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development of an automated briquetting machine

1. Electrical Diagram Poss Sense EST 24 V 1 25 A Solenoid 1 Solenoid 3 Solenoid 2 Solenoid 4 24V 0 3A DC 24V 0 3A Fuse 2 A Fuse 4 Fuse 3 8 14 7 8 14 8 14 8 14 SSR SSR SSR SSR MY4N D2 MY4N D2 MY4N D2 MY4N D2 42 138 112 123 412 33 412 213 Fuse 1 Proximity 24V Sensor 3 Out TSC1207 N OV Proximity 24V Sensor 3 Out TSC1207 N OV Proximity 24V Sensor 3 Out TSC1207 N OV AC 220 VAC 24G L l1 LJ 24V Inputs 24V 0 3A L N S S 24V 24G XO X1 X2 X3 X4 X5 X6 X7 X10 DELTA DVP 32EHOOT2 CO YO Ci Y1 C2 Y2 C3 Y3 YA C4 Y5 Y6 Y7 APPENDIX G 141 Pressure Switch Horizontal Cylinder e Pres
2. 4 with the biomass on the mold when the pressing is done It oade ana F 2 is important that it can sustain the pressure that will be oaas an DCS ce ee applied during machine operations Contact Informations 5 Mesh Information 5 Resultant FOFC S 2 6 Study Results 2 sec coscoscccee 7 2 DS Simulation of Briquette Machine v1 4 Vertical Cylinder SOLIDWORKS Analyzed with SolidWorks Simulation Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Model Information Model name Briquette Machine v1 4 Vertical Cylinder Case Current Configuration Default Solid Bodies Document Name and TUA PACA Volumetric Properties Document Path Date Reference Modified Cut Extrude3 F School Mass 3 42958 kg Se N Volume 0 000434124 m 3 CODE E Solid Body Density 7900 kg m 3 achine Design v1 ace Final Briquette Machine MERS OUEN v1 4 Vertical Cylinder Case SLDPRT Jul 08 02 56 14 2012 Fillet1 F School Mass 0 366527 kg i Meer E Volume 4 63958e 005 m 3 mn ae E y Solid Body Density 7900 kg m 3 achine Design v1 Odd Final Briquette Machine REA S APR v1 4 Vertical Cylinder Case SLDPRT Jul 08 02 56 14 2012 A 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Study Prop
3. briquettes at current PandT NO Y Increase Pressure and or A Temperature by N amount of increment Figure 3 17 Densification Process 55 cA Feedstock Ingredients Acquisition l Feedstock Preparation Densification Operation Do modifications amp improvements NO Display to Monitoring System Biomass Briquetted YES Y Continue Densification Operation Data acquisition from sensors Record for further analysis l Other forms of Data Acquisition Figure 3 18 Summary of Briquette Press Operation and Testing i 5 Error s Occurred NO Disturbance s Occurred NO v YES Control using gt Operation until machine installed functions Continue feedstock runs out Ce Use Emergency Stop Button Troubleshoot Restart Densification Operation 56 Chapter 4 RESULTS ANALYSIS AND CONCLUSION This chapter presents the data gathered through simulations and experimentations done by the group The simulations were done on the design phase of the study before the actual fabrication and procurement of materials The experiments are presented mostly in table form with their co
4. Nameplate Explanation Model Serial No Explanation 32EH00R2 0 T 6 160018 ES Production No Production week Production year 2006 Production plant Taoyuan Version No Model name n Delta PLC model name gt mopeL DVP32EH00R2 Power input specification POWERINPUT 100 240VAC 50 60Hz 30VA MAX Output module specification 3 OUTPUTMODULE 2 0A 250Vac 50 60Hz RES LOAD TUBE UEM 32EHOOR2T6160018 Firmware version VX XX X DELTAELECTRONICS INC Barcode amp series No MADE IN XXXXXX A 1 2 Product Profile amp Outline Open COM cover p 3 4 5 RE S 6 De 8 s oe eere ence eene Q 0 lt as Mt 7 E X 5 9 4 9 Communication port cover Extension module connection port cover Q I O terminal cover Input indicator Function card memory card cover Output indicator O terminals DIN rail clip IO terminal No DIN rail 35mm lof Je Je 6 2 ES E ees ex ende Al Open COM2 cover Hm 6 7 8 Cy R i d m U Ez dell m m SU WS PAN Hectora aie 3 4 5 2 Mounting screw Memory card port Direct mounting hole POWER RUN BAT LOW ERROR indicator Battery socket Extension module connection port Function card mounting hole Remove RS 485 Removable Terminal Block i terminal For slave mode Shall be changed withi
5. Max Stress1 VON von Mises Stress 31599 9 N m 2 5 04514e 008 N m 2 Node 16298 Node 14380 Model name Briquette Machine v1 4 vertical Cylinder Mounting Assembly Study name 1000 Plot type Static nodal stress Stress1 Deformation scale 71 6675 von Mises M m 2 504 513 726 0 462 473 536 0 420 433 376 0 376 393 184 0 336 353 024 0 294 312 832 0 252 272 656 0 210 232 480 0 158 132 304 0 125 152 128 0 84 111 352 0 42 071 776 0 31 599 9 Yield strength 351 571 000 0 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly 1000 Stress Stress1 2 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Name Type Min Max Displacement1 URES Resultant Displacement 0 mm 0 697117 mm Node 14729 Node 12385 Model name Briquette Machine v1 4 Vertical Cylinder Mounting amp ssembly Study name 1000 Plot type Static displacement Displacement1 Deformation scale 71 6675 URES mm 0 697 0 639 0 581 0 523 0 465 0 407 0 349 0 29 0 232 0 174 0 116 0 0581 1e 030 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly 1000 Displacement Displacement1 2 DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C J
6. Proximity Sensors 2490 eS 100 All the expenses on the production of the experimental machine are tallied on the second column For the mass production machine the expenses for the modification of the machine and the purchase of the components that were only borrowed by the group from the University are listed on the third column It can be seen that the total cost of the experimental machine and the mass production machine are Php 85 224 00 and Php 200 400 00 respectively 4 1 3 2 2 Daily Operation Expenses Table 4 11 Electrical Consumption Part Power Consumption kW Power Supply 3 Motor 1 3 hp 73 Motor 2 0 5 hp 0 37285 2 98 Electrical Consumption expenses day Php 393 01 All the equipment that needs electricity are listed on Table 4 11 together with their corresponding power rating Multiplying with the amount of time they are used in a daily basis the electrical consumption of each equipment was identified The price per kilowatt was based on the average price in Metro Manila were the experimental machine is located Table 4 12 Biomass Preparation onas eld ds Ee Consumption Unit Price Php Price p kg day kg in Php Biomass Php 30 20 kg sack 60 00 For the experimentations done in this study a sack of rice hull and starch were purchased Based on the amount of binder used in every experiment and the price of each ingredient the cost of the feedstock per day w
7. A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Contact Information Contact Image Contact Properties Type Bonded Components 1 component s Options Compatible mesh Global Contact Mesh Information Mesh Information Details of elements wi Apec Ratio si V of distorted elements Jacobian OO Time to complete mesh hh mm jss 00 00 09 2 DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Model name Briquette Machine v1 4 Vertical Cylinder Case Study name 1300 Mesh type Solid mesh Resultant Forces Reaction Forces Selection set Units SumX SumY SumZ J Resultant Entire Model 0 233231 0 266266 4690 47 4690 47 Reaction Moments Selection set Units SumX SumY SumZ Resultant Entire Model Nm X Jo 33A Jo Jo X O A 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Study Results Name Type MD Max Stress1 VON von Mises Stress 390808 N m 2 2 52896e 008 N m 2 Node 1847 Node 12009 Model name Briquette Machine v1 4 Vertical Cylinder Case Study name 1300 Plot type Static nodal str
8. BR Ed EA Ee EAE Ee L 40EH2 DVP 40EH 24in 16out Relay l 24GLY0 LY1 LY2 v3 Le Jy4tye Le Y10lY12L 1Y14lV16L E EN Ca Tor A AA AE IAA Ei tQ L 40EH2 DVP 40EH 24in 16out Transistor Y71Y10 12Le v14lY16L 48EH2 Las x1o x12 x14 x16 X20 X22 X24 X26 x30 x32 X34 x36 o T UM e H24U X1 X38 X5 X7 x11 x13 X15 x17 X21 X23 X25 X27 X31 X33 X35 X37 64EH2 DVP 64EH 32in 32out col Y2 f Jct ve c2l y12f ea vi6f c4 v22lva4lv26 MEE AMBERG EM x24 x26 x3o x32 xa4 x3e x40 X42 x44 X46 EE NM H24 x1 xS Ixo Xr e pxtt xt3 xts x17 e X21 x23 X25 X27 x31 e X41 X43 X45 XA7 80EH2 DVP 80EH 40in 40out LY 15 Y17 SNR a TO Pcoly2 ct ve e21v13 Po3lyief c41v22 cs ez e Le varare a dcr razl vaalvacl 3 3 Installation 4 How to install DIN rail DVP PLC can be secured to a cabinet by using the DIN rail of 35mm in height and 7 5mm in depth When mounting PLC to DIN rail be sure to use the end bracket to stop any side to side movement of PLC and reduce the chance of wires being loosen A small retaining clip is at the bottom of PLC To secure PLC to DIN rail place the clip onto the rail and gently push it up To remove it pull the retaining clip down and gently remove PLC from DIN rail as shown in the figure How to screw Please use M4 screw according to the dimension of the product N E 50mm gt 50
9. Cylinder Mounting Assembly De La Salle University Boss Extrude1 1 Solid Body Boss Extrude1 2 Solid Body os SOLIDWORKS _ Analyzed with SolidWorks Simulation A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SLDPRT Jul 09 21 57 02 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SLDPRT Jul 09 21 57 02 2012 Mass 2 41798 kg Volume 0 000306073 m 3 Density 7900 kg m 3 Weight 23 6962 N Mass 2 41798 kg Volume 0 000306073 m 3 Density 7900 kg m 3 Weight 23 6962 N Simulation of Briquette Machine v1 4 Vertical Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Study Properties Submme 770 WO A CS 0 o Include fluid pressure effects from SolidWorks Off Flow Simulation Compute free body forges oO oS Result folder SolidWorks document F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Units 2 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Material Properties Name AISI 102
10. 2 803e 004 2 108e 004 1 414e 004 7 190e 005 2 446e 006 Briquette Machine v1 4 Table Assembly 1300 Strain Strain1 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Name Type Min Ma Factor of Safety1 Automatic 0 901661 1392 57 Node 16103 Node 15530 Model name Briquette Machine v1 4 Table amp ssembly FOS 15 00 13 75 12 50 11 25 10 00 8 75 7 50 6 25 5 00 3 75 2 50 1 25 0 00 Study name 1300 Briquette Machine v1 4 Table Assembly 1300 Factor of Safety Factor of Safety1 Plot type Factor of Safety Factor of Safety1 Criterion Automatic Factor of safety distribution Min FOS 0 9 A 2 Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly APPENDIX D 114 Development of an Automated Briquette Machine De La Salle University Simulation of Briquette Machine v1 4 Vertical Cylinder Case Date Tuesday July 10 2012 Designer A Gatmaitan T Guanlao R Guting C Janairo Study name 1300 Analysis type Static Table of Contents D CIDE ee oo cn 1 Model Information 2 Study Properties ccccccceeecccceeececeeeees 3 Description Units sueur 3 The Ver tical Cylinder Case is the one who CAMES in contact Material Properties
11. a plantation is situated wherein their machines are automated and can be easily operated Their production is of large scale basis and supplies the country with briquettes for energy consumption RUF Briquetting Machinery 2008 Unfortunately the briquetting technology in the Philippines still needs to undergo several improvements In a research done by Daiwey et al 2010 a briquette machine was supplied in the Aurora province for their usage This machine transforms coconut husks into charcoal briquettes and uses cassava or corn starch as the binder However all the processes needed in the briquetting such as mixing and molding are done manually Also on another study done by Martin et al 2008 the briquette machine that they mentioned molds 12 cylinder shaped briquettes in every extrusion period To supply the power needed at high pressure compaction additional manpower may pull down the lever arm The automated machines used by the large plantations in the other countries can be made into small scale and can create a big leap in the current briquetting industry of the Philippines With automated machines the variation of process parameters such as the pressure and temperature will be easier and be more accurate Also the briquetting processes will be done in a simpler manner which can result tofewer accidents related to briquetting 1 2 Statement of the Problem Variation of the parameters such as temperature and pressure affect
12. and violet 66 lines behave almost identically showing that the data gathered on the three trials are almost the same However these three lines do not behave the same as the blue one showing that there are differences on the pressure read by the gauges and that set on the pressure switch These differences are explained on the Analysis part of this chapter 4 1 2 3 Briquette Formation Varying the parameters the group has identified the temperature and the pressure where the briquette actually forms is listed on Table 4 6 Pictures of some of the briquettes are shown on Figure 4 6 Table 4 6 Briquetting Parameters Overview Briquette Formed Briquette Formed Temperature deg C Pressure kgf cm2 o Ye No po po E oo a po Po Lm po po po o a o a oo a po NENNEN UN ee QN nr RE o a J 67 i pox o Lom E NENNEN pox l d ox o EE pox ox o EE dI On this table the corresponding pressure and temperature where the briquette forms a cylindrical hollow shape are recorded The group pressed briquettes using varied operating temperature and pressure as listed on Table 4 6 It was observed that at 200 C and at 80 kg cm the briquettes removed from the mold hold their form until it can be transferred to a container for further air or sun drying 68 Figure 4 6 Briquette Samples The picture on the upper left was pressed with an operating temperature and pressure o
13. High speed output points Y0 Y2 are only in DVP20EH2 and DVP32EH2 high speed output points YO Y1 Y2 Y3 Y4 Y6 are only in DVP40EH2 O Installation amp Wiring 3 1 Dimension anor Model W mm W1 mm EE RUE AE DVP16EHOOR2 T2 113 103 Awana a DVP20EHOOR2 T2 113 103 a 2 vija PH fea DVP32EHOOR2 T2 143 5 133 5 i jy nu DVP40EHOOR2 T2 158 8 153 8 eec KDE DVP48EHOOR2 T2 174 164 DVP64EHOOR2 T2 212 202 is W1 aa i DVP80EHOOR2 T2 276 266 W 3 2 Wiring terminals Apt dogs LE NE e 1244 X1 X31 X5 X7 16EH2 DVP 16EH 8in 8out yo Lyi Ly2 Lys Ly4 Lys LveL yz LI cop ce1 c2 cs c4 cs ce c7 AME xol x2 xa xe x10 xz D L 20EH2 DVP 20EH 12in 8out H24VLY0 LY1Ly2LY3Le Y4 Ye 2 6 cof c1f c2 csf C4 Y5 Y7 coe ee Se ERN x10 x12 x14 x16 ME e 24U X11 X3 X5 X7 X11 X13 X15 X17 32EH2 DVP 32EH 16in 16out Relay l LYo Y3 Y3 L YA YS Y7 JY10l Y 11 Y 13 Y 14 Y15 Y 17 co v2 cti ve c21v13l c31v16 Ae x10 x12Ix14 x16 DU F24M X1 X8 X5 X7 X11IX13IX15 X17 32EH2 f DVP 32EH 16in 16out Transistor l LYOo LY1 Ly2 LY3LY4 vs Y7 dv 10 v11 Y 13lYv14 v16lL col cif c2 ca e41 ve coljv12 ce Y15 v17
14. Units Unit system SI MKS 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Material Properties Name AISI 1020 SolidBody 7 Cut Model type Linear Elastic Isotropic Extrude7 Briquette Machine Default failure Max von Mises Stress v1 4 Table Assembly criterion SolidBody 8 Cut Yield strength 3 51571e 008 N m 2 Extrude1 1 Briquette Tensile strength 4 20507e 008 N m 2 Machine v1 4 Table Elastic modulus 2e 011 N m 2 Assembly Poisson s ratio 0 29 SolidBody 9 Cut Mass density 7900 kg m 3 Extrude1 2 Briquette Shear modulus 7 7e 010 N m 2 Machine v1 4 Table Thermal expansion 1 5e 005 Kelvin Assembly coefficient SolidBody 10 Cut Extrude3 1 Briquette Machine v1 4 Table Assembly SolidBody 11 Cut Extrude6 1 Briquette Machine v1 4 Table Assembly SolidBody 12 Trim Extend1 2 Briquett e Machine v1 4 Table Assembly SolidBody 13 Cut Extrude6 2 Briquette Machine v1 4 Table Assembly SolidBody 14 Cut Extrude3 3 Briquette Machine v1 4 Table Assembly SolidBody 15 Split Line1 Briquette Machine v1 4 Table Assembly Curve Data N A A DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Loa
15. by the piston against the feedstock an analog pressure gauge is connected to it To vary the amount of pressure that it gives to the feedstock the control knob of the pressure switch is used With this the briquetting machine is given with additional flexibility in terms of processing different raw materials at different pressures The hydraulic cylinder that was used in the study is a single action piston type with a maximum working pressure of 95 kg cm approximately 1000 psi or 9 MPa The other components of the 23 hydraulic system such as the hydraulic pump hydraulic fluid actuators and reservoir will also be considered in the design of the machine s hydraulic system Khan n d The die or mold of the briquetting machine is to be designed in such a way that it 1s replaceable with different mold sizes and shapes The machine which is specifically a prototype is to be used as an experimental machine thus it is supposed to have a mold with changeable output briquette shapes and sizes Upon having compressed the rice husk the final step is the discharging of the pressed briquette Overall the actual mechanical parts of the briquetting machine will either be designed using computer software programs or a manufacturer s catalogue or be designed based on consultations from experts Simultaneous with the designing process the search for manufacturers of the needed machine components is going on Those needed machine parts that are
16. hydraulic system of the machine will be next The figure below Figure 3 2 shows the course of the design process of the mechanical framework of the briquette press including its assembly Furthermore the approved mechanical framework assembly of the to be fabricated machine is shown in Figure 3 3 while the illustrations of the individual parts can be seen in Appendices A amp B 28 START OF DESIGN PHASE A Design Mixing Design Chamber Cylindrical Mold Stress and Stress and NO Other NO Other Simulations Simulations Mechanical Framework Assembly Stress and Other Simulations Design ME Acceptable Modify Parts Design of Other gt Mechanical Parts Stress and NO Other Simulations YES YES y END OF DESIGN PHASE A Figure 3 2 Briquette Press Mechanical Part Design 29 Figure 3 3 Approved Mechanical Framework Assembly 3 2 1 2 Hydraulic System Aside from the mechanical framework of the briquette press the machine s mechanical system is also comprised of a hydraulic system which is responsible primarily for the movement of the cylindrical mold as well as the application of the required pressure against the biomass in other words the pressing proper itself 30 Thedesign process of the hydraulic system of the briquetting machine is
17. indicator is on not flashes indicates that part of the program exceeds the preset time out In this case you have to check the program and set On Off of the power again PLC automatically returns to STOP status at this time 1 0 response time How to calculate the response time from the input signal to output operation of the PLC Response time input delay time program scan time executed by the user output delay time 10ms default 0 60ms adjustable See the reference on how to use special register D1020 D1021 See the reference on how to use special register D1010 Input delay time Program scan time Output delay time Approx 10ms for relay modules 20 30us for transistor modules How to identify abnormality of PLC To identify abnormality from the indicators on the panel please check POWER indicator When PLC is powered the POWER indicator on the front panel will be on in green If this indicator is not on when the PLC is powered remove the wiring of terminal If this indicator turns on at this time the 24V DC output is overloaded In this case DO NOT use DC power supply at terminal and have another DC24V power supply ready If this indicator turns off after the overload is eliminated your PLC is malfunctioned Send your PLC back to your distributor for repair 4 RUN indicator Check your PLC status When PLC is running this indicator will be on You can use HPP the ladder diagram editing pro
18. performance Table 4 2 shows the operating parameters and the time needed for each Table 4 2 Operating Parameters Observed during Machine Operations Operating Parameter Working parameter Stabilization of the Offshoot Heating System From the experimentations it was observed that upon turning on of the heater it takes around 3 to 4 minutes before the temperature stabilizes Also after a number of trials it was determined that the minimum preheating and pressing time are 20 minutes and 1 minute respectively 4 1 2 1 Heating System For the heating system of the machine the temperature set by the user on the temperature controller was counterchecked by a thermocouple attached to the band heater The readings on both the controller and the thermocouple are recorded on Table 4 3 Also as the temperature was 60 varied the time needed to achieve such changes was recorded The data gathered on each trial are summarized on Table 4 4 Table 4 3 Temperature Readings in C Temperature Thermocouple l Controller Difference Trial 3 Average 0 0 0 00 00 33 u 5 oo 64 61 65 73 80 8a 82 80 9 90 9 90 100 98 100 99 110 2i ET MO 140 0 000 152 160 181 js 19000 000 204 0 67 20 212 21000 09 220 214 219 225 234 28 240 242 20 29 252 25 264 258 26000 000 zo 2n 280 273 281 27 288 288 300 293 295 298 61 F
19. some of the technical specifications of the fabricated prototype On the verification part the directly measured or calculated values of some parameters such as temperature and pressure were compared with the values of those parameters displayed on the built in gauges of the machine or measuring instruments For an instance the temperature monitoring of the machine will be verified by comparing the displayed value of the temperature to the manually and directly measured temperature of the machine part where the heater is situated If any inconsistency in the machine is seen adjustment s will be made as well as 39 verification s Evidently the parameters that are being displayed on the gauges are the ones to undergo verification process Through statistical analysis of the data generated from the tests the tolerance of the machine features was then defined Overall a machine tolerance of 10 would be observed In the event that the computed tolerance is not at par with the set tolerance adjustment s will be made for it 1s considered to be a form of inconsistency The general overview on how phase 3 of the research will go about is demonstrated in Figure 3 8 As can be seen Figure 3 8 is a simple example of the features testing and verification phase with pressure and temperature being the analog signals to be measured compared and analyzed 40 C Compare T Tinput me
20. such as the addition of the binding agent Kaliyan amp Morey 2009 As discussed by Kaliyan amp Morey 2009 binders can be a liquid or a solid that forms a bridge film matrix or initiates a chemical reaction to create strong inter particle bonding With this pre heating or steam conditioning is needed to provide the required heat and moisture that will activate the inherent or added binders There are different kinds of binders molasses starch phenolic resin coal tar and others each with varying binding properties Their selection is mainly based on the cost environment friendliness and on the material of the briquette The higher the amount of binders added the higher the briquette durability Another factor that is essential and affects the production of the briquettes 1s pressure and temperature Under high pressure and temperature the natural binding components in the biomass starch protein lignin and pectin materials are squeezed out of the particles aiding in the inter particle bonding In the case of rice husks when pressure is increased from 7 8 to 31 2 MPa together with 25 molasses the durability of the rice husk briquettes also increased from 80 to 95 One more aspect that is affected by pressure is the shear strength of the biomass briquettes As the pressure increases shear strength also increases Kaliyan amp Morey 2009 The current briquetting industry in the other countries has gone a long way In Germany
21. the ground state of the rice husk is supposed to appear as nearly pulverized but not exactly pulverized The reason for grinding is fundamentally for better and easier compaction More often than not the rice husk biomass which can be obtained from the local market has a low bulk density In the case of this research one briquette sample contains about 36 65 rice husk biomass by weight which is approximately equal to 70 grams The images below Figure3 13 illustrate the before grinding and after grinding of the rice husk Figure 3 13 Rice Husk Agro Waste Pre Processing 48 Upon having a significant amount of ground rice husk ready for mixing the pre processing of the cassava starch paste which will act as a binding agent will then follow The following pictures in Figure 3 14 and Figure 3 15 show the ingredients and apparatuses needed to create the binder respectively Figure 3 14 Binder Paste Ingredients a Water and b Starch 49 Figure 3 15 Apparatuses needed for Binder Cooking a Analytical Balance b Graduated Cylinder c Cooking Pot and d Electric Stove As illustrated on the above 1mage 100 mL of water and 35 grams of cassava starch are the ingredient needed to create the binding paste for the briquette The indicated quantities for each ingredient are intended for single sample of briquette 50 To begin 60 mL out of the 100 mL of water is to be mixed with 35 grams of cassava st
22. v1 4 Table Assembly Study name 1300 Plot type Factor of Safety Factor of Safety1 Criterion Automatic Factor of safety distribution Min FOS 0 9 15 00 13 75 12 50 11 25 10 00 Figure 4 1 Factor of Safety Analysis on the Table Assembly 58 Model name Briquette Machine v1 4 Vertical Cylinder Mounting Assembly Study name 1000 Plot type Factor of Safety Factor of Safety Criterion Automatic Factor of safety distribution Min FOS 0 67 FOS 15 00 13 75 12 50 11 25 10 00 Figure 4 2 Factor of Safety Analysis on the Mounting of Hydraulic Press Assembly Model name Briquette Machine v1 4 vertical Cylinder Case Study name 1300 Plot type Factor of Safety Factor of Safety1 Criterion Automatic Factor of safety distribution Min FOS 1 4 FOS 15 00 13 75 12 50 11 25 10 00 8 75 7 50 Figure 4 3 Factor of Safety Analysis on the Hydraulic Press Casing These simulations were done using Solidworks 2012 The designs of these parts of the machine are based on readily available materials and existing parts The results of the 59 simulations done are on the figures above but detailed reports can be seen on Appendices C D amp E 4 1 2 Machine Operation The data gathered during the machine operation proper is divided into three parts heating system pressure system and the briquette formation These are the major aspects of the machine that reflects the machine
23. which was 8 to 15 binder by weight and 85 to 92 biomass by weight Later on the ratio was modified accordingly so as to fit for the purposes and bounds of this study 3 5 2 Briquetting Operation Proper Following the preparation of the feedstock the operation proper of the briquetting press will then advance First the feedstock is to be loaded into the mixing chamber In contrast with the initial mixing of the feedstock the purpose of the mixing chamber in the study is for thorough and further mixing of the feedstock as well as to prevent it from solidifying prior to its compression 52 Once the loading of the feedstock has been done the machine will now be turned on so that the briquetting operation mayofficially begin From the mixing chamber the feedstock will be conveyed to the mold through the guide tube with the aid of gravity While the feedstock accumulates and settles inside the mold it is instantaneously being heated by the heating system of the machine at a temperature that was set by the user As soon as the mold is already full and ready for compaction it will move directly below the hydraulic press which marks the start of the compression proper of the operation An initial test run is to be conducted before having the machine totally engage into full operation which involves varying of both pressure and temperature This test run will involve testing of whether the feedstock really became a briquette after going throu
24. 0 95 humidity pollution degree 2 Pbelalonslgage Storage 40 C 70 C temperature 5 95 humidity eat pea International standards IEC1131 2 IEC 68 2 6 TEST Fc IEC1131 2 amp IEC 68 2 27 TEST Ea Weight g 500 480 520 500 652 612 710 675 748 688 836 756 948 848 Input point specifications Spec 24VDC single common port input Note Items Low speed High speed 200KHz Input wiring type Change wiring from S S to SINK or SOURCE Input indicator LED display light on ON light off OFF Input voltage 24VDC 10 Input point XO X7 X10 X17 Of2O 16VDC 10 can conduct 10 60ms digital Active Level 2 uat filter adjustment On Off 12VDC 10 Response Time Noise Immunity 10 ms 0 5us Output point specifications Spec Single common port transistor output TA INST RE Single common port relay output Max frequency 10KHz 200KHz Load ON OFF control Output indicator LED display light on ON light off OFF Min load 2mA DC power supply Working voltage 5 30VDC lt 250VAC 30VDC Insulation Photocoupler isolation Magnetic isolation ge 5 1KHz 0 3A 1 point 40 C 2A 1 point BA COM cHilehkepeciieaien 0 3A 1 point 40 C 4KHz 30mA 1 point 40 C 75 VA conductive 90W resistive Off2On 20us Ma EH 0 2us 10ms SEP AUS On2Off 30us Over current protection N A Mechanical life N A 2x10 times without load 1 5x10 times 5A 30VDCy 5x10 Electrical life N A times 3A 120VAC 3x10 times 5A 250VAC
25. 0 324 970 976 0 292 499 136 0 260 027 280 0 227 555 424 0 195 083 568 0 162 611 728 0 130 139 872 0 97 558 015 0 65 196 164 0 32 724 314 0 252 461 3 Yield strength 351 571 000 0 Briquette Machine v1 4 Table Assembly 1300 Stress Stress1 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Name Tye Min Ma Displacement1 URES Resultant Displacement 0 mm 0 98271 mm Node 6694 Node 16103 Model name Briquette Machine v1 4 Table Assembly 0 983 Study name 1300 Plot type Static displacement Displacement1 Deformation scale 45 0795 0 901 0 619 0 737 0 655 0 573 0 491 0 409 0 328 0 246 0 164 0 0819 1e 030 Briquette Machine v1 4 Table Assembly 1300 Displacement Displacement1 URES mm 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Name Type Mi Max OYO Strain1 ESTRN Equivalent Strain 2 44593e 006 0 000835919 Element 6868 Element 10021 Model name Briquette Machine v1 4 Table Assembly Study name 1300 Plot type Static strain Strain1 Deformation scale 45 0795 ESTRN 8 359e 004 7 555e 004 6 970e 004 6 276e 004 581e 004 4 886e 004 4 192e 004 3 497e 004
26. 0 120 140 160 180 200 220 240 260 280 300 Temperature in degree Celsius lt Triall Trial2 Trial 3 Figure 4 4 Temperature versus time graph 63 The relationship of the values on Table 4 4 1s shown on this graph The temperature set on the controller serves as the x axis while the time needed to reach a certain temperature is on the y axis The three trials are represented by the three lines The blue and green lines representing Trials 1 and 3 are almost coinciding showing that the readings gathered on these trials do not differ much However since on the third trial there was a huge increase on the temperature setting increased by 80 C from 60 C to 140 C it can be seen that the time used for that particular trial is shorter Nevertheless it can be observed that the three lines have the same slope except for those parts where there was sudden increase in temperature 4 1 2 2 Pressure System For the next parameter the pressure the group has two pressure gauges attached to the system The pressure set on the pressure switch is counterchecked by these two pressure gauges The readings are summarized on Table 4 5 Table 4 5 Pressure Readings in kg cm Trial 1 ILES Pressure Convention 1 Pressure 5 57 60 585 598 E 60 X 63 65 66 655 076 68 68 68 294 70 CIEN B 8 73 73 B 959 70 w 90 fc 8 58 95 64 Trial 2 Press
27. 0 SolidBody 2 Structural Model type Linear Elastic Isotropic Member1 1 Briquette Default failure Max von Mises Stress Machine v1 4 Vertical criterion Cylinder Mounting Assembly Yield strength 3 51571e 008 N m 2 SolidBody 4 Structural Tensile strength 4 20507e 008 N m 2 Member1 2 Briquette Elastic modulus 2e 011 N m 2 Machine v1 4 Vertical Poisson s ratio 0 29 Cylinder Mounting Assembly Mass density 7900 kg m 3 SolidBody 5 Structural Shear modulus 7 7e 010 N m 2 Member2 1 Briquette Thermal expansion 1 5e 005 Kelvin Machine v1 4 Vertical coefficient Cylinder Mounting Assembly SolidBody 6 Structural Member2 2 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SolidBody 7 Split Line1 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SolidBody 17 Boss Extrude1 1 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SolidBody 19 Boss Extrude1 2 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly Curve Data N A A DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Loads and Fixtures Fixture Image Fixture Details Entities 2 face s Type Fixed Geometry Fixed 1 Resultant Forces Components O X Y Resultant Reaction Moment N m 0 o o 0 Load Image
28. 120 F n ny F 60 Hertz for Philippines 120 F 120 60 w 1740 n 4 13 poles 5 poles 21 Chapter 3 METHODOLOGY The research is comprised of 4 essential phases or stages namely the designing of the briquette machine the fabrication of the briquetting machine the testing and verification of the briquetting machine s features such as temperature and pressure control and testing of the operation of the briquetting press using rice husk agro waste with cassava starch binder as the feedstock 3 1 Conceptual Design Figure 3 1shows the conceptual framework that has been developed for the research The briquette making process begins with the feeding of the raw materials of the to be formed briquette in the machine s mixing chamber In the case of this research rice husk agro residue will be used as the feedstock The mixing chamber will be monitored with the use of a sensor and will have an indicator light that indicates when the biomass level is low Inside the mixing chamber rice husk will be mixed with cassava starch which is the binding agent to be used in the research It is very important that the rice husk be mixed thoroughly with the starch for it will affect the characteristics of the output briquette Furthermore when the feedstock remains stationary inside the chamber the feedstock will solidify making it unfit for operation For the design of the mixing chamber the motor to be installed should
29. Component Contact 2 2 25 Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Mesh Information Mesh Information Details of distorted elements lacobian OT 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Model name Briquette Machine v1 4 Table Assembly Study name 1300 Mesh type Solid mesh Resultant Forces Reaction Forces Selection set Units SumX SumY SumZ Resultant Entire Model 0 000152588 17595 3 0 000150681 17595 3 Reaction Moments Selectionset Units SumX SumY SumZ jResultnt Entire Model Nm JO O X jO0O JO 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Study Results Name Type Min Ma Stress1 VON von Mises Stress 252461 N m 2 3 89915e 008 N m 2 Node 15530 Node 16103 Model name Briquette Machine v1 4 Table Assembly Study name 1300 Plot type Static nodal stress Stress1 Deformation scale 45 0795 von Mises M m 2 389 914 588 0 357 442 848
30. DEVELOPMENT OF AN AUTOMATED BRIQUETTING MACHINE Proponents GATMAITAN Rey Andrew A GUANLAO Tristan Joseph L GUTING Robert John B JANAIRO Caroline Mae J Adviser Dr Alvin Y Chua DE LA SALLE UNIVERSITY July 2012 ABSTRACT Briquetting technology is one of the renewable sources of energy that was devised to address problems regarding global warming energy crisis as well as solid waste management Studies like that of Kaliyan and Morey 2009 show that varying the compression parameters during briquetting such as temperature and pressure affects the characteristics of the output briquettes such as combustion performance and durability On that note the proponents of this research made that as their motivation which eventually led to the development of an automated briquetting machine prototype for experimentation purposes that could bridge the gap between compression parameters and briquette characteristics The fabricated machine used a pressure switch and a band heater for its pressure and temperature variation mechanisms respectively while a PLC was utilized to make the machine s operation automated Moreover the machine 1s composed of a mixing chamber intended for thorough mixing of the feedstock a cylindrical mold where the feedstock would be briquetted and a hydraulic system which is responsible for the mold s movements as well as the compression mechanism of the machine Based on the data collected the machine d
31. Load Details Entities 1 face s Type Normal to selected face Value 1300 Pressure 1 Units psi Contact Information Contact Image Contact Properties Type Bonded Components 1 component s Options Compatible mesh Global Contact A 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Mesh Information Mesh Information Details of elements wih Apec Ratio gt 10 LR XofdsoredeemensUaobay o SSS 2 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Model name Briquette Machine v1 4 vertical Cylinder Mounting Assembly Study name 1000 Mesh type Solid mesh Resultant Forces Reaction Forces Selection set Units SumX SumY SumZ J mResultant Entire Model 0 000510216 155386 0 00145245 155386 Reaction Moments Selection set Units SumX SumY SumZ Resultant gt Entire Model wem JO 2 DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Study Results Name Type Min
32. Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 Simulation of Briquette Machine v1 4 Table Assembly De La Salle University Cut Extrude6 2 Solid Body Cut Extrude3 3 Solid Body Split Line1 Solid Body Zs SOLIDWORKS _ Analyzed with SolidWorks Simulation A Gatmaitan T Guanlao R Guting C Janairo Mass 0 705633 kg Volume 8 93207e 005 m 3 Density 7900 kg m 3 Weight 6 91521 N Mass 0 70847 kg Volume 8 96798e 005 m 3 Density 7900 kg m 3 Weight 6 94301 N Mass 4 37645 kg Volume 0 000553981 m 3 Density 7900 kg m 3 Weight 42 8892 N 7 10 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 Simulation of Briquette Machine v1 4 Table Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Study Properties A EC Include fluid pressure effects from SolidWorks Off Flow Simulation Compute free bodyforees OM Result folder SolidWorks document F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final
33. accurate and is effective in giving off the pressure and temperature desired for the operation Moreover due to the manual and automatic operating options of the machine it gives the machine its versatility In the manual setting the operator could control the hydraulic system 1 e movement of the cylindrical mold and briquetting operation using a toggle switch made into a joystick In the automatic setting on the other hand the machine could be left to operate in itself according to set program until the very last step of the operation 81 4 3 Conclusion From the experiments done and the data gathered it can be justified that the group achieved the objectives of this study A small scale automated briquette machine was designed and fabricated that can produce briquettes automatically without human interference upon the loading of the feedstock Along with that the primary operating parameters the temperature and the pressure can be varied through the control system utilized in the machine These parameters can be observed through the gauges and the display screen allowing the user to easily monitor the changes in the machine Also the accuracy of the heating and the pressure system were validated repetitively during several trials These were done with the use of two pressure gauges and a pocket thermocouple that simultaneously takes readings After the experimentation it was computed that the data gathered complies with the set tol
34. anairo De La Salle University 7 10 2012 Name Type Min MX Strain ESTRN Equivalent Strain 2 00253e 007 0 00164121 Element 7795 Element 1338 Model name Briquette Machine v1 4 Vertical Cylinder Mounting Assembly Study name 1000 Plot type Static strain Strain1 Deformation scale 71 6675 ESTRN 1 641e 003 1 504e 003 1 366e 003 1 231e 003 1 094e 003 8 575e 004 8 207e 004 6 640e 004 5 472e 004 4 105e 004 2 737e 004 1 370e 004 2 003e 007 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly 1000 Strain Strain1 A 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Name Type Min Max Factor of Safety1 Automatic 0 673171 11125 7 Node 185 Node 16298 Model name Briquette Machine v1 4 Vertical Cylinder Mounting amp ssembly Study name 1000 Plot type Factor of Safety Factor of Safety Criterion Automatic Factor of safety distribution Min FOS 0 67 15 00 13 75 12 50 11 25 10 00 Briquette Machine v1 4 Vertical Cylinder Mounting Assembly 1000 Factor of Safety Factor of Safety1 A 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly APPENDIX F 139 C a Ne 24V 1 25A DC 24V 1 25 A
35. arch into a bowl or container untilthe starch fully dissolved in the water and has no lumps The consistency of the starch water mixture should neither be too viscous thick nor too watery drippy The remaining 40 mL of water is to be heated in a pot or a can until it boils Once it already boils the starch water mixture from earlier is to be poured unto it while being stirred The overall mixture inside the pot should be stirred at regular intervals until becomes ready for mixing to avoid burning the binder paste which settles at the bottom of the pot The binder is said to be ready for mixing or cooked when the paste already appears to be nearly translucent and feels gelatinous At this point the preparation of the feedstock could now be realized To do so the cooked binder should be pouredinto the 70 grams groundrice husk on a separate container After that the two should be pre mixed together manually either by using a spatula or bare hands so as tomake the feedstock become nearly homogenous before the binder solidifies Presented in the portrait below Figure 3 16 is an example of a feedstock that is ready for loading into the mixing chamber 51 Figure 3 16 Sample Feedstock Ready for Loading Overall the ratio of the ground rice husk biomass to cassava starch binder is about 0 5783or 36 65 rice husk and 63 35 binder by weight This ratio that was used during the testing was initially adapted from the study of Baconguis 2006
36. as identified 74 Table 4 13 Summary of Operating Expenses per day Price n Php From Tables 4 11 and 4 12 the summary of the total expenses in the daily production of briquettes are found These values are based on actual experiments conducted by the group 4 1 3 2 3 Return of Investment Computation Daily Operation Basis e Production 35 kg day e Selling Price Php 50 00 kg same with the existing manual briquette machine Capital Equipment Expenses Php 170 400 00 Gross Income 1 750 00 Daily Operating Expenses 1 399 69 Net Income Php 350 31 Thus In the case that a mass production machine is fabricated based on the existing experimental machine the ROI of that machine is estimated to be achieved after 1 91 years or after selling 300 334 68 briquettes 75 4 2 Analysis of the Data 4 2 1 Simulations The group simulated three of the most crucial parts of the machine that are subjected to stress These parts are the table assembly the mounting of vertical cylinder and the hydraulic press vertical cylinder The group focuses on the results of simulation on deformation and factor of safety since these two quantities will be the basis for the design On Figures 4 1 4 2 and 4 3 the results of the simulation on factor of safety on the table assembly on the mounting of hydraulic cylinder press and on the hydraulic cylinder press respectively are seen The figures are composed of different colors rang
37. as used to measure the voltage between the 24G port and the input ports If the reading in the VOM in voltmeter mode flashes a value of approximately 24 VDC then the connection is deemed to becorrect otherwise 1t is considered incorrect Likewise the connection of the sensors was also verified using this method The next thing to verify after the input external wiring iswhether the output port detects an input signal or in other words whether the output signal 1s triggered by input ones To do so a very simple input output ladder program as shown on Figure 3 11 was downloaded to the PLC Figure 3 11 Program used in verifying the output signal The test for the output goes as follows While maintaining a signal on the output port YO the voltage across the common port and the output ports Y s was measured Similar to that of the input if the voltmeter reading acrossthe common port and output ports flashes a value of approximately 24 VDC then the connection 1s considered to be correct otherwise it needs rewiring for it 1s incorrect Further verification was done to the control system by repeatedly 45 turning on and off the inputs on the program while simultaneously taking note if the output port will behave as programmed 3 5Phase 4 Briquette Press OperationTesting Prior to the operation and performance testing of the fabricated briquette press the rice husk agro waste and cassava starch binding agentwere obtained Mor
38. asured data to P Pinput data from built in gauges vo T and P valid Analyze Data YES Y 1 Measure T and P Operate Machine Machine Tolerance Data from manual measurement Figure 3 8 Sample Run of the Features Testing and Verification Phase 3 4 2 Verification of the Accuracy of the Band Heater To manually test whether the temperature that is said to be being supplied by the band heater to the cylindrical mold is accurate a K type pocket thermocouple was used The thermocouple was attached to the band heater as illustrated in Figure 3 9 The readings from the 4 pocket thermocouple as well as the built in thermocouple of the band heater were taken simultaneously and were recorded for further analysis The experimentation was done three times wherein for each trial the temperature readings were taken every 10 C The initial setting of the band heater was the one closest to the room temperature which is 30 C while the peak temperature setting was 300 C which is also the maximum operating temperature of the band heater Despite that there were noticeable differences between the values of the readings of the built in thermocouple and pocket thermocouple these differences were kept under 5 margin of error J E EN E 3M m 4 T Figure 3 9 External thermocouple attached to the band heater 3 4 3 Verification of the Accuracy of the Pressure Switch To begi
39. at will be used should be properly crushed sifted and ready for compression the thorough mixing of the raw materials and the binding agent will be done by the machine Except for the manual restocking of raw materials and the harvesting of finished products the production of the briquettes will be automated In case of jamming of the raw materials manual removal and repair must be done Chapter 2 THEORETICAL CONSIDERATIONS In this chapter the equations which were used for the duration of the research are listed These equations were used to determine the basic parameters and initial specifications for the design and fabrication of the parts of the briquetting machine 2 1 Hydraulic System 2 1 1 Hydraulic Cylinder There are several factors that need to be considered when selecting pre manufactured and standardized hydraulic cylinders Such factors include but are not limited to the following operating pressure of the system force needed by the cylinder to extend forward force force needed by the cylinder to retract return force and volumetric flow rate of the hydraulic fluid needed by the cylinder to move forward and to retract Enumerated below are the equations to be used for calculating some of the said factors 2 1 1 1 Force The fluid which pushes the face of the piston produces a force against it This force is generally equivalent to the force being produced by the hydraulic cylinder and to determine such force equati
40. atch v je48_bqJu04 Sing Didar amp Kashyap M M 1985 Mechanical and Combustion Characteristics of Paddy Husk Briquettes Agricultural Wastes 13 189 196 do1 10 1016 0141 4607 85 90033 2 wisegeek com what are pressure sensors htm n d What are Pressure Sensors wisegeek com what is a briquette htm n d What is Briquette 86 APPENDIX A Actual Pictures of the Machine Mixing Chamber Hopper Mixing Chamber Motor and Pulleys Heating System Temperature controller Band Heater Hydraulic System Band Heater vett ggg 5 ENTRE M pr wt v L f eT e Se lt Horizontal Hydraulic Cylinder Pump and Motor Hydraulic System E Cl A uu aie 9 At 4 at j in p unm i Pressure switch Pressure gauge Controls System Controls connection and control panel f he 32 2 ELITE Ur J M IS w n ee6 5 6 ce UT a A Programmable Logic Controller APPENDIX B DRW NO PART NO X De La Salle University THESIS Assembly Name Briquetting Machine Assembly Part Name n a Designed by T Guanlao R Guting A Gatmaitan C Janairo T Guanlao Approved by Dr Alvin Chua QIY SCALE MATRL Date Revised Units 1 8 n a July 10 2012 mim EE EE Bottom Base Assembly From Drawing no 3 A to 7 EE NN 2 Fydraulic Tank Botto
41. ator is not on indicates that the 24VDC power supply of the PLC is overloaded You have to remove the wiring at terminal 24V and 24G and have another DC24V power supply ready That the ERROR LED indicator flashes continuously indicates that the 24V power supply for the PLC is insufficient Low voltage indication That the LOW V indicator on the front panel of the PLC extension module is on indicates that the input voltage is insufficient All outputs of the module are disabled at this time Preparation 1 Before powering DVP EH2 be sure that you have checked if the I O wiring is correct You may damage the PLC if AC110V or AC220V is directly supplied to input terminals or the output wiring is short circuited 2 When the peripheral devices are used to write program into PLC If the ERROR indicator does not flash the program you are using is legal and PLC is waiting for RUN instruction from you 3 You can use HPP to test force On Off of output contacts Operation amp test 1 Ifthe ERROR indicator does not flash you can use RUN STOP switch or peripheral device HPP or WPLSoft to give RUN instruction and the RUN indicator should be continuously on at this time That the RUN indicator does not flash indicates PLC has no program in it 2 When PLC is in operation use HPP or WPLSoft to monitor the set value or temporarily saved value in the timer counter and register and force On Off of output contacts That the ERROR
42. be able to handle the weight of the mixing blade plus the weight of the rice husk 22 Furthermore the mixing blade is to be designed such that it can perform thorough mixingof the feedstock and the binding agent After passing through the mixing chamber the mixed rice husk will be transferred to the cylindrical mold or die While it is accumulating inside the mold it will be heated up through an installed heater so that the raw materials will become easy to compress A heater display panel will be used to monitor the temperature in the cylindrical mold while a heater control panel will be used to regulate the temperature of the heater Penton 2011a The operating temperature that will be employed in the research would range from 30 C up to 300 C Subsequent to the heating of the feedstock the preheated rice husk will now be conveyed to the position directly below the piston that will compress the mixed rice husk into a rice husk briquette To be specific the rice husk inside the die will be pressed into briquettes by a hydraulic cylinder with a pressure switch connected to it The function of the pressure switch is to redirect the hydraulic fluid back to the system s reservoir when the cut off pressure that was set to it is reached Once the cut off pressure is reached the pressure switch will signal the PLC to signal the solenoid valve to redirect the hydraulic fluid back to the reservoir To monitor the amount of pressure being produced
43. before engaging the controls into actual practice computer simulations using the said software were carried out in this step mainly for the purpose of verification and debugging After having verified and debugged the program the control system wasthen tested whether rit 1s responding according to the desired response of the study In the event when the control system does not responding as per the standard set in the study reconfigurations are to be done to it until such time that it works with an acceptable quality After accomplishing such test Sub Phase B of the briquette press design phase is already done To be more visual Figure 3 5 below portray the control system of the machine was designed as well as programmed 34 START Wiring Diagram Control System Algorithm Planning Programming with WPLSoft 2 20 Design Acceptable Control System Working YES END YES Y E NO a _ _ Selection of Sensors Re configure Figure 3 5 Briquette Press Digital Part Design 3 3Phase 2 Briquetting Machine Fabrication and Assembly This stage of the research marks the start of the construction of the briquetting machine prototype Depending on the accepted blueprint the materials with their corresponding quantities and dimensions will either be purchased or will be obtained throughoutsourcing i e by recycling by borrowing or by
44. cale 135 029 ESTRN 7 032e 004 6 449e 004 5 865e 004 5 282e 004 4 699e 004 4 115e 004 3 532e 004 2 948e 004 2 365e 004 1 782e 004 1 198e 004 5 148e 005 3 143e 006 Briquette Machine v1 4 Vertical Cylinder Case 1300 Strain Strain1 2 DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Name Type Min Mal Factor of Safety1 Automatic 1 39018 899 601 Node 12009 Node 1847 Model name Briquette Machine v1 4 Vertical Cylinder Case Study name 1300 Plot type Factor of Safety Factor of Safety1 Criterion amp utomatic Factor of safety distribution Min FOS 1 4 15 00 13 75 12 50 11 25 10 00 Briquette Machine v1 4 Vertical Cylinder Case 1300 Factor of Safety Factor of Safety1 A 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case APPENDIX E 125 Development of an Automated Briquette Machine De La Salle University Description This part holds the hydraulic cylinder that applies the needed pressure on the biomass briquette Different analyses were conducted on the two feet of this part wherein most of the stress is concentrated os SOLIDWORKS _ Analyzed with SolidWorks Simulation Simulation of Briquette Machine v1 4 Vertical Cylinder Mounting Ass
45. ces C D amp E 4 2 2 Machine Operation 4 2 2 1 Heating System Based on Table 4 3 it can be seen that the percentage differences between temperature set on the temperature controller and the reading from the pocket thermocouple is within the tolerance range of 10 After three trials the average temperature was taken and compared with the designated temperature on the controller to compute for the percentage differences As seen only at one time was the fluctuation over 10 46 at the 30 C reading This can be attributed to the surrounding temperature where the experiments were conducted Since most of the experiments were done on the months of May and June 2012 when the weather once reached over 35 C the band heater had a hard time keeping the temperature down to 30 C Also eighteen out of the twenty eight readings has almost negligible percentage difference less than 1 2c It shows that the heating system provides effectively the amount of temperature it is tasked to provide 77 For the time needed to reach a certain temperature the group monitored it using a stopwatch at every increment During the experimentations at the beginning of operation it was observed that there is an offshoot of around 10 12 but stabilizes after around four minutes as seen on Table 4 4 On the two trials the time was taken at every 10 C and it can be observed that it takes approximately two minutes But when it reaches around 180 C the ti
46. ch is being rotated from quadrant to another in a clockwise direction until it reaches the north four quadrant N4 which is the maximum pressure of in the study with an equivalent numerical value of 95 kg cm 3 4 4 Verification of the Control System Circuitry The external wiring of the PLC as well as its inputs and outputs needs to be verified before engaging into operation because errors in external wiring could critically destroy the PLC or worse the whole control system itself Thus to avoid such scenario all components of the control circuit were tested to ensure that they are working properly prior toactual experiments The verification of the control circuit starts with double checking physically the actual wiring that has been done to the controls component of the system with the indicated correct wiring written in the manual The moment when the external wiring has been verified as correct another test is still to be carried out but this time with the PLC turned on To be a little bit more concrete take the proximity sensors used in the study as an example The proximity sensors that were used in the study are sink type sensors With that the 44 PLC hasto be set to a sink type DC input configuration as well Therefore the S S port of the PLC should be connected to its 24V portwhile the 24G port should be connected to the input ports X s To verify whether the wiring is correct a multimeter also called a VOM w
47. chamber guide tube dial type 15 MPa 150kgycm 36 pressure gauge pump 3 hp pump motor 2 hp mixing blade motor belt pulleys hoses bolts nuts etc When the briquettingmachine has already been constructed a test run without the feedstock yet will be done The machine will be noted if it is working or not In the event that the prototype does not work troubleshooting will be done to the briquetting machine until such time that 1t operates In terms of the acceptability of the fabricated prototype a new determinant will be used to verifywhetheritis acceptable or not Basically the prototype will be accepted if the technical specifications that it manifestssuch as maximum operating pressure tolerance input power requirement briquette diameter weight etc with tolerance being the core determinant meet tolerably or is at par with the computed or expected technical specifications of the prototype based on either computations or ratings of the individual parts The following figure Figure 3 6 1s the step by step procedure of the second phase of the research which is fabrication and assembly The output of this phase of the research is basically the actual machine prototype 37 Design Approval Materials Acquisition bu YES Materials Complete Assemble Machine Framework NO Do adjustment s Troubleshoot Integration of Actuators and Electromechanicals a Int
48. computer aided design simulation and programming software programs were used during this design phase To be specific Solidworks 2012 was used to design and simulate the mechanical framework of the briquette press while WPLSoft 2 20 was used for the control system However as for the hydraulic system as well as the heating system the design process simply involved simple calculations of the technical parameters that would be used to define or describe the systems mentioned Fundamentally a particular design or automation plan will be approved or appraised acceptable based on cost relative ease of fabrication load handling capacity factor of safety feedback time relative ease of programming size and design practicality 3 2 1 Mechanical System This section includes the design process of the mechanical system of the briquette press under study which includes the following 1 mechanical framework i e stand mixing chamber mixing blade mold etc 2 hydraulic system 1 e solenoid valve relief valve pump 26 pump motor piston cylinder etc and 3 heating system 1 e band heater thermocouple temperature controller etc 3 2 1 1 Mechanical Framework First the individual mechanical parts of the machine s framework such as the mixing chamber cylindrical mold die and ram etc were designed using Solidworks 2012 Some of these mechanical parts were patterned based on the paper of Fule et al 2010 ent
49. ds and Fixtures Fixture Image Fixture Details Entities 4 face s Type Fixed Geometry Fixed 1 Resultant Forces Components X Y Z Reutat Reaction force N 0 2 3 0 gt 3 Reaction Moment N m Load Image Load Details Entities 1 face s Type Normal to selected face Value 1300 Pressure 1 Units psi 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Connector Definitions Pin Bolt Bearing Connector Model Reference Connector Details Strength Details Entities 2 edge s Type Bolt Head Nut diameter Count erbore Head diameter 15 mm Nut diameter 15 mm Nominal shank 10 No Data diameter Preload Torque 0 Counterbore with Nut 1 Young s modulus 2 1e 011 Poisson s ratio 0 28 Preload units N m Connector Forces AiFoce N 0 0 0 0 Entities 2 edge s Type Bolt Head Nut diameter Count erbore Head diameter 15 mm Nut diameter 15 mm Nominal shank 10 No Data diameter Preload Torque Counterbore with Nut 2 Young s modulus Poisson s ratio Preload units Connector Forces Axial Force N Shear Force N 35 013 2 6959 52 127 62 852 Bending moment N m 0 088669 0 0034849 0 050049 0 10188 2 DS Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWor
50. e importantly preparation of the rice husk agro waste and cassava starch as feedstockwas done before it was fed into the machine According to Grover and Mishra 1996 for agro residues and mill residues the unit pre processing or pre treatmentto be done prior to densification or briquetting include sieving and crushing of the dried agro waste Displayed in the diagram of Figure 3 12 1s the process flow diagram developed in the study on how to compact rice husk biomass into briquettes 46 Cu Prepare Binder Rice husk l Mixing Chamber Hopper Mold Heater After 20 minutes v Pressed by cylinder After 1 minute Removed from mold l Sun or air dried for 2 days CD Figure 3 12 Briquetting Process Flow Diagram 47 3 5 1 Preparation of the Feedstock The feedstock that will be loaded into the mixing chamber of the fabricated briquetting machine is a mixture of ground rice husk biomass and cassava starch that was made into a paste To prepare this both the rice husk biomass as well as the cassava starch needs toundergo a pre processing before they could be mixed together as a feedstock First in the line is the pre processing of the raw rice husk agro waste into ground state To do so it involves grinding of the raw rice husk into smaller particles with the help of a household blender Physically
51. e of Contents DSC PRETI 1 PSSUNMMIDUIONS he de ae 990025 99 19 2 Model Information eeeeee eese 2 Study Properties cceccccccccccccecsccceeees 5 Description WES ote E A N 5 Framework of the briquette machine which will hold most of Material Properties 6 the machine parts such as the hydraulic cylinder solenoid Loads and Fixtures 7 valves and gauges Connector Definitions 8 Contact Information 10 Mesh Information uoc rrr e Enn 11 Resultant Forces 12 SHUG RESUS eoe eo cip Eu U Pis ai POR Ebu PR MUS 13 Ds SOLIDWORKS Analyzed with SolidWorks Simulation Simulation of Briquette Machine v1 4 Table Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Assumptions Original Model Model Analyzed Model Information Model name Briquette Machine v1 4 Table Assembly Current Configuration Default As Machined gt Solid Bodies p 25 Simulation of Briquette Machine v1 4 Table SOLIDWORKS Analyzed with SolidWorks Simulation Assembly De La Salle University Document Name and Reference Cut Extrude7 Trim Extend1 2 2 DS SOLIDWORKS Treated As Solid Body Solid Body Solid Body Solid Body Solid Body Solid Body Analyzed with SolidWorks Simulation A Gatmaita
52. embly Date Tuesday July 10 2012 Designer A Gatmaitan T Guanlao R Guting C Janairo Study name 1300 Analysis type Static Table of Contents Br ifelg eid o o RT DR 1 ASSUIDEIOFIS a INANE ES QUA en 2 Model Information 2 Study Properties ccecccccccscccceesccceeees 5 IES steer 5 Material Properties eee 6 Loads and Fixtures 7 Contact Information 7 Mesh Information 8 Resultant Forces 9 SEUdV ReSULES 152 8 steve seus 2 10 Simulation of Briquette Machine v1 4 Vertical Cylinder Mounting Assembly A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Assumptions Original Model Model Analyzed Model Information Model name Briquette Machine v1 4 Vertical Cylinder Mounting Assembly Current Configuration Default As Machined gt Solid Bodies 2 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Mounting Assembly De La Salle University Document Name and Reference Structural Member1 1 Structural Member 1 2 Structural Member2 1 Structural Member2 2 Split Line1 2 DS SOLIDWORKS Treated As Solid Body Solid Body Solid Body Solid Body Solid Body Analyzed with SolidWorks Simula
53. emonstrated a tolerance of less than 10 and a return of investment of about 2 years when retrofitted for mass production Furthermore the machine is safe to use because it can be operated by simply using the buttons provided in its control panel and has an emergency stop button when emergency arises In the end the machine was able to form briquettes at varied pressure and temperature and could be used for future studies regarding briquetting parameters optimization TABLE OF CONTENTS ABSTRACT EXECUTIVE SUMMARY TABLE OF CONTENTS Chapter 1 Introduction 1 1 Background of the Study 1 2 Statement of the Problem 1 3 Objectives of the Study 1 4 Significance of the Study 1 5 Scope and Limitations 2 Theoretical Considerations 2 1 Hydraulic System 2 1 1 Hydraulic Cylinder 2 1 2 Hydraulic Pump 2 1 3 Hydraulic Motor 2 2 Control System 2 2 1 Programmable Logic Controller 2 2 2 Ladder Programming 2 3 Sample Computations 2 3 1 Force 2 3 2 Volumetric Flow Rate 2 3 3 Power 2 3 4 Fluid Motor Torque 2 3 5 Fluid Motor Displacament 2 3 6 Number of windings in the motor poles 3 Methodology 3 1 Conceptual Design 3 2 Phase 1 Briquetting Machine Design Phase 3 2 1 Mechanical System 3 2 2 Control System 3 3 Phase 2 Briquetting Machine Fabrication and Assembly 3 4 Phase 3 Features Testing and Verification of the Briquetting Machine 3 4 1 Testing and Verification Overview 3 4 2 Verification of the Accuracy of the Band Heater 3 4 3 Ve
54. emperature range is 30 C to 300 C Specific Objectives 1 To implement a controller that will be able to control and adjust the briquetting 2 To implement a monitoring system that displays the status of the critical parameters of the briquetting machine such as the temperature and the pressure 3 To incorporate a sensor in the raw materials compartment that will monitor the amount or level of raw materials and the binding agent 4 To be able to create rice husk briquettes based on the process parameters determined 5 To be able to include an economic evaluation of the machine 1 4 Significance of the Study Due to the increasing demand for energy and the constant importation of fuel from other countries the need for optimization of the use of local energy sources should be given much effort Production and utilization of alternative energy sources such as briquettes can be of help to address the rising energy needs of the country With an automated machine the control and variation of the parameters of the briquetting processes can be done more accurately and with ease With that experimentations for identifying the parameters needed to yield optimum performance of briquettes can be done in the Philippines not just relying on studies done by other countries Moreover with the use of the machine there will be better homogeneity in the mixture of the biomass and the binding agent and the safety will be reassured through the monit
55. erance level With the PLC serving as the heart of this control system variations in the relationship of the inputs and outputs in this machine are done through changes in the program not through repetitive wiring Since it also has access to the primary parts of the machine immediate shutdown can be done in case uncertain circumstances arise Using the economic evaluation done on the machine it can be observed where the bulk of the expenses were spent at allowing further studies to minimize the cost By doing that the aim of using an automated briquette machine for mass production is a step closer to realization Lastly this dissertation promotes further studies on the use of biomasses to supply part of the country s energy needs with high quality briquettes This machine can help in understanding deeper the different characteristics of briquettes optimizing their use It hopes to enlighten the 82 path to more researches and to maximize the potential into this overlooked capability of our agro wastes 83 BIBLIOGRAPHY Baconguis Santiago R 2007 Abandoned Biomass Resource Statistics in the Philippines Retrieved March 05 2011 from http www nscb gov ph ncs 10thNCS papers invited 620papers ips 20 1ps20 03 pdf bdeee2 l aspx Bawagan A n d Village Level Charcoal Briquetting Powerpoint slides Bolton W 2009 Programmable Logic Controllers Retrieved June 01 2012 from http books google com ph books id _qC
56. erate the solenoid valves relay switches were utilized to trigger the usage of an external power supply The connections of the solid state relay are shown in Figure 2 3 16 Terminal Arrangement Internal Connections 8 Toad oad Loac power To 2 i Input voltage Note The plus and minus symbols shown in parentheses are for DC loads Figure 2 3 Solid state relay wiring diagram Source Omron Corporation 2008 2 2 2 Ladder Programming In using the PLC a number of terms and symbols were used These drivers and structures used by the group are shown below Table 2 1 Devices Functions It is an internal memory or storage unit in the PLC corresponding to an external input point Input relay is used for connectine to the external input Input Relay put p P y P signals making a 0 or 1 It is also an internal memory or storage unit in the PLC corresponding to an Output Rela external output point Output relay is used for connecting to the external load P y The output relay is driven by the contact of an input relay contacts of other internal devices and the contacts on itself An internal relay does not have any connection with the external It is an auxiliary relay inside the PLC Its function is similar with those of the auxiliary relay in the electric control circuit Every internal relay is similar to a basic internal storage unit and can be driven by the contacts of the i
57. ergo processes such as direct combustion gasification or liquefication for energy production As the world s biggest rice consumers the increase in rice production in the Philippines went from 5 32 million tons to 12 39 million tons in just thirty years Accounting 20 of the rice production rice husk is a processing by product of the milling processes Baconguis 2007 However the physical features of the rice husks make it difficult to store Also high volume transportation of this biomass yield high transportation costs resulting toan uneconomic usage at a place other than the source i e rice mills With these concerns new methods for storing handling and transporting rice husks have been developed One of which is in the form of briquettes Singh amp Kasyhap 1985 Briquetting 1s the process of transforming a granular or powdery substance into a larger more convenient size As discussed by Maglaya amp Biona 2010 briquetting increases the homogeneity of the mixture allowing a more uniform and controlled combustion performance Also it greatly helps in the transportation and storage of the fuel Briquetting can be done using several techniques One of which is through pressure agglomeration wherein within a confined volume high forces are applied to a mass of particulate materials to increase its density However before entering the briquette machine the feedstock must be grinded and be subjected to pre treatment processes
58. ergration of Sensors Integration of Controls oy Integration of the Electricals Integration of Other Auxiliary Parts Prototype working MES NO TEN ANM Do adjustment s Figure 3 6 Flow of the Briquette Press Fabrication and Assembly Prototype acceptable YES END 38 3 4 Phase 3 FeaturesTesting and Verification of the Briquetting Machine Aside from the to be conducted test run in the 2 phase of the researchwhich is intended to merely check whether the prototype is working or not testing and verification of the machine s functionalities will be carried out in this 3 phase of the research In this step the features of the automated briquetting machine such as pressure and temperature control and monitoring were validated manually using appropriate tools and measuring instruments Also experiments to determine the value of the machine tolerance which is as have been mentioned the core determinant for the acceptance of the prototype were performed 3 4 1 Testing and Verification Overview The testing scheme primarily involved the measurement of directly measureable analog signals e g temperature and fluid pressure through manual means and computing for the values of the parameters e g horsepower requirement and pressure exerted on the mold through equations In due course this testing scheme would be able to determine
59. erties A CS 0 o Include fluid pressure effects from SolidWorks Off Flow Simulation Compute free body forges oO oS Result folder SolidWorks document F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Units 2 DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Material Properties Name AISI 1020 SolidBody 1 Cut Model type Linear Elastic Isotropic Extrude3 Briquette Machine Default failure Max von Mises Stress v1 4 Vertical Cylinder criterion Case Yield strength 3 51571e 008 N m 2 SolidBody Tensile strength 4 20507e 008 N m 2 2 Fillet1 Briquette Machine Elastic modulus 2e 011 N m 2 v1 4 Vertical Cylinder Case Poisson s ratio 0 29 Mass density 7900 kg m 3 Shear modulus 7 7e 010 N m 2 Thermal expansion 1 5e 005 Kelvin coefficient Curve Data N A Loads and Fixtures Fixture Image Fixture Details Entities 4 face s Type Fixed Geometry Fixed 1 Resultant Forces X Y 2 J Resutant Reaction force N 0 233231 0 266266 4690 47 4690 47 Reaction Moment N m 0 0 0 Entities 1 face s Type Normal to selected face A Value 1300 Pressure 1 Units psi 2 DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS _ Analyzed with SolidWorks Simulation Cylinder Case
60. ess Stress Deformation scale 135 028 von Mises M m 2 252 896 496 0 231 854 352 0 210 812 208 0 189 770 080 0 158 727 335 0 147 685 792 0 126 643 548 0 105 601 512 0 64 559 368 0 63 517 228 0 42 475 088 0 21 432 946 0 390 807 6 Yield strength 351 571 000 0 Briquette Machine v1 4 Vertical Cylinder Case 1300 Stress Stress1 2 DS Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Name Type Mi Max Displacement1 URES Resultant Displacement 0 mm 0 163384 mm Node 127 Node 16951 Model name Briquette Machine v1 4 Vertical Cylinder Case Study name 1300 Plot type Static displacement Displacement1 Deformation scale 135 028 URES mm 0 163 0 15 0 136 0 123 0 108 0 0953 0 0817 0 0681 0 0545 0 0408 0 0272 0 0136 1e 030 Briquette Machine v1 4 Vertical Cylinder Case 1300 Displacement Displacement1 A 25 Simulation of Briquette Machine v1 4 Vertical SOLIDWORKS Analyzed with SolidWorks Simulation Cylinder Case A Gatmaitan T Guanlao R Guting C Janairo De La Salle University 7 10 2012 Name Type Min Max Strain1 ESTRN Equivalent Strain 3 14347e 006 0 000703229 Element 6933 Element 7816 Model name Briquette Machine v1 4 Vertical Cylinder Case Study name 1300 Plot type Static strain Strain Deformation s
61. f 60 C and 60 kg cm the one on the lower left at 100 C and 65 kg cm while on the upper right at 150 C and 75 kg cm and lastly the one on the lower right at 200 C and at maximum ressure of 95 ke cm It can be seen that on the first icture the briquette instantly crumbles p P q y 69 down once removed from the mold while the second and third formed into cylinders but do not stay firm for long With the proper parameters it can be seen on the last picture that the briquette was formed properly and after some drying time it became hard enough to not break even when dropped on the floor These physical characteristics of the briquette show how pressure and temperature affect the compaction texture and firmness of the briquettes 4 1 3 Economic Evaluation For the economic evaluation of the machine the number of units sold and the number of years of operation before return of investment is achieved are computed in the tables below On the computation the cost of the machine and the daily operating expenses were taken into account and are also listed below 4 1 3 1 Existing Manually Operated Briquette Machine The computations found on this section are based on for the manual briquetting machine used by the Industrial Technology Development Institute of the Philippines Department of Energy ITDI DOST These machines are used by some of the citizens in rural areas of the country These data were gathe
62. f the pump Industrial Hydraulic Services Inc 2007 HP Ef foy an x 100 Eqn 2 8 where Ef foy Pump overall efficiency unitless HPoyr Output power horsepower hp HPjy Input power horsepower hp 11 2 1 3 Hydraulic Motor Hydraulic Fluid Motor Whendetermining thespecifications of the hydraulic fluid motor to be used for the hydraulic pump the parameters listed below should be considered Industrial Hydraulic Services Inc 2007 2 1 3 1 Fluid Motor Torque According to Ramsdale 2006 equation 2 9 was used to determine the torque that a hydraulic fluid motor could sustain Alternatively equations 2 10 and 2 11 could also be used to calculate the fluid motor torque as posited by Industrial Hydraulic Services Inc 2007 pre Eqn 2 9 a Eqn 2 9 HP 63 025 Toon Eqn 2 10 n Q P 36 77 pe Eqn 2 11 where T Fluid motor torque pound inch lb in Q Volumetric flow rate gallons per minute gpm P Pressure pounds per square inch psi n Fluid motor rotative speed revolutions per minute rpm d Fluid motor displacement square inch per revolution in rev HP motor Motor rated horsepower horsepower hp 12 2 1 3 2 Fluid Motor Rotative Speed Equation 2 12 was used to determine the fluid motor rotative speed as a function of hydraulic fluid volumetric flow rate and fluid motor displacement Industrial Hydraulic Services Inc 2007 Alternatively equation 2 13 cou
63. gh the machineoperating at maximumavailable pressure and temperature If the feedstock does not form into briquettes then amendmentsare to be made such as an increase in the amount of binding agent and vary the preheatingtime until briquettes are formed The moment it has been confirmed that machine could really create briquette test run with varying pressure and temperature could already be carried out At runtime of the press the installed control panelmay be used to monitorand regulate some of the briquetting parameters such as pressure and temperature If an error occurred the machine should be stopped if no error occurred then the operation continues If a disturbance occurred the built in machinecontrols may be used however if the disturbance is uncontrollable the machine has to be stopped Nonetheless if no disturbance occurred then the operation continues Figure 3 18 summarizes the briquette operation and testing phase 53 In addition to Figure 3 18 Figure 3 17 shows a closer view of the densification operation that will be done using the machine The densification operation to be done will follow a planned scheme to see if the automated briquetting machine 1s indeed flexible 54 START y Starting Pressure P Pstart Starting Temperature T Tstart P and T gt max YES END operating pressure NO Y Press Create X number of Briquetted YES
64. gram or the switch on the panel to RUN or STOP PLC 4 ERROR indicator 1 If you enter illegal program into PLC or use instructions or devices that exceed their range this indicator will flash approx every 1 sec When this happens you have to obtain the error code from D1004 and save the address where the error occurs in register D1137 if the error is a general circuit error the address of D1137 will be invalid Find out the cause of the error amend the program and resend the program to PLC If you cannot connect to PLC and this indicator keeps flashing quickly approx every 0 2 sec there should be insufficient 24VDC power supply Please check if the 24VCD is overloaded D For details of error codes in D1004 hex coding see DVP PLC Application Manual Programming 2 If the ERROR indicator keeps flashing you have to check the special relay M1008 M1008 is on indicates that the execution time of program loop exceeds the preset time out in D1000 In this case turn the RUN STOP switch to STOP check the special register D1008 and obtain the location in the program where the time out takes place We suggest you use WDT instruction to correct this problem 4 BAT LOW indicator BAT LOW indicator will be on when the battery is in low voltage When this happens change the battery as soon as possible in case your program and data saved in the latched area will be lost The changing of battery has to be completed within 1 m
65. hat emitted by the band heater and not what the biomass actually receives It is because of the width of the mold that traps the heat reducing the actual temperature that reaches the biomass The experimentations done by the group verified that the temperature set and displayed in the temperature controller is really what the band heater emits 4 2 2 2 Pressure System Through the convention assigned by the group it can be seen that the percentage differences between the average pressure readings from the two gauges and the set pressure of the pressure switch meet the tolerance level of 10 Also based on the experimentations it was learned that a minimum of 25 kg cm is needed to move the horizontal cylinder and 55 kg cm for the vertical cylinder These operating pressures set the pressing pressure to a range of 55 to 95 25 kg cm Another factor that affects the pressure readings was the method used to record them The group recorded the pressure gauges using a digital camera and phone cameras After the machine operation the pressure readings were taken by the group members as the videos were watched Even though the videos were repeatedly watched before taking note of the pressure human error can still play a part on this aspect of the study Lastly it can be seen that at S3 the pressure switch sets only at around 73 kg cm though it should be at 85 kg cm following the convention set by the group Howe
66. having the materials becustom built by a certified manufacturer Essentially all the accepted designs that have been generated from the previous steps will now be realized into actual parts which will then be assembled later on All the important components of the machine such as the mechanical framework hydraulics system 35 heatingsystem control system and electrical parts will be actualized and later on be integrated all together to form the overall prototype of the automated hydraulic briquette press The table below Table 3 1 shows how the proponents of this study outsourced or actualized the individual parts of the machine to form the overall prototype Table 3 1 Method of Acquisition per Machine Component Component Method of Acquisition Machine Package 1 Purchased from Tipontipon Welding Shop 2 Heating System 2 Purchased from RKRS Industrial Heater Desires rd 3 Purchased from Ace Hydraulics Enterprises 4 Proximity Sensors Metal 4 Borrowed from DLSU 5 Proximity Sensor Presence 5 Purchased from E Gizmo l 6 Purchased from Sky Electrical and 6 Dial Type 10 MPa Pressure Gauge Breina e Con Cotes Programmable Logic Controller 8 Solid State Relay Switches 9 Switches Push Button Toggle etc 12 Other Electrical Auxiliaries Note that the machine package from above includes primarily of the following machine Q Ke m Un A m n a LE L3 B framework hydraulic system mixing
67. ine is Php 1 458 00 4 1 3 2 Automated Briquette Machine The expenses in manufacturing the experimental automated briquette machine were tallied and are summarized in this section From that list the group canvassed the additional expenses if the machine is to be used for mass production The operating expenses such as the electricity and the binder were also considered in computing for the payback period The expenses for both the experimental and the mass production machine are listed below 4 1 3 2 1 Assumptions In the computations the following assumptions were used Table 4 9 Assumptions B 8 hours day operation 1 briquette approximately 70 grams tious oc Binder Don l kg 15 briquettes batch of SE dE rodcion pressing batch 12 minutes thuss baches hour 25 days month operation The briquette weight was measured using a digital scale and found out to be approximately 70 grams The planned automated machine for mass production have 15 molds thus in one press batch 15 briquettes will be formed Based on the experimental machine it 72 takes 12 minutes for a batch to be formed resulting to 5 batches formed in one hour From these values the machine has an estimated 35 kg day production Table 4 10 Cost of Machine Experimental and for Mass Production rat lt a Part A Price Price Machine Fabrication 68 000 00 150 000 00 Heating System 6 224 00 20 000 00 D SemiVde 809
68. ing from red to blue that represents the factor of safety range from 0 to 15 These colors represent the intensity of the factor of safety distribution on the simulated part In Figure 4 1 it shows that the middle part of the table has an orange color which means that its factor of safety 1s in between 0 75 to 2 00 The legs are mostly blue in color implying that its factor of safety on that portion of the assembly is around 15 00 In analyzing the figure the legs of the assembly are safe but the middle of the table can be subjected to failure But since the applied load 1300 psi is 30 higher than the actual load the factor of safety is acceptable In Figure 4 2 the factor of safety distribution on the mounting of the hydraulic press assembly is shown The simulation results show that the legs and the upper base of this part are subjected to high deformation and stress because of its factor of safety ranging from 1 75 to 3 00 76 However as mentioned earlier the applied load is also 30 higher to the actual load thus this factor of safety 1s acceptable In Figure 4 3 this figure shows the simulation on the casing of the hydraulic press Based on the simulation results the component has a high factor of safety ranging from 5 00 to 8 50 these figures indicate that the component has a low chance of failing The results of the simulations done by the group are shown below while detailed report can be seen on Appendi
69. inute when the PLC is not powered in order to save your procedures and data in the PLC After the power is switched off the data in the latched area are stored in SRAM memory and its power is supplied by the battery Therefore when the battery is in low voltage and the power off has been lasted for more than 1 minute the data in the latched area will be lost If you need to permanently save the data in the latched area in the program and device D refer to Flash ROM permanently saved and recover mechanism as stated below Permanently saved mechanism You can use WPLSoft Options gt PLC lt gt Flash to indicate whether to permanently store the data in the latched area in Flash ROM memory new indicated data will replace all data previously saved in the memory Recover mechanism If the battery is in low voltage before the power is switched off when the BAT LOW indicator is on and the power is off for more than 1 minute PLC will automatically restore the data in the latched area in the program and device D of Flash ROM into SRAM memory next time when it is re powered Battery life Temperature C 0 25 50 70 Life year 9 8 6 5 Input indicator On Off of input point is indicated by input indicator or monitored by HPP When the action criteria of the input point are true this indicator will be on If abnormality is identified check if the indicator and input circuit are normal Output indicator On Off of output point i
70. itled Automated Briquetting Machine Nevertheless in general the designs of the individual parts were designed based on the reference materials obtained through research Afterwards the initial design for each of the briquetting machine parts were subjected to stress simulations and other essential machine design simulations such as factor of safety variable loading and strain simulations Designs were reviewed and eventually were accepted based on the aforementioned rubric If a certain part does not meet the set design standards it will undergo a redesigning process and the redesigned part will then undergo the same set of stress and machine design simulations When all the individual designs of the machine s framework have passed all the simulations and were regarded as up to standard the assembly of the individual mechanical parts of the machine s mechanical framework will then proceed Upon having completed the assembly of the framework stress and machine design simulations were again made but this time the loading was intended for the whole assembly 27 combined loading If the assembly is seen to possess any form of flaw during the combined loading simulations the assembly will undergo modification until it becomes an acceptable assembly design Once all simulations have been done to the assembly of the mechanical framework of the to be fabricated briquetting machine and have passed the set rubric the design of the
71. ks Simulation Assembly De La Salle University Entities Type Head diameter Nut diameter Nominal shank diameter Preload Torque Young s modulus Poisson s ratio Preload units Counterbore with Nut 3 Connector Forces A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 2 edge s Bolt Head Nut diameter Count erbore 15 mm 15 mm 10 No Data 0 2 1e 011 0 28 N m X Component Y Component Z Component Resultant Axial Force N Shear Force N 44 663 3 0235 56 643 72 197 Bending moment N m 0 17301 0 0004309 0 080116 0 19066 Entities Type Head diameter Nut diameter Nominal shank diameter Preload Torque Counterbore with Nut 4 Young s modulus Poisson s ratio Preload units Connector Forces 2 edge s Bolt Head Nut diameter Count erbore 15 mm 15 mm 10 No Data X Component Y Component Z Component Resultant Axial Force N Shear Force N 40 313 2 8815 54 889 68 164 Bending moment N m 0 13759 0 00063086 0 039696 0 1432 Zs SOLIDWORKS Analyzed with SolidWorks Simulation Simulation of Briquette Machine v1 4 Table Assembly De La Salle University A Gatmaitan T Guanlao R Guting C Janairo 7 10 2012 Contact Information Contact Image Contact Properties Type Bonded Components 8 Solid Body s Options Compatible mesh Component Contact 1 Type Bonded Components 5 Solid Body s Options Compatible mesh
72. ld also be used to determine the fluid motor rotative speed but in this case as a function of frequency and number of windings in the motor poles Rockis amp Mazur 2007 Q 231 n 7 Eqn 2 12 120 F n Egn 2 13 ny where n Fluid motor rotative speed revolutions per minute rpm Q Volumetric flow rate gallons per minute gpm d Fluid motor displacement square inch per revolution in rev F Frequency hertz Hz n Number of windings in the motor poles poles 2 1 3 3 Fluid Motor Power Equation 2 14 was used to determine the power that the fluid motor could produce Industrial Hydraulic Services Inc 2007 B T en 63 025 Eqn 2 14 where P Output fluid motor power horsepower hp T Fluid motor torque pound inch lb in n Fluid motor rotative speed revolutions per minute rpm 13 2 2 Control System 2 2 1 Programmable Logic Controller PLC One of the many types of controllers used in automating various systems mechanical electrical etc 1s a programmable logic controller PLC Compared to other controllers PLCs have an advantage of being able to use the same basic controller for a wide range of control systems Furthermore control system modification can be done by modifying the program on the PLC no need for rewiring as long as the same inputs and outputs are involved The result therefore is a flexible cost effective system that can be used with control sy
73. ll not be able to read the signal from the field device The proper wirings according to the field device type are shown below Input point loop equivalent circuit DC Signal IN n TC o XD oe SINK mode common port for current input S S DC Signal IN Input point loop equivalent circuit Wiring loop SOURCE mode common port for current output S S Figure 2 1 PLC input wiring depending on the field device type Source Delta Electronics Inc 2006 15 2 2 1 2 Output External Wiring For Delta PLCs two types of output can be present relay type outputs or transistor type outputs Each type has its own wiring diagram that should be strictly followed to avoid damage on the PLC For the PLC used on this study the wiring for a transistor type was utilized as shown on Figure 2 2 DVP T ol TRANSISTOR OUTPUT D DC power supply 2 Emergency stop J Circuit protection fuse Flywheel diode inductive load Manually exclusive output Uses external circuit and forms an interlock together with the PLC internal program to ensure S safety protection in case of any unexpected errors Figure 2 2 Wiring diagram for a transistor type PLC Source Delta Electronics Inc 2006 2 2 1 3 PLC to Solenoid Valve External Wiring For the PLC connection to the solenoid valves solid state relays were used Since the PLC cannot provide the needed current to op
74. m Base Bo Drawingnos 1 NO Solenoid Mounting Assembly From Drawing no OA x 12 Solenoid Assembly Drawing no 13 E T Hydraulic Tank Drawing no 14 Er Horizontal Hydraulic Cylinder Assembly Drawing no 15 and 16 3 7 Hydraulic Tank Horizontal Cylinder Bolt Drawing no 17 EE EE Hydraulic Tank Cap Drawing no 18 RENE REM 9 table Assembly From Drawingne 19 26 1 10 Virer Blades Assembly HomDrawngno 2Z7A 29 1 1 Wing chamber Asemoy Drawing 80 2 VeriealCyderAwemby Diwngno SlandS2 1 L M weiedcwreMeingisemby HomDuwgnodiA E T l d 1 L8 3 Ram Assembly Drawing no 47 and 48 Mold Assembly From Drawing no 49A 54 Mold Door Mechanism Assembly From Drawing no 55 58 Mixing Chamber Motor Mounting Assembly From Drawing no 59A 63 20 eo Hydraulic Tank Table Support Drawing no 64 Mixing Blades Soeed Reducer Link Drawing no 65 and 66 DRWNO 2 Assembly Name QTY n a PART NO X Bill of Materials SCALE n a De La Salle n a University Designed by T Guanlao R cR A Gatmaitan C Janairo Date July 10 2012 THESIS TGumloo Revised Approved by Dr Alvin Chua APPENDIX C Development of an Automated Briquette Machine De La Salle University Simulation of Briquette Machine v1 4 Table Assembly Date Tuesday July 10 2012 Designer A Gatmaitan T Guanlao R Guting C Janairo Study name 1300 Analysis type Static Tabl
75. me requirement decreases to one and a half minutes until it reaches 250 C wherein only a minute is needed In addition the group also tried varying the increase in temperature As seen on the Table 4 4 at Trial 2 from 60 C to 130 C and 150 C to 190 C it also takes around two minutes same as when the temperature is increased by just 10 C This signifies that regardless of how much the temperature is increased it needs only a maximum of around two minutes It indicates that the heater should be turned on at least four minutes before the operation even during binder preparation to reduce idle time Moreover it was examined that as the temperature increases the offshoot decreases thus resulting to shorter stabilization period As expressed on the Methodology part of this study the production of briquette requires a preheating of approximately twenty minutes before pressing This is to compensate the carbonization process which minimizes moisture and increases the briquette s heating value done in manual briquetting as discussed by Bawagan n d The length of preheating was identified through several trials ranging from no preheating at all to 30 minutes Below 20 minutes of preheating produces moist briquettes that deforms quickly upon removal from the mold while more than 20 minutes makes the briquette too dry and more difficult to press 78 It should also be taken note that the temperature readings on Table 4 3 are t
76. me selling price of Php 50 00 kilogram This may be attributed to the relatively large initial expense needed for manual machines since it requires a separate individual equipments such as the carbonizer For the mass production automated machine it can be seen that a capital of approximately Php 200 000 00 is needed same as with the manual machine Even though less 80 briquettes are produced in the automated machine since it weighs more less briquettes are needed for the per kilo selling However since different types of biomass and binders have different weights this can vary Also the prices may vary based on the time of machine production and project implementation 4 2 4 Overall Machine Performance The automated machine prototype that was made for this study 1s able to adjust pressure and temperature more accurately and through automated means The temperature could be adjusted by pressing buttons on the control panel while the pressure could be adjusted through a knob attached to a switch Also the machine operation was done with the use of buttons and switches thus allowing the user to operate the machine even at a distance from it When a problem arises the operator would be not affected directly and an emergency stop button could be triggered to stop the operation For all the parameters set by the group the values obtained during experimentations were within the 10 tolerance range This implies that the machine is
77. mm Please install PLC in an enclosure with sufficient space around it to allow heat dissipation as shown in the figure SS 3 4 Wiring Please note that 1 Use O type or Y type terminal See the figure in the right for its specification PLC terminal screws should be tightened to 5 8 kg cm 4 3 6 9 in Ibs and please use only 60 75 C copper een 00 E 3 conductor 2 DO NOT wire empty terminal To suit M3 5 screw terminals 3 DO NOT drop tiny metallic conductor into the PLC while screwing a or and wiring Tear off the sticker on the heat dissipation hole for Below 6 2 DID E preventing alien substances from dropping in to ensure normal heat dissipation of the PLC 3 5 Power input wiring The power input of DVP EH2 series is AC When operating the PLC please make sure that 1 The input voltage should be current and its range should be 100VAC 240VAC The power should be connected to L and N terminals Wiring AC110V or AC220V to 24V terminal or input terminal will result in serious damage on the PLC 2 The AC power input for PLC MPU and l O extension modules should be ON or OFF at the same time Use wires of 1 6mm or longer for the grounding of PLC MPU 4 The power shutdown of less than 10 ms will not affect the operation of the PLC However power shutdown time that is too long or the drop of power voltage will stop the operation of the PLC and all outputs will go OFF When the power supply tu
78. n T Guanlao R Guting C Janairo Mass 0 300489 kg Volume 3 80366e 005 m 3 Density 7900 kg m 3 Weight 2 94479 N Mass 0 524166 kg Volume 6 63501e 005 m 3 Density 7900 kg m 3 Weight 5 13682 N Mass 0 524166 kg Volume 6 63501e 005 m 3 Density 7900 kg m 3 Weight 5 13682 N Mass 0 307993 kg Volume 3 89864e 005 m 3 Density 7900 kg m 3 Weight 3 01833 N Mass 0 707603 kg Volume 8 957e 005 m 3 Density 7900 kg m 3 Weight 6 93451 N Mass 0 71044 kg Volume 8 99291e 005 m 3 Density 7900 kg m 3 Weight 6 96231 N 7 10 2012 Volumetric Properties Document Path Date Modified F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Table Assembly SLDPRT Jul 10 12 56 22 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette
79. n 1 min COM1 RS 232 Battery COM 2 RS 485 pe Part Description RUN STOP SWITCH O fog COM2 RS 485 For both master amp slave modes We a yri ll RUN STOP switch PLC RUN STOP control vent jm V4 Yep VRO Enable M1178 corresponding COM 1 RS 232 O50 value of D1178 He Enable M1179 correspondin Batiey S d value of D1179 aibi 1 3 Installation of function card memory card optional accessories Remove function card Remove memory card Close the cover For details see the instruction sheets of these accessories O Electrical Specifications PERI 20EH0002 ET 40EH0002 ET 64EHO0O2 80EHO0O2 poe UD 100 240VAC 15 10 50 60Hz 5 voltage Fuse capacity 2A 250VAC Power 50VA 50VA 60VA 60VA 60VA 80VA 80VA consumption SE PII 500mA 500mA 500mA 500mA 500mA 500mA 500mA DC24V output short circuited 1500VAC Primary Secondary 1500VAC Primary PE 500VAC Secondary PE Power protection Withstand voltage Insulation gt 5 MO all I O point to ground 500VDC resistance ESD 8KV Air Discharge EFT Power Line 2KV Digital I O 1KV Analog amp Communication I O 250V Damped Oscillatory Wave Power Line 1KV Digital 1 0 1KV RS 26MHz 1GHz 10V m The diameter of grounding wire shall not be less than that of L N terminal of the power When many PLCs are Noise immunity ES in use at the same time please make sure every PLC is properly grounded Operation 0 C 55 C temperature 5
80. n with the pressure switch that has been acquired for the study has a vague metrological graduation which cannot be understood even with the aid of the proponents 42 consultation with its vendor since there is no available user manual for the said component Hence the proponents of this research eventually decided to set their own convention for the pressure switch based on the minimum and maximum operating pressure of their machine With that the circumference of the pressure switch was divided into 4 quarters namelythe north east west and south quarters as shown in the Figure 3 10 underneath After a few trials it has been found out that each quadrant or quarterof the pressure switch signifies an increase of around 5 kg cm Sl ud 2 rotation of the knob N2 D AN W3 E2 S2 Figure 3 10 Pressure Switch Convention 43 To proceed with the manual verification of the pressure switch s accuracy two Bourdon gauges were used Pressure gauge PGI has a maximum pressure of 150 kg cm and islocated or mounted before the solenoid valve while pressure gauge 2 PG2 has a maximum pressure capacity of 100 kg cm and is located or mountedright before the vertical hydraulic cylinder The experiment is done by recording the readings of the two pressure gauges for every trial of the pressure switch while increasingthe compression pressure by an increment of 5 kg cm per trial This implies that the dial of the pressure swit
81. nput relay output relay and contacts of other internal devices STL instruction controls the transfer of step S making the writing of the control program easy If the step program is not in use Step S can be used as realy M or an alarm point Internal Relay 17 The timer is utilized for timing and has coils contact and register on it Whenever the coil is on and the given time is reached its contact will be enabled Every timer can have a fixed timing period Once the coil 1s turned off the contact will be disabled making the present value 0 The counter is utilized for counting Giving the counter a set of values 1s needed before using it The counter also has coil contact and registers Once Counter vo the coil goes from off to on the counter will consider it as an input of 1 pulse and the present value on the counter will add up or plus 1 Data Register is used for storing values or all kinds of factors Every register is able to store a word On the other hand double words occupy 2 adjacent data registers File register is utilized for storing data or all kinds of parameters This 1s File Register usually used when the data register required for processing the data and value operations are insufficient This are also 16 bit data registers as other data registers Index registers can be read and written and can be used in word devices as a constant for index indication or bit devices Data Register Inde
82. omlaiXF4C amp printsec frontcover amp dq progra mmable logic controller amp hl en amp sa X amp ei p7a7T alHqLUmAWzobWiCQ amp sqi 2 amp redir_esc y v onepage amp q programmable 20logic 20controller amp f false Cheremisinoff N Cheremisinoff P amp Ellerbusch F 1980 Biomass Applications Technology and Production New York USA Marcel Dekker Inc Daiwey A S Rotaquio E Jr L Angara E V 2010 Charcoal Briquetting Technology in the Province of Aurora Philippines ASCOT International Journal 3 Retrieved from http ascot edu ph research 2010 1 2 charcoal briquetting technology in the province of aurora philippines 2 Delta Electronics Inc 2006 DVP EH2 Instructional sheet Retrieved July 8 2012 from http www delta com tw product em control plc download manual DV P EH2 manual en pdf Department of Energy 2011a Renewable Energy Retrieved February 19 2011 from http www doe gov ph ER Renenergy htm 84 Department of Energy 2011b Renewable Energy Biomass Solar Wind and Ocean Retrieved February 19 2011 from http www doe gov ph ER BioOS W htm Fule C Go K Hua J Rabby M amp Tan I 2010 Automated Briquetting Machine Undergraduate Dissertation De La Salle University Manila Philippines Grover P D amp Mishra S K 1996 Biomass Briquetting Technology and Practices Regional Wood Energy Development Programme In Asia GCP RAS I54 NET Retrieved February 24 2010 f
83. on 2 1 was used Ramsdale 2006 F P A Eqn 2 1 where EP 1 Force pound 1b P Pressure pounds per square inch psi A Cross sectional area of the piston of the cylinder square inch in 2 1 1 2 Piston Rod Speed Hydraulic Fluid Volume and Volumetric Flow Rate The speed of the piston depends on the volumetric flow rate of the hydraulic fluid flowing through the cylinder Moreover the volumetric flow rate of the hydraulic fluid entering the piston cylinder is equivalent to the change in volume of the hydraulic fluid per unit time inside it as stated by Industrial Hydraulic Services Inc 2007 The mathematical models shown below are the equations that were used to calculate the said parameters mr si 231 Eqn 2 2 Peu Eqn 2 3 12 60 A pu Ath 231 where Q Volumetric flow rate gallons per minute gpm V Volume gallons gal v Velocity of the piston rod feet per second fps A Cross sectional area of the piston of the cylinder square inch in Cylinder stroke inch in r Cylinder inside radius inch in 2 1 1 3 Power There are two kinds of power to be considered in a hydraulic cylinder namely fluid power and mechanical power Fluid power refers to the power that a hydraulic fluid can produce or deliver to the hydraulic cylinder while mechanical power refers to the overall power that was transmitted from the fluid to the cylinder In general fluid power is greater
84. on the different heaters they offer After having identified the manufacturer with the most versatile list of the needed equipment the proponents of the research consulted with themaiming to identify the most suitable design of heaterthat is in line with their objectives 3l Having said that the band heater type of heater was chosen for the research primarily because it can be attached to the system easily without risking too much heat loss With its cylindrical hollow shape it envelops the mold and transfers heat to the feedstock through conduction A thermocouple is attached to the band heater to monitor its temperature ensuring that what is being given off by the heater is within the threshold of the preferred parameter With the desired maximum temperature of 300 C the wattage and voltage of the heating system was determinedand was eventually manufactured by the chosen supplier which was RKRS Industrial Heater Figure 3 4 is a picture showing the chosen and manufactured heater that was utilized in the study Figure 3 4 Band Heater Following the heating system the planning design and programming of the controls components and the monitoring system of the machine will be next inline 32 3 2 2 Control System The initial step in the design of the control system that was employed in the briquetting machine 1s to establish what parameters or analog signalsare to be monitored and controlled Such scheme may be referred to as C
85. ontrol SystemAlgorithm Planning At this point logic operationsof the machine are to be defined For example when the pressure exerted by the hydraulic cylinder against the feedstock 1s too highor when the mixing chamber runs out of feedstock what should be the response of the machine The design of the control system waslikewise evaluated using the same rubric aforementioned Selectionof the sensors to be used for the actual machine will go after the planning of the control system In this regard it 1s important to know what type of sensors should be used with different forms of analog signals A pressure sensor which senses pressure signals for example is different from a temperature sensor which senses temperature signals Moreover sensors used for solids e g piezoelectric sensors are different from sensors used for fluids e g digital air pressure Sensors Subsequent to the selection of sensors is the identification of the external wiring of the controls components of the press based in their manuals As have been mentioned earlier the PLC that was used in this paper was a Delta PLC with model number of DVP 3200EHT2 Its wiring requirements along with the inputs and outputs can be found in its manual which is in effect can be seen in Appendix H of this paper 33 Moving on the planned algorithm of the control system was converted into a machine code and was then programmed into the PLC using the WPLSoft 2 20 software However
86. op SINK mode common port for current input S S Input point loop equivalent circuit Wiring loop DC Signal IN Hl Sourcing SOURCE mode common port for current output S S Source Type 3 8 Output point wiring Relay R contact circuit wiring DVP R RELAY OUTPUT Flywheel diode To extend the life span of contact Emergency stop Uses external switch Fuse Uses 5 10A fuse at the common port of output contacts to protect the output circuit Varistor To reduce the interference on AC load 9 Empty terminal not in use DC power supply Neon indicator AC power supply Incandescent light resistive load Manually exclusive output Uses external circuit and forms an interlock together with the PLC internal program to ensure safety protection in case of any unexpected errors See Oe eo Transistor T contact circuit wiring DVP T m gt o t o D FH TRANSISTOR OUTPUT D DC power supply Emergency stop Circuit protection fuse Flywheel diode inductive load Manually exclusive output Uses external circuit and forms an interlock together with the PLC internal program to ensure safety protection in case of any unexpected errors Trial Operation Power indication The POWER LED indicator on the front panel of PLC MPU or extension module will be on in green when the MPU is powered That the MPU is powered but the indic
87. or each trial the temperature on the controller was set from 30 C to 300 C with 10 C increment Once the temperature on the controller stabilizes the temperature on the thermocouple is recorded then the temperature is increased until it reaches the maximum temperature capacity of the heating system This was repeated three times then the average temperature form these trials were computed The average was compared to the temperature on the controller to achieve the percentage difference between these two readings Table 4 4 Temperature Readings with Time Temperature Time in seconds Controller C Trial 2 0 00 00 00 0 25 027 5 56 0 920 939 89 1329 90 160 Skipped to 130 11 44 13 29 160 Skipped to 180 15 11 16 58 210 17 35 19 23 230 20 51 22 19 23 44 260 24 53 62 270 45 97 25 42 46 35 On another testing the temperature was again taken but now the time needed to reach the desired pressure was monitored On Table 4 4 the data from the three trials can be seen On Trial 1 the temperature was increased by 10 C from 30 C until it reaches 300 C As a pattern was observed by the group on the first trial they increased the temperature by 80 C at one point and 40 C on another part to see if it takes the same time as when it is increased by 10 C On the third trial the same increment of 10 C was used Temperature versus Time Time in seconds 60 80 10
88. oring system Also with less human interaction accidents can be minimized Using this prototype further researches on other biomass briquettes can be done The data obtained in the experiments using this automated machine can be utilized in the industry to create briquettes of high efficiency and quality This study can also be a head start for the use of automated machines in the country Other experiments which aim to produce automated machines appropriate for mass production of briquettes and suited for local use specifically in rural areas may soon be initialized 1 5 Scope and Limitations of the Study In this research the automated briquette machine will operate on the pressure range of around 55 kg cm to 95 kgr cm and a temperature range of 30 C to 300 C With that pressure and temperature ranges aside from the one specified will not be used The accuracy of the parameters will be tested through external tools wherein a tolerance of 10 will be observed The machine is used mainly for experimental purposes and not for large production of briquettes or for employment in urban or rural areas The shape of the rice husk briquettes that will be formed are hollow cylinders accordingly other forms will not be considered This shape is chosen because cylinders with a concentric hole gives better combustion characteristics brought about by larger specific area as discussed by Grover amp Mishra 1996 The raw materials th
89. readily available in the market will be purchased while those that are not readily available will be asked to be fabricated Sensors logic controls and computerized monitoring will be integrated in almost every component of the briquetting machine so that the user is able to witness what is happening inside the machine and is able to manipulate easily the briquetting operation parameters based on his her preference 24 25 Figure 3 1 Conceptual Framework of the Study AWUITXOIg oJnssoJd o1njedoduro J J9 9UIE I amp qd Jo ONUOZ 91807 T o qeurure180Jd LS ec ee Nun 7 IQON aue prougos H emo ee SS 7 JOJON OV ulojs g SuneoH PIOIN JO 9 q sayonbrig G e m 4 Joquieq SUIXIIN ae jndjno opne1pAH E jnduq 3 2Phase 1 Briquetting Machine Design Phase This phase of the research 1s further divided into two sub phases which are the design of the mechanical system and the design of the control system On one hand the mechanical system of the machine is composed of its mechanical framework hydraulic system and heating system On the other hand the control system of the machine is composed of mainly of sensors switches wiring and ladder program On that note commercially and readily available
90. red from the paper of Bawagan n d The briquettes made by ITDI DOST were sold for Php 50 00 per kilogram Based on Bawagan n d the machine capacity 1s 2 500 kilograms of briquette in a month operation The machine operates 25 days a month at 8 hours per day In their computation the payback period is 3 9 years or after selling 138 420 briquettes The following expenses are summarized on the following tables 70 Table 4 7 Cost of the Machine Equipment Price in Php Drum type carbonizer 40 000 00 Gas engine a crusher 50 000 00 Manual type mixer 7 500 00 The individual equipment needed in manual briquetting with their corresponding cost are seen on Table 4 7 Since manual briquetting utilizes separate carbonizer crusher mixer and press briquettor they all contribute to the expense of the machine Table 4 8 Daily Operation Expenses in Php Cost kg Total Cost Materials 816 00 Direct Labor Cost 500 00 Factory Overhead Utilities 36 00 Repairs and maintenance is assumed 1 of initial cost of equipment 71 In preparing the feedstock and in operating the machines needed in forming briquettes the electrical and material costs should also be taken note of Materials such as the binder and the biomass itself labor costs for the machine operators and other related fixed costs were identified for effective computation And as seen on Table 4 8 the daily operating expense of a manual briquette mach
91. rification of the Accuracy of the Pressure Switch 3 4 4 Verification of the Control System Circuitry 3 5 Phase 4 Briquette Press Operation Testing 3 5 1 Preparation of the Feedstock 3 5 2 Briquetting Operation Proper ii Page Number SAO 10 14 14 17 20 20 20 20 21 22 26 26 33 35 39 39 41 42 44 46 48 52 4 Results Analysis and Conclusion 4 1 Results 4 1 1 Simulations 4 1 2 Machine Operation 4 1 3 Economic Evaluation 4 2 Analysis of the Data 4 2 1 Simulations 4 2 2 Machine Operation 4 2 3 Economic Evaluation 4 2 4 Overall Performance 4 3 Conclusion Bibliography Appendices A Actual Machine Photos B Machine Drawing Files C Briquette Machine Framework Simulation D Briquette Machine Vertical Cylinder Mounting Simulation E Briquette Machine Vertical Cylinder Casing Simulation F Electrical Diagram G Hydraulic Circuit H PLC Spec Sheets 87 94 97 114 125 139 141 143 Chapter 1 INTRODUCTION This chapter discusses the brief background of biomass briquetting including related topics to it Itis also in this chapter where the problem that was addressed in the research is stated Furthermore the objectives to be attained the significance of the study as well asits scope and limitations can be seen in this part of the paper 1 1 Background of the Study The need for alternative sources of energy has been a sensitive issue for the past years In the Philippines the harne
92. rns normal again the PLC will automatically return to its operation Please be aware of the latched auxiliary relays and registers inside the PLC when programming e AC Power Input 100 240VAC D 0 5A is the maximum power supply for 24V power supply output terminal DO NOT connect other external power supplies to this terminal Every input terminal requires 6 7mA to be driven e g the 16 point input will require approximately 100mA Therefore 24V cannot give output to extermal load that is more than 400mA 3 6 Safety wiring Since a PLC controls many devices actions of any device may affect actions of other devices and the breakdown of any one device may cause the breakdown of the whole auto control system and danger Therefore we suggest you wire a protection circuit at the power input terminal as shown in the figure below AC power supply load Power circuit protection fuse 3A Power indicator Emergency stop This button can cut off the system power supply when accidental emergency takes place System circuit isolation device The device is made of electromagnetic contactor and relay as the switch to prevent the instability of system when the power is intermittently supplied DVP PLC main processing unit Earth OOO Power supply AC 100 240VAC 50 60Hz 3 7 Input point wiring There are two types of DC inputs SINK and SOURCE Input point loop equivalent circuit DC Signal IN Wiring lo
93. rom http wgbis ces 1isc ernet in energy HC270799 RWEDP acrobat fd46 pdf Industrial Hydraulic Services Inc 2007 Fluid Power Formulas Retrieved June 15 2012 from http www ihservice com PDF s Fluid 20Power 20Formulas pdf Kaliyan Nalladurai amp Morey Vance R 2009 Factors affecting strength and durability of densified biomass products Biomass and Bioenergy 33 337 359 doi 10 1016 j biombioe 2008 08 005 Khan Q S n d Design and Manufacturing of Hydraulic Cylinder Retrieved from http www scribd com doc 17375627 V olume2 Design and Manufacturing of Hydraulic Cylinders Maglaya A B amp Biona J B M 2010 Combustion Properties Performance And Net Energy Benefits Of Jatropha Bio Coals Briquettes Omron Corporation 2008 Solid State Relay G3F G3FD Retrieved July 8 2012 from http www ia omron com data_pdf data_sheet g3f_g3fd_dsheet_csm153 pdf Penton 201 1a AC Motor Basics of AC Motor Design Engineering Retrieved March 05 2011 from http www electricmotors machinedesign com guiEdits Content bdeee2 Ramsdale R 2006 Reference Tables Fluid Power Formulas Retrieved March 22 2011 from http www engineershandbook com Tables fluidpowerformulas htm 85 Rockis amp Mazur 2007 Motor Formulas Retrieved March 21 2011 from http www elec toolbox com Formulas Motor mtrform htm RUF Briquetting Machinery 2008 Automated Briquetting Plant Video file Retrieved from http www youtube com w
94. rresponding graphs Also the analyses of the data followed by the conclusion are discussed on the latter part of this chapter 4 1 Results The results of the experiments conducted by the group as explained in the previous chapter are summarized in this section On Table 4 1 a list of the parameters measured in the machine together with their corresponding monitoring unit used can be seen Table 4 1 Parameters Monitored Controlled Positioning of the mold 3 proximity sensors For continuous operation a proximity sensor 1s attached to the mixing chamber With the use of an indicator light the user can know when the biomass level is low and needs refilling In addition to that proximity sensor 3 more inductive proximity sensors are used to position the mold For the temperature aspect a temperature controller with a thermocouple attached to the band heater is used to monitor the temperature at the mold Lastly 2 pressure gauges one 57 attached before the solenoid valve and one attached before the vertical hydraulic cylinder and a pressure switch are installed on the system to make sure that the pressure supplied to the biomass is correct 4 1 1 Simulations Several parts of the machine have undergone simulations such as stress analysis factor of safety etc The results of the simulations done by the group are shown below while detailed reports can be seen on Appendices C D amp E Model name Briquette Machine
95. s indicated by output indicator When the output indicator On Off does not correspond to the action of its load please be aware of the follows 1 The output contact may be melted or blocked out of overloading or short circuited load which will result in poor contact 2 If you are suspicious that the output point may execute undesired action check the output wiring circuit and whether the screw is properly tightened Accuracy month second of RTC Temperature C F 0 32 25 77 55 131 Max inaccuracy second 117 52 132 The content of this instruction sheet may be revised without prior notice Please consult our distributors or download the most updated version at http www delta com tw industrialautomation
96. s the performance of the briquettes produced Along with that the amount of the binding agent used in the production can also be a factor that affects the performance of the briquettes Kaliyan amp Morey 2009 In order to be able to adjust and achieve the parameters and proportions that will yield optimum efficiency and favorable characteristics for the briquette a machine that allows the alteration of the said factors 1s needed In the Philippines the briquetting industry is not yet matured compared to the other countries The Philippines only has manually operated briquette machines that are found in a few areas of the archipelago Briquette machines are not widely available and those available are not at par with the technology exhibited in foreign regions The production of a prototype for anautomated briquette machine can address the problem stated This prototype can be used for experimentations in order to obtain the optimal parameter settings for a certain biomass briquette It can be used for the forming and production of several briquettes utilizing the desired process parameters and using the necessary amount of the binding agent 1 3 Objectives of the Study General Objective The main objective of the group is to design a small scale 1 e for experimentation purposes and not for mass production of briquettes automated briquette machine The pressure range will be around 55 kg cm 5MPa to 95 kgr cm 9MPa and the t
97. ssing and utilization of renewable energy has been a significant part of the government s strategy to supply the energy needs of the country Department of Energy 2011a To minimize the dependence on imported fuel and to solve problems on energy shortage considerable efforts have been made to utilize the country s available resources The use of the several forms of renewable energy such as the geothermal wind and solar are studied and researched upon to maximize the benefits that can be harnessed for the country As discussed by Cheremisinoff et al 1980 biomass is essentially a plant material ranging from algae to wood in form However agricultural residues such as manures straws cornstalks and other by farming products are considered to be one of the chief sources of biomass for energy production The energy content of biomass is relatively uniform on the order of 9000 Btu Ib 20 890 188 kJ kg which is roughly half to two thirds of coal s heating value Moreover there are major advantages of biomass as fuelwhich are as follows biomass contains negligible sulfur generates little ash and most importantly is continually renewable These advantages make it more appropriate to use biomasses as fuel As projected by the Department of Energy or DOE 2011b the biomass supply in the Philippines is expected to reach 323 1 MMBFOE by 2012 These abundant supplies of waste products coconut husks corn husks saw dust etc can und
98. stems which vary quite widely in their nature and complexity Bolton 2009 In the case of this research a PLC acquired from Delta Electronics Inc with model number of DVP 32EHOOT2 was used All the inputs in this PLC basically serve as the trigger for the movement of various briquetting machine components These inputs include three proximity sensors which control the position of the mold a pressure switch which controls the pressure given by the hydraulic cylinder to the biomass binder mixture when pressing and switches which serve as additional control to various steps in briquette production Then the PLC is downloaded with a ladder program that will manage the relationship between the inputs and outputs of the PLC The outputs of the PLC control the solenoid valves that in turn control the hydraulic cylinder s movement The electrical diagram and the hydraulic circuit of the briquette machine are show inAppendix A and B respectively 14 2 2 1 1 Input External Wiring The wiring for the inputs of the PLC is based on the manual The two types of DC inputs namely sink and source differ on how the S S is connected The type is determined by the field device or the sensor used If the field device is a sourcing output PNP the PLC input will be a source type and if the field device 1s a sinking output NPN the PLC input will be a sinking type However if the type of field device does not match with the PLC input type the PLC wi
99. sure Gage S ANDIAK ML a n E amp Pressure Relief Valve Hydraulic Oil Reservoir 5 HP Electric Motor r Filter APPENDIX H 143 2006 10 24 5011650900 H2E0 A DELTA http www delta com tw industrialautomation LM Instruction Sheet A Warning This instruction sheet only provides introductory information on electrical specification functions wiring trouble shooting and peripherals For detailed information on programming and instructions please refer to DVP PLC Application Manual Programming For how to purchase its peripheral devices please refers to the manual enclosed with the product High Speed Multi Functional Programmable Logic Controller Yv DVP EH 2 is an OPEN TYPE device and therefore should be installed in an enclosure free of airborne dust humidity electric shock and vibration The enclosure should prevent non maintenance staff from operating the device e g key or specific tools are required for opening the enclosure in case danger and damage on the device may occur Yv DO NOT connect input AC power supply to any of the I O terminals otherwise serious damage may occur Check all the wiring again before switching on the power and Do NOT tough any terminal when the power is switched on Make sure the groud terminal is correctly grounded in order to prevent electromagnetic interference Introduction 1 1 Model Explanation amp Peripherals
100. than mechanical power because of the friction losses occurring inside the cylinder Equation 2 5 was used to determine the power that the hydraulic fluid could produce Industrial Hydraulic Services Inc 2007 HP Eqn 2 5 1714 where HP Power horsepower hp P Pressure pounds per square inch psi Q Volumetric flow rate gallons per minute gpm 2 1 2 Hydraulic Pump Inchoosing the appropriate kind of pump to be used in a certain hydraulic system the following characteristics should be determined pump outlet flow pump input power and pump overall efficiency 2 1 2 1 Pump Outlet Flow Equation 2 6 was used to determine the volumetric flow rate that a pump could deliver Industrial Hydraulic Services Inc 2007 n d Q Eqn 2 6 where Q Volumetric flow rate gallons per minute gpm n rotative speed revolutions per minute rpm 10 d Pump Displacement cubic inch per revolution in rev 2 1 2 2 Pump Input Power Equation 2 7 was used to determine the input power needed by the pump for it to operate Industrial Hydraulic Services Inc 2007 Q P HPiy C ATA SE Eqn 2 7 where HP y Pump input power horsepower hp Q Volumetric flow rate gallons per minute gpm P Pressure pounds per square inch psi Effoy Pump overall efficiency unitless 2 1 2 3 Pump Overall Efficiency Equation 2 8 was used to calculate the overall efficiency o
101. tion A Gatmaitan T Guanlao R Guting C Janairo Mass 1 25173 kg Volume 0 000158447 m 3 Density 7900 kg m 3 Weight 12 267 N Mass 1 25173 kg Volume 0 000158447 m 3 Density 7900 kg m 3 Weight 12 267 N Mass 1 25173 kg Volume 0 000158447 m 3 Density 7900 kg m 3 Weight 12 267 N Mass 1 25173 kg Volume 0 000158447 m 3 Density 7900 kg m 3 Weight 12 267 N Mass 4 15355 kg Volume 0 000525766 m 3 Density 7900 kg m 3 Weight 40 7048 N 7 10 2012 Volumetric Properties Document Path Date Modified F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SLDPRT Jul 09 21 57 02 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SLDPRT Jul 09 21 57 02 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SLDPRT Jul 09 21 57 02 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SLDPRT Jul 09 21 57 02 2012 F School Files THESIS Machine Essentials Briquette Machine Design v1 4 Final Briquette Machine v1 4 Vertical Cylinder Mounting Assembly SLDPRT Jul 09 21 57 02 2012 Simulation of Briquette Machine v1 4 Vertical
102. ure Switch Position W2 80 Pressures PS Pressure PG1 s 60 a 63 Se a 15 e e 67 448 70 14 n 2 9 s 46 94 94 5 Trial 3 Pressures Pressure Switch Pressure wee s x Lom f s asje e EE L 9 s Je le 5 06 w o lo le 65 370 M 35 o B 3 mils s s 79 Low wo s m wm 9 s On the three trials the pressure setting on the pressure switch was increased by 5 kg cm The tests done were based on the convention set by the group as explained on the Methodology part of this study After setting the pressure on the switch the two pressure gauges were observed while the machine was operating The readings from the two pressure gauges 65 were also recorded together with their computed average Afterwards the percentage difference between the set pressure and the actual pressure was calculated For the first trial most of the readings are within the tolerance limit of 10 except that on S3 The same observations can be done on both Trials 2 and 3 The analysis of this data can be seen on the Analysis part of this Chapter e PS Pressure Trial 1 Trial 3 Trial 2 Pressure in kg cm Figure 4 5 Graph of the Pressures at Different Trials On the graph the set pressure on the pressure switch is represented by the linear blue line while the three other lines represent the three trials It can be seen that the green red
103. ver at W4 the pressure abruptly increases to approximately 85 kg cm which is within the tolerance range 79 set by the group but breaking the 5 kg cm increment convention This can be attributed to a malfunctioning dial or to a not well distributed pressure increment of the pressure switch since at N4 the pressure on the pressure switch corresponds again to those on the pressure gauges 4 2 2 3 Briquette Formation On Table 4 6 the minimum and maximum pressure and temperature needed to form briquettes are identified It shows that at least 200 C and 80 kg cm is needed to form briquettes that will not crumble upon removal from the mold From the experimentations of the group it was found out that if the temperature or the pressure is less than 200 C or 80 kg cm the briquette cannot withstand the force applied to remove it from the mold it instantly crushes upon removal On the other hand if the temperature and the pressure are increased above the minimum less air sun drying needed it do not make the briquette stick to the mold or more difficult to remove 4 2 3 Economic Evaluation Taking into account the machine expenses and the machine daily operation expenses such as rice hull and binder prices and electrical consumption it was computed that the return of investment ROJ will be achieved after approximately 2 years more than a year shorter than that of the manual machine Bawagan n d with the sa
104. very much different from that of the design process of its mechanical framework At one point the design of the hydraulic system no longer underwent any computer aided designing and simulation Basically the design processinvolvedtwo main considerations 1 theselection of appropriate hydraulics equipment for the system such as the pump solenoid valve piston cylinder hoses etc based on the a calculations made b design of pre existingmanually operated briquette machines and c availability of supplies and 2 the mounting and connection of these equipment in accordance with the machine s overall operation Furthermore the design of the briquette press hydraulic systemwas based on the two primary sources which are published reference materials 1 e journals books manufacturer s catalogues and user s manuals and consultations from experts in hydraulics i e thesis adviser professors and manufacturers Nonetheless the approved hydraulic system circuitry of the machine is depicted in Appendix G 3 2 1 3 Heating System Another component of the briquette machine which is under the mechanical system bracket 1s the heating system As the temperature aspect of briquetting 1s an indispensable factor it is of great importance to choose the right device to attain the desired temperature for the machine s operations With that 1n mind potential manufacturers were looked into the internet directories and catalogues taking into considerati
105. x Register 18 Explanation Normally open contact Normally closed contact Normally open in serie connection Normally closed in series connection Normally open in parallel connection Normally closed in parallel connection Rising edge trigger switch Falling edge trigger switch Rising edge trigger in series connection Falling edge trigger in series connection Rising edge trigger in parallel connection Falling edge trigger in parallel connection Block in series connection Block in parallel connection Multiple output Coil driven output instruction step ladder Basic instruction Application instruction Inverse logic Figure 2 4 Ladder programming structure Source DVP PLC Application Manual 19 2 3 Sample Computations 2 3 1 Force IRE P 1000 psi 19 6851 Ne 304 342 in F 1000 304 342 304242 397 lbs 2 3 2 Volumetric Flow Rate P 36 77 py eee n Where Q Volumetric flow rate gallons per minute gpm Ton 108 664 1740 P 3677 1000 36 77 Q 5 14 gpm Q 2 3 3 Power rU HP a P 1000 psi Q 5 14 gpm 1000 x 5 14 i 1714 2 3 4 Fluid Motor Torque HP motor 63 025 n T HPmotor 3 n 1740 20 _ 3 63 025 1740 T 108 664 Ib in 2 3 5 Fluid Motor Displacement ON sae 2n P 1000 psi 2nT 2n 108 664 oO P 1000 in d 0 6828 rev 2 3 6 Number of windings in the motor poles

development of an automated briquetting machine

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