Automatic Garbage Sorting Machine Design (Small-scale model)
SINCE WE WILL USE FULL SCALE MEASUREMENTS FOR CAD WE CAN MULTIPLY THE
SMALL SCALE BY A FACTOR TO MAKE IT FULL SCALE.
PS:
THE MEASUREMENTS ARE JUST SUGGESTIONS TO PAINT A PICTURE OF THE
ACTUAL MACHINE.
1. Overview
This document details the design specifications, measurements, and component selection for a
small-scale automatic garbage sorting machine prototype. The design includes a conveyor belt
system, sensors, sorting mechanism, and collection bins, with mechanical and electronic
components integrated into a compact frame.
2. Frame & Structure
● Material: Aluminum (lightweight, rust-resistant)
● Dimensions:
○ Length: 800 mm
(Reason: Provides enough space for a short conveyor belt, sensor placement, and a
basic sorting mechanism without being too large for a desktop or small lab setup.)
○ Width: 400 mm
(Reason: Offers sufficient width for the conveyor belt and side-mounted components
like motors and potentially small control boxes.)
○ Height: 500 mm
(Reason: Allows vertical space for the conveyor belt incline (if any), sorting mechanisms
positioned above the belt, and collection bins underneath.)
● Purpose: Houses all components including conveyor belt, sensors, actuators, and bins.
3. Conveyor Belt System
● Belt Material: PVC (easy to clean, cost-effective)
● Belt Dimensions:
○ Width: 300 mm (Reason: Wide enough to carry small pieces of waste
individually and allow for sensor scanning and sorting, but not so wide as
to make the overall machine bulky.)
○ Length: 700 mm (Reason: Needs to be longer than the frame to wrap
around the rollers and provide a working section within the frame.)
○ Thickness: 3 mm
● Roller Diameter: 40 mm (Reason: Small enough to maintain a compact design but
large enough to provide good belt traction and prevent excessive bending of the
belt.)
● Motor: 12V DC motor with speed controller
○ Speed: ~0.1 m/s
○ RPM: 60-100
Mounting dimensions will depend on the specific motor chosen, but plan for a mounting
plate of around 50 mm x 50 mm. (Reason: Provides controlled movement of the belt.
Geared motors offer higher torque at lower speeds, suitable for moving waste.)
● Motor Shaft Diameter: Specify based on the motor chosen (e.g., 6 mm or 8 mm)
for coupling with the roller.
● Speed Controller: Compact electronic speed controller compatible with the
chosen DC motor. Plan for a small enclosure (e.g., 50 mm x 40 mm x 25 mm) for
mounting. (Reason: Allows for adjusting the belt speed for optimal sorting.)
● Belt Tensioning Mechanism: Simple sliding mounts for one of the rollers with
adjustment screws (e.g., M4 or M5 screws with a travel of about 20 mm).
(Reason: Necessary to keep the belt taut and prevent slipping.)
● Function: Moves waste items along the belt for scanning and sorting
4. Sorting Mechanism
● Type: Pneumatic flippers or servo-controlled arms
● Actuator Details:
○ Stroke Length: 100 mm
○ Force: ~10N
○ Quantity: 2-3 units
Choose One or Design for Modularity):
● Pneumatic Pushers (Example):
● Cylinder Bore Diameter: 10-16 mm (Reason: Small cylinders are sufficient
for pushing small pieces of waste.)
● Cylinder Stroke Length: 20-50 mm (Reason: Enough travel to push waste
off the conveyor belt into the collection bins.)
● Mounting Bracket: Small L-shaped brackets (e.g., 30 mm x 30 mm x 2 mm thick)
with holes matching the cylinder mounting points.
● Pneumatic Tubing: 4 mm or 6 mm outer diameter.
● Solenoid Valves: Compact 3/2 or 5/2 way solenoid valves with appropriate port
sizes for the tubing. Plan for a small mounting plate (e.g., 40 mm x 30 mm) for
the valves.
● Air Compressor (External to the model): Specify a small, low-pressure
compressor suitable for the pneumatic cylinders.
● Robotic Arms (Conceptual for a small model):
● Reach: Approximately 50-100 mm (from the base to the end effector).
● Actuators: Small servo motors (e.g., micro servos with a torque of 1-3 kg-
cm). Mounting dimensions will vary based on the servo.
● End Effector: A simple gripper or suction cup designed for small waste
items.
● Base: A small mounting plate (e.g., 40 mm x 40 mm) for securing the arm
to the frame.
● Flippers (Example):
● Flipper Length: 50-80 mm.
● Pivot Point Diameter: 5-8 mm.
● Actuation: Small servo motors or miniature linear actuators with a stroke of
around 10-20 mm. Mounting dimensions will depend on the actuator.
5. Sensor Placement
● Sensor Types:
● IR Sensor: Object detection
● Color Sensor (TCS34725): Material identification
● Inductive Proximity Sensor
Metal detectionSensor Type: Consider proximity sensors (inductive, capacitive, or
photoelectric) or a small camera system (if more complex sorting based on material or
color is desired).
Number of Sensors: At least one sensor positioned above or beside the conveyor belt
before the sorting mechanism. Multiple sensors can be used for more sophisticated
identification.
Sensor Dimensions: Compact sensor housings (e.g., cylindrical with a diameter of 10-
18 mm or rectangular with dimensions around 20 mm x 10 mm x 5 mm).
Mounting Brackets: Small L-shaped or custom-designed brackets to position the
sensors at the optimal distance and angle from the conveyor belt. Allow for adjustability
in the mounting.
Distance from Belt: Approximately 10-30 mm (depending on the sensor type and
sensing range).
● Mounting Details:
● Height: 100 mm above the belt
● Spacing: Every 200 mm along the belt
● Function: Detects and identifies waste type before sorting
6. Collection Bins
● Number of Bins: 3 (plastic, metal, organic)
● Bin Dimensions:
○ Length: 250 mm
○ Width: 300 mm
○ Height: 300 mm-(Reason: Sufficient volume for a small-scale
demonstration.)
● Material: Thin plastic sheet (e.g., 2-3 mm thickness) or fabricated from the same
material as the frame.
● Arrangement: Positioned underneath the sorting mechanism to catch the directed
waste. Consider a sloped design to guide waste into the bins.
● Function: Stores sorted waste materials
7. Control Box & Wiring
● Controller: Arduino Uno or Raspberry Pi
● Box Size: 150 mm x 100 mm x 70 mm
● Power Supply: 12V adapter
● Purpose: Controls sensors, motors, and actuators
8. Simulation Software & Analysis
● CAD Tools: SolidWorks, Fusion 360, AutoCAD,Inventor
● Simulations:Using the suggested measurements, you can:
● Create a detailed 3D model of all components.
● Assemble the components virtually to check for fit and interference.
● Simulate the movement of the conveyor belt and the sorting mechanism.
●
○ Motion analysis (belt and actuators)
○ Stress test on frame (material strength)
○ Sensor placement and detection validation
○ Perform basic material strength and stress analysis on the frame and
critical components (e.g., motor mounts, sorting mechanism arms) to
ensure they can withstand the expected loads. You'll need to assign
material properties (steel, aluminum, rubber, PVC) in your CAD software
for this.
9. Diagrams
The sizes are subject to change
The key is to maintain a logical scale and consider the functional requirements of each
part within the overall system.
Other Necessary Components:
● Power Supply: A suitable DC power supply to power the motors, sensors, and
control electronics. Size will depend on the power requirements of the chosen
components.
● Microcontroller/Control Board: Arduino, Raspberry Pi Pico, or a similar
microcontroller to process sensor data and control the sorting mechanism and
motor speed. Plan for a small enclosure (e.g., 60 mm x 40 mm x 20 mm) for
mounting.
● Wiring and Connectors: Plan for appropriate wiring (gauge and type) to connect
all the electrical components. Use suitable connectors for easy assembly and
disassembly.
● Fasteners: Screws, nuts, bolts, and washers of appropriate sizes (e.g., M3, M4,
M5) for assembling the frame and mounting components.
Why These Measurements?
● Small Scale: The dimensions are chosen to create a model that can be easily
handled, fits on a workbench, and uses smaller, more readily available
components.
● Proportionality: The relative sizes of the components (belt width vs. frame width,
roller diameter vs. belt thickness, etc.) are kept proportional to what might be
found in a larger system, allowing for a more realistic simulation of the
mechanics.
● Component Availability: The suggested sizes often correspond to commonly
available sizes for materials like steel profiles, conveyor belts, rollers, motors,
and sensors.
● Simplicity: The design aims for simplicity in construction and operation for an
initial simulation. More complex features and larger scales can be explored in
later iterations.
● Visualization in CAD: These measurements provide concrete values for creating
an accurate 3D model in software like SolidWorks, AutoCAD, or Fusion 360,
allowing for visualization, interference checking, and simulation of movement and
stress.