American Journal of Engineering Research (AJER) 2022
American Journal of Engineering Research (AJER)
e-ISSN: 2320-0847 p-ISSN : 2320-0936
Volume-11, Issue-03, pp-140-47
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Research Paper Open Access
Design Modification, Development and Performance
Evaluation of a Cereal crop Thresher
A.B. Istifanus1, M. Abang2, C. Okechukwu2, T. O. Oloyede2
1
Department of Agricultural and Bioresources Engineering, Taraba State University, Jalingo.
2
Advance Manufacturing Technology Development Institute, Wukari Road, Via Taraba State Polytechnic,
Jalingo
ABSTRACT: The design and development then performance evaluationof a suitable Threshing Machine to cope
with the limitations of the existing small-scale thresher with a view to modifying it, test and evaluate its
performance and making same available to farmers in the hinterland by way of mitigating the post-harvest
challenges of threshing the two major cereals, corn cum sorghum was undertaken: hence a comprehensive
performance evaluation was conducted on the old machine to identify its capabilities or otherwise any
limitations on maize and sorghum threshing. In the threshing unit of the existing machine, it was identified to
have some defects in the form of inadequate number of beaters, as well as the result showed that its
performance parameters were low generally. The throughput capacity, threshing efficiency, cleaning efficiency,
grain damages and scatter losses of maize were found to be 422 kg/hr., 89.87%, 60.95%, 5.17% and 8.30%;
and, that of sorghum were 408kg/hr., 86.54%, 61.79%, 5.28% and 7.81% respectively for the modified thresher.
The multi- crop thresher was however modified to achieve increased threshing effectiveness; thus, the number of
beaters around the threshing cylinder were increased by mounting three rows of beaters on the cylinder. The
redesigned thresher was fabricated using locally available materials. Its performance was evaluated under
three phases. Test result of the modified thresher indicate an average throughput capacity, threshing efficiency,
cleaning efficiency and grain damages values for maize to be 534 kg/hr., 92.00%, 73.33 %, 10.43% while for
sorghum the corresponding values were obtained as follows; 531.43kg/hr., 89.10%, 74% and 1.596%
respectively affirming an improvement over the modified thresher.
KEYWORDS: Design Modification, cereal crop, throughput capacity, cleaning efficiency, scatter losses,
performance evaluation.
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Date of Submission: 10-03-2022 Date of acceptance: 26-03-2022
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I. INTRODUCTION
A threshing machine is device used to undertake threshing. [1] define threshing as removal of grains
from its cobs either by stripping, impacting by rubbing. It can also be defined as the process of detaching grains
from the heads or from the plants, threshing separates grains from panicles, crops and pods. Threshing or
detaching the kernels from the ears or pods is accomplished by combination of impact and rubbing action.
Threshing and cleaning operation are necessary steps after which grains are further processed into flour
for domestic or industrial uses. In addition, annual yield evaluations by farmers are only possible after threshing
operations. The by-products of threshing such as straws and chaff could be accumulated in stack, and be saved
for future use as animal feed.
Nigeria heavily relies on imported technology in areas of machinery and equipment, [2]. These
machineries have only made limited impact on increased food production due to several problems such as
regular break down. Experience has shown that, a number of these machinery and equipment break down as
early as few days after commissioning due to improper usage, [3] Seed losses were of unacceptable levels and
cleaning efficiency was unsatisfactory.
The predominant farming of maize, sorghum and millet production in Nigeria, especially in northern
part is based on manual labor provided by the family members. Each family operates a small farm, producing
enough grains for family consumption until next season’s harvest.
With the migration of rural youths to cities for better employment opportunities, there is shortage of
labor during peak crops harvesting and threshing period. This causes delay in crops harvesting and threshing.
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Hence, it increases both quantitative/qualitative post-harvest losses and production has become too laborious for
many farmers.
The traditional threshing methods of human or animal foot trampling and manually beaten against hard
element are less efficient, require high labor capacity and may cause crop seed crack or scatter around. A lot of
small-scale farmers use this kind of traditional threshing method as they cannot afford to buy conventional large
threshing machines which are more expensive. This is because the conventional machine only suitable for big
scale farmer.
Furthermore, different types of threshers are needed for different crop which is economically unwise
and space consuming.
In design, modification and fabrication of any threshing agricultural machine, Design parameters such
as cylinder speed, cylinder diameter, shape, size,spike, shelling length,clearance between the spikes and the
concave, diameter holes in the concave aand arrangement on the shelling drum and the blower type should be
considered so as to determine the efficiency of the theperformance of thresher in terms of threshing efficiency,
damage percentage, output capacity, cleaning efficiency, and power requirement[4].
There is a growing need to provide small scale farmers with an appropriate multi-crop thresher with
higher throughput capacity, low processing losses and mechanical grain damage. That will reduce the
processing losses by threshing thereby increasing the economic return to the farmers. Similarly, efficient power
operated multi-crop thresher will also eliminate the large drudgery involved in manual method of threshing.
This will certainly encourage more farmers including the youth to engage in crop production thereby reducing
unemployment.
Furthermore, it will assist the farmers to thresh large quantities of maize and millet, per unit time and
reduce the heavy postharvest losses increasing food availability and security in the nation. The use of available
local materials will help to reduce cost of producing a multi-crop thresher, so that small scale and average
income farmers can afford.
In this paper, multi-crop threshers which are used to handle a number of crops are highly successful for
threshing cereal crops and pulses. The advantage of multicrop threshers is that with minor adjustments it can be
used to thresh different crops, whereas other threshers can thresh a particular crop only, efficient threshing does
not only require substantial time but also cause considerable threshing losses of grain. The main objective of this
is the desgn modification and performance evaluation of a cereal multi-crop thresher.
II. MATERIALS AND METHODS
The Description of the multi crop thresher:The development of modified design of a thresher
generally made use of local materials including metals, iron rod, angle iron, metal sheets and 6.5kw power
generating machine purchased from the Jalingo building materials market: the crops used for performance
evaluation were grown by the researchers and used in November, 2022. The fabrication was done at the Taraba
State Polyethnic workshop while performance evaluation was carried out at the farm.
The machine comprises of a hopper, frame, threshing unit, cleaning unit and sieve. The hopper serves
as the feeding chute to the threshing chamber where the grains are threshed and separated. It was constructed
using a 2mm thick metal sheet. The crop fed into the hopper go down to the threshing chamber where the
panicles are threshed by the action of rotating drum against the stationary concave. After the panicles are
threshed, some of the threshed seeds, unthreshed crop and some impurities pass down through the perforated
concave unto a stream of air blown by the drum through the perforated concave which also removes some
portion of the impurities. The rest are passed together with impurities onto a set of aspirators and sieves. The air
blown by the drum takes away chaffs and impurities, while the cleaned grains pass through the sieves down to
the grain delivery outlet by the action of vibration produced by power source of the thresher.
Limitations of the ExistingCereal Crop Thresher:The primary purpose of a crop thresher is to perform
the postharvest duty of separating grains of cereal crops (such as maize, sorghum, millet and so on) from the
chaff and deliver clean grains to the farmer or consumer. The existing thresher though functionable had obvious
gaps among which are the following that necessitated the modification of the thresher:
The existing machine did not have suction chamber, thereby allowing dirt to enter the threshed grain.
The handle is stationary and requires heavy machine to pull.
The sieveswere welded to the frame which madetheir replacement difficult.
Introduction of blower for effective achievement of threshed grain cleaning quality.
More to these, the cylinder drum, the shaft and shaft speed, blower volume, beater capacity required to be
improved to enhance the efficiencies of operations and the general throughput capacity of the cereal thresher.
Design Considerations:A cylinder-concave clearance of 10 mm was used for the thresher. This is in
accordance with the recommendations of [5]. To keep the mechanical grain damage low, 9.21 m/s (800 rpm)
was chosen as the threshing cylinder peripheral speed. This is within the range of values recommended by [6]
for sorghum threshing. Sieve hole size of 6 mm was used, this is based on [7] recommendation. The shaking
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frequency and amplitude of oscillation were 360 rpm and 7 mm respectively. A threshing drawing of the
thresher is shown below in Figure 1.cylinder diameter of 220 mm and length of 230 mm was maintained from
the previous machine. To increase threshing capacity, the number of pegs around the cylinder was increased
from 4 to 5 and cutting knives were mounted on the cylinder cover. The assembly
Figure 1: Assembly Drawing of the Thresher
The Major Considerations in Modification of the Machine
Belt Selection:
Length of Belt was calculated as:
(3.1)
L= Effective length of belt (m),
C= Centre distance from drive to driven pulley (m)
D= Diameter of driven pulley (m),
d= Diameter of driving pulley (m) [8]
The equation above will be used to estimate the following lengths
L1= Belt length from engine to thresher pulley (m), and L2= Belt length from thresher to fan pulley (m)
Belt speed: The belt speeds was calculated using [9] equation:
(3.2)
V= belt speed (m/s),
N= drive speed (rpm),
D= diameter of drive pulley (m)
Calculation of Belt Tension
The formula for the torque producing power, T is given byθ
(3.3)
P = Power of engine (kW),
T = Torque (Nm) and N = Speed of thresher pulley (rpm)
The tension in the tight side, T1 and slack side, T 2 of belt was calculated using the formula given below;
[9] (3.4)
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Fan Design:
Fan case design: The radius of the fan case was calculated from:
(3.5)
r=radius of fan case
R=Distance from shaft to tip of blades
= Angle
Fan Blade Selection: A 20-gauge mild steel sheet blade was used.
Determination of air velocity of fan
(3.6)
Q = Volumetric flow rate (m/s), A = Cross sectional area (m), V = Air velocity (m/s) [8].
Determination of fan speed:
(3.7)
N = Speed of fan (rpm), D = Diameter of fan (mm) and V = Velocity of fan (m/s)[9].
Components of the machine:.
Petrol Engine: this is the power source for thresher providing mechanical energy to the threshing drum
in a form of rotation through belt. This engine is of 6.5 kW petrol engine with a speed rating of 3500 rpm.
Threshing drum/ blower: this is a component that revolves and rubs the grain panicles against a
stationary plate thereby detaching the grains from the Plate cob, it blows away or separates the unwanted chaffs
from the threshed grain and other impurities.
Grain plate: it contains holes and against which the panicle is rubbed by the threshing drum. It is where
threshed grain passes through after been detached by the threshing drum.
Feeding hopper: it is where the panicle is fed.
Set of sieves: it sorts grain from the chaff and other unwanted materials through the action of vibration
of the machine.
Grain delivery outlet: where the threshed grain is delivered.
Frame: it serves as the body of the thresher
Design analysis and calculation:
Belt speed: The belt speeds will be calculated using [9] equation:
N=V/
V= belt speed (m/s),
N= drive speed (rpm),
D= diameter of drive pulley (m)
V=N (3.8)
Calculation of Belt Tension
The formula for the torque producing power, T is given by
T = 60P/2 N [9] (3.9)
P = Power of engine (kW),
T = Torque (Nm) and N = Speed of thresher pulley (rpm)
The tension in the tight side, T1 and slack side, T 2 of belt will be calculated using the formula given below;
T = (T1 – T2) r Nm [9]
Pulley Selection: The drive speed is the criteria for which the pulley sizes are based.
N1 D2 = N2 D2
Where;
N1 = Speed of driving pulley (rpm)
D1= Diameter of driving pulley (m)
N2= Speed of driven pulley (rpm)
D2= Diameter of driven pulley (m) The selection of the following pulley sizes is based on [10]: Prime mover
pulley, Threshing drum pulley and Fan pulley.
Estimation of pulley dimensions: Pulleys dimensions were determined by using expression given by [11];
N1 D1=N2 D2
Where:
N1= Speed of drive pulley;
D1 = Diameter of drive pulley;
N2= Speed of driven pulley;
D2=Diameter of driven pulley
For cylinder and prime mover:
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N1 = Speed of the prime mover (3500 rpm);
D1 = Diameter of the prime mover pulley (60 mm);
N2 = Speed of the threshing cylinder (1312.5 rpm);
D2 = Diameter of the threshing cylinder pulley. Therefore,
D = 160 mm
Determination of concave sieve radius:
The radius of curvature of concave sieve rc, was determined by the following expression as used by [12]:
Rc = rd + hp+ Cc
Where:
Rc = Radius of concave sieve (mm); r
d = Radius of cylinder drum (110 mm); h
p= Height of peg above the drum (78 mm);
Cc= Cylinder concave clearance (10 mm);
Rc= 198 mm
Determination of the volume of cylinder and spike tooth:
Determination of the volume of cylinder and spike tooth: This was obtained by summing up the volume of the
threshing cylinder which is hollow and peg teeth volume which is solid
(3.13)
Where:
Vc = Cylinder and peg tooth Volume (m3);
R1 = Outer radius of the cylinder (110 mm);
R2 = Inner radius of the cylinder (105 mm);
R3 = Radius of the peg tooth (10 mm);
L = Length of the cylinder (230 mm);
H = Height of the peg tooth (78 mm);
N = Number of peg tooth (40);
Vc =
Vc = 3613.3 + 98030.4
Vc = 101643.7
Vc = 101 X 103
Fan Design:
2.6.6 Actual discharge
: Is the actual flow rate of fan can be estimated as
Qa = VtDW (3.14)
Where:
Qa = Actual flow rate (m3/s);
Vt = Terminal velocity of air (m/s);
D = Depth of air stream over the screen (400 mm);
W = Width over which air is required (450 mm).
An air stream terminal velocity Vt is selected such that it is greater than the terminal velocity of the light
contaminants and smaller than that of the principal grain materials. At 10–20% moisture content, the terminal
velocity of sorghum seeds ranges from 3.73 – 5.13 m/s [13]. Therefore 3.70m/s was chosen as the terminal
velocity of air; Qa=0.670 m3/s.
Determination of the shaft diameter:Design of a shaft involves determination of the minimum diameter of the
shaft material that can withstand certain loading conditions; it is a ductile material base on strength which is
controlled by maximum shear theory. It is subjected to torsion, to bending, to axial tension or compression or to
a combination of any or all of these actions. Therefore, there is the need to take all of the above into
consideration to avoid shaft failure. To get the shaft diameter (d), the following relationship would be used, [14].
d=16/ SS( (KbMb)2+(KtMt)2(m) (3.15)
Where;
Ss= Allowable shear stress (42N/mm2for shafts with keyways), according to ASME Code
Kb=1.5 (constant)
Mb= Maximum bending moment (kNm)
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Kt= 1.0 (constant)
Mt= Maximum torsional moment (kNm)
2.6.8 Power required for uploaded cylinder
Power required turning the unloaded threshing cylinder: This was calculated by the formula used by [15];
P1=2 (3.16)
Where:
Nt = Speed of the threshing cylinder (800 rpm);
MC = Mass of threshing cylinder (13.79 kg);
r = Radius of cylinder (110 mm);
Vtp = Peripheral velocity of the threshing mechanism (9.21 m/s); P1=1.32 kW
Torque transmitted by shaft
T=P/W (3.17)
Where
W=Angular Velocity
T=Px60/2 (3.18)
N=No of revolution of shaft per minute
From equation (3.4) torque transmitted
r = radius of the shaft
Px60/2 N – (T1-T2) x r
Power required of the prime mover on the multi crop thresher
1. Threshing power = Ptr
2. Winnowing power = Pw
3. Feeding power = Pfm
4. Transmitting power of the cob = Ptrc
Total power = Ptr + Pw + Pfm + Ptrc (3.19)
III. RESULTS AND DISCUSSIONS
Design calculation results were obtained for all the components as shown below.
Diameter of threshing cylinder pulley = 160 mm; Radius of curvature of concave sieve = 198 mm;
Speed of the prime mover = 3,500 rpm; Diameter of prime mover = 60 mm; Speed of the threshing cylinder =
1312.5 rpm; Outer radius of cylinder = 105 mm; Radius of peg tooth = 10 mm; Length of cylinder = 230 mm;
Height of the peg tooth = 78 mm; Number of peg tooth = 40; Radius of cylinder = 110 mm; Speed of the
threshing cylinder = 800 rpm; Mass of the threshing cylinder = 13.79 kg; Peripheral velocity of the threshing
mechanism = 9.21 m/s; Length of beater = 90 mm; Threshing chamber diameter = 300 mm; Length of the
threshing chamber = 520 mm
Volume of the drum = 12.37 x 103m3 ;Volume of the threshing chamber with the beaters = 6.363 x
10 m Volume of beaters = 3.7115 x 103m3 ;Volume of the threshing chamber = 2.2985 x 103m3 ;Threshing
3 3;
power = 295.74 W; Volume of the blower shaft and the blade = 6.72706 x 103m3 ;Angular velocity = 314.2
rad/sec; Threshing force = 3524.30 N; Threshing torque = 126.46 N ;Tortional moment = 78.79 Nm.
These values certify to the fact the machine performance was optimal within the range of these basic
design values. The volumes of the threshing chamber,that of the beaters, the volume of the chamber as well as
the power rating of the thresher as specified in the design results below enhanced the quantity of material fed
into the machines well as the quantity and quality of grain exited. The blowers design capacity of 6.72706 x
103m3 raise the quality and quantity of the material giving rise to an improved material throughput Capacity. The
assembly diagram in (figure1) above is a product of these various parameters which served as the data used in
coupling the new machine. (Also, see appendices for component drawings using pro e):
The machine was designed to thresh grains by impact and it derives its power from a petrol engine
prime mover. The thresher with a new design modification has a reasonable configuration as seen in figure
1comprises of a moderate energy consumption and a relatively high output as contained in Tables 1and 2.
The un-threshed grain, when fed into the hopper, falls down to the threshing chamber which rotates
against the concave by the threshing drum. The impact of the drum results in the grain being threshed. The seeds
and chaff are separated through the concave sieve. The broken cobs are ejected through the drum outlet.
Cleaning of the seeds is done through the airstream produced by the fan, by suction process and then the
threshed clean seeds pass down to the discharge outlet.
Tables 1 and 2 below represent the performance evaluation carried out on the new thresher using two
major cereals (maize and sorghum). Various parameters such as threshing efficiency, percentage of unthreshed
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grain, percentage of mechanical damage, percentage of blown grain,Percentage of sieve loss, throughput
Capacity,threshing performance index,total grain loss etc. determined which displays adequate superiority over
the existing thresher.
TABLE 1: QUANTITY OF GRAIN (MAIZE) THRESHED IN (Kg) PER TIME
S/N Qty of Time taken to Qty of threshed Qty of grain Qty of Qty of Qty of grain
unthreshed thresh (T) min grain (x1) Kg cobs (yb) Kg damage grain unthreshed seed stuck in
grain (x) Kg (y2) (y1) sieve (yc)
1 63 10 48 8.80 2.70 0.90 2.00
2 240 20 218 17.10 3.00 1.90 4.00
3 320 40 300 13.10 4.80 2.10 5.00
TOTAL 623 70 566 39 10.50 4.90 11.00
TABLE2: QUANTITY OF GRAIN (SORGHUM) THRESHED IN (Kg) PER TIME
S/N Qty of Time taken to Qty of threshed Qty of grain Qty of Qty of Qty of grain
unthreshed thresh (T) min grain (x1) Kg cobs (yb) Kg damage grain unthreshed seed stuck in
grain (x) Kg (y2) (y1) sieve (yc)
1 70 10 41 9.1 2.30 0.70 1.80
2 250 20 211 18.5 2.90 1.60 3.70
3 300 40 291 14.1 4.20 1.80 4.40
TOTAL 620 70 543 41.7 9.41 4.10 9.9
These results demonstrate a high efficiency of the machine. This actually shows a great improvement on the
existing which is virtually below 65%.
IV. CONCLUSIONS
The purpose of this research was the design modification, development and performance evaluation of
a thresher. This effort seeks to respond to the need to provide local farmers with appropriate multi-crop
threshers with high throughput and mechanical grain damage that will reduce processing losses which invariably
increases economic returns to the farmers. In the same vane, efficient poweroperated multi-crop threshers would
also eliminate large drudgery involved in the manual method of threshing.
The threshing machine has been developed which offers the potentials of a number of basic design
advantages which implies from the performance test its ability to be used for minimizing energy, high
productivity, affordability and ease of operation by local farmers. The adoption a petrol engine as a power
source is a featurealso makes it available right down to the grassroot. The cylinder and concave sievesare
easilyreplaced for different cereal crops it’s been portable ease of movementfrom farm to farm.
The performance of the modified thresher was carried out using maize and sorghum. The threshing efficiency of
the modified thresher was determined as 92.54% for maize and 89.096% for sorghum as against the 58.72% for
maize, and 56.49% for sorghum respectively.
REFERENCES
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59-62.
[3]. Yisa M.G. (1999) Agricultural Mechanization, how far? And what is next? Paper presented at NSE quarterly dinner in Minna, Niger
state Nigeria.
[4]. Denis Nsubuga, Isa Kabenge, Ahamada Zziwa,Nicholas Kiggundu, Joshua Wanyama and Noble Banadd (2021):Improving Maize
ShellingOperation Using MotorizedMobile Shellers: A Step towardsReducing Postharvest Losses in LowDeveloping Countries:
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[5]. Saeidirad, M. H., Esaghzade, M., Arabhosseini, A. and S. Zarifneshat, S. (2013). Influence of Machine-Crop Parameters on the
Threshability of Sorghum. Agric Eng Int: CIGR Journal, 15(3): 55-59.
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[11]. Mohammed, J. (2009). Development of a maize dehusker thresher. An unpublished master degree thesis, department of agricultural
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[13]. Dauda, A. and Aviara, A. N. 2001. Effect of threshing methods on maize grain damage viability. AMA 32(4):43-46.
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[14]. ASME. 1995. Design of Transmission Shafting. American Society of Mechanical Engineering, New York, NY, USA
[15]. Olaoye, J.O., Oni, K.C and, M.O. (2011) computer applications for selecting operating parameter in a stationary grain crop thresher.
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APPENCICES
Cleaning Efficiency Ce (%)
This is defined as the ratio of the weight of grain collected at the grain outlet to the weight of the total mixture of
grain and chaff received at the main outlet expresses as percentage. It can be determined according to [16] as
stated below.
Ce = (Wt – Wc)/Wt x 100%
Where:
Ce = cleaning efficiency (%)
Wt = Total mixture of grain and chaff received at the main outlet (kg) =63 kg
Wc = Weight of chaff at the main outlet of the thresher (kg) =16.8 kg
Therefore
Ce = (Wt – Wc)/Wt x 100%
= 63 – 16.8/6.3 x 100
= 46.2/63 x 100
= 73.33%
Percentage of Unthreshed Grain
Partially threshed material coming out of the thresher was collected on analysis approach tarpaulin. All the
unthreshed and partially threshed ear heads were sorted out from the straw. The unthreshed heads were re-
threshed manually and the grain recovered was weighed. Percentage of th unthreshed loss was calculated by the
following formula:
Percentage of unthreshed grain, p = Y1/X x100
P = 4.9/623 x 100%
= 0.78%
Cracked Grain
Five samples of clean grain weighing approximately 1 kg each were taken at random from the clean grain and
divided into smaller fraction of about 200 gm. Cracked grain was sorted out manually from each of these
samples and weighed. Percentage of cracked grain was calculated by using following formula:
YC =w/W x100
Where;
YC = Percentage cracked grain w = weight of cracked grain in (g)
W = weight of sample in gm
Throughput Capacity
The throughput capacity is the rate at which T 1 is down linking data at a particular point in time, it is expressed
in megabits per second
Throughput Capacity (kg/min), Ts = (X/T) x 100%
Ts = 623/70
= 8.9 kg/min
Converting to hour;
= 8.9 x 60
= 543 kg/hr
.B. Istifanus, et. al. "Design Modification, Development and Performance Evaluation of a Cereal crop
Thresher.”American Journal of Engineering Research (AJER), vol. 11(03), 2022, pp. 140-147.
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