Task of the week	What I have did
Propose a final project masterpiece that integrates the range of units covered. By answering some questions.	I have analyzed the different things about my final project to developed a project model.

Week-10 :

Final project : - Solar automatic shredder

Who's done what beforehand ?

A shredder is a machine that reduces the size and tears up, different kinds of materials. Various types of shredders are available in the market like paper shredders, scrap metal shredders,...etc. They are used in different industries as per the type of material to be cut. They are available in different design. Based on the purpose of use, shredders can be categorized as consumer shredders and industrial shredders. The key difference between Industrial and Consumer shredder, is industrial shredders can be used in an industrial applictions instead of consumer applications.

1) Consumer Shredders : -

Paper shredder normally falls into the category of consumer shredder as mostly it is used by people for dispossing there personal document in there houses. In most of the

2) Industrial Shredders : -

Paper shredders (If they are used for industrial purposes), plastics shredders, Tire shredders and Scrap metal shredders are mostly used for the industrial applications. I have visited following sites for getting information about shredder.

Types of Industrial Shredders.

Types of paper shredders.

Supplieres of shredders

Things to be consider about shredders.

What will it do ?

The rular areas of India faces the problem related to energy cut-off and shredder is an important equipment to shred the dry matter for prepairing the daily feed(fodder) for animals. This machine runs with solar energy which is available to us free of cost in a day time. So, we can utilize this energy for running the shredder and we don't have to depend upon the grid power supply. To design a shredder which will start when there will be ample amount of sunlight is available. Which will runs with speed and will cut the brown matter for cattle feed inthe day time.

What will you design ?

The system is started with solar panel. They are further connected to the motors through Luminance LDR module, charge controller and relay. Here I am going to use two motors one is for rotating the cutting blades of system and second is to rotate the blades in hopper which convey the material towards cutting section.

When the sunlight falls on the solar panels first LDR sensor will séance the light .If sufficient intensity of sunlight is available then it will sent signal to my mobile and will ask me whether I want to start my motor or not. Then first I will load grass into the hopper and will press the ON button. This will send signal to the charge controller and relay circuit to trigger the motors and in this way my system will get on. When there is no grass inside the hopper then I will press the OFF button on my mobile to stop the motor.

For clearification about the system. I have divide the system into two part.



1) Hopper blades running through wiper motor : -

The system contain following components, connected with each other as follow.

Solar panels ⇒ Charge controller ⇒ Battery backup(12 Volt, 7 Amp) ⇒ Relay module(30 Volt, 10 Amp ) ⇒ Wiper motor for hopper(12 Volt 10 Amp)




In the above connections realy is trigger by the signal comming from atmega328p microcontroller. Also BH1750 light sensor which will sense the light intencity readings is powered by atmega328p as shown below.

BH1750 light detecting senser ⇐ ATmega328p microcontroller ⇒ Relay module(30 Volt, 10 Amp)

What materials and components will be used ?

Solar panels : -

A solar panel works by allowing photons, or particles of light, to knock electrons free from atoms, generating a flow of electricity. As I mensioned above this system is operates Here I am going to use two solar panels with different capacities. One which have the voltage rating of 120watt-12volt solar panel for driving 160watt wiper motor (Which operates on 12volt 10amp) and for the second DC motor of 250watt capacity which I am using for driving the cutting blades will operates with SMPS( AC to DC convertor ). Which have the capacity of 280watt. For more details visit the site.

BH1750 Light sensitive module : -

BH1750 is the ambient light sensitive module. This module is commonly used to detect ambient light. It is connected to the hopper motor through relay which is trigger by the signal from microcontroller (Atmega328p). It set output to LOW logic (on DO pin) if the light intensity is higher than set point. Here in this system I hvae set the limit to 500lux. BH1750 only supports to the digital output and not have the Analog output. The reason I am going to use this sensor for this project is; solar panels are connected to the conveyer blades which are continouslly in rotating condition.

In Ashram we are using small DC fans which are powered through solar panels, one day I have observed the variation in it's speed due to variation of sunlight. We can not allow this variation in the speed of conveyer blades. Because, if variation in the speed get happen, blades my get stope. Because the dry matter gradually block the baldes of hopper. Which will further damages the motor.

This sensor will be operated by the signal comming from the micro-controller and I have designed an Application for my android. On which I will get the readings of light intencity. If the intencity of sunlight is greater than 500lux then only I will turn on the motor by pressing the 'ON' button in the app. I have noted the time when the sun intensity is greater than 500lux by using Lux meter. We get the maximum intensity of sunlight from 9am to 4pm as per the Indian Stanserd Time. For more details visit the site.

Charge controller : -

A charge controller or charge regulator is basically a voltage and/or current regulator. It regulates the voltage and current from the solar panels to the system. Here in this system I have used the charge controller which will only allows 12volt, 10amp to the system.

Relay : -

A relay is an electrically operated switch. It consists of a set of input terminals for a single or multiple control signals, and a set of operating contact terminals. The switch may have any number of contacts, break contacts, or combinations thereof. In this system the relay will operate the hopper motor which is " 12 Volt, 10 amp wiper motor ".




Note : - The picture of the relay module shown below is downloaded from internet for describing relay. It is not the actual relay module I am using for my project.

The relay I am using for my project is the single channel electromechanical relay having the rating of 10Amp and 30Volt DC. Which means that this is the amount of voltage and current that the NC, NO or Common terminal of the relay could withstand and the load I am going to use for my project is 12Volt, 10Amp which can withstand by this relay.

Atmega328p micro-controller : -

ATMEGA328P is high performance, low power controller from Microchip. ATMEGA328P is an 8-bit microcontroller based on AVR RISC architecture. It is the most popular of all AVR controllers as it is used in ARDUINO boards. ATMEGA328P is a 28 pin chip as shown in pin diagram below.

Many pins of the chip here have more than one function. Where,

• VCC: Connected to positive voltage. Pin number 4 and 6 are VCC.

• GND: Connected to ground. Pin number 3 and 5 are GND.

• PB3 (MOSI/OC2A): MOSI (Master Output Slave Input). When controller acts as slave, the data is received by this pin. [Serial Peripheral Interface (SPI) for programming]

• PB4 (MISO): MISO (Master Input Slave Output). When controller acts as slave, the data is sent to master by this controller through this pin. [Serial Peripheral Interface (SPI) for programming]

• PB5 (SCK): SCK (SPI Bus Serial Clock). This is the clock shared between this controller and other system for accurate data transfer. [Serial Peripheral Interface (SPI) for programming]

• PC5 (ADC5/SCL): ADC5 (ADC Input Channel 5) SCL (Two-wire Serial Bus Clock Line)

• PC4 (ADC4/SDA): ADC4 (ADC Input Channel 4) SDA (Two-wire Serial Bus Data Input/output Line)

• PC6 (RESET): Pin by default is used as RESET pin. PC6 can only be used as I/O pin when RSTDISBL Fuse is programmed.

• PD0 (RXD): RXD (Data Input Pin for USART) USART Serial Communication Interface [Can be used for programming]

• PD1 (TXD): TXD (Data Output Pin for USART) USART Serial Communication Interface [Can be used for programming]

Motor of hopper blades : -

For blades in hopper which will convey the material towards cutting section I will use a Wiper motor with 12volt, 10amp i.e. 120watt power supply. Wiper motors are device that functions on a power supply in order to move the blades in a smooth motion. Like other motors, the wiper motor rotates continuously in one direction.

Lead acid battery : -

To avoid the fluctuations in the system I have used small battery backup of 12 Volt, 10 amp. Which is a lead acid battery. The reason I have include this in the system that we can not run the syetem directly on solar panel. We need to add some backup so that our system should run safely and continouslly.

BLDC motor : -

Initially I have desided to run this section with BLDC motor. But due to lockdown I have shifted on the electric motor. The BLDC motor will control with SSR(Solid State Relay) module with following specifications.

• DC Reversing Solid State Contactor

• Ratings of 20, 40, & 60Amps

• Load voltage ratings of 1-48 VDC

• Optional Soft Start w/Brake, Soft Start/Soft no Brake

• LED input status indicator. Green(Forward), Yellow(Reverse)

• DC control

• cULus Recognized, IEC Rated, CE & RoHS Compliant

A brushless DC electric motor (BLDC motor) also known as electronically commutated motor and synchronous DC motor, are powered by direct current (DC) electricity via an inverter. It also have the facility of switching power supply which produces electricity in the form of alternating current (AC) . It will drive each phase of the motor windings that control the speed and torque of the motor. This control system replaces the commutator (brushes) used in many conventional electric motors. The construction of a brushless motor system is similar to a permanent magnet synchronous motor (PMSM).

" Due to lockdown of COVID-19 we does not have access to the market for purchassing the project material. It is also not possible to buy the BLDC motor. So I am not using BLDC motor. "

2) Cutting blades running with electric motor : -

In this project of FAB academy I am running the system of cutting blade section with the power conversion system i.e. Switch Mode Power Supply.

230Volt AC power supply ⇒ SMPS(Switched-Mode Power Supply) ⇒ Electric Motor

SMPS : -

The Electric motor is running through SMPS which have the following specifications.

• Constant output voltage.

• Input voltage : - 110V/230V is selected by switch.

• Converts AC voltage to 24 V DC, LED indicator.

• Output current 20 Amp, Power 480 Watt. Efficiency more than 80%.

• Smart device surge protection for Shortage Protection, Overload Protection, Over Voltage Protection.

Electric motor : -

I am using the " electric DC motor " which was there in the campous of Vigyan Ashram. It is the motor which we use in E-bicycle.

For more details visit the site.

This motor have following specifications : -

• Output Power: 250 Watt.

• Rated Voltage: 24V

• Rated Speed: 360 RPM

• Full load Current: ≤13.4A

• No load Current: ≤2.2A

As I have mentioned I will run the hopper blade section with solar power. But to run the system directly on solar energy is not possible. Because avalability of sunlight is not constant it is variable. If we connecte this supply directly to the DC motor then the variation in the speed occers. So I have provieded the system with the small backup of 12 Volt 7 amp lead acid battry. This battery is connected between the Solar panels the wiper motor. This is a rechargable battery.

Mechanical System : -

Mechanical system is consisting of 2 sections :

1) Cutting section: - This section having 2 long blades connected each other to their centre perpendicular to each other. Further they are connected to universal motor through shaft.

2) Conveying blade section: - In this section the system is consist of following components.

a) Hopper :

The main function of the hopper is to store the dry material to be placed into the pulverizer for pulverizing. The pulverizer had a large hopper for storing the material and delivers it through conveying mechanism into the pulverizer. The hopper was provided for easy placement of dry material for shredding. Another purpose is to reduce the time required to put material into the pulverizer. The selection of the shape of the hopper was done with the basic consideration that hopper should carry the desired quantity of dry material and their bulk density. The hopper was situated at top of the conveying mechanism.

b) Blades :

The shredder blade plays a major role in the dry matter shredder machine. There are many types of shredder blades and the one which is used is a three-edged blade and tow edges blades. Space is also provided between each of the Blades for the shredded pieces to come down. The blades which were made up of MS sheet of 0.8 mm size, the dimension of the blade was selected from the hopper inclined portion, to convey the material through mechanism the blades are made mild steel and of length of different dimensions, four types of blade all blade fixed to the shaft with the help of the fixing nut.

C) Shaft :

In this chapter, the general design considerations related to to the plastic shredding machine are discussed. This chapter highlights on general design considerations and procedure of main components and accessory components of the developer conveying mechanism of pulverizer. The conveying of material is done by different conveying systems. Screw conveyor belts etc which was used to convey the material.

Main Shaft :

A shaft is a rotating machine element which is used to transmit power from one place to another. The power is delivered to the shaft by some tangential force and the resultant torque (or twisting moment) set up within the shaft permits the power to be transferred to various machines linked up to the shaft. The shafts are classified as follows,

Transmission shaft :

These shafts transmit power between the source and the machines absorbing power. The countershafts, line shafts, overhead shafts, and all factory shafts are transmission shafts. Since these shafts carry machine parts such as pulleys, gears chain and sprocket, etc, A 12 mm outer edge diameter high strength shaft was selected for the mechanism, they were cut into the three same lengths and single one took extra large for large sprocket mounting.

d) Bush and bearings :

The 6201 deep-grooved ball bearing were used for the mechanism. Deep-grooved ball bearing is used to transmit loads from rotating parts to housing with minimum friction loss. This will be obtained by a high hardness. minimize the deformation of the bearing elements. Single row deep groove ball bearing are the most widely used roller bearing type in the world due to their versatility and overall performance. The bush was made by the polypropylene material to fix the bearing into it. the polypropylene is a tough and rigid crystalline thermoplastic produced from propane or propylene monomer. It is a linear hydrocarbon resin. The chemical formula of polypropylene is C3H6.

e) Chain and sprocket :

Chain drives ,gear drives and belt drive system are all effective power transmission systems each offer advantages and disadvantages with respect to each other, A chain drive is relatively easy to installed assembly tolerance are not as restrictive as those for gear drive .chain performance better than the gear under shock loading conditions. Chain drive does not require tension on the sack side. Chain drive required less space for a given loading and speed condition than the pulley and belt. It is less costly to build and maintain. For the conveying mechanism, we used the 1.2 m chain, 5 small sprockets and one large sprocket to transmit the power from motor to the mechanism.

Where will come from ?

I have provided the links from where I will buy the above components for the project : -

Solar panels

Another link for Solar panels

BH1750 Luminance sensor.

Charge controller.

Relay module.

BLDC motor.

Electric motor.

Wiper motor.

Another link for wiper motor.

Atmega328p Microchip.

How much will they cost ?

• Solar panel: Rs. 6,090

• BH1750 light sensor: Rs. 129

• Charge controller: Rs. 500

• Relay module: Rs. 271

• BLDC motor: Rs. 11,600

• Electric motor: Rs. 4000

• Wiper motor: Rs.3,450

• Atmega328p: Rs.138.74

From the above components I have used Electric motor instead of BLDC motor which operates with same efficiency.

So, the total cost of components : - 6,090+138+129+500+271+4000+3,450 = Rs. 14,578

What parts and system will be made ?

In this project I will design and fabricate the following things : -

• Conveying section which involves : -

1) A foldable hopper

2) Conveying blades of different shapes.

• Design and milling of the PCB for controlling the system.

• Design the casing for the electronic components in the system.

• The casing design for BH1750 light sensor and it's holder.

• Here is the project plan : -

What processes will be used ?

• I will use Solidworks software for designing all components I have mensioned above.

• Foldable hopper and conveyer blades invovles the Plasma cutting operation which is the degital fabrication process.

• I will use SRM-20 maechine for milling the PCB.

• To made a casing for electronic component I will use Laser cutter.

• I am going to use 3D printer for the casing of BH1750 light sensor.

For designing and manufacturing above components I will use following tools.

What questions need to be answered ?

I will design this system to run with solar power. So that people should not depend upon the grid power supply to preparing the feed for animals.

• Does the system works properly on solar energy.

• It should cut the matter in the required size.

• Does it is beneficial for the rural people.

How will it be evaluated ?

Cutting of dry matter with DC power is a heavy duty operation. It require more electricity which leads with cost of overall system. Solar system invalvs large installation cost. This cost should be get reduesed. By using less costly components which gives effective operation of the system. It should be properly work on the solar system. This project is especially for rular areas of India. So, this project should get evaluate on the output from the rular people.