Design of Shredder and textile waste clothes recycling machine

Transcription

1 Design of Shredder and textile waste clothes recycling machine Assist. Prof. Dr. Jassim Mohammad Abdulkarim 1, Shadi Bakr Ahmed 2 1 Assist. Prof in Sulaimani Polytechnic University- College of Technical Engineering- Sulaimani IRAQ 2 Master student in Sulaimani Polytechnic University- College of Technical Engineering- Sulaimani IRAQ ABSTRACT Recycling is one the most important actions that have both environmental and economic benefits and recycling waste clothes is the one type of material recycling. This paper presents the design of Shredder and textile waste clothes recycling machine that used to convert waste and old clothes to a new product that it can be used again. Our design consists of three parts, the first part is shredder machine that cut waste clothes, and is consist of the three main parts; they are system drive, a shaft with seven blades rotating cutter and hopper. The second part is flat belt conveyor that used to transfer cut waste clothe from shredder to the textile machine, and the capacity of the belt depend on the area, volume, and density. The third part is textile machines that textile cut clothes to a useful product such as (fabric, nonwoven, fiber, yarn, rag, and etc ) by cylindrical card or (taker-in) roller that consists of many teeth, the quality and size of the final product depend on the teeth angle. Therefore calculations for our design were done for all part in each machine. Also safety factor was found four shredder machines, and all of the machine parts are displayed by 2D, 3D drawing. Keywords: Recycling clothes, shredder machine, belt conveyor, textile machine, safety factor. 1. INTRODUCTION Recycling is a process that bringing material or product at the end of its usable life and turning it into a usable raw material to make another product or to change other useful product. Waste processing technologies containing the secondary processes make possible waste utilization on the basis of methods (chemical, resources, thermal, material, and biological) recycling, but material recycling is the most available and the most often used method of recycling. It depends upon following direct waste processing with the aim of material obtaining which is full value raw material to the further processing[1]. In addition, many of the waste clothes and the fibrous waste are constitute of natural synthetic polymeric materials such as nylon, polyester, polypropylene, and cotton, among others material. "Typically recycling technologies are divided into primary, secondary, tertiary, and quaternary approaches. Primary approaches involve recycling a product into its original form; secondary recycling involves melt processing a plastic product into a new product that has a lower level of physical, mechanical and/or chemical properties. Tertiary recycling involves processes such as pyrolysis and hydrolysis, which convert the plastic wastes into basic chemicals or fuels. Quaternary recycling refers to burning the fibrous solid waste and utilizing the heat generated; all these four approaches exist for fiber recycling"[2]. Also Textile waste recycling is the process which tends to recycle clothes and convert to new clothes that can be used in different form, and the same kind of clothes depending on the nature, substance, and type of recyclable. So the best and efficient way to develop new products under sustainability is to increase demand and textile recycling [3]. 1.1 Roles of recycling Recycling has both environmental and economic benefits. a. Recycling helps to conserve natural resources b. Recycling helps to save money. c. Recycling conserves energy. d. Recycling saves landfill space e. Recycling provides jobs for people f. Recycling provides alternate materials [4]. Volume 6, Issue 1, January 2018 Page 1

2 1.2 LITERATURE REVIEW: 1.2.1SHREDDER MACHINE: Shearing is an action involves the actual cutting of material; the tolerance of the space between cutting edge and sharpness of the cutting edges effect on the shearing efficiency. Therefore, in figure (1) an industrial shredder is designed and described to shred the most types of materials, such as rubber, plastic, wood, paper, metals, clothes, and etc... Which contain two shafts inversely-rotating and there are parallel to each other(1), where each shaft are keyed disc shaped blades (2) and each blade has one or more teeth (3), separated with busher (4) the thickness of the blade and busher are same, but diameter is smaller than the blades, so that the spacers (4) of the first shaft are blades and a diameter smaller than the blades one, so that the blades (2) of the one shaft are opposed to the spacers (4) of the second shaft, one shafts (1)so spaced that the blades of first shaft cross with other of the shaft to force the material poured into an upper cutting chamber (7) to be sheared between blades, and hollow supports (14) having a circular view (15) it fixed blades (17), which interact with blades (2) to operate cutting process, material already sheared between the opposed blades and fixed supports (14) extending until they almost come into contact with the spacers (4) of the other shaft to perform cleaning thereof [5]. Figuer1 Shredder machine [5] MECHANISMS OF TRANSMISSION SPEED AND POWER BY BELT OR ROBE DRIVE: The belts or ropes are used to transfer power and speed from one shaft to another by means of pulleys which rotate at the same speed or at different speeds. The quantity of power transferred depends on the (the speed of the belt, the tightness under which the rope is located on the pulleys, the arc of contact between the smaller pulley and the rope). Also, there many factor the affect for selections of a belt drive which are: 1. Speed of driven shafts and the driving 2. Power to be transferred. 3. Speed reduction ratio. 4. Positive drive necessities.. 5. Distance between the centers of the shafts. 6. Available space. 7. Shafts design. 8. Administration states [6] BELT CONVEYOR: Belt conveyor is the transformation of material from one space to another space. It has simple design, high load carrying capacity, easy maintenance, high reliability of operation, and long length of conveying path, also Conveyor belt system is used in material transfer in ground shop like distribution and supply of molding sand, removal of waste and molds, during the project design stage for the transport of raw materials or finished products, the choice of the method must favor the most cost effective solution for the volume of material moved; the plant and its maintenance; its Volume 6, Issue 1, January 2018 Page 2

3 flexibility for adaptation and its ability to carry a variety of loads and even be overloaded at times and it shown in figure (2), the parameters that needs for design belt conveyors are (drive pulley shaft, power, belt width, and belt speed)[7]. Figure 2 Basic drawing of a belt conveyor [7] CARD OR TEXTILE MACHINE: Carding or textile process utilizing a brush attached to a cylinder carding machine for inhibiting the buildup of napped fibers. Mounted just downstream of the transfer region where carding takes place, the brush is stationary with respect to the revolving cylinders, the brush is disposed across the face of the carding drum with the nylon bristles of the brush engaged in the card cloth wires of the drum. The bristles continuously brush, straighten and force napped fibers down into the wires of the carding cylinder, which results in a thicker, heavier web of carded fibers and virtually eliminates buildup of fluffy fibers on the carding drum as well as the input drum shown in figure(3) [8] EFFECT OF TOOTH ANGLE ON THE CARDING: The teeth that used in carding, garmenting and similar working of natural and synthetic fibers, have been made with the front or working edges thereof at various angles to the direction of tooth movement. In some instances, the said front or leading edges lean forwardly or in the direction of tooth movement. In other cases, the tooth edge leans backwardly; and in still other cases, the forward edge of the tooth is normal to the direction of movement. If the angle of lean is too great in the forward direction, there is a tendency for some staples to load on the tooth. If the angle of leaning is too great to the rear, less carding, garneting, or working of the staple takes place. If the forward edge of the tooth is normal to the direction of tooth movement, too little carding will take place with some staples and with other staples the tooth will tend to load. The tooth is superior functionally also to teeth whereof the leading or working edge is normal to the direction of carding movement shown in figure (4) [9]. Figure 3 Carding process[8] Figure 4 Tooth angle [9] 2. METHODOLOGY 2.1 PROPOSED OUR DESGIN FOR SHREDDER AND TEXTILE WASTE CLOTHES RECYCLINE MACHINE The idea of this design is combine two machines (shredder and textile machine), the idea of design shredder is to cut the waste clothes and textile machine to convert this cut clothes to useful and new product such as (fabric, nonwoven, rag, yarn, fiber, and etc...) that we can use again, and between this two machines I put flat belt conveyor to transfer clothes from shredder to textile machine, all part of machine it shown in figure (5-a,5-b) by 2D and 3D. In addition, Volume 6, Issue 1, January 2018 Page 3

4 each machine separately worked by electrical motor because it has many advantages such as (low cost, low noise, essay to start, etc ).The objective of this idea is beneficial to (reduce the work step, conserve raw material, lower power consumption, safe land spaces, and avoid transportation of material from one factory to other factory machines to mi). Also, it is a very simple machine and easy to change all its part it consists of the following parts: Figure 5-a 2D drawing for shredder and textile machine. Figure 5-b 3D drawing for shredder and textile machine. 2.1 SHREDDER MACHINE This machine used to cut clothes, the shredder is consist of two shafts and each shaft has seven blades that connected with the shaft by flat key and between two blades there is one busher. Which transmit torque and speed from the electrical motor through belt and pulley type vee to shaft one, and second shaft is counter-rotating with shaft one, and it transmit power and speed from shaft one by spur gear which is equal in diameter to rotate in same (r.p.m), also two bearing need for each shaft to support shaft. The all part of shredder machine are shown in figure (6). Figure 6 2D and 3D of shredder machine Volume 6, Issue 1, January 2018 Page 4

5 2.2 BELT CONVEYOR: I use flat belt conveyor to transfer cut clothes to the textile machine. It consists of two flat rollers (driver and driven) which is rotated by the electric motor as shown in figure (7). Figure 7 2D and 3D of flat belt conveyor. 2.3 TEXTILE MACHINE: It s the third and final part of the design it used to textile waste clothes to the new and useful product, and it consists of two feeding rollers and one cylindrical card or (taker-in) roller which transmit power and speed from the electrical motor through belt and pulley showed in figure (8). The rotating of the feeding roller should be slower than taker-in roller for this reasons we need use a smaller pulley on the taker-in roller and pig pulley on the feeding roller and connected by a belt. Taker-in roller has many teeth to carding clothes and the angle of the teeth which effect on the final product. Figure 8 3D Textile machine 3. THEORETICAL DESIGN AND RESULT FOR PROPOSED DESIGN 3.1 DESIGN OF SHREDDER MACHINE: All part of the shredder machine designed by this way: PULLEY AND BELT The principle work of shredder is the rotation of shaft by using a motor and transmitting the torque from the motor to shaft through the belt by using pulley shown in figure (9), and this needs a motor when the capacity of motor is equal to 3.5 KW, and 500 R.P.M. all equation for determining the torque of motor, diameter of each pulley, load that obtained from pulley and belt and all assumed data that need for calculation belt and pulley I took from [10], and also it shown in table (1) Volume 6, Issue 1, January 2018 Page 5

6 Figure 9 Vee pulley Volume 6, Issue 1, January 2018 Page 6

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8 3.1.2 DIAMETER OF THE SHREDDER ROLLER SHAFT. The shaft of shredder machine is subjected to combined stresses due to the application of bending strength (σ) and torsional strength (τ), one can determine the diameter of this shaft, and this will need to find the maximum bending moment (Mb) by vertical plane, horizontal plane, torque (T) and torsional strength (τ Mpa), all part of the shredder shaft shown in figure (10). Figure 10 All parts of shredder shaft To find the shear force (F) applied to the shaft can be determined by the ultimate shear strength (τ =40MPa) for polyester elastomer [11] and all assumed data that need for this part shown in table (1) and area of cutting (A= 1750 mm²) when contact to clothes the shear will accrue it shows in figure (11), and by using equation (17) we can find (F). This shear force for one blade and we have seven blades. So the value of (F) equals to each blade. (18) Figure 11 Blade The transmission torque form motor to shaft by pulley and belt can find by this equation Volume 6, Issue 1, January 2018 Page 8

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14 Figure14-a Vertical shear force and bending moment diagram for shredder shaft Figure 14-b Horizontal shear force and bending moment diagram for shredder shaft Volume 6, Issue 1, January 2018 Page 14

15 In theoretical design it appear that one belt cannot withstand this load because when we found maximum stress of belt the result less than the stress allowable. Also it not needs two find the diameter of the second shaft because we took shaft that have maximum load so the maximum diameter that withstand this load is (17cm). In addition safety factor was found for torsion and bending stress and torsional stress according to Sodar berg and Good man diagram it has higher safety factor, and type of dynamic load its repeated cycle because (. Finally it appears that life of deep groove ball Bering for third part of the machine is more than hours. 4. CONCLUSION 1- Recycling is a complex method of environment protection, which aim is to conserve raw materials consumption and a decrease in waste quantity. 2- The machine can be used for shredding and textile waste clothes. 3- It is easy to maintain all parts. 4- Each part can work separately it means the product line continuous. 5- Lower noise and good. 6- It has high performance it can recycle different type of clothes. 7- It has a very simple machine structure, can be easily cleaned, and all item is easily changed. Table 1: All assumed data that need for calculation Specification Symbol Quantity Unit Speed for shredder motor N 500 r.p.m Motor power for shredder N 3.5 kw Belt width B 6 mm Belt thickness S 4 mm Minimum diameter 32 mm Factors 1.4,1,1.11,1.05,1.2,1,1 Unit less Reduction ratio i 1.8,1.6,2 Unit less Ultimate shear strength Τ 250 Mpa for polyester elastomer Angle for spur gear 20 Gear diameter 200 mm Thickness of blade cm Width of blade - 5 cm Number of blade Ultimate shear stress for steel Τ 250 Mpa Temperature factor Ft 1 - Speed factor for (280 and 257) rpm Fn 0.55, 0.51 Thickness of key (2.3,7.9) mm Width of key B 32 mm Ultimate shear stress for steel 250 Mpa Bearing stress for steel 150 Mpa Belt width B 800 mm Belt of the belt S 10.1 mm Length of belt conveyor L 2000 mm Density of rubber clime 560 Kg/ Volume 6, Issue 1, January 2018 Page 15

16 Hopper open width 0.3 m Hopper open length 0.3 m Belt speed V 3 m/s diameter of the roller belt conveyor Dr 250 mm Motor power for textile machine N 2 kw Speed for textile machine N 400 Outer Radius of the cylindrical roller Inner Radius of the cylindrical roller 250 mm 150 mm Density of the wood 450 Kg/ Minimum yield stress for st Kg/mm² Tensile strength for st Kg/mm² Table 2: All nomenclatures Volume 6, Issue 1, January 2018 Page 16

17 REFEENCES [1]. M. Spilka, A. Kania, and R. Nowosielski, Integrated recycling technology, nternational OCSCO World Press, vol. 31, no. 1, pp , [2]. Y. Wang, Y. Zhang, M. Polk, S. Kumar, and J. Muzzy. Recycling of carpet and textile fibers. A Handbook, Edited by A. L. Andrady (John Wiley & Sons, New York, 2003), , pp. 1 27, [3]. I. Muhammad. German textile recycling benchmarking. HAMK University of applied sciences. Supply Chain Management, Degree program, Bachelor's Thesis. [4]. P. For and U. S. Customers, Recycling Program, [5]. F. Rota. TWO-SHAFT INDUSTRIAL SHREDDER. United States patent , Nov. 3, [6]. Khurmi, R. et al. Theory of Machines.14th ed.; S. Chand & Co. Ltd., New Dehli 2005; ISBN [7]. K. N. S. Ananth, V. Rakesh, and P. K. Visweswarao. Design and Selecting the Proper Conveyor-Belt.Int. J. Adv. Eng. Technol. E, vol. IV, no. Ii, pp , [8]. R.N.Duncan, E.Clackamas. CARDING MACHINE HAVING A FINEFIBER BRUSH.U.S. Patent, 5,333, 357, Aug. 2, [9]. J. D. Hollingsworth. CARDING TOOTH. U.S. Patent, 2,937,413, MAY 24, [10]. G. Niman. Mshine Elements:Design and Calculation in Mechnical Engineering. Volume II,New Delhi Bombay Calicultta Madras Bangalore,1978. [11]. F.P.Beer, E.A.Johnston, and J.T.DEWOLF. MECHANICS MATERIAL. Fourth Edition,NEWYORK: MCGrraw-Hill,2006. [12]. F. Dunlop. Conveyor handbook. Australia.update June, Volume 6, Issue 1, January 2018 Page 17