PROJECT DEMO

DESIGN PROPOSALOF

AUTOMATED WASTED DISPOSAL SYSTEM

FOR HINDUSTAN NEWSPRINT LIMITED,

VELLOR

PRESENTED BY,KRISHNA KUMAR. B

SANDEEP.S.SSHYAM.K

THOMAS.P.S

Project members with guide Mr.Prasad Rajan (Sr.Manager ,Mechanical engg,HNL)

Project members with college guide Mr.Jithu.J (Lecturer, Mechanical Dept, TIST)

OBJECTIVES

The main objectives of this project are:• To study the current waste management system

in the industry.• To replace the manually transported waste into

automated waste transportation to the truck.

INTRODUCTION

De-inking Plant

• In de-inking plant the pulp is produced from waste paper. It is soaked in water and then slushed to slurry form.

• Hopper seperates the pulp from the plastic and other waste.

• Those waste are removed manually after the hopper removes it.

• Sodium hydroxide is added .The ink and other impurities are removed and the good fiber is separated.

• Hydrogen peroxide is in the first stage bleaching. The de-inking pulp is sorted in a concrete tank and it is pumped to paper machine plant.

• Production capacity of the de-inking plant is 100 metric tons perday.

• In the De-inking plant the waste coming out of the hopper is collected in a 1m x 1m x 1m box.

• From the hopper the waste comes in equal interval of time. Later on, this after getting piled up, is manually transferred to the truck using a shovel. This process is repeated and requires much time which is a hectic job.

• The installation of this Automated Waste Disposal System (AWDS) will be a substitute for that human labour.

• Through this project the design proposal of the Automated Waste Disposal System (AWDS) is clearly shown.

HOPPER

Waste Collected From Hopper

DESIGN LAYOUT

PARTSThe different parts used for the design of the AWDS are:

• Box• Chain and Sprocket drive• Motor• Shaft• Bearing• Pneumatic Piston• Rails and Roller Wheels• Sensors

– Limit Switch Sensor– Transmitter- Receiver- Light- Barrier Sensor

WORKING• There is a 1 mX 1 mX 1m box placed under the hopper. After the

box is filled up the box starts moving using a chain mechanism according to the contour.

• A sensor senses as the box reaches the truck triggering the piston attached at the bottom door of the box for opening the exit of the waste.

• The chain is moving using an outsource which is a motor. After a time interval of One and Half hours ie, three time waste collection from hooper to the box it starts moving. As it reaches the truck the box movement stopping sensor senses stops the box and gives signal for the opening of the door. And thus the waste is been exited.

• After the waste exit the door is closed and the box reaches back to the initial position. This process is repeated.

• Small modifications are made for the automation system such as :

• Bottom doors are attached to the box• Chains are included at the sides of the box for its

movement• Sensors are added for :

– detection of the truck– starting and stopping of the box movement

PARTSThe different parts used for the design of the AWDS are:

• Box• Chain and Sprocket drive• Motor• Shaft• Bearing• Pneumatic Piston• Rails and Roller Wheels• Sensors

– Limit Switch Sensor– Transmitter- Receiver- Light- Barrier Sensor

BOX

CHAIN

SPROCKET

MOTOR

PNEUMATIC PISTON

LIMIT SWITCH

SHAFT

TRANSMITTER- RECEIVER-LIGHT BARRIER SENSORS

ASSEMBLED FIGURE

CALCULATIONSTotal waste coming from the hooper = (water+ pulp+ plastic)

= 100 kgTotal amount of plastic waste = 40% of total waste

= 40 kg = 40000 gDensity of plastic waste = 0.56 g/cm3Volume = Mass/Density

= 40000/0.56 = 71428.57 cm3

Considering the space available and safety factors, the dimension of the metal box is selected to be 1m x 1m x 1 m

Box size = 1m x 1m x 1 mie, Volume of box = 1000000 cm3So we can fill the box in almost 14 times.

Design of BoxBottom gate:

Length = 1 mHeight = 1 mThichness = 0.01 m

Total volume of the gate = Length x Height x Thickness= 1 x 1 x 0.01 = 0.01 m3

Material selected for the gate = Cast IronDensity Cast Iron ranging from = 6800 – 7800 kg/m3Selecting Density of Cast Iron = 7000 kg/m3Therefore Mass of gate = Volume x Density

= 7000 x 0.01= 70 kg (Perforated bottom)

Frame:Dimensions of outer sideLength = 1 mHeight = 1 mThickness = 0.005 mVolume = Length x Height x Thickness

= 1 x 1 x 0.005= 0.005 m3

Dimensions of inner sideLength = 1- 0.02

= 0.98 mHeight = 0.98 mThickness = 0.005 m

Volume = Length x Height x Thickness= 0.98 x 0.98 x 0.005

= 4.802 x 10-3 m3Hence Volume of the constructed frame = Outer dimension – Inner dimension

= 0.005 – (4.802 x 10-3)= 1.98 x 10-4 m3

Mass of one frame = Volume x Density= 1.98 x 10-4 x 7000= 1.386 kg

Total weight for 4 sides = 4 x 1.386 = 5.544 kg

Side walls:Length = 1 mHeight = 1 mThickness = 0.005 m3

Volume of one bar = Length x Height x Thickness =1 x 1 x 0.005

= 0.005 m3Volume of 23 bars = 23 x 2 x 10-2 x 1 x 0.005

= 2.3 x 10-3 m3Selected Density of Cast Iron = 7000 kg/m3Mass = Volume x Density

= 2.3 x 10-3 x 7000 = 16.1 kg (which is mass of one

grill ,ie one side)Total mass for 4 grills ,ie 4 sides = 4 x 16.1

= 64.4 kg

Angle plate:Length = 3 cmBreadth = 3 cmHeight = 100 cmThickness = 0.5 cm

Area of the cross section of the angle plate1st part = 3 x 3

= 9 cm22nd part = (3 - 0.5) x (3 - 0.5)

= 2.5 x 2.5= 6.25 cm2

Therefore the area = 9 – 6.25= 2.75 cm2Volume of one plate = Area x Height

= 2.75 x 100= 275 cm3

Volume of 4 angle plates = 4 x 275 cm3 =1.1 x 10-3 m3

Selected Density of Cast Iron = 7000 kg/m3Mass = Volume x Density

= 1.1 x 10-3 x 7000 = 7.7 kgTotal box weight = 70 + 64.4 + 7.7+ 5.544 kg

= 147.644 kgApproximate weight for safety ≈ 160 kg (considering welding and hinges)So total weight of box including water, pulp, waste and pneumatic piston = 300 kg

Force AnalysisIn horizontal:

Frictional force on the rail and rotor = µRNCoefficient of Friction, µ =0.2 for cast ironNormal Reaction, RN = 300

= 0.2 x 300= 60 kgf

Inertia force = m aMass, m = 300 kgAcceleration of the chain = 0.2 m/s

= 300 x 0.2 = 60 kgf

Total force during starting time = 60 + 60 = 120 kgf

In inclination:

Force in the direction of motion = mg sin 450Mass x Acceleration due to gravity = Weight (w)

= w sin 450 = 300 x (1/√2) = 212.13 kgf

Force due to friction = mg cos 450 x µ = w x cos 450 x µ

= 300 x (1/√2) x 0.2 = 42.42 kgf

Hence total Force required in inclination = 42.42 + 212.13= 254.55 kgf

FREE BODY DIAGRAM

Force acting downwards = mgCouple due to that force = mg x half the length

= 300 x 9.8 x 0.5= 1470 Nm

Frictional Force = µRN= 0.2 x 300= 60 kgf

Couple due to Frictional Force = µRN x g x height = 60 x 9.8 x .5 = 294 Nm

Here couple due to the downward force is greater than couple due to frictional force so the box will not trip and fall.

Chain SelectionForce acing in one chain = 254.55/2

= 127.27 kgfTaking factor of safety = 3Calculated Breaking Load = 127.27 x 3

= 381.81 kgfTherefore selecting a chain with a breaking load greater than 381.81 kgf is from PSG

Design Data Book.Taking the chain R830, with Breaking load = 460 kgfPitch = 8 mmRoller diameter maximum = 5 mmWidth between inner plates minimum, w = 3.10 mmPin body diameter maximum, Pp = 2.31 mmPlate depth maximum, G = 7.05 mmOverall over joint masses , A1, A2, A3 = 11.10 mmBearing area = 0.11 mmWeight per meter = 0.18 kg/mChain Material = Cast Iron

Sprocket SelectionISO 05 BI (8 x 3.0 mm) Simple Roller Chain selected from Sprocket

CatlogueNo of teeth = 45Pitch circle diameter, d0 = 114.69 mmTip circle diameter, dk = 118.6 mmPilot bore, di = 38mmPitch = 8 mmInner width = 5 mmRoller diameter = 5 mmTeeth width = 2.8 mmRadius = 114.69/2

= 57.34 mmSprocket Material = Stainess Steel

Calculation for Power and Torque

Load = 254.55kgfRequired velocity = 0.4 m/sPower = Force x Velocity

= 254.55 x 10 x 0.4= 1018.2 W

In HP = Power/746=1018.2/746

=1.36 HPTorque required = Force x Radius = 2550 x 0.05769

= 147.11 NmPower = (2 ∏ NT)/60 1018.2= (2 ∏ x N x 147.11)/60Therefore N = 66.12 rpm

≈ 66 rpm

Motor SelectionGeared Motor Selected from Hindustan Motors catalogueH_M402050_0904(1.5Hp)

From the above conditions, motor is selected with,RPM = 63 rpmTorque = 161.7 NmService Factor = 1.4Phase and Voltage = 3 phase, 415 VRating = 0.12 to 7.3 kw =Taking 7.3

kwRatio = 3.6/1 to 45/1 = Taking

23 /1Shaft diameter = 24 to 60 mm = Taking 40

mmMounting = Foot and Flange

Shaft Selection

Taking shaft diameter = 40 mmLength of shaft = 3.25 mShaft Material = Forged SteelDensity of Shaft = Forged Steel = 7850 kg/m3

Shaft Volume = ∏r2l= ∏ x (0.02)2 x 3.25 = 4.084 x 10-3 m3

Shaft Mass = Volume x Density= 4.084 x 10-3 x 7850= 32.059 kg

Bearing DesignDensity of Sprocket = Stainless Steel = 7480-8000 kg/m3Selecting Density of Stainless Steel = 7500 kg/m3Sprocket Volume = ∏r2l

= ∏ x ([118.6/2]2 – [40/2]2) x 2.8 = 27414.0778 mm3

Sprocket Mass = Volume x Density = 27414.0778 x 10-9 x 7500 = 0.205 kg x 2 = 0.411 kg

Total Radial Load Acting on the Bearing = Shaft Mass + Bearing Mass= 32.059 + 0.411 = 32.4702 kg

Axial Load, Fa = 0 kgfRadial Load, Fr = 32.4702 /2

= 16.23 kg (for one bearing)Equivalent Load , P = ( X Fr + Y Fa) STaking ,Radial Factor, X = 1Thrust Factor, Y = 0 Service Factor, S = 1.3Therefore ,P = X Fr S

= 1 x 16.23 x 1.3 = 21.099 kg

Length of Chain at InclinationAccording to Pythagoras Theorem

AC2 = √( AB2 +BC2) AC = (2.52 + 2.52)AC = 3.5 m

Total travel distance = 2.5 +3.5 + 1.5 = 7.5 m

Velocity, V = ω rRadial Velocity, ω= [(2 x ∏ x N)/60]rpm, N = 63 rpm

Therefore, V = [(2 x ∏ x N)/60] x r = [(2 x ∏ x 63)/ 60] x (0.11469/2) = 0.37 m/s

Therefore time of travel = Distance / Velocity = 7.5 / 0.37 = 19.83 sec

Two way travel = 2 x 19.83= 39.67 sec

Work time ≈ 60 secs = 1 minTotal work time for one day = 16 minsIn hours = 16/60

= 0.27 hrs

Required Life of Bearing in million revolutions, for 8 yearsL = 0.27 hrs x (365days/1yr) x 8 yrs x 63 rev/min x (60min/1hr) x (1mr/106 rev) = 2.98 mrTherefore Dynamic Capacity, C = (L/L10)1/K x P

L10 = 1 mrK = 3 for ball bearings

Therefore, C = (2.98/1)1/3 x 21.099 = 30.36 kgf

Selecting Bearing SKF 6008d = 40 mmD1 = 45 mmD = 68 mmD2 = 63 mmB = 15 mmr ≈ 1.5 mmr1 = 1.0 mmBasic Static Capacity, C0 = 980 kgfBasic Dynamic Capacity, C = 1320 kgfMaximum Permissible Speed, rpm = 10000 rpm

Bearing Probability of Survival

We know that, C1 = (L101/L10)1/K x P1= (L101/1)1/3 x 21.099

Therefore, L101 = 244870.336 mrL/L101 = [ln(1/p1)/ln(1/p10)]1/b

L101 = calculated life of the selected bearing, for given load for 90% survivalLn(1/p10) = ln(1/0.9) = 0.1053b = 1.34 for deep grove ball bearings

2.98/244870.336 = [ln (1/p)/ 0.1053)1/1.34

Therefore, p1 = 0.9999 = 99.99%

Piston Selection

NORGREN RN920 (stroke 300mm)Force acting on the piston = 100 kgf

= 1000 NTaking diameter of the piston = 2 inchStroke = 300 mmOperating Pressure = 2 – 10 barOperating temperature = -20˚C - 80˚C

Area = ∏ r2= ∏ x 2.542= 20.258 cm

Therefore Pressure acting = Force / Area= 1000 / (20.258 x 10-

4)= 493632.14 Pa= 4.936 bar.

CONCLUSION

• By completion of this project the Industry gets a good profit.

• This machine can also be used in many Industry. Can used also in various raw material transportation.

• Though this kind of system exists in various fields, the AWDS is one of a kind which is so simple and is ecofriendly.

BIBLIOGRAPHY

• PSG Data book• www.fotoelectik-pauly.de• www.imis.com• Hindustan electric motors Catlogue• Norgen RM Cylinders Catlogue