PNEUMATIC ARECA TREE CLIMBER

CHAPTER-1

INTRODUCTION

1.1 ABOUT ARECA NUT

Areca nut (Areca catechu), a tropical crop, is popularly known as betel nut, as its common
usage in the country is for mastication with betel leaves. In Karnataka, in the Uttar Kannada
District the crop is grown extensively, and is considered by the plantation owners as a
prestige symbol.

Fig1.1 Areca nut tree

Areca nut production in India is the largest in the world, as per FAO statistics for 2013,
accounting for 49.74 % of its world output, and is exported to many countries. Within India,
as of 2013-14, Karnataka produces 62.69% of the crop followed by Kerala and Assam; all
three states together account for 88.59% of its production. In Karnataka, in the Uttar
Kannada District the crop is grown extensively, and is considered by the plantation owners
as a prestige symbol.

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1.2 Current scenario of area nut cultivation

Inform all the people who can do the areca nut cutting job. Please remember this work
needs highly skilled people who know how to peal areca nut. Keep in mind that the areca
nut harvesting and processing is a complete people intensive work. It is difficult to be a one
man show for this venture. It is a complete team work.

During the harvest season, the ripened fruits have to be harvested. Minimum three &
maximum five people with required skills are necessary to accomplish this. One
professional tree climber with experience of plucking the fruits and another person who
uses gunny bag to catch it when the fruits are falling down. Before the tree climber decides
to pluck all the fruits, first he plucks only one/two fruits and indicates the other person to
check it.

Fig1.2 Areca nut harvesting

Once the fruit bunches are plucked from the tree, it has to be separated to get the individual
fruits. This can be done simultaneously when the plucking process is going on. As the farm
will be full of trees, unless there is a big enough space it'll be done on a rather flat place.

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1.3 LITERATURE SURVEY

1.4 ABOUT PNEUMATIC SYSTEM

Pneumatics is an aspect of physics and engineering that is concerned with using the energy
in compressed gas to make something move or work. The origins of pneumatics trace back
to the first century when the Greek mathematician Hero of Alexandria created mechanical
systems powered by wind and steam and documented his processes. Today, pneumatics
plays an important role in manufacturing and mechatronics.

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With pneumatics, valves control the flow of energy from pressurized gas, which is often
simply compressed air. The device that converts energy from the pressurized gas into motion
is called a pneumatic actuator. Pneumatic actuators are often powered by electric
compressors and are capable of producing either linear or rotary motion. A nail gun is an
example of a linear pneumatic actuator. When the user pulls the nail gun's trigger, a valve
opens and compressed air is released with enough force to drive the nail into a solid
surface. In manufacturing, pneumatic technology and automated solenoid valves can be used
in an assembly line to move process and package product.

Pneumatic systems are similar to hydraulics in function, but hydraulic systems use liquid to
power movement and work instead of gas. Pneumatic systems are simpler to design and
simpler to manage than hydraulic systems, but hydraulic systems are capable of greater
pressures: up to 10,000 PSI (pounds per square inch) with hydraulics, compared to about 100
PSI with pneumatics. In general pneumatic systems are more sustainable than hydraulic
systems because air can be exhausted into the atmosphere, while hydraulic fluid must be
exhausted into a fluid reservoir and eventually disposed of.

1. A compressor is the first element of the pneumatic system, which is responsible for
transferring atmospheric air into the energetic medium.
2. Air preparation unit is the second element of the pneumatic system, and it is responsible
for the compressed air treatment
3. Control elements are the third part of the pneumatic system
4. Cylinders are the fourth and the last element of the pneumatic system, and their task is to
transform the compressed air energy into to mechanical energy

This block diagram shown is applicable to most practical applications of pneumatic

systems.

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PNEUMATIC SYSTEM

AIR FUNCTIONAL
DRIVING ACTUATOR
MEANS COMPRESSOR CONTROL
S

DIRECTIONAL CONTROL
PRESSURE VALVE

CONTROL

FILTER LUBRICATOR

REGULATOR

Fig.1.4 Pneumatic system

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CHAPTER-2

CONSTRUCTION AND WORKING

2.1 CONSTRUCTION:

The main body consist of one main cylinder (300mm stroke,50mm bore) and two sub
cylinders (50mm stroke,25mm bore). The one sub cylinders is clamped to the top of the
piston and other is clamped to the bottom of the cylinder with the help of rectangular block.

In sub cylinders the round shaped clamps are used to clamping the tree. The other side of
the clamps the springs are attached which can be used to open and close the clamps of the
system from the areca tree.

2.2 WORKING:

Pneumatic areca tree climber basically consist of compressor, FRL Unit, 5/2 lever operated
Direction control valve, double acting pneumatic cylinders and hoses.

The airs from the atmosphere is sucked by the reciprocating compressor and compress the
atmospheric air from low pressure to high pressure then it stores in the compressor tank.

The high-pressure air is then passed to FRL (Filter, Regulator, and Lubricator) unit. In FRL
the high-pressure air is filtered i.e., removes the dust particles in air. Them it regulates the
air to the required pressure and lubricated the high-pressure air to provide easy movement
between the piston and cylinder.

The air from the FRL unit then flows through 5/2 lever operated DCV to actuators in which
contraction and retraction of the actuator is controlled by 5/2 DCV. The three cylinders
which is controlled by 5/2 DCV. Firstly, the all 3 cylinders are in contraction in position
and attached to the areca tree.

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When we operate the 1st DCV the top sub cylinder is expanding the clamp and by operating
the 2nd DCV the main cylinder extends its piston simultaneously with the top sub cylinder.
By operating the 1st DCV the top sub cylinder is contracts. Then the 3rd DCV is operate to
open the clamp of the bottom sub cylinder and simultaneously by operating the 2nd DCV
which cylinder itself contracts and then operating the 3rd DCV to close the bottom clamping
to attach the tree and cycle repeats.

2.3Flow diagram of the system:

LEVER
COMPRESSOR FRL UNIT OPERATED 5/2
DCV

ACTUATORS

Fig.2.3 Flow diagram

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CHAPTER-3

DESCRIPTION AND SPECIFICATION

3.1 DESCRIPTION

5/2 LEVER OPERATING DIRECTION CONTROL VALVE:

In certain design of DC valves, 5 openings are preferred instead of 4 openings. This

ensures easy exhausting of the valve. Figure shows a 5/2 lever type DC valve. Here the
spool slides inside the bore as given below:

Position-1: When the spool is actuated towards outer direction, port ‘P’ and connects
to ‘B’ and remains closed while ‘A’ gets connected to ‘R’.

Position-2: When the spool is actuated towards inner direction, port ‘P’ and ‘A’ get
connected to each other and ‘B’ to ‘S’ while port ‘R’ remains closed.

Fig.3.10 5/2 Lever operated DCV

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FRL UNIT (FILTER, REGULATOR AND LUBRICATOR):

The air from the compressor is clean and purified by the filter. The system performance
and accuracy depends much on the pressure-stability of the air supply. An air line filter
and a pressure regulator along with the lubricator, finds a very important place in the
pneumatic system. The main function is to provide the air with a lubricating film of oil.
These three units together are called service unit or FRL unit.
The main three elements of an FRL unit are;

1. Air filter
2. Pressure regulator
3. Lubricator

Fig.3.11 FRL Unit

CONNECTORS:
In our system we used the hose connectors. Hose connectors normally comprise an
adoptee hose nipple and cap nut. These types of connectors are made up of brass or
aluminium or hardened pneumatic steel.

PU TUBES AND FITTINGS:

Polyurethane flexible tubing is available in sizes from 1/16” to 1” inside diameter. This
pure polyurethane tubing is recommended for use with high-purify applications,
instrumentation and handling of pneumatic based products.

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PNEUMATIC DOUBLE ACTINNG CYLINDER:

A double acting cylinder is employed in control system with the full pneumatic
cushioning and it is essential when the cylinder itself is required to retard heavy loads.
This can only be done at the end positions of the piston stock. In all intermediate
position a separate externally mounted cushioning devices must be provided with the
damping features.
The normal escape of air is out off by a cushioning piston before the end of the stock is
required. As a result, the sit in the cushioning chamber is again compressed since it
cannot escape but slowly according to the setting made on reverses.
The air freely enters the cylinder and piston stokes in the other direction at full force
and velocity.

Fig.3.12 Cut section of double acting cylinder

3.2 PNEUMATIC COMPONENT AND SPECIFICATION

The pneumatic tree climbing unit consists of the following components

1. Air compressor
2. Double acting pneumatic cylinder
3. 5/2 lever operated DC valve
4. Flow control valve
5. Hose pipes
6. FRL unit
7. Other materials

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1. Air compressor: Minimal power consumption build this solution is operating

with air, so we trying for the 15liter air compressor to reserve and meet the
requirements
Specification of the air compressor used;
 Power- 0.5 HP
 Pressure- 8 Bar
 Voltage- 220 VAC
 Frequency - 50 Hz
 Tank Capacity- 15 L
 Weight- 15 Kg
 Power Rating- 0.34 KW
 Flow Capacity- 50 L/Min.
2. Double acting pneumatic cylinders: These are the cylinder operates with
air and provide good results in reducing total weight of the system, add on to the 50
mm in stroke length to 300 mm stroke lengths for two different motions in the
product.
Specification of the cylinder used;
 Bore Size- 50 & 25 mm
 Stroke- 50 & 300 mm
 Port size- G1/8 inch
 Operating Pressure - 1-10 Kgf/cm2
 Operating temperature range- 5 to 70°C
 Cylinder weight - 800 to 2000 grams
3. Bidirectional valves: With a better controlling panel and bidirectional valves
are helping to control air flows and moving mechanism of the pneumatic cylinder.
Specification of the controlling valve used;
 Port- Inlet, Outlet, Exhaust
 Port size- G 1/2
 Working Medium- Compressed Air

 Applicable Temperature- 0～60 ℃

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4. Hose pipes: We used polyurethane material pipes for carrying high pressure air
to long distances
Specifications of used material;
 Burst Pressure- 25 Kgf/cm²
 Size ID (mm)- 6mm
 Fluid- Air, Water
 Size Outer Diameter(mm)- 8mm
 Operating Temperature- 5 to 60 ºC
 Operation Pressure- 0-10 Kgf/cm
5. FRL: Filter regulation and lubrication unit is helping to filter dust particles and
maintain the proper pressure in the system.
Specification
 Port size- 1/2 Inch
 Applicable Temperature- 0-60 ºC
 FRL Type- 2-stage
 Operating Pressure- 0.5-10 Kgf/cm²
6. Other materials/ parts used to support the systems are;
 Cutting blade
 Clamping equipment
 Hand levers
 Connectors for pipes and hosing’s
 Grippers & springs
 Nut and bolts

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CHAPTER-4

FABRICATION
4.1 METHOD OF FABRICATION
The following operations that are carried out while the construction of climber.

1. Cutting
2. Drilling
3. Bending
4. Assembly

Cutting operation

In all machining process, the work piece is a shape that can entirely cover the final part
shape. The objective is to cut away the excess material and obtain the final part. The cutting
usually requires to be completed in several steps- in each step, the part is held in a fixture,
and the exposed portion can be accessed by the tool to machine in that portion. Common
fixtures include vise, clamps, 3-jaw or 4-jaw chucks, etc. Each position of holding the part
is called a setup. One or more cutting operations may be performed, using one or more
cutting tool, in each setup. To switch from one setup to the next, we must release the part
from the previous fixture, change the fixture on the machine, clamp the part in the new
position on the new fixture, set the coordinates of the machine tool with respect to the new
location of the part, and finally start the machining operations for the setup.

Fig.4.10 Cutting operation

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Drilling operation

Drilling is a process that uses a drill bit to cut a hole of circular cross-section in solid
materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed
against the work-piece and rotated at a rate of hundreds to thousands of revolution per
minute. This forces the cutting edge against the work piece, cutting off chips from the hole
as it is drilled.

Bending operation

Bending of sheets and plates is widely used in forming parts such as corrugations, flanges,
etc. Bending is a forming operation in which a sheet metal is subjected to bending stress
thereby a flat straight sheet is made into a curved sheet. The sheet gets plastically deformed
without change in thickness. Die and punch are used in bending. If a V shaped die and
punch are used, thee bending is called v-bending. If the sheet is bent on the edge using a
wiping die it is called edge bending. In the process, one end of the sheet is held like a
cantilever using a pressure pad and the other end is deformed by a punch which moves
vertically down, bending the sheet. Usually edge bending is done in order to obtain an angle
of 90 degree.

Fig.4.11 Bending operation

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Assembly operation

Assembly is the connection and attachment of parts, subassemblies and modules in a

definite sequence to produce a finished machine. A module is a detachable or non-
detachable grouping of parts. The characteristic feature of a module is that it can be
assembled part from the other elements of the final product. A combination of two or more
parts in a module is called a subassembly. There are primary, secondary and higher order
subassemblies. The higher order subassemblies may be separated only into parts.

Fig.4.12 Assembly operation

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CHAPTER-5

MECHANISM, DESIGN AND CIRCUIT DIAGRAM

5.1 MECHANISM

The robot consists of three pneumatic actuators. The main actuator has a 30cm effective
stroke and can deliver 500 Newton force at 5 bar (it could carry a 50kg payload). The two
actuators are smaller with a stroke of 5cm and their task is to open and close the upper arm
and lower leg. Special aluminium seats were designed to hold the small actuators in a
horizontal position on the arm and leg. Each small actuator is attached with two seats one
for the base another for the bases of stainless steel flat blocks have been manufactured to
connect the main actuator with arms. The upper base is cubic with one hole on the datum to
join with the main actuator and another on the side connecting with the arm. The lower end
of the main actuator is attached directly to the base of the actuator with four screws. It has a
part to connect lower arm to it. The arms were manufactured from aluminium to keep
minimum weigh.

It connects together to embrace the trunk to control the system manually at first, two 3/2
way push button control valves were used. One is responsible for raising the upper arm and
opening it while keeping the grip of the lower arm to the trunk of the tree. Providing
compressed air to the other small actuator does the opposite, opening the lower arm while
closing the upper arm to grip the trunk.

The air that operates the system comes from a 7 bar compressor. The assembly drawing of
the robot mechanism and an exploded view of this robot are shown in Fig.5.1.

Fig.5.1 Exploded view of robot mechanism

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Below is a list of components used in the climbing machine:

1. The main actuator

2. The auxiliary actuator
3. Fork arm
4. Circular tube
5. Upper base
6. Lower base
7. The platform
8. Cylindrical box (x2)
9. U-shaped bar
10. Rods final design

From the primary design to the "final" design there were many experiments and iterations
that led to several modifications to the robot design and consequently arrived at the "final"
design shown in Fig.9.

Fig.5.11 Final design of robot mechanism

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5.2 CAD MODELING

Fig.5.2 3D Modeling of assemble model

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Fig.5.21 Arm

Fig.5.22 Auxiliary actuator

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Fig.5.23 Fork arm

Fig.5.24 Extension Springs

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Fig.5.25 Nut-1

Fig.5.26 Nut-2

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Fig.5.27 Main cylinder

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5.3 CIRCUIT DIAGRAM

Fig.5.3 Circuit diagram of working of double acting cylinder

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CHAPTER-6

MAINTENANCE AND OPERATION GUIDANCE

SAFETY CAUTIONS:

 Always use clean and dry air to operate the tool and keep working area clean.
 Loose fittings and connections should be avoided.
 Do not use damaged, frayed or deteriorated air hoses and fitting.
 When the work is finished turn off the air source.
 Turn on the air source such as air compressor and allow air tank to be filled.
 Set the regulator of air source to 10 bar. This tool are operated at the maximum 10 bar
pressure.
 Do not lubricate tool with flammable or volatile liquids such as kerosene, diesel or
fuel.
 Make sure that arms are fixed correctly or not.
 Operate the valves according to the sequence of motion.
 When the work is finished turn off the air source.

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CHAPTER-7

ADVANTAGES AND DISADVANTAGES

7.1 ADVANTAGES

• It uses air as a working medium; it is available in wide ranges.

• Overall and maintenance cost is low.
• It is economically and eco-friendly.
• Easy maintenance.
• It requires less time.
• Minimizes labour cost.
• Harvesting rate is high compared to manual.
• Unskilled labours are also can operate.
• Break down chances are less.

7.2 DISADVANTAGES

• Initial cost is more.

• Periodic maintenance of FRL unit is required.

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CHAPTER-8

FACTORS DETEMINING THE CHOICE OF

MATERIALS
The various factors which determine choice of material discussed below are

1. Properties:

The material selected must possess the necessary properties for the proposed application,
the various requirements to be satisfied can be weight, surface finish, rigidity, ability to
withstand environmental attack from chemicals, service life, reliability etc.

The following four types of principle properties of materials of decisively affect their
selection

a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical

The various physical properties concerned are melting point, thermal conductivity, specific
heat, co-efficient of thermal expansion, specific gravity, electrical conductivity, magnetic
purposes etc.

The various physical properties concerned are strength in ensile, compressive shear,
bending, torsion and buckling load, fatigue resistance, impact resistance, elastic limit,
endurance limit and modulus of elasticity, hardness, wears resistance and sliding properties.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of special
materials.

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3. Quality required:

This generally affects the manufacturing process and ultimately the material. For example,
it would never be desirable to go for casting of a less number of components which can be
fabricated much more economically by welding or hand forging the steel.

4. Availability of materials:

Some materials may be scarce or in short supply. It then becomes obligatory for the
designer to use some other material which though may not be a perfect substitute for the
material designed. The delivery of materials and the delivery date of product should also be
kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the forces involved are high
and the space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an important part
and should not be ignored. Sometimes factors like scrap utilization, appearance, and non-
maintenance of the designed part are involved the selection of proper materials.

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CHAPTER-9

DATA SHEET, OBJECTIVE AND FUTURE SCOPE

9.1 DATA SHEET

9.10 Upward motion

SL NO. Time (sec) Height (Meter) Pressure (PSI)

01 11 1 7.25189

02 22 2 11.603

03 33 3 17.4045

04 44 4 23.206

05 55 5 29.0075

Average pressure required 17.6945 PSI

Upward motion
60
T 50

I 40

M 30

20
E
10

0
1 2 3 4 5
Height
Time (sec) Height (Meter) Pressure (PSI)

Graph.9.1 Upward motion

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9.11 Downward motion

SL NO. Time (sec) Height (Meter) Pressure (PSI)

01 11 1 4.35113

02 22 2 4.35113

03 33 3 4.35113

04 44 4 4.35113

05 55 5 4.35113

Average pressure required 4.35113 PSI

Downward motion
60

T 50

I 40

M 30

E 20

10

0
1 2 3 4 5
Height
Time (sec) Height (Meter) Pressure (PSI)

Graph.9.11 Downward motion

9.2 OBJECTIVE OF PROJECT

The main objective of this system is to perform “climbing operation” by using “tree
climbing machine” in which pneumatic equipment’s performs a major role. By using this
equipment human efforts will be reduced. Time and energy will be saved to a possible state
or rate. By using this equipment the accidents that happen during harvesting will be
minimized. And moreover harvesting will be much easier than conventional method.

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9.3NEED FOR PNEUMATICS

Pneumatics forms an attractive medium for low cost. The main advantage of a pneumatic
system is that it is economical and simple in construction which makes it different from
other sources of system. Maximum power can be transmitted and controlled by operating
simple levers. Much simple than complicated circuits.

Pneumatic system plays an important role in mass production. Now-a-days almost all the
manufacturing process is changing to pneumatics. In order to deliver the products with
better quality and a faster rate. The manufacturing operation is being pneumatics for the
following reasons.

 To achieve mass production

 To reduce man power
 To increase the efficiency of harvesting
 To reduce harvesting time and cost
 To achieve good quality of harvesting
 Less maintenance

9.4 FUTURE SCOPE

In the future, the climber can be fully automated. Instead of manual controlling, the whole
operation can be programmed into a micro controller. Pressure sensors can be used to
determine how much pressure to be applied after the bush comes in contact with the tree. A
robotic arm can be used to harvest areca nut.

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CHAPTER-10

LIST OF MATERIALS AND COST ESTIMATION

10.1 Materials

SL NO DESCRIPTION QUANTITY MATERIAL

1 Double acting pneumatic cylinder 3 aluminium

2 5/2 lever operated DCV 3 Mild steel

3 FRL unit 1 Steel

4 Manifold 1 Aluminium

5 PU tubes 35 meter Polyurethane

6 Connector 22 Steel

7 Push-Pull valve 1 Steel

8 Arms 4 Aluminium

9 Block 1 Aluminium

10 Clamp 3 Aluminium

11 Springs 2 Steel

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10.2 COST ESTIMATION

SL NO. COMPONENTS QUANTITY AMOUNT

01 VAC Non-magnetic double 1

acting cylinder (300mm Stroke
50mm Bore),

JELPC 5/2 Hand lever valve, 1 9080/-

1
Instamod air pipe1/4” FRL unit

02 JELPC Double acting 2 1895/-

Cylinder(50mm Stroke 25mm
Bore)

03 1/4 “8mm connector 13

1/8” 8mm connector 4

¼” Air silencer 6 3581/-

5 Way ½” Manifold 1

½” Dummy plug 1

8mm Hose pipe 30m

04 Nut 8 245/-

Washers 16

05 Wood sheets, drilling, bar - 2330/-

bending

06 Springs, Bolts, Gripper - 1300/-

07 Aluminium sheets - 1800/-

08 Bar bending, labour cost and other - 9657/-

charges

TOTAL 29888/-

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CHAPTER-11

CONCLUSION
The disadvantage of the manually harvesting and conventional method can be eradicated by
using this pneumatic areca nut tree climbing machine. It can be more efficient in future
application. Even unskilled labour can operate easily. It is safest method of harvesting. It
requires less time to harvest. With its lots of advantages, it will be definitely used in the
future.

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REFERNCES

1. Journal of Automation and Control Engineering Vol.4

2. K.R. Asfar, "Pole climbing robot, Patent Application,2013
3. B. Yazdani, M. Ahmadabadi, A. Harati, H. Moaveni, and N. Soltani, "Design and
development of a pole climbing robot mechanism”.

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