WEATHER-INDEPENDENT ONION PROCESSING SYSTEM WITH AUTOMATED HARVESTING AND PRECISION DRYING

Abstract

The invention presents a novel integrated machine designed for onion post-harvest processing, combining harvesting, soil removal, and drying functions into a single automated system. Featuring a reciprocating cutter bar and adjustable digging blades, the harvesting unit efficiently severs the onion canopy while minimizing damage to the bulbs. The subsequent shaking unit utilizes a gentle shaker mechanism to effectively remove soil without harming the onions. A solar-powered drying unit circulates hot air to reduce moisture content to optimal levels of 10-15%, with a moisture sensor and thermostatic valve ensuring precise control of the drying environment. This innovative design addresses key challenges in onion cultivation, such as labor intensity, weather dependency, and spoilage risks. By enhancing efficiency and product quality, the machine promotes sustainability through solar energy use, ultimately providing a cost-effective solution that improves the economic viability of onion farming and contributes to better agricultural practices.

Specification

Description:The following specification particularly describes the invention and the manner it
is to be performed.
TECHNICAL FIELD
[001] The technical field of the invention pertains to agricultural engineering and mechanization, specifically focusing on the post-harvest processing of onion cultivation. This includes innovations in harvesting technology, soil removal mechanisms, and controlled drying systems. The invention integrates these components into a single automated machine designed to enhance efficiency, reduce labor costs, and minimize post-harvest losses. By utilizing solar energy for drying, it also addresses sustainability concerns in modern agriculture. The invention aims to provide farmers with a reliable, weather-independent solution for maintaining onion quality and improving overall productivity.
BACKGROUND
[002] Traditional onion harvesting methods are inherently labor-intensive and heavily dependent on favorable weather conditions for effective drying. After harvesting, onions typically possess a moisture content ranging from 70% to 80%. This high moisture level presents significant challenges for storage and processing, as excess moisture can lead to spoilage, decay, and reduced shelf life. Farmers generally rely on sun drying as a primary method; however, adverse weather conditions, such as unexpected rainfall or high humidity, can disrupt this process, resulting in substantial yield losses and diminished product quality. Consequently, there is an urgent need for innovative, reliable solutions that can provide consistent drying and maintain the integrity of the onions.
[003] Existing technologies have made strides in agricultural machinery, but many, such as those outlined in patents like CN100544580C, focus primarily on harvesting equipment designed for crops like garlic and peanuts. While these innovations enhance certain aspects of agricultural practices, they fail to provide integrated systems specifically tailored for onion cultivation. This highlights a significant research gap in the agricultural machinery sector. Farmers are still left to contend with separate, often inefficient processes for harvesting, soil removal, and drying, which leads to wasted resources and time, ultimately impacting profitability.
[004] US20190345678A1, addresses drying methods applicable to a range of crops; however, it does not incorporate automated harvesting or soil removal mechanisms into its design. This separation of functionalities results in labor-intensive operations that not only consume more time and resources but also leave harvested crops vulnerable to pest and disease pressures during the drying phase. The lack of an integrated solution exacerbates existing inefficiencies, further emphasizing the urgent need for a comprehensive system that streamlines harvesting, shaking, and drying into a single operation.
[005] Research consistently shows that inadequate drying processes can lead to nutrient loss and reduced marketability of onions. For optimal processing and storage, it is crucial to maintain moisture levels within the range of 10-15%. However, many existing machines fall short in delivering a controlled drying environment, which is vital for minimizing post-harvest losses. Without proper moisture management, onions are more likely to spoil, which not only affects quality but also incurs financial losses for farmers, underlining the need for effective post-harvest technologies.
[006] The agricultural sector is facing increasing scrutiny regarding sustainability and environmental impact, with a growing interest in eco-friendly solutions that reduce energy consumption and carbon footprints. Many existing drying technologies are reliant on non-renewable energy sources, raising concerns about their long-term viability and ecological consequences. The proposed invention addresses these sustainability challenges by integrating solar energy as the primary power source for its drying unit, providing a cost-effective and environmentally friendly solution for onion post-harvest processing.
[007] Economic pressures on farmers are mounting due to the inefficiencies of current post-harvest practices, which can result in significant financial losses. The demand for high-quality produce necessitates a more efficient approach to onion processing. By developing a comprehensive system that integrates harvesting, soil removal, and drying into one cohesive machine, the invention aims to alleviate these economic challenges. It provides a streamlined solution that enhances productivity while reducing labor costs, thus improving overall profitability for farmers.
[008] Current drying practices, especially sun drying, expose harvested onions to several risks, including mold development and pest infestations. These risks can significantly compromise product quality and shelf life, leading to financial losses for farmers. Controlled drying environments are essential for mitigating these risks, yet many existing systems lack the necessary capabilities to ensure such conditions. The proposed invention aims to fill this critical gap by providing a reliable, weather-independent drying process that maintains the quality of the onions while reducing the likelihood of spoilage.
[009] The commercial potential for a machine that combines harvesting and drying processes into a single automated system is considerable. As the global demand for high-quality onions continues to rise, farmers are increasingly seeking innovative technologies that enhance yield and quality while minimizing labor and resource costs. The invention not only addresses current inefficiencies and challenges faced by onion producers but also positions itself as a viable solution in a competitive agricultural market. By streamlining the post-harvest process, it promises to improve profitability and product quality, making it an attractive option for a wide range of agricultural operations.
SUMMARY
[010] The invention presents a novel weather-independent onion processing system that integrates harvesting, soil removal, and drying into a single automated machine. This comprehensive design aims to streamline post-harvest operations, addressing the challenges faced by farmers, such as labor intensity and reliance on favorable weather conditions. By combining multiple processes, the machine significantly reduces the time and effort required for onion processing, enhancing overall efficiency in agricultural practices.
[011] The harvesting unit utilizes a reciprocating cutter bar and digging blades to effectively sever the onion canopy and extract the bulbs with minimal damage. This design ensures a clean cut and facilitates the lifting of onions along with a small amount of surrounding soil. The tractor-powered operation allows for smooth and efficient functioning, making the harvesting process quicker and more effective compared to traditional methods.
[012] Following harvesting, the shaking unit employs a gentle shaker mechanism integrated with a conveyor system to remove soil from the harvested onions. This mechanism ensures that the bulbs are cleaned without causing damage, preserving their quality. The conveyor system facilitates a consistent flow of onions through the shaking unit, optimizing the soil removal process and preparing the onions for drying.
[013] The drying unit is a key feature of the invention, employing a solar-powered heating chamber that circulates hot air to reduce the moisture content of the onions to the optimal range of 10-15%. This controlled drying environment is crucial for maintaining the quality and nutritional value of the onions while preventing spoilage. The integration of a moisture sensor and thermostatic valve allows for real-time monitoring and precise adjustments, ensuring consistent drying regardless of external weather conditions.
[014] The invention addresses significant gaps in current agricultural technology by providing a holistic solution for onion processing. Its emphasis on sustainability, through solar energy utilization, alongside its ability to operate independently of weather conditions, positions it as a valuable asset for farmers. By enhancing efficiency, reducing post-harvest losses, and improving product quality, the machine offers substantial economic benefits and promotes more sustainable agricultural practices.
BRIEF DESCRIPTION OF THE DRAWINGS
[015] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating of the present subject matter, an example of the construction of the present subject matter is provided as figures; however, the invention is not limited to the specific method disclosed in the document and the figures.
[016] The present subject matter is described in detail with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer to various features of the present subject matter.
[017] Figure 1 provides the working prototype of the invention
[018] The given figures depict an embodiment of the present disclosure for illustration and better understanding only.
DETAILED DESCRIPTION
[019] Some of the embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open-ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.
[020] The invention is designed as an integrated system for onion post-harvest processing, combining three essential functions: harvesting, soil removal, and drying. This all-in-one approach minimizes the need for separate machines, thereby reducing the overall operational costs and labor requirements for farmers. The compact design allows for easy maneuverability in various field conditions, ensuring that the machine can be effectively utilized across different farm sizes and types.
[021] The harvesting unit features a reciprocating cutter bar paired with specially designed digging blades. This configuration effectively severs the onion canopy while lifting the bulb and a small amount of surrounding soil. The design minimizes damage to the onions during extraction, which is crucial for maintaining their quality. The digging blades are engineered for precise operation, ensuring that the onions are harvested cleanly without excessive soil disturbance, which could lead to spoilage.
[022] In one embodiment it is provided that, the Powering the harvesting unit is a tractor's Power Take-Off (PTO) shaft, which connects directly to the machine. This efficient power transmission system allows the harvesting mechanisms to operate smoothly, leveraging the tractor's engine power. By utilizing existing agricultural equipment, the invention promotes cost-effectiveness and simplifies the integration of the machine into current farming operations.
[023] The shaking unit is designed to remove soil from the harvested onions gently. It employs a shaker mechanism that vibrates the onions as they move along a conveyor system, effectively dislodging dirt without damaging the bulbs. This gentle agitation is crucial for maintaining onion quality, as excessive force can lead to bruising and other forms of damage. The conveyor system is tailored to ensure a consistent flow of onions, enhancing the efficiency of the soil removal process.
[024] In one embodiment it is provided, that the drying unit is a standout feature of the invention, employing a solar-powered heating chamber that circulates hot air around the onions. This process reduces moisture content to the optimal level of 10-15%, which is essential for long-term storage and milling. By harnessing solar energy, the drying unit provides an environmentally sustainable solution that significantly lowers operational costs compared to traditional energy sources.
[025] Central to the drying process is a sophisticated control system that includes a moisture sensor and a thermostatic valve. The moisture sensor continuously monitors the onions' moisture levels, providing real-time data to the control system. The thermostatic valve adjusts the airflow and temperature within the heating chamber based on this data, ensuring that the drying process is consistent and efficient. This automation enhances the reliability of the drying process, reducing the risk of spoilage due to inadequate drying.
[026] The methodology of the invention begins with the harvesting unit operating in the field, where it cuts and lifts the onions. Once harvested, the onions are transported to the shaking unit, where soil is removed. After this, they move to the drying unit, which uses solar power to maintain an optimal drying environment. This streamlined workflow minimizes delays and maintains the quality of the onions throughout the entire post-harvest process.
[027] Results from initial testing of the machine have demonstrated significant improvements in efficiency and quality. The integration of harvesting and drying operations has reduced the time required for post-harvest processing by up to 50% compared to traditional methods. Additionally, the controlled drying environment has led to higher product quality, with minimal spoilage observed during trials. Farmers reported greater satisfaction with the uniformity of moisture levels in the dried onions, enhancing their marketability.
[028] The advantages of the invention extend beyond efficiency and quality. By utilizing solar energy for the drying process, the machine supports sustainable agricultural practices, reducing dependence on fossil fuels. This not only benefits the environment but also aligns with the growing trend of eco-conscious farming. The ability to operate independently of weather conditions ensures that farmers can maintain consistent processing schedules, minimizing risks associated with climate variability.
[029] In one embodiment it is provided, that the Discussions with farmers who tested the machine revealed a strong demand for such integrated solutions. Many expressed that the traditional methods were cumbersome and often led to financial losses due to spoilage and labor costs. The comprehensive nature of the invention provides a compelling alternative, positioning it as an attractive option for modern agricultural operations that seek to enhance productivity while reducing risks.
[030] Furthermore, the machine's scalability makes it suitable for both small-scale and large-scale farming operations. Its adaptable design allows farmers to easily adjust the machine for different field conditions and onion varieties. This flexibility ensures that a wide range of producers can benefit from the technology, contributing to its potential for widespread adoption in the agricultural sector.
[031] The invention represents a significant advancement in onion post-harvest processing technology. By addressing the key challenges faced by farmers-such as labor intensity, weather dependency, and spoilage risks-it provides a robust, efficient, and sustainable solution. The integrated design not only enhances operational efficiency but also improves product quality and market competitiveness for onion producers, paving the way for better economic outcomes in the agricultural industry.
[032] Referring to Figure 1, depicts an advanced agricultural machine specifically designed for onion post-harvest processing, showcasing its streamlined and integrated features. At the front, the harvesting unit is prominently featured, equipped with a reciprocating cutter bar and specialized digging blades that effectively sever the onion canopy and lift the bulbs with minimal soil. Moving along the machine, a conveyor system connects to the shaking unit, where a gentle shaker mechanism removes excess soil from the harvested onions, ensuring they remain intact and undamaged. The rear section of the machine houses the drying unit, characterized by a solar-powered heating chamber that circulates hot air to reduce moisture content to optimal levels. Visual indicators and control panels suggest an automated control system that monitors moisture levels and adjusts airflow accordingly. The entire design emphasizes efficiency, with a compact form that allows for easy maneuverability in various field conditions, making it suitable for both small and large-scale onion farming operations. The incorporation of solar energy highlights the machine's commitment to sustainability, positioning it as a modern solution for the challenges faced in onion cultivation.
, Claims:1. An integrated onion processing machine comprising;
A. A harvesting unit featuring a reciprocating cutter bar and digging blades for severing the onion canopy and extracting the bulbs along with surrounding soil;
B. A shaking unit with a shaker mechanism and conveyor system to remove soil from the harvested onions while minimizing damage;
C. A drying unit powered by solar energy, equipped with a heating chamber that circulates hot air to reduce onion moisture content to an optimal level of 10-15%, regulated by a moisture sensor and thermostatic valve for precise control.
2. The integrated onion processing machine of claim 1, wherein the harvesting unit includes adjustable digging blades to accommodate varying soil types and onion sizes.
3. The integrated onion processing machine of claim 1, wherein the shaker mechanism is designed to provide variable agitation levels to prevent damage to delicate onion bulbs.
4. The integrated onion processing machine of claim 1, wherein the conveyor system is equipped with a gentle handling feature that minimizes jarring during transport to the drying unit.
5. The integrated onion processing machine of claim 1, wherein the solar-powered drying unit includes an auxiliary heating element for enhanced drying efficiency during low sunlight conditions.
6. The integrated onion processing machine of claim 1, further comprising an automated control system that allows for real-time monitoring and adjustment of drying parameters based on moisture content.
7. The integrated onion processing machine of claim 1, wherein the harvesting unit is detachable, allowing it to be used independently or in conjunction with other agricultural equipment.
8. The integrated onion processing machine of claim 1, further comprising safety features that prevent operation when the moisture sensor detects excessive moisture levels in the onions, ensuring optimal drying conditions.

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