1. ME 4182 Final Presentation Manual Trash Compactor December 06, 2006 Team Moondogs From Left Elias Krauklis, Mike Widerquist, Chris Culver, Chris Sampson, Rahul Kirtikar

2. Objectives Review Review Problem Statement Problem Statement Conceptual Designs Conceptual Designs Evaluation Suggestions/Concerns Evaluation Suggestions/Concerns Chosen Design Chosen Design Design Systems with Engineering Analysis Design Systems with Engineering Analysis Hydraulic Hydraulic Inner Container Inner Container Outer Container Outer Container Baseline Comparisons Baseline Comparisons Prototype Review Prototype Review

3. Problem Statement A typical trash bag holds about 13 gallons, a lot of which is empty space A typical trash bag holds about 13 gallons, a lot of which is empty space One person fills a bag with 3.3 gallons per day on average One person fills a bag with 3.3 gallons per day on average For a family of four, this equates to taking out the trash at least once per day For a family of four, this equates to taking out the trash at least once per day Current automatic trash compactors exist but are expensive and require installation Current automatic trash compactors exist but are expensive and require installation A manual trash compactor can perform the same duty without the high cost and permanent fixture A manual trash compactor can perform the same duty without the high cost and permanent fixture

4. Conceptual Designs Grinder Side Trash Top – Bottom AugerDual Bottom – Top

5. Evaluation Suggestions/Concerns Will lid be too heavy? Will lid be too heavy? It is made of plastic and is hinged with support cables It is made of plastic and is hinged with support cables How many pumps? How many pumps? The design maximized force by having no more than 15 pumps The design maximized force by having no more than 15 pumps How does the container release from the top? How does the container release from the top? A ball valve will be used as the pressure release system A ball valve will be used as the pressure release system Cleanliness Issue Cleanliness Issue A standard trash bag will be used A standard trash bag will be used

6. Chosen Design: Top-Bottom Compactor User’s foot powers hydraulic system User’s foot powers hydraulic system Inner container of trash rises into latched compaction plate Inner container of trash rises into latched compaction plate User’s foot actuates pressure release system User’s foot actuates pressure release system User input : 100 lb-f User input : 100 lb-f Compaction force : 742 lb-f Compaction force : 742 lb-f

7. Hydraulic System: Overview Forces the inner container upwards from an input force Forces the inner container upwards from an input force Master Cylinder on outside to center the user’s force (reduce moments) Master Cylinder on outside to center the user’s force (reduce moments) Other Ideas: Other Ideas: Crank Crank Ratchet Ratchet Lever Lever Hydraulic maximizes human ability Hydraulic maximizes human ability Maximum force from leg Maximum force from leg Translational motion Translational motion Relatively fast Relatively fast Mechanical Advantage: 7.42 Mechanical Advantage: 7.42

8. Hydraulic System: Foot Pedal and Master Cylinder Materials Materials Slave Cylinder and ramrod: Al 6061 Slave Cylinder and ramrod: Al 6061 Foot Pedal: 4”x6” polypropylene Foot Pedal: 4”x6” polypropylene Withstand 600 psi Withstand 600 psi Spring Spring Needs to oppose weight of foot pedal (2.5 lbs) Needs to oppose weight of foot pedal (2.5 lbs) k= 4.51 ksi k= 4.51 ksi Compressed length of 0.81” Compressed length of 0.81”

9. Hydraulic System: Hosing Subsystem Components Components Rubber Hosing Rubber Hosing Check valves (CV) Check valves (CV) Sump Sump Pressure release valve Pressure release valve Ball valve Ball valve Easy 90º rotation Easy 90º rotation Rejected Alternatives Rejected Alternatives Gate Valve (Can’t Handle Pressures) Gate Valve (Can’t Handle Pressures) Needle Valve (Too Cumbersome) Needle Valve (Too Cumbersome)

10. Hydraulic System: Slave Cylinder Rises 0.675” for 5” of travel in master Rises 0.675” for 5” of travel in master Total displacement: 10” Total displacement: 10” 15 pumps required 15 pumps required Output force: Output force: 7.42*Input force 7.42*Input force

11. Inner Container System Holds Trash Holds Trash Separate inner container Separate inner container Trash bag can be used Trash bag can be used Can be removed to clean Can be removed to clean Inner container made of ¼“ polypropylene Inner container made of ¼“ polypropylene

12. Inner Container Finite Element Analysis Results: A tension band will be installed on upper part of container

13. Outer Container: Overview Houses inner container and hydraulic assembly Houses inner container and hydraulic assembly Made predominantly of 1 / 8 ” propylene Made predominantly of 1 / 8 ” propylene Seals lid shut by latches and hinge Seals lid shut by latches and hinge Bears all of the force from the trash onto the compaction plate Bears all of the force from the trash onto the compaction plate Lid must not tip Lid must not tip

14. Outer Container: Deflection on Compaction Plate 3 ribs, ½” long and 3” high in a grid pattern were inserted to reduce deflection Maximum deflection on the compaction plate is 0.125” for both the x and y directions

15. Outer Container: Lid Square Box used to compact trash instead of plate This prevents trash from spilling onto top side of plate Also, it distributes the force better than a single rod and plate

16. Outer Container: Deflection on Top of Lid from Compaction Deflection on a beam by two concentrated loads: Method of Superposition P/4 Maximum Value: 556 lbf Aluminum plate used to reinforce plastic lid P/4 1.125”

17. Outer Container: Hinge Hinge rotates 100 degrees, prevents tipping Hinge rotates 100 degrees, prevents tipping rated to fail at 31.2 ksi, which is much larger than the 0.5 ksi it is expected to encounter rated to fail at 31.2 ksi, which is much larger than the 0.5 ksi it is expected to encounter

18. Outer Container: Latch Two latches rated for 625 lb-f to counteract up to 1,100 lb-f Two latches rated for 625 lb-f to counteract up to 1,100 lb-f ¼” plastic used in latch areas to counteract tensile forces from bolts ¼” plastic used in latch areas to counteract tensile forces from bolts

19. Baseline Comparisons Cost Max Pressure (psi) Reduction(%)Weight(lbs)Hydraulic < $200 7.1 > 50 > 5058 Automatic > $500 15.075 > 150 Bettermaid$1302.040 N/A (30) HydraulicAutomaticBettermaid

20. Prototype Differences Outer container 5/8 inch thick particle board instead of molded polypropylene Prototype is much bigger than the design Compaction plate is column supported instead of box supported

21. Hydraulic System Slave Cylinder smaller Slave Cylinder smaller Output force Output force Prototype : 661 lb-f Prototype : 661 lb-f Design : 742 lb-f Design : 742 lb-f Spring Coefficient Spring Coefficient Prototype: 3.77 lb- f/in Prototype: 3.77 lb- f/in Design : 4.5 lb-f/in Design : 4.5 lb-f/in Water instead of hydraulic fluid Water instead of hydraulic fluid Check Valves Master Cylinder Slave Cylinder Sump Ball Valve Inner Container Holder Spring Foot Pedal

22. Prototype Problems Plunger heads and o-ring groove machined inaccurate Plunger heads and o-ring groove machined inaccurate Spring not strong enough Spring not strong enough

23. Prototype Proof Normal kitchen trash bag did not tear or crinkle Normal kitchen trash bag did not tear or crinkle Compacted to around half of initial volume Compacted to around half of initial volume Two people weighing a combined weight of 425 lbs were lifted Two people weighing a combined weight of 425 lbs were lifted Max output force of 661 lb-f could be reached Max output force of 661 lb-f could be reached

24. Future Work Spring sizing needs to be re-evaluated to account for friction and suction Spring sizing needs to be re-evaluated to account for friction and suction Increase the volume of compaction, by adding additional telescoping arms to the slave ram Increase the volume of compaction, by adding additional telescoping arms to the slave ram Reduce number of pumps in order to quicken the compaction process Reduce number of pumps in order to quicken the compaction process Make it more aesthetically pleasing shape Make it more aesthetically pleasing shape Make it lighter by experimenting with different materials Make it lighter by experimenting with different materials Utilizing a two O-ring system for a more thorough seal and stability Utilizing a two O-ring system for a more thorough seal and stability

25. Prototype Video http://helix.gatech.edu/Classes/ME4182/2006 S3/projects/TeamMoondogs/ http://helix.gatech.edu/Classes/ME4182/2006 S3/projects/TeamMoondogs/ http://helix.gatech.edu/Classes/ME4182/2006 S3/projects/TeamMoondogs/ http://helix.gatech.edu/Classes/ME4182/2006 S3/projects/TeamMoondogs/

26. Questions?