CHAPTER ONE

INTRODUCTION

1.0 Background

Coconut (Cocos nucifera) is a very useful and essential perennial plant in

Nigeria and the world at large (Ohler and Magat, 2012). It belongs to the family
arecaceae. Philippines are the world largest producers of coconut. It is found in
the tropic and sub-tropic areas (Chan and Elevitch, 2006). Coconuts are large,
dry drupes, ovoid in shape, up to 381mm long and 305mm wide. The coconut is
smooth on the outside greenish or yellowish in colour. Within the outer shell is a
fibrous husk 25-50mm thick (Samuel and Stephen, 2015). The inner shell is
brown and hard, surrounding the white coconut meat. The coconut husks (which
are the rough exterior shells of the coconut) have to be removed for the usage of
coconut. The coconut is known for its great versatility as seen in many domestic,
commercial, and industrial uses of its different part. They are part of the daily diet
for many people. Coconuts are different from any other fruits because they
contain large quantity of water and when immature they are known as tender-
nuts or jelly-nuts and may be harvested for drinking. When they mature they still
contain some water and can be used as seed nuts or processed to obtain
coconut oil, charcoal from hard shell and coir from fibrous husk (Anon, 2011).

The husk is used for manufacturing variety of products such as nets,

ropes, mats and carpets (Foale, 2005). The coconut husk is made up of coir
which is light weight, elastic, strong and has high durability. Coir fibre can be
compared to waterproof because it cannot be damage by salt water and
microbial degradation. By virtue of these qualities, the husk is very stressful to
remove from the fresh fruit. Virtually every part of the coconut palm can be used
by humans in some manner and has significant economic value. Coconut
versatility is sometimes noted for its naming. In Sanskrit, it is Kalpa vriksha (the
tree which provides all the necessities of life); in the Philippines, the coconut his
commonly called ″the tree of life″ (Margolis, 2006). The use of cutlass for

1
coconut dehusking endangered the life of people involved, because during
dehusking process, some may end up cutting their hands, and face as the
cutlass bounces back on the hitting husk.

As a means of resolving the problem associated with manual dehusking,

Chandra (1987) developed a coconut dehusking machine that is made up of
three rollers in which one is in between the other two which rotate in opposite
direction with some in built spikes which perpetrates into the husk of the coconut
and a base structure which provides support for the rollers. The interaction of the
rollers in combination with the gripping action of the spikes causes tearing of the
husk from the nut. However, this invention still left us with nut breakage and
discharging problems. Apart from these problems, the machine can only dehusk
dry coconut which leads to additional cost as a result of the search for
appropriate drying methods for the fruit. During rainy season where over 95% of
the fruit is produced in our rural area, the farmers still use the manual methods of
dehusking by cutting with cutlass so as to avoid excess loss of the product.
Therefore, a need arises for a machine that can dehusk both fresh and dry
coconut without nut breakage.

1.1 Statement of Problem

The coconut dehusking machine designed and developed by

Nwankwojike et al (2012) reduced drudgery and accident that has to do with the
manual method of coconut dehusking by cutting and also eliminated the problem
of operation with electric power. The machine performs fairly better with dry fruits
which lead to more cost of drying in the process. Also, this machine has
discharging and gripping problems as the coconuts moves along the length of
the conveyor while being dehusked, therefore causing excessive nut breakage.
The operation of the existing coconut dehusking machine is also not smooth;
therefore, more power is needed to operate it. Hence, there is need to modify the
design so as to achieve a smooth operation of the machine and also to reduce
coconut breakage and power needed for its operations.

2
1.2 Objective and Scope of the Study
1. To redesign the existing coconut dehusking machine to reduce nut
breakage
2. To redesign the existing coconut dehusking machine that can be used by
rural dwellers
3. To evaluate the performance of the dehusking machine

1.3 Significance of Study

1. Modification of the existing coconut dehusking machine for both fresh and
dry fruits will help to reduce drudgery, cost of processing and also
enhances its efficiency.

2. The use of locally sourced materials in the modification and production, of

this machine makes it affordable to low-income earners of our rural
communities and equally enhances its maintainability.

1.4 Limitation

1. There will be a little percentage of problems associated with nut breakage

since machines are not always 100% efficient.
2. Non availability of some component parts of the machine like speed
reducer, plain shaft etc. in the area where this machine was fabricated
(Calabar).
3. Non availability of functional machines in the school workshop for turning
of shafts, cutting of key ways and milling of gears during the fabrication of
this machine.
4. Lack of finance for proper funding of this project.

3
 CHAPTER TWO

LITERATURE REVIEW

2.1 Coconut Production

Much is not known about the origin of coconut palm, probably because it
was so widely spread throughout the tropical areas of the world so many years
ago. It has been known to be native to the Malay Archipelago, the south pacific
and Tropical America (APCC, 1996). Coconut palm starts bearing fruits from the
period of three to six years after seed germination and reaches the period of
production at fifteen or twenty years. It continues to bear fruit until it is about
eighty year with yearly production of seventy to hundred fruits per tree. The fruit
is usually green or yellow in colour when it is not fully ripe and brown when
matured (Romney, 1997).

Coconut palm can tolerate blackish soil and salt spray (Foale, 2005).
However, salt is not required for healthy growth of plants and they can be
successfully grown inland. Coconut palm grows well on much type of soils
provided they are well drained with a wide pH range from 5.0 to 8.0. Coconut
palm requires a minimum temperature of 22.2 oC and annual rainfall of 980 to
1470mm or more, fairly evenly distributed throughout the year. The tress may be
injured by cold when the temperature falls below 0 oC. They require full sunlight,
and are tolerant to wind and flooding (Thampan, 1981). Commercially, the trees
are planted at spacing of 7.35 x 7.35m to 8.82 x 8.82m, resulting in about forty-
eight to seventy tress per acre (Foale, 2005).

An individual coconut fruit as shown in Figure 2.1 is made up of an outer

exocarp, a thick fibrous fruit coat known as husk; underneath lies the hard
protective endocarp and shell. The nut is 147 to 196mm in diameter and 245 to
294mm long. There are three holes of softer tissues called “eyes” found at one
end of the nut. Inside the shell is a thin, white, fleshy layer, about 12.25mm thick
known as “coconut meat”. Inside the nut is partially filled with a watery liquid
called “coconut milk”.

4
 Figure 2.1: Structure of a Coconut fruit

According to Tilledaratne (1995), there are more than hundred application

of coconut, the meat of immature coconut fruit can be eaten with a spoon or be
scooped out and made into ice cream, coconut milk is a refreshing and nutritious
drink. The meat of mature coconut fruit is firm and can be eaten fresh or may be
used for making shredded coconut. The most important economic product of this
fruit is obtained by drying the meat into copra and pressing it to extract the oil
which is primarily used in soap making. Coconut oil is also used for cooking and
making margarine. The meat is also a source of vegetable protein used as an
ingredient for livestock feed. The shell is used for fuel purpose as an alternative
source of heat energy. The husk yields fibres, which is converted into coir
products viz; coir carpets, coir geo-textile, coir composite, coir safety belts, coir
boards, coir asbestos and coir pith (Thampan,1996).

Although coconut is of immense economic importance to both the

industrialist and rural dwellers, dehusking of its fruit after harvesting constitutes
the most difficult and dangerous operation in its processing.

5
 The flow diagram of the various steps involved in coconut processing
shown in Figure 2.2 indicates dehusking as the first operation after harvesting.

Harvested coconut
fruit

Dehusking Coconut husk

De-shelling Coconut shell

Coconut meat

Grinding

Coconut cake

Pressing Coconut chaff

Coconut milk

Storage tank

Figure 2.2: Flow-chart of coconut fruit processing

According to Dinanath (1987), the problem of separating the outer shell

and husk of the fruit has been in existing for hundreds of years. APCC (1996),
states that this problem of dehusking of coconut fruit started right from the time
man planted coconut for stratification of his needs. There are two methods of
dehusking coconut fruits:

1. Traditional method
2. Mechanical method

6
2.2 Traditional Coconut Dekusking Method

The traditional method of dehusking coconut fall under two major variant
processes: Dehusking using matchet and dehusking using metal spike.

2.2.1 Manual Dehusking using Matchet

The very first process of extracting coconut meat involves splitting of the
harvested fruit into two or three parts using matchet without removing the husk
(Ohler, 1984). This method is very simple but concentrates only on the coconut
meat thereby wasting other coconut by- products such as water/milk, shell and
husk. However, this method poses a threat on human life as people cut their
fingers hand during the operation. Also, the technique shortens the actual length
of coir fibre extracts.

2.2.2 Manual Dehusking using Metal Spike

To tackle the irreversibility associated with the use of matched in

dehusking coconut, the use of metal spike was later developed (Thampan,
1996). In this process, a metal spike is secured on the ground in a slightly
slanting position with the point upwards. The nut is brought down with force on
the spike, followed by twisting the fruit against the spike thereby loosening the
husk. Although this process reduced the human injury, it also focuses on the
extraction of coconut meat only and consumes both time and energy. The
number of fruits one man can dehusk per day depends solely on the type of the
coconut and the thickness of its husk (Risseeuw, 1980). Care is usually taken
when the point of the spike enters the husk at the stalk end so as to avoid
damaging of the shell which leads to nut breakage.

2.3 Mechanical Coconut Dehusking Method

In 1984, a coconut dehusking machine with a dehusking capacity of 800

hybrid coconut fruits per hour was developed in Malaysia (Pau and San, 1986).
The major components of this machine are; a rotating table, plunger, a circular

7
saw, rotating cone and vertical knife. The machine is powered using a field
tractor. In this machine, the coconut with its stalk end facing down is manually
placed in the cavity of a rotating table after which the plunger pressing the
coconut down to the pre-set level. As the rotating advances, a circular saw slices
off pieces of the husk at the stalk end of the coconut before the fruit is pushed
into the dehusking section where vertical knife cut the husk into a vertical
section. Thereafter, the plunger in the dehusking feeds the fruits into a rotating
cone and where it is firmly gripped thereby, facilitating the tearing of the husk
from the nut as the cones rotates. Though, this machine saves time, energy and
also helps to recover all the coconut by-products, it cuts the husk into pieces and
at times break the coconut during dehusking process. In recent innovation on
fibre technology, it has been proved that the coir fibres can be used as effective
reinforcement and bonded in polyster matrix. In the studies on mechanical
performance and properties of fibre reinforced polymer composites, it was shown
that both fibre length and orientation distribution play a very vital role in
determining its mechanical properties. Consequently, dehusking of coconut with
the full length of the extracted husk maintained becomes necessary (Farad,
1989).

Dinanath (1987) developed a machine for removing the husk from the nut
of a coconut fruit in a manner that leaves the nut intact and ensures that the
husk is separated from the fruit without cutting into pieces. This machine
comprises of a base or frame positioned on a supporting surface, two rollers
(each having an elongated configuration and substantially parallel to one
another). The rollers are interconnected to the drive such that they rotate in
opposite directions relative to one another and in a preferred embodiment at
relatively different speeds. The rotation of the rollers is such that a coconut
placed on it will be forced into the space between the rollers. An important
feature of this innovation is the existence of a penetrating means on each roller
in the form of plurality of spikes. The spikes were arranged in a plurality of row
having an elongated curvilinear configuration extending at least along a major
portion of the roller’s length. The spikes are sharpened and spaced from one
another in a substantially whereby the patterned array in which the plurality of

8
spikes of each roller were positioned facilitate the penetrating, gripping and
tearing of the coconut husk. The husk once separated from the nut, passing
through the spacing between the rollers to the supporting surface/collecting tray.
This machine has discharging problem due to absence of conveyor. Also due to
the shape of the spikes used, there is high rate of nut breakage and cutting of
the husk in relative pieces even though it is aimed at producing a full-length
husk.

In addition the machines are not popular among the small scale coconut
producers due to the above deficiencies and high cost. Thus, separation of the
husk using matchet remained the common means of dehusking coconut fruits
among our rural dwellers in Nigeria despite the risk associated with this method.
Therefore, a coconut dehusking machine that will enable the extraction of the
coir fibre with its full length without any damage to the nut and also affordable by
our low income earners is required in this sector for effective processing of
coconut in our rural and urban communities (Nwankwojike et al., 2012).

2.4 Description of the Existing Coconut Dehusking Machine

The existing coconut dehusking machine shown in figure 2.3 consist of

the following major component; frame, dehuking unit, conveying unit, barrier
plates/clearer, handles and bearing housing.

9
Figure 2.4: Isometric View of the Existing Coconut Dehusking Machine

The frame is the main supporting structure upon which other components
of this machine were mounted. The frame is a welded structure from
50x50x5mm angle iron with dimension of 920mm length, 480mm, width and
400mm height. The dehusking unit comprises of two rollers with spikes, two spur
gears and shaft. The rollers with spikes were formed by welding metal bars of
5mm thickness on a mild steel pipe of 80mm diameter (Nwankwojike et al.,
2012).

Each of the roller shafts is a mild steel rod of 55mm diameter and 870mm
long supported at both ends by ball bearings. Two spur gears having 42 and 57
teeth each with addendum circle diameter of 188mm and 248mm respectively
were attached to the driving and driven rollers respectively. The conveying unit
consists of screw conveyor, shaft and pulley and belt system. The screw
conveyor was formed by welding a coil of 10mm diameter mild steel rod on a
mild steel pipe of 75mm diameter and 7.5mm thickness. The conveyor shaft is a
mild steel rod of 30mm diameter and 870mm long supported at both ends with
ball bearing. The conveyor shaft is driven by a v-belt pulley with diameter of
100mm which runs at the same speed with the low speed roller (57 teeth gear).
The barrier plates were constructed by cutting u-notches on one edges of a mild
steel plate of thickness 2mm. The barrier plates are fastened on the frame
adjacent to the rollers (Nwankwojike et al., 2012).

The machine requires one operator at a time. When the handle is wound,
the rollers with spikes rotate in opposite directions towards the centre causing
both the gripping and tearing of husk of coconut fruit placed in between the
rollers. While the rollers rotate, a screw conveyor mounted between them 70mm
below rotates in the same direction and speed as the driven roller with the help
of a pulley-belt system to ensure proper discharging of dehusked nut.

2.4.1 Faults in the Design of the Existing Coconut Dehusking Machine:

10
1. Equal and uniform length of spikes throughout the rollers: The spikes on
the existing coconut dehusking machine are of equal dimensions, thus
making it impossible to dehusk different sizes of coconut which results to
the breakage experienced while dehusking very large coconuts.
2. Sharp edges of spikes at the machine extreme point: The spikes
positioned towards the outlet of the machine are too sharp. Thus, if a
coconut that has already being dehusked gets to this point and there is a
contact of its shell with the sharp edge of the spikes, the spike pierces into
the coconut damaging it. In other words, the coconut cracks as soon as
the spikes get a direct contact with the coconut.
3. Coconut Breakage due to High Torque: The torque of the existing
machine is unsteady and cannot be controlled. Its torque is extremely
high and because of this, the impacts on coconut are also high. This high
torque makes it difficult for the coconut to be properly dehusked, and most
times the coconut jumps out of the dehusking track or the conveyor
system, and this continues as nothing is achieved.
4. Dehusking consumes excess energy due to the position of the machine
handle: The existing design has two gears of which one is a little bigger
than the other. The handle or manual turner of this machine is on the
smaller gear. This means the smaller gear is driving the bigger one
therefore causing excess energy input because the smaller gear was
supposed to be the driven while the bigger one is the driver. This handle
position at the driving gear (smaller gear) makes the turning very hard
because it has to turn more than twice before the driven gear (bigger
gear) can turn once.

Therefore, the existing coconut dehusking machine is associated with the

following problems:

1. It has very low efficiency.

2. It operates with very low productivity.
3. It is not easy to use and ergonomic.
4. It is not safe to use and not environmentally friendly.

11
5. It consumes a lot of human energy.

12
 CHAPTER THREE

MATERIALS AND METHODS

3.1 Description of the Modified Coconut Dehusking Machine

The modified coconut dehusking machine shown in Figure 3.1 below

consist of the following major components ; frame, speed reducer, modified
dehusking unit which has dimensioned spikes in ranging order, conveying unit,
discharge funnel, barrier plates or clearer, electric motor, belt and pulley, gears
and bearing housing.

Figure 3.1: The modified coconut dehusking machine.

The machine consists of the frame as the main supporting structure upon
which other components of this machine were mounted. The frame is a welded
structure constructed from 50x50x5mm angle iron with dimensions of 860mm
length, 605mm width and 400mm height. The dehusking unit consists of three
rollers with spikes, shafts and four spur gears. The driving and driven rollers are
mild steel pipe of 110mm diameter, 7.5mm thickness, 820mm and 635mm long
respectively. The spikes were formed by welding metal bars of 5.2mm thickness
on the rollers. The driving and driven roller shafts are mild steel rod of 40mm
diameter, 1400mm and 1000mm long respectively supported at both ends by
ball bearing. Four spur gears having 60 teeth, 56 teeth, 36 teeth and 36 teeth

13
with addendum circle diameter of 252mm, 247mm, 140mm, 140mm, and pitch
circle diameter of 190mm, 1I5mm, 80mm and 80mm respectively were
proportionally attached to the driving and driven rollers based on its function on
the machine. The conveying unit consists of screw conveyor and shaft. The
speed reducer shaft has a pulley attached to it, which is driven by a V- belt. The
screw conveyor was formed by welding a coil of 10mm diameter mild steel rod
and also 18mm on same as it ranges in ascending order. This 10mm diameter
and 18mm diameter coil were welded on a galvanized mild steel pipe of 90mm
diameter and 5mm thickness.

The conveyor shaft is driven by a speed reducer of 30:1 which runs at the
same speed with the idler gear (36 teeth and 36 teeth gear); the essence of the
idler gear is to achieve the desired direction of the driven gear (anti-clockwise
direction). The length of the conveyor shaft is 1000mm supported at both ends
with ball bearing while the conveyor pipe in between the rollers is 630mm long.
The barrier plates were constructed by cutting flat plate on one edge of a mild
steel plate of 4mm thickness. The barrier plates are fastened on the frame
before the rollers. The modified coconut dehusking machine requires the service
of one operator. When the motor is switch on with the aid of a direct online
starter, the rollers with spikes rotate in opposite directions towards the centre
causing both the gripping and tearing of husk of coconut fruit placed in between
the rollers. While the rollers rotate, a screw conveyor mounted between them
50mm below rotate in the same direction and speed as the driven roller with the
help of a speed reducer system to ensure proper discharging of dehusked nut.

3.2 Modification made in the existing Coconut Dehusking Machine.

3.2.1 Smoothening of the spike edges:

Smooth spikes edges when they come into contact with the coconut shell
will never break it but will tend to brush some of the husk. This smooth spike will
also help a lot when the coconut is closer to the discharge point (when it’s almost
dehusked). At the extreme of the machine the spikes will have a direct contact

14
with the coconut shell because all the husk are off and when in contact with the
shell it will only brush out the remaining strands of husk on the shell, and
because it has a smooth edge, it will never crack or break the coconut.

3.2.2 Change in gearing arrangement and incorporation of speed reducer:

The driving gear was transferred to the position of the driven gear. The
reason for this change is to ensure that the bigger gear drives the smaller gear.
This reduces the energy input and also enhances a smooth and fast dehusking
process since one turning of the bigger gear results to two turning of the smaller
gear thereby causing the movement of the rollers and conveyor where the
coconut is placed for dehusking very fast. To maintain a constant torque, a
speed reducer was introduced to balance the machine to a slow and steady
operation. Effective dehusking takes place at low torque, but at high torque the
coconuts breaks in the machine or may even run out of key way because of
unbalance speed. This speed reducer makes the torque of the machine to be
balance, and reduces the machine to the optimal torque needed for dehusking. It
also reduces the energy input to the machine and dehusking becomes easy
making the machine to be more efficient.

3.2.3 Increase in the length of the spikes towards the discharge chute:

The spikes of this modified machine are tapered to the discharge chute.
At every turning, the spike will increase in length. This is to enable the spikes
grab and grip the coconut husk on each turning until it gets to the shell. If there is
no change or increase in the spike size, the machine only dehusks at first turning
and remains in the same way due to equal spikes length. Due to this increase of
spike length, the coconut will progressively undergo dehusking on every turning
of the rollers and this produces positive result.

15
3.2.4 Incorporation of Electric motor: In order to solve the problem associated
with manual operation and to also increase efficiency, a standard single phase
one horse power (1-phase, 1hp) electric motor was chosen to drive this machine.
The power from the motor was transmitted using a V-belt with a mild steel pulley
attached to the speed reducer shaft.

These modifications will lead to the following advantage over the existing
one:

1. It will save time and energy

2. It will be more productive
3. It will be safe for operation
4. It will be more efficient
5. It will be human and environmentally friendly

3.3 Design Consideration

The existing coconut dehusking machine was modified based on the

following considerations:

1. The availability of materials locally to reduce cost of production and

maintenance of the machine.
2. The screw conveyor was placed in between the rollers for effective
twisting of the coconut fruit during dehusking and also for appropriate
discharging of dehusked nut.
3. Tapering of the roller by increasing the length of spikes along the roller
accounts for reduction in the size of the fruit to enable proper gripping as
tearing of the husk progresses across the length of the machine.
4. It is desired that there should be no husk on the nut, no nut breakage and
the removed husk should have its full length intact. Hence, the electric
motor, gears, pulley and speed reducer were carefully selected to meet
the required speed of the dehusking and conveying units to achieve this
objectives.

16
3.4 Design Analysis of the Modified Coconut Dehusking Machine

The shear yield strength of coconut fruit was determined as

101N/mm2using Equation 3.1 (Rajput, 2006).

τ yt = 0.577 σ yt………………………………………………………………( 3.1)

Where: τ ytis shear yield strength

σ yt is tensile yield strength = 175N/mm 2 for coconut fruit (Mohd et al.,

2007).

In order to gear a full-length husk, a rectangle-shaped spike was selected.

The area of spike that penetrates and as well shears the husk during dehusking
was computed as 27mm2 using the relation below (Khurmi and Gupta, 2005).

A = t2 …………………………………………………………………….(3.2)

Where: A is Cross sectional area of spike tip=?

t is thickness of the spike = 5mm

Substituting numerical values into equation 3.2 we have,
A = (5 x 5) mm2 = 25mm2
The tangential load acting on the spikes during dehusking process was
determined as 2730N using equation 3.3 (Rajput, 2006).
Ft = τ A ………………………………………………………………………(3.3)

Where: τ is shear stress of coconut coir fibre = 100.97N/mm 2

Ft is tangential load on the spikes=?

Substituting values into equation 3.3 we have,

Ft = 101N/mm2 x 25mm2 = 2730.23N

17
3.4.1 Determination of Power Required by the Machine

The pitch diameter of the driving gear and the required speed of the
driving roller are 190mm and 25rpm respectively. To determine the power
required for dehusking, the peripheral velocity of the driving gears was first
determined as 0.249m/s using equation 3.4 (Khurmi and Gupta, 2005).

V = π D1 N1/ 60…………………………………………………………..................(3.4)

Where: V is the peripheral velocity the driving roller shaft gear =?

D1 is the pitch diameter of the driving roller shaft gear = 190mm

N1isthe required speed of the driving roller shaft = 25rpm

Substituting values into equation 3.4 we have,

V= π x (190x10-3) x 25 / 60 = 0.249m/s

The power required for gripping and tearing of husk by the modified coconut
dehusking machine was determined as 679W (0.91hp) as shown below,

P=FxV

Where: F is force required to grip and tear the husk = 2730N

V is the peripheral velocity of the driving gear = 0.249m/s

P = 2730 x 0.249 = 679W

∴P = 679/746 = 0.91hp (∵1hp =746W)

Hence, a standard 1hp electric motor was chosen to drive the machine with a
service factor of 1.

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3.4.2: Selection of Pulley, Belt and Determination of Speed on the Driving
Roller Shaft

The machine requires one pulley which is mounted on the speed reducer.
Due to availability, cost and performance, a mild steel pulley with groove angle of
380was selected.

The following parameters are required to determine the speed and

diameter of the pulley on the speed reducer shaft:

Speed reduction gear required = 30:1

Speed of electric motor, Nm= 1400rpm

Diameter of pulley on the motor shaft, Dm = 40mm

Required speed of driving roller, N R = 25rpm

1

Since speed reduction gear required is 30:1, with an output of 25rpm, an

inlet speed of 30×25rpm =750rpm is required to drive the pulley on the speed
reducer shaft.

The pulley diameter to be attached to the speed reducer shaft was

determined as 75mm using equation 3.5 (Khurmi and Gupta, 2005).

NmDm = N SR DSR ………………………………………………………………. (3.5)

Where: DSR is diameter of the pulley on the speed reducer shaft =?

N SR is inlet speed of the pulley on the speed reducer shaft = 750rpm

Substituting values into equation 3.5 we have,

D SR = (1400 x 40) / 750 = 74.67mm

The speed ratio between the two pulleys was determined as 0.53 using equation
3.6 (Khurmi and Gupta, 2005).

19
 Dm
VR= ……………………………………………………………………………….
DSR
(3.6)

Where: VR is the speed ratio between the two pulleys.

The centre distance, C. between the two pulleys was computed as 212mm using
equation 3.7 (Sharma and Aggarwal, 2006)

D SR
C = 1.5 1 /3 ……………………………………………………….. ……..
VR
(3.7)

The peripheral velocity of the belt was determined as 2.95m/s using equation 3.8
(Khurmi and Gupta, 2005).

π DSR N SR
V= ………………………………………………………………………........
60
(3.8)

The pitch length of the belt was estimate as 1485mm using equation 3.9 (Khurmi
and Gupta, 2005)

π
L= ( D + Dm) + 2c +¿ ¿…………………………………………………. (3.9)
2 SR

Substituting values into equation 3.9,

π
L= (75 + 40) +2(212) +¿ ¿= 620mm
2

According to Indian standard pitch length of V-belt, a type A V-belt with a

standard pitch length of 645mm was selected due to the power to be transmitted
(Khurmi and Gupta, 2005).

Angle of contact for the smaller (driving) pulley (i.e. pulley on the motor shaft)
was estimated as 2.84 radian using equation 3.10

20
 π
θ = (180-2∝) rad ……………………………………………………………....
180
(3.10)

Whereθ is Angle of contact (lap)

DSR− D
∝= sin-1 m

2C

75−40
∝= sin-1( ) = 4.730
2 x 212

Substituting the value of ∝into equation 3.1,

π
θ = (180 – (2 x 4.73)) × rad = 2.98rad
180

Centrifugal tension on the belt was determined using equation 3.11 (Khurmi and
Gupta, 2006) as follows:

TC = MV2………………………………………………………………… (3.11)

Where: TC is centrifugal tension on belt

W
M is mass of belt =
g

V is the peripheral velocity of the belt= 2.95m/s

From dimensions of standard V- belts according to IS: 2494-1974 (Khurmi

and Gupta, 2006) for a belt transmitting less than 3.75KW.

W = 1.06 N/m, 2 β = 38; μ = 0.3

Where: W is weight per unit length of belt

2 β is groove angle of the pulleys

μis coefficient of friction between the belt and the pulleys

Substituting values into equation 3.11,

21
 TC =1.06 X ¿ ¿ = 0.94N

Tension in the tight and slack sides of the belt was determined using
equation 3.12 and 3.13 respectively (Khurmi and Gupta, 2005).

P = (T1 – T2) V …………………………………………………………..(3.12)

Where: P is Power transmitted by the belt

T1 is tension in the tight side of the belt

T2 is tension in the slack side of the belt

V is the peripheral velocity of the belt

P = T1 (1- T2/T1) V

T 1 μθ
Also, ¿e
T2

1
∴ P = T1 1 - μθ V
e

Substituting values into the above expression we have:

1
679 = T1 1 - 0.3 x 2.98
× 2.95
e

Hence, T1 = 389.5N

T 1−¿T 1
¿ = e μθCosec β ……………………………………………………….. (3.13)
T 2−¿T ¿C

T1 – T2 = T2e μθCosec β - TCe μθCosec β

T2 (e μθ Cosec β +1) = T1 + TCe μθ Cosec β

(T 1+ T C e μθ Cosec β )
T2 =
(1+ e μθCosec β )

Substituting values into the above expression we have:

22
 0
389.5+(0.94 x e ¿ ¿ 0.3 x 2.98 x cosec 1 7 )
T2 = 0.3 x2.98 x cosec1 70
¿
1+e

Hence, T2 =18.38 N

3.5.3 Design of shaft diameter of driving roller

Due to the presence of spur gear on the driving roller shaft, the tangential
load acting on the driving gear teeth was computed as 2727N using equation
3.14 (Khurmi and Gupta, 2005)

P
Ft= x Cs………………………………………………………………… (3.14)
V

Where: Ft is tangential load acting on the driving gear teeth =?

P is power transmitted by the driving roller shaft = 679W

V is the peripheral velocity of the driving gear =0.249m/s (equation 3.4)

Cs is the service factor = 1. Assuming steady load conditions and 8-10 hours of
service per day (khurmi and Gupta, 2005)

Substituting values into equation 3.14 we have:

679 x 1
Ft = = 2726.91N
0.249

The normal force FN, acting on the driving gear was computed as 2902N using
equation 3.15 (Khurmi and Gupta, 2005)

Ft
FN = ………………………………………………………………..…
cos ∅
(3.15)

Where: ϕ is pressure angle = 200 (Khurmi and Gupta, 2005)

The angle of inclination of F N to the horizontal, θ is 300. The directions and

magnitude of FN is clearly shown in Figure 3.1 below,

Driving roller shaft gear

23
FN

FN sin
Screw conveyor shaft gear
 Figure 3.1 Vertical effect of FN on the driving gear

Resolving FN vertically,

F N = FN Cos θ = 2902 Cos 300 = 2513N

V

Where F N indicate the actual value of the normal force.

V

The resultant effect of the weight of the driving gear on the driving roller shaft
, F N + Wg = 2528N.
V

Where: Wg is weight of driving gear = 15N

The reactions of the bearings and the weight of the pulley, speed reducer
and gear were analyzed across the length of the driving roller shaft as shown in
Figure 3.2. The weight of the shaft was also considered while analyzing the
forces acting across the shaft.

Due to these applied loads and the reaction of the bearings, bending
moments occurs on the driving roller shaft. Hence, the maximum bending
moment and the maximum twisting moment on the shaft were determined using
Figure 3.2 below.

WP + T1+T2= 209.41N 15N 2528N 54N

Bearing Bearing

A B C D E F

Pulley
50mm 50mm 495mm
495mm Driving roller shaft
24 RF
RD
Speed reducer
Gear
 Figure 3.2: The Driving Roller shaft showing the Applied Forces

Weight of speed reducer,w SR = 15N

Weight of pulley,w p =15N

Weight of roller, w R =¿15N

The reactions of bearing, RD and RF were determined by taking moment about D.

Where: RD and RF are the reactions of the ball bearing at point D and F

∑MD. = 0:

(209.41 × 150)+ (15×100) + (2528 ×50) + 990RF= 54× 495

159311.5 +990RF = 26730

RF= - 134N

Summing vertical forces, ∑ F Y = 0:

RD + RF = 209. 41 +15+2528 +54

RD= 2940N

Taking downward forces to be negative (-) and upward forces positive (+), the
shear forces acting on the driving roller shaft were computed as follows:

SFA-B= - 209.41N

SFB-C= 209.41-15= - 224.41N

SFC-D= - 224.41-2528= - 2752.41N

25
 SFD-E= - 2752.41 +2940 = 188N

SFE-F= 188 -54= 134N

SFF= 134-134 = 0

The bending moments on this shaft was computed as follows:

BM A = BM F= 0

BM B= 209.41×50= 10471Nmm

BM C = (209.41×100) + (15×50)= 21691Nmm

BM D= (209.41209.41N 15N 2528N

×150) + (15×100) + (2528×50) = 159312Nmm
54N

BM E= (209.41×645) + (15×595) + (2531×545) - (2943.48 × 495) = 66367Nmm

A B C D E F

50mm50mm 50mm 495mm 495mm

188N
134N

+ +
- -
SF
-
--

209.41N
224.41

2752.41N

BM

BM
BM
BM +

BM

26
Figure 3.3: The bending moment and Shear force diagram of driving roller
shaft

Therefore, the maximum bending moment, M b on the driving roller shaft is

at point D with magnitude of 159312Nmm.

The twisting moment on this shaft at point A and C were computed as

19601. 12Nmm and 240445Nmm using equation 3.16 (Khurmi and Gupta, 2005)
as expressed below:

DSR
T = (T1-T2) × ………………………………………………………….…
2
3.16

Twisting moment at point A,

DSR
M T = (T1-T2) ×
A
2
224
= (184.71-9.70) ×
2
= 19601.12Nmm
Twisting moment at point C,
M T = 2531 × 190 = 240445Nmm
C

Hence, the maximum twisting moment on the driving roller shaft M t, is

240445Nmm.
Since the dehusking of coconut fruit by the driving roller is gradual and steady
hence, Kb = 1.5, and Kt = 1.0 (Khurmi and Gupta, 2005)
Where: Kb is combined shock and fatigue for bending.
Kt is combined shock and fatigue for twisting.
The diameter of the driving roller shaft was determined as 35mm using
equation 3.17 (Khurmi and Gupta, 2005).

16
d= (K M ) 2+ (KtMt)2 ⅓………………………………………………….. (3.17)
πτ b b
Where τ = maximum allowable shear stress for shaft material with allowance for
Keyways. The value of τ = 42N/mm2 for steel shaft (Khurmi and Gupta, 2005).

27
3.4.4 Design of shaft diameter of driven roller
The weight and pitch circle diameter of the driven gear are 12N and
115mm respectively. The speed of the driven gear was determined using
Equation 3.18 (Khurmi and Gupta, 2005).
N1T1 = N2T2= N3 T3 = N4 T4………………………………………………………(3.18)
Where: N1= 25rpm and N4 =? are speeds of the driving and driven roller shaft
gears
T1= 60and T4= 56 are number of teeth on the driving and driven gears
N2 is speed of the conveyor shaft gear =?
N3 is speed of the Idler gear =?
T2 = T3= 36 are the number of teeth on the conveyor shaft gear and the idler
gear
From Equation (3.18),
N 1 T 1 25× 60
N2 = = = 41.67 ≈ 42rpm
T2 36
Since T2 = T3
∴N2 = N3 = 42rpm
Similarly,
N 3 T 3 42 ×36
N4 = = = 27rpm
T4 56
The tangential, the normal, and the resultant loads acting on the driven roller
shaft gear were computed using Equations 3.14 and 3.15 as follows:
From Equation 3.14,
679
Tangential load, Ft = x1
V
But V = π D4N4/ 60
Where: V is the peripheral velocity of the driven roller shaft gear =?
D4 is the pitch diameter of the driven roller shaft gear = 115mm
N4 is the speed of the driven roller shaft gear = 27rpm
∴ V = π x (115 x 10-3) x 27/ 60 = 0.163m/s
Substituting the value of V into the above expression we have,
679
Ft = x 1= 4166N
0.163

28
From Equation 3.15:
4166
Normal load, FN = 0 = 4433N
cos 20
The resultant load acting on the driven roller shaft gear = F N + Wg (Wg is the
weight of the driven roller shaft gear = 12N)
Hence the resultant load acting on this gear, F = 4433 + 12= 4445N
The maximum bending moment on the shaft was determined with the aid of
Figure 3.4 as shown below.

4445N 54N

A B C D

50mm 494mm 494mm

988mm

Figure 3.4: The Driven Roller Shaft showing the Applied Forces.
The reactions of bearings, R B and R D were determined by taking moment
v H

about B.
Where: R B and R D represent the vertical and horizontal reactions of the ball
v H

bearing on the driven roller shaft.

∑ M B 0:
¿

4445 x 50 + 988 R D =54 ×494

H

222250 + 988 R D = 26676

H

R D = - 197.95N
H

Summing vertical forces,

R B + R D = 4445+ 54
v H

29
R B = 4696.95N
v

Taking downward forces to be negative (-) and upward forces positive (+), the
shear force acting on this shaft were computed as follows:

SFA-B = - 4445N

SFB-C = - 4445 + 4696.95 =251 .95N

SFC-D = 251.95 -54 = 197.95N

SFD = 197.95 – 197.95 = 0

Thus, the bending moments on this shaft are as follows:

BMA =BMD=0

BMB = 4445×50 =222250Nmm

BMc =4445 × 544 - 4696.95× 494=97786.7Nmm

BMD = 0

Therefore, the maximum bending moment on the driving roller shaft is

222250Nmm. The twisting moment M t, on this shaft was computed as
145532.5Nmm using Equation 3.16.

The dehusking of coconut fruit by the driven roller is gradual and steady hence,
Kb = 1.5 and Kt = 1.0 (Khurmi and Gupta, 2005).

The diameter of this shaft can be determined using Equation 3.17. Thus, a
standard 35mm diameter solid mild steel shaft was selected as the driven roller
shaft.

3.4.5 Design of Shaft Diameter of Screw Conveyor

Due to the presence of spur gear on the conveyor shaft, the tangential
force and the normal force acting on the gear were computed as 385.95N and

30
410.72N respectively (i.e. if the same power is to be transmitted) using Equation
3.14 and 3.15 as shown in Figure 3.5.

300

Wg
Figure 3.5: Screw conveyor shaft gear showing vertical and horizontal
loading

Where: A and B are the driving roller shaft and screw conveyor shaft gears

C is the idler gear

F N is the normal load acting on the driving roller shaft gear

1

F N is the normal load acting on the screw conveyor shaft gear and,
2

Wg is weight of the screw conveyor shaft gear = 5.5N

990mm
RB RD

Figure 3.6: The Screw Conveyor Shaft Showing Forces Acting on it

31
Where: F B is force acting on conveyor gear due to vertical loading
v

WC is the weight of the conveyor shaft = 45N

F B = F N sin 300 + Wg (∵ Wg is weight of the conveyor shaft gear = 5.5N)
v 1

F B = 2905.3 sin 300 + 5.5 = 1458.15N

v

The reacting of bearings RB and RD were determined by taking moment about B

∑ M B 0; ¿

1458.15×50 990 RD = 45 × 495

RD= - 51.14N
Summing Vertical forces,
RB + RD = - 1458.15+ 45
RB = 1554. 29N

Twisting moment for vertical loading,

80
TM = 1458.15 × = 58328N-mm
V
2

Where 80 is pitch diameter of conveyor gear.

Bending moment for vertical loading was computed as follows:

BMA = BMD = 0

BMB = 1458.15× 50 = 72910N-mm

BMC = 1458. 15 × 545 - 1554.29 × 495= 25318.2N-mm

= 2105.25 45N
=1458.15N

AA BB CC DD

50mm 50mm
495mm4495mm 495mm
990mm495mm
RB RD WC

32
Figure 3.7: Force acting on the screw conveyor shaft by virtue of
Horizontal loading

From Figure 3.7,

F B = F N Cos 300- 410.72

H 1

= 2905.5 Cos 300-410.72

= 2105.52N

∑ M B 0;
¿

2105.52 + 990 RD = 0

RD = - 106.34N

Summing horizontal forces,

RB + RD = 2105.52

RB = 2211.86N

Twisting moment at A (by virtue of horizontal loading),

80
T M = 2105.52 x = 84221Nmm
H
2

Bending Moment for Horizontal loading, BMH was computed as follows:

B.M at A = B.M at D = 0

B.M at B = 2105.52 × 50 = 105276N-mm

Resultant Bending moment on the screw conveyor shaft = √ 1052762 +729102

= 128058.21N-mm

Resultant twisting moment on the screw conveyor shaft =√ 583282 +842212

33
 = 102443.88N-mm

The conveying of coconut fruit by the screw conveyor is gradual and steady,
hence, Kb = 1.5 and Kt = 1.0 (Khurmi and Gupta, 2005).

The diameter of this conveyor shaft can be determined using Equation

3.17. Thus, a standard 30mm diameter solid mild steel shaft was selected for the
screw conveyor shaft.

3.5 Performance Testing Procedure

In order to actualize the aims of this project the dehusking capacity and
efficiency of the modified coconut dehusking machine will be evaluated using
twenty experimental runs. Number of dehusked nuts, N T during the tests with
their respective dehusking time t, will be recorded. The number of nuts that will
be dehusked with full-length of fibre W gf , together with number of dehusked nut
with distorted fibre Wt, will also be recorded. The dehusking time will be
measured using a stop-watch. Thereafter, the efficiency, and capacity C of the
machine will be computed in each case using the following relations:

W gf
η (%) = × 100 ……………………………………………………………… (3.19)
NT

NT
C (nuts/hr) = ……………………………………………………………….….(3.20)
t

34
 CHAPTER FOUR
RESULT AND DISCUSSION

4.1 Experimental Result

The result of the performance testing of the modified coconut dehusking

machine is shown in Table 4.1.

Table 4.1: Performance Testing Result

S/N No. of No. of No. of No. of Time, t Efficiency, Capacity,

coconut broken nuts dehuske (seconds) η (%) C
dehusked, nuts dehusked d nut (nuts/hr)
NT with full with
length of distorted
fibre, Wgf fibre, Wt
1 31 0 30 1 1140.00 96.77 98
2 30 0 29 1 1100.11 96.67 98
3 32 0 31 1 1111.00 96.88 104
4 32 0 31 1 1121.01 96.88 103
5 31 0 29 2 1121.23 93.55 99
6 32 0 29 3 1154.33 90.63 99
7 30 0 29 1 1129.88 96.67 95
8 31 0 30 1 1131.33 96.77 98
9 32 0 30 2 1150.22 93.75 100
10 32 0 29 3 1149.04 90.63 100
11 31 0 30 1 1131.22 96.77 98
12 30 0 29 1 1130.99 96.67 95
13 31 0 30 1 1140.02 96.77 97
14 30 0 29 1 1131.33 96.67 95
15 32 0 30 1 1144.69 93.75 100
16 32 0 29 3 1160.01 90.63 99
17 30 0 29 1 1130.55 96.67 95
18 32 0 30 2 1139.22 93.75 101
19 31 0 30 1 1121.33 96.77 99
20 32 0 29 3 1160.00 90.63 99
Average 95.91 98

It is observed from this table that the dehusking capacity of the modified machine
is 98 coconuts per hour while its efficiency is 95.91%

35
 4.2 Cost Analysis of the Modified Coconut Dehusking Machine

The material used for the fabrication of the machine were quantified and
the estimated cost of labour involved in the fabrication and other logistics were
summarized and presented as shown in Table 4.2.

Table 4.2: Cost Estimation of the Modified CoconutDehusking Machine

S/N Description Quantity Unit price Amount
used (N) (N)
1 Mild steel Angle Iron (50x50x5mm) 1 length (18ft) 3,400.00 3,400.00
2 Mild steel Flat bar (50x5mm) 1 length 2,000.00 2,000.00
3 Mild steel pipe (ϕ 110mm with 0.364 length 5,000.00 5,000.00
7.5mm thickness). (6.56ft)
4 Mild steel Galvanized pipe (ϕ 90mm 0.182 length 1,000.00 1,000.00
with 5mm thickness). (3.2ft)
5 Mild steel shaft (ϕ 40mm) 1length 15,000.00 15,000.00
6 Mild steel rod (12mm) 0.5 length 1,000.00 1,000.00
7 Metal sheet (Guage 16 plate) 0.5 length 2,000.00 2,000.00
8 Speed Reducer (20:1) 1 30,000.00
9 4 spur gears (60, 56, 36, and 36 1 each 5,000.00 20,000.00
teeth respectively).
10 Radial ball bearing (ϕ 35mm 6 1,500.00 9,000.00
internal)
11 Nuts and bolts (19mm) 18 70.00 1,260.00
12 Welding electrode (Guage 12) 100 sticks 15 1,500.00
(1 packet)
13 Pulley (ϕ 75mm) 1 1,000.00
14 Electric motor (1- phase, 1hp) 1 10,000.00
15 V- belt (A25) 1 1,000.00
16 Oil paint (Green colour) 2 litres 300.00 600.00
17 Labour LS 10,000.00 10,000.00
Total 113,760.00

36
 4.3 Discussion of Result

Although the cost of production of the modified coconut dehusking machine is

higher than the cost of production of the existing machine by N33, 160.00 (the
price of the existing machine is N 80, 600.00 and the price of the modified
machine is N113, 760.00).

The efficiency has increased from 92.70% to 95.91%, thus justifying the
increase in price. The operation of the machine is now easy and smooth and
requires very small human effort. Hence, the introduced modification reduced
drudgery.

37
 CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion
The design of an existing coconut dehusking machine for rural farmers
was modified, developed and tested in Cross River University of Technology,
Calabar. The performance evaluation shows that there is no nut breakage and
there is increase in efficiency from 92.70% to 95.91% and capacity from 79 to 98
coconuts per hour. Although the price of the modified coconut dehusking
machine is higher than the existing one but the efficiency of the modified
machine is higher than the existing one.
In addition, because of the introduction of electric motor, speed reducer, four
gear systems, increased spike size in ascending order, discharge funnel and
rectangular spikes, the smooth operation of the machine has been facilitated
thereby reducing drudgery and coconut breakage associated with the old design.

5.2 Recommendation
Deriving from the conclusions, it is recommended that:
 Small scale coconut processors should adopt and maintain the modified
coconut dehusking machine for dehusking coconuts.
 The modified coconut dehusking machine should be redesign in a tabular
form to further ease the operation of the machine.
 The shafts, gears and speed reducer should be properly aligned to
enhance a smooth running of the machine in order to achieve the
maximum torque required for dehusking.
 Government and other agencies should grant credit to small and medium
scale coconut processors to enable them adopt the use of this machine
as this will go a long way in achieving vision 20:2020 of the Federal
Government in the areas of employment and raw materials utilization.

38
 REFERENCES

(APCC) (1996) Coconut Food process-Coconut processing Technology

information document. In: Arancon, Jr., R. N, (ed.) Jakarta, Indonesia:
Asian and Pacific Coconut Community.

Anon. (2011), Coconut, www.wikipedia.com, Accessed: June 22, 2015.

Chan, E. and Elevitch, C. R. (2006), Specific Profile for Pacific Island

Agroforestry, www.traditionaltree.org, Accessed: June 23, 2015.

Dinanath, (1987) Coconut Dehusking Machine. Caribean Industrial Research

Institute (CARIRI) US4708056.

Farad, M. M. (1989) Selection of Materials for Engineering Design. Prentice hall:

New York.

Foale, M. A. (2005 The coconut palm. In: Chopra, V. L. and Peter K. V. (eds.).
Handbook of Industrial Crops. New York: Haworth press.

Khurmi, R. S. and Gupta, J. K. (2005). A Textbook of Machine Design (S. I.

Units).14th ed. Ram Nagar, New Delhi-110053: Eurasia Publishing House
(PVT) Ltd, pp. 525-1045.

Margolis, J. (2006), Coconut Fuel, www.wikipidia.com, Accessed: June 23,

2015.

Nwankwojike, B. N. et al., (2012). International Journal of Innovative Technology

& Creative Engineering (ISSN: 2045-8711) VOL. 2 No.3, March 2012.

Ohler, J. G. (1984). Coconut, Tree of Life. FAO. Plant Production and Protection.
Rome, Italy pp. 57.

Pau, T. Y. and San, T. T. (1986). UPB’s Coconut Dehusking Machine. Chew, P.

S., and Pushparajah, E. (eds.), Cocoa and Coconuts, progress and
outlook. Incorporated Society of Planters, Kuala Lumpur: Malaysia pp.
911-916.

Rajput, R. K. (2006). Strength of Materials.6 th ed. Ram Nagar, New Delhi: S.

Chand & Company Ltd, p.304.

39
Risseeuw C. (1980).The wrong end of the rope. Women coir workers in Sri
Lanka. Research Project Women and Development. University of Leiden:
Netherlands, p.253.

Romney, D. H. (1997). Growing Coconuts in South Florida. Self-published,

Redland: Florida.

Sharma, P. C. and Aggarwal, D. K. (2006). Machine Design.3 rd ed. Nai Sarak

Dechi: S. K. Kataria & Sons, Katra books @yahoo.com. p. 657.

Thampan, P. K. (1981), Handbook on Coconut Palm. Oxford & IBH Publishing

Co. (PVT), New Delhi, pp 311.

Thampan, P. K. (1996). Processing of Coconut Products in India. Jakarta,

Indonesia: Asian and Pacific Coconut Community.

Tilledaratne, H.A. (1995) Processing of Coconut Products in Sri Lanka. Jakarta,

Indonesia: Asian and Pacific Coconut Community.

40
 A

SERMINAR WORK

ON

DESIGN AND FABRICATION OF COCONUT DEHUSKING

MACHINE

PRESENTED BY

EKPO, EMMANUEL OWOGOGA - 09/MEN/028

ETIM, BASSEY BASSEY -
09/MEN/034
IBAH, NDANYONGMONG CHARLES - 09/MEN/040

SUPPERVISED BY

ENGR. F. A. OVAT

SUBMITTED TO

DEPARTMENT OF MECHANICAL ENGINEERING

FACULTY OF ENGINEERING
CROSS RIVER UNIVERSITY OF TECHNOLOGY (CRUTECH),
CALABAR

41
IN PARTIAL FULFILMENT OF THE COURSE REQUIREMENT
(MEC 5110) FOR THE AWARD OF BACHELOR OF
ENGINEERING (B.ENG) IN MECHANICAL ENGINEERING
AUGUST, 2014.

42
 CERTIFICATION

The project Redesign and Fabrication of Coconut Dehusking Machine

carried out by: Emmanuel Owogoga Ekpo, Bassey Bassey Etim, and
Ndanyongmong Charles Ibah with registration numbers: 09/MEN/028,
09/MEN/034 and 09/MEN/040 meets the regulation governing the award of the
degree of bachelor of Engineering (B.ENG) of the Cross River University of
Technology, Calabar and it is read and approved by the undersigned.

Engr. Dr. F. A. OVAT

________________________

(SUPERVISOR) Signature

________________________
Date

Engr. Dr. F. A. OVAT ________________________

Head of Department Signature

________________________

Date

External Examiner ________________________

Signature

________________________
Date

DEDICATION

43
 This project is dedicated to our heavenly Father and spiritual mentor for
guiding and protecting us throughout the duration of this research and also to our
parents, family members and friends for their immeasurable supports.

44
 ACKNOWLEDGEMENT

We would like to take this ample opportunity to express our profound

gratitude and deep regards to our supervisor Engr. Dr. Friday A. Ovat for his
guidance, critical criticisms and constant motivation throughout the course of this
project. The corrections, inputs and observations provided by him time to time
shall carry us a long way in the journey of life on which we are about to embark.

We also wish to express a deep sense of gratitude to Mr. Ekoro N. Ekoro; a

patience and humble technician, who invested his precious time in ensuring that
our design is properly fabricated.

We are obliged to all the technical and teaching staffs of the department of
mechanical engineering for the valuable information and supports provided by
them in their respective areas of specialization.

Finally, we thank our parents for their financial and moral supports, our
brothers, sisters, colleagues and well-wishers for their constant encouragement
without which this assignment would not be possible.

45
 ABSTRACT

Generally, coconuts are dehusked manually using machets and metal

spikes. These methods require skilled labour and are laborious to use. Attempts
made so far in the development of dehusking tools have only been partially
successfully and not effective in replacing manual methods. The reasons stated
for the failure of these tools include unsatisfactory and incomplete dehusking,
breakage of coconut shell while dehusking, distortion of the extracted fibre
length, greater effort needed than manual methods etc. Consequently, a coconut
dehusking machine which comprises of main parts like frame, electric motor (1-
phase, 1hp), pulley, speed reduction unit, four spur gears, two rollers with spikes
and screw conveyor was developed for small scale production in the rural and
urban areas. Performance test analysis conducted shows that the machine
dehusks coconut fruits without nut breakage and distortion of the extracted fibre
length and also that its average dehusking efficiency and capacity is 95.91% and
98 coconuts per hour. All materials used in the fabrication of this machine are of
standard specifications and locally sourced. The estimated cost of producing one
unit of the machine is one hundred and thirteen thousand, seven hundred and
sixty naira (₦113,760.00).

46
 TABLE OF CONTENT

Certification -- -- -- -- -- -- -- --

Dedication -- -- -- -- -- -- -- -- --

Acknowledgement -- -- -- -- -- -- -- --

Abstract -- -- -- -- -- -- -- -- -- --

Table of contents -- -- -- -- -- -- -- -- --

List of Tables -- -- -- -- -- -- -- -- --

List of Figures -- -- -- -- -- -- -- -- --

CHAPTER ONE: INTRODUCTION

1.0 Background -- -- -- -- -- -- -- --

1.1 Statement of Problem -- -- -- -- -- -- --

1.2 Objective and Scope of the Study -- -- -- -- --

1.3 Significance of Study -- -- -- -- -- -- --

1.4 Limitation -- -- -- -- -- -- -- -- --

CHAPTER TWO: LITERATURE REVIEW

2.1 Coconut Production -- -- -- -- -- -- --

2.2 Traditional Coconut Dekusking Method -- -- -- --

2.2.1 Manual Dehusking using Matchet -- -- -- -- --

2.2.2 Manual Dehusking using Metal Spike -- -- -- -- --

2.3 Mechanical Coconut Dehusking Method -- -- -- --

47
2.4 Description of the Existing Coconut Dehusking Machine --

2.4.1 Faults in the Design of the Existing

Coconut Dehusking Machine -- -- -- -- -- --

CHAPTER THREE: MATERIALS AND METHODS

3.1 Description of the Modified Coconut Dehusking Machine --

3.2 Modification made in the existing

Coconut Dehusking Machine -- -- -- -- -- --

3.2.1 Smoothening of the spike edges:

3.2.2 Change in gearing arrangement and

incorporation of speed reducer -- -- -- -- -- --

3.2.3 Increase in the length of the spikes

towards the discharge chute -- -- -- -- -- --

3.2.4 Incorporation of Electric motor -- -- -- -- -- --

3.3 Design Consideration

3.4 Design Analysis of the Modified Coconut

Dehusking Machine -- -- -- -- -- -- --

3.4.1 Determination of Power Required by the Machine -- -- --

3.4.2: Selection of Pulley, Belt and Determination of

Speed on the Driving Roller Shaft -- -- -- -- --

3.4.3 Design of Shaft Diameter of Driving Roller -- -- -- --

3.4.5 Design of Shaft Diameter of Screw Conveyor -- -- -- --

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3.5 Performance Testing Procedure -- -- -- -- --

CHAPTER FOUR: RESULT AND DISCUSSION

4.1 Experimental Result -- -- -- -- -- -- --

4.2 Cost Analysis of the Modified Coconut Dehusking Machine --

4.3 Discussion of Result -- -- -- -- -- -- --

CHAPTER FIVE: CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion -- -- -- -- -- -- -- -- --
5.2 Recommendation -- -- -- -- -- -- -- --
References -- -- -- -- -- -- -- --

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 LIST OF TABLES

Table 4.1: Performance Testing Result -- -- -- -- --

Table 4.2: Cost Estimation of the Modified Coconut

Dehusking Machine -- -- -- -- -- --

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 LIST OF FIGURES

Figure 2.1: Structure of a Coconut fruit -- -- -- -- --

Figure 2.2: Flow-chart of coconut fruit processing -- -- -- --

Figure 2.4: Isometric View of the Existing Coconut

Dehusking Machine -- -- -- -- -- --

Figure 3.1: The modified coconut dehusking machine. -- --

Figure 3.1 Vertical effect of FN on the driving gear -- -- --

Figure 3.2: The Driving Roller shaft showing the Applied Forces --

Figure 3.3: The bending moment and Shear force

diagram of driving roller shaft -- -- -- -- --

Figure 3.4: The Driven Roller Shaft showing the Applied Forces. --

Figure 3.5: Screw conveyor shaft gear showing

vertical and horizontal loading -- -- -- -- --

Figure 3.6: The Screw Conveyor Shaft Showing Forces

Acting on it -- -- -- -- -- -- -- --

Figure 3.7: Force acting on the screw conveyor shaft by

virtue of Horizontal loading -- -- -- -- --

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 LIST OF TABLES

Table 4.1: Performance Testing Result -- -- -- -- --

Table 4.2: Cost Estimation of the Modified Coconut

Dehusking Machine -- -- -- -- -- --

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