Design and Fabrication of Portable Cableway System for Efficient Transportation of Agricultural Commodities

Abstract

In order to enhance productivity on the farms and reduce post-harvest losses, agricultural commodities must be transported efficiently. In order to overcome the difficulties of manual transport in various agricultural commodities like Banana, Tender Coconut, Jack fruit this project proposes the creation of a portable cableway system. The implementation of a reinforced tripod stand, which improves stability and load-bearing capacity over conventional frame structures, is a significant feature of this system. This design greatly increases the system\'s adaptability by enabling dependable operation on uneven terrain. High-tensile cables, pulleys, a motorized or manual hauling mechanism, and a lightweight yet robust frame make up the system. The tripod structure ensures dependability and durability by preventing structural deformation under various loads. By lowering labour dependency and increasing transportation efficiency, this innovation seeks to assist small and medium-sized farmers.

Introduction

Overview

The project introduces a portable cableway system designed to improve the transportation of agricultural products like crops and fertilizers, especially for small and medium-sized farmers operating on sloped or uneven terrain. Traditional manual transport methods are inefficient and prone to post-harvest losses. The system’s key innovation is a reinforced tripod frame, offering enhanced stability and load-bearing capacity. It uses high-tensile cables, pulleys, and a motorized or manual hauling mechanism, making it portable, durable, and well-suited to rural areas with poor infrastructure.

2. Objectives

• Develop a portable and scalable cableway system.

• Use a tripod stand to enhance structural strength and stability.

• Reduce manual labor and post-harvest losses.

• Offer an affordable, user-friendly design for small to mid-sized farmers.

• Apply modern engineering to agricultural logistics to improve productivity.

3. Literature Survey Highlights

• Bi-cable systems have been implemented for sugarcane transport in Tamil Nadu.

• Classical mechanics models have been used for banana bunch transportation in Venezuela.

• Studies emphasize mechanization and automation to reduce labor costs and increase safety.

• Highlight the importance of transportation infrastructure in reducing post-harvest losses and improving food security.

• Ropeway systems have been successfully applied in steep terrains and urban transport.

• Use of motorized pulleys, weight sensors, and improved handling methods are key to minimizing food spoilage.

4. Methodology

A. Materials Used

• Wire Rope (10 mm, 6x19 steel): High strength and flexibility.

• Trolley with Hook and Ball Bearings: Ensures stable and smooth travel.

• Tripod Frame: Distributes weight evenly; built from steel or aluminum.

• Nylon Rope: Lightweight, wear-resistant, and drives the pulley system.

• Pulleys: Guide both wire and nylon ropes; reduce friction.

• DC Motor: Controls trolley motion via an H-Bridge circuit and STM32 microcontroller.

B. Construction

• The cableway spans 6 meters and uses tripods ~1.5 meters tall at each end.

• A middle support pole prevents sagging of the wire rope.

• Pulley wheels and ball bearings enable smooth trolley movement.

• Motor is controlled digitally to move the trolley back and forth.

• A ratchet mechanism is used for rope tensioning.

C. Working

• The trolley runs along a tensioned steel rope, driven by a motorized nylon rope loop.

• The motor, managed by a microcontroller and H-bridge, allows bidirectional movement.

• The design enables transportation of bulky produce like jackfruit or banana bunches with minimal manual effort.

• Modular and scalable, suitable for rugged terrain and low-infrastructure areas.

5. Results and Discussion

Performance Testing

• The system was tested with banana bunches, jackfruit, and tender coconuts.

• Metrics evaluated: time taken, rope sag, and stability.

• Heavier loads increased transport time and caused more sag, but the tensioning system mitigated these effects.

• Findings suggest that further optimization of speed and tension control can enhance performance.

Sample Transport Times (selected examples):

Conclusion

Throughout several trials, the system operated consistently and effectively while transporting loads. Heavy loads caused some sag and decreased speed, but modifications to the tensioning mechanism allowed for safe operation to continue. The trolley\'s controlled and energy-efficient movement was made possible by the use of a brushed DC motor. Additionally, testing verified that the system is lightweight, terrain-adaptable, and simple to assemble. All things considered, the cableway system provides a dependable and farmer-friendly solution that lowers manual labour, minimizes losses after harvest, and improves transportation efficiency. The system has the potential to be widely used in small and medium-sized agricultural operations with additional optimization in automation, structural design, and speed control.

References

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Copyright

Copyright © 2025 S Jenefar, A Suresh, Nandhini T, Abinayaa B, Rasika M, Sanjay M. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.