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RECYCLEBOT 2016 2
Abstract
Plastic has become the most common material since the beginning of the 20th century and modern life is
unthinkable without it. Unfortunately, what makes it so useful, such as its durability, light weight and low
cost, also makes it problematic when it comes to its end of life phase. It's nearly impossible for nature to
decompose.
With the emergence of 3D Printers all around the world there occurred one big problem: Waste
Plastic. Newfilaments aren'tthatcheapand every day we create newwaste plastics.That'swhy we wanted
to work on this project. We wanted to recycle waste plastic and create new filaments for 3D printers. A
brief research is conducted in the second part of the machine which consists the sub assembles as Puller
Roller, Level Wind and Spool Filament Wind Assemblies and electronic box.
With this prototype several tests were conducted. These tests proved to be very valuable in
obtaining new insight in problems that still have to be overcome. The most important problems that were
faced are getting constant diameter filament and cooling that filament. While trying to solve these
problems other point of interest came along. This research can be seen as the starting point of the
development of a better kind of Recyclebot.
RECYCLEBOT 2016 3
Table of content
Introduction 5
Project 2014 6
Components 6
Working Principle 6
Project 2016 6
Components 6
Working Principle 7
Parts 8
Extruder Assembly Parts 8
Puller Roller Assembly Parts 10
Level Wind Assembly Parts 11
Spool Filament Wind Assembly Parts 11
Electronics Case Assembly Parts 13
3D Printed Parts 14
Laser-cut Parts 16
Wiring Diagrams 18
Arduino Uno and LCD 18
Arduino and buttons 19
Arduino sabretooth 20
Sabertooth and motors 21
Arduino Code 23
Schedule 28
Bill of Materials 29
Conclusions and Discussion 30
Recommendations for Further Development 31
References 32
RECYCLEBOT 2016 4
RECYCLEBOT 2016 5
Introduction
3D Printers nowadays became so popular that almost everywhere we can find one of them, in our
offices, schools, even in our homes. We became the manufacturers of ourselves. But this easy access to
these printers created one problem. With every attempt to print an object we create waste material. Even
though 3D printing is by the media generally presented as a process where no waste is produced, with a
simple demonstration we can see that it’s not the case. And we thought it would be very interesting to use
these waste and create new products.
Therefore,in 2014 a group of community members started designing a machine that can recycle
waste plastic and create new usable filament. The process shortly was they shred the waste plastic then
melt it and then adjusting the diameter by pulling it. The machine they built worked but not perfectly
that’s why we got the task to make it better and more efficient. Our task involves two steps. The first step
is being able to extrude plastic and the second step is to gather enough amount of filaments on the spool
with the right dimension. The machine has to be low budget and easy to use. Also all pieces must be
reproducible in a lab or in a simple way.
This project is carried out for Timelab. In 10 weeks, the project was executed by a team of 2
students working on it.
If you go through this document and if you have a little knowledge of 3D printers and laser cut
machines you can built this Recyclebot by yourself. Also you may need to know the basics of Arduino
and electronics so you can follow the schematics of the project.
Our special thanks go out to Koen Verstringe for his advices for our problems, Jeffrey Thielens
for helping us with the pipe and nozzle, Filip D’hoore and Michel D’hoore for their advices and help,
Pieter Dauwe and Timelab crew for their supervision and support.
RECYCLEBOT 2016 6
Project 2014
Components
Power supply 240 S 24
Sabertooth
2 potentiometers
2 DC motors 24/12V
Temperature controller (REX-C100)
Solid State Relay
You can find detailed information about the mechanical parts in the previous report.
Working Principle
The power supply is to change the 240voltage from the socket to a 24/12V DC.
The two potentiometers are controlling the 2 DC motors with Sabertooh.
Temperature controller(REX-C100) has its own LCD screen where you can set the temperature.
It controls the heat with the Solid State Relay.
The working principle is simple. The drill pushes PLA pellets to heated pipe (180 Celsius
degrees),plastic melts and comes out of the nozzle as a filament.
The technic of using the potentiometers is not so reliable, if someone changes the
potentiometers then it’s difficult to change them back. So this was not user friendly, therefore we
wanted to do something which we can control the speed of the motors. Also there was a problem of not
obtaining a constant thickness diameter filament.
Here you can see two photos of the previous design.
Project 2016
Components
RECYCLEBOT 2016 7
2 Sabertooths
1 Arduino Uno
1 DC motor 24/12V
2 DC motors 12V
4 rotary fan DC motors 12V
1 LCD display 20x4
4 Buttons
5 Resistors 220Ω
1 Resistor 1KΩ
1 Temperature controller (REX-C100)
1 Solid State Relay
1 Power supply 240 S 24
Working Principle
The power supply is to change the 240voltage from the socket to a 24/12V DC (same as project 2014).
We used an Arduino and LCD display to control the DC motors, with Sabertooths, because it’s
easier when we don’t have to work with PWM signal. The Arduino is connected to the LCD screen,4
buttons and Sabertooths. Through the buttons you go to the menu on the LCD and set the motors’ speed.
Temperature controller(REX-C100) has its own LCD screen where you can set the temperature. It
controls the heat with the Solid State Relay.
The working principle is again simple but a bit more advanced. The extruder melts the plastic,
extrudes it then the pulling motor pulls it to a correct diameter and then the spool motor gathers the
filament in a uniform way on the spool.
RECYCLEBOT 2016 8
Parts
Extruder Assembly Parts
All the needed dimensions for the parts are given in a
separate section below.
Nozzle:
This is a custom brass nozzle but you can also use
parts like in the second photo as a nozzle.
Pipe:
This is a custom part made out of aluminum block. You can use instead of
this a weldless 18 mm inner diameter aluminum pipe. The dimensions of
the pipe is, length is 25cm, outer diameter is 28 mm, inner diameter is
18 mm.
3D printed thrust bearing house and the bearing.
Coupling:
Metal coupling, you can use a typical coupling.
Laser cut 12mm multiplex to assemble the motor
RECYCLEBOT 2016 9
Funnel:
Due to heating problems we decided to make the funnel out of mdf not PLA.
It’s 6 mm multiplex. It also has 2 bottom parts to connect it to the pipe.
Supports:
12 mm multiplex to carry the extruder assembly. Also there is a 20 mm
multiplex under the machine to fix it. With small 3D printed parts, we
connected these supports to the 20 mm multiplex.
Fans:
12V fans for cooling the extruded filament. The small 2 fans are connected
to Sabertooth and the others are connected directly to 12V.
Motor:
We used 24V DC motor to rotate the drill. And we used a thin aluminum
plate to connect motor to 12mm multiplex.
Metal Cage:
To cover the heated blocks and insulation material. And there is little metal
part to connect the fans to the cage.
RECYCLEBOT 2016 10
Aluminum Blocks:
2 aluminum blocks drilled in right dimensions. Dimensions are posted below.
Threaded Rod:
4 M6 threaded rods, length is 35cm. This rods go into the 2 aluminum blocks
and all the multiplexes are connected to those rods.
Drill:
We tried to use a common drill, it’s an 18 mm wood drill we used.
Heating Element:
We used 6x50mm 220V 250W cartridge heaters.One is in the nozzle,
the others are in the aluminum blocks.
Puller Roller Assembly Parts
There are one 12V DC motor, two rubber wheels, one is
at top, one is at the bottom and the 3D printed parts.
This assembly pulls the extruded filament and adjusts the
diameter of the thickness of the filament. You can design
your own puller roller. While designing you should
consider one thing and it is that the rubber wheel at the
top should be heavy to have a grip but not to heavy not
to squeeze the extruded filament.
RECYCLEBOT 2016 11
Level Wind Assembly Parts
We got the design idea from Lyman Extruder Machine. All the parts
except the metal shaft are 3D printed parts designed by us. When the
pulley starts to rotate the pawl starts to go back and forth thus we get
even distribution on the spool. As you see there are mounting
brackets, red one is designed differently to hold the metal shaft inside.
The filament guide holds the pawl inside and there is a gap at the bottom
where you place the filament. Worm gear is designed as two parts,
because when we tried to print it as one part it was not smooth enough.
So we printed separately then glued them around the metal shaft, it should
hold the bar. When the metal shaft rotates the worm gear is also rotates.
The pulley here is larger than the spoolpulley, wherein the rpm’s are
correct to turn the worm gear proper level winding on the spool. The shaft
is 8mm in diameter and the length is 15cm. There are two bearings to hold
the shaft and the pipe, they are 3d printed as well. Pawl is fixed with a
small rubber band to the filament guide. PVC pipe shroud is a common
pipe which you can find almost everywhere, the slot was cutout with a
small hand saw, its length is 11cm. The STL files of the parts are given in a
separate file.
SpoolFilament Wind Assembly Parts
This assembly consists both wood, 3D printed and metal parts.
The spool is a common filament spool where you can find
anywhere. The motor rotates the threaded shaft and the spool
rotates also the pulley at the end. You can also design this on
your own. The STL files are given in a separate file.
RECYCLEBOT 2016 12
We used a 12V DC motor to rotate the spool. As you
see, first we connected the motor to 4 mm multiplex then
connected it to the 3d printed mounting bracket and this
sub assembly is connected to the wooden part with screws.
There is a coupling between motor and the M10 nut.We
tightened 3 M10 nuts and connected the coupling to the last
nut.
Inside of the spoolthere are 2 laser cut circle parts to hold the spool and they
are fixed with M10 nuts to the threaded shaft. On the other side of the shaft there is
a pulley which is also fixed with M10 nuts and this pulley is connected to the level
wind assembly pulley with a timing belt. We cut the belt then connected it with a
plastic lock.
There are both assemblies connected. The distance between
assemblies is arbitrary, you can decide it and adjust the belt
according to the distance.
RECYCLEBOT 2016 13
Electronics CaseAssemblyParts
Case is laser cut 3mm multiplex, you can find a website
to create the dxf files for the laser cut machine (you can
search for “laser cut box”). The dimensions are arbitrary
you can decide according to the components that you use.
Ours was 220x160x90 mm. The components are listed as;
- 2 Switches
- 4 buttons for the LCD
- Power Receptacle
- Power Cord
- Power Supply 240 S 24
- Temperature Controller (REX-C100)
- LCD connect to Arduino
- Arduino Uno
- 2 Sabertooth 2x12 Dual Motor Driver
- 5 Resistors 220Ω
- 1 Resistor 1KΩ
- Solid State Relay
Wiring is posted below. You can find all the
wirings between all the components under the
section of “Wiring Diagrams”.
RECYCLEBOT 2016 14
3D Printed Parts
BEARING HOUSE
PART TO FIX THE MACHINE
LEVEL WIND BRACKET #1 LEVEL WIND BRACKET #2
PAWL
FILAMENT GUIDE
RECYCLEBOT 2016 15
LEVEL WIND PIPE AND SHAFT
BEARING
HALF WORM GEAR
PULLER MOTOR COUPLING
LEVEL WIND ASSEMBLY PULLEY
SPOOL MOTOR MOUNTING BRACKET
SPOOL MOTOR COUPLING
SPOOL FILAMENT ASSEMBLY PULLEY
RECYCLEBOT 2016 16
Laser-cut Parts
SPOOL MOTOR CONNECTOR
4MM MULTIPLEX
EXTRUDER MOTOR CONNECTER
12MM MULTIPLEX
EXTRUDER SUPPORTING LEG 12MM MULTIPLEX
RECYCLEBOT 2016 17
HOOPER BOTTOM
HOOPER #1
SPOOL STABILIZER
HOOPER #2
RECYCLEBOT 2016 18
Wiring Diagrams
Arduino Uno and LCD
LCD DISPLAY ARDUINO
GND(1), CONTR(3), R/W(5) and NC(15) GND
VCC(2) and NC(16) 5V
RS(4) Pin 12
E(6) Pin 11
D4(11) Pin 5
D5(12) Pin 4
D6(13) Pin 3
D7(14) Pin 2
RECYCLEBOT 2016 19
Arduino and Buttons
BUTTONS ARDUINO
Resistor GND
Pin under resistor 5V
Pin across the resistor From pin 7 to 10
RECYCLEBOT 2016 20
Arduino and Sabertooth
SABERTOOTH ARDUINO
0V GND
5V 5V
S1 first Sabertooth A5
S1 second Sabertooth A4
RECYCLEBOT 2016 21
Sabertoothand Motors
SABERTOOTH MOTOR/POWER SUPPLY
B- VSS power supply
B+ VCC power supply
M2A/B first Sabertooth Extruder motor
M1A/B first Sabertooth Diameter motor
M2A/B second Sabertooth Spool motor
M1A/B second Sabertooth Ventilation
RECYCLEBOT 2016 22
RECYCLEBOT 2016 23
Arduino Code
// include the library code:
#include <LiquidCrystal.h>
#include <SabertoothSimplified.h>
#include <SoftwareSerial.h>
// initialize the library with the numbers of the interface pins
LiquidCrystal lcd(12, 11, 5, 4, 3, 2);
byte arrow[8] = {//arrow lcd set bloks
B00000,//line 1
B00100,//2
B00010,//3
B11111,//4
B00010,//5
B00100,//6
B00000,//7
};
const int button = 7;//set button to pin 13
const int button2 = 8;//set button to pin 10
const int button3 = 9;//set button to pin 9
const int button4 = 10;//set button to pin 8
int state = 0;//variable
int statesetting = 0;//variable
int big = 0;//variable
int dia = 0;//variable
int spool = 0;//variable
SoftwareSerial SWSerial(NOT_A_PIN, A5); // RX on no pin (unused), TX on pin A5
SabertoothSimplified ST(SWSerial); // Use SWSerial as the serial port.
SoftwareSerial SW1Serial(NOT_A_PIN, A4); // RX on no pin (unused), TX on pin A4
SabertoothSimplified ST1(SW1Serial); // Use SW1Serial as the serial port.
void setup()
{
SWSerial.begin(9600);// This is the baud rate you chose with the DIP switches.
SW1Serial.begin(9600);// This is the baud rate you chose with the DIP switches.
lcd.createChar(0, arrow);//create a character
lcd.begin(20, 4);//lcd screen is 20x4
lcd.setCursor(0,1);//set cursor to line 2
lcd.print("TIMELAB RECYCLEBOT");//print on lcd
delay(3000);//delay of 5s
}
void loop()
{
RECYCLEBOT 2016 24
int buttonstate = digitalRead(button);//variable
int buttonstate2 = digitalRead(button2);//variable
int buttonstate3 = digitalRead(button3);//variable
lcd.clear();//lcd clear
lcd.setCursor(0,0);//set cursor to first line
lcd.print("MENU");//print on lcd
if(buttonstate2 == 1){//if button is pressed then
state++;//variable +1
if(state>3)state = 0;//if variable is bigger then 3 then it becomes 0
}
if(buttonstate == 1){//if button2 is pressed then
state--;//variable -1
if(state<0)state = 3;//if variable is lower then 0 it becomes 3
}
if(state == 0){//if variable is 0
lcd.setCursor(0,1);//set cursor to line2
lcd.write(byte (8));//print arrow on line 2
lcd.print(" 1) PLA 2.85mm");//print on lcd
lcd.setCursor(0,2);//set cursor to line 3
lcd.print(" 2) PLA 1.75mm");//print on lcd
lcd.setCursor(0,3);//set cursor to line 4
lcd.print(" 3) MANUAL");//print on lcd
state = 0;//set state to 0
delay (200);
if(buttonstate3==HIGH){//if button3 is pressed then
while(digitalRead(button4)==LOW){//if button4 is LOW
ST.motor(1,50);//big motor speed 50
ST.motor(2,10);//diameter motor speed 10
ST1.motor(1,10);//spool motor speed 10
ST1.motor(2,127);//ventilation speed 127
lcd.clear();
lcd.setCursor(0,2);//set cursor to line 3
lcd.print("extrude");//print on lcd
lcd.setCursor(0,3);//set cursor to line 4
lcd.print("PLA 2.85mm");//print on lcd
big = 0;//big motor speed 0
dia = 0;//diameter motor speed 0
spool = 0;//spool motor speed 0
delay(50);
}
}
}
else if(state == 1){// if state is 1
lcd.setCursor(0,1);//set cursor to line 2
lcd.print(" 1) PLA 2.85mm");//print lcd
lcd.setCursor(0,2);//set cursor to line 3
lcd.write(byte (8));//arrow on line 3
lcd.print(" 2) PLA 1.75mm");//print on lcd
lcd.setCursor(0,3);//ser cursor to line 4
lcd.print(" 3) MANUAL");//print on lcd
state = 1;//set state to 1
delay(200);
RECYCLEBOT 2016 25
if(buttonstate3 == HIGH){//if button3 is pressed
while(digitalRead(button4)==LOW){//if button4 is LOW
ST.motor(1,50);//big motor speed 50
ST.motor(2,10);//diameter motor speed 10
ST1.motor(1,10);//spool motor speed 10
ST1.motor(2,127);//ventilation speed 127
lcd.clear();
lcd.setCursor(0,2);//set cursor to line 3
lcd.print("extrude");//print on lcd
lcd.setCursor(0,3);//set cursor to line 4
lcd.print("PLA 1.75mm");//print on lcd
big = 0;//big motor speed 0
dia = 0;//diameter speed 0
spool = 0;//spool speed 0
delay(50);
}
}
}
else if(state == 2){//if state is 2
lcd.setCursor(0,1);//set cursor to line 2
lcd.print(" 1) PLA 2.85mm");//print lcd
lcd.setCursor(0,2);//set cursor to line 3
lcd.print(" 2) PLA 1.75mm");//print lcd
lcd.setCursor(0,3);//set cursor to line 4
lcd.write(byte (8));//arrow line 4
lcd.print(" 3) MANUAL");//print lcd
state = 2;//set state to 2
delay(200);
if(buttonstate3==HIGH){//if button3 is pressed
while(digitalRead(button4)==LOW){//if button4 is LOW
lcd.clear();
lcd.setCursor(0,0);//set cursor to line 1
lcd.print("SETTING MOTOR");//print lcd
if (digitalRead(button)==HIGH){//if button is pressed
statesetting++;//statesetting variable +1
if(statesetting>2)statesetting=0;//if variable is above 2 set to 0
}
if(digitalRead(button2)==HIGH){//if button2 is pressed
statesetting--;//statesetting variable -1
if(statesetting<0)statesetting=2;//if variable is lower than 0 set to 2
}
if(statesetting == 0){//if statesetting is 0
ST.motor(1, big);//big motor speed
ST.motor(2, dia);//diameter motor speed
ST1.motor(1, spool);//spool motor speed
ST1.motor(2 ,127);//ventilation speed 127
lcd.setCursor(0,1);//set cursor to line 2
lcd.write(byte (8));//arrow line 2
lcd.print(" big motor");//print lcd
lcd.setCursor(0,2);//set cursor to line 3
lcd.print(" diameter motor");//print lcd
lcd.setCursor(0,3);//set cursor to line 4
RECYCLEBOT 2016 26
lcd.print(" spool motor");//print lcd
delay(50);
if(digitalRead(button3)==HIGH){//if button3 is pressed
while(digitalRead(button4)==LOW){//is button4 is LOW
lcd.clear();
if(digitalRead(button)==HIGH){//if button is pressed
big++;//big motor +1
if(big>127)big=127;//if big motor speed above 127 set to 127
}
if(digitalRead(button2)==HIGH){//if button2 is pressed
big--;//big motor -1
if(big<-127)big=-127;//if big motor speed lower than -127 set to -
127
}
lcd.setCursor(0,0);//set cursor to line 1
lcd.print("BIG MOTOR");//print lcd
lcd.setCursor(0,1);//set cursor to line 2
lcd.print(big);//print value lcd
ST.motor(1, big); //big motor speed
delay(50);
}
delay(500);
}
}
else if(statesetting == 1){//if statesetting is 1
lcd.setCursor(0,1);//set cursor to line 2
lcd.print(" big motor");//print lcd
lcd.setCursor(0,2);//set cursor to line 3
lcd.write(byte (8));//arrow on line 3
lcd.print(" diameter motor");//print lcd
lcd.setCursor(0,3);//set cursor to line 4
lcd.print(" spool motor");//print lcd
delay(50);
if(digitalRead(button3)==HIGH){//if button3 is pressed
while(digitalRead(button4)==LOW){//if button4 is LOW
lcd.clear();
if(digitalRead(button)==HIGH){//if button is pressed
dia++;//diameter motor +1
if(dia>127)dia=127;//if diameter motor is above 127 set to 127
}
if(digitalRead(button2)==HIGH){//if button2 is pressed
dia--;//diameter motor -1
if(dia<-127)dia=-127;//if diameter motor is lower than -127 set to
-127
}
lcd.setCursor(0,0);//set cursor to line 1
lcd.print("DIAMETER MOTOR");//print lcd
lcd.setCursor(0,1);//set cursor ro line 2
lcd.print(dia);//print value lcd
ST.motor(2, dia);//diameter motor speed
delay(50);
}
RECYCLEBOT 2016 27
delay(500);
}
}
else if(statesetting == 2){//if statesetting is 2
lcd.setCursor(0,1);//set cursor to line 2
lcd.print(" big motor");//print lcd
lcd.setCursor(0,2);//set cursor to line 3
lcd.print(" diameter motor");//print lcd
lcd.setCursor(0,3);//set cursor to line 4
lcd.write(byte (8));//arrow to line 4
lcd.print(" spool motor");//print lcd
delay(50);
if(digitalRead(button3)==HIGH){//if button3 is pressed
while(digitalRead(button4)==LOW){//if button4 is LOW
lcd.clear();
if(digitalRead(button)==HIGH){//if button is pressed
spool++;//spool motor +1
if(spool>127)spool=127;//if spool motor is above 127 set to 127
}
if(digitalRead(button2)==HIGH){//if button2 is pressed
spool--;//spool motor -1
if(spool<-127)spool=-127;//if spool motor is lower then -127 set to
-127
}
lcd.setCursor(0,0);//set cursor to line 1
lcd.print("SPOOL MOTOR");//print lcd
lcd.setCursor(0,1);//set cursor to line 2
lcd.print(spool);//print value lcd
ST1.motor(1, spool);//spool motor speed
delay(50);
}
delay(500);
}
}
delay(50);
}
}
}
else if(state == 3){//if variable is 3
lcd.setCursor(0,1);//set cursor to line2
lcd.print(" 2) PLA 1.75mm");//print on lcd
lcd.setCursor(0,2);//set cursor to line 3
lcd.print(" 3) MANUAL");//print lcd
lcd.setCursor(0,3);//set cursor to line 4
lcd.write(byte (8));//arrow to line 4
lcd.print(" 4) STOP ");//print lcd
state = 3;//set state to 3
delay (200);
if(buttonstate3==HIGH){//if button3 is pressed
ST.motor(1,0);//big motor speed is 0
ST.motor(2,0);//diameter motor speed is 0
ST1.motor(1,0);//spool motor speed is 0
RECYCLEBOT 2016 28
ST1.motor(2,0);//ventilation speed is 0
lcd.clear();
lcd.print("stop all motors");//print lcd
delay(1000);
}
}
// Delay a little bit to avoid bouncing
delay(50);
}
Schedule
RECYCLEBOT 2016 29
Bill of Materials
We mostly used parts from the previous project, and we used the 3D printers and Laser-cut machines in
Timelab. For some electrical components we needed to buy, and they are listed as;
Date
18-22 July
 Documentations on the wikifab and the report of the Recyclebot were read.
 Problems/concerns from the report were obtained.
 Steps of period(internship) were determined.
 Both the old and new version of the Recyclebot were disassembled and
cleaned.
 The possible list of missing parts was made.
 Electrical parts were viewed to see if there were any missing/broken parts.
 Both motor and the heating element was working properly.
 Questions were prepared to be asked to the Recyclebot builders.
25-29 July
 Some parts for the Recyclebot were designed and printed/laser-cut.
 Some parts from the old version were taken out and put into the new version.
 Meeting was made about some necessary parts and tools.
 Motor was assembled and the machine was started. It worked!
 Some parts were given to get new parts
1-5 August
 Existing motors were tested and assembled.
 Missing/broken parts were reprinted for puller roller.
 Level Wind Filament Assembly parts were designed.
 Parts from Lyman Extruder V5 were taken and 3D printed for Level Wind
Filament Assembly.
 To make it more user friendly a led screen was considered to be added.
 New and more efficient nozzle and pipe were obtained.
 Adjustment for the pipe were made
 First test was done without the heating elements.
 First test was done with the heating elements but we found out heating
elements are not working properly.
 Spool filament wind assembly was improved.
 Spool motor supporter were designed and 3D printed.
8-13 August
 Missing/Broken parts were ordered (Temperature Controller)
 New parts for the spool and level wind assembly were designed and printed
 Spool and level wind assemblies assembled together
 More improvements were done on spool filament assembly
 Instead of adjusting motors speed manually, there was put an Arduino with LCD
screen which will automatically set motors speed according to the thickness
 Arduino with LCD screen was connected to the motors and was tested (it’s
working)
 Insulation cage is fixed and assembled
15-19 August
 New funnel was designed.
 Insulation cage was fixed, assembled and cooling fans were assembled to the
cage.
 Cables were extended.
 New box was designed to put the electronics in.
 Necessary soldering was done.
 Extruding motor, level wind assembly, spool filament wind assembly were
assembled together.
 Controlling motors with Sabertooth and Arduino was tested. 2 motors are
working but third motor is not. We are working on it.
 All options were added to Arduino to show on LCD screen.
 Electronic Schematic was done
RECYCLEBOT 2016 30
- Temperature Controller (REX-C100) 12 Euro
- 3 Cooling Fans 13 Euro
- Solid State Relay 19 Euro
Conclusions and Discussion
RECYCLEBOT 2016 31
The main question during this project was if the waste plastic from 3D printers could be used as input
for the Recyclebot and if we could extrude usable filament for 3D printers. In short: yes, it’s possible.
Although there were a lot of problems we could extrude usable filament and print with it.
At this moment the biggest problem is feeding. When it’s not even it’s not possible to get constant
diameter thickness.
There are certain cases when the feeding is not even. They are like when:
- Pipe gets too hot and when you use shredded plastic pieces they melt and get stuck in the
hopper.
- We use big pieces instead of small pellets, they cannot go into the pipe which causes air
gaps in the filament.
Sometimes due to lack of heat the extruded filaments have gaps and this leads to a non-consistency. To
overcome this, we set the temperature higher but when we do that the filament gets fluidlike which is
hard to cool down.
When the filament is too hot and when you put it on the puller roller wheels it stuck on them, but now
it’s quite okay with the existing cooling fans.
Due to friction on the spool, it’s not easy to rotate it with a slow speed. And sometimes it stops even
though it should, when this happens you can set a higher speed value or push the spool with your hand a
bit.
Also sometimes when we turn on the motor switch, one of the motors go fast suddenly or the LCD
screen doesn’t look god. When this happens you should turn it off and on again.
After shredding the waste plastic with the shredder we still don’t get small pieces which can go into the
pipe. Make sure that they are small enough and don’t get stuck in the hopper.
Overall, it can be concluded that it’s possible to recycle %100 the plastic though the machine still needs
some improvements.
Recommendations for Further Development
RECYCLEBOT 2016 32
To finalize this project, recommendations for further development in the field of a recycling the waste
plastic were thought. If someone wants to elaborate further on this subject, then these are interesting
fields to look into.
Test Other Plastic Types
We didn’t have enough time to test other plastic types but only PLA. It would be interesting and
enlightening to test other type of plastics and see which ones are recyclable.
Making Smaller Input Plastic
One problem we faced when we tried the shredded plastic is that it doesn’t go into pipe evenly. So one
concern should be to make the pieces smaller. So we are thinking that a second phase of shredding
could be useful. It can be a different machine like a blender or a new type of shredder but it’s needed to
be done.
Cooling Element
One of the biggest problem was cooling the extruded filament. When it’s too hot the puller roller wheels
squeeze the filament so it gets an oval shape. To overcome this a new system can be designed like a
water bath which was already thought but not applied. Or some other systems can be thought.
Spool Filament Wind Assembly
A better design of this assembly can be done which is detachable easily. And also due to friction and
miss alignment the spool stops rotating sometimes so a better design can be better.
Setting The Values
Since the feeding was not even we couldn’t set exact values for the speed of the motors to adjust the
thickness of the filament. After fixing the feed material this values can be set according to the thickness.
Connection of The Extruder Motor
Better connection for the extruder motor can be provided. Since it cannot be aligned perfectly it moves
which is not a problem but it would be better to make everything fixed and stable.
References
KKrr aka De Recyclebot. (2013). Retrieved September 15, 2016, from
http://www.timelab.org/project/kkrr-aka-de-recyclebot
RECYCLEBOT 2016 33
Lyman filament extruder. (2012). Retrieved September 3, 2016, from
https://en.wikipedia.org/wiki/Lyman_filament_extruder
TUdelft, G.B. (2014). Wordpresscom. Retrieved 5 September, 2016, from
https://reprapdelft.files.wordpress.com/2010/04/reprap-granule-extruder-tudelft1.pdf
RECYCLEBOT 2016 34
A. O. Dülger
N. Lisabeth
Timelab Brusselspoortstraat 97
Gent 9000 Gent
+32 9 391 96 10
www.timelab.org
Contact:
hello@timelab.org
ali@timelab.org

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RECYCLEBOT REPORT

  • 1.
  • 2. RECYCLEBOT 2016 2 Abstract Plastic has become the most common material since the beginning of the 20th century and modern life is unthinkable without it. Unfortunately, what makes it so useful, such as its durability, light weight and low cost, also makes it problematic when it comes to its end of life phase. It's nearly impossible for nature to decompose. With the emergence of 3D Printers all around the world there occurred one big problem: Waste Plastic. Newfilaments aren'tthatcheapand every day we create newwaste plastics.That'swhy we wanted to work on this project. We wanted to recycle waste plastic and create new filaments for 3D printers. A brief research is conducted in the second part of the machine which consists the sub assembles as Puller Roller, Level Wind and Spool Filament Wind Assemblies and electronic box. With this prototype several tests were conducted. These tests proved to be very valuable in obtaining new insight in problems that still have to be overcome. The most important problems that were faced are getting constant diameter filament and cooling that filament. While trying to solve these problems other point of interest came along. This research can be seen as the starting point of the development of a better kind of Recyclebot.
  • 3. RECYCLEBOT 2016 3 Table of content Introduction 5 Project 2014 6 Components 6 Working Principle 6 Project 2016 6 Components 6 Working Principle 7 Parts 8 Extruder Assembly Parts 8 Puller Roller Assembly Parts 10 Level Wind Assembly Parts 11 Spool Filament Wind Assembly Parts 11 Electronics Case Assembly Parts 13 3D Printed Parts 14 Laser-cut Parts 16 Wiring Diagrams 18 Arduino Uno and LCD 18 Arduino and buttons 19 Arduino sabretooth 20 Sabertooth and motors 21 Arduino Code 23 Schedule 28 Bill of Materials 29 Conclusions and Discussion 30 Recommendations for Further Development 31 References 32
  • 5. RECYCLEBOT 2016 5 Introduction 3D Printers nowadays became so popular that almost everywhere we can find one of them, in our offices, schools, even in our homes. We became the manufacturers of ourselves. But this easy access to these printers created one problem. With every attempt to print an object we create waste material. Even though 3D printing is by the media generally presented as a process where no waste is produced, with a simple demonstration we can see that it’s not the case. And we thought it would be very interesting to use these waste and create new products. Therefore,in 2014 a group of community members started designing a machine that can recycle waste plastic and create new usable filament. The process shortly was they shred the waste plastic then melt it and then adjusting the diameter by pulling it. The machine they built worked but not perfectly that’s why we got the task to make it better and more efficient. Our task involves two steps. The first step is being able to extrude plastic and the second step is to gather enough amount of filaments on the spool with the right dimension. The machine has to be low budget and easy to use. Also all pieces must be reproducible in a lab or in a simple way. This project is carried out for Timelab. In 10 weeks, the project was executed by a team of 2 students working on it. If you go through this document and if you have a little knowledge of 3D printers and laser cut machines you can built this Recyclebot by yourself. Also you may need to know the basics of Arduino and electronics so you can follow the schematics of the project. Our special thanks go out to Koen Verstringe for his advices for our problems, Jeffrey Thielens for helping us with the pipe and nozzle, Filip D’hoore and Michel D’hoore for their advices and help, Pieter Dauwe and Timelab crew for their supervision and support.
  • 6. RECYCLEBOT 2016 6 Project 2014 Components Power supply 240 S 24 Sabertooth 2 potentiometers 2 DC motors 24/12V Temperature controller (REX-C100) Solid State Relay You can find detailed information about the mechanical parts in the previous report. Working Principle The power supply is to change the 240voltage from the socket to a 24/12V DC. The two potentiometers are controlling the 2 DC motors with Sabertooh. Temperature controller(REX-C100) has its own LCD screen where you can set the temperature. It controls the heat with the Solid State Relay. The working principle is simple. The drill pushes PLA pellets to heated pipe (180 Celsius degrees),plastic melts and comes out of the nozzle as a filament. The technic of using the potentiometers is not so reliable, if someone changes the potentiometers then it’s difficult to change them back. So this was not user friendly, therefore we wanted to do something which we can control the speed of the motors. Also there was a problem of not obtaining a constant thickness diameter filament. Here you can see two photos of the previous design. Project 2016 Components
  • 7. RECYCLEBOT 2016 7 2 Sabertooths 1 Arduino Uno 1 DC motor 24/12V 2 DC motors 12V 4 rotary fan DC motors 12V 1 LCD display 20x4 4 Buttons 5 Resistors 220Ω 1 Resistor 1KΩ 1 Temperature controller (REX-C100) 1 Solid State Relay 1 Power supply 240 S 24 Working Principle The power supply is to change the 240voltage from the socket to a 24/12V DC (same as project 2014). We used an Arduino and LCD display to control the DC motors, with Sabertooths, because it’s easier when we don’t have to work with PWM signal. The Arduino is connected to the LCD screen,4 buttons and Sabertooths. Through the buttons you go to the menu on the LCD and set the motors’ speed. Temperature controller(REX-C100) has its own LCD screen where you can set the temperature. It controls the heat with the Solid State Relay. The working principle is again simple but a bit more advanced. The extruder melts the plastic, extrudes it then the pulling motor pulls it to a correct diameter and then the spool motor gathers the filament in a uniform way on the spool.
  • 8. RECYCLEBOT 2016 8 Parts Extruder Assembly Parts All the needed dimensions for the parts are given in a separate section below. Nozzle: This is a custom brass nozzle but you can also use parts like in the second photo as a nozzle. Pipe: This is a custom part made out of aluminum block. You can use instead of this a weldless 18 mm inner diameter aluminum pipe. The dimensions of the pipe is, length is 25cm, outer diameter is 28 mm, inner diameter is 18 mm. 3D printed thrust bearing house and the bearing. Coupling: Metal coupling, you can use a typical coupling. Laser cut 12mm multiplex to assemble the motor
  • 9. RECYCLEBOT 2016 9 Funnel: Due to heating problems we decided to make the funnel out of mdf not PLA. It’s 6 mm multiplex. It also has 2 bottom parts to connect it to the pipe. Supports: 12 mm multiplex to carry the extruder assembly. Also there is a 20 mm multiplex under the machine to fix it. With small 3D printed parts, we connected these supports to the 20 mm multiplex. Fans: 12V fans for cooling the extruded filament. The small 2 fans are connected to Sabertooth and the others are connected directly to 12V. Motor: We used 24V DC motor to rotate the drill. And we used a thin aluminum plate to connect motor to 12mm multiplex. Metal Cage: To cover the heated blocks and insulation material. And there is little metal part to connect the fans to the cage.
  • 10. RECYCLEBOT 2016 10 Aluminum Blocks: 2 aluminum blocks drilled in right dimensions. Dimensions are posted below. Threaded Rod: 4 M6 threaded rods, length is 35cm. This rods go into the 2 aluminum blocks and all the multiplexes are connected to those rods. Drill: We tried to use a common drill, it’s an 18 mm wood drill we used. Heating Element: We used 6x50mm 220V 250W cartridge heaters.One is in the nozzle, the others are in the aluminum blocks. Puller Roller Assembly Parts There are one 12V DC motor, two rubber wheels, one is at top, one is at the bottom and the 3D printed parts. This assembly pulls the extruded filament and adjusts the diameter of the thickness of the filament. You can design your own puller roller. While designing you should consider one thing and it is that the rubber wheel at the top should be heavy to have a grip but not to heavy not to squeeze the extruded filament.
  • 11. RECYCLEBOT 2016 11 Level Wind Assembly Parts We got the design idea from Lyman Extruder Machine. All the parts except the metal shaft are 3D printed parts designed by us. When the pulley starts to rotate the pawl starts to go back and forth thus we get even distribution on the spool. As you see there are mounting brackets, red one is designed differently to hold the metal shaft inside. The filament guide holds the pawl inside and there is a gap at the bottom where you place the filament. Worm gear is designed as two parts, because when we tried to print it as one part it was not smooth enough. So we printed separately then glued them around the metal shaft, it should hold the bar. When the metal shaft rotates the worm gear is also rotates. The pulley here is larger than the spoolpulley, wherein the rpm’s are correct to turn the worm gear proper level winding on the spool. The shaft is 8mm in diameter and the length is 15cm. There are two bearings to hold the shaft and the pipe, they are 3d printed as well. Pawl is fixed with a small rubber band to the filament guide. PVC pipe shroud is a common pipe which you can find almost everywhere, the slot was cutout with a small hand saw, its length is 11cm. The STL files of the parts are given in a separate file. SpoolFilament Wind Assembly Parts This assembly consists both wood, 3D printed and metal parts. The spool is a common filament spool where you can find anywhere. The motor rotates the threaded shaft and the spool rotates also the pulley at the end. You can also design this on your own. The STL files are given in a separate file.
  • 12. RECYCLEBOT 2016 12 We used a 12V DC motor to rotate the spool. As you see, first we connected the motor to 4 mm multiplex then connected it to the 3d printed mounting bracket and this sub assembly is connected to the wooden part with screws. There is a coupling between motor and the M10 nut.We tightened 3 M10 nuts and connected the coupling to the last nut. Inside of the spoolthere are 2 laser cut circle parts to hold the spool and they are fixed with M10 nuts to the threaded shaft. On the other side of the shaft there is a pulley which is also fixed with M10 nuts and this pulley is connected to the level wind assembly pulley with a timing belt. We cut the belt then connected it with a plastic lock. There are both assemblies connected. The distance between assemblies is arbitrary, you can decide it and adjust the belt according to the distance.
  • 13. RECYCLEBOT 2016 13 Electronics CaseAssemblyParts Case is laser cut 3mm multiplex, you can find a website to create the dxf files for the laser cut machine (you can search for “laser cut box”). The dimensions are arbitrary you can decide according to the components that you use. Ours was 220x160x90 mm. The components are listed as; - 2 Switches - 4 buttons for the LCD - Power Receptacle - Power Cord - Power Supply 240 S 24 - Temperature Controller (REX-C100) - LCD connect to Arduino - Arduino Uno - 2 Sabertooth 2x12 Dual Motor Driver - 5 Resistors 220Ω - 1 Resistor 1KΩ - Solid State Relay Wiring is posted below. You can find all the wirings between all the components under the section of “Wiring Diagrams”.
  • 14. RECYCLEBOT 2016 14 3D Printed Parts BEARING HOUSE PART TO FIX THE MACHINE LEVEL WIND BRACKET #1 LEVEL WIND BRACKET #2 PAWL FILAMENT GUIDE
  • 15. RECYCLEBOT 2016 15 LEVEL WIND PIPE AND SHAFT BEARING HALF WORM GEAR PULLER MOTOR COUPLING LEVEL WIND ASSEMBLY PULLEY SPOOL MOTOR MOUNTING BRACKET SPOOL MOTOR COUPLING SPOOL FILAMENT ASSEMBLY PULLEY
  • 16. RECYCLEBOT 2016 16 Laser-cut Parts SPOOL MOTOR CONNECTOR 4MM MULTIPLEX EXTRUDER MOTOR CONNECTER 12MM MULTIPLEX EXTRUDER SUPPORTING LEG 12MM MULTIPLEX
  • 17. RECYCLEBOT 2016 17 HOOPER BOTTOM HOOPER #1 SPOOL STABILIZER HOOPER #2
  • 18. RECYCLEBOT 2016 18 Wiring Diagrams Arduino Uno and LCD LCD DISPLAY ARDUINO GND(1), CONTR(3), R/W(5) and NC(15) GND VCC(2) and NC(16) 5V RS(4) Pin 12 E(6) Pin 11 D4(11) Pin 5 D5(12) Pin 4 D6(13) Pin 3 D7(14) Pin 2
  • 19. RECYCLEBOT 2016 19 Arduino and Buttons BUTTONS ARDUINO Resistor GND Pin under resistor 5V Pin across the resistor From pin 7 to 10
  • 20. RECYCLEBOT 2016 20 Arduino and Sabertooth SABERTOOTH ARDUINO 0V GND 5V 5V S1 first Sabertooth A5 S1 second Sabertooth A4
  • 21. RECYCLEBOT 2016 21 Sabertoothand Motors SABERTOOTH MOTOR/POWER SUPPLY B- VSS power supply B+ VCC power supply M2A/B first Sabertooth Extruder motor M1A/B first Sabertooth Diameter motor M2A/B second Sabertooth Spool motor M1A/B second Sabertooth Ventilation
  • 23. RECYCLEBOT 2016 23 Arduino Code // include the library code: #include <LiquidCrystal.h> #include <SabertoothSimplified.h> #include <SoftwareSerial.h> // initialize the library with the numbers of the interface pins LiquidCrystal lcd(12, 11, 5, 4, 3, 2); byte arrow[8] = {//arrow lcd set bloks B00000,//line 1 B00100,//2 B00010,//3 B11111,//4 B00010,//5 B00100,//6 B00000,//7 }; const int button = 7;//set button to pin 13 const int button2 = 8;//set button to pin 10 const int button3 = 9;//set button to pin 9 const int button4 = 10;//set button to pin 8 int state = 0;//variable int statesetting = 0;//variable int big = 0;//variable int dia = 0;//variable int spool = 0;//variable SoftwareSerial SWSerial(NOT_A_PIN, A5); // RX on no pin (unused), TX on pin A5 SabertoothSimplified ST(SWSerial); // Use SWSerial as the serial port. SoftwareSerial SW1Serial(NOT_A_PIN, A4); // RX on no pin (unused), TX on pin A4 SabertoothSimplified ST1(SW1Serial); // Use SW1Serial as the serial port. void setup() { SWSerial.begin(9600);// This is the baud rate you chose with the DIP switches. SW1Serial.begin(9600);// This is the baud rate you chose with the DIP switches. lcd.createChar(0, arrow);//create a character lcd.begin(20, 4);//lcd screen is 20x4 lcd.setCursor(0,1);//set cursor to line 2 lcd.print("TIMELAB RECYCLEBOT");//print on lcd delay(3000);//delay of 5s } void loop() {
  • 24. RECYCLEBOT 2016 24 int buttonstate = digitalRead(button);//variable int buttonstate2 = digitalRead(button2);//variable int buttonstate3 = digitalRead(button3);//variable lcd.clear();//lcd clear lcd.setCursor(0,0);//set cursor to first line lcd.print("MENU");//print on lcd if(buttonstate2 == 1){//if button is pressed then state++;//variable +1 if(state>3)state = 0;//if variable is bigger then 3 then it becomes 0 } if(buttonstate == 1){//if button2 is pressed then state--;//variable -1 if(state<0)state = 3;//if variable is lower then 0 it becomes 3 } if(state == 0){//if variable is 0 lcd.setCursor(0,1);//set cursor to line2 lcd.write(byte (8));//print arrow on line 2 lcd.print(" 1) PLA 2.85mm");//print on lcd lcd.setCursor(0,2);//set cursor to line 3 lcd.print(" 2) PLA 1.75mm");//print on lcd lcd.setCursor(0,3);//set cursor to line 4 lcd.print(" 3) MANUAL");//print on lcd state = 0;//set state to 0 delay (200); if(buttonstate3==HIGH){//if button3 is pressed then while(digitalRead(button4)==LOW){//if button4 is LOW ST.motor(1,50);//big motor speed 50 ST.motor(2,10);//diameter motor speed 10 ST1.motor(1,10);//spool motor speed 10 ST1.motor(2,127);//ventilation speed 127 lcd.clear(); lcd.setCursor(0,2);//set cursor to line 3 lcd.print("extrude");//print on lcd lcd.setCursor(0,3);//set cursor to line 4 lcd.print("PLA 2.85mm");//print on lcd big = 0;//big motor speed 0 dia = 0;//diameter motor speed 0 spool = 0;//spool motor speed 0 delay(50); } } } else if(state == 1){// if state is 1 lcd.setCursor(0,1);//set cursor to line 2 lcd.print(" 1) PLA 2.85mm");//print lcd lcd.setCursor(0,2);//set cursor to line 3 lcd.write(byte (8));//arrow on line 3 lcd.print(" 2) PLA 1.75mm");//print on lcd lcd.setCursor(0,3);//ser cursor to line 4 lcd.print(" 3) MANUAL");//print on lcd state = 1;//set state to 1 delay(200);
  • 25. RECYCLEBOT 2016 25 if(buttonstate3 == HIGH){//if button3 is pressed while(digitalRead(button4)==LOW){//if button4 is LOW ST.motor(1,50);//big motor speed 50 ST.motor(2,10);//diameter motor speed 10 ST1.motor(1,10);//spool motor speed 10 ST1.motor(2,127);//ventilation speed 127 lcd.clear(); lcd.setCursor(0,2);//set cursor to line 3 lcd.print("extrude");//print on lcd lcd.setCursor(0,3);//set cursor to line 4 lcd.print("PLA 1.75mm");//print on lcd big = 0;//big motor speed 0 dia = 0;//diameter speed 0 spool = 0;//spool speed 0 delay(50); } } } else if(state == 2){//if state is 2 lcd.setCursor(0,1);//set cursor to line 2 lcd.print(" 1) PLA 2.85mm");//print lcd lcd.setCursor(0,2);//set cursor to line 3 lcd.print(" 2) PLA 1.75mm");//print lcd lcd.setCursor(0,3);//set cursor to line 4 lcd.write(byte (8));//arrow line 4 lcd.print(" 3) MANUAL");//print lcd state = 2;//set state to 2 delay(200); if(buttonstate3==HIGH){//if button3 is pressed while(digitalRead(button4)==LOW){//if button4 is LOW lcd.clear(); lcd.setCursor(0,0);//set cursor to line 1 lcd.print("SETTING MOTOR");//print lcd if (digitalRead(button)==HIGH){//if button is pressed statesetting++;//statesetting variable +1 if(statesetting>2)statesetting=0;//if variable is above 2 set to 0 } if(digitalRead(button2)==HIGH){//if button2 is pressed statesetting--;//statesetting variable -1 if(statesetting<0)statesetting=2;//if variable is lower than 0 set to 2 } if(statesetting == 0){//if statesetting is 0 ST.motor(1, big);//big motor speed ST.motor(2, dia);//diameter motor speed ST1.motor(1, spool);//spool motor speed ST1.motor(2 ,127);//ventilation speed 127 lcd.setCursor(0,1);//set cursor to line 2 lcd.write(byte (8));//arrow line 2 lcd.print(" big motor");//print lcd lcd.setCursor(0,2);//set cursor to line 3 lcd.print(" diameter motor");//print lcd lcd.setCursor(0,3);//set cursor to line 4
  • 26. RECYCLEBOT 2016 26 lcd.print(" spool motor");//print lcd delay(50); if(digitalRead(button3)==HIGH){//if button3 is pressed while(digitalRead(button4)==LOW){//is button4 is LOW lcd.clear(); if(digitalRead(button)==HIGH){//if button is pressed big++;//big motor +1 if(big>127)big=127;//if big motor speed above 127 set to 127 } if(digitalRead(button2)==HIGH){//if button2 is pressed big--;//big motor -1 if(big<-127)big=-127;//if big motor speed lower than -127 set to - 127 } lcd.setCursor(0,0);//set cursor to line 1 lcd.print("BIG MOTOR");//print lcd lcd.setCursor(0,1);//set cursor to line 2 lcd.print(big);//print value lcd ST.motor(1, big); //big motor speed delay(50); } delay(500); } } else if(statesetting == 1){//if statesetting is 1 lcd.setCursor(0,1);//set cursor to line 2 lcd.print(" big motor");//print lcd lcd.setCursor(0,2);//set cursor to line 3 lcd.write(byte (8));//arrow on line 3 lcd.print(" diameter motor");//print lcd lcd.setCursor(0,3);//set cursor to line 4 lcd.print(" spool motor");//print lcd delay(50); if(digitalRead(button3)==HIGH){//if button3 is pressed while(digitalRead(button4)==LOW){//if button4 is LOW lcd.clear(); if(digitalRead(button)==HIGH){//if button is pressed dia++;//diameter motor +1 if(dia>127)dia=127;//if diameter motor is above 127 set to 127 } if(digitalRead(button2)==HIGH){//if button2 is pressed dia--;//diameter motor -1 if(dia<-127)dia=-127;//if diameter motor is lower than -127 set to -127 } lcd.setCursor(0,0);//set cursor to line 1 lcd.print("DIAMETER MOTOR");//print lcd lcd.setCursor(0,1);//set cursor ro line 2 lcd.print(dia);//print value lcd ST.motor(2, dia);//diameter motor speed delay(50); }
  • 27. RECYCLEBOT 2016 27 delay(500); } } else if(statesetting == 2){//if statesetting is 2 lcd.setCursor(0,1);//set cursor to line 2 lcd.print(" big motor");//print lcd lcd.setCursor(0,2);//set cursor to line 3 lcd.print(" diameter motor");//print lcd lcd.setCursor(0,3);//set cursor to line 4 lcd.write(byte (8));//arrow to line 4 lcd.print(" spool motor");//print lcd delay(50); if(digitalRead(button3)==HIGH){//if button3 is pressed while(digitalRead(button4)==LOW){//if button4 is LOW lcd.clear(); if(digitalRead(button)==HIGH){//if button is pressed spool++;//spool motor +1 if(spool>127)spool=127;//if spool motor is above 127 set to 127 } if(digitalRead(button2)==HIGH){//if button2 is pressed spool--;//spool motor -1 if(spool<-127)spool=-127;//if spool motor is lower then -127 set to -127 } lcd.setCursor(0,0);//set cursor to line 1 lcd.print("SPOOL MOTOR");//print lcd lcd.setCursor(0,1);//set cursor to line 2 lcd.print(spool);//print value lcd ST1.motor(1, spool);//spool motor speed delay(50); } delay(500); } } delay(50); } } } else if(state == 3){//if variable is 3 lcd.setCursor(0,1);//set cursor to line2 lcd.print(" 2) PLA 1.75mm");//print on lcd lcd.setCursor(0,2);//set cursor to line 3 lcd.print(" 3) MANUAL");//print lcd lcd.setCursor(0,3);//set cursor to line 4 lcd.write(byte (8));//arrow to line 4 lcd.print(" 4) STOP ");//print lcd state = 3;//set state to 3 delay (200); if(buttonstate3==HIGH){//if button3 is pressed ST.motor(1,0);//big motor speed is 0 ST.motor(2,0);//diameter motor speed is 0 ST1.motor(1,0);//spool motor speed is 0
  • 28. RECYCLEBOT 2016 28 ST1.motor(2,0);//ventilation speed is 0 lcd.clear(); lcd.print("stop all motors");//print lcd delay(1000); } } // Delay a little bit to avoid bouncing delay(50); } Schedule
  • 29. RECYCLEBOT 2016 29 Bill of Materials We mostly used parts from the previous project, and we used the 3D printers and Laser-cut machines in Timelab. For some electrical components we needed to buy, and they are listed as; Date 18-22 July  Documentations on the wikifab and the report of the Recyclebot were read.  Problems/concerns from the report were obtained.  Steps of period(internship) were determined.  Both the old and new version of the Recyclebot were disassembled and cleaned.  The possible list of missing parts was made.  Electrical parts were viewed to see if there were any missing/broken parts.  Both motor and the heating element was working properly.  Questions were prepared to be asked to the Recyclebot builders. 25-29 July  Some parts for the Recyclebot were designed and printed/laser-cut.  Some parts from the old version were taken out and put into the new version.  Meeting was made about some necessary parts and tools.  Motor was assembled and the machine was started. It worked!  Some parts were given to get new parts 1-5 August  Existing motors were tested and assembled.  Missing/broken parts were reprinted for puller roller.  Level Wind Filament Assembly parts were designed.  Parts from Lyman Extruder V5 were taken and 3D printed for Level Wind Filament Assembly.  To make it more user friendly a led screen was considered to be added.  New and more efficient nozzle and pipe were obtained.  Adjustment for the pipe were made  First test was done without the heating elements.  First test was done with the heating elements but we found out heating elements are not working properly.  Spool filament wind assembly was improved.  Spool motor supporter were designed and 3D printed. 8-13 August  Missing/Broken parts were ordered (Temperature Controller)  New parts for the spool and level wind assembly were designed and printed  Spool and level wind assemblies assembled together  More improvements were done on spool filament assembly  Instead of adjusting motors speed manually, there was put an Arduino with LCD screen which will automatically set motors speed according to the thickness  Arduino with LCD screen was connected to the motors and was tested (it’s working)  Insulation cage is fixed and assembled 15-19 August  New funnel was designed.  Insulation cage was fixed, assembled and cooling fans were assembled to the cage.  Cables were extended.  New box was designed to put the electronics in.  Necessary soldering was done.  Extruding motor, level wind assembly, spool filament wind assembly were assembled together.  Controlling motors with Sabertooth and Arduino was tested. 2 motors are working but third motor is not. We are working on it.  All options were added to Arduino to show on LCD screen.  Electronic Schematic was done
  • 30. RECYCLEBOT 2016 30 - Temperature Controller (REX-C100) 12 Euro - 3 Cooling Fans 13 Euro - Solid State Relay 19 Euro Conclusions and Discussion
  • 31. RECYCLEBOT 2016 31 The main question during this project was if the waste plastic from 3D printers could be used as input for the Recyclebot and if we could extrude usable filament for 3D printers. In short: yes, it’s possible. Although there were a lot of problems we could extrude usable filament and print with it. At this moment the biggest problem is feeding. When it’s not even it’s not possible to get constant diameter thickness. There are certain cases when the feeding is not even. They are like when: - Pipe gets too hot and when you use shredded plastic pieces they melt and get stuck in the hopper. - We use big pieces instead of small pellets, they cannot go into the pipe which causes air gaps in the filament. Sometimes due to lack of heat the extruded filaments have gaps and this leads to a non-consistency. To overcome this, we set the temperature higher but when we do that the filament gets fluidlike which is hard to cool down. When the filament is too hot and when you put it on the puller roller wheels it stuck on them, but now it’s quite okay with the existing cooling fans. Due to friction on the spool, it’s not easy to rotate it with a slow speed. And sometimes it stops even though it should, when this happens you can set a higher speed value or push the spool with your hand a bit. Also sometimes when we turn on the motor switch, one of the motors go fast suddenly or the LCD screen doesn’t look god. When this happens you should turn it off and on again. After shredding the waste plastic with the shredder we still don’t get small pieces which can go into the pipe. Make sure that they are small enough and don’t get stuck in the hopper. Overall, it can be concluded that it’s possible to recycle %100 the plastic though the machine still needs some improvements. Recommendations for Further Development
  • 32. RECYCLEBOT 2016 32 To finalize this project, recommendations for further development in the field of a recycling the waste plastic were thought. If someone wants to elaborate further on this subject, then these are interesting fields to look into. Test Other Plastic Types We didn’t have enough time to test other plastic types but only PLA. It would be interesting and enlightening to test other type of plastics and see which ones are recyclable. Making Smaller Input Plastic One problem we faced when we tried the shredded plastic is that it doesn’t go into pipe evenly. So one concern should be to make the pieces smaller. So we are thinking that a second phase of shredding could be useful. It can be a different machine like a blender or a new type of shredder but it’s needed to be done. Cooling Element One of the biggest problem was cooling the extruded filament. When it’s too hot the puller roller wheels squeeze the filament so it gets an oval shape. To overcome this a new system can be designed like a water bath which was already thought but not applied. Or some other systems can be thought. Spool Filament Wind Assembly A better design of this assembly can be done which is detachable easily. And also due to friction and miss alignment the spool stops rotating sometimes so a better design can be better. Setting The Values Since the feeding was not even we couldn’t set exact values for the speed of the motors to adjust the thickness of the filament. After fixing the feed material this values can be set according to the thickness. Connection of The Extruder Motor Better connection for the extruder motor can be provided. Since it cannot be aligned perfectly it moves which is not a problem but it would be better to make everything fixed and stable. References KKrr aka De Recyclebot. (2013). Retrieved September 15, 2016, from http://www.timelab.org/project/kkrr-aka-de-recyclebot
  • 33. RECYCLEBOT 2016 33 Lyman filament extruder. (2012). Retrieved September 3, 2016, from https://en.wikipedia.org/wiki/Lyman_filament_extruder TUdelft, G.B. (2014). Wordpresscom. Retrieved 5 September, 2016, from https://reprapdelft.files.wordpress.com/2010/04/reprap-granule-extruder-tudelft1.pdf
  • 34. RECYCLEBOT 2016 34 A. O. Dülger N. Lisabeth Timelab Brusselspoortstraat 97 Gent 9000 Gent +32 9 391 96 10 www.timelab.org Contact: hello@timelab.org ali@timelab.org