Design, development and performance evaluation of small-scale fodder chopping machine for farmers

A straw chopper is a mechanical device used to uniformly chop fodder into small pieces to mix it together with other grass and then feed it to livestock. The objective of this research was to design and develop an animal fodder chopping machine to be utilised by dairy farmers within their purchase range. The drawing of these machine parts was undertaken in AutoCAD software and the construction was performed in a local workshop. After development of this machine, performance tests were carried out on a farm. The chopping machine tests were carried out with commonly grown fodder (namely: straw, grass, and maize) in Bangladesh. The performance evaluation of the developed machine was carried out in terms of the chopping efficiency, machine productivity, and energy consumption. The economic analysis of the straw chopping machine was assessed by indicating the cost effectiveness to the poor farmers. Analysis of the data in regard to chopping efficiency and machine productivity varied from 93 to 96% and from 192 to 600 kg×h^–1, respectively. The energy consumption during the chopping process ranged between 0.0025 and 0.01 kWh for the different types of fodder. The break-even point of the fodder chopping machine was 3 793 kg of cut straw and the payback period was within one year depending on the use.

Distributed parameter modeling and model predictive control of weft insertion in air-jet weaving

In air-jet weaving, the braking of inserted weft threads plays a significant role in fabric quality and machine productivity. This contribution presents Model Predictive Control (MPC) which controls the weft tip’s position and velocity with an optimal braking force. The inserted weft thread is firstly modeled as a distributed parameter system. The relation between the braking force and the weft tip’s position is described by a Partial Differential Equation (PDE). By analyzing the PDE with Laplace transform and solving the PDE with a Galerkin method, a state-space model is presented. Subsequently, identification experiments of the constructed yarn brake are performed and the whole model is analyzed as well as reduced using balanced truncation. Based on the system states and input disturbance estimated by a dual Kalman filter, an MPC controls the weft tip’s position and velocity appropriately without any backward movement. Regarding model deviations and simulated measurement errors, the MPC performs robustly.

Design, Simulation and Experimentation of an Axial Flow Sunflower-Threshing Machine with an Attached Screw Conveyor

Sunflower threshing is one of the most interesting field processes for making the sunflower ready for seed handling, drying, cleaning and oil extraction. One of the biggest problems observed during the sunflower threshing process is the accumulation of threshed crop on the first third of the threshing roller and passing off some unthreshed parts of sunflower heads. To solve the aforementioned problem and optimize the efficiency of the sunflower threshing process, this research was focused on devising and testing a sunflower threshing machine with a close threshing box system equipped with a screw conveyor that evenly distributed the feedstock of sunflower heads on the entire length of the threshing roller. The machine was tested to assess the seed damage rate, unthreshed seed percentage, threshing efficiency, machine productivity, power requirements and specific energy consumption. The evaluation was done under different roller rotational speeds (150, 200, 250 and 300 rpm) and feeding rates (600, 700, 800 and 900 kg/h). The obtained results revealed that the threshing evaluation parameters were affected significantly by the roller rotational speed and feeding rate. The threshing efficiency was observed to rise with the rise in the roller rotational speed, and it also rose with the increasing feed rate up to 800 kg/h and then started to descend. The unthreshed seed percentage decreased with the increase in the roller rotational speed for all feed rates, and it decreased with the increasing feed rate up to 800 kg/h and then started to increase at the higher feed rates. The damaged seed percentage, power requirement and machine productivity increased with the increase of the roller speed and feed rate. The Buckingham π theorem was followed to find an equation to predict the threshing efficiency, resulting in an equation with an R2 value of 0.9309. With elimination of the blockage problem and better threshing efficiency, this machine could be a good choice for small- to medium-sized sunflower farms.

Performance Evaluation of a Melon Shelling Machine with Different Power Sources

Performance evaluation of an electric motor and a fuel-engine powered machine used for shelling melon seeds was performed in this study to determine the effects of shelling speed and moisture content on machine productivity. The melon seeds used for the evaluation of the existing melon shelling machine were sourced locally from Umungasi market in Aba, Abia state, Nigeria. The unshelled melon seeds as used were weighed (25g each), sprinkled with water and partially dried with natural air for 25 minutes. This enabled the skin coat became slightly softened and the cotyledon easily detached from the shell, thus making the shelling more efficient. To evaluate the parameters (machine productivity, throughput capacity and percentage seed damage), the melon seeds were employed. For the shelling performance, melon seeds of five different moisture contents (7.48, 10.24, 13.92, 18.36, 21.44%) dry basis (d.b.) at different shelling speeds (850, 1000 and 1200 rpm) were utilized in the evaluation. From the evaluation, results revealed that the machine has an optimal productivity of over 83% and percentage seed damage of 14.2% at seed moisture content of 21.44% and drum speed of 1200 rpm for both power sources. Maximum machine throughput capacity of over 940 kg/h was recorded at 1200 rpm and 21.44% moisture content for both power sources. Overall, results obtained indicated that the machine can effectively shell melon seeds and that seed moisture contents and shelling speed affected the machine productivity.Keywords— Performance operation, evaluation, motorized, melon, shelling machine

laboratory test for different designs of feeding mechanism of subsoil manuring machine

"Laboratory experiment was carried out at the Department of farm Machinery / college of Agriculture, in order to study the effect of the types of feeding arms (straight arms, Lshaped arm, and arched arms) and tractor engine speed (600, 1200, 1800) rpm on some performance properties included manure discharge rate, manure quantity per hectare and machine productivity. All tests were conducted according to the complete randomized bolck design with three replicates. The results showed an increase in fertilizer discharge rate, manure quantity per hectare and productivity of the machine while increasing engine speed. The feeding mechanism with L-shaped arm was superior to other designs which gave the highest values for the manure discharge rate, the amount of manure per hectare and the productivity of the machine as compared to the feeding mechanism with straight and arched arms"

Linking Federal Forest Restoration with Wood Utilization: Modeling Biomass Prices and Analyzing Forest Restoration Costs in the Northern Sierra Nevada

Over half of California’s forestland is managed by the US Forest Service, and the agency has identified a need to scale up forest restoration treatments in the state to one million acres per year by 2025. However, the high costs of mechanical fuel reduction and lack of markets for biomass pose significant barriers to accomplishing this target. The objectives of this case study were: (1) to identify costs of forest restoration treatments on federally-managed land in the Northern Sierra under a variety of harvesting scenarios and haul distances to biomass facilities, and (2) to understand what market prices for biomass must be offered to support such efforts. We modeled silvicultural prescription and harvesting options, machine productivity and costs, and transportation costs to assess economic thresholds. Biomass harvest, chip, and haul costs ranged from $55/bone dry ton to $118/bone dry ton, depending on the harvesting system scenario and distance from the biomass disposal site. Results suggest that the cost of forest restoration far exceeds current market prices for biomass, and additional investment is needed to adequately pay for federal forest restoration in California. Additional takeaways include that biomass outlets closer to supply sources can reduce both haul costs and production costs, and local wood utilization campuses can play a key role in supporting forest restoration.

Application of fuzzy TOPSIS in the Analyze phase of the DMAIC cycle to aid decision-making

This paper reports the use of multicriteria analysis in the Analyze phase of the DMAIC (Define-Measure-Analyze-Improve-Control) cycle for continuous improvement. The research was carried out in a tissue paper factory located in southern Brazil. A sample of 64 parts of 16 different reels of recycled paper was used. A problem regarding paper quality variability was detected, presenting a scrap index ranging between 9% and 23%, compromising machine productivity and product sales. This motivated the implementation of a structured project supported by the application of the DMAIC cycle. The project team (machine operators, maintenance staff, supervisor, and data analyst) defined the evaluation criteria and determined the control intervals and their equivalence with linguistic variables to support the necessary evaluations for the application of fuzzy TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution). The criteria were C1-Longitudinal Strength (Kgf), C2-Longitudinal Elongation (mm), C3-Cross-strength (kgf), C4-Cross-elongation (mm), C5-Weight (g/m²), and C6-Humidity (%). The results showed that samples with the same ranking had the lowest scrap indexes in the subsequent process. Also, the criterion C5 had a more significant impact on the quality of the product than the other criteria, which was determined from the DMAIC sequence. Improvements related to C5 should be prioritized. The fuzzy TOPSIS method presented is a flexible tool, adapting itself to the solution of the problem and contributing to the decision-making process.

Operational Costs of Mid-Performance Forwarders in Czech Forest Bioeconomy

Cut-to-length (CTL) operations are expanding in Central European bio-economies. However, they are costly, so efficiency must be maximized. The objective of this study was to analyze direct operational costs of three forwarders from the year 2006 until 2019. Annual amortization, services, materials, and personnel costs were analyzed and compared through ANOVA, trends were analyzed through linear regression. Forwarders LVS 5, John Deere 1010, and John Deere 1110E were deployed in coniferous forest stands with a mean stem volume between 0.10 and 0.84 m3/stem, forwarding distance between 261 and 560 m. The machines forwarded between 4045 and 34,604 m3 of timber per year, over operational times between 490 and 3896 MH (machine hours)/year, reaching machine utilization between 58% and 89%, machine productivity between 3.5 and 12.3 m3/MH, and costs between 20.95 and 84.39 €/MH. The most substantial were personnel costs (35 to 66% of the total costs), followed by materials (14.9–27.1%), amortization (12.5–15.7%), and services (3.3–22.1%). Differences between total operational costs per m3 of machines with different engine powers were not observed.

Application of Kaizen philosophy for enhancing manufacturing industries’ performance: exploratory study of Ethiopian chemical industries

PurposeKaizen is an umbrella concept for a management philosophy based on a set of principles and values with different tools and techniques that form part of Company-Wide Quality Control. The purpose of this study to explore the empirical evidence of Kaizen philosophy practice and its effect on Ethiopian manufacturing industries, chemical companies in particular.Design/methodology/approachAfter the literature review, an exploratory empirical research, supported on a company observation, was adopted. The eight companies visit giveaway collecting annual technical reports and Kaizen award presentations. The review structure encompassed four major approaches. The first approach is conducting extensive literature review and adopting methodologies. The second approach is examining secondary data and developing SWOT analysis. The third is exploring Kaizen practices, developing framework, identifying drivers and barriers using charts, diagrams and graphs. The final approach is proposing way forward and implications based on the findings from the investigative study to emphasize the link between Kaizen practice and its effect on manufacturing industries’ performance.FindingsThe findings indicate practice of Kaizen brought in achieving monetary, nonmonetary and qualitative results. However, results vary from company to company. The average attained improvements of productivity, production volume, machine productivity and sales volume are 2.77%, 28.69%, 10.14% and 31.53% respectively. Moreover, a total of 71,932,472.19 ETB is saved by following structured framework and practice of social and technical factors. However, companies could not sustain Kaizen activities and unable to maintain the attained substantial improvements due to less effort made on some of the Kaizen practices identified as barriers on the cause and effect diagram of this exploratory study.Research limitations/implications:A sample size of eight companies is not adequate to generalize key findings of this study. This will be put right by carrying out further surveys in the future using questionnaire and semistructured interviews.Practical implicationsThe findings of this study underlined that practice of Kaizen philosophy on chemical companies supported by structured implementation framework, full practice of drivers, eradicating barriers, sustaining practices and maintaining improvements enable in enhancing chemical companies performance through achieving quantitative (monetary and nonmonetary) and qualitative results.Originality/valueAlthough there are a number of studies published on Kaizen, currently it is found that there is lack of literature on practice and effect of Kaizen philosophy. Based on this exploratory study and assessment, the framework and circumstance of Kaizen philosophy practices are providing valuable insights for chemical companies, other manufacturing industries and organizations, which will be on board on this voyage including Ethiopian Kaizen Institute, practitioners and academicians.