluated against the technical
and economical criteria’s can be carried out to be suitable with the most Ethiopians low farmers capacity.

Keywords: Agricultural mechanization, design and development, grain, harvesting machinery, reaper,

1. Introduction  Developing conceptual design and selecting based on

Harvesting is the first and major post-harvest operation for the digital logic approach procedure of product design
separation, processing and storage of grains. Harvesting of and development.
grains by machines is an important part of mechanized  Finally preparing the embodiment design of the product
agriculture. At present, developed countries all over the
world are using automatic combine harvester for harvesting 2. Literature review
grains. Some developing countries are also using combine
harvesters for harvesting as a high-grade technology. As a 2.1. Background
medium grade technology, many developing countries are Until the 19th century, most grain was harvested by cutting
using reaper for harvesting to minimize production cost, and with a sickle, scythe, cradle or manual mowers then
are thereby, making agricultural production economical. [1] manually flailed or beaten to break the bond of the grain with
The harvesting of grain crops in our country Ethiopia is the stalk, then winnowed to separate the grain from material
traditionally done by manual methods. Harvesting of major other than grain. In the developing world, these practices or
cereals, pulse and oilseed crops are done by using sickle. All the use of small stationary threshers are still in use for grain
these traditional methods involve drudgery and consume harvesting. A sickle is a curved, hand-held agricultural tool
long time. [3] typically used for harvesting grain crops before the advent of
modern harvesting machinery. The inside of the curve is
1.1. Objective sharp, so that the user can swing the blade against the base of
Objective of this project is investigating, acquiring, the crop, catching it in the curve and slicing it at the same
reviewing and product development of simple harvesting time. Scythe is a similar tool with the sickle used to harvest
machine, mechanical or manual driven reaper with a grain crops. The most noticeable difference between a sickle
reasonable cost for our farmers to an end of the tedious and the scythe is the shape of the blade of which the Scythe
handiwork, the harvesting using sickle, develop or to blade is more linear whereas a sickle blade is more in the
increase their income by minimizing harvesting cost, their shape of a C with a point at the top.
time and number of workers that participating during
harvesting season.

1.2. Methodology
In this project the main goal is the development of manually
driven reaper by reviewing the previous reaper used for grain
harvesting and drawbacks of the reapers. The objective
identified to accomplish the goal were:
 Studying and identifying the present mechanisms
 Identifying the potential problem through abstraction.
 Collecting useful data. Figure 1: a) Sickle b) Scythe [18]
 Interpreting data as the problem definition

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Cradle is a more developed tool for reaping and harvesting. It bunches behind the cutter bar. The special feature of this
consists of an arrangement of fingers attached by a light machine is transformation of low soil thrust developed at the
frame work to the snatch of a scythe. Its purpose is to gather traction wheel into a higher for cutting crops by a crank and
the straw as it is cut and deposit it in a swath. At the end of level mechanism at the cutter bar. Singh et al. (1995)
the cutting stroke, the cradle is tilted to drop the straw in a designed and constructed an animal drawn reaper with an
pile. Also, substantially more grain can be cut in a day with engine operated cutting and conveying mechanism for
the cradle. However, loss due to shattering (grain dislodged harvesting wheat and rice [24]. However, field trails
from heads due to shock) is greater with the cradle which indicated that further improvements in the power
makes to continue using the sickle to harvest grain. Reapers transmission system are needed. Farming in Ethiopia is also,
are harvesting-machines used for cutting grain-crops. They generally labor intensive. However, in some localities of Arsi
either deliver the grain to one side in gavels ready to bind (Asasa, Etheya, Lole, and Dhera) there has been a shift
into sheaves, or elevate the gavels upon a platform where towards the use of agricultural machinery, especially for
two operators bind them into sheaves by hand. During the wheat production since the inception of Chilalo Agricultural
19th century, mechanical reapers and binders were developed Development Unit (CADU) in 1969. [3] Farmers in the
to cut and windrow grain for field drying. The sheaves were aforementioned areas have been interested in mechanical
then hauled to stationary threshers. Around the start of the harvesting due:
twentieth century animal drawn machines, “combines,” were  To the initial promotion of agricultural machinery
developed that integrated cutting, threshing, and separating  CADU’s research section evaluated the performance of
wheat and small grains. A reaper has been designed and local farm implements against new farm
fabricated at the University at the Agriculture, Faisalabad  Machines various models of harvesting and threshing
Pakistan [19]. machines were evaluated, and a substantial output loss
resulting from traditional harvesting and threshing
techniques was found.
 The main consequences of introducing mechanical
technologies during the 1970s were the eviction of
Tenants, increased unemployment, and soil erosion. [25]

Based on the literature reviewed above it may be inferred

that the identification of the problems of the reaper is an
important aspect to popularize it among the farmers level.
Figure 2: a) Cradle b) Reaper [18] Previous studies had been gone through only improvement,
development and settings of the machine. No one did find
This was a 5kw gasoline engine fitted self-propelled reaper out the main functional problems of reaper and as a result
(without conveyor) can harvest a hectare in 2.5hours, and is there was very little number of reapers available in the
equally effective for wheat, rice and forage crops. A tractor farmer’s field in working condition. So the present study
front mounted reaper has been developed in 1980, at was designed to find out the main functional problems of the
Agricultural Mechanization Research Institute (AMRI), reaper and popularize it among the farmers level.
Multan, Pakistan [20]. The drive for its power requiring
mechanism is drawn through the shaft with the help of V-belt 2.2. Statement of the problem
drive. The mechanism is hydraulically through the 3 point In the present Scenario due to the gradual increase in
linkage and has a field capacity of 0.5 ha/hr. The vertical population, there is too much of demands in the farm
conveyor type reaper was developed in People’s Republic of sector due to the scarcity of daily labors. The output from
China [21]. This was an 8.95kw diesel engine fitted reaper these labors is less productive due to manual or hand
having a field capacity of about 0.65 ha/hr. and is equal operations adopted by them. Since heavy machines cannot be
effective for both wheat and rice crop. It is an engine introduced due to affordability and limited area of
operated, walking type harvester suitable for harvesting and cultivation, it is very essential to bring in a machine which is
windrowing cereals & oilseed crops. The engine power is cost effective, compact and easy to use for low end farmers.
transmitted to cutter bar and conveyor belts through belt- So there is the need to make a machine which can
pulleys. Grag et al. (1985) designed and developed a front perform the following operations,
mounted vertical conveyor reaper windrower of 1.9m cutting  Easy harvesting of grains
width, operated by a tractor of about 25hp, could effectively  Less manual efforts
harvested wheat and rice and place the harvested crop on the  Low cost and less maintenance
ground in net windrows that they could be easily collected
[22]. An increase in the cutting width of the machine to 2.2m 3. Problem definition
vas recommended for commercial manufacturing to
overcome its minor operational problems. Yadav and Yadav 3.1. Defining the problem and objective clarification
(1985) designed and developed a tractor drawn side mounted As being stated in the statement of the problem in order to
reaper [23]. The basic design criteria of the machine were to develop the product which solve the specified problem the
cut the crop green and from crop bunch. The crop is gathered following basic product design specification should be
simultaneously with harvesting and dried for threshing at a considered. The need to make a machine which should
date. Yadav et al. (1991) designed and developed a light- perform the following operations,
weight, simple and sloped animal-drawn reaper requiring  Easy harvesting of grains
low draught compared to earlier machines [23]. The crops  Less manual Efforts
harvested, cereal, pulses, and oilseeds are delivered in liar

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 Low cost and less maintenance Regarding the mechanically operated reaper machine, the
following questions to help us know what their need is.
The machine should be functional, reliable, feasible,  When and why do they use the manually operated reaper
affordable, etc. The aim is to clarify design objectives and machine?
sub-objectives, and the relationship between them. A design  What do they encounter about the existing manually
has to start from some basic information when confronted operated reaper machine?
with the design task. Sources of the information the data  What do they want to be improved about the existing
gathered and analyzed from customer or an invention method?
proposition.  What issues do they consider when purchasing the
manually operated reaper machine?
3.2. Project mission statement
In order to provide guidance during product development 3.5. Interpreting data
phases, which usually formulates a detailed definition of the While interpreting the data the following guidelines are
product, target market and assumptions under which product considered
will be developed. These decisions are highlighted in the  Express the need as specifically as the raw data
product mission statement which includes the following  Express the need as an attribute of the product
 Mission statement:- Mechanically or manually operated
reaper machine for grain Based on the above questions and guidelines, data were
 Key business goals: gathered from the customers through data collection method
 To spread appropriate technology to the country stated in the methodology and interpreted as follows.
 Serve as plant form for all future grain cropping  The harvesting reaper machine will crop grain
products and solutions  The harvesting reaper machine is light weight
 Primary market:- Farmers  The harvesting reaper machine is easily push able and
 Secondary market:- Medium Investors operated
 Assumptions and constraints
 Manually operated: mechanically
4. Conceptual Design
 Weight of the machine: should be driven by human
force
4.1. Definition of Conceptual Design
 Can be manufactured in Ethiopia The feasibility study of manually operated reaper machine is
 Stake holders: the process by which its design is initiated, carried to
 Purchasers and farmers the point of creating a number of possible solutions of
 Manufacturing operations manual reaper, and narrowed down to a single best
 Service operations concept, we call this Conceptual design phase. Dieter, G.E.,
 Distributors and resellers (1991) had given the definition of conceptual design as
follow as: “It is the phase that requires the greatest
3.3. Customer needs process creativity, involves the most uncertainty, and requires
Identifying customer needs is itself a process, for which we coordination among many functions in the business
present a five-step method. We believe that a little structure organization. The goal in this phase is to validate the need,
goes a long way in facilitating effective product development produce a number of possible solutions, and evaluate the
practices, and we hope and expect that this method will be solutions on the basis of physical realizability, economic
viewed by those who employ it not as a rigid process but worthwhileness, and financial feasibility.” [16]
rather as a starting point for continuous improvement and
refinement. The five steps are:- 4.2. Concept Generation Methods
1. Gather raw data from customer: through reviewing In the concept generation phase we should ask the following
different literature, existing solution etc. questions to start with,
2. Interpret the raw data in terms of customer needs  What existing solution concepts, if any, could be
3. Organize the needs into a hierarchy of primary and successfully adapted for this application?
secondary  What new concept might satisfy the establishment needs
4. Establish the relative importance of the needs and specifications?
5. Reflect on the result and the process  What methods should be used to facilitate the concept
generation process?
3.4. Gathering raw data
During analyzing the customer need process, raw data should
be gathered by the following methods
 Reviewing different international and national journal
papers
 Observing the traditional method in use and the existing
technical problems of a solution

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ISSN: 2456-9992

Basically there are five concept generation methods:- 4.5. Functions means tree
Using function tree means we are going to further analyzing
the function of the mechanically operated reaper machine we
can divide the main function of the harvester into sub
functions and we can determine the means for these sub
functions.

Figure 3: Concept generation method structure [16]

4.3. Decomposition into Main Function and Sub Function

Decompose complex problem into simpler sub-problems is
essential because many design challenges are too complex to Figure 6: Function Tree means
solve as a single problem. Consequently let’s decompose the
harvesting machine in to simpler sub problems in order to 4.6. Generating alternative design
tackle the problems one by one in a focused way. This is the To select one of the superlative choices given for each
main function of the manually operated reaper machine with component, there are steps to be followed.
the input and output diagram. 1. Setting Criteria
2. Calculating a weighting factor for each criterion
3. Evaluating each design with respect to the selected
criteria by using a decision matrix.
4. Select the preeminent design based on the decision
matrix.

The type and number of criteria are determined by individual

judgment. There are no proper set of rules for setting design
Figure 4: Input Output Diagram [15] criteria, since it depends on the type and application of
design and its complication. The aim is to generate the
complete range of alternatives design solutions for a product,
and hence to widen the search for potential new solutions. Of
course this is achieved by analyzing the functions and means
that we have established in the previous section. Here we
should think exhaustively what possible solution we might
get to achieve every sub functions of the reaper. As a result
we get number of design alternatives. In the design of
mechanically operated reaper machine out of the possible
alternatives four of them will be analyzed here just to show
the methods.
Figure 5: Main Functional decomposition a) Single person driven light duty
b) Two person driven medium duty
4.4. External and Internal search c) Three person driven medium duty
By conducting external searches from literature to find d) Animal driven medium duty
existing solutions to satisfy either the overall problem or a
sub-problem identified during the decomposition step. These Labelling the above concepts as concept 1, 2, 3 and 4.
results are found; Tractor driven reaper machine which is
1. Heavy duty. 4.7. Evaluating alternative design concept
2. Medium duty. In order to make any kind of evaluation, it is necessary to
3. Light duty and for small size row. have a set of criteria and these must be based on the design
objectives i.e. what it is that design is meant to achieve. The
Conducting internal searches to find the new solution to objective will include technical and economic factors, user
satisfy the overall or sub function. Finally come up with the requirements and so on. Hence the following objectives are
following solution. chosen to evaluate the design characteristic of each feature.
1. Human force driven reaper machine. Cost, performance, reliability, availability, maintainability,
2. Manual and Animal driven reaper machine power we may have the same or different evaluating criteria,
which depend on the type of features to be evaluated as well

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ISSN: 2456-9992

as the amount of dependency if it affects adversely, we could 4.11. Product structure

use as a measuring criteria for that feature. The construction of a decision tree is a useful technique
when decisions must be made in succession into the future.
4.8. Determination of weighting Factor Determining weighting factors for criteria is an inexact
When many design criteria’s are used to specify the degree process. Intuitively we recognize that a valid set of weighting
of importance of each, it may be difficult to re-establish factors should sum to 1. Therefore, when n is the number of
weighting factors. One way to do so is to use a digital logic evaluation criteria and w is the weighting factor,
approach. Each property is compared in every combination
taken two at a time. To make the comparison, the property
that is considered to be the more important of the two is ∑
given a one and the less important a zero, the total number of
properties under consideration are:

Where N- The total number of possible comparison pairs.

n- The total number of criteria
wi - the weighting factor =mi /N
mi - the total number of positive decisions for the i th
criteria

Now using this principle we can apply for the listed design
alternative in generating alternative to select the best one.

4.9. Basic selection criteria

 Durability
 Ease of handling
 Ease of maintenance
 Ease of manufacture
 Ease of mountable
 Ease of use
 Few disturbing factors
 Low complexity of components
 Low cost Figure 7: Product structure division tree
 Low susceptibility of vibration
 Low wear of moving parts a) Selection of driving and power unit
 Many standards and bought out parts Gear box- path ABEGH=1*0.3*0.67*0.78*0.9=0.141102
Engine- path ABF=1*0.3*0.33=0.099
 Portability
 Simple assembly
b) Gear selection
 Small number of components [15] Helical gear – path ACIK=1*0.3*0.5*0.28=0.042
Bevel gear – path ACIL=1*0.3*0.4*0.5=0.06
These criteria are general ones. We may evaluate component Sur gear – path ACIM=1*0.3*0.5*0.32=0.048
wise and for the design as a whole too. But we may not use
all the criteria for the every component. That is we make
c) Type of shaft
selection of criteria to suit the much intended purpose of the Solid shaft – path ACJN=1*0.3*0.5*0.6=0.09
component. Now let us screen our design alternative using Hallow shaft – path ACJO=1*0.3*0.5*0.4=0.06
the set of above selected criteria and let us give their scored
values in order to have the best screened design alternatives
d) Torque Transmitting Elements
for the manually operated reaper machine Key – path ADSP=1*0.4*0.5*0.4=0.096
Shrink fit – path ADSQ=1*0.4*0.5*0.4=0.096
4.10. Selection of Mechanically Operated Reaper Spline – path ADSR=1*0.4*0.5*0.3=0.06
Table 1: Selected design of major components
e) Belt Selection
Flat belt –path ADTUX=1*0.4*0.5*0.67*0.2=0.0268
Design of single person driven light duty Round belt - path ADTUY=1*0.4*0.5*0.67*0.2=0.0268
Design of Shifting belt
spoke wheels V-belt – path ADTUZ=1*0.4*0.5*0.67*0.6=0.0804
Design of fold frame using RHS Chain and sprocket - path ADTV=1*0.4*0.5*0.33=0.066
solid tyres Note: The bold lines are selected one.
Hence the weighted value of the selected design is
=0.141102+0.06+0.09+0.096+0.0804=0.467502

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5. Embodiment Design belt housing, and others might be selected as their level of
importance. The product configuration, architecture of the
5.1. Definition of embodiment design reaper is prepared using solidwork software. In the 3D
Embodiment design is well known in product development. figures below, the geometry and mechanism by which the
Kesselring (1654) was the first to refer to embodiment design components assembled together is clear and understandable,
and introduced a set of principles: minimum manufacturing while the working principle in which the machine is human
costs, minimum requirements, minimum of weights, force operated by transmitting motion from the wheel to the
minimum losses and optimal handling. [17] The definition of gear box by means of belt driving mechanism and the cutter
embodiment design according to Pahl and Beitz (1996) runs assembly operates by converting the rotational motion to
as follow as: “Embodiment design is the part of design slider crank mechanism in order to generate back forth
process starting from the principle solution or concept of motion. The grain collector from the front which helps to
consumer product. The design should be developed in collect the grains from the overhead of the cutter at the time
accordance with engineering and economical criteria’s.” [15] of cutting/reaping directly operated by the rotational motion
Structured development of the design concept occurs in this supplied from gearbox with the help of belt driving
engineering design phase. It is the place where flesh is placed mechanism. The castor which assembled from the back side
on the skeleton of the design concept. Embodiment design of helps the stability of the machine during operating and also
the manually operated reaper machine is concerned with two keeping it in stationary.
major tasks: product architecture and configuration design.
 Product architecture: It is concerned with dividing the 5.5. Bearings, bolt and key selections
overall design system into subsystems or modules. In
this step we decided arrangements and combinations of a. Bearings
the component; tyre with wheel, shaft with gear & Depending on the type of design, size and operational
bearing, frame with shaft, gearbox placement and belt parameters of the driving mechanism, we use deep groove
driving mechanism, the cutting blade positioning and ball bearings for the shaft and other motion transferring.
means of motion transferred to it, and etc. of the reaper Since it takes both radial and axial loads. These bearings
machine to carry out the cutting operation properly. require little maintenance and their starting resistance is
 Configuration design of parts and components: negligible. [14] Strength check type: ISO Bearing type: Deep
Parts are made up of features like holes, ribs, RHS, groove ball bearing single raw
and curves. Configuring a part means to determine
what features will be present and how those features b. Bolts
are to be arranged in space relative to each other Here the bolts are used to connect two parts together for
assembling.
5.2. The basic rules of embodiment design
The final design phase will finish the development of the c. Keys
reaper. At the end it has to be completely defined in the The keys are used to connect the gear and pulley with the
following three basic rules of embodiment design: simple, shaft and transfer motion.
unambiguous, reliable.
 Unambiguous: - fulfillment of technical use of 5.7. Conclusion
manually operated reaper is clear and uncomplicated Manually operated reaper machine is very crucial for our
country Ethiopia, even though is not currently produced in
 Simple: - there are no unnecessary functions or shapes
industries as well as in a small enterprise industries. As
other than fulfilling the main function in which any one
clearly the design worked out in this paper we can have the
can simply understand how it will work, can use the
production of manually operated reaper machine that is
machine
produced in local industries with the available and cheap
 Reliable:- the reaper is usable in a myriad of conditions
materials. The design can be carried out with affordable
without harming the user or environment
capacity of most of Ethiopians. And also a better quality
product can be produced. That in turn will save a huge
5.3. Principles of embodiment design [16]
amount of foreign currency which was paid to import these
 Minimum manufacturing cost: machining huge machineries and also able to provide the low farmers to
manufacturing procedure will be used to simple use the machine in affordable cost.
production of the machine.
 Minimum space requirement: all the designed part
after assembly
 Minimum weight: spoke wheel, RHS frame, hallow
shaft of the product
 Minimum losses : during manufacturing, by means of
machining and welding
 Optimum handling: caster will be used for the stability
of the machine from the back of the wheel

5.4. Component construction

The main components of the machine are; gear box, RHS
frame, spoke wheel, hallow shaft, pulley, cutter assembly,
castor, and sub components like bearing, bolt, key, belt & Figure 8: Solidwork software Drawings

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Reference [20] Chaudhry, A. D. 1978, “Design and Fabrication of

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[9] Thomas D. Etal. Development Of Working Prototype Of Author Profile

For Ragi Harvesting And Threshing Tesfaye Olana received B.Sc. degrees in
Mechanical/Design Engineering from
[10] Sharmin A. 2014, “Identification of the Functional Adama Science and Technology
Problems of Reaper Available,” India. University in 2015. And now studying
MSc in Design of Mechanical System at
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Operated Rice Combine Harvester for Small Holder University. During 2015-2016, he stayed
Firmest,” Tanzania. in Mizan-Tepi University serving as
Assistant Lecturer in Mechanical
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[13] Handaka and Joko Pitoyo, 2011, “Modification of A Author pervious work
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