ERT 464 DESIGN OF MACHINE AND SYSTEM

Transcription

1 ERT 464 DESIGN OF MACHINE AND SYSTEM Machinery for Land Drainage, Reclamation and Estate Maintenance Dr Mohammud Che Husain

2 -AMBITION- There is nothing like a DREAM to help you plan your future

3 Drainage requirement Flash Flood Water Logged

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5 5.1 Machinery for Land Drainage 1. Dragline excavators: for canal/waterway dredging Components: large bucket, wire ropes, boom, ropes drum, diesel engine. Limitations: boom height & length, limits where it can dump the waste material. their digging Depth, limited by the length of rope it can utilize. most efficient when excavating material below the base level high capital cost, but popular due to it reliability & extremely low operation cost 100hp Drain= 20m wide, 10m deep 1.5m 3 bucket

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7 2. Excavators for construction of primary drain Components: boom, stick, bucket & cab on a rotating platform, undercarriage (tracks or wheels) All movement & functions of a hydraulic excavator are accomplished thro the use of hydraulic fluid, with hydraulic cylinders & hydraulic motors. 200hp 10m wide, 7m deep 1.0m 3 bucket

8 Excavator for drain construction Stick Hydr. Cylinder Boom Bucket Hydr. Cylinder Stick Boom Hydr. Cylinder Track Bucket

9 Excavator for drain construction

10 Excavator (long arm) for drain construction and maintenance

11 Small excavator for secondary & tertiary drain construction

12 Hydraulic Power System in excavator deployed in most excavator Components: hydraulic cylinder motor Tank/reservoir hydraulic hoses Advantages: Faster cycle times Outstanding control of attachments High overall efficiency Smoothness & ease of operation greater accuracy & precision

13 3. Backhoes: For construction of tertiary drain 2 main items: hydraulically powered back-acters & front-loader Powerful hydraulic pump is directly driven from tractor engine 65hp 4m wide, 4m deep 0.3m 3 bucket

14 Very popular choice for b cos cheap & versatile Disadvantages: Advantages:»difficult to form a uniformly graded bed & uniform side slope»less efficient as spends much of it time in rotating, discharging & return to its original digging position (drudgery)»work well in stony soil & can carefully explore the soil condition (robust)

15 4. Trench- cutting machines 4.1. Continuous trenchers: Cutting tools attached to a wheel or endless chain machine stands centrally along the line of proposed drain excavated material deposited at the side Digging operation never interrupted and efficiency 2x than backhoe. For any type of soil but not suitable for rock. crawler mounted for stability & distribute the weight over area.

16 Continuous trenchers

17 Excavate the trench by rotating chain cutters & lays the pipe simultaneously Clay tile or plastic pipe can laid at depth up to 1.5 m (deep) Gravel can be placed around drain pipe as continuous sequence operation (efficient & fast) Soil removed can be back-filled after introducing porous-fill layer (gravel) Disadvantage:» need more workers ~5 men (operator, asst operator & 3 laborers)» only work well in stone-free soils (limited)

18 4.2 Trenchless machine (crawler): Cutting narrow slits enough to allow the pipe to be passed down at depth up to 0.35 m (very shallow) has an engine of 250 hp (big engine) has hopper & long narrow chute for putting gravel fill over the pipe (efficient & fast)

19 Plastic pipe are popularly used but clay tiles up to 150mm dia. can also be laid (few choice) Soil removed can be deflected & spread-out Advantages:» work faster (2-3X ~ 5km/d) & more economical than trencher» suitable for installation of corrugated plastic pipe ( mm dia.)» can be used on stony soil Disadvantage:» require more power than trencher especially when working at great depth in heavy clay soil» need adequate traction under wet surface-condition

20 4.3. Trenchless machine (winched) Operate by winching itself along cables towards a ground anchor Disadvantages:» Main problem is it needs adequate anchorage.

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23 5. Mole plough: Used to installed Mole channels A bullet (mole) attached to vertical tine/blade drawn thro the soil, create a mole channel. mole is followed by an expander which expands & strengthens the channel. practical only on very heavy clay in a moist condition. Vertical tine mole expander

24 Mole channel size: mm dia. & spaced every m. Installation depth: m below surface. Machine working rate: 5 km/hr. had been practices since 150 yrs ago can be function for 5-15 years.

25 mole plough has long 3.7m floating beam with skids at front & rear, a pneumatic-tyre carriage & hydraulic lift 7.5 cm mole, 0.8m working depth required hp tractor

26 Jetter for drain cleaning for cleaning of tile drains from silts & sands. 3-point-linkage-mounted & has reel carrying 400 m of plastic hose. A PTO driven pump deliver 60 l/m at 40 bar water pressure. cleaning nozzle is propelled in the pipe by push-pull head with multiple forward & rear-facing nozzles.

27 Machine capacity No. of units which mc can process/cover in a specific time (eg: ha/hr) Effective Field Capacity (EFC): the measure of a machines ability to do a job under actual field conditions. EFC = Theoretical Field Capacity X field efficiency. theoretical Field Capacity, TFC (ac/hr) = Speed (mph) x Machine Width (ft)/8.25

28 The machine cannot operate at its theoretical capacity in the field due to the following factors: Turning & idle travel Operating at less than full capacity (width) Machine adjustment Lubrication & refueling during the day Waiting for other machines Waiting for repairs to be made Consequently, the field efficiency is always <100%

29 Field Efficiency % of time the machine operates at its full rated speed & width while in the field. Using the field efficiency compute the actual or effective, EFC = Theoretical Capacity x Field efficiency Typical values of field efficiency (60%) & speed (4 mph)

30 Example 1 (FEQ13/14) Dragline excavators to be used to construct 1.6 km long main drain. Calculate the number of working day required by 2 dragline excavators if the working rate of a machine is 15 m/hr, 8 hr/day and work efficiency is only 70%. Solution: L= 1.6 km = 1600 m No of machine = 2 working rate = 15 8 hr/day work efficiency = 70%. 1 machine, Actual field capacity = 15 m/hr X 70%.= 10.5 m/hr 2 machines, actual field capacity = 10.5 m/hr X 2 = 21 m/hr For One 8 hr/day = 21 m/hr X 8 hr/day = 168 m/day For 1600 m drain it take = 1600 m/(168 m/day) = 9.52 days No. of working day = 9.5 days

31 Example 2 (T22012) The citrus farm plan to construct a drainage system that consists of a main (14m wide & 4.5 m deep) and secondary drains (10m W & 3m deep) in their 50 ha undulating & stony soil area. Q1:Select the suitable machines for this operation by giving your reasons for choosing the machines. Main drain > 14m W & 4.5m D= dragline Secondary drain-> 10m W & 3m D = excavator

32 Q2: List the advantages and disadvantages of using these machines. Dragline Advantages Efficient excavating material below their base Reliability Low waste removal cost Disadvantages High capital cost Limits where it can dump the waste material Limited by the length of rope the dragline can utilize. Excavator Advantages Cheap and versatile Work well in stony soil & can carefully explore the soil condition (robust) Longer reach & larger bucket (better capacity) Disadvantages Difficult to form a uniformly graded bed & uniform side slope Less efficient

33 Example 3 Machine = continuous trencher Area (wheat) = 10 ha (500m L X 200m W) Working speed, WC = 4 km/hr Drain spacing, S = 10 m Machine efficiency, E = 75% Calculate No. of working hour (WH) to construct the drain.

34 W, 200 m S, 10 m slope Farm ditch L, 500 m Drain Length (m), DL = W/S x L =200/10 x 500 = 10,000m Working hour (hr), WH = DL/(WC X E) = 10,000m/(4000m per hr X 75%) = 3.3 hr

35 Assignment 3 UniMAP is developing a new orchard farm at INSAT, Sungai Chuchuh. The area to be developed is about 200 ha which currently under secondary jungle and prone to serious water logged. Q1: Excavators are to be used to construct the 6km long perimeter drain around the farm. Calculate the number of excavator required if the working rate is 0.2 km per hour and efficiency of 75%. The job to be finish by one day (8 working hours).

36 Q2: Proposed the effective machinery system for land drainage for upland crop such maize and sugarcane in soft clay area. Provide the advantages and disadvantages of using this machinery system.

37 Part ii

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39 5.2 Machinery for land reclamation for clearing trees, bushes & scrub for earth work (grading, leveling & land fill) choice of machine depend on: vegetation soil condition Required amount of earthwork size of the area to be clear Single or multi level/grade

40 LAND RECLAIMATION - step Remove vegetation Rough grading (cut & fill) Final leveling

41 1. Bull-dozers Used for: bush & hedge clearing, filing drainage trenches rough land grading/leveling Component: Earth-moving devices (bucket) mounted in front of machine with hydraulic lift system. A blade used to push large quantities of soil/sand/rubble, typically equipped at the rear with a claw-like device (ripper) to loosen densely-compacted materials.

42 either on track (crawler) or wheel (more effective on track than on wheel) Tracks: give excellent ground hold & mobility thro very rough terrain. help distribute the bulldozer's weight over a large area (decreasing pressure), thus preventing it from sinking in sandy/muddy ground.

43 2. Angle dozers Used for: pushing, side casting & spreading loose soils as for clearing land, or leveling access roads Component fitted with a blade (adjustable in height & angle)

44 3. Earth scoops or scraper used for: earthmoving in the finish grading Component: rear part has a vertically moveable hopper (bowl) with a sharp horizontal front edge.

45 hopper can be hydraulically lowered & raised. When the hopper is lowered, the front edge cuts into the soil & fills the hopper. When the hopper is full (8-34 m 3 ) it is raised, and closed with a vertical blade (apron). scraper can transport its load to the fill area

46 4. Motor graders or leveler used for: accurate leveling It move the soil & creating a smooth surface & making certain the appropriate gradient. in building roads & maintenance

47 Component: grader blade consists of a curved body with a hard steel cutting edge. has a big steel cutting edge found under the centre portion of the machine. blade can be adjusted which allows the operator to manage the angle & height of the cutting edge

48 Assignment 4 UniMAP is developing a new Sport Complex at Pauh Putra. The area to be developed is about 500 ha which currently under virgin jungle. The area comprises heavy clay soil and undulating. Proposed appropriate machinery for bushes and scrub clearing and earth work such as grading, leveling and land-fill the area. Give your reason for choosing such machinery.

49 Part iii

50 5.3 Machinery for Estate Maintenance

51 1. Tractor winches For pulling heavy objects or loads such as timber

52 Winch drum Wire rope

53 2. Bracken cutting machines Used for clearing light scrub (eg: fern/resang) PTO-driven rotary slasher (with hinged horizontal bars) Slasher mounted on the 3-point linkages & adjusted by position-control Alternative machine: Flail-type pulverizers

54 Rotary slasher

55 3. Hedge-cutting machines Classification: a) Tractor-mounted: i. high speed rotating cutter (capable of cutting wood 5-15 cm thick) ii. iii. reciprocating cutter-bars with cutting blade 7.5 cm apart (capable of cutting growth 3 cm thick) flail-type, can handle light-medium growth on hedges & also for trimming banks at below tractor level b) Hand-held: i. Trimmers with short cutter-bar (capable of dealing with shoots up to 1.5 cm thick).

56 High speed rotating cutter

57 Flail type hedge cutter

58 Flail type hedge trimmer

59 Hand-held Trimmers with short cutter-bar

60 4. Post-hole diggers used for: digging post holes. auger is driven thro bevel gears by tractor powertake-off (PTO) Auger blades; replaceable, come in different shape & size. Auger speed:-80 rpm Working depth: m Auger diameter: cm

61 Hole digger

62 Example 3 (T22012) Q1: For hedge cutting operation, the hand-held trimmers with short cutter-bar are to be deployed for this operation instead of a tractor-mounted flail-type machine. Compare the two machines components and provide the drawbacks using the hand-held trimmers? Hand-held trimmers Components Cutter bar Motor Handle Tractor-mounted flail-type Components Hydraulic pump Hydraulic arm PTO shaft Flail type cutter blade Drawbacks using the hand-held trimmers lower efficiency lower working rate small coverage drudgery

63 Assignment 5 Proposed a machine to extract timber from the cleared area (Assignment 2) and to construct perimeter fence around the sport complex Flail-type hedge trimmers are use in trimming light to medium growth on hedges and also be used for trimming banks. Give your reason why this machine so popular for above uses.

64 REFERENCES Smedema, L. K. and Rycroft, D. W (1983). Land Drainage. Batsford Academia and Education Ltd, London. Culpin, C. (2008). Farm machinery. 12 th Edition, Wiley-Blackwell.