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Machine-

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OMKAR CHAFF CUTTER, Model: 3 HP RF Tiger Safety (Power Operated)

[Commercial] i

S.R. FARM MACHINERY TRAINING & TESTING INSTITUTE, TRACTOR NAGAR,

PO: GARLADINNE, ANANTAPUR (A.P)

Manufacturer: M/s Omkar Industries,

Plot No. W-57, MIDC,

Gokul Shirgaon,

KOLHAPUR – 416 234

(Maharashtra State)

CHAFF CUTTER (Power Operated)

Report No. Machine-9/284 Month: MAY Year: 2010

GOVERNMENT OF INDIA

SOUTHERN REGION FARM MACHINERY

TRAINING AND TESTING INSTITUTE

TRACTOR NAGAR

PO: GARLADINNE – 515 731

DISTRICT: ANANTAPUR (A.P)

Telephone No. 08551-86441 Fax No.08551-86441

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[Commercial] 19



o The Chaff Cutter is provided with side plates and top cover plates to protect the

feed rollers.

o There is provision for changing the direction of rotation of feed rollers by engaging

the gear lever to remove the clogging of throat and feed rolls.

7 WEAR OF CRITICAL COMPONENTS

7.1 Wear of chaff cutter blade on mass basis: -

S.

No.

Notation Initial

wt.(g)

Final wt. after 25.47h of

test (g)

% wear Wear rate (%)

1 A 893.7 879.4 1.60 0.06

2 B 885.7 870.9 1.67 0.07

7.2 Wear of Chaff Cutter blade on Dimensional Basis:-

S.

No.

Nota-

tions

Initial width (mm) Final width after

25.47 h (mm)

Wear (%)

Total Per hour

1 A Width at hole 1, W1=127.35 124.84 1.96 0.08

Width at hole 2, W2=133.05 132.17 0.66 0.03

Width at hole 3, W3=128.08 126.12 1.53 0.06

2 B Width at hole 1, W1=127.57 125.27 1.80 0.07

Width at hole 2, W2=133.72 132.10 1.21 0.05

Width at hole 3, W3=127.95 126.13 1.42 0.06

8 DEFECTS, BREAKDOWNS & REPAIRS

No breakdown was occurred during entire course of test.

9 SUMMARY OF OBSERVATION, COMMENTS & RECOMMENDATIONS

9.1 Quantity of Cut: -

(a) The feed rate was observed as 785 to 1191 and 1316 to 1429 kg/h in Elephant

grass and Sugarcane top respectively.

(b) The quantity of cut fodder received was measured as 772 to 1171 and 1305 to

1417 kg/h in Elephant grass and Sugarcane top respectively.

(c) The corrected quantity of cut was calculated as 262 to 462 and 445 to 505 kg/h

in Elephant grass and Sugarcane top respectively.

(d) The quantity of cut per unit energy consumed was calculated as 1302 to 1545

and 1495 to 1632 kg/kWh in Elephant grass and Sugarcane top respectively.

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[Commercial] 20



(e) The corrected quantity of cut per unit energy consumed was calculated as 513

to 525 and 495 to 631 kg/kWh in Elephant grass and Sugarcane top

respectively.

The quantity of cut was observed to be less than the range specified by the

manufacturer in it’s literature. 9.2 Quality of cut: -

The quality of cut was determined from the standard deviation of measured length of

cut from the theoretical length of cut pieces of plastic pipe. The variation was recorded

as -1.24 to -0.95 and -1.68 to -1.17 in Elephant grass and Sugarcane top respectively.

The variation in the length of plastic cut pieces was recorded as 7.9 to 13.8 and 0.2 to

11.7 % in Elephant grass and Sugarcane top respectively. The variation in length of cut

is found to be on higher side than the requirement of relevant Indian Standard.

9.3 Power requirement: -

The No-load power consumption of the chaff cutter was recorded as 0.5 kW, which is

22.7 % of rated power of the prime mover.

The on-load power consumption was measured as 0.5 to 0.9 and 0.8 to 0.9 kWh in

Elephant grass and Sugarcane top respectively. The capacity of the prime mover as

provided by the manufacturer on the machine is found adequate.

9.4 Performance Index: -

The overall performance of the chaff cutter was determined by its performance Index

and it was measured as -1915 to -1237 and -2741 to -1750 in Elephant grass and

Sugarcane top respectively.

9.5 Long Run Test: -

During and after the completion of long run test, no breakdown in the cutter head,

feeding mechanism, transmission system & body of the chaff cutter was noticed. Major

repairs were also not carried out during the entire course of test.

9.6 Labour Requirement: -

Six labours are required for continuous operation of the chaff cutter, three for feeding

the fodder crop and three for handling the chaff.

9.7 Ease of operation, adjustments and safety provisions: -

o The machine is easy for installation and operation.

o The adjustment of clearance between the fixed and rotating blade is easy to

perform.

o The cutter head and main power transmission is guarded by providing a safety

cover.

o The feed rollers are provided with spring loaded arrangement.

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o The Chaff Cutter is provided with side plates and top cover plates to protect the

feed rollers.

o There is provision for changing the direction of rotation of feed rollers by engaging

the gear lever to remove the clogging of throat and feed rolls.

9.9 The provision for changing the angle of placement of trough should be made as per

the requirements of IS: 15542 – 2005. This may be looked into.

9.10 A support should be given at the rear side of feeding trough as per the requirements of IS:

15542 – 2005. This needs to be provided.

9.11 Flywheel locking pin should be provided to avoid the accidents when the machine is not

in use, as per the requirements of IS: 15542 – 2005. This should be looked into.

9.12 The front safety guard for the blades should be provided to prevent the injuries to the

limbs as per the requirements of IS: 15542 – 2005. This should be looked into.

9.13 The warning roller and blade cover should be provided with the machine as a safety

measure, as per the requirements of IS: 15542 – 2005. This should be looked into.

9.14 The guard provided for the transmission drive is made of MS wire mesh. The guards shall

be made of blind sheets of mild steel having min. thickness of 1.6 mm as per the

requirements of IS: 15542 – 2005. this needs to be looked into.

9.15 A plate having „Danger Signal‟ shall be rigidly fixed near the blades of the chaff cutter as

per the requirements of IS: 15542 – 2005. This should be looked into.

9.16 A suitable arrangement shall be provided for clutching or declutching of drive as per the

requirements of IS: 11459 – 1985. This may be provided.

9.17 The lever provided for changing the direction of rotation of feed rolls is easily accessible

and capable of being locked in a chosen position. However the ON/OFF switch of the

prime mover shall be within the easy reach of the operator for emergency stop. This

should be looked into.

9.18 The minimum cautionary notices as stated in Cl. 9.1 of IS: 15542: 2005 should be

written in vernacular languages and fixed on the main body of the chaff cutter.

9.19 Wear of critical components: -

The wear rate of chaff cutter blade on mass and dimensional basis was measured as 0.06

to 0.07 % and 0.03 to 0.08 %, respectively.

9.20 The specifications of blades do not conform in full to the requirements of IS: 1511 –

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1979. This needs to be looked into.

9.21 Marking: - The chaffer blades shall be marked with the following particulars:

- Size code

- Thickness of blade

- Batch Code number

The identification plate riveted on the main frame of chaff cutter is marked with the

following particulars, except “Recommended rpm of the fly-wheel”, this should be looked into:

- Manufacturer‟s name and/or recognized trade mark

- Model Number

- Type

- Batch, code or serial number

- Power rating

- Rated input capacity

9.22 The dimensions of chute for power operated chaff cutter are conforming to the

recommendations of Dangerous Machines (Regulation) Rules, 2007 and are mentioned

below-

S.

No.

Description Dimensions

recommended (mm)

Dimensions

observed (mm)

Remarks

i) Min. length of chute 900 900 Conforms

ii) Min. thickness of sheet metal 1.6 1.8 Conforms

iii) Min. length of chute cover 450 500 Conforms

iv) Height of chute from ground level 750 to 1100 935 Conforms

9.22.1 The machine does not meet the requirements of IS: 11459 – 1985 and IS: 15542 – 2005

and the details are given below-

S.

No.

Relevant

Indian Standards

Clauses not meeting the requirements in Chapter 5 of this test report

i) IS: 11459 – 1985 4.2 (xv); 6.2 (a); 7.3 (2 points); 7.6 (1 point); 8.2 (a, & b); 10.1 (g)

and 10.1.1 (d, e, f, g, h, i & j)

ii) IS: 15542 – 2005 4(iii & xiv); 6.4; 7.2 (2 points); 7.2.1; 7.2.2; 7.2.4; 7.2.5; 8.3 (1

point); 9.2; 9.3; 11.1 (f) and 11.2

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