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Requirements for the electronics

A project log for Aluminum Recycling Micro Factory

What if you could recycle your aluminum cans at home and could process a large volume of cans semi-autonomously?

hominidaehominidae 05/28/2020 at 23:360 Comments

This is a brief description of the electronics requirements:

First, we'll need a Raspberry Pi or an Arduino to control things. Among the system's being controlled by the Raspberry Pi or Arduino will be a UL listed voltage relay and PID controller to supply power to the kiln heating wire inside the forge. This will have it's own temperature sensor to measure the temperature inside the forge during operation.

Next, a motor controller will need to supply power to the Windshield Wiper motor shredder and it will need to have a sensor to detect the current being drawn by the windshield wiper motor. The current sensor will need to periodically measure for a surge in current which would indicate a jam. The motor controller will need to go through a jam clearing process that involves reversing polarity to go into reverse and back to forward and repeat this several times until the jam is cleared. The Arduino or Raspberry Pi will need to raise an alarm condition if the jam cannot be cleared automatically and user interaction is needed to clear the jam. Safety features will need to be setup so that in the process of clearing a jam any operator of the system is not put in danger of losing fingers or electrocution.

Additionally, two stepper motors will be needed. One will be for moving a conveyor belt or gate for the shredded pop can material into the forge inlet and another stepper motor will be needed in order to raise and lower a lead screw that tilts a graphite crucible inside the forge and dumps the content of the crucible into a steel spigot that the molten aluminum pours into a revolving tray of bread pan baking trays at aluminum recycling miro factory at it's base. This might need to be another stepper motor, but it can also likely be accomplished using a more affordable low RPM DC motor and a position sensor.

The entire system operation would entail pre-heating the forge with the PID controller, dumping the contents of a plastic bag full of popcan's into the hopper, turning the system on and the shredder would begin shredding and the stepper motor conveyor belt or gate would direct the contents into the forge inlet where it's dropped into the crucible where the contents are melted, it's likely that the stepper motor can be installed on some form of load cell to detect the weight of contents inside the crucible and once a certain threshold is reached, the lead screw can dump the contents onto the spigot plate and be directed into a series of the baking trays revolving at the system's base.

It's likely that additional safety precautions are needed as well. However, the whole system should be able to have a camera and web based monitoring system, a physical warning bell/siren and other safety features involved.

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