International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
“Pneumatic sugar cane cutting Machine”
Mr. Mundewadi S.J 1 , Mr. Mulla S.A2 , Mr. Shaikh N.S 3 Mr. Patel A.Y 4 , Mr. Swami B.R 5
Mr. Nanaware M.H 6
1,2,3,4,5 Student Department of Mechanical Engineering, SPM polytechnic Kumathe, Solapur, India 6 Lecturer, Dept. of Mechanical Engineering, SPM Polytechnic Kumathe, Solapur, India ***
Abstract - The Pneumatic Sugarcane Cutting Machine is a semi-automated system designed to enhance the efficiency, safety, and precision of sugarcane harvesting. Traditional manualcuttingmethodsarelabor-intensive,time-consuming, and often lead to worker fatigue and inconsistent cutting quality. This project introduces a mechanized solution utilizingpneumaticactuation,whichemployscompressedair topoweracuttingblademechanism.Themachinecomprisesa pneumatic cylinder, cutting blade, compressor, and a supporting frame. Upon activation, the pneumatic system deliversrapidandforcefullinearmotiontotheblade,enabling clean and consistent cuts with minimal human effort. The design prioritizes portability, ease of use, and costeffectiveness, making it suitable for small to medium-scale farms.Byreducingmanuallaborandimprovingproductivity, the Pneumatic Sugarcane Cutting Machine offers a practical solution for modernizing agricultural practices and supporting sustainable farming.
Key Words: Pneumatic, labour, intensive time-consuming, Sugarcane Cutting Machine , agricultural practices, blade
1.Introduction
The Pneumatic Sugar Cane Wood Cutter Machine is a mechanized device designed to efficiently cut sugar cane wood into desired sizes and shapes. Utilizing pneumatic power, this machine offers a reliable, precise, and laborsaving solution for sugar cane wood processing. With its innovative design and automated functionality, the PneumaticSugarCaneWoodCutterMachineisanidealtool forindustriesandindividualsinvolvedinsugarcanewood processing, biomass production, and sustainable energy generation.Theneedforapneumaticsugarcanecutterarises from several practical challenges and inefficiencies in traditional sugarcane harvesting methods. Here's a breakdownofthereasonsThemechanizationofsugarcane harvesting is a crucial area of research in agricultural engineeringduetothelabor-intensiveandtime-consuming natureoftraditionalcuttingmethods
1.1 Pneumatic Power System
AirCompressor:Suppliescompressedairtooperatethe machine .Pneumatic Cylinder/Actuators: Converts air pressure into linear motion for cutting. Control Valves: Regulateairflowandpressuretocontrolthespeedandforce of cutting. Finally, complete content and organizational
editingbeforeformatting.Pleasetakenoteofthefollowing itemswhenproofreadingspellingandgrammar:
1.2
Cutting Mechanism
High-SpeedBladeorSaw:Designedfortoughmaterialslike sugar cane or wood Reciprocating or Rotary Motion: Dependingonthedesign,bladesmaymoveback-and-forth orrotate.Material-SpecificBlades:Hardenedorserratedfor bettergripandcleancutsonfibrouscaneordensewood.
2. Need of Sugar cane cutter machine
The need for a pneumatic sugarcane cutter arises from severalpracticalchallengesandinefficienciesintraditional sugarcaneharvestingmethods.Here'sabreakdownofthe reasons
2.1 Labour Shortage in Agriculture
Manual cutting of sugarcane is labour intensive and timeconsuming. Agricultural labour is becoming scarce due to urban migration and aging rural workforce .A pneumatic cuttercanreducedependencyonlargenumbersofworkers.
2.2 Increased Efficiency & Speed
Manual cutting is slow; pneumatic tools can speed up the harvestingprocess.Increasedproductivityleadstoquicker harvesting within the short ideal cutting window for sugarcane.
2.3 Reduction of Human Fatigue
Manual harvesting requires repetitive bending, swinging, and lifting. A pneumatic cutter reduces physical strain, minimizinginjuriesandfatigueamongworkers.
2.4 Precision & Consistency
Pneumatictoolsoffermoreuniformcutting,leadingtobetter qualitycontrol.Uniformcanelengthimprovesefficiencyin transportationandprocessingatsugarmills.
2.5 Minimized Crop Damage
Manual methods can damage nearby stalks or roots. Pneumaticcutters,whendesignedwell,aremoretargeted andgentle,reducingcollateraldamagetothecrop.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
2.6. Cost Efficiency over Time
Though the initial investment in pneumatic tools may be higher, they reduce long-term operational costs: Lower labourcosts,Lesscropwastage
2.7. Eco-Friendliness (vs combustion machines)
Pneumaticsystemsusecompressedair,whichcanbemore environmentallyfriendlythangas-poweredcutters.
3. LITERATURE SURVEY
Pneumatic Sugarcane Cutter Machine
Themechanizationofsugarcaneharvestingisacrucialarea of research in agricultural engineering due to the laborintensiveandtime-consumingnatureoftraditionalcutting methods.Manualcuttingnotonlyleadstoworkerfatiguebut alsoresultsinunevencuttingandrootdamage,whichaffects theregrowthofratooncrops.Severalstudiesandprojects have proposed mechanized alternatives, with pneumatic systemsgainingattentionduetotheirefficiency,simplicity, and lower maintenance compared to hydraulic or fully electricsystems
3.1 Use of Pneumatic Systems in Agriculture
Pneumaticsystemsusecompressedairtopoweractuators and tools. In agricultural machinery, these systems have been used for applications such as seed sowing, spraying, and cutting. Pneumatic cutters are valued for their quick response,lightweightcomponents,andcleanoperation(no oilleakslikeinhydraulics).
3.2 Design of Pneumatic Cutter Mechanisms
Researchshowsthatdouble-actingpneumaticcylinderscan be used to drivesharp rotaryor reciprocating blades that cancleanlycutthroughsugarcanestalks.Thesesystemsare often powered by portable air compressors mounted on smallvehiclesortrolleys.Theuseoffootorhand-operated valves ensures ease of use and better control during field operations.
3.3.
Benefits over Traditional Methods
Compared to manual cutting:
Efficiency increases significantly (reduced time per cane stalk).Operator fatigue is minimized. Risk of injury is reducedduetocontrolcuttingmechanisms.Betterqualityof cutimprovesregrowthinratooncrops.
3.4. Recent Developments
Recent prototypes incorporate ergonomically designed handles, adjustable height systems, and rotary blades to improve comfort and precision. Integration with AI or
sensor-basedautomationisanemergingtrendfordetecting canepositionandadjustingbladeoperationaccordingly.
3.5. Limitations & Future Scope
Pneumatic systems depend on a reliable source of compressedair.Fieldmobilityandcompressorsizearestill design challenges. Future research could focus on solarpowered compressors, automation, and integration with GPS-basednavigationsystemsforprecisionfarming
4. Problem Statement:
Traditionalsugarcaneharvestingreliesheavilyonmanual labor,whichistime-consuming,physicallydemanding,and often leads to inconsistent cutting quality and injuries to workers. The manual process also results in improper cutting height, damaging the crop's root system and negativelyimpactingratooncropyield.Additionally,labor shortagesandincreasinglaborcostsarecreatingademand for efficient, affordable, and easy-to-operate mechanized solutions
5. Objectives of Project
The objective of a pneumatics-based sugarcane cutter machineistoenhancetheefficiency,safety,andeaseofthe sugarcaneharvestingprocessusingpneumaticpower.Here's adetailedbreakdown:
6. SCOPE OF THE PROJECT
ScopeoftheProject:PneumaticSugarcaneCutterMachine
6.1 Design and Development
Designacompactandefficientsugarcanecuttingmechanism using pneumatic systems (cylinders, valves, compressors).Focusonergonomics,safety,andeaseofuse forfieldworkers.
6.2 Field Application
Targetedforuseinsmalltomedium-scalesugarcanefarms. Capable of functioning in uneven or rural field conditions wheretraditionalmachinerymaynotbesuitable.
6.3 Automation Potential
Basic model to be manually operated with pneumatic assistance, but scalable to semi-automatic or automatic versions. Future integration with sensor-based control systemsormobileplatforms(robots/tractors).
6.4 Efficiency Improvement
Designed to increase harvesting speed, reduce manpower requirements,andminimizefatiguecomparedtotraditional manualcutting.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
6.5 Cost Optimization
Focus on low-cost components to ensure affordability for farmers. Lower maintenance and operational cost due to simplepneumaticmechanism.
6.6 Safety and Sustainability
Improvedsafetyfeaturescomparedtosharpmanualtools. Uses compressed air a clean and non-polluting power source.
7. METHODOLOGY
Themethodologyoutlinesthesystematicapproachfollowed todesign,develop,andtestthepneumaticsugarcanecutter machine. It includes research, design, prototyping, and testingphasesasdescribedbelow:
7.1 Literature Review
Studiedexistingsugarcaneharvestingtoolsandmachines. Analyzedthelimitationsofmanualcuttingandthepotential of pneumatic systems in agriculture. Reviewed similar pneumaticapplicationsincuttingandautomation.
7.2. Requirement Analysis
Identifiedkeyfunctionalrequirements:
Efficientcutting,PortabilityLowcostSafetyDeterminedthe required cutting force, stroke length, and operational pressure.
7.3. Design Phase
CreatedpreliminarysketchesandCADmodels.Designedthe frame, blade mechanism, and placement of pneumatic components.
Selected appropriate components: Pneumatic cylinder CompressorControlvalvesBladematerialcalculatedforce outputusingpneumaticformulas (F=P×A).
7. 4 Fabrication and Assembly
Procuredmaterialsandcomponents.Fabricatedthemachine frameusingmildsteel.Mountedthepneumaticcylinderand blade mechanism. Connected pneumatic lines with valves andhoses.
7 5. Pneumatic Circuit Setup
Developed a simple pneumatic circuit using Singleacting/double-acting cylinder3/2 or 5/2 control valve Air compressor Assembled the circuit with flow control and safetymechanisms
7.6. Testing and Validation
Tested the machine on actual sugarcane stalks under controlled conditions. Measured: Cutting time Blade efficiency Pressure requirements User safety Collected feedbackandnotedmechanicalorfunctionalissues.
7.7 Modifications and Optimization
Adjusted blade sharpness, angle, and cylinder stroke .Improvedstabilityoftheframeandenhancedergonomics .Ensuredsafeoperationwithpressureregulation.
7.8. Final Evaluation
Conducted multiple trials to confirm consistency and performance. Compared results with manual cutting in termsofspeedandeffort.Finalizeddesignanddocumented allfindings.
8.DETAILS
OF DESIGN, WORKING & PROCESSES
The main components of the pneumatic sugarcane cutter machineinclude:
8.1 Pneumatic Cylinder
Converts compressed air energy into linear motion to operatethecuttingblade.
8.2 Cutting Blade
Asharp,high-carbonsteelbladedesignedtocutsugarcane stalks efficiently. Compressor -Provides compressed air (usuallyat6–8bar)topowerthepneumaticsystem.Control Valve(3/2or5/2DirectionalValve)Regulatesthedirection ofairflowtoextendorretractthecylinder. AirHosesand Fittings Used to connect the compressor, valves, and cylinder,ensuringsmoothairflow
Frame Structure A stable and rigid frame that holds all components in place and supports the cutting operation. Safety Valve and Pressure Regulator Maintains safe air pressureandprotectsthesystemfromoverpressure.Foot Pedal/ManualSwitch(Optional)Usedtoactivatethecontrol valve,allowinghands-freeormanualcontroloftheblade.
WorkingPrinciple
Theworkingofthepneumaticsugarcanecuttermachineis based on the principle of compressed air converting into mechanicalmotionviaapneumaticcylinder:
Step-by-StepWorking:
1. Air Compression:
Acompressorgeneratescompressedairandstores itinatank
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
2. Air Flow Control:
Theoperatoractivatesthecontrolvalve(manually orwithafootpedal).Thevalvedirectscompressed airintothepneumaticcylinder.
3. Blade Activation:
The pressurized air pushes the piston of the cylinderforward.Thispistonisconnectedtothe cutting blade, which moves downwards (or forwards)tocutthesugarcanestalk.
4. Return Stroke:
After the cut is made, the air is released or redirected. A spring (in single-acting) or reverse air flow (in doubleacting)retractsthebladetoitsoriginalposition
5. Repeat Cycle:
Theprocessrepeatsforeachcutwithminimalhumaneffort andmaximumconsistency.
8.3 Key Advantages of Pneumatic Operation:
Fastandrepeatablecuttingaction
Minimalmanualforcerequired
Safeandcleanenergysource
Easytoautomateorcontrol
5.4Key disadvantages of Pneumatic Operation:
LowerPowerOutputCompressedAirCosts
AirLeaksLowerControlPrecision
NoiseMoistureandContamination
LimitedLoadCapacityShorterComponent
Lifespan
9 Major Parts
9.1. Pneumatic Cylinder
9.1PneumaticCylinder
A pneumatic cylinder is a mechanical device that uses compressedairtoproducelinearmotionandforce.It'sakey component in many automation and machinery systems. Working Principle: Compressed air enters the cylinder,
pushingapistoninside.Thepistonmovesinastraightline, performingworklikelifting,pushing,orpressing.
MainParts:
Cylinderbarrel
Pistonandpistonrod
EndcapsSealsandport
Types:
Single-acting:Airpressuremovesthepistoninonedirection; a spring returns it. Double-acting: Air pressure moves the piston in both directions Applications: Used in factory automation, robotics, packaging machines, automotive systems,etc.Advantages:Simpledesign,quickaction,clean (nooil),andrelativelylowmaintenance.
A cutting blade is a tool or component designed to slice, shear,orsevermaterialsbyapplyingforce
9.3. Compressor
9.3Compressor
9. 2 Cutting Blade
9.2Cuttingblade
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
9.4 . Direction Control valve (3/2)
9.4DirectionControlvalve(3/2)
A3/2DCvalve(3-way,2-positiondirectionalcontrolvalve) is a valve used to control the flow of air (or fluid) in pneumaticsystems.
9.5.Air Hoses and Connectors
Air Hoses and Connectors
Air Hoses and Connectors are essential components in pneumaticsystems,usedtotransportcompressedairfrom onecomponenttoanother(likefromacompressortoatool orcylinder).
10.DESIGN of Project
11. RESULTS AND APPLICATIONS
After successful design, fabrication, and testing, the pneumaticsugarcanecuttermachine followingresults:
11.1 Effective Cutting Performance
The blade cleanly cuts through sugarcane stalks with minimal effort. Average cutting time per stalk: 1.5–2 seconds.ReducedManualLaborRequiresverylittlephysical strengthcomparedtotraditionalmachetecutting.Increases operatorsafetybyreducingriskofinjury. ConsistentCutting Force Thepneumaticsystemprovidesuniformpressure, ensuringconsistentcuttingacrossstalksofdifferentsizes. LowPowerConsumptionCompressedairsystemoperates efficiently using a small-capacity compressor (6–8 bar range). Compact and Portable Design Easy to move and operateinfieldconditions. Suitable forsmall- tomediumscale sugarcane farms. Maintenance-Friendly Simple mechanical and pneumatic layout makes it easy to clean, service,andreplaceparts.
11.2 Applications
9.6 Frame Frame
The pneumatic sugarcane cutter machine can be used in variousagriculturalandindustrialsettings,suchas:
1. SugarcaneharvestingForcuttingsugarcanestalks cleanlyduringharvestinginfarmsandplantations.
2. Agro-ProcessingUnitsPre-cuttingsugarcanestalks before they are crushed in juice or jiggery processingmachines.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 12 Issue: 04 | Apr 2025 www.irjet.net p-ISSN: 2395-0072
3. Biofuel and Bagasse Production Preparing sugarcane as raw material for biomass energy or pulpforpapermanufacturing.
4. ResearchandAgriculturalInstitutionsUsefulinlabs andfieldtrialsfortestingsugarcanevarietiesand plantgrowthstudies.
5. MechanizationTrainingProjectsDemonstratesthe integrationofpneumaticsintofarmmechanization forstudentsandengineers.
12. CONCLUSIONS
ThePneumaticSugarcaneCutterMachinehasproventobe an efficient and practical solution for modernizing the sugarcane harvesting process. Through the use of compressedairandasimplemechanicalsetup,themachine significantly reduces manual labor, enhances operator safety,andincreasescuttingconsistency.Itscompactdesign, cost-effectiveness,andeaseofusemakeitsuitableforsmall to medium-scale farming operations. The successful implementationandtestingofthemachinedemonstratethat pneumaticscanplayavitalroleinagriculturalautomation, especiallyinregionswherelabor-intensivemethodsarestill inus
13. REFERENCES
Books&Journals:
R.K.Rajput,ATextbookofManufacturingTechnology,Laxmi Publications,2013.
P.N.Rao,ManufacturingTechnology:Foundry,Formingand Welding,TataMcGraw-Hill,2009.
S.Rattan,TheoryofMachines,TataMcGraw-HillEducation, 2014.
International Journal of Agricultural and Biological Engineering,ResearchonMechanizedSugarcaneHarvesting.