Automatic Can Crusher

GANPAT UNIVERSITY

U. V. Patel College of Engineering Ganpat University, Kherva-382711

Ta & Dist.: Mehsana (North Gujarat)

Ph.: 02762-286805, 286081

Fax (D): 286080

E-mail: [email protected]

Web: www.uvpce.ac.in

AUTOMATIC CAN CRUSHER

Project Report

By

Aman Baviskar (09MC03)

Vihar Doshi (09MC17)

Taher Parekh(09MC47)

Automatic Can Crusher

2

CERTIFICATE

Towards partial fulfillment of requirement for the award of Degree of

Bachelor of MECHATRONICS ENGINEERING of GANPAT

UNIVERSITY, this is the record of candidates own work carried out by

them under our supervision & guidance. In our opinion the work

submitted has reached a level required for being accepted for exam. The

matter embodied in this project has not been submitted to any other

university or institute.

Project Report on AUTOMATIC CAN CRUSHER

Submitted By:



Taher Parekh (09MC47)

GUIDE: COUNTERSIGNED:

Prof. N. J. Thakkar Prof. J. P. Patel

Assistant Professor, Head of Department,

Mechatronics Department, Mechatronics Engg.,

U.V. Patel College of Engineering, U.V. Patel College of Engineering,

Mehsana. Mehsana.


3

INDEX

Contents Page no.

Index 3

List of Figures 5

List of Tables 6

Abstract 7

Acknowledgements 8

1. Introduction 9

1.1. Project Synopsis 10

1.2. Problem statement 10

1.3. Scope Of The Project 10

1.4. Requirements 10

1.5. Why To Recycle? 11

2. Concept 12

2.1. Can Crusher Calculations 12

2.2. Objectives 13

3. Design and Construction 15

3.1. Components Design 15

3.1.1. Pneumatic Cylinder 15

3.1.2. Can Basher And Feed Strip 16

3.1.3. Can Placing Area And Guideway 17

3.1.4. Foundation 18

3.1.5. Hopper 19

3.1.6. Complete Assembly 20

3.2. Material Selection 22

3.3. Components Details 23

3.3.1 Pneumatic cylinder 23


4

3.3.2 Solenoid valve 23

3.3.3 Microcontroller (P89V51RD2) 24

3.3.4 MAX232 IC 27

3.3.5 ULN2003APG IC 31

3.3.6 Sensor 32

3.3.7 MCT2E: Optocoupler, Phototransistor Output 33

3.3.8 Hopper 33

3.3.9 Guideway 33

3.3.10 Can basher and feed strip 33

4. Serial communication 34

4.1. Serial Communication Between Computer And P89V51RD2 35

5. Circuit diagram 36

5.1. Pneumatic circuit 36

5.2. Electrical circuit 37

6. Working 38

7. Future scope 40

8. Conclusion 40

9. References 40


5

LIST OF FIGURES:

Fig. No. Contents Pg. No.

1. Types of can crusher 9

3.1.1.a 3D drawing of Pneumatic Cylinder 15

3.1.1.b 2D drawing of Pneumatic Cylinder. 15

3.1.2.a 3D drawing of Can Basher and Feed Strip 16

3.1.2.b 2D drawing of Can Basher and Feed Strip 16

3.1.3.a 3D drawing of Can Placing Area and Guideway 17

3.1.3.b 2D drawing of Can Placing Area and Guideway 17

3.1.4.a 3D drawing of Foundation 18

3.1.4.b 2D drawing of Foundation 18

3.1.5.a 3D drawing of Hopper 19

3.1.5.b 2D drawing of Hopper 19

3.1.6.a 3D drawing of Complete Assembly 20

3.1.6.b 2D drawing of Complete Assembly 21

3.3.1 Janatics Pneumatic Cylinder 23

3.3.2 Janatics Solenoid Valve 24

3.3.3 Microcontroller (P89V51RD2) Pin Diagram 25

3.3.4.a MAX232IC Pin Diagram 28

3.3.4.b MAX232IC Block Diagram 29

3.3.5.a ULN2003APG 31

3.3.5.b ULN2003APG Pin Connections 32

3.3.5.c ULN2003APG Schematics 32

3.3.6. Infrared Sensor Schematic 32

3.3.7 MCT2E Opto-coupler 33

4. Serial Port Pin Diagram 34

4.1 Serial Communications 35

5.1 Pneumatic Circuit 36

5.2 Electronics Circuit 37


6

LIST OF TABLES:

Table No. Contents Pg. No.

2.2 Objectives of Project 13

3.2 Mechanical Properties, composition and

specifications of Cold rolled steel as per

IS 513: 22

3.3.3 Microcontroller Pin Description 26

3.3.4 MAX 232 Pin description 30

4. Serial Port Pin Description 35


7

Abstract

An automatic can crusher is a product that fulfils customer needs. This project uses

many materials such as sheet metal, hollow steel bar and others. The pneumatic

system and a microcontroller make up the backbone for this project. Overall, this

project involves processes like design, fabrication and assembling procedures. Even

though there are many types of the can crusher machine in the market, the completion

of this new model provides a more practical usage.

A can crusher can be defined as A device used for crushing aluminum cans for easier

storage in recycling bins thereby giving you extra space by flattening of cans.

Pneumatics is a section of technology that deals with the study and application of

pressurized gas to produce mechanical motion.

In autonomous mode the pneumatic system, microcontroller and sensor system work

in unison to successfully crush the cans while in assistive mode, the pneumatic system

can be manually operated.

The project incorporates the study of pneumatic systems, Computer Aided Design

softwares and microcontroller.


8

Acknowledgments

Our project has been a result of our own hard work but this project could not have

become a reality without the support and help of many of our friends and faculty

members. We take this opportunity to acknowledge their help and thank them for their

goodwill.

We would like to thank our Vice-Principal and Head of Department Prof. J. P. Patel

for his unwavering support and kind co-operation. He has been a great teacher and

true mentor to us throughout our degree.

We would also like to thank our project guide Prof. Nehul Thakkar for his support

and conceptual help at various technical problems. Weve had the opportunity of

being his students during three semesters and have learnt a great deal from him. The

very concept of the project as well as its realization would not have been possible

without him.

We would also like to acknowledge and thank Mr. Chirag Patel (B.R. Enterprise) for

his help in fabrication work of the project.

We would also like to thank Prof. J.P. Patel, Prof. N.J. Thakkar and Prof. K.J.

Patel for teaching us the challenging subjects like Pneumatic systems and

Microcontrollers.

Lastly we would like to thank all the faculty members of Mechatronics department

for their support throughout the year.

Apart from our faculty members weve also gained a lot of experience and expertise

from interacting with our classmates and friends. We would like to thank them all for

being with us in this journey and making it memorable.



Taher Parekh (09MC47)


9

1. Introduction

This project consists of designing and fabrication of an automatic can crusher. In

order to reduce the waste, we planned to create a can crusher that will reduce the

volume of aluminum cans by eighty percent. Can crushers are primarily used to

save space and for recycling. It can be placed everywhere, in the park, restaurants,

canteens etc. This project needs skills, information and knowledge of Computer

Aided Design softwares like AutoCAD and Solidworks, use of laser cutting

machine, Truma Bend V Series(bending machine), shearing machine, vertical

bend saw, bench work and welding processes.

A can crusher can be defined as A device used for crushing aluminum cans for

easier storage in recycling bins thereby giving you extra space by flattening of

cans.

Different types of existing can crushers:

Manual single can crusher Manual multiple can crusher

Pneumatic single can crushers

Figure 1


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1.1 Project Synopsis:

Recycling is wonderful way to help the environment, even if you think otherwise

when you're hauling big, bulky bags crammed with empty cans to the curb. One

device that will make our life easier, and our recycling haul much more compact,

is the can crusher. Can crushers are available in a number of styles, sizes and

speed, with models to suit everyone from the heavy soda drinker to the recycling

center manager.

In this project, we have developed an automatic can crusher that can crush the tin

as flat and as symmetrically as possible before landing into the bin. The design is

environment friendly and uses simple mechanism and automation properties.

1.2 Problem Statement:

In today's times, most of the food items available in the market are canned. Cold

drinks and other beverages are also packed in cans. Commercial establishments

like cafeterias and bars, have to deal with these empty or leftover cans. Storage is

often a problem as these cans consume too much space, thereby increasing the

total volume of the trash. As canned beverages and foods are frequently consumed

even in homes, these cans can take up a lot of storage space. The transportation

cost is also high for moving such huge no of cans.

Even if people footstep on the tin after finishing their drink, the tin does not

always look symmetrically flat and it looks messy. This condition of the tin

sometimes leads to sharp edges that can harm or injure people.

Furthermore, people always throw the can here and there. These conditions lead to

polluting the environment and surroundings.

So this design is used to crush the can as flat as possible and try to reduce time,

volume, cost consumption, save fuel and eliminate sharp edges.

1.3 Scope of the project:

The main aim of a can crusher is to smash an empty aluminum can into the

smallest unit possible. Anyone who drinks a couple of sodas a week may never

see the need to compact the cans, but others who are heavy drinkers may find

these devices very helpful. Canteens, restaurants, bars, catering halls, cinema halls

and recycling plants are places where a can crusher is pretty much a must.

1.4 Requirements:

Design must have a continuous can feeding mechanism.

Only one can must be fed at a time for crushing.

Can must be in good condition when supplied to the device (i.e not dented,

twisted or pressed).

Device must be a standalone unit.

80% volume reduction must be achieved.


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Crushed aluminum can must immediately fall into the aluminum can bin

without human intervention.

Arrangement for the aluminum can to slide from hopper to the crushing area.

Must be completely automated using microcontroller and sensor system.

Compressed air for reciprocating of pneumatic cylinder.

1.5 Why to Recycle?

Aluminum doesnt occur naturally in the earths crust, it has to be extracted from

its ore bauxite which is mined and then smelted in a very energy-intensive

process. Although great care is taken to rebuild the land after mining, changes do

occur as a result of mining that are detrimental to the surrounding environment. It

takes 80-100 years for aluminum can to decompose.

Compared to mining and smelting, recycling aluminum drink cans is far less

energy intensive. Recycling aluminum requires only 5% of the energy and

produces only 5% of the CO2 emissions as compared with primary production. A

recycled aluminum can saves enough energy to run a television for three hours.

More than 100 billion aluminum cans are sold in the United states each year, but

less than half are recycled. A similar number of aluminum cans in other countries

are also incinerated. Aluminum cans are one of the easiest materials to recycle.

New drinks cans appear on the shelf just six weeks after recycling. A single

aluminum can is said to, when recycled, saves about as much as oil as would be

poured into it to fill up.


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2. Concept:

The design can be decomposed into different mechanisms according to the

functions i.e. crushing mechanism, slot disposal, retraction mechanism and

automatic feeding mechanism.

2.1 Can Crusher Calculations:

Can dimensions: 65mm diameter (32.5 mm in radius) and height 120mm.

Volume of an uncrushed can:

V = r2h

V = x 32.52 x 120

V=398196.86 mm3

Volume of a crushed can:

V = r2h

V = x 32.52 x 20

V=66366.144 mm3

Percentage reduction in volume= 88%

No of crushed cans that can be stored in the space occupied by an

uncrushed can=6.

Force required to crush a can:

Experimentally it is found that the force required to crush a can is about

2300N.

Bore diameter of our pneumatic cylinder = 60 mm (0.06m).

We know P=

P = 4 2300

0.06 (0.06)

= 813458.59 N/m

8 bar


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2.2 Objectives:

Table 2.2: Objectives

Performance Safety Appearance Inexpensive

Performance

Ease of operation

Easy to use

Easy to start

Easy to stop

Easy to maintain

Easy to clean

Easy to disassemble

Easy accessible

interior

Convinience

Quick

Low loading height

Operator free

operation

Cans removed automatically

Runs on standard

power supply

Efficiency

Low vibrations

Utilizes gravity

Stand-alone unit

High Material strength

Large capacity Hoppper

Safety

Closed crushing

area

Risk-free

Low noise

Virtually accident free

No flying debris

Little or no heat produced

No sharp corners

Wiring kept away from moving parts


14

Appearance

Appearance pleasing to eye

Blends with surrounding


15

3. Design and construction:

3.1 Components design:

3.1.1 Pneumatic cylinder

Fig. 3.1.1.a

Fig. 3.1.1.b


16

3.1.2 Can Basher and feed strip

Fig. 3.1.2.a

Fig 3.1.2.b


17

3.1.3 Can placing area and guideway

Fig. 3.1.3.a

Fig. 3.1.3.b


18

3.1.4 Foundation

Fig. 3.1.4.a

Fig. 3.1.4.b


19

3.1.5 Hopper

Fig. 3.1.5.a

Fig 3.1.5.b


20

3.1.6 Complete Assembly Design:

Fig. 3.1.6.a


21

Fig. 3.1.6.b


22

3.2. Material selection:

Factors considered for material selection:

Cost of the material

Weight of the material

Welding and forming ability of the material.

We have used mild steel sheets to build all the components. Mild steels used in

sheet metal work have low carbon content. They are commonly categorized as

either "hot rolled" or "cold rolled". Cold rolled steel sheets offer a variety of

outstanding properties, including easy formability, a smooth, clean surface,

material consistency, accuracy in thickness and are available in a wide variety of

thicknesses. One main advantage of cold rolled steel is the ease of resistance spot

welding. They are used in precision sheet metal applications, automobiles,

appliances, furniture, and many other everyday items.

Cold rolling increases the strength and hardness and decreases ductility of steel by

rolling it at ambient temperature (or below its recrystallization temperature). In

addition to improvement of mechanical properties, the cold rolling produces steel

sheet of the desired physical dimensions. Steel may be annealed subsequent to the

cold rolling process to restore the original mechanical attributes. Even with

multiple passes through rollers, cold rolling is more limited in its ability to effect

dimensional changes (versus hot rolling) because of the increased hardness and

decreased ductility.

Table 3.2

Mechanical Properties, composition and specifications of Cold rolled steel used as

per IS 513:

Chemical composition

% (Max.)

Mechanical properties

3.3. Components Details:

Grade Process requirement

C Mn S Ph Tensile strength Kgf/mm2

% Elongation

(Min.)

Yield stress

Kgf/mm2

Rockwell B

Hardness HRB

Drawing

D

Moderate

Bending,

forming &

welding

0.12

0.5

0.04

0.04

32-40

27

20

65


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3.3.1 Pneumatic Cylinder:

Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices

which use the power of compressed gas to produce a force in a reciprocating

linear motion. Pneumatic cylinders force a piston to move in the desired direction.

The piston is a disc or cylinder, and the piston rod transfers the force it develops

to the object to be moved. Pneumatic cylinders are preferred because they are

quieter, cleaner, and do not require large amounts of space. Because the operating

fluid is a gas, leakage from a pneumatic cylinder will not drip out and contaminate

the surroundings, making pneumatics more desirable where cleanliness is a

requirement.

Janatics model no: A12063160O

Fig. 3.3.1

Specifications:

Type: Double acting

Maximum pressure: 10 bar

Stroke length: 160 mm

Bore diameter: 60 mm

3.3.2 Solenoid valve:

A solenoid valve is an electromechanically operated valve. The valve is controlled

by an electric current through a solenoid. Their tasks are to shut off, release air.

They are found in many application areas. Solenoids offer fast and safe switching,

high reliability, long service life, good medium compatibility of the materials

used, low control power and compact design.

Janatics model no: DS255SR61


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Fig. 3.3.2

Specifications:

Type: 5/2 spring return

Operating voltage: 24 V

Pressure range: 2-10 bar

Power: 5 W

3.3.3. Microcontroller (P89V51RD2):

A microcontroller is a small computer on a single integrated circuit containing a

processor core, memory, and programmable input/output peripherals. Program

memory in the form of NOR flash or OTP ROM is also often included on chip, as well

as a typically small amount of RAM. Microcontrollers are designed for embedded

applications, in contrast to the microprocessors used in personal computers or other

general purpose applications.

How Microcontroller works:-

The original task of a Microcontroller involved the interconnection of input signals

according to a specified program and, if "true", to switch the corresponding output.

Microcontroller will generally have the ability to retain functionality while waiting for

an event such as a button press or other interrupt; power consumption while sleeping

(CPU clock and most peripherals off) maybe just nanowatts, making many of them

well suited for long lasting battery applications. In our Project, we are going to Control

a solenoid valve with the help of a microcontroller which will give a signal when the

sensor senses the can.

Features:


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o 80C51 Central Processing Unit

o 5 V Operating voltage from 0 to 40 MHz

o 64 kB of on-chip Flash program memory with ISP (In-System Programming)

and IAP (In-Application Programming)

o Supports 12-clock (default) or 6-clock mode selection via software or ISP

o SPI (Serial Peripheral Interface) and enhanced UART

o PCA (Programmable Counter Array) with PWM and Capture/Compare

functions

o Four 8-bit I/O ports with three high-current Port 1 pins (16 mA each)

o Three 16-bit timers/counters

o Programmable Watchdog timer (WDT)

o Eight interrupt sources with four priority levels

o Second DPTR register

o Low EMI mode (ALE inhibit)

o TTL- and CMOS-compatible logic levels

Pin diagram:

Fig. 3.3.3

Table 3.3.3 Symbol Pin Type Description:


26

SYMBOL TYPE DESCRIPTION

P0.0 to P0.7 I/O Port 0: Port 0 is an 8-bit open drain bi-directional I/O port. Port 0 pins that have 1s written to them float, and in this state can be used as high-impedance inputs .Port 0 is also the multiplexed low-

order address and data bus during accesses to external code and

data memory. In this application, it uses strong internal pull-ups

when transitioning to 1s. Port 0 also receives the code bytes during the external host mode programming, and outputs the code bytes during the external host mode verification. External pull-ups

are required during program verification or as a general purpose

I/O port. P1.0 to P1.7 I/O with

internal pull-up

Port 1: Port 1 is an 8-bit bi-directional I/O port with internal pull-

ups. The Port 1 pins are pulled high by the internal pull-ups when

1s are written to them and can be used as inputs in this state. As inputs, Port 1 pins that are externally pulled LOW will source

current (IIL) because of the internal pull-ups. P1.5, P1.6, P1.7 have

high current drive of 16 mA. Port 1 also receives the low-order

address bytes during the external host mode programming and

verification.

P1.0 I/O T2: External count input to Timer/Counter 2 or Clock-out from

Timer/Counter 2

P1.1 I T2EX: Timer/Counter 2 capture/reload trigger and direction

control

P1.2 I ECI: External clock input. This signal is the external clock input

for the PCA.

P1.3 CEX0: Capture/compare external I/O for PCA Module 0.Each capture/compare module connects to a Port 1 pin for external I/O.

When not used by the PCA, this pin can handle standard I/O.

P1.4 I/O SS: Slave port select input for SPI

CEX1: Capture/compare external I/O for PCA Module 1

P1.5 I/O MOSI: Master Output Slave Input for SPI


P1.6 I/O MISO: Master Input Slave Output for SPI CEX3: Capture/compare external I/O for PCA Module 3

P1.7 I/O SCK: Master Output Slave Input for SPI


P2.0 toP2.7 I/O with

internal pull-up

Port 2: Port 2 is an 8-bit bi-directional I/O port with internal pull-

ups. Port 2 pins are pulled HIGH by the internal pull-ups when 1s are written to them and can be used as inputs in this state.

P3.0 toP3.7 I/O with

internal pull-up

Port 3: Port 3 is an 8-bit bidirectional I/O port with internal pull-

ups. Port 3 pins are pulled HIGH by the internal pull-ups when 1s are written to them and can be used as inputs in this state.

P3.0 I RXD: serial input port

P3.1 O TXD: serial output port

P3.2 I INT0: external interrupt 0 input

P3.3 I INT1: external interrupt 1 input

P3.4 I T0: external count input to Timer/Counter 0

P3.5 I T1: external count input to Timer/Counter 1


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P3.6 O WR: external data memory write strobe

P3.7 O RD: external data memory read strobe

PSEN I/O Program Store Enable: PSEN is the read strobe for external

program memory. When the device is executing from internal

program memory, PSEN is inactive(HIGH). When the device is

executing code from external program memory, PSEN is activated

twice each machine cycle, except that two PSEN activations are

skipped during each access to external data memory. A forced

HIGH-to-LOW input transition on the PSEN pin while the RST

input is continually held HIGH for more than 10 machine cycles

will cause the device to enter external host mode programming.

RST I Reset: While the oscillator is running, a HIGH logic state

on this pin for two machine cycles will reset the device. If the PSEN pin is driven by a HIGH-to-LOW input transition while the

RST input pin is held HIGH, the device will enter the external host

mode, otherwise the device will enter the normal operation mode.

EA I External Access Enable: EA must be connected to VSS in order to

enable the device to fetch code from the external program memory.

EA must be strapped to VDD for internal program execution.

However, Security lock level 4 will disable EA, and program

execution is only possible from internal program memory. The EA

pin can tolerate a high voltage of 12 V.

ALE/PROG I/O Address Latch Enable: ALE is the output signal for latching the

low byte of the address during an access to external memory. This

pin is also the programming pulse input (PROG) for flash

programming. Normally the ALE is emitted at a constant rate of 16 the crystal

frequency and can be used for external timing and clocking. One

ALE pulse is skipped during each access to external data memory.

However, if AO is set to 1,

NC I/O No Connect

XTAL1 I Crystal 1: Input to the inverting oscillator amplifier and input to the

internal clock generator circuits.

XTAL2 O Crystal 2: Output from the inverting oscillator amplifier.

VDD I Power supply

VSS I Ground

3.3.4. MAX232IC:

The MAX232 IC is used to convert the TTL/CMOS logic levels to RS232 logic levels

during serial communication of microcontrollers with PC. The controller operates at

TTL logic level (0-5V) whereas the serial communication in PC works on RS232

standards (-25 V to + 25V).


28

Pin Diagram:

Fig. 3.3.4.a

The intermediate link is provided through MAX232. It is a dual driver/receiver that

includes a capacitive voltage generator to supply RS232 voltage levels from a single

5V supply. Its a 16pin IC which accepts logic level from PC & connects it to

microcontroller. Each receiver converts RS232 inputs to 5V TTL/CMOS levels. These

receivers (R1 and R2) accept 30V inputs.


29

Block Diagram:

Fig. 3.3.4.b

& R ) can 1 2

The transmitters take input from controllers serial transmission pin and send the output to RS232s receiver. The receivers, on the other hand, take input from transmission pin of RS232serial port and give serial output to microcontrollers receiver pin. MAX232 needs four external capacitors whose value ranges from 1F to

22F. Here, we have used capacitors of 10 F.


30

Table 3.3.4: Pin Description:

Pin No Function

Name

1

Capacitor connection pins

Capacitor 1 +

2 Capacitor 3 +

3 Capacitor 1 -

4 Capacitor 2 +

5 Capacitor 2 -

6 Capacitor 4 +

7 Output pin; outputs the serially transmitted data at

RS232 logic level; connected

to receiver pin of PC serial

port

T2 Out

8 Input pin; receives serially

transmitted data at RS 232

logic level; connected to transmitter pin of PC serial

port.

R2 In

9 Output pin; outputs the serially transmitted data at

TTL logic level; connected to

receiver pin of controller.

R2 Out

10 Input pins; receive the serial data at TTL logic level;

connected to serial

transmitter pin of controller.

T2 In

11 T2 Out

12 Output pin; outputs the

serially transmitted data at

TTL logic level; connected to receiver pin of controller.

R1 Out

13 Input pin; receives serially

transmitted data at RS 232

logic level; connected to transmitter pin of PC serial

port

R1 In

14 Output pin; outputs the

serially transmitted data at RS232 logic level; connected

to receiver pin of PC serial

port

T1 Out

15 Ground (0V) Ground

16 Supply voltage; 5V (4.5V 5.5V)

Vcc


31

3.3.5. ULN2003APG:

The ULN2003APG/AFWG Series are high voltage, high current Darlington drivers

comprised of seven NPN Darlington pairs. All units feature integral clamp diodes for

switching inductive loads. Applications include relay, hammer, lamp and display

(LED) drivers.

Features:

Output current (single output): 500 mA max.

High sustaining voltage output: 50 V min.

Output clamp diodes.

Inputs compatible with various types of logic

Package Type-APG: DIP-16pin

Package Type-AFWG: SOL-16pin

Fig 3.3.5.a


32

Fig. 3.3.5.b Fig. 3.3.5.c

3.3.6. Sensor:

Schematic:

Fig. 3.3.6

Description:

The LM2904, LM358/LM358A, LM258/LM258A consist of two independent, high

gain, internally frequency compensated operational amplifiers which were designed

specifically to operate from a single power supply over a wide range of voltage.

Operation from split power supplies is also possible and the low power supply current

drain is independent of the magnitude of the power supply voltage. Application areas

include transducer amplifier, DC gain blocks and all the conventional OP-AMP

circuits which now can be easily implemented in single power supply systems.


33

3.3.7 MCT2E: Optocoupler, Phototransistor Output

Fig. 3.3.7

Description:

In electronics, an opto-isolator, also called an optocoupler, photocoupler, or optical

isolator, is a component that transfers electrical signals between two isolated circuits

by using light. Opto-isolators prevent high voltages from affecting the system

receiving the signal. Commercially available opto-isolators withstand input-to-output

voltages up to 10 kV and voltage transients with speeds up to 10 kV/s. A common

type of opto-isolator consists of an LED and a phototransistor in the same package.

Opto-isolators are usually used for transmission of digital (on/off) signals, but some

techniques allow use with analog (proportional) signals.

3.3.8. Hopper:

This is a component that stores bulk of cans. It is tapered in shape. An opening is

provided at the bottom. Hopper needs to be vibrated in order to facilitate cans to fall

on the guideway via the opening.

3.3.9. Guideway:

This is a channel shaped component which enables the can to slide under gravity. It is

placed at an angle of 40 degrees with respect to ground. It is placed in such a way that

the can falls exactly in the crushing area.

3.3.10. Can basher and feed strip:

Can basher is a strong rigid stepped cylindrical shaped that crushes the can by

pressing it against the opposite face of M.S. plate.

Feed strip is attached to the can basher in order to feed only one can at a time in the

crushing area.


34

4. Serial Communication:

Serial communication is used to transfer data to a device located many meters

away. In serial communication single data line is used to transfer data instead of

8-bit data line. The fact that serial communication uses a single data line instead

of 8 bit data lines of parallel communication not only makes it much cheaper but

also enables computer located in two different cities to communicate over the

telephone.

For serial data communication to work, the byte of data must be converted to

serial bit using a parallel-in-serial-out shift register, that it can be transmitted over

a single data line. This also means that at the receiving end there must be a serial-

in-parallel-out shift register to receive the data and pack them into a byte. Of

course if a data is to be transferred on a telephone line, it must be converted from

0s and 1s to audio terms, which are sinusoidal shaped signals. This conversion is

performed by a periphery devise called a modem, which stands for a

modulator/demodulator.

Serial data communication used two methods, asynchronous and synchronous.

The synchronous method transfers a block of data (characters) at a time, while

asynchronous method transfer a single byte at a time. There are special IC chips

made by many manufactures for serial communication. These chips are commonly

referred to as UART (Universal Asynchronous Receiver Transmitter) and USART

(Universal Synchronous Asynchronous Receiver Transmitter). 8051 chip has a

built in UART.

Fig. 4 Serial Port Pin Diagram


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Table 4: Pin Description

4.1. Serial Communication between Computer and P89V51RD2:

To allow compatibility among data communication equipment made by various

manufactures, and interfacing standard called RS232 is used. As input and output

voltage levels of RS232 is not TTL compatible a line driver such as the MAX232

chip to convert RS232 voltages to TTL levels, and vice versa. One advantage of

the MAX232 chip is that it uses a +5 V power source which is the same as the

source voltage for the 8051.

The 8051 has two pins that are used specifically for transferring data serially.

These two pins are called TxD and RxD and are part of the port 3 group (P3.0 and

P3.1). Pin 11 of the 8051 is assigned to TxD and pin 10 is designated as RxD. The

T1in pin (11) is the TTL side and is connected to TxD of the microcontroller,

while T1out (14) is the Rs232 side that is connected to the RxD pin of Rs232 DB

connector. The R1IN (13) is the RS232 side that is connected to the TxD pin of

the RS232 DB connector, and R1out (12) is the TTL side that is connected to the

RxD pin of the microcontroller.

Fig. 4.1


36

5. Circuit Diagram:

5.1. Pneumatic circuit:

Fig. 5.1


37

5.2 Electrical circuit:

Fig. 5.2


38

5.3 Program

//Header Files for P89V51RX2 MCU's

#include

#include

sbit signal= P1^0;

sbit solenoid= P2^0;

//Loop for Initializing Serial Communication

void init_serial()

{

SCON = 0x50; //SCON BIT Configuration

//Bit 7 = 0


39

//Bit 1 = 0


40

}

}

}


41

6. Working

A bulk of cans is put into the hopper. The opening provided at the bottom of the

hopper facilitates cans to fall one after the other on the guideway.

The guideway which is kept at an angle enables the cans to slide down under

gravity.

The feeding strip which is attached to the can basher allows feeding of only one

can at a time into the can placing area.

Once, the can appears in front of the can basher, the IR sensor which is interfaced

with the microcontroller senses the can.

After receiving the input, from the sensor the microcontroller provides 5 volt

output. This 5 volt output is then given to ULN through an opto-coupler.

A 24v DC is given to common pin of ULN IC. A 24 volt relay is used to operate

solenoid valve.

When input is given to ULN, relay is operated and 24 volt is given to solenoid

valve.

The single acting spring return 5/2 solenoid operated direction control valve is then

operated.

This enables the pressurized air to pass through and the cylinder extracts to

complete the forward stroke.

The can basher attached to the piston rod of the cylinder crushes the can by

pressing it against the opposite M.S. plate.

The crushed can falls under gravity into the bin via the opening provided below the

crushed can.


42

Flowchart:

Step 1

Cans are put in the

hopper

Step 2

Guideway guides the

can onto the crushing

area

Step 3

Can is sensed by the IR

sensor

Step 4

Solenoid valve activates

and the cylinder starts

the forward stroke

Step 5

Can gets crushed

Step 6

Crushed can falls in the

bin


43

7. Future Scope:

This project has various futuristic technologies which are still under R&D and hence

itll surely have use in the near future. Much work in the project is constrained

because of lack of essential resources and their high-cost.

With an Industrial grade camera this system can become more robust.

Image processing is a cheap and comparatively more robust option for

environmental sensing for an AGV. It needs to be experimented with to understand

its true potential.

Crushing multiple cans with the help of a strong, rigid and larger can basher.

Developing code and hardware to calculate number of cans crushed.

Providing red light to indicate crushing mechanism in operation.

Yellow light to indicate improper use of machine.

Crushing plastic bottles can also be thought of.

Adjustable mechanism to accommodate varying can and bottle sizes.

8. Conclusion:

In our project we carried out the study of the current can crushers and the various

mechanisms employed. We also successfully implemented some of the technological

aspects. Overall the project was very enriching in terms of technical fabrication and

design process along with electronics knowledge. The knowledge gained while

solving and understanding the complexities of our project would help us in our

professional life.

9. References:

http://myzerowaste.com/articles/food/why-recycle-tins-and-cans/

http://seminarprojects.com/Thread-electro-pneumatic-cancrusher.

http://www.google.co.in/url?sa=t&rct=j&q=can%20crusher%20project%20report

&source=web&cd=5&cad=rja&ved=0CFEQFjAE&url=http%3A%2F%2Fcancrus

her2011.wikispaces.com%2Ffile%2Fview%2FPowerpoint.ppt%2F228354074%2F

Powerpoint.ppt&ei=AHZzUcXELIiQrQfM6AE&usg=AFQjCNFc5mvVkahFMrV

OL13UByMyg7s2Lw&bvm=bv.45512109,d.bmk

http://books.google.co.in/books?id=4EQAK2eLxLgC&pg=PA110&lpg=PA110&dq=automat

ic+feed+mechanism+for+can+crusher&source=bl&ots=sy0r-

7cKjA&sig=wb_HiCx3AcdEI0Jy-

BTLzAxQ5Ko&hl=en&sa=X&ei=eyVVUcKjGMm8rAeDyYDwCQ&sqi=2&ved=0CFcQ6AEwBA

#v=onepage&q=automatic%20feed%20mechanism%20for%20can%20crusher&f=false

http://books.google.co.in/books?id=fM1mRDtxxdsC&pg=PA121&lpg=PA121&dq=automa

tic+feed+mechanism+for+can+crusher&source=bl&ots=9LitlWjhKk&sig=lg5LXh5fIYWBW4

GPOEVeGS-

Dxfs&hl=en&sa=X&ei=eyVVUcKjGMm8rAeDyYDwCQ&sqi=2&ved=0CEsQ6AEwAg#v=onep

age&q=automatic%20feed%20mechanism%20for%20can%20crusher&f=false

http://en.wikipedia.org/wiki/Aluminium_recycling

http://www.tmaintl.com/cold-rolled-steel-sheets.html

Design Data Book PSG College of Technology, Coimbatore

Documents

Automatic Can Crusher