DESIGN, FABRICATION AND TESTING OF MELON SHELLING MACHINE

BY

OLUYORI, BLESSING ODUNAYO

HND/21/ABE/FT/196

SUBMITTED TO

THE DEPARTMENT OF AGRICULTURAL AND BIO- ENVIRONMENTAL

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF

AUGUST, 2023

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 CHAPTER THREE

MATERIALS AND METHODS

3.1 Description of the Machine

The melon shelling machine (Plate 3.1) is a remarkable innovation designed to efficiently

shell melons, providing a streamlined solution for agricultural processing. This ingenious device

is composed of a series of meticulously engineered components, such as: main frame, a user-

friendly hopper, an efficient shelling drum, a sturdy shaft, a cleansing blower, and purposeful

outlets each contributing to its functionality and effectiveness. By harnessing the power of a

gasoline prime mover, this machine transforms the laborious process of melon shelling into a

seamless and automated operation. At the heart of this machine lies the main frame, a robust

structure constructed from 45 X 45 X 5 mm mild steel 'L' iron. Serving as the foundation for all

other parts, this main frame ensures stability and durability. Its dimensions of 400mm in length,

390mm in breadth, and 820mm in height exemplify a balanced design that accommodates the

various components harmoniously.

The hopper, a pivotal element of the melon shelling process, is thoughtfully integrated

into the machine. Crafted from mild steel sheet, the hopper showcases a square-based frustum

shape. This design enables easy loading of melons into the machine, facilitating the seamless

flow of the shelling process. With a base diameter of 200mm and a vertical height of 190mm, the

hopper efficiently directs melons into the machine for processing. Central to the shelling process

is the shelling drum, meticulously engineered for optimal efficiency. The shelling drum,

constructed from mild steel sheet, employs a rotary drum with strategically positioned fins. This

configuration, enclosed within a stationary drum, maximizes the shelling effectiveness. The

shelling drum boasts a diameter of 290mm and a width of 390mm, ensuring that melons are

subjected to thorough shelling.

motion. Fabricated from a 25mm diameter mild steel shaft, the 450mm long shaft efficiently

drives the rotary drum with fins. Pillow bearings secure the shaft at both ends, providing stability

and facilitating smooth rotation. The inclusion of a centrifugal blower in the machine showcases

a commitment to meticulous design and efficiency. This blower, with a diameter of 290mm,

effectively removes dirt and debris from the shelled melon kernels. The blower's suction

mechanism efficiently cleans the kernels and channels the waste material through the chaff

outlet, streamlining the post-shelling process.

To ensure effective output, the machine incorporates a kernel outlet and a chaff outlet, both

crafted from mild steel sheet. These outlets facilitate the separation of melon kernels from

unwanted materials, ultimately enhancing the quality of the shelling process.

The machine's power source, a gasoline prime mover, is an ingenious inclusion that elevates its

capabilities. By harnessing the energy of this prime mover, the machine operates with impressive

efficiency, effectively automating the melon shelling process and reducing the need for manual

labor.

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 Plate 3.1: The Melon Shelling Machine

3.2 Design Consideration

The design of the melon shelling machine takes into account a range of important

considerations to ensure its efficiency, usability, and suitability for its intended purpose. The

following factors have been meticulously addressed to create a well-rounded and effective

machine:

i. Engineering Properties of Melons: The machine's design is tailored to the engineering

properties of melons, recognizing their size, shape, and toughness. The shelling drum's

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dimensions and fin arrangement are optimized to efficiently shell various types of melons, while

the hopper's frustum shape accommodates easy loading and flow of melons into the machine.

The machine's rotational speed and blade configuration are carefully selected to strike a balance

between effective shelling and minimizing damage to the melon kernels.

ii. Ergonomics of the Machine: Ergonomics plays a crucial role in the machine's design to

enhance user comfort and operational efficiency. The height of the machine is designed

to facilitate comfortable loading and unloading of melons.

iii. Gender Friendliness: The machine's design takes into consideration the diverse

workforce that may operate it. The machine's components are designed for easy

maintenance and servicing, promoting inclusivity and enabling operators of all genders

to efficiently operate and maintain the equipment.

iv. Small Scale Operation: Recognizing the target audience of small-scale farmers and

processors, the machine is designed to be compact and easily transportable. Its compact

footprint allows it to be used in limited spaces, making it suitable for small farms or

processing facilities with space constraints.

v. Durability: The machine's longevity is a key consideration, ensuring it withstands the

demands of continuous operation in agricultural settings. High-quality materials, such as

mild steel, are used for critical components like the main frame, hopper, and shelling

drum, enhancing the machine's resistance to wear, tear, and corrosion.

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3.3 Design Calculations and Analysis

3.3.1 Design for the Hopper

The hopper was designed based on the flowability of the melon seeds. The hopper was

designed to tilt 100 more than the angle of repose of the melon seed as recommended for hopper

design. The angle of repose of melon seed was given as 40°. The hopper was also designed to

ensure easy feeding by the operator and such that it does not obstructs any other part of the

machine during operation. The shape of a right triangular prism was then chosen.

Determination of Hopper Dimensions

To determine the hopper dimensions, a hopper of 1kg capacity was proposed to be designed for.

Bulk density of melon seed: 307kg/m3

massofmelon seed
Volume of melon seed , V = 3.1
bulk density of melon seed

Mass of melon seed, M =1 kg

1 −3 3
V= =3.25 × 10 m
307

1
Volume of ¿ triangular prism= a × b ×h 3.2
2

Where;

a: opposite side of the triangle

b: adjacent side of the triangle

h: length of the prism

c: hypotenuse side of the hopper

let b be the unknown, assume a, h to be 0.1m and 0.3m respectively

−3 1
3.25 ×10 = ×0.1 ×b × 0.3
2

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 −3
3.6 ×10 =0.03 b
−3
6.5× 10
b=
0.03

b=0.22 m

Therefore, the following dimensions were selected for the hopper: a, b, c, h are: 0.10m, 0.22m,

0.16m, 0.30m respectively.

3.3.2 Design for the Shaft

The design of the shaft is very important, as it is a component that is coupled with the

shelling drum for transmission of power. The diameter of the shaft was determined from

Equation given by Khurmi and Gupta (2008).

π 3
T= × τ ×d 3.3
16

2 πNT
P=
60

Where:

d = is the diameter of the shaft (m)

T= is the twisting moment (or torque) acting upon the shaft

τ = is the maximum bending moment, which is 42 MPa

P = Shelling power (N)

N= selected speed of the roller (rpm) 3.4

P × 60
T=
2 πN

1256 ×60
T=
2× 3.14 ×250

T = 48 Nm or 48 × 103 N/mm

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 3 3.14 3
48 × 10 = × 42 × d
16
3
d =5823.48

d = 17.99 mm, which is approximately 18 mm. therefore, the shaft of the machine should not be

less than 18mm. Hence a shaft of 25mm diameter was selected considering a safety gap of

unforeseen circumstances in the design.

3.3.3 Design for the Power Required for Shelling

The crushing power required for the operation of the machine was determined by the size

of the roller, and the peripheral velocity of the roller. The design of this determines the power of

electric motor selected for the machine. The power required by the designed melon shellerwas

determined by using the formula given below

P=F×V 3.5

Where:

P = power (Watts)

F = cracking force required to shell melon (N)

V = velocity of the shelling drum (m/s)

P = 478 × 0.85

P = 406.3 W

3.3.4 Determination of Length of Belt

The length of belt would be determined using the relation given by Khurmi and Ghupta

(2005) as:
2
π ( D1 −D2 ) 3.6
L=2 x + ( D1+ D 2) +
2 4x

Where;

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L – Length of belt

x – Centre distance between the two pulleys

D1 – diameter of power source pulley

D2 – diameter of machine pulley

Determination of Length of Belt between Prime mover and Machine

D1= 70mm = 0.07m

D2= 100mm = 0.10m

x= 400mm = 0.40m
2
3.142 ( 0.07−0.10 )
L=2 × 0.4+ ( 0.07+ 0.1 )+ =1.07 m
2 4 ×0.4

3.3.5 Bearing Selection

The bearing to be used was selected based on the type of load the shaft would carry and

working conditions. A pillow bearing with internal bore corresponding to the diameter of the

shaft was selected.

3.4 Materials Selection

The material selection for the melon shelling machine involves a careful evaluation of

various factors to ensure that the chosen materials meet the specific requirements of the

machine's design, performance, and longevity. Each criterion plays a crucial role in determining

the suitability of materials for different components of the machine:

i. Availability of the Material: The availability of the chosen material is an essential

consideration to ensure a steady supply for manufacturing and repairs. Selecting

materials that are locally sourced or widely accessible helps prevent delays in

production and maintenance.

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 ii. Corrosion Resistance: Since the melon shelling machine may come into contact

with moisture, humidity, or other corrosive agents, it's vital to choose materials that

exhibit strong corrosion resistance. This prevents deterioration and extends the

machine's lifespan.

iii. Ease of Fabrication: Materials should be chosen with consideration for ease of

fabrication. Materials that can be easily machined, welded, or formed simplify the

manufacturing process and reduce production time and costs.

iv. Cost: Material cost is a significant factor in determining the feasibility of

manufacturing the machine. Balancing performance with cost-effectiveness is crucial

to ensure the machine remains affordable without compromising its functionality.

v. Ease of Maintenance: Materials that allow for straightforward maintenance

procedures, such as cleaning, lubrication, and part replacement, contribute to the

overall usability and longevity of the machine. Easy maintenance reduces downtime

and operational disruptions.

vi. Durability:Materials must be selected to withstand the wear and stress that the machine

will undergo during its operational life. Durable materials contribute to a longer lifespan,

reducing the need for frequent replacements and repairs.

3.5 Fabrication Procedure and Assembly

The machine was fabricated following standard procedures of machine fabrication. The

various components were fabricated separately and the assembly was by bolt and nut fastening to

the main frame.

3.5.1 Fabrication of Main Frame

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 The length of the ‘L’ iron was cut to the required size with hacksaw after appropriate

measuring with a steel tape and marking out with a scriber. The bottom bracings were also

measured, marked out with the scriber and cut with hack-saw to ensure they are neatly cut out

ease of welding. The main frame was assembled and joined permanently with an electric arc

weld machine using gauge 12 electrode. Holes for attaching other components to the mainframe

were made using a pillar drilling machine.

3.5.2 Fabrication of Hopper

The mild steel sheet was measured with a steel tape and marked out with a scriber

according to the design specification. It was then cut using an angle grinder and attached to the

top of the machine according to the design specification by welding it with an electric arc

welding machine using gauge 12 electrode.

3.5.3 Fabrication of Shaft

The shaft was made from 30mm mild steel solid rod. It was then machined on the lathe

according to the design by step turning and facing. The key way was slotted on the shaping

machine to match the size of the pulley.

3.5.4 Fabrication of Prime Mover Seat

The length of the ‘L’ iron was cut to the required size with hacksaw after appropriate

measuring with a steel tape and marking out with a scriber. The bottom bracings were also

measured, marked out with the scriber and cut with hack-saw to ensure they are neatly cut out

ease of welding. The reduction gear box seat was assembled and joined permanently with an

electric arc weld machine using gauge 12 electrode. Holes for attaching the prime mover to the

seat were made using a pillar drilling machine.

3.5.5 Fabrication of Seed Collector

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 The mild steel sheet was measured with a steel tape and cut with an angle grinder. It was

then bent using a manual bending machine and welded fully with an electric arc welding

machine.

3.5.6 Fabrication of Chaff Outlet

The sheet was measured with a steel tape and cut with an angle grinder. It was then bent

using a manual bending machine and welded together with gauge 12 electrode. It was then

attached to the main frame by bolt and nut fastening.

3.6 Principle of Operation of the Machine

The melon shelling machine operates on a well-coordinated and precisely engineered

principle, designed to efficiently shell melon seeds while ensuring ease of use and optimal

performance. This principle of operation encompasses a series of interconnected steps, each

contributing to the seamless and automated process of melon shelling.

Coupling and Power Transmission: The initial step involves coupling the various components

of the melon shelling machine together. A gasoline prime mover, the source of power for the

machine, is securely mounted onto the machine's structure. The prime mover's energy is

harnessed and transformed into mechanical power through a belt drive arrangement. This

arrangement effectively transfers the prime mover's rotational force to the rest of the machine,

setting the stage for the shelling process to commence.

Loading and Feeding: With the machine primed for operation, conditioned melon seeds are

carefully and systematically fed into the machine through the hopper. The hopper, strategically

positioned, facilitates the entry of melon seeds into the machine's processing area. This

ergonomic design ensures ease of loading and promotes a steady and controlled input of melon

seeds.

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Shelling Drum Action: As the conditioned melon seeds enter the machine, they come into

contact with the shelling drum, which is equipped with fins. The shelling drum is a central

component responsible for the actual shelling process. Through a combination of rotary motion

and the abrasive action of the fins, the shelling drum exerts gentle yet effective pressure on the

melon seeds. This rubbing action cracks the melon seeds' outer shells, progressively freeing the

valuable kernels within.

Seed and Chaff Separation: Following the shelling process, the shelled melon seeds, now

separated from their husks, as well as residual chaff, are released from the shelling drum. Gravity

plays a pivotal role in guiding the shelled seeds and chaff downward within the machine's

processing chamber.

Airflow and Blower Mechanism: The machine's blower system comes into play. The blower, a

centrifugal type, generates a stream of air within the processing chamber. This stream of air

serves multiple purposes: it carries away the lighter chaff particles, effectively separating them

from the valuable melon kernels, and aids in cleaning and removing debris from the shelled

seeds.

Collection and Disposal: The shelled melon seeds, now freed from their shells and cleaned of

chaff, are directed toward the seed outlet. This designated outlet provides a clear path for the

collection and retrieval of the shelled melon seeds. Simultaneously, the chaff, being lighter, is

carried away by the air current produced by the blower and expelled through a separate chaff

outlet. This efficient separation process ensures that the shelled seeds and chaff are effectively

sorted and directed to their respective exit points.

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3.8 Performance Evaluation

3.8.1 Sourcing of Experimental Materials

Melon was purchased from Ganmo market, a local market in Ilorin South Local

Government Area, Kwara State, Nigeria.

3.8.2 Sample Preparation

The melon was sorted to be free from foreign materials such as stones and pebbles. The melon

was then measured into the various samples using a digital weighing scale according to the

design layout.

3.8.3 Experimental Design and Layout

i. Feed rate – 500g, 1000g, 1500g

ii. Machine Speed – 1500rpm

iii. Moisture Content - 18.5%

3.8.4 Experimental Procedure

The sample prepared was fed into the machine via the feeding hopper while the gasoline prime

mover was put on to power the machine. The operation of the melon shelling machine assisted in

obtaining a clean melon seeds from the seed outlet while the chaff was collected from the chaff

outlet. The seed and the chaff were measured with a digital weighing scale and recorded while

the time taken for each experiment was taken with a stopwatch and recorded.

3.8.5 Output Parameters

The output parameters were determined using the following expressions

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 ms
i. Throughput capacity(Kg/h) T c= ×60 3.7
T

Where;

ms is mass of samples fed into the machine

T is time taken for the sample ¿ be processed

ii. Shelling efficiency, n o = 100(w su +W Sδ )/W t 3.8

Where

W SU = Weight of unbroken shelled seeds;

W Sb = Weight of broken shelled seeds;

W t = Total Number of seeds poured into the machine

iii. Unshelled Efficiency, n o = 100(w st +W Sδ )/W t 3.9

Where

W St = Weight of shelled seeds;

W Sb = Weight of broken shelled seeds;

W t = Total Number of seeds poured into the machine

3.8.6 Materials and Instruments Used for Testing

The following materials and instruments were used in the course of this study.

i. Digital weighing scale: A digital weighing scale plate A1 with model no NBL-2602e

with an accuracy ±0/01g was used to measure the samples for the experiment.

ii. Digital tachometer: A contact/non- contact digital tachometer plate A2 with accuracy ±

(0.05% + 1 digits) was used to measure the speed of the machine during operation.

iii. Bowl: Three bowls of equal size was used to prepare the sample and also to collect the

seeds from the machine.

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iv. Stopwatch: A digital stopwatch was used to measure the time taken to complete each

experiment.

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APPENDIX

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