Scrap Metal03

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Introduction

SCRAP METAL:Scrap metal is a term used to describe recyclable metals left over

from every industrial production. It also includes any old metal,and any broken,worn out, defaced or partly manufactured articles made wholly or partly ofmetal and any metallic wastes.

Uses: The scrap industry processes more than 145 million tons of recyclablematerial each year into raw material feedstock for industrial manufacturingaround the world. The industry contributed $65 billion in 2006 and is one of thefew contributing positively to the U.S. balance of trade, exporting $15.7 billion inscrap commodities in 2006.

Scrap recycling also helps reduce greenhouse gas emissions and conserves energyand natural resources. For example, scrap recycling diverts 145 million tons ofmaterials away from landfills. .

SCRAP IRON CARRIER:

It means a vehicle to carry scrap iron. In order to carry huge amount of scrapiron we are introducing a new type of scrap iron carrier.

Background

Scrap is often taken to a wrecking yard where it is processed for latermelting into new products. A wrecking yard, depending on its location,may allow customers to browse their lot and purchase items . Customersare typically required to supply all of their own tools and labor to extractparts, and some scrapyards may first require waiving liability for personalinjury before entering.

In the scrap metal industry a great potential exists for accidents in which ahazardous material present in scrap causes death, injury or environmental

damage. A classic example is radioactivity in scrap; see the Goiniaaccident for an example of an accident involving radioactive materialwhich entered the scrap metal industry and some details of the behavior ofcontaminating chemical elements in metal smelters. So to avoid injuriesand environmental damage we need srap metal carrier.


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Objective

To make the sorting easy in a wrecking yard.

To ensure the safety of the customers in a wrecking yard.

To avoid the environmental damage such as radioactivity.

To carry the scrap metals in an organized way.

To separate the metals and non-metals.

To increase the rate of sorting metals.

Design

The design can be divided into three steps:

Mechanical part

Electrical part

Controller part

MECHANICAL PART:

Components:

1. ShaftMaterial : Alumnium

Dimension : length -1.5 ftdia. - 2 inch

Coupled to stepper motor and rotates 180degree clockwise and anticlockwise along with thetruss.Aluminium shaft has been used due to its lowweight and high ductility.


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2. TrussMaterial : G.I. wireDimension : 1.5 ft

The truss is fabricated from straight pieces of metalto form a series of triangles lying in a single plane.A trianglecannot be distorted by stress.The truss gives a stable formcapable of supporting considerable external load over alarge span with the component parts stressed primarily inaxial tension or compression.The individual pieces intersect

at truss joints,or panel points.The connected pieces formingthe top and bottom of the truss are referred to respectivelyas the top and bottom chords.The sloping and vertical piecesconnecting the chords are collectively referred to as the webof the struss.For this project G.I. wire of 3 mm diameter hasbeen used to make an attractive truss.

3. PlatformMaterial : WoodDimension : 1ft*1ft

Stationary platform has been used to provide stability.

Ball bearing along with the shaft is fixed into it.Holder plateof the stepper motor is attached to the bottom side of thePlatform.

4. Two GearsMaterial : PlasticDimension : same module and dia.

A gear is a component within a transmission device that transmits rotation ional

force to another gear or device. A gear is different from apulley in that a gear is a roundwheel which has linkages ("teeth" or "cogs") that mesh with other gear teeth, allowing
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force to be fully transferred without slippage. Depending on their construction andarrangement, geared devices can transmit forces at different speeds, torques, or in adifferent direction, from the power source.

The most common situation is for a gear to mesh with another gear, but a gear can mesh

with any device having compatible teeth, such as linear moving racks.

A gear's most important feature is that gears of unequal sizes (diameters) can becombined to produce a mechanical advantage, so that the rotational speed and torque ofthe second gear are different from that of the first. In the context of a particular machine,the term "gear" also refers to one particular arrangement of gears among otherarrangements (such as "first gear"). Such arrangements are often given as a ratio, usingthe number of teeth or gear diameter as units. The term "gear" is also used in non-geareddevices which perform equivalent tasks:

In the scrap iron carrier two gears of same diameter and module has been used.One of

them is coupled with the stepper motor which meshes with the other gear.For theclockwise and counterclockwise rotation of the first gear the second one rotates in theopposite direction.The second gear is attached to the truss and causes the truss to moveupward or downward direction.

5. BearingMaterial : SteelDimension : Dia.-1.5 inch

The function of a ball bearing is to connect two machinemembers that move relative to one another in such a mannerthat the frictional resistance to motion is minimal.The shaft istightly fixed with the inner race of the bearing.The surfaces inthe bearing are separated by balls;they are known as rollingbearings.

6. Holder PlateMaterial : SteelDimension : 4inch*4inch
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The holder plate which is attached to the platform holdsthe stepper motor at a position suitable for the motor to becoupled with the shaft.

7. Solenoid [U-shaped]

Material : Mild SteelDimension : Length-6 inch

A solenoid (1827, fr.solnode, gr.solen "pipe, channel" + comb. form of gr. eidos"form, shape"[1]) is a three-dimensionalcoil. Inphysics, the term solenoid refers to aloop of wire, often wrapped around a metallic core, which produces amagnetic fieldwhen an electric current is passed through it. Solenoids are important because they cancreate controlled magnetic fields and can be used as electromagnets. The termsolenoidrefers specifically to a magnet designed to produce a uniform magnetic field in a volumeof space (where some experiment might be carried out).

In engineering, the term solenoid may also refer to a variety oftransducerdevices thatconvert energy into linear motion. The term is also often used to refer to asolenoid valve,which is an integrated device containing an electromechanical solenoid which actuates

either apneumatic orhydraulic valve, or a solenoid switch, which is a specific type ofrelay that internally uses an electromechanical solenoid to operate an electrical switch;for example, an automobile starter solenoid, or a linear solenoid, which is anelectromechanical solenoid.
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Electromechanical solenoids consist of an electromagnetically inductive coil, woundaround a movable steel orironslug (termed the armature). The coil is shaped such thatthe armature can be moved in and out of the center, altering the coil'sinductance andthereby becoming an electromagnet. The armature is used to provide a mechanical forceto some mechanism (such as controlling a pneumatic valve). Although typically weak

over anything but very short distances, solenoids may be controlled directly by acontroller circuit, and thus have very low reaction times.

The force applied to the armature is proportional to the change in inductance of the coilwith respect to the change in position of the armature, and the current flowing through thecoil. The force applied to the armature will always move the armature in a direction thatincreases the coil's inductance.

The magnetic field inside a solenoid is given by:

where henries per meter, B is the magnetic field magnitude in teslas,n is the number of turns per meter, I is the current inamperes, N is the number of turnsand h is the length of the solenoid in meters. See also:Electromagnet.

8. Counter weight

Material : Mild Steel

As the stepper motor cannot provide sufficienttorque counter weight is used to balance the truss.

Mechanical System: flow chart

Initial position

Arm moves down 50 degree

Magnetization

Arm moves up 50 degree
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Shaft rotates 180 degree counter clockwise

Arm moves down 50 degree

Demagnetization

Arm moves up 50 degree

Shaft rotates 180 degree counter clockwise

Returns to initial position

After supplying power the truss will come down and the solenoid will be magnetized.Then it will pick up the scrap metal and rise upto the beginning height.Now the shaft

will rotate a certain angle .Again the truss will come down, the solenoid will getdemagnetized and the scrap metal will be delivered to the destination.

ELECTRICAL PART:

Components:

Relay:A relay is an electrical switch that opens andcloses under the control of anotherelectrical circuit.In the original form, the switch is operated by an

electromagnet to open or close one or many sets of contacts.Because a relay is able to control an output circuit of higher power

than the input circuit, it can be considered to be, in a broad sense,a form of an electrical amplifier.

Microcontroller:
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A microcontroller (also MCU or C) is a functional computersystem-on-a-chip. It

contains a processor core, memory, and programmableinput/output peripherals.

Microcontrollers include an integrated CPU, memory (a small amount of RAM, programmemory, or both) and peripherals capable of input and output.[1]

It emphasizes high integration, in contrast to a microprocessorwhich only contains aCPU (the kind used in a PC). In addition to the usual arithmetic and logic elements of ageneral purpose microprocessor, the microcontroller integrates additional elements suchas read-writememory for data storage, read-only memory for program storage, Flashmemory for permanent data storage, peripherals, and input/output interfaces. At clockspeeds of as little as 32KHz, microcontrollers often operate at very low speed compared

to microprocessors, but this is adequate for typical applications. They consume relativelylittle power (milliwatts or even microwatts), and will generally have the ability to retainfunctionality while waiting for an event such as a button press or interrupt. Powerconsumption while sleeping (CPU clock and peripherals disabled) may be just nanowatts,making them ideal for low power and long lasting battery applications.

Microcontrollers are used in automatically controlled products and devices, such asautomobile engine control systems, remote controls, office machines, appliances, powertools, and toys. By reducing the size, cost, and power consumption compared to a designusing a separate microprocessor, memory, and input/output devices, microcontrollersmake it economical to electronically control many more processes.

IC ULN2003:

IC 7805:
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IC 7812:

Transformer :(12-0-12)V ,6A

A transformer is a device that transferselectrical energy from one circuitto anotherthroughinductively coupledelectrical conductors. A changing currentin the first circuit(theprimary) creates a changing magnetic field. This changing magnetic field induces achanging voltage in the second circuit (thesecondary). This effect is called mutualinduction.

If aload is connected to the secondary circuit, electric charge will flow in the secondarywinding of the transformer and transfer energy from the primary circuit to the loadconnected in the secondary circuit.

The secondary induced voltage VS, of an ideal transformer, is scaled from the primary VPby a factor equal to the ratio of the number of turns of wire in their respective windings:

By appropriate selection of the numbers of turns, a transformer thus allows an alternatingvoltageto be stepped up by makingNS more thanNP or stepped down, by making itless.

Transformers are some of the most efficient electrical 'machines',[1] with some large unitsable to transfer 99.75% of their input power to their output.[2] Transformers come in arange of sizes from a thumbnail-sized coupling transformer hidden inside a stagemicrophoneto huge units weighing hundreds of tons used to interconnect portions ofnationalpower grids. All operate with the same basic principles, although the range ofdesigns is wide.
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Diode:

6A.

In electronics, a diode is a two-terminal device ( thermionic diodes may also have one ortwo ancillary terminals for a heater).

Diodes have two active electrodes between which the signal of interest may flow, andmost are used for their unidirectionalelectric current property. The varicap diode is usedas an electrically adjustable capacitor.

The directionality of current flow most diodes exhibit is sometimes generically called therectifyingproperty. The most common function of a diode is to allow an electric currentto pass in one direction (called theforward biasedcondition) and to block the current inthe opposite direction (the reverse biasedcondition). Thus, the diode can be thought of asan electronic version of a check valve.

Real diodes do not display such a perfect on-off directionality but have a more complexnon-linearelectrical characteristic, which depends on the particular type of diodetechnology. Diodes also have many other functions in which they are not designed tooperate in this on-off manner.

Early diodes included cats whisker crystals and vacuum tube devices (also calledthermionic valves). Today the most common diodes are made from semiconductormaterials such as silicon orgermanium.

Battery

12V, 4.5A

Capacitor:

A capacitor is apassiveelectrical component that can store energy in theelectric fieldbetween a pair ofconductors (called "plates"). The process of storing energy in thecapacitor is known as "charging", and involves electric charges of equal magnitude, but
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opposite polarity, building up on each plate. A capacitor's ability to store charge ismeasured by its capacitance, in units offarads.

Capacitors are often used in electricandelectronic circuits as energy-storagedevices.They can also be used to differentiate between high-frequency and low-frequency signals.This property makes them useful in electronic filters. Practical capacitors have seriesresistance, internal leakage of charge, series inductance and othernon-ideal properties notfound in a theoretical, ideal, capacitor.

Capacitors are occasionally referred to as condensers. This term is considered archaic inEnglish, but most other languages use a cognate ofcondenserto refer to a capacitor.

A wide variety of capacitors (see photos) have been invented, including smallelectrolyticcapacitors used in electronic circuits, basic parallel-plate capacitors, mechanical variablecapacitors, and the earlyLeyden jars, among numerous othertypes of capacitors.

Heat sink:

A heat sink(orheatsink) is an environment or object that absorbs and dissipates heat

from another object usingthermal contact(either direct or radiant). Heat sinks are used

in a wide range of applications wherever efficient heat dissipation is required; majorexamples include refrigeration
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Heat sinks function by efficiently transferringthermal energy ("heat") from an object at arelatively high temperature to a second object at a lower temperature with a much greaterheat capacity. This rapid transfer of thermal energy quickly brings the first object intothermal equilibrium with the second, lowering the temperature of the first object,fulfilling the heat sink's role as a cooling device. Efficient function of a heat sink relies on

rapid transfer of thermal energy from the first object to the heat sink, and the heat sink tothe second object.

The most common design of a heat sink is a metal device with many fins. The highthermal conductivity of the metal combined with its large surface area due to the finsresult in the rapid transfer of thermal energy to the surrounding, cooler, air. This cools theheat sink and whatever it is in direct thermal contact with. Use offluids(for examplecoolants in refrigeration) andthermal interface material (in cooling electronic devices)ensures good transfer of thermal energy to the heat sink. Similarly a fan may improve thetransfer of thermal energy from the heat sink to the air by moving cooler air between thefins.

Veroboard:

Motors:

We used two stepper motors.

1. Vexta stepper motor (24V & 0.3A)

2. xingsufu stepper motor (5V & 1A)

Block diagram:

Circuit Diagram:

:
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Controller part: we used a microcontroller Atmega32L.

Algorithm:

We have used AVRstudio4 to code the algorithmThe code used is given below:

#include #include int main(){

DDRA=0x0F;DDRD=0x0F;DDRB=0x0F;unsigned int i; // arm drops 60 deg

_delay_loop_2(65535);_delay_loop_2(65535);_delay_loop_2(65535);_delay_loop_2(65535);

for(i=0;i


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for(i=0;i


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{_delay_loop_2(65535);

}

for(i=0;i


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We were not getting maximum flux from the solenoid; so we bend the two ends toderive maximum flux.

Applications & Commercialization:

In the wrecking yard.

In the ship breaking yard.

In the car repairing industries.

Future Development:

The scrap metal carrier can be designed in such a way that it can collect anddeliver scrap metal more than one time at a single rotation.

It gives only two dimensional movement.Further improvement can be made todevelop three dimensional movement.

If the scrap iron is too heavy, then the solenoid consumes more power andgenerates more heat.

Further improvement can be done so that the carrier itself can find scrap metal;and deliver it to the desired place.

To make the sorting more perfect,sensors can be used.

Merits:

This project is very much cost effective.

The system is fully automated.So it requires less man power and reduces cost.


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This system is precise since there is no human controlled device.

It is more efficient and fast ,thus reducing working hour.

Materials used in this project are locally available.

Since we are using solenoids for lifting the scrap iron,they can be of irregularshapes to derive maximum magnetization.

COST ANALYSIS:

No. Components Materials

Dimension

Quantity

UnitPrice

Total(TK)

MECHANICALPART

01 Shaft Aluminium 1.5ft 01 585 585

02 Gears Plastic Same dia &module

02 30 60

03 Truss G.I.wire 1.5ft 01 45 4504 Platform Wood 1ft* 1ft 01 150 15005 Bearing High

carbonsteel

OD =1.5inchID=1 inch

01 30 30

06 Holder plate Mild steelpart

4*4 inch 01 Weldingshop

0

07 Solenoid Mild steelrod

08 Counter weight Alloy steel 750gm 01 150 150

09 Nut & bolts Alloy steel 20 pairs 02 80

ELECTRICALPART

01Transformer 12V -6A 01 180 180

02 Battery 12V-4.5A 01 400 40003 Diode 6A 04 6 24


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04 Capacitor 50V-4700uf 02 50 10005 IC ULN 2003 03 20 60

06 Resistor 10K 05 01 0507 Stepper motor 01 24V-0.3A 01 350 35008 Stepper motor 02 5V- 1A 01 350 350

09 Verroboard 02 20 4010 Breadboard 01 250 25011 Transistor 7805 01 15 15

12 Transistor 7812 01 15 1513 Microcontroller ATmega32L 01 160 16014 Rail 03 15 45

15 Electrical wire normal 10 gauge 12 12016 Heat sink Metal plate 02 01 02

Total cost: 3220

Conclusion:


19/21

We really enjoyed doing our project.It helped a lot to enhance our concept aboutmany things and apprehend that there is a lot of difference between theory and inpractice.For unavailability of required quality components,our inexperience,we could notaccomplish our desired goal.But we think the students of upcoming batches will try toimprove this project.


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Scrap Metal03

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