GUJARAT TECHNOLOGICAL UNIVERSITY

Chandkheda, Ahmedabad
Affiliated

(Tatva institute of technological studies, Modasa)

A
Project on

FABRICATION OF AGRICULTURAL PESTICIDES

SPRAYER WITH WEEDER
B. E. , Semester 7
(Mechanical Branch)

Project: UDP
Submitted by:

SR.
NAME OF
1
PATEL BIREN PRAVINBHAI

STUDENT ENROLLMENT NO
[130900119051]

PATEL UMANG CHANDUBHAI

[130900119077]

PATEL ANIKETKUMAR RAJNIKANT

[130900119048]

Prof. Mohit B Diwan

(Faculty Guide)

( Head of the Department )

CERTIFICATE

DECLARATION
2

AKNOWLEGEMEBT
3

ABSTRACT
4

 The aim of our project is to take a system wide approach to preventing the
machine accident. The system includes not just the machine and the
operator; but rather it includes everything from the initial design of the
machine to the training of every one that is responsible for any aspect of it,
to the documentation of all changes to regular safety audits and a finally a
corporate culture of safety first. Design is the part of a machine life where
the greatest impact can be made in relation to avoiding accidents. The
designer should ensure that the machine is safe to set up and operate, safe to
install, safe to maintain, safe to repair and safe to decommission.

INDEX
SR.NO.

DISCRIPTION

PAGE NO.
5

Title page

Certificate

Declaration

Acknowledgements

Abstract

Index

List of figure

Chapter - 1

Introduction

Chapter - 2

Literature review

Chapter 3

Design details

Chapter 4
Chapter 5
Chapter 6
Chapter 7

Conclusion

Chapter - 8

References

Appendix

LIST OF FIGURE
SR.NO.

DISCRIPTION

PAGE NO.

LIST OF TABLE

SR.NO.

CHAPTER 1

DISCRIPTION

PAGE NO.

INTRODUCTION

 The designer should make the machine as reliable as reasonably possible to

minimize the maintenance requirement and allow for long intervals between
routine maintenance tasks. It is also important to design the machine and its
control system so that maintenance can be carried out safely.

For example, hold-to-run controls can be installed that allow a machine to be

run at a reduced speed, or removable tool holders can be used so that sharp
blades can be replaced on a workbench instead of in an difficult position
inside a machine. In addition, operators and maintenance technicians must
be discouraged from bypassing safety equipment.

Safety components are often designed to interrupt processes in the event of a

fault and will have an impact on machine availability. In order to minimize
this effect - and the temptation to interfere with the safety circuits - highreliability safety components should be specified so as to keep the number of
nuisance faults at a minimum.

 Designing safety into a new machine is important, but it has to be

remembered that the vast majority of machines do not remain unaltered,
with unchanged operating procedures, for their entire lifetime.

CHAPTER - 2

PROBLEM DEFINITION

PROBLEM SUMMARY

10

 NEED FOR SAFETY SYSTEM IN MACHINERY

Modifications are almost inevitable and working practices can evolve or be

deliberately revised by managers in an attempt to improve throughput. Any
changes made to the machine or the way it is operated also changes the
original risk assessment. Research has shown that a significant number of
industrial accidents result from uncontrolled changes. It is usually via a
complex sequence of events that a change leads to an accident.

Clearly it is necessary to ensure that machinery and operating procedures are

fully documented. Even if a machine and its associated safety systems are all
properly designed and documented, it is vital that the machine is monitored
during installation, commissioning and first-off production. Often it is
necessary to make small changes during any or all of these stages.
It is imperative that any proposed change is first subjected to a rigorous risk
assessment, and any changes that are implemented must be fully
documented. After production has commenced, a further review should take
place to make certain that no further changes have been made. Note also that
11

"no further changes" also refers to the raw materials or components that are
being processed by the machine. Audits should be undertaken on a regular
basis to check that the machine and operating procedures are still in the
documented state.

Furthermore, functional audits should also be carried out on the machinery

safety systems. Often the components in a safety control system are only
used in the event of an emergency, which can make them very difficult to
test. Nonetheless these systems should be tested at regularly scheduled
intervals.

Safety field buses such as AS-i Safety At Work (AsiSafe) and Profisafe can
support intelligent field devices able to perform self-monitoring functions
and transmit diagnostic data to a central controller that can alert the machine
operator prior to the failure becoming an unacceptable risk.

Education and training is another aspect of the company-wide approach to

machinery safety. Increasingly complex modern machinery makes education

12

and training ever more important. There are new standards and regulations
with which companies must comply. On-the-job experience may have
sufficed in the past but this is unlikely to be acceptable in the future.

Obviously training for machine operators and maintenance technicians is a

requirement, but there is also an important need for more general education
of the workforce and management in order to generate a safety-first
corporate culture.

CHAPTER - 3

LITERATURE REVIEW

1. DESIGN AND FABRICATION OF PAPER PUNCHING MACHINE

Paper punching is one of the important processes in spiral binding industry.

The project selected is based on automation and this help to improve spiral
13

binding works. The motor is used for operating the punching head. Hence
human fatigue is reduced. So it can find application in all spiral binding
shops.

An eccentric cam mechanism is used for punching papers for spiral binding .
It can be used in all spiral binding shops.To operate the punching head an
electric motor is needed. If the motor is ON, the cam attached to the motor
with speed reduction mechanism will rotates. As it rotates the pull rod will
oscillates up and down.

This reciprocating motion is transmitted to punching head and it punch the

papers when the punching head moves in downward direction.This machine
reduces human fatigue and reduces punching time than manually operated
machine. Due to this number of sets of paper can be punched in a very short
time. So this machine finds application in all spiral binding shops.

2. REVIEW

ON

PNEUMATIC

PUNCHING

MACHINE

AND

MODIFICATION IN PUNCH TOOL TO REDUCE PUNCHING

FORCE REQUIREMENT

14

By p.goyal, g.srivastava, r.singh, n.singh ug students [mechanical], dept. Of

mechanical engineering, jss academy of technical education, noida,uttar
pradesh, india

This project work deals with the design of pneumatically controlled small
scale punching machine to carry out piercing operation on thin sheets (1-2
mm) of different material (aluminium and plastic). Reduction in punching
force requirement being the main aim of this project work is obtained by
modification in punch tool design i.e. by provision of shear on punch face.
Subsequently it results in reduction in amount of punching force
requirement. And further a CATIA model of the machine is developed on the
basis of calculations with respect to punching force requirement.
A pneumatic punching machine is always a better choice than a hydraulic
punching machine for the production of similar products if it is suited for the
method. It is comparatively more economical for production of large
quantities of products as it uses compressed air rather than some hydraulic
fluid which is rather expensive. A pneumatic punching machine uses
compressed air to generate high pressure to be applied on the piston. A
solenoid valve controls the directional flow of air into and out of the
cylinder. Polyurethane tubes are used for pressure transmission from the
15

pneumatic cylinder to the punch assembly. The high pressure air fed to the
punch, forces it on the material and as the punch descends upon the sheet,
the pressure exerted by the punch first cause the plastic deformation of the
sheet.
Since the clearance between the punch and the die is very small, the plastic
deformation takes place in a localized area and the sheet material adjacent to
the cutting edges of the punch & die edges becomes highly stressed, which
causes the fracture to start on both sides of the sheet as the deformation
progresses.

CHAPTER - 4

METHODOLOGY

WORKING PRINCIPLE
This project involves controlling accident or defecting due to machines.
Here one IR transmitter and IR receiver is fixed in machine where if
anybody gets close contact with the machine then the relay circuit will trip
off the machine. Fault out by pt which connected to ADC through precession

16

rectifier. This value is read out by controller and processed through that
according to solenoid value that returns. This machine operates
pneumatically.

AIM AND OBJECTIVES

The aim of our project is to take a system wide approach to preventing the
machine accident. The system includes not just the machine and the
operator; but rather it includes everything from the initial design of the
machine to the training of every one that is responsible for any aspect of it,
to the documentation of all changes to regular safety audits and a finally a
corporate culture of safety first.
Design is the part of a machine life where the greatest impact can be made in
relation to avoiding accidents. The designer should ensure that the machine
is safe to set up and operate, safe to install, safe to maintain, safe to repair
and safe to decommission.
Although safe operation is usually at the forefront of a designer mind safe
maintenance and repair should also be a high priority. Around 50% of fatal
accidents involving industrial equipment are associated with maintenance
activities and design contributory factor in some 32% of these fatalities.
This project involves controlling accident or defecting due to machines.
Here one IR transmitter and IR receiver is fixed in machine where if
17

anybody gets close contact with the machine then the relay circuit will trip
off the machine. In our project Accident Avoiding System For Punching
Machine the IR sensors are used to avoiding the accident. The system
automatically stops, when the IR sensor detecting the any parts of the
operator inside the machine.

CHAPTER - 5

DESIGN AND COMPONENTS

DESIGN PROCEDURE:1. Material Selection:To prepare any machine part, the type of material should be properly selected
considering design and safety .The selection of material for engineering
application is given by the following factors:1) Availability of material
2) Suitability of the material for the application of the product.
3) Suitability of the material for the desired working conditions,
4) Cost of the materials.
18

The machine is basically made up of mild steel. The reasons for the selection
are:
1. Mild steel is readily available in market,
2. It is economical to use,
3. It is available in standard sizes,
4. It has good mechanical properties i.e. it has good machinability.
5. It has moderate factor of safety, because high factor of safety results in
unnecessary wastage of material and heavy selection. Low factor of safety
results in unnecessary risk of failure,
6. It has high tensile strength,
7. Low coefficient of thermal expansion.
The materials of the sheets to be punched are taken as aluminium and plastic as
they are replacing many metals in the present scenario because of their
distinguished properties and features.

2. Force Calculation for existing punch design:Terms and formulae used:

Cutting force: - The force which has to act on the stock material in order to cut
the blank or slug.
19

Stripping force: - The force developed due to the spring back (or resiliency) of
the punched material that grips the punch.
Cutting force = L x t x Tmax
Stripping force =10% -20% of cutting force
L= Length of periphery to be cut in mm
t= Sheet thickness in mm
Tmax= Shear strength in N/mm
Accident Avoiding System For Punching Machine

20

Fig. 5.1 - Accident Avoiding System For Punching Machine

21

Fig. - 5.2 - Sketch of Accident Avoiding System For Punching Machine with
components details

22

 MAIN COMPONENTS AND ITS DESCRIPTION:

The major parts used in our project are
Frame
Electric motor
Reduction gear box
Eccentric cam mechanism
Punching head
Punching head mechanism.

FRAME:

It is the basic skeleton structure withstands all components such as electric

motor, gear box, pull rod and punching head and loads acting while
punching paper.

23

 ELECTRIC MOTOR:

It is mounted at bottom of the frame and its shaft is mounted by a pulley and
a V belt drive which drives the gear box. It converts electrical energy into
mechanical energy. A 1HP motor, single phase, with 1440 rpm is used for
our project.

REDUCTION GEAR BOX:

It is also mounted on the bottom of the frame. It has pulley at one end to
which motor drive is connected and another end (output shaft) is connected
to eccentric cam mechanism. It uses a speed reduction gear box with ratio of
40:1. Worm and worm wheel is used for speed reduction

ECCENTRIC CAM MECHANISM:

In this mechanism a flat plate is mounted to the gear box output shaft.
Another pin is fixed with an eccentric distance in the flat plate to perform
cam function. In the pin a bearing is mounted over which a bush is mounted.
The pull rod is attached to the bush. And the whole eccentric plate
24

mechanism is bolted to the gear box shaft.

RAM HEAD:

It is a flat plate to which pull rod is attached, and it slides with respect to
sliding mechanism as eccentric cam rotates. In sliding mechanism a bush
slides over a circular rod, which is mounted on the frame. The punching die
is attached to the bottom side of the flat plate. The follower of punching die
is attached to the frame in which punching pins reciprocate.

CONSTRUCTION:

This machine has a rigid frame made with L angles and it is welded rigidly.
The electric motor is connected to reduction gear box through V belt, here
first reduction of speed takes place. The reduction gear box has a warm and
warm wheel in which second speed reduction takes place.

In reduction gear box a worm and worm wheel is used for speed reduction.
At the output of reduction gear box an eccentric cam plate is used to obtain
reciprocating mechanism.
25

 A follower (pull rod) which connects both eccentric cam and punching head.
The punching head is guided in a bushed shaft. The shaft is clamped to
frame by U clamp on both sides. The bottom side of punching head has
punching pins which actually make holes on papers. The bottom side of the
punching pins will slide in a guide plate which helps in good quality of
punching.
If the electric switch is ON the motor will rotates, as it rotates it drives the
gear box shaft. As the diameter of gear box pulley is larger than the motor
pulley speed reduction takes place. In gear box worm and worm wheel is
used high speed reduction takes place in the order of 40:1 ratio.
Then the output of gear box is connected to eccentric cam plate. Due to
speed reduction the will rotates at very slow speed. As the eccentric cam has
a follower over it makes the pull rod to reciprocate. The movement of
punching head depends upon the eccentricity of cam. The punching head has
a sliding mechanism in which the punching head is guided up and down.
The bottom of the punching head has a whole plate to guide the pins
accurately without bending. After switch ON the motor the paper is placed
between the head and base. The punching action takes place when the
punching head moves down wards. This process is repeated for as number of
times for punching number of sets of papers.
26

 In designing and fabricating this project, we gained invaluable technical

knowledge, regarding material solution, planning the project, group efforts
in achieving the target, cost estimation and also gained confidence in doing
works.
However, in completing the project we felt that aims of the implementation
of project work in our courage is completely fulfilled.

CHAPTER - 6

GENERAL DETAILS

APPLICATIONS
27

All Heavy Cutting Machine

All Ramming Machine
In all Foundries
In all Machine Shop
All the industries

ADVANTAGES
This system is more safety to the operator
Simple type of automatic accident avoiding system
Quick in response
Simple in construction
It is very useful in all industries

DISADVANTAGES

28

The addition cost is required (sensor, Control Unit cost.

CHAPTER - 7

CONCLUSION

29

CHAPTER - 8

REFERENCES

30

[1] R. Joshua, V. Vasu and P. Vincent Solar Sprayer An Agriculture

Implement, International Journal of Sustainable Agriculture 2 (1): 16-19, 2010
ISSN 2079-2107
[2] R. D. Fox, R. C. Derksen, Visual and image system measurement of spray
deposits using watersensitive paper Applied Engineering in Agriculture Vol.
19(5): 549552 2003 American Society of Agricultural Engineers ISSN 0883 8542
[3] M. A. Miller, B. L. Steward, M. L. Westphalen Effects of multimode
fourwheel steering on sprayer machine performance, American Society of
Agricultural Engineers ISSN 00012351
[4] A. Taiwo K. Oje, Development and testing of a swirl chamber nozzle, Journal
of Agricultural Engineering and Technology (JAET), Volume 16 (N0. 1) June,
2008
WEBSITES:1.http://ocw.metu.edu.tr/pluginfile.php/6885/mod_resource/ content/1/ch7/7-2.htm
2. http://en.wikipedia.org/wiki/Sprayer
3. http://en.wikipedia.org/wiki/Weeder
4.http://www.hindu.com/seta/2010/04/29/stories/20100429 50601500.html
5. http://www.skybirdagro.com/agriculture-sprayers.html

APPENDIX
CANVAS

31

1. AEIOU CANVAS

2. EMPATHY CANVAS

32

3. IDEATION CANVAS

33

4. PRODUCT DEVELOPMENT CANVAS

34

PLAGIARISM REPORT

35

PATENT SEARCH ANALYSIS REPORT (PSAR)

36

PROJECT PROGRESS REVIEW (PPR)

37

38