Pneumatic Aluminium Can Crusher - PHASE REPORT

 

1. INTRODUCTION

 

             A mechanical tin can crusher is basically one of the most aid able machines. It helps to reduce the pollute environment of this world. Thus helps create a better place to live in. apart from that, this tin can crusher can actually be the future mode of recycles apart from the recycle bins. It can be placed everywhere, in the park, houses, even in cars. Using a similar type of a design from the diagram below, but with the added a bin bellow the tin can crusher concept of recycling can be apply. this project interest and expose me the field of mechanism and design engineering.

 

PROJECT SYNOPSIS

In this project, development of a recycle bin tin can crusher so the tin can might crush as flat and look as symmetrically as possible and inserted the bin. The designs are an environment friendly and use simple mechanism properties such as fulcrum system.

 

The design is done so that the knowledge of designing, mechanism and forces.

 

SCOPE OF WORK

Ø      Literature review on the knowledge of mechanism design

Ø      design the mechanical part of a tin can crusher using CAD software Solid Work.

Ø      Develop the model tin can crusher using bending process, welding process, drilling  process and cutting process

Ø      Fabricate the model tin can crusher using welding skill and machining

 

PROJECT PLANNING

       To start of this project, a meeting with supervisor in the first week is done to manage the schedule of weekly meetings. The purpose is to inform the supervisor on the progress of the project and guided by the supervisor to solve difficulty.

 

            Briefing based on the introduction and next task of the project is given by supervisor. Make research of literature review with the means of the internet, books, available published articles and materials that is related to the title.

 

            Designing phase start of by sketching few model models using manual sketch on A4 papers. Following up, is the fabrication of make some method for this project. Choose the material, make some list for the material and dimension. Do it planning of fabrication process for this project.

 

          After that, start the fabrication process. It would take seven weeks to get this design and fabrication process alteration done. Make some analysis and testing for the project. Do it correction for error this project. Finish the fabrication process with painting process. After that, the final report writing and final presentation will be the last task to be accomplished. The supervisor will review the final presentation and revise mistakes to be amended. The final presentation then again will be presented to three panels. A draft report would then be submitted to the supervisor to be point out the flaws. Corrections are done and the real final report is handed over as a completion of the final year project.

2. LITERATURE SURVEY

 

PNEUMATICS

            The word ‘pneuma’comes from greek and means breather wind. The word pneumatics is the study of air movement and its phenomena is derived from the word pneuma.today pneumatics is mainly understood to means the application of air as a working medium in industry especially the driving and controlling of machines and equipment.

 

            Pneumatics has for some considerable time between used for carrying out the simplest mechanical tasks in more recent times has Played a more important role in the development of pneumatic technology for automation.

 

            Pneumatic systems operate on a supply of compressed air which must be made available in sufficient quantity and at a pressure to suit the capacity of the system. When the pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the question of compressed air supply.

 

            Compressor capacity is the actual quantity of air compressed and delivered and the volume expressed is that of that of the air at intake conditions namely at atmosphere pressure and normal ambient temperature.

 

            The compressibility of the air was first investigated by Robot Boyle in 1962 and that found that the product of pressure and volumes of particular quantity of gas.

 

The usual written as

            PV =C    (or) P₁V₁ =P₂V₂

          In this equation the pressure is the absolute pressured which for free is about 14.7Psi and is of courage capable of maintaining a column of mercury, nearly 30 inches high in an ordinary barometer. Any gas can be used in pneumatic system but air is the mostly used system now a days.

 

SELECTION OF PNEUMATICS:

            Mechanization is broadly defined as the replacement of manual effort by mechanical power. Pneumatic is an attractive medium for low Cost mechanization particularly for sequential (or) repetitive operations. Many factories and plants already have a compressed air system, which is capable of providing the power (or) energy requirements and control system (although equally pneumatic control systems may be economic and can be advantageously applied to other forms of power).

 

            The main advantage of an all pneumatic system is usually Economic and simplicity the latter reducing maintenance to a low level. It can have out standing advantages in terms of safety.

 

PNEUMATIC POWER:

          Pneumatic systems use pressurized gases to transmit and control power. Pneumatic systems typically use air as the fluid medium because air is safe, low cost and readily available.

 

THE ADVANTAGES OF PNEUMATICS:

1. Air used in pneumatic systems can be directly exhausted back

      In to the surrounding environment and hence the need of special reservoirs and      no-leak system designs are eliminated.

2. Pneumatic systems are simple and economical

3. Control of pneumatic systems is easier

THE DISADVANTAGES OF PNEUMATICS:

1. Pneumatic systems exhibit spongy characteristics due to compressibility of air.
2. Pneumatic pressures are quite low due to compressor design limitations(less that 250 psi).

 

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made available. In sufficient quantity and at a pressure to suit the capacity of the system. When pneumatic system is being adopted for the first time, however it wills indeed the necessary to deal with the question of compressed air supply.

 

At intake conditions namely at atmosphere pressure and normal ambient temperature. Clean condition of the suction air is one of the factors, which decides the life of a compressor. Warm and moist suction air will result increased precipitation of condense from the compressed air.

 

Compressor may be classified in two general types.

1. Positive displacement compressor
2. Turbo compressor

Positive displacement compressors are most frequently employed for

Compressed air plant and have proved highly successful and supply air for pneumatic control application.

 

The types of positive compressor

1. Reciprocating type compressor
2. Rotary type compressor

 

            Turbo compressors are employed where large of air required at low discharge pressures. They cannot attain pressure necessary for pneumatic control application unless built in multistage designs and are seldom encountered in pneumatic service.

RECIPROCATING COMPRESSORS:

            Built for either stationary (or) portable service the reciprocating compressor is by far the most common type. Reciprocating compressors lap be had is sizes from the smallest capacities to deliver more than 500m³/min.In single stage compressor, the air pressure may be of 6 bar machines discharge of pressure is up to 15bars.

 

            Discharge pressure in the range of 250bars can be obtained with high pressure reciprocating compressors that of three & four stages. Single stage and 1200 stage models are particularly suitable

 

            For applications, with preference going to the two stage design as soon as the discharge pressure exceeds 6 bars, because it in capable of matching the performance of single stage machine at lower costs per driving powers in the range.

 

 

3. PROBLEM DEFINITION

 

            When people footstep the tin after finishes their drink, the tin always not look symmetrically flat and it look messy. This condition sometime makes tin produce the

sharp adage will harm or injured the people. Furthermore, people always throw the can anywhere. These conditions makes pollution for this environment, become bad surrounding and separate the ditches. So this design is use to crush the can as flat as possible and try to reduce time, cost consuming and the sharp edge also have been bellow the crusher.

 

4. EXISTING SYSTEM

 

PNEUMATIC CONTROL COMPONENT

PNEUMATIC CYLINDER:

An air cylinder is an operative device in which the state input energy of compressed air i.e. penuamtic power is converted into mechanical Output power, by reducing the pressure of the air to that of the atmosphere.

 

a) SINGLE ACTING CYLINDER:

          Single acting cylinder is only capable of performing an operating medium in only one direction. Single acting cylinders equipped with one inlet for the operating air pressure, can be production in several fundamentally different designs. Single cylinders Develop power in one direction only.

 

Therefore no heavy control equipment should be attached to them, which requires to be moved on the piston return stroke single action cylinder requires only about half the air volume consumed by a double acting for one operating cycle.

 

b) DOUBLE ACTING CYLINDERS:

       A double acting cylinder is employed in control systems with the full pneumatic cushioning and it is essential when the cylinder itself is required to retard heavy messes. This can only be done at the end positions of the piston stroke. In all intermediate position a separate externally mounted cushioning derive most be provided with the damping feature.

 

The normal escape of air is out off by a cushioning piston before the end of the stroke 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 the piston strokes in the other direction at full Force and velocity.

 

VALVES

SOLENOID VALVE

            The directional valve is one of the important parts of a pneumatic system. Commonly known as DCV; this valve is used to control the direction of air flow in the pneumatic system. The directional valve does this by changing the position of its internal movable parts.

 

This valve was selected for speedy operation and to reduce the manual effort and also for the modification of the machine into automatic machine by means of using a solenoid valve.

 

            A solenoid is an electrical device that converts electrical energy into straight line motion and force. These are also used to operate a mechanical operation which in turn operates the valve mechanism. Solenoid is one is which the plunger is pulled when the solenoid is energized.

 

            The name of the parts of the solenoid should be learned so that they can be recognized when called upon to make repairs, to do service work or to install them.

               

5. PROPOSED SYSTEM

 

1. COIL

            The solenoid coil is made of copper wire. The layers of wire are separated by insulating layer. The entire solenoid coil is covered with a varnish that is not affected by solvents, moisture, cutting oil or often fluids. Coils are rated in various voltages such as 115 volts AC,230volts AC,460volts Ac,575 Volts AC.6Volts DC,12Volts DC, 24 Volts DC, 115 Volts DC &230Volts DC. They are designed for such Frequencies as 50Hz to 60Hz.

 

2. FRAME

The solenoid frame serves several purposes. Since it is made of laminated sheets, it is magnetized when the current passes through the coil. The magnetized coils attract the metal plunger to move. The frame has provisions for attaching the mounting. They are usually bolted or welded to the frame. The frame has provisions for receivers, the plunger. The wear strips are mounted to the solenoid frame, and are made of materials such as metal or impregnated less Fiber.

3. SOLENOID PLUNGER

The solenoid plunger is the mover mechanism of the solenoid. The plunger is made of steel laminations which are riveted together under high pressure, so that there will be no movement of the lamination with respect to one another. At the top of the plunger a pin hole is placed for making a connection to some device. The solenoid plunger is moved by a magnetic force in one direction and is usually returned by spring action.

 

Solenoid operated valves are usually provided with cover either the solenoid or the entire valve. This protects the solenoid from dirt and other foreign matter, and protects the actuator. In many applications it is necessary to use explosion proof solenoids.

 

WORKING OF SOLENOID VALVE:

The solenoid valve has 5 openings. These ensure easy exhausting of 5/4Valve.the spool of the 5/4 valve slide inside the main bore according to spool position: the ports get connected and disconnected.

The working principle is as follows.

 

Position-1

            When the spool is actuated towards outer direction port ‘P’ gets

            Connected to ‘B’ and ‘S’ remains closed while ‘A’ gets connected to ‘R’.

 

Position-2

          When the spool is pushed in the inner direction port ‘P’ and ‘A’

            Gets connected to each other and ‘B’ to ‘S’ while port ‘R’ remains closed.

 

SOLINOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off valve or solenoid valve. This solenoid cutoff valve is controlled by the electronic control unit.

 

            In our project separate solenoid valve is used for flow direction of vice cylinder. It is used to flow the air from compressor to the single acting cylinder.

 

FLOW CONTROL VALVE:

In any fluid power circuit, flow control valve is used to control the speed of actuator. The flow control can be achieved by varying the area of flow through which the air in passing.

 

When area is increased, more quantity of air will be sent to actuator as a result its speed will increase. If the quantity of air entering into the actuator is reduced, the speed of the actuator is reduced.

 

PRESSURE CONTROL VALVE:

          The main function of the pressure control valve is to limit (or) Control the pressure required in a pneumatic circuit. Depending upon the method of controlling they are classified as

1. Pressure relief valve
2. Pressure reducing valve

 

HOSES:

Hoses used in this pneumatic system are made up of polyurethane. These hose can with stand at a maximum pressure level of 10N/m² .

 

Connectors:

In our system there are two type of connectors used. One is the Hose connector and the other is the reducer. Hose connectors normally comprise an adopt hose nipple and cap nut. These types of connectors are made up of brass (or) aluminum (or) hardened pneumatic steel.

 

PRESSURE GAUGE:

Pressure gauges are usually fitted with the regulators. So the air Pressure adjusted in the regulator is indicated in the pressure Gauge, is the line pressure of the air taken to the cylinder.

6. OBJECTIVES

 

Ø      To develop of a recycle bin tin can crusher.

 

Ø      To fabricate recycle bin tin can crusher low cost and time consuming

7. METHODOLOGY

 

            Designing a pneumatic aluminum can crusher involves a combination of mechanical, electrical, and pneumatic systems. The goal is to create a device that efficiently and safely crushes aluminum cans to reduce their volume for easier storage and recycling. Here's a general outline of the methodology for creating a pneumatic aluminum can crusher:

 

Define the Requirements:

            Clearly outline the functional requirements of the can crusher. Consider factors such as crushing force, speed, size, safety features, capacity, and ease of use.

 

Conceptual Design:

Generate various conceptual designs that fulfill the defined requirements. This could involve sketching ideas or using CAD software to visualize potential designs.

 

Evaluate Design Options:

            Analyze each conceptual design's pros and cons. Compare factors like cost, complexity, efficiency, and user-friendliness. Select the most promising design for further development.

 

Detailed Design:

            Create a detailed design of the chosen concept. This involves specifying the dimensions, materials, and components needed to build the can crusher.

 

Mechanical System:

            Design the mechanical components responsible for crushing the cans. This usually includes a crushing mechanism, crushing plate, and crushing arm.

Pneumatic System:

            Design the pneumatic system responsible for providing the necessary force to crush the cans. This typically involves an air compressor, air cylinders, control valves, and tubing.

 

Electrical System:

            If the can crusher requires any electrical components (e.g., sensors, limit switches, or a control panel), design the electrical system accordingly.

 

Safety Features:

            Incorporate safety features to prevent accidents and ensure the crusher operates safely. These may include emergency stop buttons, safety guards, and safety interlocks.

 

Prototype Construction:

            Build a working prototype of the can crusher based on the detailed design. This allows you to test and refine the device before finalizing the design.

 

Testing and Iteration:

            Conduct rigorous testing to evaluate the performance of the prototype. Identify any issues and make necessary improvements.

 

Optimization:

            Fine-tune the design to improve efficiency, reduce material waste, and enhance user experience.

 

Manufacturing and Assembly:

            Once the design is optimized and tested thoroughly, proceed with manufacturing and assembly of the final product.

 

Quality Control:

            Implement quality control measures to ensure each unit meets the required standards.

 

User Manual and Instructions:

            Prepare a comprehensive user manual with clear instructions on how to operate the can crusher safely and efficiently.

 

Marketing and Distribution:

            If applicable, plan for marketing and distribution of the product to reach the target audience.

 

            Throughout the entire process, it's essential to adhere to safety standards and regulations. Engaging with experts in mechanical engineering, pneumatic systems, and product design can help ensure a successful and safe pneumatic aluminum can crusher.

REFERENCES

 

 

1. Mr. Ramkrushna S.More, Sunil J.Rajpal publishes a paper on “study of crusher”.    International Journal Of Modern Engineering Research (IJMER), Vol 3, Issue.1, 2013 PP-518-522 ISSN: 2249-6645
2. Mr. Che Mohd Akhairil Akasyah B Che Anuar Faculty of Mechanical Engineering in University Malaysia Pahang in the year Nov.2008 in his project report entitled “Development of the Can Crusher Machine”
3. Design data for machine elementsby B.D.Shiwalkar 2013 edition and a Textbook of Machine Design by R.S. Khurmi andJ.K.Gupta 14^th revised edition S. Chand publication
4. Mr.Shoichi Kitani, Keicchiro Hayashi , Mitsiuro Yamashina and Keiko Takei present paper on “Automatic can crusher”.
5. Mr. Patel Ronak A. presents a paper on “Slider Crank Mechanism for Four bar linkage”. IJSRD - International Journal for Scientific Research & Development| Vol. 1, Issue 9, 2013 | ISSN (online): 2321-0613.
6. Mr. Shadab Husain, Mohammad Shadab Sheikh presents paper on “Can crusher machine using scotch yoke mechanism”. IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684, p-ISSN: 2320-334X PP 60-63.