Group 12 Stanley Andrews Brandon Jefferson The Can Crusher Group 12 Stanley Andrews Brandon Jefferson

Motivation Wanted to incorporate more electrical and software design into the idea of the “Can Crusher” Use pneumatic cylinders (3 pneumatic cylinders in this project) Thought it would be something different from previous senior design projects

Objectives Step 1: Can or water bottle is placed into the trash can. Can/Water bottle enters hopper and waits for it to be identified by the optical and reflective sensor. Step 2: Double acting cylinder pushes the object and sends it to the can crusher . Step 3: Sorter determines route of the object based on feedback from the sensors. Step 4: If object is a water bottle, it will be routed towards a push cylinder and crushed Step 5: If the object is an aluminum can, it will be routed towards a push cylinder and crushed Step 6: Push cylinder crushes the aluminum cans and water bottles and sends remains to the storage bin Step 7: Process continues until storage sensor alerts operator that storage bin is 90% filled. Step 8: Once storage reaches 90%. Can crusher goes into “Stop” mode. Items from storage bin, can then be removed.

Features Fully automatic Can Crusher and Sorter Detect when an object is placed in the hopper Be able to distinguish between an aluminum can and a water bottle Sort the water bottle into a separate storage bin from the aluminum cans Detect when the storage bins are 90% full Will have three different modes “Standby”, “Operational (Go)”, “Stop”

Hopper Full view of the Hopper Inside the Hopper

Hopper Where the bottle and cans will be placed Be able to hold 8 FL oz. water bottle and 12oz. aluminum cans Two sensors are mounted to detect the object inside the hopper Need to change size of water bottles. Originally we were planning to use 16.9 fl oz but it didn’t fit our mechanical design

Sensors Parallax Ultrasonic Sensor Reflective Optical Sensor

Parallax Ultrasonic Sensor Part a) Sensor is sending a ultrasonic pulse but object is outside of operating distance Part b) Sensor facing object at a angle. Pulse is reflected at another angle Part c) Sensor is facing object on level plane but object is too small. Will not reflect transmitted signal Using the Ultrasonic sensor as a detector and also as distance operator

Parallax Ultrasonic Sensor PING Ultrasonic Sensor Detector Type Ultrasonic Dimensions 16 x 46 x 22(mm) Peaking Operating distance 2(cm)-3 (m) Supply Current 30 mA Voltage 5 V

Reflective Optical Sensor TCRT5000 Reflective Optical Sensor Detector type Phototransistor Dimensions 10.2 x 5.8 x 7(mm) Peak operating distance 2.5 mm Output current 1 mA Emitter Wavelength 950 nm Voltage 5 V Banner SM2A312LV Detector Type Retro-reflective Dimensions 66 x 12.2 x 30.7 (mm) Peak operating distance 50mm – 2m Output current Minimum of 5 mA Voltage 24- 240 V AC Banner SM2A312LV cost 45$ has a much further peak operating distance than the TCRT5000. TCRT5000 cost about 10$ for 10 of them. Only concern is getting the TCRT5000 close enough to the object. We placed the TCRT5000 where the object would fall directly on top of it. So getting close enough to the object wouldn’t be a problem

Reflective Optical Sensor Get the best results (peak operating distance) at 2.5 mm One of the challenges will be to get it close enough to the object stored in the “hopper”

Aluminum Cans/ Water bottles

Terms of Service We ask that all contents are empty All objects must be placed horizontally in the hopper By default system will be in “standby mode”, once an object is placed inside, the system will go into operational mode If storage bin is full no objects will be crushed.

Design Overview Hopper Sensors Pneumatic cylinder Can Crusher Sorter Storage bin What is the fail safe we have? Water bottles get crushed also right? Or are they identical?

Sorter The idea is called the “Swinging lid” Uses a pneumatic cylinder to be able to “swing” the lid and alter the objects path Routes Aluminum Cans to proper bin Routes Water bottles to proper bin Which bin Is to what? Will the right most bin be for bottles and left most bin be for cans?

Motors/ Air Compressor Electric motors Air Compressor Pros Uses Standard Outlet Option to convert AC to DC Very Compact and small to maneuver and place anywhere Cons Most motors only have one speed No way to speed up or slow down the project Very Expenses for high power motors Pros Uses a Standard Outlet Able to adjust the air pressure Ability to control the speed of the motor by the PSI Option to convert AC to DC Not to expensive economy for the budget Can use air solenoid valves that can control of a multiple operated air pressure components Cons Tank will have to be refilled when low on air Will need multiple air hoses Very big hard and to hide and maneuver Very loud when filling up the tank

Air Compressor Horsepower (HP) 0.33 HP Tank Capacity (Gallons) 2.0 Gal Tank Type Portable Voltage 120 V Amps (Amps) 2.0 A Price $99.99

Air Compressor DeWalt Horsepower (HP) 1.6 HP Tank Capacity (Gallons) Tank Type Portable Voltage 120 V Amps (Amps) 15.0 A Max Pressure 200 PSI Price Free

Pneumatic cylinders Two Mini cylinder Double Acting Cylinder (can crusher) All will be operated via 3 solenoids . All connected to the microcontroller

Cylinders Can Crusher Kick-Door Sorter

Vertical or Horizontal Kevinkrusher 11.0 KevinKrusher II.0 Chamber Length 6 1/2" minimum PSI 60 -120 Cylinder Type Double action Mounted Vertical or Horizontal Price $157.00

Can Crusher Double Action Stroke Pneumatic Cylinder Max Pressure: 1.0 Mpa Diameter: 8.5mm (Approx.) Thread Rod Diameter: 9mm (Approx.) Size: 4.5 x 4.5 x 32cm Price $38.98

Mini Cylinder Double Action Max Pressure: 1.0 Mpa Diameter: 1- 1/16” Cylinder Type: Stainless Steel Rod Thread Length : 0.50 inches Price: $37.50 (each)

Air Solenoid Type: 2 Position 5 way Voltage: 12V DC Power 2.5W Current .208 Amps Valve Fittings: 1/8" BSPT (British standard pipe tapered) Total Needed 3 Price $ 11.39 (each)

Micro Controller Solenoids connected to 3 digital pins ( 8, 9, 10 ATMega 328p Operating Voltage 5 V Input Voltage (recommended) 7-12 V Input Voltage (limits) 6-20 V Digital I/O Pins 14 Analog Input Pins 6 DC Current per I/O 40 mA DC Current for 3.3V Pin 50 mA Flash Memory 32 KB Clock Speed 16 Solenoids connected to 3 digital pins ( 8, 9, 10 Ultrasonic Sensor & TCRT5000 connected to 4 analog pins (A0, A2, A3, A4) LEDS connected to 3 digital pins (5-7)

Software code Hopper (object detection) TCRT5000 Ultrasonic Sensor Loop

Automatic Can Crusher Schematic

Printed Circuit Board

Storage Bins Two storage bins Aluminum Can and Water Bottle Each bin will have Parallax Ultrasonic sensor Once storage reaches 90%. Can crusher goes into “Stop” mode

Enclosure Trash Can Cabinet

LEDs Green Operational mode Yellow Standby Mode Default Red Stop Mode

LED Schematic

Bridge Rectifier +- 12V regulator Power Supply 120 AC Transformer AC/DC Fuse Switch (On/Off) Bridge Rectifier +- 12V regulator +-5V regulator 12 V DC Air Solenoid (3) 5 V DC Microcontroller LEDs Sensors

Automatic Can Crusher Schematic Schematic of microcontroller design . What pins are connected to what

Work Distribution Sensors Power Supply Solenoids/ Cylinders Stanley Andrews Brandon Jefferson Sensors Power Supply Solenoids/ Cylinders Microcontroller Printed Circuit Board Software Implementation

Budget Nomenclature Cost (each) Number Total Cost Optical Sensor $29.99 3 95.35 TCRT5000 Reflective Sensor $1.00 10 $10.00 Double Acting Cylinder $37.50 2 $38.46 Mini Cylinder $16.47 1 $21.61 Air Solenoid $11.39 4 $57.54 Air Valve Fittings $1.48 14 $26.63 Air Valve Mufflers $1.19 8 $15.05 LEDs $1.99-$3.50 5 $20.00 Development Board $12 $14.78 Air Compressor $99.99 Free PCB $65.00 Air Regulator $19.99 21.18 Transfomer $30.00 Miscellaneous $140.00 $1040 $554.42 Histogram

Progression Where do we stand? How much more research, testing, ordering of parts, completion of project? How far are we from being done? We’re almost done ordering all our sensors and sensors

Issues TCRT5000 Software Design Water bottles Ultrasonic Sensor Ambient light affecting the read out of the TCRT5000 Manipulating the microcontroller to distinguish between a water bottle and aluminum can Water bottles not crushing Placement of how the object falls into the hopper affected if it was detected or not TCRT5000 Software Design Water bottles Ultrasonic Sensor Ambient light seemed to be an issue we did not expect. Ambient light affects what the sensor will read which in turn affect the coding. We needed to manipulate the code for the readout to determine if it was a can or bottle. Software was trouble but we were able to figure it out.

Questions