SEMI- AUTOMATED PNEUMATIC VEGETABLE CHOPPING MACHINE

CHAPTER 1
INTRODUCTION
In the late 90’s, Automation was the rage of the engineering world. The best of the minds,
rallied day and night to bring forth improvements of significant magnitude, something which
could make an impact in the day-to-day life. Today, it’s a plethora of fields which have
embraced with automation, from manufacturing to food processing, bio-medical and
pharmaceutical industries. In such scenario, domestic applications have also been developed
with the common man in mind.

Pneumatic devices are used in many industrial applications. Generally appropriate for
applications involving less force than hydraulic application and less expensive than electric
applications. Most pneumatic devices are designed to use clean dry air as an energy source.
The actuator then converts that compressed air into mechanical motion. The type of motion
produced depends on the design of actuator. Pneumatics is employed in a variety of settings.

Knife and plastic grater were the most common devices used for slicing and cutting
vegetables such as potatoes, tomatoes, carrots, onions and lettuce. In the early 1960s, the
world’s first automatic vegetables cutting machine was developed. The slicing technology
has been developed in 1970s where most of the slicers can process mono crystal with large
diameter up to 125mm. In 1980s, the slicing technology has experienced its peak of
development with the commercials of automatic multi-function slicers. It is not easy for those
who want to cut a large number of vegetables into smaller sizes in a short period. It may also
cause injuries as a result of carelessness. As the time goes by, the slicing technology has been
developed to overcome these problems. Slicing machine was designed to ease the cutting of
vegetables, to eliminate the time wasted and to avoid injuries when using the knife.[1]

Vegetable slicing machine can be operated by manual or powered or automated. The design
of manual vegetable slicing machine eliminates the usage of electricity, safer, consistent and
affordable. However, it can be time consuming and less efficient. An automated slicing
machine basically includes a base housing a motor, feeder part, feeder mouth which houses a
presser and cutting knife. It allows the user to cut a large number of vegetables precisely in a

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shorter period. However, it is more expensive and difficult when it comes to maintenance
operation. This can be minimized by using pneumatic chopping machine. [1]

In pneumatic chopping machine vegetables can be cut into the pieces with specified sequence
of period. This automatic process requires less man power to place the vegetable on the
cutting table. This type of system is very useful in bulk processing in the hotels. Initially
compressor supplies the air at 8 bar pressure to the solenoid valve. 5/2 solenoid valve is used
to control the direction of flow of air to the pneumatic cylinder. Pneumatic cylinder actuates
the piston due to high pressure of air. At the end of the piston rod vegetable cutting knife is
fitted. So, the reciprocating motion of piston gives cutting action on the vegetables, which are
placed on the table. Then the flow direction is reversed by the solenoid valve. So, this will
actuate the piston rod to retard position. Now the solenoid valve changes the direction of flow
of air to the pneumatic cylinder. This process is carried continuously.

1.1 OBJECTIVES

 To perform chopping of vegetables with minimum human intervention

 To automate unloading of chopped vegetables
 To develop it as a flexible system to accommodate variety of vegetables

1.2 PROBLEM STATEMENT

Chopping of vegetables is necessary in both domestic and industrial applications. Automation of

vegetables chopping is required when it has to be done in larger quantity. At present, vegetables
are chopped manually or by using semi-automated machines and electrically powered machines.
Electro-pneumatic systems can be used to perform vegetable chopping operation. This project is
an attempt to develop one such electro-pneumatic based vegetable chopping machine.

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1.3 LITERATURE SURVEY

1.3.1 AUTOMATED VEGETABLE CUTTING MACHINE

The Automated Vegetable Cutting machine was fabricated by R. Ramakrishna Reddy, et al. This
work consists of two major parts. One is the mechanical setup involving the base, frame, rotating
disc cutter, side plate/tray carriage, and hopper. While another part involves motor and battery.
The regulatory system and switch of the motor are connected to the battery. The frame is fixed
on the base with the help of bolts and nuts. The rotating disc cutter shaft is connected to the
motor shaft with the help of bolt and nut. The blades are arranged at an angle of 90° to each
other. The blades are fixed at an angle of 50° at its position. The side plate is used to cover the
cutting chamber and it is fixed to the frame with the help of screws. The hopper is directly
connected to the cutting chamber. The vegetables enter into the cutting chamber through hopper.
Vegetables are chopped in rotary cutter. [1]

1.3.2 VEGETABLE CUTTING MACHINE

The Vegetable Cutting Machine was designed by A Nishanth, et al. It works with the help of
electric DC motor (rotation motion crank lever mechanism). The vegetable was kept on the
cutter bed made of stainless-steel sheet which carries blade made of stainless steel. The chute
was constructed of stainless steel. It accepts the chopped vegetables and releases it out with the
aid of gravitational force. [2]

1.3.3 HAND OPERATED SEMI-AUTOMATIC CHOPPING MACHINE FOR LEAFY

VEGETABLES AND MEDICINAL HERBS

Fig. no.1.1 Hand-operated semi-automatic chopping machine

A hand operated semi-automatic chopping machine for leafy vegetables and medicinal herbs was
designed by P.D Kahandage, et al. The main features and components of the chopping machine

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were integrated cutting and feeding mechanism, operating handle, piston, collecting drawer, and
the frame. The performance test was done for this machine using four different leafy vegetable
and medicinal herbs. The average width of a particular cut by machine and kitchen knife was
1.87mm and 3.38mm respectively. According to the user feedback, this machine was safe,
affordable and convenient device for processing vegetables and medicinal herbs.[3]

1.3.4 AUTOMATIC VEGETABLE CHOPPER USING IMAGE PROCESSING

Fig.no.1.2 Vegetable chopper

Image processing-based vegetable chopping machine was designed by K Adithya Prathap, et al.
In this project the complete process of vegetable chopping right from the detection up to the
chopping was automated. Image processing was used to identify the vegetable, in a python open
CV environment. This eliminates the need for maintaining a huge database of all the vegetables.
Various parameters related to the vegetables such as texture, hardness, colour, size and shape are
analysed and a suitable blade is selected. [4]

1.3.5 SLICING MACHINE FOR SELECTED VEGETABLES

Slicing machine for selected vegetables was designed by Nnaemeka Charles Ezeanya. This
slicing machine equipped with two slicing blades. The machine was powered by 0.25 HP single
phase motor. The three selected vegetables used in this research are Onion, Carrot, and Irish
Potatoes, grouped into small sized samples and medium sized samples; at four various machine
speeds of 53 rpm, 58 rpm, 62 rpm and 69 rpm. The parameter investigated was slicing efficiency

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and throughput capacity. After obtaining result and comparing they observed that the machine
could slice the vegetables satisfactorily with slice thickness ranging from 5mm to 6mm. [5]

1.3.6 SPRING CASSAVA CHOPPING MACHINE FOR FARMERS

Spring cassava chopping machine for farmers was developed by R Kiruba Shankar, et al. The
cultivation of cassava can be done by using planted sprigs of cassavas. This recultivation process
was cyclic process which requires manual power. In this project cassava sprigs as per the
requirement for the further cultivation was to be designed and fabricated. The sprigs that stocked
after harvesting was placed in the stock section of the sprig cassava machine. Arduino takes the
signal from sensor as the input and provide the output to the servomotor to actuate at the input
time and it allows the stoked cassava sprigs to feed to the chopper. The chopper connected with
the bane motor by gear drives that makes the shaft to rotate at required RPM.[6]

1.3.7 NORMAL VEGETABLE CHOPPER

Normal choppers, which contain 2-5 litre plastic jar in which shaft like arrangement made in
centre with multiple blades oriented to it. It is connected to long thread which was pulled and left
free, it will rotate the shaft and vegetables inside the jar will chopped.

Fig.no.1.3 Vegetable choppers available in the market

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CHAPTER 02

METHODOLOGY
HARDWARE REQUIREMENTS

 Pneumatic cylinders
 Frame
 Motor
 Stainless steel grid
 Conveyor
 PLC

SOFTWARE REQUIREMENTS

 Electro-pneumatic circuit design and simulation using automation studio

 Programming PLC using ladder logic

Keeping in view of required hardware components, 3D model was designed using solid works.
Fabrication of the model will be carried out as per the designed model. After fabrication of
model, a suitable electro-pneumatic circuit will be designed and simulated using automation
studio.

Afterwards the designed electro-pneumatic circuit will be considered for actual implementation.
Then PLC programming will be carried out using ladder logic. At the end hardware setup of the
project will be integrated with PLC and testing will be carried out.

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2.1 DESIGN OF MODEL

Fig.no.2.1 Schematic diagram of semi-automated vegetable chopping machine

Fig.no.2.2 3-D model of semi-automated vegetable chopping machine

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2.2. DESIGN AND FABRICATION OF INDIVIDUAL COMPONENTS

2.2.1. HOPPER

There are various feeding mechanisms like: Vibratory feeder bowls, Centrifugal feeder, Linear
conveyor system, Hopper systems, Step feeder and Machine vision technology (Robotic
guidance system). In this project, we used both hopper and linear conveyor system. Gravity
feeding method is used here as shown in the fig.no.4.2. The reasons for choosing hopper over
other feeding devices are: it is cost effective, specific for our application, less complex and easy
to fabricate.

Here we used sheet metal for fabrication process. First, we developed two components: Frustum
of cone and Cylinder as per the required dimension and later joined them using brazing
technique. We used brazing technique because it is most suitable for joining metals with lesser
thickness. Design and Fabrication of hopper are shown in below figures.

Fig.no.2.3 3-D Model of Hopper

Fig.no.2.4 Fabricated Hopper

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2.2.2 CONVEYOR

A conveyor system is a common piece of mechanical handling equipment that moves materials
from one location to another. Conveyors are especially useful in applications involving the
transport of heavy or bulky materials. In this project, purpose of using conveyor is to move the
vegetables from hopper to cutting chamber. Reasons for choosing conveyor over other methods
are: speed of the movement can be adjusted and it is possible to move one vegetable at a time to
cutting chamber.

Two pulleys are used, one 60rpm DC motor, one long belt and side guides to prevent the falling
of vegetables to ground. Conveyor is supported over the L shaped frame and that is fastened to
the base frame using bolts and nuts. It is powered through DC Motor.

Fig.no.2.5 3-D Model of Conveyor

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Fig.no.2.6 Fabricated conveyor belt

2.2.3 BASE FRAME

As shown in below figure, the cylinder is mounted to base frame in the form of L beam. We
came across many mountings as you can see in the previous design model, we mounted the
cylinder to the board but later we changed the design because it is most convenient, lesser
complexity and it also gives better strength.

Brazing technique is used to join the metals, because it is most suitable technique for metals of
lesser thickness as mentioned earlier and finally completed the base frame to the required
dimension. Here we used 200mm stroke length cylinder because we need more amount of
horizontal space to collect and cut the vegetable efficiently. Design and Fabrication are shown in
figure.

Fig.no.2.7 3-D Model of Base Frame

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Fig.no.2.8 Fabricated Base Frame

Fig.no.2.9 Fabrication of base frame

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2.2.4 PNEUMATIC CYLINDER

Pneumatic cylinders are mechanical devices which use the power of compressed gas to produce a
force in a reciprocating linear motion . Uses force to move in both extraction and retraction
strokes. They have two ports to allow air in, one for out stroke and one for in stroke.

Pneumatic cylinder consists of piston, piston rod and body or tube. Compressed air enters at one
end of the tube imparting force on the piston which is displaced in order to balance the force
exerted on the piston. Cylinders are available in variety of sizes and shapes and have varying
stroke length. In this project, double acting pneumatic cylinder of stroke length 200mm is used,
because more amount of horizontal space is needed to collect and cut the vegetable efficiently.

Fig.no.2.10 Double Acting Pneumatic Cylinder

Fig.no.2.11 3-D Model of Double Acting Pneumatic Cylinder

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2.2.5 5/2 Way Pneumatic Solenoid Valve

5-way 2-position pneumatic solenoid valve is used. There are two-positions: on and off, which
are controllable. The five-way means there are five ports for air flow, namely one inlet (inlet air
source), one positive-action outlet and one reverse-action inlet (one positive-action air source
and one reverse-action air source for the target equipment, respectively), one positive-action
exhaust vent and one reverse-action exhaust vent (installed with the silencer). The 5/2-
way solenoid valve is usually used together with the double-acting cylinder.

A solenoid valve consists of two basic units: an assembly of the solenoid (the electromagnet) and
plunger (the core), and a valve containing an orifice (opening) in which a disc or plug is
positioned to control the flow of fluid. The valve is opened or closed by the movement of the
magnetic plunger. When the coil is energized, the plunger is drawn into the solenoid
(electromagnet), and flow through the orifice is allowed. The valve returns automatically to its
original position when the current ceases due to the pressure of spring and flow through the
orifice is restricted.

Fig.no.2.12 5/2 Way Pneumatic Solenoid Valve

2.2.6 CUTTING CHAMBER

Cutting chamber contains stainless steel grid (series of blade arranged to get the desired cutting
shape) which is placed on a metal chamber and fitted with the nuts and bolts. It is joined to the L

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frame by welding process. Various grids are used to get different vegetable shapes. Grids are
easily interchangeable as they are fastened with nut and bolts.

Fig.no.2.13 3-D Model of cutting chamber

Fig.no.2.14 Cutting chamber

Entire cutting chamber is covered by acrylic sheets. Acrylic sheets are used because it is
transparent and it also reduces the chance of vegetables spill out from the chamber. Acrylic
sheets are fastened to cutting chamber with the help of bolts and nuts. Guides are provided to
conveyor to prevent the vegetables from falling off. Guides are also connected to acrylic sheets
through bolts and nuts.

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Fig.no.2.15 Fabrication of cutting chamber

2.2.7 RAM/ DIE

Ram is made up of mild steel. Bolt is welded to a ram and that part is screwed to the cylinder.
The function of ram is to force the vegetable through the grids.

Fig.no.2.16 3-D Model of ram

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Fig.no.2.17 Ram

2.2.8 RELAY

A relay is an electrically operated switch. It consists of a set of input terminals for a single or
multiple control signals, and a set of operating contact terminals. The switch may have any
number of contacts in multiple contact forms, such as make contacts, break contacts, or
combinations thereof.

Fig.no.2.18 24V Relay

2.2.9 PIR Sensor

PIR sensors allow you to sense motion, almost always used to detect whether a human has
moved in or out of the sensors range. They are small, inexpensive, low-power, easy to use and
don't wear out. For that reason, they are commonly found in appliances and gadgets used in

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homes or businesses. They are often referred to as PIR, "Passive Infrared", "Pyroelectric", or "IR
motion" sensors.

Fig.no.2.19 PIR Sensor

PIRs are basically made of a pyroelectric sensor (which you can see above as the round metal
can with a rectangular crystal in the centre), which can detect levels of infrared radiation.
Everything emits some low-level radiation, and the hotter something is, the more radiation is
emitted. The sensor in a motion detector is actually split in two halves. The reason for that is that
we are looking to detect motion (change) not average IR levels. The two halves are wired up so
that they cancel each other out. If one half sees more or less IR radiation than the other, the
output will swing high or low.

2.2.9 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A programmable logic controller (PLC) or programmable controller is an industrial computer

that has been ruggedized and adapted for the control of manufacturing processes, such as
assembly lines, machines, robotic devices, or any activity that requires high reliability, ease of
programming, and process fault diagnosis.

PLCs can range from small modular devices with tens of inputs and outputs (I/O), in a housing
integral with the processor, to large rack-mounted modular devices with thousands of I/O, and
which are often networked to other PLC and SCADA systems.

They can be designed for many arrangements of digital and analog I/O, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control
machine operation are typically stored in battery-backed-up or non-volatile memory.

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PLCs were first developed in the automobile manufacturing industry to provide flexible, rugged
and easily programmable controllers to replace hard-wired relay logic systems. Since then, they
have been widely adopted as high-reliability automation controllers suitable for harsh
environments.

A PLC is an example of a hard real-time system since output results must be produced in
response to input conditions within a limited time, otherwise unintended operation will result.

The 5 most popular types of PLC programming languages are:

 Ladder Diagram (LD)

 Sequential Function Charts (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)

Each one of these languages has advantages, weaknesses, and best uses cases . In this project
ladder logic is used because it is simple and flexible. Error identification in the ladder
programming is easy compared to other programming languages.

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Fig.no.2.20 Programmable logic controller

2.2.10 Ladder logic PLC programming

Before Programmable Logic Controllers became popular, relay-based controls were the norm at
most manufacturing sites. Relays drove loads based on the simple logic that was implemented
through the physical wiring of the devices. The wiring of these devices was specified in electrical
drawings that assumed the layout resembling a ladder. As the most basic PLCs were introduced
into the field, ladder logic PLC programming was designed to mimic the layout of relay-based
circuits. In other words, ladder logic was one of the first PLC programming languages that are
still used today due to simplicity.

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Fig.no.2.21 PLC Program

When the toggle switch is turned on, the motor will start to rotate. Motor is connected to
conveyor. Conveyor carries the vegetables into cutting chamber. Eventually vegetables will
move into the cutting chamber one by one. IR sensor is placed in the cutting chamber. When
vegetable fall into the cutting chamber IR sensor became active high and motor will stop to run.
Timer is placed in between the sensor and conveyor in the rungs. After 2 seconds delay 5/2-way
solenoid valve will be energized then, cylinder will actuate and cut the vegetables. After 5
seconds delay Cylinder will retract back into its initial position. IR sensor will become active low
then motor will start to run again. In the similar manner cycle will continue.

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2.3 ELECTRO-PNEUMATIC CIRCUIT

Fig.no.2.22 Electro-pneumatic circuit

Inputs

 On/off toggle switch

 PIR Sensor

Outputs

 Motor
 5/2 Way solenoid valve

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Specifications

Specifications of pneumatic cylinder

Description Cylinder

Type of actuation Double Acting Cylinder

Material Aluminium Alloy

Operating Temperature Range -20°C - 80°C

Operating Speed Range -

Stroke 150 mm

Bore 50 mm

Working Pressure 0-12 Bar

Cushioning Type Air

Pneumatic Connection G¼

Table no.1 Specifications of pneumatic cylinder

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Specification of Relay module

Sl No Description

1 Channel 4

2 Voltage 5V

3 Current 10A

4 AC Control voltage 250V at 10A

5 DC Control Voltage 30V at 10A

6 Relay operating voltage 3.3 to 5V

7 Length 75mm

8 Width 55mm

9 Height 18mm

10 Weight 55gram

Table no.2 Specifications of Relay module

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2.4 ASSEMBLY MODEL

Fig.no.2.23 3-D Model of Pneumatic Vegetable Chopping Machine

In the initial stage of our project we designed a model but we find flaws in the model. In the first
model there are practical difficulties in the placement of cylinder. L-frame is used for cylinder
placement in the final model. Because it is easier, convenient and flexible it can change the ram
easily.

In the previous model cutting chamber is supported by the base but later we found the
difficulties in collecting the vegetable pieces. So, later the design was changed. It is connected to
L-frame to get the large space to collect vegetable pieces.

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Fig.no.2.24 Fabricated semi-automated pneumatic vegetable chopping machine

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CHAPTER 03

RESULTS AND DISCUSSIONS

CALCULATION

3.1 PRESSURE CALCULATION

The double acting cylinder is used to perform the chopping of vegetables. For the cutting of
vegetables following calculations were made. Since the force required for cutting process can’t
be determined practically, a simple theoretical force calculation was done and the cylinder was
selected using working pressure as the major consideration. During trial and error
experimentation the minimum pressure required for the cutting process was found to be 7 bar.
The vegetable used for calculation was a potato.

Working pressure P= 7 bar = 7×105 N/m2

Cylinder diameter d1 = 30 mm= 0.03 m

Piston diameter d2= 10 mm= 0.01m

Therefore, the force generated by the double acting cylinder
F=P×A

=P×π(d1²-d2²)/4

=7×105×π(0.03²-0.01²)/4

= 439.823 N

3.2 CYCLE TIME

Time required for a vegetable to move into the grid= 6 seconds

Time delay in actuation = 2 seconds

Time required for chopping the vegetable = 3 seconds

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Time delay in retraction of cylinder = 5 seconds

Total time required for chopping a vegetable = 16seconds

In 1 hour = 3600/16

= 225

In 1 hour 225 vegetables can be chopped in our project

3.3 PNEUMATIC CYLINDER DESIGN

P= F/A

F= 439.823 N

P= 439.823/(πD2/4)

Assumed pressure is 7 bar

D2= 439.823/(π×7×105/4)

D= 0.0283m = 28.3 mm

For the availability of higher capacities we have selected 30 mm diameter and stroke length as
200 mm

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CONCLUSION

This project provides an alternative to the existing automatic vegetable cutter, in terms of
automating the vegetable entry into the cutting apparatus with lesser initial investment. Time
consumption is less when compared to manual cutting. Pneumatic chopping machine provides
the desired output and the variety of the cuts is done by use of different cutting grid.

This project has its own limitation. The space provided for cutting of vegetables is small. If the
space is large enough to hold more than 3 or 4 vegetables at a time then it is more efficient for
industrial application. This chopping machine is more suitable for food processing industries.

SCOPE FOR FUTURE

 Programming can be done using Arduino

 Feeding of vegetables can be automated
 Large space in cutting chamber can be provided
 It can be used in food processing industries.

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REFERENCES

1. R. Ramakrishna Reddy, B.Venkata Chaitanya Kumar, B. Madhu, B.Pradeep, V.Sathish

Kumar Reddy, S.Sayyed Saleem, K.Nagarjuna, “Fabrication of Automated Vegetable
Cutting Machine”,International Research Journal of Engineering and Technology,
Volume No-08, July 2021
2. A. Nishanth , M. Raghavan , G. Rajesh Kumar , P. Vigneswaran , T. Ramakrishnan,
“Vegetable Cutting Machine”,International Journal of Research in Engineering, Science and
Management, Volume No-03, February2020
3. P. D. Kahandage, D.A.N. Darmasena, E.J. Kosgollegedara, “Design, Fabrication and
Evaluation of a Hand-Operated Semi-Automatic Chopping Machine for Leafy
Vegetables and Medicinal Herbs”, Sri Lankan Journal of Agriculture and Ecosystems,
Volume NO-2, December, 2020, Pages 153-163
4. K. AdityaPratap, S. Roji Marjorie and M. Saikumar, “Automatic vegetable chopper using
image processing”, Materials Today: Proceedings, Volume No-33, Part 7, 2020, Pages
4787-4789
5. Ezeanya, Nnaemeka Charles, “Development and Performance Evaluation of a Slicing
Machine for Selected vegetables”, Greener Journal of Physical Sciences Vol. 6(1), Pages
1-9, 2020
6. R. Kiruba Shankar, M. G. Ramjee, M. Saran, S. Sasivengat, “Design and Fabrication of
Sprig Cassava Chopping Machine for Farmers” International Journal of Scientific and
Technology Research Volume 9, Issue 02, February 2020

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