Design Calculations

*COFFEE DEPULPER

According to R. J. Clarke and R. Macrae in their book titled Coffee Technology Vol. 2, p

11-12

Disc Specifications:

Diameter: 18 inches

N = 120 RPM

P = 1 hp for single disc, 2.5 hp for 4 discs

Capacity = 1000 kgs

Material: Cast iron or stainless steel with bulb projections

Use a 6 inch, cast iron disc.

For robusta coffee cherry, space between the discs is in the range of 6 mm-10mm

Disc Specifications:

Diameter: 6 inches

Solving for the Depulper Power

From the design Hp Formula:

Design Hp = Tansmitted Hp X Nsf

Where:

Nsf = 1.4 -0.2 (Table 17.7, Service factors by Faires, p. 460)

Nsf = 1.2

Design Hp = 1.5 (by interpolation)

Transmitted Hp = 1.5/1.2 = 1.25

Solving for the Torque

P = 2TN

T = P / 2N

Where:

P= 1.25 Hp

N = 120 (As per PAES standard speed for mechanized pulper)

1.25 hp 33000 lb ft/min

T=
2 (120RPM) 1 hp

T = 54. 71 lb ft

T
F=
r

Where: r = 3 inches

T 54.71 lb ft 12 in
F= = = 218.84
r 3 in 1 ft
Design Horsepower to drive mechanism including losses

According to Morse, p. 452, losses in V-belt is 5%

Transmitted power on V-belt

Transmitted power on V-belt = Required power to drive the depulper / 0.95

Transmitted power on V-belt = 1.25 hp / 0.95

Transmitted power on V-belt = 1.31579 hp

DRIVING SYSTEM DESIGN

V Belt Design

Design Considerations:

Motor type: Squirrel cage motor

Type of service: quite intermittent or seasonal

V Belt material: Leather belt

From: http://www.engineeringtoolbox.com/electrical-motors-hp-torque-rpm-d_1503.html

Power versus torque and motor velocity in electric motors table

Nearest capable of driving is:

Motor Power = 1.5 hp

RPM = 1750 RPM

(Speed and power are subjected to change depending on the availability.)

Solving for Design Hp

Design Hp = Transmitted Hp x Nsf

Where:

Nsf = 1.4 -0.2 (Table 17. 7 Service factors by Faires, p. 460)

Design Hp = 1.31579 * 1.2

Design Hp = 1.57895

(From Fig. 17.14 Belt Selection from Horsepower and Speed by Faires, p. 457, choose

Section B)

Pulley Diameters
D1 = 4 in
D2 = 10 in
D1 + D2
C=( ) + D1
2

4 + 10
C=( )+4
2

C = 11 in

Actual adjustment: C = 31 in
Solving for belt length (Equation by Faires, p. 446)

(D2 D1 )2
L = [ (D2 + D1 )] + 2C + [ ]
2 4C

(10 4)2
L = [ (10 + 4)] + 2(31) + [ ]
2 4(31)

L = 84.28147 in

From Table 17.3 Standard V-Belt Lengths by Faires,p. 458 at Section B, select B85 with

pitch equal to 86.8 in.

Solving for V-belt Speed

D1 N1
VM =
12

(4)(1750)
VM =
12

VM = 1832.595715 ft/min

The required speed for v-belt is 4000 RPM. If the belt runs faster than 5000 RPM or

much slower than 1000 RPM trouble may be encountered [Joseph et al, 1983].

Solving for Kd (small diameter factor)

From Table 17.4 Small-Diameter Factors by Faires, p. 459

D2 10
= = 2.5
D1 4

Kd = 1.13
Solving for Rated Hp (From equation by Faires, p.456)

0.09
103 13.962 VM 2 VM
Rated Hp = [4.737 ( ) 0.0234 6 ] 3
VM K D D1 10 10

0.09
103 13.962 (1832.595715)2
Rated Hp = [4.737 ( ) 0.0234 ]
1832.595715 (1.13)(4) 106

1832.595715
( )
103

Rated Hp = 2.415628502

Solving for Adjusted Hp

Horsepower rating must be corrected fot the length of belt (KL) and arc of contact (K).

(Faires, p.457)

Adjusted Hp = K L K (Rated Hp)

Where:

KL = length correction factor, 0.97 from Table 17.6 Length Correction

Factors by Faires, p. 459

K = arc of contact factor

From Table 17.5 Arc of Contact Factors by Faires, p.459

(D2-D1)/C = (10-4)/31

(D2-D1)/C = 0.1935483871
 By interpolation,

0.1 0.99

0.1935483871 K

0.2 0.97

K = 0.9712903226

Therefore,

Adjusted Hp = (0.9712903226)(0.97)(2.415628502)

Adjusted Hp = 2.275888289

Solving for Number of Belts

Number of belts = Design Hp / Adjusted Hp

Number of belts = 1.57895 / 2.275888289

Number of belts = 0.6937730676

Say 1 belt

Shaft Design

Design Consideration:

Material Used: AISI 1018 Mild/Low Carbon Steel

Tensile Strength: 63,800 psi

 Yield Strength: 53,700 psi

For line shafts carrying pulleys (PSME Code, p.18)

ND3
P=
53.5

Where:

P= power transmitted,hp

D= diameter of shaft,in

N=speed,RPM

(120)D3
1.5 =
53.5

3 (1.5)(53.5)
D=
120

D = 0.8744894981 in

Say 1 shaft

Bearing Selection for Shaft

Type: Pillow Block #205

Internal Diameter: 1

Design for Key for the Pulley on the Shaft

Material used: AISI 1018 Mild/Low Carbon Steel, same material as used in shafting
 Su: 63,800 psi

Sy: 53,700 psi

From Table A19 Key Dimensions by Faires,p. 394

For shaft diameter of 1 in

b= .25 t=3/16

Hopper Dimension

Upper dimensions: 18x18

Bottom dimensions: 4x4

Inclination Angle: 45

Height: 17

Shape: Square Frustum

Material: Mild Steel

*COFFEE HULLER

Hulling Shaft

Diameter: 4

= 449 lb/ft3

d2 L
V=
4
 Where: d= 4 L=12

4 2
(12) (1)
V=
4

V = 0.0872664626 ft 3

m = V

449lb
m=( ) (0.0872664626 ft 3 )
ft 3

m = 39.18264171 lb or 17.76990554 kg

W = mg

32.2 ft
W = (39.18264171lb) ( )
s2

W = 1261.681063 lbf

Solving for Torque

N1 D1 = N2 D2

(1750)(4) = N2 (10)

N2 = 700 RPM

F = T/r

T = Fr

T = (1261.681063 lbf)(2 in)

T = 2523.362126 lb in

P = 2TN

2(2523.362126 lb in)(700 RPM) 1Hp

P=
(12)(2.205) 33,0000 ft lb
min

P = 0.8703750459 hp

Solving for the Depulper Power

From the design Hp Formula:

Design Hp = Tansmitted Hp X Nsf

Where:

Nsf = 1.4 +0.2 (Table 17.7, Service factors by Faires, p. 460)

Nsf = 1.6

Design Hp = 0.8703750459

Transmitted Hp = 0.8703750459 /1.6 = 0.5439844037

Design Horsepower to drive mechanism including losses

According to Morse, p. 452, losses in V-belt is 5%

Transmitted power on V-belt

Transmitted power on V-belt = Required power to drive the depulper / 0.95

Transmitted power on V-belt = 0.5439844037hp / 0.95

Transmitted power on V-belt = 0.5726151618 hp

DRIVING SYSTEM DESIGN

V Belt Design

Design Considerations:

Motor type: Squirrel cage motor

Type of service: quite intermittent or seasonal

V Belt material: Leather belt

From: http://www.engineeringtoolbox.com/electrical-motors-hp-torque-rpm-d_1503.html

Power versus torque and motor velocity in electric motors table

Nearest capable of driving is:

Motor Power = 1 hp

RPM = 1750 RPM

(Speed and power are subjected to change depending on the availability.)

Solving for Design Hp

Design Hp = Transmitted Hp x Nsf

Where:

Nsf = 1.4 +0.2 (Table 17. 7 Service factors by Faires, p. 460)

 Design Hp = 0.5726151618 * 1.6

Design Hp = 0.9161842588

(From Fig. 17.14 Belt Selection from Horsepower and Speed by Faires, p. 457, choose

Section A)

Shaft Design

Design Consideration:

Material Used: AISI C1117 Carbon Steel

Tensile Strength: 62,000 psi

Yield Strength: 40,500 psi

From Table AT 8 Typical Properties of Steel (Faires, p.578)

For line shafts carrying pulleys (PSME Code, p.18)

ND3
P=
53.5

Where:

P= power transmitted,hp

D= diameter of shaft,in

N=speed,RPM

(700)D3
1=
53.5
 3 (1)(53.5)
D=
700

D = 0.4243770739 in

Use a factor of safety equal to 2.

D = 0.8487541478 in

Say 1 shaft

Belts and Pulleys

D1= 4 D2 = 10

C = 25

Solving for belt length (Equation by Faires, p. 446)

(D2 D1 )2
L = [ (D2 + D1 )] + 2C + [ ]
2 4C

(10 4)2
L = [ (10 + 4)] + 2(25) + [ ]
2 4(25)

L = 72.35115 in

From Table 17.3 Standard V-Belt Lengths by Faires,p. 458 at Section A, select A75 with

pitch equal to 76.3 in.

Solving for V-belt Speed

D1 N1
VM =
12

(4)(1750)
VM =
12

VM = 1832.595715 ft/min

The required speed for v-belt is 4000 RPM. If the belt runs faster than 5000 RPM or

much slower than 1000 RPM trouble may be encountered [Joseph et al, 1983].

Solving for Kd (small diameter factor)

From Table 17.4 Small-Diameter Factors by Faires, p. 459

D2 10
= = 2.5
D1 4

Kd = 1.13

Solving for Rated Hp (From equation by Faires, p.456)

0.09
103 VM 2 VM
Rated Hp = [a ( ) e 6] 3
VM K D D1 10 10

Constants: a= 2.684 b= 5.326 e=0.0136

0.09
103 5.326 (1832.595715)2
Rated Hp = [2.684 ( ) 0.0136 ]
1832.595715 (1.13)(4) 106

1832.595715
( )
103
Rated Hp = 2.414633685

Solving for Adjusted Hp

Horsepower rating must be corrected fot the length of belt (KL) and arc of contact (K).

(Faires, p.457)

Adjusted Hp = K L K (Rated Hp)

Where:

KL = length correction factor, 0.97 from Table 17.6 Length Correction

Factors by Faires, p. 459

K = arc of contact factor

From Table 17.5 Arc of Contact Factors by Faires, p.459

(D2-D1)/C = (10-4)/25

(D2-D1)/C = 0.24

By interpolation,

0.2 0.97

0.24 K

0.3 0.96

K = 0.966
Therefore,

Adjusted Hp = (0.966)(0.97)(2.414633685)

Adjusted Hp = 2.262560056

Solving for Number of Belts

Number of belts = Design Hp / Adjusted Hp

Number of belts = 0.9161842588/ 2.262560056

Number of belts = 0.4049325703

Say 1 belt

Bearing Selection for Shaft

Type: Pillow Block #205

Internal Diameter: 1

Design for Key for the Pulley on the Shaft

Material used: AISI C1117 Carbon Steel, same material as used in shafting

Su: 62,000 psi

Sy: 40,500 psi

From Table A19 Key Dimensions by Faires,p. 394

For shaft diameter of 1 in

b= .25 t=3/16

Fabrication:

Design of Blower

Shaft Diameter: 1

Blower Diameter: 15

No. of Blades: 6

Reciprocating Screen:

Dimension: 10 x 29

Hole: No. 22

Hopper Dimension

Upper dimensions: 18x18

Bottom dimensions: 2x 2

Height: 15.5

Inclination Angle: 45

Shape: Square Frustum