TABLE OF CONTENTS

Certificate i

Acknowledgement ii

Abstract iii

List of Figures iv

List of Tables vi

Chapter 1: Introduction 1-3

1.1 Overview 1

1.2 Scope of Work 2

1.3 Survey 3

Chapter 2: Introduction to Mechanism 4-17

2.1 Concept of Degree of Freedom 4

2.2 Kutzbach criterion Equation 5

2.3 Four bar chain Mechanism 5

2.4 Single slider crank Mechanism 6

2.5 Degree of Freedom of Whole System 8

2.6 Numerical Analysis on Leaf Log Mechanism 9

Chapter 3: Introduction to Design and Fabrication 18-30

3.1 Sketching and drawing selection 18

3.2 Concept generation and evaluation 20

3.3 Final design 20

3.4 Fabrication 22

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3.5 Process of making Leaf Log 29

Chapter 4: Application and Future Scope 31-32

4.1 Applications 31

4.2 Future Plans 31

Conclusion 33

References 34

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UTTAR PRADESH TECHNICAL UNIVERSITY LUCKNOW

BONAFIDE CERTIFICATE

This is to certify that the project entitled “Leaf Packing Machine” is

being submitted by (Deepankar Mondal:1123040030, Balraj

Choudhary:1123040026, Charit Pant:1123040027, Abhishek

Saxena:1123040003 , Avneesh Pal:1123040025) in partial fulfillment for the

degree of Bachelor of Technology in Mechanical Engineering of the

Dronacharya College of Engineering, Greater Noida (Affiliated to U.P.T.U.

Lucknow) is a record of their own work, carried out under my supervision.

SIGNATURE SIGNATURE

Ankush Yadav Prof. D V Bhise

(Assistant Professor) (Head of Department)

Department of Mechanical Engineering Department of Mechanical Engineering

Dronacharya College of Engineering Dronacharya College of Engineering

Greater Noida Greater Noida

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ACKNOWLEDGEMNENT

It give us a great sense of pleasure to present the report of the B.Tech Project undertaken during B.Tech final year. We owe our special debt to Prof. Ankush Yadav Department of Mechanical Engineering, Dronacharya College of Engineering, Greater Noida for his constant support and guidance throughout the course of our work. His sincerity, thoroughness and perseverance have been a constant source of inspiration for us. It is only by his cognizant efforts that our endeavors have seen light of the day.

We also take the opportunity to acknowledge the contribution of Prof. D V Bhise, HOD, Department of Mechanical Engineering, Dronacharya College of Engineering, Greater Noida for his full support and assistance during the development of the project.

We would not miss the opportunity to acknowledge the contribution of all the faculty members of the department for their kind assistance and cooperation during the development of our project. They have been very kind and helpful to us. We want to thank all teaching and non‐teaching staff to support us. And last but not the least we would also like to thanks our parents for their support.

Signature: Signature:

Name: Deepankar Mondal Name: Balraj Choudhary

4

Signature: Signature:

Name: Charit Pant Name: Abhishek Saxena

Signature:

Name: Avneesh Pal

5

ABSTRACT

The purpose of our project was to design a model which can help to use the dry leaves as a conventional source of energy for the burning purpose by not wasting dry leaves for land filling or pile burning. The dry leaves can be used by compressing the pile of dry leaves into a wood log like structure.For designing this project we considered various compressor such as can compressor , wood pulp compressor for paper, brick compressor etc. So we considered three basic compressor for designing this project pneumatic, hydraulic and reciprocating slider crank mechanism. We rated these three concept on the basis of reliability, maintenance, cost of parts, handling and designing. Slider Crank Mechanism is considered as best rated compressor so we continue our design for slider crank mechanism.

For making our design we considered the main goal of our project that it can be easily manufactured, parts are easily available at all places and cost should be less, so we used the simple waste product from our surrounding to make the project by using cycle, ac motor, hand pump rod ,hand pump coupler ,wood and sheet metal. The leaf is first mixed with the common adhesive like corn flour paste then feed into the cylinder where piston compress the leaf and reduce it size to 30% , then these leaf logs are left in open sun to dry for 3-4 hours which gives us the final product.

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LIST OF FIGURES

Fig 1 : Rigid body in plane

Fig 2 : Rigid body in space

Fig 3 : Four bar chain mechanism

Fig 4 : Single Slider crank machanism

Fig 5 : AC Motor

Fig 6 : RPM of crank

Fig 7 : Layout of mechanism

Fig 8 : Force on Link 2

Fig 9 : Force on Link 3

Fig 10 : Force on Link 4

Fig 11 : Torque on crank pedal arm

Fig 12 : Free body diagram of piston

Fig 13 : Pneumatic force to compress the leaves

Fig 14 : Hydraulic force to compress the leaves

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Fig 15 : Slider Crank Mechanism to compress the leaves

Fig 16 : Final Design

Fig 17 : Measuring tape

Fig 18 : Engineer’s Square

Fig 19 : Spirit level

Fig 20 : Ruler

Fig 21 : Wood saw

Fig 22 : Shearing machine

Fig 23 : Pliers

Fig 24 : Different drill bits

Fig 25 : Upright drilling machine

Fig 26 : The London anvil

Fig 27 : Mallet and Hammer

Fig 28 : Jack Plane

Fig 29 : Wood and Metal files

8

Fig 30 : Grinding Machine

Fig 31 : Process of making leaf log

Fig 32 : Dry leaf log

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LIST OF TABLES

Table 1 : Links and their degree of freedom

Table 2 : Concept generation and Evaluation

Table 3 : Design Specification

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CHAPTER: 1

INTRODUCTION

1.1 OVERVIEW

Leaves fall every autumn and then the major clean-up around- the-yard process begins. But if the leaves you collect could be repurposed and made into fire logs instead of making their way into the seasonal yard waste collection trucks. It is common knowledge that dry leaves burn easily, so an economical home heating solution is to make fire logs from them. We took the concept to action by developing the low-profile, renewable and energy-efficient Leaf Log. You can save a lot of money by making your own fire logs with leaves from your backyard. Leaf Logs are environmentally friendly Eco log products, a renewable and sustainable source of energy in the form of solid fuel which is suitable for homes and industry.

Leaf log products offer a number of benefits, they are:-

Easy to use/light :- Simply place any Leaf log product on the grate, light the bag and sit back and enjoy the warmth of a real fire. Providing immediate ignition from an open flame, the ecologs require no kindling or firelighters and produce a clean smoke free flame.

Clean: - Our ecologs are very clean with a low ash residue, the fine dust which is left (less than 1%) can then be used to fertilize gardens.

Versatile: - The Leaf log ecology range can be used on wood burning /multi fuel stoves, chimneys and for recreational use such as camp fires.

Easy to handle and store: - Our eco logs are conveniently wrapped in old newspapers. Each log weighs approx. 200grams and a dozen will last indefinitely if stored in a dry place.

Value for money: - Independent test results of Leaf Log provided a net calorific value of 27,840 kJ per kg proving that Leaf Log burns as hot as coal and 3 times longer than wood (weight for weight).

Cost effective:-The Leaf log ecologs range is competitively priced. When the cost of the coal plus the periphery requirements such as firelighters and kindling are added on, our ecologs are much cheaper than other fuels in price comparisons.

Ethical: - There are other natural products on the market, such as soft or hardwood logs. However, unlike our ecologs, for those products to exist, something has to die. Even some logs made of sawdust are made directly from trees that have been cut down in order to produce the logs.

Environmentally friendly: - Independent tests revealed less than 1% sulphur content in each ecolog. As the Leaf Log range uses foliage, they are 70% carbon neutral which automatically places it as a kinder alternative to burning conventional fuels such as wood and coal.

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Unlike some other sawdust or straw based products that still need chemical basedProducts such as paraffin fire lighters to light them, the Leaf Log products ignite immediately from an open flame, just light the bag.

1.2 SCOPE OF WORK

The Leaf Log ecolog range is 70% carbon neutral which automatically places it as a kinder alternative to burning conventional fuels such as wood and coal. There is a huge need for Governments and individuals globally to reduce their dependency on fossil fuels and to find alternative renewable and sustainable fuels from more natural resources within the environment. India provides 7% of total annual coal production. It is the 5 th largest coal consumer in the world. Total annual production of coal in India is 222.4 million tons of oil equivalents and consumption is 295.6 million tons of oil equivalents. Based on this information, India consumes more coal than it currently produces and therefore it has to import.In addition, deforestation accounts for 25% of CO2 emissions across the globe. Deforestation costs more than global banking meltdown and researchers from The Economics of Ecosystems and Biodiversity (TEEB) project have told the World Conservation Congress that the disappearance of the world’s forests costs between $2 trillion and $5 trillion each year more than the current Wall Street estimate of losses since the start of the global banking crisis.

But we no longer need to cut down trees for fuel, nor do we need to use valuable land space to grow crops for fuel as leaves are naturally produced every year without fail. Leaf Log takes what would currently be regarded as green waste into a sustainable and environmentally friendly bio fuel. Leaf log use waste leaves sourced from stockpiles. Turning the annual leaf collection (thousands of tonnes) into Leaf Log not only eliminates the need to landfill this organic waste, but also reduces the release of methane gas into the environment when the foliage is decomposing in landfills. Methane gas is twenty times more harmful than carbon dioxide which significantly contributes to climate change.Using a renewable energy source like the Leaf Log ecology product range reduces the planet’s dependence on energy sources that significantly contribute to climate change, which is of course at present a very prominent concern for future generations.Nothing needs to die for Leaf logs to exist. The Leaf Logs ecologs consist purely of dried leaves which have been gathered from parks and other locations, this product will burn for up three hours independently. Nothing needs to die for this product to exist and each year nature provides us with an abundance of leaves. Typically, dead leaves are dumped in masses in landfills and one of the problems with leaving wet leaves to decompose like this is that they give off methane (a 20 times more poisonous gas than carbon dioxide). In contrast, when leaves are burnt, they only give off the carbon they absorb while on the tree – they add nothing extra to the environment.

Leaf Log ecologs do not cost more to the end user than any other manufactured heat log. When the cost of the coal plus the additional requirements such as firelighters and kindling are added on, Leaf Log ecologs are much cheaper than other fuels in price comparisons. Test results of Leaf Log provided a net calorific value of 27,840 kJ per kg proving that Leaf Log burns as hot as coal and 3 times longer than wood (weight for weight).

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1.3 SURVEY

Why we should not burn leaves:

Because of the moisture that is usually trapped within leaves, they tend to burn slowly and thus generate large amounts of airborne particulates—fine bits of dust, soot and other solid materials. These particulates can reach deep into lung tissue and cause: coughing, wheezing, chest pain, shortness of breath and sometimes long-term respiratory problems.

Leaf smoke contains hazardous compounds such as: 1. Carbon Monoxide – This can bind with haemoglobin in the bloodstream and reduce the amount of oxygen in the blood and lungs.2. Benzopyrene - This has been believed to be a major factor in lung cancer caused by cigarette smoke.

Breathing in leaf smoke can irritate the eyes, nose and throat of healthy adults, it can really wreak havoc on small children, the elderly and people with asthma or other lung or heart diseases.

There are various alternatives to burning:-

• Mulching of LeavesSoil Enrichment, Water Conservation, Insulation and Mulch prevents compaction and erosion of soils from wind and rain.

• Composting

• Put Leaves out for collection

• Or use Leaf Packing Machine

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CHAPTER: 2

INTRODUCTION TO MECHANISMS

2.1 CONCEPT OF DEGREE OF FREEDOM

In the design or analysis of a mechanism, one of the most important concern is the number of degrees of freedom (also called movability) of the mechanism. It is defined as the no. of input parameters which must be independently controlled in order to bring the mechanism into a useful engineering Purpose.

Degrees of Freedom of a Rigid Body in a Plane

The degree of freedom (DOF) of a rigid body is defined as the no. of independent movements.Figure shows a rigid body in a plane. To determine the DOF of this body we must consider how many distinct ways the bar can be moved. In a two dimensional plane, the bar can be translated along the x axis, translated along the y axis and rotated about its centroid.

Fig 1: Rigid body in plane

Degrees of Freedom of a Rigid Body in Space

An unrestrained rigid body in space has six degrees of freedom:Three translating motions along the x ,y and z axes and three rotary motions around the x ,y and z axes respectively.

Fig 2: Rigid body in space

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2.2 KUTZBACH CRITERION EQUATION

Consider a plane mechanism with l number of links. Since in a mechanism one of the links is to be fixed, therefore the number of movable links will be (l-1) and thus the total number of degrees of freedom will be 3(n-1) before they are connected to any other link. In general, a mechanism with l number of links connected by j number of binary points or lower pairs (i.e. single degree of freedom pairs) and h number of higher pairs (i.e. two degree of freedom pairs) , then the number of degrees of freedom of a mechanism is given by

n = 3(l-1)-2j-h -equation 1

This equation is called Kutzbach criterion for the movability of a mechanism having plane motion. If there are no two degree of freedom pairs (i.e. higher pairs), then h=0, substituting h=0 in equation 1, we have n=3(l-1)-2j

2.3 FOUR BAR CHAIN MECHANISM

The simplest and the basic kinematic chain is a four bar chain or quadratic cycle chain, as shown in below figure. It consists of four links p, q, l and s, each of them forms a turning pair. The four links may be of different lengths. According to Grasshof’s law for a four bar mechanism, the sum of the shortest and longest link lengths should not be greater than the sum of the remaining two link lengths if there is to be continuous relative motion between the two links.

Fig 3: Four bar chain mechanism

 According to Grasshof’s law for a four bar mechanism, the sum of the shortest and longest link lengths should not be greater than the sum of the remaining two link lengths if there is to be continuous relative motion between the two links. A very important consideration in designing a mechanism is to ensure that the input crank makes a complete revolution relative to the other links. The mechanism in which no link makes a complete revolution will not be useful. In a four bar chain, one of the links, in particular the shortest link, will make a complete revolution relative to the other three links, if it satisfies the Grasshof’s law. Such a link is known as crank or driver.

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2.4 SINGLE SLIDER CRANK MECHANISM

A single slider crank chain is a modification of the basic four bar chain. It consists of one sliding pair and three turning pair. It is, usually, found in reciprocating steam engine mechanism. This type of mechanism converts rotary motion into reciprocating motion and vice versa.

Fig 4: Single Slider Crank Mechanism

In single slider crank chain, as shown in below fig the links 1 and 2, links 2and 3, and links 3 and 4 form three turning pairs while the links 4 and 1 form a sliding pair. The link 1 corresponds to the frame of the engine, which is fixed. The link 2 corresponds to the crank, link 3 corresponds to the connecting rod and link 4 corresponds to cross-head. As the crank rotates the cross-head reciprocates in the guides and thus the piston reciprocates in the cylinder. 

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DEGREE OF FREEDOM OF DIFFERENT LINKS

Table 1: Links and their Degree of Freedom

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LINK MATERIAL DEGREE OF FREEDOM

CRANK(crank pedal arm of a bicycle)

Chromoly Steel 1(Rotational motion along x direction)

COUPLER(made up of hand pump rod) Mild steel electro galvanised 2

(Translation motion along x and y direction)

FIXED LINKBicycle framecuboid

Carbon SteelSheet Metal

0(neither translation motion nor rotation motion along any direction)

SLIDERWooden blockRodCuboidal piston

WoodIronSheet Metal

1(Translation motion along x direction)

2.5 DEGREE OF FREEDOM OF WHOLE SYSTEM

The degree of freedom of the slider crank mechanism as a whole system can be found out by Kutzbach Criterion Equation given below

n = 3(L-1)-2j-h

where,

L= no. of link

j= no. of binary joint

h= no. of higher pair

In the four bar slider crank mechanism,

There are 4 links, i.e. fixed link, crank, coupler and slider. Hence, L=4

There are 4 binary joint present , j=4

There are 0 higher pair, h=0

Hence, according to Kutzbach Criterion Equation

n=3(4-1)-2(4)-0

n=1

Hence for slider crank mechanism, the degree of freedom is 1

Kinematic Pair

The following kinematic pair is used in the slider crank mechanism

1) Turning pair2) Sliding pair

There are three turning pair and one sliding pair

The turning pair is present in between the following links

1) Bicycle frame (fixed) and Crank pedal arm2) Crank pedal Arm and coupler3) Coupler and wooden block

The sliding pair is present in between the piston and the metal sheet cuboid.

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2.6 NUMERICAL ANALYSIS ON LEAF-LOG MECHANISM

AC MOTOR

An AC motor is an electric motor driven by an alternating current (AC). The AC motor

commonly consists of two basic parts, an outside stationary stator having coils supplied with

alternating current to produce a rotating magnetic field, and an inside rotor attached to the

output shaft producing a second rotating magnetic field. The rotor magnetic field may be

produced by permanent magnets, reluctance saliency, or DC or AC electrical windings.

Fig 5: AC Motor

An industrial type of AC motor with electrical terminal box at the top and output rotating

shaft on the left. Such motors are widely used for pumps, blowers, conveyors and other

industrial machinery. Less commonly, linear AC motors operate on similar principles as

rotating motors but have their stationary and moving parts arranged in a straight line

configuration, producing linear motion instead of rotation.

OPERATING PRINCIPLE

AC motors operate with two rotating (or moving) magnetic fields on the rotor and stator respectively. Pulling or pushing the poles of the two magnetic fields along, the speed of the stator rotating magnetic field (Ws) and the speed of the rotor rotating magnetic field (Wr), which is relative to the speed of the mechanical shaft (Wm), must maintain synchronism for average torque production by satisfying the synchronous speed relation (i.e., ±Ws ±Wr = Wm). Otherwise, asynchronously rotating magnetic fields would produce pulsating or non-average torque.

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The two main types of AC motors are classified as:-

1) Induction Motor

2) Synchronous Motor

1) Induction Motor

The induction motor (or asynchronous motor) always relies on a small difference in speed

between the stator rotating magnetic field and the rotor shaft speed called slip to

induce rotor current in the rotor AC winding. As a result, the induction motor cannot

produce torque about synchronous speed where induction (or slip) is irrelevant or ceases

to exist. In contrast, the synchronous motor does not rely on slip-induction for operation

and uses either permanent magnets, salient poles (having projecting magnetic poles), or

an independently excited rotor winding.

2) Synchronous Motor

The synchronous motor produces its rated torque at exactly synchronous speed. The

brushless wound-rotor doubly-fed synchronous motor system has an independently

excited rotor winding that does not rely on the principles of slip-induction of current. The

brushless wound-rotor doubly-fed motor is a synchronous motor that can function exactly

at the supply frequency or sub to super multiple of the supply frequency.

Other types of motors include eddy current motors, and also AC/DC mechanically

commutated machines in which speed is dependent on voltage and winding connection.

The rpm of an AC motor can be calculated with the help of tachometer

The tip of tachometer can be connected to the shaft of an AC motor to determine the rpm.

Hence,

The rpm of ac motor = 1480

The rotor of an AC motor is directly connected to the rear tires of the cycle with the help of a pulley.

The rear tyre of the cycle is rotating with an rpm of 138 when the pulley is made in direct contact with the rear tyre. The rpm of tyre can be noted down with the help of tachometer.

Now, to calculate the rpm of crank, it is compulsory to calculate the gear ratio.

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GEAR RATIO

The gear ratio of a gear train, also known as its speed ratio, is the ratio of the angular velocity of the input gear to the angular velocity of the output gear. The gear ratio can be calculated directly from the numbers of teeth on the gears in the gear train. The torque ratio of the gear train, also known as its mechanical advantage, is determined by the gear ratio. The speed ratio and mechanical advantage are defined so they yield the same number in an ideal linkage.

GEAR TRAIN WITH TWO GEARS

The simplest example of a gear train has two gears. The "input gear" (also known as drive gear) transmits power to the "output gear" (also known as driven gear). The input gear will typically be connected to a power source, such as a motor or engine. In such an example, the power output of the output (driven) gear depends on the ratio of the dimensions of the two gears.

Formula

The teeth on gears are designed so that the gears can roll on each other smoothly (without

slipping or jamming). In order for two gears to roll on each other smoothly, they must be

designed so that the velocity at the point of contact of the two pitch circles (represented by v)

is the same for each gear.

Mathematically, if the input gear GA has the radius rA and angular velocity , and meshes

with output gear GB of radius rB and angular velocity , then,

The number of teeth on a gear is proportional to the radius of its pitch circle, which means

that the ratios of the gears' angular velocities, radii, and number of teeth are equal.

Where NA is the number of teeth on the input gear and NB is the number of teeth on the output

gear, the following equation is formed:

This shows that a simple gear train with two gears has the gear ratio R given by

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This equation shows that if the number of teeth on the output gear GB is larger than the

number of teeth on the input gear GA, then the input gear GA must rotate faster than the output

gear GB.

This gear ratio can be determined by calculating the number of teeth in the front sprocket and the rear sprocket.

Now, number of teeth in rear sprocket= 44

Number of teeth in front sprocket= 16

Now, to calculate the rpm of crank, the following method of gear ratio will be used

Rpm of crank= (16/44)*138

i.e., rpm of crank = 50

Fig 6: RPM of crank

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Now, to calculate force on each member of the link, first we will draw the layout of the mechanism,

Fig 7: Layout of Mechanism

Here, Link 1 represents the fixed frame which includes the frame of bicycle and the support on which the cuboidal cylinder is mounted.

Link 2 represents the crank of the mechanism which is the crank pedal arm of the bicycle.

Link 3 represents the connecting rod.

Link 4 represents the slider which compromises a wooden block, an iron rod and the cuboidal piston of wood.

Let θ be the angle between the crank and the fixed link and β be the angle between the connecting rod and the slider.

Now, the dimensions of the following links are as follows

Crank radius= 0.19m

Length of connecting rod=0.24m

The force on each individual links is given below

The force on link 2 is as follows

It consists of F12 and F32 which are at a distance of h apart.

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Fig 8: Force on Link 2

Here, force F12 and F32 form a couple which is equal to the applied torque and the perpendicular distance between these two forces is h.

Force F12 is the force applied by the link 1 on links 2 and the force F32 is the force applied by the link 3 on link 2.

The force on link 3 is as follows

Fig 9: Force on Link 3

The forces F23 and F43 are of same magnitude which is acting along the same line and are in opposite direction

Force F23 is applied by the link 2 on link 3 and is equal to the force F32, force F43 is applied by the link 4 on link 3.

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The force on slider link 4 is as follows

Fig 10: Force on Link 4

Here, F34 is the force applied by link 3 on link 4 which is equal to the F43 and the force F14 is applied by the fixed link 1 on slider 4, normal force and F is the force which is applied on the piston i.e., piston effort.

Calculation part

Now, the rpm of an AC motor=1480

Power of an ac motor= 373 W

Therefore, torque produced by the motor is given by the following formula

P = ωT i.e.

P= (2πNT÷60)

373 = (2×π×1480×T) ÷60

Therefore, T = 2.41Nm

The rpm of rear tyre having diameter of 0.72m is made in direct contact with a pulley of diameter of 0.08m.

Since, according to speed ratio,

The rpm of tyre should be (R2 ÷ R1) ×1480

i.e., (0.04÷0.36) ×1480

Rpm of tyre= 164

But, when, it is calculated with the help of the tachometer it is found to be 138 because some of its energy is lost in friction, heat etc.

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Hence, rpm of tyre is 138.

The rpm of front pedal crank arm which is acting as a crank is 50 and the torque measured on the crank pedal arm is found to be of 2.5Nm.

Fig 11: Torque on crank Pedal arm

The value of h when determined graphically, founds out to be 0.153m

Hence, h=0.153m

Now,

F32× h = T

i.e., F32 × 0.153 = 2.5Nm

F32 = 16.34N

Since,

F32=F12=F23=F43=F34

Therefore, F32=F12=F23=F43=F34= 16.34N

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Now, to calculate the horizontal force on the piston considering the free body diagram of piston.

Fig 12: Free Body diagram of piston

Resolving the horizontal and vertical components of this slider, we get

On resolving the vertical component, we get

F34sin(23.32◦) + mg = F14

Now, on resolving the horizontal component, we get

F34cos (23.32◦) = F

i.e., F = 16.34×cos (23.32◦)

Hence, F = 15N

Therefore, the driving force of the piston which compresses the leaf log up to 70% reduction in its volume is of 15N.

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CHAPTER: 3

INTRODUCTION TO DESIGN AND FABRICATION

3.1 SKETCHING AND DRAWING SELECTION

From the existing ideas, only 3 sketching had been chosen to be considered as the final idea, which are:

CONCEPT 1

Fig 13: Pneumatic force to compress the leaves

This concept is using the pneumatic force from above to compress the leaves entered from sides to fill the container below with corresponding layers of compressed leaves. Holes are incorporated in the container to supply oxygen and heat to be used for burning purpose.

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CONCEPT 2

This concept uses hydraulic force from right side to compress piston inside the cylinder and

compress the leaves entered from above through hopper in multiple stages.

Fig 14: Hydraulic force to compress the leaves

CONCEPT 3

This concept uses a slider crank mechanism to compress a piston inside cuboid and slits are introduced in between to compress leaves introduced through hopper in stages and avail easy

access to output.

Fig 15: Slider Crank Mechanism to compress the leaves

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3.2 CONCEPT GENERATION AND EVALUATION

CRITERIA CONCEPT1

CONCEPT 2

CONCEPT 3

BEST CONCEPT

Portable **** * * 1Light weight *** ** ** 1Good looking * *** *** 3Easy to manufacture

*** **** ** 2

Reliable ** *** **** 3Easy to use ** *** **** 3Material cost *** * **** 3Safety * *** *** 3Strength * **** **** 3Easy to maintain ** *** **** 3Product stability * **** *** 2

Table 2 : Concept generation and Evaluation\

Three concepts were developed and are evaluated under twelve criteria of importance. Study of concept selection reveals that CONCEPT 3 scores highest value.

3.3 FINAL DESIGN

Concept3 is manufactured with following design and dimensioning.

Fig 16: Final Design

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DESIGN SPECIFICATION

Concept 3 is the best design that can be evaluated. Table below is the detail product design specification of concept 3.

S.NO MATERIAL TYPE SIZE(cm) QUANTITY

1 IRON STRIPES SHEET METAL Height-53.5Base -41.5

2

2 MILD STEEL SHEET METAL 11.5*11.5*64 1

3 WOOD CARDBOARD 10.5*15*0.5 2

4 PLASTIC THIN PLASTIC BOX Dia.-15Height-18

1

5 WOOD CARDBOARD 10.5*10.5*10.5 1

6 IRON ROD IRON Length-44Dia.-0.5

1

7 WOOD WOODEN BLOCK 14.5*5*8 1

8 WOOD CARDBOARD 117.5*41.5*2 1

9 STEEL ROD MILD STEEL ELECTRO GALVANISED

Length-24Dia.-0.6

1

10 STEEL ROD CHROMOLY STEEL Length-12.5Dia.-0.4

1

11 STEEL PLATE CHROMOLY STEEL Dia.-20 1

12 STEEL ROD CHROMOLY STEEL Length-18.5Dia.-0.6

1

13 STEEL FRAME CARBON STEEL Multiple dim. 1

14 RUBBER TYRE RUBBER Dia.-67 1

15 STEEL SPROCKET

CHROMOLY STEEL Dia.-9 1

Table 3: Design Specification

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3.4 FABRICATION

After design phase fabrication processes takes place. These processes are about using material selection and make product based on design by following design dimensions. Many methods can be used to fabricate a product like Welding, Drilling, Cutting, Bending, Grinding, Finishing and many more. This process includes part by part fabrication and assembling of components.

Processes involved: In order to transform our design into reality, fabrication needs to be done first. The fabrication starts from dimensioning the raw materials until it finishes as a desired product. The processes that involves are:

1. Getting material

Our project includes various material like Sheet Metal (Mild Steel), Wood, Iron rod, Plastic for hopper, Cardboard, Rubber tyre etc.

2. Measuring and marking

After getting the material, the next step is measuring and marking. The Equipment used are measuring Tape, Engineer’s Square, Spirit Level and ruler.

Measuring tapeA tape measure or measuring tape is a flexible ruler. It consists of a ribbon of cloth, plastic, fiber glass, or metal strip with linear-measurement markings. It is a common measuring tool.

Fig 17: Measuring tape

Engineer’s SquareA machinist square or engineer's square is the metalworkers' equivalent of a try square. It consists of a steel blade inserted and either welded or pinned into a heavier body at an angle of 90°

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Fig 18: Engineer’s Square

Spirit LevelA spirit level, bubble level or simply a level is an instrument designed to indicate whether a surface is horizontal (level) or vertical (plumb)

Fig 19: Spirit level

RulerA ruler, sometimes called a rule or line gauge, is an instrument used in geometry, technical drawing, printing as well as engineering and building to measure distances or to rule straight lines.

Fig 20: Ruler

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3. Cutting material

After measurement and Marking various tools are used like Metal and Wood Saw, Metal Sheer Cutter, Plier and Shearing machine for cutting material.

Wood sawA saw is a tool consisting of a hard blade, wire, or chain with a toothed edge. It is used to cut through relatively hard material, most often wood. The cut is made by placing the toothed edge against the material and moving it forcefully back and forth. This force may be applied by hand, or powered by steam, water, electricity or other power source. 

Fig 21: Wood saw

Shearing MachineShearing machines (sheet metal) use a shearing or scissor-like action to cut metal into sheets or strips.

Fig 22: Shearing Machine

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PliersPliers are a hand tool used to hold objects firmly. They are also useful for bending and compressing a wide range of materials.

Fig 23: Pliers

4. Drilling

Vertical drilling machine was used with various bits of varying sizes for Drilling holes in Wood, Mild Steel etc.

Fig 24: Different drill bits

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Upright Drilling Machine A upright drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other materials. Drilling machines may be used to perform other operations. They can perform countersinking, boring, counterboring, spot facing, reaming, and tapping.

Fig 25: Upright drilling Machine

5. Bending

After marking sheet metal, iron rods etc. was beaten on Anvil to bend along the marked lines by using Mallet and hammer.

The London AnvilAn anvil is a basic tool, a block with a hard surface on which another object is struck.

Fig 26: The London Anvil

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Mallet and HammerA mallet is a kind of hammer, often made of rubber or sometimes wood, that is smaller than a maul or beetle and usually with a relatively large head.Hammer is a tool with a heavy metal head mounted at right angles at the end of a handle, used for jobs such as breaking things and driving in nails.

Fig 27: Mallet and Hammer

6. FINISHING TOOLS

Various pieces after cutting are finished to remove sharp edges by using tools like Jack planar, Wood & Metal files and Grinding Machine.

Jack PlaneA jack plane is the general-purpose bench plane, used for general smoothing of the edges, sizing of timber but only making it smaller to correct size.

Fig 28: Jack Plane

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Wood and Metal filesA file is a metalworking, woodworking and plastic working tool used to cut fine amounts of material from a work piece.

Fig 29: Wood and Metal Files

Grinding Machine

A grinding machine, often shortened to grinder, is any of various power tools or machine tools used for grinding, which is a type of machining using an abrasive wheel as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the work piece via shear deformation.

Fig 30: Grinding Machine

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3.5 PROCESS OF MAKING LEAF LOG

Fig 31: Process of making leaf log

STEP-1: Collect dry leaves

Dry and brittle leaves are collected from bottom of Trees are shredded into smaller pieces and stored in Large bags.

STEP-2: Prepare binding agent

Binding Agent is prepared by mixing 2 parts of Maida (All Purpose Flour) with 1 part of Water. Also mix natural, biodegradable binding substances like Resins.

STEP-3: Blend binding agent with leaves

Blend binding agent prepared in previous step with shredded dry leaves collected in bags to create mushy, sticky consistency.

STEP-4: Feed the blended mixture into leaf packing machine

Feed the blended mixture into leaf packing machine through Hopper provided in middle of compressor in between the return stroke piston.

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STEP-5: Compression of leaves

Blended mixture of dry leaves and binding agent is compressed in multiple stages due to slits provided inside cuboidal block by sliding piston action of slider crank mechanism. This helps total volume of leaves to be reduced by up to 70% thus making the leaves easy to handle.

STEP-6: Dry leaf log

Compressed form of leaves are available as output from the leaf compressor. This block of compressed leaves is sun dried for one afternoon to be available as a moisture free source of clean and green energy.

Thus many such leaf logs can be stacked for future to be used together for various applications.

Fig 32: Dry Leag Log

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CHAPTER: 4

APPLICATIONS AND SCOPE

4.1 APPLICATIONS

1) Industrial Application Cement and steel industries uses coal and its ash in furnaces which can be substituted by renewable source of energy leag log.

2)Cook FoodTraditional chulha in rural areas uses wood that promotes deforestation which can easily be substituted by cleaner energy resource.

3)Thermal Power GenerationThermal Power Stations uses high calorific value pulverised coal which is non-renewable and air polluting fuel and this makes it easier to replace it with environment friendly leaf logs.

4)Warm our homesFireplaces are used in winter to warm our homes, offices, hotels, etc which uses conventional wood or gelled isopropyl alcohol. These are either expensive or non-renewable which makes leaf logs perfect fireplace fuel.

4.2 FUTURE PLANS

The Future plan in the area of:-

a. Design is to make the size of leaf packing machine more compact and introduce wheels into the base to make it easily movable. It is also required by absolute necessity to incorporate more leaves into the leaf log and make it denser. So, the total volume is reduced further from 70% to 75% or more.

b. Final product is to make use of easy to dry binding agents. So, the leaf log will dry quickly, thus reducing the drying time and making it ready to use.

c. Manufacturing is to reduce the cost per unit of product. So, it is easy to target the rural population which is mostly responsible for deforestation to burn chullah in their homes and warm there houses in winter.

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d. Efficiency of leaf packing machine is to reduce the time required to make a leaf log by increasing the force in every stroke of piston inside the compressor.

It will be efficient practice to introduce a shredder with the feeding mechanism through hopper, to reduce time required to shred the leaves.

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CONCLUSION

This project work has provided us an excellent opportunity and experience, to use our limited knowledge. We gained a lot of practical knowledge regarding, planning, purchasing, assembling and machining while doing this project work. We feel that the project work is a good solution to bridge the gates between institution, industries and rural areas.

We are proud that we have completed the work with the limited time successfully. The Leaf Log Maker is working with satisfactory conditions. We are able to understand the difficulties in maintaining the tolerances and also quality. We have done to our ability and skill making maximum use of available facilities.

In conclusion remarks of our project work, let us add a few more lines about our impression project work. Thus we have developed a Leaf Log Maker which helps to know how to achieve low cost alternative fuel source with simple products which can easily available at any place so that many people can utilises our project. The application of reciprocating mechanism produces smooth operation. By using more techniques, this project can be modified and developed according to the applications.

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REFERENCES

1. http://www.leaflog.com/

2. http://www.logmaker.org.uk/

3. http://www.ehow.com/how_6969367_make-fire-logs-out- leaves.html

4. http://inventionsusa.blogspot.in/2013/07/leaf-pac-leaf- log.html

5. http://www.dailymail.co.uk/sciencetech/article-1226943/ British-inventors-green-idea-using-leaves-make-logs.html

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