INTRODUCTION

Agriculture is the backbone of our country. Nearly for our population

resides in villages. And those residing in villages are in way or other, draw their

income via agriculture. A prosperous village could certainly result in a prosperous

country.

Keeping these things in mind and after looking out areas of problems

faced by farmers, we stumbled upon this project. This project was entrusted upon us

by Mr. Promod Dhotre of L & T - John Deere Limited.

As we all know, irrigation forms most important part of farming.

Generally, for irrigation a set of generator & pump or an electric pump is used. It

presented following set of problems :

 Un-availability / not easy accession of electricity in for flung areas

 In case of generator & pump set, loading & unloading of set

 Small fuel capacity of generator

 Problem of solid foundation

 Problem of mobility

 A feeling of under - utilization of generator set.

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 And, above all, farmers queuing up to buy tractors have to fork out

extra money for buying a generator set to drive pump (Where electricity is

unavailable).

CONVENTIONAL METHOD OF IRRIGATION

The traditional way for irrigating is to use a generator and pump set,

i.e. generator drives the pump which in turn draws water and disperses them. In this

case, some problems are faced as mentioned in introduction. And, above all,

generator becomes a liability, say in months of monsoon. Those, who already had a

tractor harped about under utilization of machines.

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 REQUIREMENTS OF CUSTOMER

In order to gauge the needs of customers, we went to places where

already farmers had mounted pump on tractor. One such place we went to was a

village Aagar, and to other village named Ugwa.

The problems faced by them were :

 The unit needed to be lighter in weight, so as to be hauled around easily.

 The unit needed to be study in design.

 The unit needed to be easy to mantle & dismantle.

 The unit should be easy to handle.

 The unit should provide a good value for money.

Keeping these requirements our mind as a focal point, we designed

this object.

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 WHAT IS THIS PROJECT ABOUT

This project is about designing a fixture for a tractor, through which

pump can be directly driven by tractor. This project was entrusted upon us by Mr.

Pramod Dhotre of L & T – John Deere Ltd. This project is to be used in for

flung areas, where electricity is not readily available.

Principle

The power provided by tractor, transmitted through Power Take Off

(PTO) shaft is harnessed to drive the main shaft. The main shaft drives the shaft of

pump by means of v-belt and pulleys.

Problem

So, we had to design the fixture, choose appropriate pump, design the

shaft, bearings, coupling and of course v-belt and pulleys.

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 The Tractor

We were generously allowed to choose a tractor from L & T - John

Deere Showroom for our project by Mr. Pramod Dhotre.

The model chosen by us was 5103. The specifications of the model

are :-

Engine Model :- 3029 D P Y 03

Engine B.H.P. = 40

Rated RPM ( of engine ) = 2300

Cylinders = 3

Bore = 106.50 mm

Stroke = 110 mm

Displacement = 2930 mm

Power Take Off shaft (PTO) :-

Type :- Independent six splines

H.P. :- 35 H.P.

RPM :- 540

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 BILL OF MATERIALS OF TRACTOR FIXTURE

1) V-belt Drive :- A v-belt is mostly used where a great amount of power is to be

transmitted from one pulley to another when two pulleys are very near to each

other. A V-belt have advantage over gear – drive in the matter that it is almost

maintenance free and investment is low too. It can be easily installed and removed.

They have cushioning properties too, when the machine is started. It reduces the

slippage problem too.

2) Bearings :- Rotating shafts transmitting power needs supports. The problems

that arise at supports are, the wear of rotating shaft and the support itself, generation

of heat due to friction of support, loss of power, maintenance, safety etc. The

inevitability of the support attended by undesirable factors as mentioned above is to

large extent answered by “Bearings”, thwarting the undesirable factors. So as such,

good bearings offer suitable fits to the shafts, after provision for good lubrication

and easy replacement of worn-out surfaces. They can be grouped under two

categories, namely :-

The sliding contact bearings.

The sliding contact bearings or Antifriction bearings.

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3) Pulleys :- They are used to transmit power from one shaft to another shaft by

means of belts or ropes. Pulleys are made of cost iron, pressed steels wood and

paper in standard sixes as regards diameter, width of face and bore for the shaft.

The principal parts of the pulley are hub, which is adjacent to shaft, the arms

extending radially from the hub and the rim at circumference. Instead of arms,

some pulleys have a solid web between the hub and the rim. Some pulleys are

made in two semi-circular halves and bolted or riveted together.

4. Shaft :- A shaft is rotating member which transmits power from one point to

another point. It may be divided into two main groups :-

Transmission shafts

Machine shafts

Shafts which are used to transmit power between the source and the

machines absorbing power, are called transmission shaft. Such shaft carry machine

parts such as gears and pulleys and therefore they are subjected to bending in

addition to twisting. Machine shafts are those which form an integral part of

machine itself, the common example being the crank shaft.

Shafts are usually cylindrical but occasionally, they may be square or

cross-shaped in section.

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(5) Universal (Hooke’s Coupling):-

A universal coupling is used to connect two shafts whose axis

interested at a small angle. The inclination of two shaft may be constant, but in

actual practice, it varies when the motion is transmitted from one shaft to another .

The main application of this is found in the transmission of gear box to the axel of

automobile. It is also used in transmission of power to different spindles of multiple

drilling machine.

(6) Equal angles :-

The process of manufacturing the angles is usually rolling. In this

project, we are using Rolled steel equal angles having thickness 3 mm.

(7) Pump :-

The pump being used for irrigating purpose is of Laxmi make. This

has been given to us by Mr. Pramod Dhotre. The pump has following

specifications

Head :- 29/34

Size :- 80 x 66

Type :- L C 3

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 RPM :- 1800 rpm

Power :- 8 HP

The pump being used is of centrifugal tape.

Splined shaft

Some times keys are made integral with shaft which fits in keyways

broached in hub. Such shafts are known as splined shafts. They are used when

force to be transmitted is large in proportion to size of shaft as in automobile

transmission. It provides for axial movement as well as positive drive is obtained.

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 PROPERTIES OF MATERIAL USED

1)Shaft

The material being used for shaft is 40C8. Its composition being 0.35

– 0.45 Carbon & 0.60 – 0.90 Manganese.

Its properties are :-

Tensile strength : – 80 N/mm2

Yield strength :- 110 N/mm2

Shear stress :- 42 N/mm2

2)Frame :-

The material being used is rolled steel the designation being 2020,

thickness 3 mm.

3) Universal Coupling :-

The material being used is 40C8.

4) Bearings :-

The bearing selection is according to standard procedure the

designation being 6305.

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5) Belt :-

The belt selected Ps of B – selection, keeping in mind the value of

power to be transmitted and rpm of faster shaft.

6) Pulley :-

Same as belt. The material is cast iron.

7) Splined Shaft :-

The material being used is 40 C 8.

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 WORKING

The power house of whole system is 3-cylinder tractor engine. This

engine, driven by diesel, drives the PTO shaft. The PTO shaft drives the main shaft

via universal coupling. The shaft is supposed by bearings and a pulley is attached

in middle of two bearings. Power is transmitted from main shaft to pump shaft via

V-belt. Shaft of pump has a pulley attached to its end.

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 DESIGN OF FIXTURE

1) Design of Pulley :-

Applying Saverin’s empirical formula to determine the dia. of smaller

pulley :-

P(KW )
d = 630 3
2π η Max

Where,

P = Power to be transmitted = 5.76 KW

η
Max = Maximum speed of shaft = 1800 rpm

d = 51 mm.

But due to design consideration and as we have to mount it on a shaft

of 25 mm diameter, according to hand book we take

d = 75 mm.

From the relation,

N 2 d1
=
N1 d 2

Where, N1 = rpm of PTO shaft = 540 rpm (Given)

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 N2 = “ “ Pump “ = 1800 rpm ( u )

d2 = diameter of pulley on pump shaft = 75 mm

d1= “ “ “ “ main shaft = ?

1800 d 1
=
540 75

d1 = 250 mm.

(2) Design of Shaft :-

πdN
Velocity of belt =
60

Where, d = diameter of pulley = 250 mm = 0.25 m

N = rpm of PTO shaft = 540 rpm.

πx 0.25 × 540
V=
60

= 7.068 m/s

Power Transmitted,

(T1 − T2 )V
P=
1000

P = Power needed in KW = 5.76 KW

T1= Tension in tight side of belt

T2 = “ “ slack “ “ “

V = Velocity of belt = 7.068 m/s

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Putting these values,

(T1 − T2 ) × 7.068
5.76 =
1000

(T1 – T2) = 814.94 N

Applying the relation,

π
T= fs d 3 ( considering only twisting moment )
16

Where, T = torque transmitted by shaft

= ( T1 – T2 )r

= (814.94 x 125) N mm.

fs = Shear stress of mild steel

= 42 N/mm2

d = ? diameter of shaft = ?

Putting these values in equation :-

π
814.94 × 125 = × 42 × d 3
16

d = 23.23 mm

= 25 mm.

(3) Design of Universal Coupling :-

Since, the pin is in double shear, therefore torque transmitted,

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 π
T = 2 × (dp) 2 × fs × d
4

Where, T = torque transmitted by shaft

dp = diameter of pin

fs = allowable shear stress of pin

d = diameter of shaft

Putting these valves in equation,

π
814.94 × 125 = 2 × × (dp) 2 × 42 × 25
4

dp = 7.9 mm

= 8 mm

(4) Design of Equal Angles :-

Using the relation,

π EI
Wer =
L2

Wt. of pump
Whereas Wcr = Crippling load =
4

500
= = 125 N
4

E = Young’s modulus of the material

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 = 130 kN/mm2

I = Moment of inertia

=?


L = Equivalent length =
2

257
= = 128.5 mm
2

where  = length of equal angle

Putting these values, we get

I = 0.0125 mm4

Consulting from table, according to Z ( section modulus )

we designate Rolled steel equal angle of designation 2020, Thickness = 3 mm

(5) Design of splined hole :-

Inner dia. of splined hole = Outer dia. of PTD shaft

d = 30 mm.

D = dia. of spline

= 1.25 d

= 1.25 x 30 = 37.5 mm

b = width of spline

= 0.25 D

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 = 0.25 x 37.5 = 9.375 mm

= 10 mm.

L = length of splined hole

= length of notch on PTO shaft

= 80 mm.

(6) Design of bearing :-

L10 = Bearing life = years of use (approx.) × Days in a yr

× hours/day × min × rpm of shaft

= 6 × 300 × 8 × 60 × 540

= 466.56 × 106 rev.

Using the relation,

3
 Ca 
L10 =   millions of rev.
 pa 

Where, Ca = dynamic load

Pa = Static load = 832.67 N

We get Ca = 6458 N

From the design data handbook and considering the diameter of shaft, we choose

Bearing of basic design No. 6305

(7) Design of belt :-

Power to be transmitted by belt = 8 H P = 5.76 KW

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 Rev/min of faster shaft = 1800 rpm

From the cross – section selection chart, according to given data, we

choose B section.

Length of belt = 1290 mm.

Standard belt according to length of belt = B 51.

BILL OF QUANTITY

SR.NO. ITEM SPECIFICATIONS Qty.

1. Shaft Minimum dia = 25 mm. 1

Length = 400 mm.

2. Splined Hole Maximum outer dia = 33 mm 1

Minimum Inner dia.= 30 mm

3. Bearing Bearing No :- 6307 2

4. Pedestal Length :- 75 mm 2

5. Angles Designation :- 2020 1

length :- 3865 mm

t = 3 mm

6. Flat strip length = 210 mm 1

thickness = 50 mm

width = 50 mm

7. Pulley (V-grooved ) 1. D1 = 75 mm 1

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 2. D2 = 250 mm 1

8 V - belt length 1290 mm 1

9. Flange dia. = 35 mm 1

10. Universal Coupling dia. of pin = 8 mm 1

PROCESS PLANNING CHART

CHART 1

Name of the part : - shaft

Raw material quantity – 1

Length = 410 mm, diameter = 28 mm

Mild steel

Sr. Operation Standard Description of Tool used Gauge used Operation

No. m/c used operation time
1. Facing Lathe 4-Jaw Facing the shaft Single _ 8 min.
point
cutting tool

2. Turning Lathe 4-jaw Turning the shaft Single Vernier 22 min

cutting tool

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 CHART - 2

Name of the Part :- Flange

Raw Material Quantity - 1

Diameter - 52 mm

Width - 10 mm.

Sr. Operation Standard m/c Description of Tool Gauge Operation time

No used operation used used

1 Facing Lathe 4-jaw Facing the flange single _ 10 min

point
cutting
tool

2 Turning Lathe Turning the flange single vernier 4 min

4- Jaw point
cutting
tool

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 3 Drilling Vertical Drilling 4 holes of Drill _ 8min
drilling dia. 8 mm
machine

CHART - 3

Name of the Part :- Pulley ( B - Section )

Raw Material Quantity - 2

Diameter - 250 mm

Diameter - 75 mm.

Sr. Operation Standard m/c Description of Tool Gauge Operation time

No used operation used used

1. Boring Lathe 4- Boring the central Boring Vernier 20 min

jaw hole of dia. 25
mm

2. Boring Lathe 4- Boring the central Boring Vernier 18 min

jaw hole of dia. 23.8
mm

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 CHART - 4

Name of the part :- Fixture

Raw material quantity :- 1

Length = 3865 mm

Thickness = 3 mm

Designation = 2020

Sr. Operation Standard m/c Description of Tool used Gauge Operation

No used operation used time

1 Welding Arc welding Welding the angle Welding _ 55 min

machine equipment

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 BILL OF MATERIAL

Sr.No. Items Quantity Cost in Rs.

1. Shaft 1 150
2. Splined hole 1 80
3. Bearing & Pedestal 2 1080
4. Angels 1 270
5. Flat strip 1 10
6. Pulley 2 240
7. V-belt 1 160
8. Flange 1 15
9. Universal coupling 1 380
11. Machining 1290

Charges
Total 3675

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 COST ESTIMATION

Cost of Pump :- Rs. 3000

Cost of material and machining charges :- Rs 3675

Total Rs 6675

The total cost incurred in manufacturing this project is Rs. 6675

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 ADVANTAGES

1) The unit is sturdy in design.

2) The unit negates the factor of unavailability of electricity.

3) The unit is easy to handle

4) The maintenance cost is effectively nil.

5) The unit is mobile.

6) The unit can provide variable output by varying pulley ratio.

7) The unit ensures full utilization of tractor.

8) For those already having tractor, initial investment is low, as it eliminates the

need to buy generator.

DISADVANTAGES

1. As the tractor's engine has 3 cylinder, while generator is of single cylinder, fuel

consumption is high.

2. The belt life is greatly influenced with temperature changes, improper belt

tension & mismatching of belt length.

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 APPLICATION

1. This unit is primarily to be used by farmer, already having tractors for

irrigation.

2. This unit is to be used in those places, where electricity is not easily available.

3. This unit can be successfully used in villages where power shortages are

prominent for a longer period of time as a alternative.

4. The unit may find its applications in construction work in remote area where

water is required.

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 CONCLUSION

We have designed a "Fixture for pump mounting on Tractor". This

fixture is to be used in those for flung areas where electricity is not readily or easily

available.

This project will prove fruitful to those farmers who already have

tractor and need pump for irrigation.

This project is bound to satisfy the consumers.

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 BIBLIOGRAPHY

1. A text book of Machine Design

R.S.Khurmi & J.K.Gupta

2. John - Deere Information Leaflets

3. A text Book of Machine Design

Dr. Sadhu Singh

4. Design Data Hand book

K. Mahadevan

5. Thermal Engineering

R. K. Rajput

6. Work shop Technology

Hajra & Chaudhary

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Rev/min of faster shaft

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