AASTU PROJECT 2021

Chapter 4

Project contribution

4.1. Abstract of the project

Our project is a reciprocating bottle crusher machine that can be applied in all soft drinks and
brewery factory. It contains 7 main topics with some subtopics. All concerns with from the idea of
the project up to making of the project. The first four main topics concerns with the background,
objective, significance, and feasibility of the project. The rest all concern with the overall design
process of the machine starting from taking the standards of some machine devices like motor,
bearings as it is and showing the methodology and the design calculation to fit with the standards
that we take as it is to avoid the disturbance and deformation of parts and to make the machine to
perform efficiently and effectively, to give long lifetime it.

Finally we tried to show every parts and overall the prototype in solid works or catia and showing
the animation. But we cannot make the prototype due to the cost of parts and the time we have left
becomes short as well.

4.2. Background of the project

Moha soft drinks produce different type of soft drinks in glass and in plastics. There are many
problems with in it that have to be resolved to increase the efficiency. Just to list some are the bottle
crushing system is manually with 3 4 5 laborers, the damaged glass is selected manually, the
volume level detector has also errors, emission of the gas from the co2 room and boiler room,

We chose the bottle crusher machine even though it has more compact structure, its importance
regarding in decreasing the cost to the company and labor force as well. We thought different ways
to make it. Like gear mechanism, or simple reciprocating crusher or by using the waste water to run
the reciprocating machine. But to make it more efficient and simple we chose the reciprocating
machine with motor as a source.

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4.3. Objective of the project

The problem is the way of bottle crushing is manually with 3 or more labor forces. The objective is
to reverse the forces with machine.,

General objectives

To avoid the risk of harming the workers {sharp bottle pieces}

To decrease tiredness
To facilitate the time of crushing
To decrease cost of the company relatively
To make easy for transportation {relatively same shaped pieces}

Specific objectives

 To design shaft

 To design bearing

 To design bearing house(case)

 To design all the parts by using the software solid works

Figure 4.1: Manual breaking of bottles

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4.4. Significance of the project

Simply the objective is the significance.so some main importance of fabricating this machine are as
follow:

 To avoid the labor forces.

 To avoid the risk of to be harmed of the workers body parts {fingers, hands, legs, eyes}.
 To minimize the cost and the time to change to small pieces.
 It takes small space.
 To get the desired output with low cost.
 To increase the efficiency.

4.5. Feasibility of the project

 Feasibility is the degree to be successful in designing or applicable and fit to the objectives.
 As We have selected materials that are easily available in the market with low cost like
 woods,
 pieces of cast iron
 concrete
 As far as we developed the design of the machine using solid works, it can come to true if
we can get financial support even though we cannot develop the prototype. Therefore we
can say this project is feasible.

4.6. Overall design process

4.6.1. Literature review

To be more profitable and effective we sited related literature reviews concerned with the bottle
crushing machine and the industries or other places which use that kind of mechanism to resolve the
problems and to be more profitable.
According to Waste production equipment by PROFOUND (2017) ‘Jaws’ waste glass bottle
crusher is a low height standalone glass bottle crusher or glass bottle breaker that generates savings

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on labor, creates space and reduces overall waste glass disposal costs for businesses producing
waste glass bottles. Benefits of the BB03 ‘Jaws’ include:

REDUCE LABOUR AND DISPOSAL COSTS

The ‘Jaws’ eliminates the need to sort waste glass bottles into different colors which dramatically
reduces the labor cost associated with managing those waste bottles, the frequency of glass
collections required and the overall waste glass disposal costs for your business.

SAVES SPACE

The BB03 reduces was glass bottle volume by 5:1 or 80%, dramatically reducing the space required
for storage of waste glass prior to collection.

BB03 IS MOBILE

Wheels built into the machine base makes it easy to move and store if space is at a premium.

‘PLUG & PLAY’ INSTALLATION

The BB03 requires a 220V/50Hz mains electricity supply, is connected via a standard 3 pin socket
and with dimensions of 1085mm (W) x 1060mm (D) x 1220mm (H) is easy to install.

WIDE 530MM X 240MM CHUTE

Large bottle loading chute allows multiple bottles to be fed and crushed simultaneously reducing
time required for managing waste glass bottles

CRUSHED GLASS IS 100% RECYCLABLE

The crushed glass produced by the BB03 is 100% re-processable into new bottles saving on C02
emissions and carbon footprint associated with production of glass bottles.

 According to Harden Zhongshan, Guangzhou, Shenzhen (2019) GB101 Glass Bottle

crusher GB series are special design for shredding glass bottle, which can reduce the
volume of glass-bottles by 75%, thus greatly saving storage space. Our glass bottle crusher

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is widely used in bars, restaurants, hotels, kitchens and supermarkets, on the ship/boat and
other offshore installations and marine situation.
Features
-Energy saving
-Safety in-feed port
-Low noise
-Foot print, light weight
-Easy and save operation
-Knives made of wear-resistant alloy

Specifications
Motor power------------------------1.1 KW
Feed opening-----------------------D80 mm
Feeding way------------------------one by one
Machine dimension---------------1200*400*1300 mm
Machine weight-------------------140Kg
Volume reduction----------------->75%
Speed--------------------------------1450 rpm
Output range----------------------30/min

4.6.2 Design methodology

The design methodology involves the following processes.
Let us see one by one
4.6.2.1 Planning method

 Think by ourselves and Contact talk with the company workers about the problems in the
company.
 Select the problem and Collect data using primary and secondary ways of collecting data
{primarily by asking the authorized individuals and secondarily by surveying different
literatures and searching on the web}.
 Selecting materials for each component by studying the working conditions of all the
COMPONENT.

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 Analyze the stress of the shafts.

 Design the rest of the components in relation to the crusher.
 Draw both the part and assembly drawing as per the dimensions designed using catia or solid
work.

 Conclude the project.

4.6.2.2 Data collection method

 Primary way of collection –by contacting some workers of MOHA soft drinks at Dessie
and talk about the way of crushing and the exhausting power and about the way to how we
can develop the machine.
 Secondary way of collection –by searching how we can perform the task and making
profitable by decreasing the size, the structure, the parts like motor, and the cost as well.

4.6.2.3 Data analyses method

 Material selection is a means of selecting material that best suited for the member of
machine to be designed. As a designer material selection should be done carefully in order
to design each components, that will serve till the end of service life.
 The basic considerations done in selecting materials are; Strength, Toughness, Ductility,
Hardness…etc. for each components of the crane.
 There will be a geometric analysis of the components of the machine by using solid works
application software. The force analysis of the machine will be considered and the
components of the machine will be designed and analyzed by calculation.
4.6.2.4 Evaluation methods
The designed machine will be seen by the software solid works to determine and investigate
whether it is satisfying the objective of the research or not.
4.6.3 Detail design process
4.6.3.1 Detail sizing, analyses and making of equipment of the project
We make the project using the following main and supporting parts.
Main part
 Motor

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 Gear
 Shaft
 Hammer
 Bearings
 Mortar (concrete)
Supporting parts
 Table
 Hammer holder
 Circular plate
 Bolt and nut
 Key
 Hopper
 Connector
Main parts’ Calculation to select the right sizes.
 Motor
 Shaft
 Bearing
 Keyways
This is why?
 To select the right motor respective to their power with low cost as much as possible.
 To prevent destruction of parts.
 To increase its efficiency.
The most important thing is using simple, less costed motors that can perform our task. So
We prefer to select the motor starting the calculation from the weight of the hammer.
 Motor selection
To select the motor we have used the following steps.
1. Finding the weight of the hammer, its holder and the circular plate and connector.
2. Finding the torque for the circular plate at the shaft.
3. Finding the torque for the motor at the shaft.
4. Equating the two torque and determining force for the motor.

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5. Selecting the right motor that can have appropriate motor torque, power, speed and
low cost as much as possible.
Step by step calculation
1. Weight of hammer total
As we have used the hammer made of cast iron. So Cast iron has a density of 7.2 g/cm3. We can
see the structure below.
Density =mass/volume
Mass=density*volume

Mass of the hammer Mass of hammer holder (hollow shaft)

Vh = Vbox-Vtriangle Vholder ¿ π r 2∗h
= (l*w*h)-2(0.5*lt*bt*ht) = 3.14*(62-5.52)*50cm
= (15*10*20)-(5*10*20) = 903.2 cm3
= 2000cm3 Mhh = density* volume
Mh=density*volume = 7.2*903.2= 6.5 Kg
= 7.2g/cm3*2000cm3
Mh = 14.4 Kg

Mass of the circular plate Mass of the connector

Vp = π r 2∗t Vc = Vlarger-Vsmaller = ((32*8)+3.14*42)-((4*32)+3.14*22))*4
= 3.14*(20cm)2*5cm = 662.72 cm3
= 6280 cm3 Mc=662.72*7.2
Mp = 6280*7.2 = 4.772 Kg
= 45.2 Kg

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Total mass of the hammer and others is M total = MH+Mhh+Mp+Mc= 70.872 Kg

Weight of the hammer and others overall = mass*gravity
= 70.872* 9.81
= 695.25 N
2. Torque at the contact with circular plate
Torque at A
TA = F*rA
= weight of hammer*r
= 695.6 N* 15cm
TA = 104.3 Nm

3. Torque at B from the motor side

The motor has power P, torque Tm, speed N, radius of motor shaft rm
We take 30cm and 15cm root diameter to the larger and smaller gear respectively.
Tm=Fm*rm
Turning Effect of force at B
TB= Fm*(rlarger+rsmaller)
TB= Fm*(15cm+7.5cm)
TB= Fm*0.225m
4. Equating the two torque
The torque at A is equal to the torque at B
TA=TB
Fm*0.225m=104.3 Nm
Fm= 463.5 N
This value is the minimum force needed to withstand the effect of the weight of the hammer.
5. Selecting the desired motor
After searching of motor standards we have taken WEG 6.4HP Electric motor 23 AMP 7/8"
diameter shaft that has 3450 RPM.
Because it fulfils the minimum force of 460.4N as we see below.
P= 6.4HP=6.4*746 W=4.774 KW
Tm=Fm*rmotor shaft

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p∗60
Tm=
2 πn
4.774∗1000∗60
Tm=
2 π∗3450
Tm=13.2166 Nm
Tm=13247 Nmm
Tm=Fm*rmotor shaft
Fm= 13247Nmm/11.1125 mm
Fm= 1192 N
This force is highly sufficient to perform the task. it is more than two times of the minimum
required force. It is not necessary to be more high force of motor because the cost become high and
take more power and its lose will increase.
Let us see the overall selection process as follow;
Motor standards Force vs Fneeded Weight Cost Effectiveness

WEG 1189.4N(> 2.5 56 pound Medium (Mini. More

6.4HP,7/8"Dia,3450RPM times) 285 dollar)
Air Handler Furnace 11.88pound( sm Less(74.99 Less(time
HVAC Blower 5- all structure) dollar) consuming)
5/8"dia.1/3HP,1075/3RPM
High(costy) Highly

By comparing these motors, we selected WEG motor that is relatively better with its standards to
this project. Because
- Its force is high. This means with short time the bottle will get crushed fully.
- Its cost is relatively good to the purpose.
- Its mass is relatively medium and better.
 Design of the shaft diameter
We take the shear stress of the shaft τ = 42 MPa = 42 N/mm2.
Let ‘d’ be the diameter of the shaft. We can calculate the diameter using the shear force or twisting
formula. We have the shear force, we can calculate as follow;

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TB=Π/16 * τ*d3
Fm*0.225m=3.14/16 *42 N/mm2*106 m2*d3
1192 N*0.225 m=3.14/16 *42 N/mm2*106 m2*d3
d3=32.54*10-6m3
d=3.193*10-2m
d=31.93mm
dshaft =32 mm.
 Selection of bearing
A bearing is machine elements which support another moving machine element (known as
journal). It permits a relative motion between the contact surfaces of the members, while carrying
the load. Depending upon the nature of contact, the bearings under this group are classified as
Sliding contact bearings, and Rolling contact bearings.

For this project Rolling contact bearings is selected because of Low starting and running friction
except at very high speeds. Ability to withstand momentary shock loads.

As the load is mostly radial (perpendicular to the shaft), we use a radial ball bearing.

According to the table below inner diameter means the shaft diameter. So our shaft diameter is
32mm or 1.25"(inch), it will have outer diameter 72 with width length of 17.

We think this bearing is the right one because

- It is appropriate for the machine’s usage environment and the operating condition that
being demanded of the bearing.
- It is easy to acquire replacement bearings and facilitate maintenance/inspection of the
machine.

Therefore, damage of the machine can be reduced, the time needed to replace the bearings when
performing repairs can be shortened, and the machine can be used for a longer period of the time.

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Bearing case

-The bearing case is used as housing of the bearing to prevent and easily connected with the frame.
The bearing houses have internal diameter of 72 mm (from the bearing outer diameter) and outer
diameter of 100mm.
Bearing and its case structure on solidwork

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 Selection of keyways

For this machine we have used rectangular keys because if the size of the key to be selected based
on the shaft size, they are standardized for rectangular keys.

Our diameter of the shaft is 32 mm. So as we used the standard key stock table, the key structure
has to be number 6 and 7 as we see on the table below.

We have used keys in the gear mechanism and to connect the shaft to the circular plate.

The key we used to connect the gear to the shaft and the shaft to the circular plate fulfils number 7
according to the shaft diameter 32 mm. This means the key has breadth 10, height 8, depth 28, t1 5,
t2 3.3.

But the key to the motor shaft and the larger gear is under number 6 below because the motor shaft
is 22.225 mm or 7/8". This means the key will have breadth 8, height 7, depth 24, t1 4, t2 3.3.

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Keyway structure on solidworks

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The others are;

 Gears
- to convert the power input to a desired one to the other body of the machine.
- we took 30cm and 15cm root diameter to the two gears.
Gear structure on solidwork

 Hammer
- is a prism with trapezium at the base structure.
- It is designed with safe surface to hammer the bottle.
- It has 5 and 15 cm at the two bases and 10 cm breadth.

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 Hammer holder (hollow shaft)

- we used a hollow structure that has internal and external diameter of 11cm and
12cm with height 50cm.
- we made it to minimize the weight of the holder.
Hammer holder structure on solid work

 Mortar
- It is the surface that hammering of the bottle is takes place.
- It can be of concrete or some pieces of iron connected together to save cost.
- We make it by considering the size of the bottle and to contain many bottles at once.
- Its structure is slanted at the top, two same structures mesh together and have some gaps to
let pass in small crushed pieces.
Mortar on solid work

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 Bolt and some supporting structure like table…

-Bolt -used to connect two or more parts together.
- Nut- used to fix in position or to resist disturbance.
-Supporting structure-applied just to give a support to the system.
Example,
Table
- To carry all the equipment together.
- It can be of wood.
- Its dimension must fulfil the minimum size of the assembly.

Hopper
- Simply it is a bottle container that has an inlet and an outlet.

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- It is designed the inlet and outlet based on the bottle shape.

- As the bottle in the mortar gets crushed and fall down to the gap, the hopper let pass in another
bottle and the process goes like this.
-This it is not such a big issue to have a man to control the opening and closing.

 Circular plate
- a circular body that hangs the hammer and connected to the shaft with keyway.
- has a radius of 15cm, 4cm thickness and contain a fixed pin that enable the weight to have a
reciprocating motion with a supporter.

- The aim is to find the time to break the bottle completely or the pressure on the bottle.
The hammer at the base has rectangular structure with 10 cm and 5cm sizes.

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The pressure is simply the force divided by the area of contact (between the hammer and the
bottle).

4.6.3.2 Assembly of major equipment of the project

Overall assembly of the reciprocating machine

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4.6.4 Result and Discussion

Result of the design procedure
The design procedure has several criteria to get a successful machine. we used two bearings with a
supporter to withstand the weight of the hammer and other parts. As we used catia and solidwork
technology, we could develop the design with detail procedure. Overall it looks perfect because we
considered all the criteria that have a significant effect on the system in the calculation.

Usage
As the name reciprocating indicates the machine hammers the bottle in up and down direction. It
has a hopper at the base with an inlet that can let pass a bottle alone as they get hammered. It is
already designed a gap at the mortar to let pass the crushed bottle when it fulfils the needed
maximum shape. We can insert bottles to the mortar as the number of bottle remains decrease. We
will do till the end.
Discussion
Project outcome
When it finished, this project gives a lot of profitable things to the industry. The industry needs this
kind of machine to increase its quality as an industry. The achievements gained by the project are:

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 it reduces the time waste to crush the bottles manually.

 it is safe to the crusher.
 it increases the profit to the industry because it is not time consuming.
 it saves the energy of the labours.
So in general the project outcome is worthy to the industry and it is simple and understandable to
use the machine by the workers.

Further development

This project is just simple to design and to interpret its prototype by materials found in the industry.
To increase its efficiency and effectiveness, we can add other mechanisms like:

 Use conveyor system to insert the bottles to the hopper and to left out the crushed bottles
from the bottom of the frame of the machine.
 Using sensors to run and stop automatically the machine.
 Increase the size of the machine by increasing the parameters like motor capacity, mortar
and hammer size,….
By those kinds of ideas we can improve the project we are working with and we can upgrade its
outlook too.

4.7 Conclusion and recommendation

Conclusion
Generally the reciprocating glass bottle crushing machine is a machine used to crush glass bottles in
order to sell it and get a new glass bottles. The main purposes to crush the bottles are to save space,
time and energy. This project deals about the design of bottle crusher. So as a conclusion the
industry needs bottle crusher machine to increase its profit as a company because the bottle melting
and producing companies buy crushed glass bottles in a higher money than the non-crushed ones.
Recommendation
Some ideas that we want to recommend to the company besides its good strength are listed below;

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 This project can be improved by adding more helpful materials and by increasing the size so
that the number of crushed bottles at one time will be greater.
 Regarding to the workshop when we were working in a company we see some problems on
work shop area of the factory. If it was not a big workshop there is no enough area to
perform a task.
 The company should treat internship students.
 The company should give good supervision and advice and appreciation to the students to
works and projects.
5.2. RECOMMENDATION
5.2.1. Recommendation to UIL office
The condition which the official of the UIL office arranges in relationship with an internship
hosting company for the students who choice their hosting company by their own interest and
students who have not got their own hosting company that are assigned by the UIL office is a good
situation for the students. Personally, we recommend that the office should keep its current good
sides and have to work for better things.
Some points which we think should need some improvements are; -
• It’s better for students if the office arranges them to work in different companies.
• The office should strictly warn the host companies to give a focus for students.
• As much as the office should deal with the company’s managers to help the students to get a
financial support.
• The office should Increase the awareness of the companies about the internship program and
motivate them to give projects for students.
5.2.2. Recommendation to host company
Even if the company has several strong sides there are some things we think can be corrected.
• Regarding to the workshop: when we were working in the company, we have seen some
problems on workshop area of the factory. It is a big workshop but there is no enough area to
perform a task. In addition, it is found near to the manufacturing area. Because of that there is a
noisy environment around the workshop area. This will hurt the workers’ health. And since all
machining processes is performed in a small place this will expose the workers to a danger.
• Regarding to health and safety: regarding to health they have a good focus on it. But there
are some problems regarding to sound pollutions. In addition to this they use Asbestos to damp the

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sound of the generator. The dust of this asbestos will cause the lung cancer on the workers.
Personally, we recommend that the company should have full access of safety material since the
working technicians are not well protected in the company.
• Regarding to material wastage: MOHA soft drink has a full store. We can get the spare parts
of almost all machines. But there are some problems regarding to material usage. we have seen that
most technicians tend to completely change the machines’ part even they can modify it easily. This
will decrease the creativity of the technicians and will expose the factory to a material wastage. So,
the company should have work to develop the mechanism that will appreciate them to use their
experience rather than always changing the parts.
• Regarding to waste treatment: There are several wastages that come out from the company.
It includes several chemicals, washer machine…etc. But the company has no proper waste
treatment plant. This will cause damage on the environment. So, they should have to look for the
opportunities. I recommended that there should be recycling mechanism these wastes for further
application example water can be recycled through treatment and used for several purposes like for
washing some material and as an input for different demands on the factory.
• Regarding to surface area of the company: the company produce so many soft drinks.
Because of more need in the company’s product, they will not be stored that mean they have to be
transported quickly. This transportation needs enough space, but the factory has no enough space
for loading and parking the cars. So, this may will lead to a car accident and decreased distribution
of the products and wastage of time. In addition, if some problem occurs in the transportation
system, they have no enough stores to store their products. So, if those products didn’t leave the
store quickly, they forced to stop their production. This will alter their soft drink quality that is
stored in the tanker. So, they have to look on it.
Additionally, we recommended the Company to,
• Employee skilled worker.
• Fair payment for workers.
• Recycle scrap material.
• Have a good clinic.
We recommend the workers/employers about their good and weak aspects.
we appreciate for their good aspects like: -
• Their Activity to protect the environment from pollution.

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• Punctuality
• Honesty to the manager
• Work ethics
• Quality of the product
We also recommend over their weakness: -
• Poor in material protection
• The workers have not enough wear.
• Production’s workers wear is not clean.

5.2.3. Recommendation for the Department

The department of electrical and mechanical engineering is very wide and interesting department,
we wish there are
• more practical learning,
• arranged visiting to some companies to see how they operate,
• more workshop subjects and more practices,
• Full organized workshops with skillful supervisors.
We appreciate everything you done for us, but we also hope there is more practical learning to the
future, which help us to learn more and make us familiar with our department.

References

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