HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING HCMUTE GRADUATION PROJECT RESEARCH, DESIGN AND IMPLEMENTATION OF AN AUTOMATIC PAPER MAKING
Overview of Vietnam's paper IndUStty Ác S2 eect ri, 2 1.2 Problem na
Vietnam's paper industry plays a significant role in driving the country's economic growth While experts recognize the potential for expansion within the current framework of international integration, they also highlight several challenges and obstacles that the sector must overcome.
While not a primary industry, the paper sector in Vietnam plays a crucial role with essential products like pulp, printing paper, and tissue Recently, this industry has witnessed significant growth, driven by the adoption of advanced technologies and a commitment to producing environmentally friendly products.
Vietnam's booming export sector has led to an increased demand for packaging paper, especially among industries like textiles, footwear, seafood, components, and electronics that are heavily reliant on exports.
In 2019, the demand for domestic paper packaging in Vietnam reached 4.2 million tons, as reported by the Vietnam Pulp and Paper Association (VPPA) The country's paper exports have seen remarkable growth, increasing by over 200 percent annually for the past three years Additionally, paper production output in the first half of 2020 is projected to exceed 2.79 million tons, reflecting a 12.2 percent increase.
Production in million metric tons z in
Paper production volume in Vietnam from 2010 to 2020
Figure 1.1: The graph illustrates the paper production volume from 2010 to 2020 [2]
In the first seven months of 2020, paper exports reached 933.2 thousand tons, marking a remarkable 100.6 percent increase compared to the same period in 2019 Notably, exports of packaging and tissue paper saw significant growth, while exports of printing and writing paper experienced a decline.
Currently, Vietnam exports packaging paper to 33 nations across five continents, with Asia accounting for the majority (98.9%), Africa (0.5%), Australia (0.4%), Europe America, and Europe accounting for the remaining 0.2 percent
Vietnam boasts an abundant supply of wood chips, essential for pulp production, coupled with low labor costs This advantageous combination is poised to deliver substantial benefits to the paper industry, fostering sustainable growth and resilience in the future.
Millions of Vietnamese families and wet markets are using non-biodegradable nylon bags and plastic items, often overlooking the significant harm these practices inflict on both health and the environment This issue represents a critical challenge not just for Vietnam, but for the global community as a whole.
According to a recent assessment by the International Union for Conservation of Nature, over 80% of marine waste originates from land, with plastics constituting 50-80% of this pollution This percentage is expected to increase, as plastics can take more than 2,000 years to decompose, significantly contributing to environmental pollution and threatening marine ecosystems.
On average, a Vietnamese individual generates 1.2 kilograms of waste daily, with plastic comprising 16% of this total Consequently, Vietnam produces approximately 18,000 tons of plastic waste each day.
In 2019, a WWE analysis revealed that the United States exported 83,000 tons of waste to Vietnam for recycling, equivalent to the plastic waste generated by nearly 300,000 American households.
Many destination countries, like Vietnam, struggle with inadequate waste management systems, leading to a staggering 72% of plastic waste being mismanaged and contributing to plastic pollution This pollution has severe consequences, including contaminated water supplies, crop failures, and respiratory illnesses caused by exposure to burning plastic.
Recently, numerous countries have begun utilizing agricultural residues like straw, corn husks, peanut shells, and banana stalks as sustainable raw materials for the production of paper and cartons.
In Vietnam, the banana tree is primarily valued for its fruit, while its dried leaves, fresh leaves, and blossoms are utilized by a limited number of individuals Unfortunately, banana stems are often discarded after harvesting, leading to waste and environmental pollution, as farmers incur costs for their removal and disposal.
Recent studies reveal that banana stems, rich in cellulose, could serve as a sustainable source for producing plastic alternatives Our team faced challenges in manually creating paper due to the lengthy and complex material processing methods, which led to low productivity To address these issues, we have developed an automatic paper-making system that utilizes agricultural waste and employs an eco-friendly pulp-making process.
The automatic paper-making system enhances the efficiency of the paper production process while minimizing manual labor Utilizing banana stems not only reduces pollution but also promotes human health and benefits the ecosystem The pulp-making machine streamlines the process through essential stages, including incubation, dehydration, washing, and grinding, facilitated by a pressing machine and a washing and grinding machine Upon completion, the system produces an impressive output of 80 A2 sheets of paper daily.
Research objective and research SCOpe . - 4s ke + HT 1H 4 1.5 sa
+ To dehydrate the incubated materials by applying the spiral shaft
+ To wash and grind the pressed materials at high speed
+ To process the banana stems to make pulp.
+ Research and design the stirring mechanism for two incubation machines
+ Research, design and implement the pressing method with a spiral shaft to dehydrate chemical solution from the incubated banana stems
+ Research, design and implement the washing and grinding machine at high speed to make pulp with proposed fineness
+ Pulp making machine in the paper making system produces pulp to create 80 sheets A2 per day This machine is transferred and evaluated to develop the scale
- The final goals: Making 421.2L of the pulp (80 sheets A2 per day)
- Quantitative method: Using the practical parameters and theorical basis to determine the input and output of the machine
At the Chemical Laboratory of the Faculty of Chemical and Food Technology at Ho Chi Minh City University of Technology and Education, an experimental method was employed to handcraft paper This process aimed to evaluate the finished products against established criteria and to optimize the paper-making process, ultimately facilitating the implementation of an automated paper-making system.
We conduct visits to paper factories and enterprises to explore various technologies involved in the paper-making process This hands-on research enables us to effectively plan, design, and implement solutions that align with production scales and meet proposed demands.
Timeline and work arran#€Im€I - ôc5 +4 +4 k1 TH HH HH HH 5 0: )400.0200000.4.400.3408.4 002003 1
The table illustrates research content and progress In the “Members and teachers” column, please allow us to abbreviate the names of the group members as follows:
Vo Le Bao An- An
Lao Vi Thien Tu — Tu
Table 1.1: Timeline and work arrangement
No Completed tasks Goals Time embers and teachers
Visit paper making - Mr Pham
- Approach to industrial processes at factories - Bach Duong
1 (Hoc Mon, Dong Nai) paper making processes 3d Khoi n6 60, one a - Gain knowledge about the ays x or and at companies (Nha og - “Green
Be, Tan Binh) Paper” team
Handmade paper - Find the optimal solution - Khoi making at the for implementing an - Trung
Department of Food and | automatic paper making - Tu
tk - Select the machine - An -
Meetings with “Green Di th ki 3 ks | Khoi
Paper” team and advisor | _ semis ie Paper mains Ween | - Trung process
On the idea methods ơ 2 weeks | Khoi
- Create overall vision for - Trung
Mectings with “Green 77° cone ueme - Trung os mechanism for pulp 2 days
Paper” team - Tu making machine x
Work assignments environmen Iday | - Khoi
- To save time and increase productivity
Design block diagram Lo 1 week | - Khoi operational description
Draft drawing ~ Model how machine 1 week | - Tu works
- Determine input and output of pulp making - An hi - Khoi
Calculation and me ue - - or
- - Determine dimension of 1 week | - Trung selection : - pulp making machine
- Find the suitable materials - An and devices - Tu
10 | CAD Drawing | Export sheet metal 1 month | Trung drawing for machining - Tu
- Export 2D drawing for - Khoi report - Trung
- Cost nu for machinin TC - Khoi
11 | Cost plan receive financial 1 week
Machine th - Find address for ” là - achine the - Khoi
12 machining with reasonable | 3 days components - Trung prices Tu
- Find address for buying electrical devices with reasonable prices and right
13 | devices and assemble - Assemble the pressing 1 month
: : - Trung pulp making machine machine, and washing and T grinding machine nu
- Arrange electrical devices and water tanks
15 Set up electrical cabinet | binet’s position 3days |-Tu and wiring :
- Prepare input material for "An
16 | Operation test - Determine the proposed - An specifications through free- - Khoi
- Determine the proposed - Tu specifications through free- load tests
17 Optimize operational process - Completed process 1 week
18 Evaluation - Review of “Green Paper”’ team 1 day Paper” team - “Green
Introduction to paper making industry c5 S5 S51 + Sexy 9 1 Materials for making DaeT . c5 4< HH TH HH HH HH Hy 9 2 Paper manufacturing DTOCۤS - 5 + ke +3 HH HH re 10 2.2 Making paper from banana stems (Adopted from current handmade paper
Introduction to the project “Green Paper” -cccccsecsscreereeeserxee 12 2.2.2 Handmade paper making process from banana stems
The project titled “Research, Design, and Implementation of an Automatic Paper Making System from Agricultural Wastes Using an Environment-Friendly Process (Pulp Making Machine)” focuses on utilizing agricultural waste as a sustainable resource for packaging paper Led by Dr Hoang Thi Tuyet Nhung from the Faculty of Chemical and Food Technology, this innovative initiative has been recognized and awarded as the winner of a prestigious competition, highlighting its potential impact on eco-friendly paper production.
Dr Hoang Thi Tuyet Nhung, representative of the "Green Paper" project, partnered with Mr Pham Bach Duong to advance a mechatronics graduation project from the experimental phase to pilot implementation.
According to the order, a pulp making machine is researched, designed, and implemented, then transferred to “Green paper” team
2.2.2 Handmade paper making process from banana stems
Cutting and l Stage 4 drying the banana Paper stems || product
1 ith Mixing ml os li hi i we => Squeezing Washing =! Grinding 1 ` preading P
!| NaOH 3% giue " the mold HH
Figure 2.5: Handmade paper making process Stage 1: Cutting and drying the banana stems
After harvesting, banana stems will be divided into segments and skived
Figure 2.6: Fresh banana stems After handling, the cut is used directly or is dried to store for subsequent parts
Figure 2.7: The chopped and dehydrated banana stems
Stage 2: Incubating, squeezing, washing, grinding, and mixing glue
- Incubating banana stems with chemical solutions (3% NaOH) within 12 hours
Figure 2.8: The incubated banana stems after 12 hours
- Squeezing and washing the incubated materials with pure water to reduce pH concentration
- Grinding and mixing glue to make the pulp
- Mixing the pulp into water
- Using the 8 mesh inox grid attached to the wooden mold to create a spreading paper mold
- Using pre-cut felt sheets as a surface for spreading paper
Figure 2.10: Spreading paper in Chemical Laboratory Stage 4: Natural dry
- Papers are naturally dried at the outdoor temperature
Note: Avoiding drying with scorching weather
Figure 2.11: The final paper after drying
Field trips nh
We organize field trips to paper-making factories in Ho Chi Minh City to explore diverse technologies These visits provide valuable insights and inspiration for designing and constructing paper-making systems through discussions with industry leaders and experienced professionals.
Figure 2.12: Thuan Phat Hung Company in Figure 2.13: Xuan Mai Paper Tan Binh District, Ho Chi Minh City Factory's paper making processes in
Nha Be District, Ho Chi Minh City
Figure 2.14: Recycled paper production factory in Trang Bom, Dong Nai Province
Design paper production CH4111 - - <5 S< + xxx 17 2.3 Componenf đ@SCTIDẨIOIN .- -Q- Ác 2 12.11231111 H1 21 1H TH HH HH HH 18 2.3.1 Pillow block bearInng - - 5 << +s <4 +4 9111313115112 131111121 H11 rkt 18 2.3.2 Solenoid ha
2.2.4.1 Overview of paper production chain
Based on results of the handmade paper making process, the paper production chain is illustrated as figure 2.15
The banana Machine 1 Machine 2 Final papers stems Pulp making machine
Handling Vy ‹ and Grinding Spreading Drying raw ằ> sả ằ ,
Dehydrating and Mixing the paper (Future design) materials materials glue
In summary, the process involves two key machines: the first machine focuses on separating cellulose fibers and producing pulp, while the second machine is responsible for spreading the paper Following the completion of these machines, two initial stages and a drying stage will be implemented to finalize the production process.
2.2.4.2 Machine selection in the paper production chain
This project focuses on the research, design, and implementation of a pressing machine, as well as a washing and grinding machine, to effectively produce pulp from incubated banana stems.
The dried !| Incubating Grinding |! The pulp
—— anana stems | (ongoing — still ằ> Dehydrating ° ằ and Mixing 8 — |
Figure 2.16: Pulp making machine production chain
The function of pulp making machine includes three main steps:
Step 1: Incubating banana stems with chemical solutions (ongoing — still under development)
The handled materials are incubated with 3% NaOH solution within 12 hours Then, those are shifted to the pressing mechanism through an inclined plane
Step 2: Removing chemicals from materials and reuse the pressed water
The incubated materials are conveyed through a spiral shaft to a washing tank, where they undergo a pressing process Once completed, the pressed water is redirected back to the incubation tank for reuse in subsequent cycles.
Step 3: Washing, Grinding, and Mixing glue
Dehydrated materials undergo a thorough washing process, being rinsed 3-4 times for 5 minutes each To enhance cleaning efficiency, this washing is combined with grinding The initial wash water is designated as washed water level 1, while the second and third wash waters are categorized as washed water level 2 Following this, the materials are mixed with glue and ground for 10 minutes before being transferred to the powder tank.
2.2.4.3 The proposal specifications of pulp making machine
Finally, the proposed specifications are designed according to the order from “Green Paper” project
Productivity At least 80 sheets A2 per day
Power consumption 2kW / 1 cycle / 10 sheets A2
Pillow block bearings come in various shapes, including round, square, mango, and omega, tailored to specific applications These bearings feature a robust cast iron alloy shell that provides exceptional durability and resistance to cracking under heavy impacts While they boast a significant load capacity, their rotational speed is somewhat limited Designed for industrial use, pillow block bearings share similarities with round bearings in terms of shape, static load capacity, reliability, and overall functionality.
Table 2.2: Pillow block bearings specifications
- Inner diameter: 25mm UCF Bearing 205 [11] - Weight: 0.82 kg
- Inner diameter: 45mm UCFE Bearing 209 [11] - Weight: 2.3 kg
An electrically operated valve, known as a solenoid valve, consists of a solenoid with a movable ferromagnetic core, or plunger, at its center In its resting state, the plunger seals a small opening When an electric current passes through the coil, it generates a magnetic field that lifts the plunger, thereby opening the orifice.
- Contact: NC, open when power is Solenoid valve applied and can be controlled
- Pressure difference: 0.4Mpa (4kg) Electric Ball Valve
Inverter oo
An inverter is an electrical device that converts input current frequency (typically 50Hz or 60Hz) to a different output frequency, ranging from 0 to 400Hz It primarily controls the speed of AC motors by adjusting the frequency Inverters are categorized into two main types based on their input power source: single-phase inverters and three-phase inverters Additionally, they can modify both voltage and frequency values according to user settings.
Modern inverters have evolved significantly, featuring advanced configurations that support various control modes tailored for different load types They now come equipped with PID control and simple PLC controllers, enabling effective communication with other devices.
Table 2.4: Specifications of Inverter Toshiba VF-SI5 [14]
Relay Contact sets, RJ45 port for
Inverter - Speed Control Range: 0.1-500Hz
A contactor is a vital low-voltage electrical device used for the regular switching of electrodynamic circuits, playing a crucial role in power systems It enables the control of various devices, including motors, capacitors, and lighting systems, through push buttons, automatic settings, or remote control.
The switching operation of the contactor can be done by means of an electromagnetic mechanism, a pneumatic mechanism or a hydraulic mechanism But the most common are electromagnetic contactors
- Contact: INO+1NC Contactor Chint | - Dimensions: 75x45.5x88mm
- Contact: INO+1NC Contactor Chint | _ Dimensions: 75x45.5x88mm
An intermediate relay, also known as a miniature electromagnetic relay, is essential for switching control signals and amplifying tasks within a control system Positioned strategically in the system, it acts as a bridge between low-capacity devices and high-capacity control appliances, ensuring efficient operation Additionally, overload relays play a crucial role in protecting these systems from excessive current.
Overload relays are essential safety devices designed to protect electric motors from overloads and phase failures They monitor the motor's operation and, upon detecting an overload condition, promptly disconnect the power supply to prevent overheating and potential winding damage.
In addition to, overload relays may shield the motor against phase loss or failures and phase imbalance Typically, they are referred to as thermal overload relay
A PLC, or programmable logic controller, is used in industrial automation These controllers have the ability to automate a particular procedure, a machine feature, or even a whole manufacturing line ¢ Specifications
Table 2.7: Specifications of PLC Siemens S7-200 CPU 226 CN (AC/DC/RLY) [21]
Components Stainless steel Steel Plastic
- High hardness => dehydrating from material
Spiral shaft with proposed specifications
Water tank - Less reactive with chemicals at room temperature
NHÀ pc on ố ố
Selection of dehydrating method -c S5 c+e + re, 26 “Nha con cố ố ố
Table 2.9: Selection of dehydrating method
Pneumatic press Spiral shaft Roller
- Easy to use, low - It has large load - Low machine maintenance, and carrying capacity noise levels incredibly durable
- They may be stopped at any time if necessary, and they are also fast
- It is smooth and noiseless service
- It provides very precise motion,
The use of dry, moisture-free air in machine tool applications offers several advantages, including the prevention of issues with internal components Additionally, these systems are easy to manufacture and do not necessitate specialized machinery.
Not suitable for works Because of high Not effective requiring high pressure friction, wear is a on fiber or 2D Disadvantages serious problem in power screws [23] products [24]
Conclusion: Based on the advantages and disadvantages of the three methods to dehydrate, pressing with the spiral shaft is a suitable measure because of its benefits
Chain drive Belt drive Muff coupling
- They are compact, have small overall dimensions
- Temperature and environmental conditions do not affect their working
- It is simple and affordable
- Its operation is smooth and silent
- It is durable and require low maintenance [26]
- It is straightforward and merely include a key and a sleeve
- It is safe to use
- It is cheaper than others types of couplings
[27] heavy load on shafts and bearings [26]
Advantages |_ Having high efficiency (up to
- They can operate in wet conditions
- It needs frequent | - Restricted speed | - It is not easy to lubrication range assemble or dismantle
- It has less load - It is not compact | - It requires more axial capacity - Significant space
- It is not suitable | power loss - It can not absorbs for non-parallel - Short service life | shocks and vibrations shafts [25] - They put much | [27]
Disadvantages strain on the shafts and bearings
The pressing machine utilizes a low-speed, high-pressure method to effectively separate cellulose fibers from banana stems, which are naturally fibrous The chain drive mechanism is essential in meeting these operational requirements.
The washing and grinding machine is designed to achieve fine pulp consistency by effectively dividing cellulose fibers into tiny segments Its high-speed operation, facilitated by a muff coupling, ensures efficient transmission while maintaining a compact design, making it the optimal choice for this process.
DESIGN AND IMPLEMENTATION .-.cccceieeeeee 29 3.1 Block diagram ố
Block diagram ố ố
Control Signal —> Water aroe ty a "1 bbG L- _—————-l ea ‘ ;
II 1 š i ' "level 1 tank ' ¡| fi ' 1 Incubation area, | vu Washed water +
' ' ! 1 ' ¥! Vs ; Man — ạ ' tÍ | Incubation Incubation ; water ạ ;
' — ' c rost-lock ec rosi-lock k = 4 ' ' ' ' ain Pe valrel — a! valve? et ' :
Bp a a ee ee ee ee ee m ~ r ' k
NT ¡ng TH NGÔ Tố Ôn ” tank ụ
(mem Sm Sm mm mm m x-=‡†-l -=“
Output the machine? Lock valve 1) |Lock valve 2
Figure 3.1: Block diagram for the pulp making machine
Operational description eee eee eee
The block diagram outlines a four-stage process for processing banana stems, beginning with incubation and concluding with pulp distribution In the initial phase, banana stems are placed in incubation tank 1, where they are treated with a 3% NaOH solution, while incubation tank 2 processes the raw materials Incubation motor 1 activates mixing blade 1 to thoroughly combine the materials, which then flow to an inclined plane via exhaust valve 1 after 12 hours The second stage involves transferring the mixture to a pressing machine, where pressing motor activates the spiral shaft to dehydrate the materials The extracted water is then pumped back to tank 2 through pump reverse and cross-lock valve 2, facilitating reuse.
In the processing system, after the initial 31 units are released, the incubation motor 2 activates to mix the raw materials for the next 12 hours Subsequently, the supply pump discharges water from the pure water tank while the compressor emits air to transport the processed materials to the washing and grinding machine, where the grinding motor immediately engages to grind the mixture Following the first wash, the processed material moves to washed water level 1 tank via lock valve 1, with the second and third discharges directed to washed water level 2 tank through lock valve 2 During the fourth washing stage, the mixture incorporates glue from the glue tank using the glue pump, and the pulp is then transferred to the next machine through exhaust valve 3 In subsequent stages, new materials are incubated with water from washed water level 1 via a non-return valve, while the released materials are pumped back to incubation tank 1 through cross-lock valve 1, utilizing washed water level 2 via the recycle pump for further washing of the processed materials.
3.3.1.1 Calculating inputs and outputs for two incubation tanks, the pressing machine, the washing and grinding tank:
1.3 kg banana stems Incubation (20 sheets) / 1 turn - 1.5 kg pressed - - 5.2 kg banana stems (V = 105.2 L) (4 tums) >| Spiral system >| Washing /—ằ| Grinding
Figure 3.2: Inputs and outputs for two incubation tanks, the pressing machine, and the washing and grinding tank
After conducting experiments in the Chemical Laboratory, making a sheet paper needs 65g of the cut banana stems
Regarding the productivity, the machine must finish 80 sheets per day
Hence, 65 x 80 = 5200(g) = 5.2(kg) is total needed mass for 80 sheets A2
32 ¢ Calculation the parameters for the incubation tank
Incubation (20 sheets) / 1 turn ! 5.2 kg banana stems (V = 105.2 L) F Tgum_ + tums)
5.2(kg) of the dried materials are entirely incubated in the incubation tank
Hence, the minimum volume of an incubation tank is:
Vicmin) = 5.2kg(pre — handled banana stems) + 100L(Na0H solutio = 105.2L(1)
From this minimum volume (Viimin)) and the cylindrical shape for the incubation tank resulting in obtaining the final volume for an incubation tank
Let 7; be the radius of the incubation tank
Let h, be the radius of the incubation tank
Vi¢ginai) = 1 X72 X hy = m X 0.3? X 0.6 = 0.17 m3 = 170L (2) ¢ Calculation the parameters for the pressing machine
33 ¢ Calculation the parameters for the washing and grinding tank
After overcoming experiments, specific parameters are determined In particular, the mass of the banana stems attaches the volume of water and glue
0.001(kg) of the pressed materials need 0.8(L)H 0 and 0.001(L) glue
=> 13 (kg) of the pressed materials need 104(1)H;O and 1.3(L) glue Hence, the minimum volume of the washing and grinding tank:
Vivg(min) = 1.3kg(pressed banana stems) + 1041(H,0) + 1.3L(Glue) = 105.3L(3)
From this minimum volume Vig (min) ) and the conical shape for the washing and grinding tank leading to determining the final volume for the washing and grinding tank
Let %yg(internal) be the bottom radius for the internal structure
Let Rwg(internal) be the top radius for the internal structure
Let Ainterngibe the height for the internal structure
The final volume for the internal structure of the washing and grinding tank is:
Vivg(internalf) = 3 TPhiwernal (Pug(merna) + Rwg(internat)” + Rwg(internal)"wg(internal)
Let Tg (externat)be the bottom radius of the external structure
Let Ry o(external) be the top radius of the external structure
Let Rexterngbe the height for the internal structure
The final volume for the external structure of the washing and grinding tank is:
Vivg(externaif) — 3 TRexternal (Tg (external) + Rwg (external) + Rwg(external) Twa(external)
= 3X1 x 0.85 x (0.25? + 0.3257 + 0.25 x 0.325 = 222L 1 (5) ¢ Calculation the density of the incubated banana stems solution
The experiment is conducted in Chemical Laboratory, consisted of two times
We begin by measuring 10 grams of cut materials placed in a beaker, followed by the addition of 188 mL of NaOH solution, which results in a total mass of 432 grams for the solution.
Let Mincubated solution be the final mass of the solution Hence, we gain:
Mincubated solution = 432 — 172.8(the mass of beaker) = 259.2(g) (6)
After that, we add water and obtain the final volume of the solution
(Vincubated solution = 270mL) leading to gaining the density of incubated banana stems:
To begin the experiment, we measure 30 grams of the cut materials placed in a beaker Next, we add 566 mL of NaOH solution, which allows us to calculate the mass of the resulting solution.
Let Mincubated solutionbe the final mass of the solution Hence, we gain:
Mincubated solution = 594.25 — 165.86(the mass of beaker) = 428.39(g) (8)
After that, we add water and obtain the final volume of the solution
(Vincubated solution = 445mL) leading to gaining the density of the incubated banana stems:
Finally, we take average of the density the incubated banana stems in 2 turns:
3.3.1.2 Motor calculation and selection a Calculation and selection motor for an incubation machine ¢ Determining the Reynolds of the solution (Re) [32]
The solution of the incubated banana stems has several parameters:
- The dynamic viscosity at room temperature: „ = 2.9 12(mPa s) compounded the dynamic viscosity of banana stems, NaOH solution and water
Depending on the table 3.1, the stirring speed is determined with types of stirring blades
Table 3.1: The required stirring speed for several stirring blades
Type of stirring Stirring speed blades (revolutions per second)
Because we choose blade shape for the stirring blades, the stirring speed is:
With an aim to compute Re and power at the maximum stirring blades, we select:
Let dstirringbe the diameter of the stirring blades, dgtirring = 0.42(m)
Hence, the Re of the incubated solution is: stirring’ ND _ 0.42 x 1.7 x 961.5 u ~ 2.912
36 © Determining the power factor (Po)
Figure 3.3: Relationship between Py and Re
1 Rushon Turbine; 2 Six blade turbine backswept; 3 Six pitched blade turbine;
4 Three blade turbine; 5 Three pitched blade; 6 High-shear impellers
From the figure 3.3 indicating the relationship between the Reynolds and power factor, we selected the three pitched blade shape shown line graph 5 Thus, we determine the power factor is:
Py =6 ¢ Determining the stirring power (P)
Finally, the stirring power are computed by the equation:
Therefore, we choose a motor 3 phase (0.5Hp) with gear box and the speed of shaft n= 75(rpm)
Table 3.2: Specifications of the pressing motor
37 © Calculating the shaft of the stirring blades [33]
The materials that we choose to design the stirring blades is Inox with various specifications:
The torsion moment on the shaft of the stirring blades:
The preliminary diameter of the stirring blades (dspare):
Figure 3.4: Stirring blades b Calculation and selection motor for the pressing machine [34] ¢ Determining the pressing productivity for incubated banana stems
Firstly, we have a spiral shaft with specifications:
-_ The internal diameter of the spiral shaft: đz„y„¡ = 0.025(m)
- The external diameter of the spiral shaft: D„„¡ = 0.08(m)
From table 3.3, computing the screw speed depends types of material and the diameter of the spiral shaft
Table 3.3: The factors for types of material moving in the spiral shaft
Material properties Calculation coefficient oO K oO
Because cut banana stems are light (cereals, coal dusts) and not sharp, we choose
K = 51 resulting in the screw speed:
Let € be the porosity ratio, € = 0.35 because cut banana stems are light (cereals, coal dusts) and not sharp
Let cg be the influence ratio of the inclined angle representing for fixing the machine,
Cg = 1 are determined by table 3.4
Table 3.4: Effect coefficient due to the inclined angle representing for fixing the machine
The inclined angle representing for fixing the 0 5 10 15 20 machine 8
The average area of the materials in the spiral shaft:
The velocity of the materials in the funnel:
0.045 x 217 Prtow = — == = 0.16275 (7), (16) where p is the pitch of the spiral shaft
Finally, the pressing productivity is determined by the equation:
= 442 (kg/h) (17) ¢ Determining the power on the spiral shaft
- The efficiency factor of machine: = 0.8
- The amount of NaOH solution and water contains in incubated materials:
105.2L(water + NaOH + cut banana stems) 100 = 95.1% (18)
- The final amount of NaOH solution and water contains in incubated materials after pressing:
The final productivity for the mass of cut banana stems which need to provide for the pressing machine:
Let L be the length of the spiral shaft, L = 0.26(m)
Let w be the drag coefficient, @ = 1.2 because cut banana stems are heavy (salts, coals) and not sharp
Finally, the power on the spiral shaft is:
Evcrew — 360 (w + sinB) = arn 360 _ (1.2 + sin0) = 0.381kW/ (21) s Determining the power for the motor with gearbox
Let 7 be the efficiency factor of the gear box, 7 = 0.8 > 0.85
Hence, the power for the motor with gearbox:
The safety factor is 1.5 © The final power for motor with gearbox:
From this power, we choose motor 3 phase (1 HP) with gear box and the speed of motor shaft Noressing motor = 95 (rpm)
Table 3.5: Specifications of the pressing motor
+ Shaft diameter: 24 mm © Calculating the torsion torque of the spiral shaft and motor shaft
The torsion torque of the spiral shaft is computed by the formula:
The torsion torque of the motor shaft is computed by the formula:
Npressing motor 95 c Calculation for the chain drive [33]
- The power for the motor with gearbox: Pyorpy = 0.75 KW
- The speed of motor shaft: Npressing motor = 95 (rpm)
- The torsion torque of the motor shaft: T,,5¢5- = 67855.3 (N mm) ¢ Choosing the number of teeth on sprockets
With an aim to reduce the impact, we should not choose the minimum sprocket Therefore, we can choose Z,);, = 11 —> 15 Besides, the chain drive applies to reduce the speed leading to Z, < Z>
Hence, the number of teeth on the driving sprocket for the roller chain: Z, = 15
The limit of the sprocket: Z),¢, < 100 — 120, the number of teeth on the driven sprocket for the roller chain: Z, = 25
Z1 15 © Specifying the condition factor for using chain (K)
Let K, be the load factor: Because driving with electric motors and external loads acting on the drive system are smooth, K, = 1
Let K, be the factor related to the center distance Qcentory = (30 + 50)pe K,=1
Let K, be the factor related to how to place the drive system when the line among two centers with horizontal lines is less than 60°, K, = 1
The factors influencing the tension adjustment of chains include Kz, which is set at 1, indicating optimal adjustment capability The lubricant condition is represented by K, and is also rated at 1, reflecting effective lubrication through drops Additionally, the working mode is denoted by K,, with a value of 1.12, highlighting its impact on operational efficiency.
The condition factor for using chain (K) is:
The factor: Kạ =——= ”— = 0.53 (28) pressing motor
We choose the chain with one line, K, = 1 © Computing the calculated power (P,)
From table 3.6, we choose p, = 15.875(mm)
Table 3.6: Selecting the chain pitch according to the allowed pressure [P, |
The allowed pressure [P,,| when the speed of driving Chain pitch p, sprockets ny, (rpm)
From table 3.7, we choose nz, = 1000(rpm) (roller chains, z, > 15) with
P= 15.875(mm), SO Npressing motor < Neh Tesponses
Table 3.7: Limit values of chain step according to the speed of Np,
The e aoe ME) allowed chai 19.7 | 15.875 | 19.05 | 25.4 | 31.75 | 38.1 | 44.45 | 50.8 pitch [p_] (mm)
Determining the average velocity and tangent force:
Checking p, with choosing the allowed pressure [p,| = 35MPa from table 3.8 Table 3.8: The allowed pressure [po|
The allowed pressure in chain hinge [pạ] (MPa) when the The chain speed of driving sprocket n, (rmp) pitch p, (mm)
Choosing the preliminary shaft distance:
* Computing the number of links on chain:
44 ô_ The length oƒchains: L.wa„ = p¿x = 15.875 x 80 = 1270(mm) — (36)
* Computing exactly the shaft distance
Qcenter = ` X Dc [x ~ 12) + V(x — C12) ) 8 wa = 465(mm) (37) © The number of times of impact in one second:
— Z1Tipyressing motor — 15x95 ơ 15x ~ 15 x 80 © Checking the chains with a safety factor
The tension force is caused by the radial force:
From table 3.9, we choose qin = 0.9(kg), Q = 22700N depending on p, = 15.875(mm)
Table 3.9: The roller chain with one line p, (mm) Hinge area A (mm?) Destructive load Weight of Im
The initial tension force of the chains:
Because we use the chain drives with vertical drive, Ky =1
The force acting on the shaft:
Because the chain lies vertical plane, K,, =1
Checking the chains with a safety factor:
45 © Calculating the diameter of sprockets
The diameter of the driving sprockets:
_ phy _ 15.875 x 15 a TẾ ~ TẾ dy = 75.8(mm) => d, = 80mm (43)
The diameter of the driven sprockets: dạ = a = wenn’ = 126.3(mm) => d,8mm (44)
Figure 3.6: The chain and sprocket d Calculation and selection motor for the washing and grinding machine [35] Initially, the parameters of the blade for the washing and grinding machine compound:
When adding the solution of pressed materials, the washing and grinding machine contains 105.3(L) According to the figure, the height (Rsotution) and radius (Reotution) of this solution are determined
Figure 3.7: Initial dimension of the washing and grinding tank
Looking closely at the picture, the angle (a) is computed: tan(a) = — > a@° (45) Besides, depending on two exterior — interior angles, the angle (a) is calculated:
Moreover, regarding the equation for the conical volume, the relation between Neontion and R solution are determined:
Finally, the height of the pressed materials is Agonition = 0.46 (m) and the radius of the pressed materials is Ryomeion = 0.29(m)
47 ¢ The area of each blade
With regard to figure 3.8, the area of a blade is determined:
Figure 3.8: The area of the blade
The trapezium's area is calculated using the formula A = x9.8x (11.8 + 15.9), resulting in an area of 135.73 cm² The area of the top section is determined by summing various components, yielding a total of 38.27 cm² For the left-bottom area, the combined measurements give an area of 27.91 cm² Ultimately, the area of each blade is found by subtracting the areas of the other sections from the total trapezium area, resulting in 65.76 cm².
Let hy represent the height of the surfaces of blades 1 and 2 relative to the solution's surface, while h34 denotes the height of the surfaces of blades 3 and 4 in relation to the same solution surface.
According to the relation of Agonzion and Ay2, N34 as the figure , hy, hg, are determined: hyp = 0.44(m), hz4 = 0.42(m)
Figure 3.9: The kinematics analysis for the blades
When incorporating materials with a density of 961.5 kg/m³, the blades generate forces N1 and N2 for blades 1 and 2, and N3 for blades 3 and 4 Additionally, the material solution exerts a force Ny on blades 1 and 2.
The volume of the material solution acts the blade 1 and 2
The force of the material solution acts the blade 1 and 2:
Mi = VịyDg = 5.78 x 1073 x 961.5 x 9.81 = 54.5(N) (53) © The force of the material solution acts the blade 3 and 4 (N34)
The volume of the material solution acts the blade 3 and 4
The force of the material solution acts the blade 3 and 4
Nzq = V34Dg = 5.52 X 107° x 961.5 9.81R(N) (55) © The friction between the blades and the banana stems
Let f be the coefficient of friction between the material solution and the material for machining the blades, f = 0.49 + 0.55
F = (Nip + Ngq) x f = (54.5 +52) x 0.49R.2(N) (56) ¢ The moment acts the shaft
Let Dpiade be the diameter of the blades, Diiage = 32.8(cm)
M 2 2 = 8.7 (N.m) (57) © The power of the motor
Pressed banana stems contain large cellulose fibers that require high-speed blade rotation to effectively break down their structure Operating at a frequency of 50 Hz, various motor types can achieve speeds of 3000 rpm, 1500 rpm, and 1000 rpm, with the rotational speed (n in rpm) calculated using a specific equation.
Where 60 is the number of seconds, and 2 is negative and positive pulses in I cycle
To achieve high-speed grinding with low power consumption, it is essential to select a motor with a minimal number of poles, specifically two poles (P = 2) The speed can be calculated using the formula: [38] fx60x2 50x60x2.
Mug motor = TC TC 3000(rpm) (59)
However, the motor with 2 poles is reduced the speed remaining 2900(rpm) because of slip and load
The safety factor is 1.5, the final power is determined:
From this power, we choose motor 3 phase (SHP) and the speed of motor shaft
Table 3.10: Specifications of the washing and grinding motor
3.3.1.3 Pump motor calculation and selection [31] a Calculating and selecting pump motor for the washing and grinding machine’ s position to the washed water level 2 tank ¢~ Calculation
Let h, be the height of water column, h, = 2 (m)
Let d, be the diameter of the water pipe, d; = 27 (mm)
Let v, be the velocity of flow, v, = V2gh, = V2x 981 x2 b6(m/s) (62)
Let A, be the cross — section of the water pipe,
Q, = vA, = 3.59 x 1073 (m/s) (64) © The power for water pump:
P, = 1" "1200 120 x 0.8 = 0.075(kW), (65) where D is the density of water and o is pump ef ficiency (0.8 — 0.9)
31 ¢ The power for motor of water pump:
The safety factor is 0.43 Py, © The final power for motor of water pump:
The power required for the water pump is significantly influenced by the elevation of the washed water level 2 tank When the tank is positioned at a lower height of 2 meters, the necessary power is optimal; however, if the tank's height is increased to 6 meters, the required power rises to 370 watts.
Table 3.11: Specifications of pump motor for the washing and grinding machine’s position to the washed water level 2 tank
+ Power: 370W Tolsen 79970 370W water pump [28] + Flow: 35 liter/min
+ Dimension: width 29cm, height 17cm
+ Standard: IPX4 b Calculating and selecting pump motor for the pure tank’s position and the washed level 2 tank’s position to the pressing machine ¢ Calculation
Let hy be the height of water column, hy = 0.5 (m)
Let dy be the diameter of the water pipe, d, = 27 (mm)
Let v2 be the velocity of flow, ạ = V2gh; = V2 x 9.81 x1 = 1.98 (m/s) (68) Let A> be the cross — section of the water pipe,
Q; = 0;4; =1.1x10”3(m3/s) (70) © The power for supply pump:
2 where D is the density of water and o is pump ef ficiency (0.8 — 0.9) © The power for motor of supply pump:
The safety factor is 0.43 Py> © The final power for motor of supply pump:
Puafinat = Puz + 0.43Py2 = 0.0202 (kW) ~ 20(W) (73) ¢ Selection
Table 3.12: Specifications of pump motor for the pure tank’s position and the washed level 2 tank’s position to the pressing machine
+ Power: 26W JT-750 water pump motor [29] + Flow: 900 L/h
+ Standard: IPX8 c Calculating and selecting pump motor for the bottom of the washing and grinding machine to the top of the washing and grinding machine ¢ Calculation
Let hạ be the height of water column, h3 = 1 (m)
Let d3 be the diameter of the water pipe, d; = 10 (mm)
Let v2 be the velocity of flow, v3 = V2gh3 = V2x 981 xX1C (m/s) (74)
Let A> be the cross — section of the water pipe, rdạ” _ x (0.01)?
Q3 = v3A3 = 3.5x10* (m/s) (76) © The power for glue pump:
P; = op = 0D x08 = 0.0041(kW), (77) where D is the density of water and o is pump ef ficiency (0.8 — 0.9) © The power for motor of glue pump:
The safety factor is 0.43 Py3 © The final power for motor of glue pump:
Puafinat = Pug + 0.43Py3 = 6.4 x1073(KW)~7(W) (79) ¢~ Selection
Table 3.13: Specifications of pump motor for the bottom of the washing and grinding machine to the top of the washing and grinding machine
+ Flow: 2 l/min d Calculating and selecting pump motor for the body of the pressing machine to the bottom of the pressing machine ¢~ Calculation
Let h¿ be the height of water column, hy = 0.8 (m)
Let d, be the diameter of the water pipe, d, = 12 (mm)
Let v, be the velocity of flow, vy = V2ghy = V2 X 9.81 x 0.4 = 3.96 (m/s) (80)
Let A, be the cross — section of the water pipe, md,” _ mx (0.012)?
Qy = 4A, = 4.510 (m3/s) (82) © The power for pump reverse:
*~ 1020 — 102 x 0.8 = 0.0044 (kW), (83) where D is the density of water and o is pump ef ficiency (0.8 — 0.9) ¢ The power for motor of pump reverse: p, — fe _ 0.0044 Man 0.9 = 0.0049(kW) (84)
The safety factor is 0.43 Py © The final power for motor of pump reverse:
Table 3.14: Specifications of pump motor for the bottom of for the body of the pressing machine to the bottom of the pressing machine
ITEM NO PART NAME DISCRIPTION QTY
Grinding Machine Full name Signature] Date RESEARCH DESIGN AND IMPLEMENTATION OF me AGRICULTURAL WASTES
USING ENVIRON MENT-FRIENDLY PROCESS (PULP M [AKING MACHINE)
Mr Pham Rach Duong PULP MAKING MACHINE Material lo Chí Minh City L tượng of Technology and Education Quanity | Weight | scale | unit
1 Bearing UCF 205 4B Inox Pipe For Input Maieral
2 Material Ouspt Chate 1 Fuse! For Input Material
Cine Plate For Meusting, Ball
3 Đang Is Micide Suppost Plate :
4 Screw Shaft 6 Chain Aad Sprocket ] |
? ‘brent Suppor: Mate 1s Drive Shatt
8 Meth Pipe +0 Back Support Plate i Gecko’: sooo (, Pressing Metce Full name Signature} Date RESEARCH, DESIGN AND DIFLEMENTATION
AN AUTOMATIC PAPER MAKING SYSTEM FROM AGRICULTURAL WASTES rr Prumg Reverse 2 Bearing UCF 295 Designer USING PROCESS (PULP MAKING MACHINE)
' (Circle Mate For Welding Inox Pape | 22 Fane ‘THE PRESSING MACHINE
“ Cover Ia The Fret Sie z Cove Ia The Back Side Ho Chi Minh City University Quantity | Weight | Sele | Unit E : = Page
25 \Cover is The Back Machine For Mow] of Technology and Education 1 1s | mn MỊ
Figure 3.12: Exploded view of the pressing machine
Full name Sigrature Date RESEARCH, DESIGN AND IMPLEMENTATION OF
AN AUTOMATIC PAPER MAKING SYSTEM FROM AGRICULTURAL WASTES: Designer USING ENVIRONMENT-FRIEN DEY PROCESS (PULP MAKING MACHINE)
Cheeked | Mr Pham Back Duong TOTAL DIMENSION OF Material Approved | Ms Than Back Duong THE PRESSING MACHINE
Ho Chi Minh City University Ovaatity | weiste [Scale [unit Page of Technology and Education T | [tm | mm trị
Figure 3.13: Total dimension of the pressing machine
The Glue Tank is an essential component of the washing and grinding machine, which includes a lid for easy access Key parts of the system comprise the glue pump, blades, inner mesh tank, and outer tank, all working together to enhance efficiency The grinding motor powers the blades, while the coupling between the blade and motor ensures seamless operation Additionally, the exhaust valve and water pump contribute to effective waste management and fluid circulation The electrical cabinet and inverter cabinet are crucial for controlling the machine's operations, making the washing and grinding process streamlined and efficient.
RESEARCH, DEMGN AND DIPLEMEN TATION OF
AN AUTOMATIC PAPER MAKING SYSTEM FROM AGRICULTURAL WASTES
Ho Chi Minh City University of Technology and Educati
Figure 3.14: Exploded view of the washing and grinding machine
T20 oe sẹo oeooo oooo oooo
Full name Signature] Date RESEARCH, DESIGN AND IMPLEMENTATION OF
KING SY! WASTES name PROCESS (PULP MAKING MACHINE)
Checked | Mr Pham Bach Duong TOTAL OF WASHING Material
‘Approved | ir Phan Bach Duong AND GRINDING MACHINE
He Chỉ Minh City University Quanity | Weight | Scale [Unit of Technology and Education
Figure 3.15: Total dimension of the washing and grinding machine
Figure 3.16: Electrical block diagram tht]
A power supply is essential for powering a PLC, enabling it to receive signals from a computer based on predefined code conditions This unit processes the input and sends feedback signals to manage and control motors, pumps, and valves The entire operation is regulated through button signals, ensuring precise control of the processes.
The wiring diagram between the PLC $7 200 and the devices zm ay jo
@oo000900 @o0000000 STTY 41 E7 591112 % 87 CPU226 AC/DC/RLY
Stat Stop Mmnual PureRecyele VW®ww Pump Gnncing Prosalig Lock Lock Exhmnt Glue pump reverse “moter” "meee? “pump, SEY wee sae Tate pum
220VA€ The wiring diagram for motor 3 phases |
Pressing eto | FM CC VỊC VB
The wiring diagram for devices 24VDC/AC
3.4.4 Part-list for electrical devices
Table 3.15: Part-list for electrical devices
10 (2 states) Ị ll Selector Switch (3 I states)
The operation will be managed based on the chosen automation method for the manufacturing process, with the entire procedure depicted in the pulling and control sequences flowcharts shown in Figures 3.18 and 3.19.
Operating with Operation manual mode
Ce mares `9 / a r4 km vu Soren (oi Po reeeter Try
Figure 3.19: Control sequences flowchart for programing in PLC
1 Supply power to the machine
Press functional buttons depending on the using purpose
Press Stop to shut down all devices which are activated previously
1 Supply power to the machine
3 Switch pure/recycle button to choose the water type
4 Press Start button to begin the operational loop
5 Press Stop to shut down machine
3.6.1 Implementation for the pressing machine
Figure 3.20: The right view of the pressing machine
Figure 3.21: The front view of the pressing machine
3.6.2 Implementation for the washing and grinding machine
Figure 3.22: The washing and grinding machine
3.6.3 Implementation for the pulp making machine
Figure 3.23: The making pulp machine in the right-hand side
Figure 3.24: The making pulp machine in the left-hand side
Gia chỉ tiết chốt ổ bi
Tiền 1.000.000 nắm cho nắp bồn ủ, rửa 25.000 50.000 Con dao cho bồn rửa 950.000 950.000 rửa 8.000.000
Nối rửa 650.000 650.000 bơm nước 760.000 760.000 bơm 24v 200.000 400.000
6 khoa 33.000 ndi domino 11.650 domino CB 25 16.500 lo xo 1 15.000
BỒn nước 213.000 640.000 Ông nước (ống cứng, mềm, 621.000
EXPERIMENTS AND ANALYSIS ẶẶcSeeiieiee 69 4.1 Design Ọ eXD€TIT€TS - ĐÀ 4L HH HH HH TH TH Hà HH HH HH Hư 69 4.1.1 List of needs oo Ầ.ẦẦ.Ố
List of Metrics nh
No Metrics Needs Unit List
M10 Shape N1, N2, N5 4 List circle, square, conical mit | Dehyerating Í NI N2, N5 4 ability
M12 Fineness of the NI 4 pulp
Note: M is Metric Example: M1 is Metric 1 - Cost
Needs and metrics correlations 0.0.0.0 cece cece eet e cee eeeeteeteeeeeeeaee 70 4.1.4 Proposed sp€CIÍTCALIOINS .- - - se 71 4.1.5 Experimental methOdS - c Se + S112 HH HH HH HH HH re 72 4.2 Operaflonal eXP€TITT€TIẨS .- -Á - G S2 S2 113123 1313119118313 1 12113 H1 HH Hy 74 “Anh 5 na
Table 4.3: Needs and metrics correlation
Il Total weight Kg 100 120 BASIC
6 Power Consumption KWhi 2 +0.5 BASIC cycle
8 Dryness after pressing 1kg of Ke 0.45 40.2 BASIC incubated materials
9 Density of pulp per 1 sheet A2 g/L 75 +5 BASIC
10 The concentration of NaOH pH 7.5 +1 BASIC
11 Time to press enough Ikgof | s.ond | 270 +45 BASIC incubated materials
Time so that the pressing
12 machine fully absorb 1 kg of | Second | 80 +15 BASIC incubated materials
BASIC is all static measurable metrics, functions that a typical product should have ADVANCED is all static measurable metrics, functions that improve the product performances and cost more than 10%
ADDTIONAL is all static measurable metrics, functions that add value to the product but not making the product cost higher than 10%
Sample Types of Test sóc
Specifications Unit No Method description
Total Weight Kg 1 x Scale details and sum
Width mm 1 x Using roll ruler lock to determine
Power consumption of the pressing kWh I x machine in free-load case
Power consumption f th hi d ofthe washing nd | yy | ị : grinding machine in Us; \ free-load case sing ampere clamp to measure the current
Power consumption - f the pressin by using formula eee) kWh 1 x machine in full-load case
Power consumption of the washing and kWh I x grinding machine in full-load case
Noise data of the pressing machine in dB 10 x free-load case
Noise data of the washing and grinding machine at 30Hz in free-load case dB 10
Noise data of the pressing machine in full-load case dB 10
Noise data of the washing and grinding machine at 30Hz in full-load case dB 10
Using application on smartphone to measure
Density of pulp per 1 sheet A2 g/L 10
Second 10 Using the watch on smartphone to measure
Time so that the pressing machine fully absorb 1 kg of incubated materials Second 10 Using the watch on smartphone to measure
To assess the accuracy and reliability of the machine, we conduct two essential evaluations: the Static Test and the Dynamic Test The Static Test measures static parameters such as weight and dimensions, focusing on non-electric characteristics In contrast, the Dynamic Test evaluates the machine's performance under various conditions, including free-load and full-load tests, while also monitoring the electricity consumption during operation.
A thorough evaluation of the mechanical design is essential, as it significantly influences both the machine's stability and the quality of its output To ensure seamless operation of the electrical and control designs, we conduct various tests in mechanical design, including assessments of the machine's weight, dimensions, pressing mechanism, and the washing and grinding mixing mechanism Additionally, we measure the workpiece weight, which includes the mass of the banana post-pressing and the mass of the pulp solution after the washing and grinding processes.
Table 4.6: The results of static test
No | Specifications | Unit | Ideal value valne Measured value | Result
After confirming the static status of the machine, we proceed to operational experiments to assess its performance and mechanical design capabilities This phase includes a total of 13 tests, comprising 4 free-load tests and 9 full-load tests, aimed at evaluating the efficiency and effectiveness of the machine's operations.
Free-load tests check the power consumption and the noise generated by the machine during the pressing, washing and grinding process
Full-load tests check the productivity of the machine, the dryness rate of bananas after pressing and the percentage of pulp solution generated during operation, power
74 consumption and noise Power consumption and noise tests can produce similar results to free-load tests
The system comprises six primary components that consume power: the controller, the pressing machine motor, the washing and grinding machine motor, the water pump motor, and the valves A free-load power consumption test evaluates the system's maximum power usage under optimal conditions.
Table 4.7: Test the power consumption of the pressing machine in free-load case
Power consumption of the pressing machine (kWh)
Ideal value Marginal value Measured value Result (%)
Table 4.8: Test the power consumption of the washing and grinding machine in free-load case
Power consumption of the washing and grinding machine (kWh)
Ideal value Marginal value Measured value Result (%) 0.563 0.475 — 0.616 0.555 85
Table 4.9: Test the noise of the pressing machine in free-load case
Noise data of the pressing machine in free-load case
Ideal value Marginal Measured Result
Table 4.10 presents the noise levels of the washing and grinding machine operating at 30Hz under free-load conditions The recorded noise data highlights the acoustic performance of the machines in this specific setting.
Ideal value Marginal Frequency Sample _— Result
The power consumption in the full-load test will measure the maximum power consumption of the entire system under the condition of the machine operating continuously
Table 4.11: Test the power consumption of the pressing machine in full-load case
Power consumption of the pressing machine (kWh)
Ideal value Marginal value Measured value Result (%) 0.133 0.128 — 0.146 0.135 84.6
Table 4.12: Test the power consumption of the washing and grinding machine in full-load case
Power consumption of the washing and grinding machine (kWh)
Ideal value Marginal value Measured value Result (%)
Table 4.13: Test the noise of the pressing machine in full-load case
Noise data of the pressing machine in full-load case
Ideal value Marginal Sample Measured value Result
In a full-load scenario, the noise levels of the washing and grinding machine operating at 30Hz were thoroughly tested, as detailed in Table 4.14 The collected data highlights the acoustic performance of the machine under maximum operational conditions.
"(aB) ue value “i Sample value Result
Following the evaluation of all quantitative experiments, we proceed to the final assessment of the dryness rate of banana stems post-pressing and the pulp wastage rate This crucial test will demonstrate the effectiveness of the mechanical design.
Table 4.15: Test the dryness of the pressed banana stems from Ikg of incubated materials Dryness of the pressed banana stems from 1kg of incubated materials
Ideal value | Marginal value Measured Result
Table 4.16: Test the density of pulp / I sheet A2
Density of pulp per 1 sheet A2
Ideal value Marginal Sample Measured Result
Table 4.17: Test the time to press enough Ikg of incubated materials
Time to press enough 1kg of incubated materials
Ideal value argina easured Result
Table 4.18: Test the time so that the pressing machine fully absorb | kg of incubated materials
Time so that the pressing machine fully absorb 1 kg of incubated materials
Ideal value argina easured Result
Table 4.19: Test the concentration of NaOH in water after washing 3 times
The concentration of NaOH in water after washing 3 times
Ideal value argina easure Result
The percentage of approved tests: 80%
The analysis of static and dynamic test results reveals why achieving a perfect score of 100% is unattainable In static tests, key parameters such as weight, size, power supply, working time, and operation mode of both machines demonstrate reasonable accuracy against pre-set values Dynamic tests indicate that the machine's capacity, precision, and the quantity and quality of pressed banana stems and pulp exhibit minimal failure rates The findings are visually represented in the accompanying graphs, including the noise test results.
Noise data of the pressing machine in free-load case
Sound intensity (dB) ~ ~ ~ 4s Fy HF ys meu au au ~ u
Sample ôœ â so Sound intensity (dB)
Noise data of the pressing machine in full-load case
Figure 4.1: Noise data of the pressing machine in free-load and full-load case graphs
Noise data of the washing and grinding machine at
30Hz in free-load case sity (dB)
Noise data of the washing and grinding machine at 30Hz in full-load case
Figure 4.2: Noise data of the washing and grinding machine at 30Hz diagram machine in ree-load and full-load case graphs
The noise levels observed during the four tests, both under free-load and full-load conditions, exhibited slight fluctuations These variations can be attributed to the influence of the surrounding environment on the measured results.
The noise levels recorded for both machines comply with the National Technical Regulation on noise, remaining below the 85 dB limit set by the Ministry of Health in Circular 24/2016/TT-BYT Additionally, the dryness of pressed banana stems was tested using 1 kg of incubated banana stems.
Dryness of the pressed banana stems from 1kg of incubated materials
The weight of pressed banana stems
Figure 4.3: Dryness of the pressed banana stems from Ikg of incubated materials graph
The dryness of pressed banana stems varies between 0.45 kg and 0.5 kg, influenced by the incubation duration and pressing time of the materials Longer incubation periods result in softer banana stems, highlighting the importance of optimizing both incubation and pressing times for effective processing.
Time to press enough 1kg of incubated materials second) sing time ~ res p
Figure 4.4: Time to press enough Ikg of incubated materials graph
Looking closely at the graph, the time to press enough 1kg of incubated materials fluctuates between 270 seconds and 285 seconds, which is also affected by previous incubating time,
The firmness or softness of incubated banana stems is influenced by the duration of incubation, which affects how effectively the pressing machine absorbs the materials It is essential to test the optimal time required for the pressing machine to fully absorb one kilogram of incubated banana stems to achieve desired results.
Time so that the pressing machine fully absorb 1 kg of incubated materials
Figure 4.5: Time so that the pressing machine fully absorb I kg of incubated materials graph
The incubation time and the firmness or softness of the materials significantly influence the duration required for the pressing machine to fully absorb 1 kg of incubated materials, with this interval varying between 83 to nearly 86 seconds Additionally, the concentration of NaOH in water was tested after washing the materials three times.
The concentration of NaOH in water after washing 3 times
Figure 4.6: Test the concentration of NaOH in water after washing 3 times graph
The concentration of NaOH in water typically falls within a pH range of 7.5 to 9.5 However, if the pH value exceeds 8.5, it fails to meet the required standards, as it surpasses the permissible limits for basic solutions.
84 © Test the density of pulp per I sheet A2
Density of pulp per 1 sheet A2
Figure 4.7: Test the density of pulp per I sheet A2 graph
Looking closely at the chart, the density of pulp per sheet A2 fluctuates the range from
295 to 305 (g/L) This specification is extremely important in determining the thickness of paper
CONCLUSION AND RECOMMENDA TIÒN
Our graduate project focused on the "Research, Design, and Implementation of an Automatic Paper Making System from Agricultural Wastes Using Environment-Friendly Processes." This initiative aims to tackle significant environmental issues by reducing plastic waste, utilizing agricultural byproducts that are often burned or left to decompose, and providing new income opportunities for citizens through the sale of banana stems We believe this project represents a transformative step for the paper industry in Vietnam, with broad applications across various sectors Additionally, our team enhanced our skills in Solidworks for 3D modeling and 2D drawing exports, while applying theoretical knowledge to calculate technology specifications and select appropriate devices Ultimately, we successfully developed an automatic pulp-making process utilizing PLC $7 200 and Microwin software.
- Conducted handmade paper-making process in chemical laboratory to have experiences and pieces of knowledge to design and implement the suitable machine
- Field trips: Visited paper-making factories in Vietnam
- Finished 3D drawings, and exported 2D drawings for machining
- Finished selection motor and material suitable for calculation’s data and cost
- Completed machining, programming, and testing
- Manufacture two incubation tanks to advance the process according to full automation
- Apply Raspberry Pi to control and follow the process through smartphones
- Apply industrial communication networks for PLC and Inverter to control speed of the motor
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Công ty Cổ phần Kỹ thuật Dtech chuyên cung cấp thiết bị điện công nghiệp chính hãng, với hơn 10 năm kinh nghiệm và hơn 10.000 khách hàng tin tưởng Chúng tôi cam kết mang đến giải pháp mua hàng tối ưu, bao gồm bán hàng chính hãng, giao hàng tận nơi và tư vấn miễn phí Địa chỉ văn phòng tại Hà Nội và Hải Phòng, liên hệ qua hotline hoặc email để được hỗ trợ kỹ thuật tận tình.
Overload relays are essential devices used to protect electric motors from damage caused by overloads and overcurrents, which can lead to overheating and failure They monitor the current flowing through the motor circuit and trip when the current exceeds a preset limit for an extended period, thereby cutting off power to prevent damage There are several types of overload relays, including bimetallic thermal, electronic, eutectic, and solid-state relays, each operating on different principles Overload relays can be manually reset or automatically reset after a fault is cleared, ensuring the motor can be restarted safely They are critical components in motor control centers and starters, contributing to the reliable operation of electric motors across various industries.
[10] unitronicsple.com “What 1s the definition of PLC?” Available: https://www.unitronicsplc.com/what-is-plc-programmable-logic-controller/
[11] ene24h.com “GOI DO VONG BI UCE” Available: https://cnc24h.com/goi-do-vong- bi-ucf
Van điền ttr phi 21mm/27/34/48/60 là sản phẩm chất lượng cao, sử dụng điện áp 220V hoặc 24V Với thiết kế từ nhựa bền bỉ, van có khả năng chống nước và chịu được mưa nắng hoàn hảo, đảm bảo hiệu suất hoạt động ổn định Thông tin chi tiết có thể tìm thấy tại trang web shopee.vn.
[13] shopee.vn “[Van bi điện 2 lỗ] Van khoá nước dong mo diéu khién bang motor dién 220v phi 42 49 60” Available: hffps://bom.so/ASQOPVu
[14] inverterdrive.com “Toshiba VF-S15 15kW 400V 3ph AC Inverter Drive, DBr, C3 EMC” Available: https://inverterdrive.com/group/AC-Inverter-Drives-400V/Toshiba- VES15-4150PL-W-400V-Vector-Inverter/
[15] codienhaiau.com “Contactor Chint NXC-09 9A 4kW” Available: https://codienhaiau.com/product/khoi-dong-tu-nxc-09-dong-amper-9a/
[16] codienhaiau.com “Contactor Chint NXC-22 22A I11kW” Available: https://codienhaiau.com/product/khoi-dong-tu-nxc-22-dong-amper-22a/
[17] shopee.vn “Relay kính trung gian Omron 14 chan MY4NJ Kém dé 12VDC 24VDC 220VAC 380VAC” Available: https://by.com.vn/oUIzSi
[18] shopee.vn “Relay trung gian 14 chan My4n 220v omron (tang chan dé)” Available: https://by.com.vn/8H8ydz
[19] codienhaiau.com “Relay nhiệ Chín: NXR-2S (17-25A)” Available: https://codienhaiau.com/product/relay-nhiet-nxr-25-17-25-day-amper-17-25/
[20] codienhaiau.com “Relay nhiệt Chín NXR-25 (7-10A)” Available: https://codienhaiau.com/product/relay-nhiet-nxr-25-7-10-day-amper-7-10/
[21] Siemens “SIMATIC $7-200 Programmable Controller System Manual”
[22] janesvilletool.com “Comparison: the main differences between pneumatic, hydraulic and hydropneumatic presses” Available: https://by.com.vn/KKmKrn
[23] clubtechnical.com “Power Screw | Applications, Types, Advantages, Disadvantages, Parts” Available: https://by.com.vn/qFFQja, October 24, 2018
[24] pharmapproach.com “Roller Mill” Available: https://www.pharmapproach.com/roller-mill/?fbclid=IwA R1-
CrixP9 lawfZM041t7ufSKLivA5O8Nqz4jKkzMINuB8TsO6UxmSIaEVE, July 5, 2020
[25] clubtechnical.com “Chain Drive | Definition, Types, Advantages, Disadvantages”
Available: https://clubtechnical.com/chain- drive?fbclid=IwAR1_16QTd13RqGMD6XW/JxoxkDcdG1te VhOhR WigqLsgsj8N YIShU6 Y2oZpAE, October 31, 2018
[26] mecholic.com “Belt Drive - Types, Advantage And Disadvantage” Available: https://www.mecholic.com/2015/11/belt-drive-advantage-and- disadvantage html?fbclid=IwAROCRc YO09kafHoW yttKcQ7FLmsul57M3c VdUL6q1294 yFlwStKK77708B4M
[27] clubtechnical.com “Coupling | Types, Advantages, Disadvantages, Applications” Available:
88 https://clubtechnical.com/coupling?fbclid=IwAROWJ2xnA Wc46uGeGgybjIMB8UPQaai V CIg5vUs8csm7ZJojin45colIK X48, October 28, 2018
[28] dienmayxanh.com “Máy bơm nước đây cao Tolsen 79970 370W” Available: https://www.dienmayxanh.com/may-bom-nuoc/may-bom-nuoc-tolsen-79970-O5hp
Bơm nước dòng điện 12V và 24V không chổi than với ren ống phi 21mm là sản phẩm siêu mạnh, lý tưởng cho hồ cá, hòn non bộ và thủy canh Sản phẩm này có thể được tìm thấy trên Shopee tại địa chỉ: https://shopee.vn/product/42630023/8853504386.
[30] lazada.vn “Máy bơm nước mini bơm tự mỗi DC 12V-24V động cơ 385 bơm 2 lít/phút
- LK0082” Available: https://www.lazada.vn/products/may-bom-mini-bom-tu-moi-de- 12v-24v-dong-co-385-bom-2-litphut-1k0082-1296246688.html
Công suất máy bơm nước là yếu tố quan trọng quyết định hiệu suất và khả năng hoạt động của máy bơm Để lựa chọn máy bơm phù hợp, người dùng cần hiểu rõ cách tính công suất dựa trên các yếu tố như lưu lượng nước và độ cao cột nước Việc nắm vững thông tin này sẽ giúp bạn chọn được thiết bị hiệu quả nhất cho nhu cầu sử dụng của mình.
[32] N.T.D.Tram “TINH TOAN VA THIET KE THIET B] CO DAC MOT NOI DUNG
DICH NaOH” Graduate thesis of Industrial University of HCMC, August 4 2014
[33] N.H.Léc “Co so thiết kế máy”
[34] T.V.Minh, D.V.Huy “THIET KE HE THONG EP NUOC COT DUA”
[35] V.T.D6 “TINH TOAN THIET KE MAY XAY THIT 8KG/ME” Graduate thesis of
Mức tiếp xúc cho phép tiếng ồn tại nơi làm việc được quy định cụ thể: không vượt quá 112 dBA trong 1 phút, 94 dBA trong 1 giờ, và 85 dBA trong 8 giờ Tại các vị trí lao động trực tiếp, giới hạn là 85 dBA; trong các phòng chức năng như hành chính và kế toán là 65 dBA; và trong các phòng nghiên cứu, lập trình máy tính là 55 dBA Ngoài ra, mức áp âm cực đại không được vượt quá 115 dBA trong mọi thời điểm làm việc, và quy chuẩn này không áp dụng cho người sử dụng tai nghe.
Để tính toán tốc độ của động cơ điện, cần hiểu rõ các yếu tố ảnh hưởng đến vòng quay và lý do tại sao động cơ không đạt được tốc độ lý thuyết Bài viết trên trang diencobacninh.com cung cấp hướng dẫn chi tiết về cách tính tốc độ và các nguyên nhân phổ biến dẫn đến sự chênh lệch giữa tốc độ thực tế và lý thuyết Việc nắm vững các khái niệm này sẽ giúp người dùng tối ưu hóa hiệu suất của động cơ.
[38] maybomnuoc99.com “Dinh nghia va so sanh déng co dién 2 cuc, 4 cực và 6 cực” Available: https://Amaybomnuoc99.com/dong-co-dien-2-cuc-4-cuc-va-6-cuc/, August 29
20 WWE World Wide Fund for Nature
Appendix 2: User manual for pulp making machine ¢ Assemble pulp making machine
Pulp making machine compounds 3 main parts namely pressing machine, washing and grinding machine and water tanks
Step 1: Assemble dehydration and output material part
Dehydration and output material part
Step 2: Assemble the spiral part
Step 3: Assemble the transmission part
The cover for the machine
The washing and grinding machine
Step 1: Assemble the muff coupling into the shaft of grinding motor
Step 2: Assemble the washing and grinding tank into the frame
Step 3: Assemble the blades into the muff coupling
Step 4: Assemble the lid onto the washing and grinding machine
Step 5: Assemble the water pump into the frame
Arrange water tanks and pipes suitably with the pressing machine, and the washing and grinding machine
The washing and grinding machine a ¢ Operating manual
Manual mode with pure water
Note: Each step is interrupted by “STOP” button
Step 1: Supply power to the machine
Step 4: Provide the incubated materials into the pressing machine
Step 5: Press “Pressing motor” button to run the pressing motor, and press “Pump reverse” button to pump into the washed water level 1
Step 6: Press “Supply pump” button to move the pressed materials to the washing and grinding machine
Step 7: Press “Grinding motor” button to run the washing and grinding machine
Step 8: Press “Water pump” button and “Lock valve 1” button to pump the washed water into the washed water level 1 tank
Step 9: Repeat step 6 and 7, respectively
Step 10: Press “Water pump” button and “Lock valve 2” button to pump the washed water into the washed water level 2 tank
Step 11: Repeat step 6, 7 and 10, respectively
Step 12: Press “Glue pump” button to pump the glue
Step 13: Repeat step 6 and 7, respectively
Step 14: Press “Exhaust valve” button to exhaust pulp
Step 15: Press “STOP” button to stop the process
Manual mode with recycle water
" Each step is interrupted by “STOP” button ô Press “E-STOP” in emergency case
Step 1: Supply power to the machine
Step 4: Provide the incubated materials into the pressing machine
Step 5: Press “Pressing motor” button to run the pressing motor, and press “Pump reverse” button to pump into the washed water level |
Step 6: Press “Recycle pump” button to move the pressed materials to the washing and grinding machine
To operate the washing and grinding machine, first press the "Grinding motor" button to initiate the grinding process Next, activate the "Water pump" button along with the "Lock valve 1" button to transfer the washed water into the level 1 tank.
Step 9: Repeat step 6 and 7, respectively
Step 10: Press “Water pump” button and “Lock valve 2” button to pump the washed water into the washed water level 2 tank
Step 11: Repeat step 6, 7 and 10, respectively
Step 12: Press “Glue pump” button to pump the glue
Step 13: Repeat step 6 and 7, respectively
Step 14: Press “Exhaust valve” button to exhaust pulp
Step 15: Press “STOP” button to stop the process
Auto mode with pure water
Step 1: Supply power to the machine
Step 4: Press “START” button to operate the full process
Step 5: Press “STOP” button to stop the process
Auto mode with recycle water
Step 1: Supply power to the machine
Step 4: Press “START” button to operate the full process
Step 5: Press “STOP” button to stop the process
Step 1: Supply power to the machine
Step 3: Press “Pressing motor” to run the pressing machine, and press “Pump reverse” to clean the chemicals storage
Step 4: Pour water into the funnel of pressing machine
Step 5: When the output of spiral part only has pure water, it means the pressing machine is completely clean
Step 6: Use a towel to clean the housing of pressing machine
Step 7: Press “STOP” button to stop the machine
The washing and grinding machine
Step 1: Supply power to the machine
Step 3: Take and clean the lid with water
Step 4: Spray water into the internal structure and use plastic brush to clean and remove completely pulp
Step 5: Press “Exhaust valve” button or “Water pump” button to exhaust water Step 6: Press “STOP” button to stop the machine ¢ Common troubles
When excessive incubated materials are fed into the pressing machine funnel, it leads to improper distribution, preventing the materials from moving to the spiral section effectively.
" We have to gradually provide the incubated materials ô We can use a stick to transfer the incubated materials to the spiral part
Cause: When the system has more than two electrical devices run during the operation, the system turns off suddenly
Solution: We have to interrupt power supply and check whether is enough or not
Symbol Var Type Data Type Comment
Sart 100 Stop_bution 101 Step_2 M02 Recycle_water O3 Manual 102
Step 2 M02 Stop_bution 101 Lœk vawe 3 @02
Step 5 M05 Stop bution 101 Lock _valve_1 Q00
Slep 37 :M57 pump 2 _bt :Ð5 Manual :10.2 purp_2 :Q05
T42 Siep_9 :M10 Stop_button 1101 Stp_8 :MO7
Slep 10 :M11 Stop_bution 10.1 Lœk vadw 2 @01
T53 Sop bon 10.4 SEp 22 M30 ‘Step_1 MO1 Seo 21 :M22
Sep 21 :M22 Stop_bution 10.1 = Exhausted va~ -Q14
T54 SEp 23 M31 Stop_bution 'l01 Manuel 102 Pure_weter “104
T101 Stop_button 10.4 Manual 102 Step_24 M32 Sep 23 M31
Slap 23 M31 Stop_bution 10.1 Lock_vave_ 4 -Q03
T102 Step 25 M33 Stop_butian 101 Manual 102 Step_24 :M32
T104 S&p 27 :MS5 Stop_bution :10.1 Manual :10.2 Step_25 :M3.4
T107 Step 31 M40 Stop_butian 101 Manual 102 Sep ® :M37
T108 Sp 32 M56 Stop_bution 101 Manual 102 Step_31 M40
T128 Step 34 M42 Sœp bướm 101 Manual 102 Sep 33 :M41
T10 Sp 35 M43 Stop_bution 101 Manual 102 Sp 31 M42
T11 Sep 36 :M44 Stop_bution :I01 Manual :10.2 Siap % :M43
TH2 Step_37 M57 Stop_bution 10.4 Step 36 M44