Can Crusher Project

4th Period- Tech

Kartikey Desai, Courtney Jones, Sarah Kasi, and Jon Ko Table of Contents

Section Page #

Group Development……………………………………………………………………..……3

Roles and Responsibilities……………………………………………………….…….3

Team Constitution………………………………………………………………..…….3

Timeline……………………………………………………………………………………….4

Problem Statement……………………………………………………………………………5

Background………………………………………………………………………….………..5

Customers……………………………………………………………………………………. 5

Scope……………………………………………………………………………………….… 5-6

Deliverables………………………………………………………………………………….. 6

Brainstorming………………………………………………………………………...………7

Research and Generate Ideas……………………………………………………….………8-11

Research…………………………………………………………………………………

Calculations………………………………………………………………………………

Criteria and Constraints…………………………………………………………….………11

Explore Possibilities………………………………………………………………….…… 12-15

Designs…………………………………………………...…………………………..13-16

Adhesives…………………………………………………………………………….17

Materials……………………………………………………………………………...14-15

Selecting an Approach………………………………………………………………………15-17 Designs………………………………………………………………………………15

Adhesives……………………………………………………………………………16

Brackets……………………………………………………………………………...17

Developing a Design Proposal…………………………………………………………..….21-24

Bill of Materials………………………………………………………………………….21

Build Process…………………….………………….………………………………..21-23

Test Plan…………………………………………………...……………………………..24

Prototype………………………………………………………………………………………....X

Test and Monitor………………………………………………...... …………………………X

Refine……………………………………………………………………………………………..X

Lessons Learned………………………………………………………………………………....X

Summary…………………………………………………………………………………………X

CAD Drawings……..……………………………………………………………………...…….X Group Development

Role Person Responsibility Keep everyone on task and Leader Courtney Jones assign assignments Write documents and keep Scribe Kartikey Desai notes of everything Write documents and keep Scribe Sarah Kasi notes of everything Keep us on schedule and tells Timekeeper Jon Ko us where we are in our timeline

Team Constitution

Rules, Regulations, and Expectations

1. All team members should respect each other and the ideas that are shared.

2. All team members must do work.

3. All team members must help in the building process of the can crusher.

4. We must be open to working outside of class.

5. We must stay on task and focused at ALL TIMES.

6. Everyone MUST put forth their maximum effort.

7. No one dominates the team.

8. All team members must STAY POSITIVE. Timeline Can Crusher Project Timeline Group Members: Kartikey Desai, Courtney Jones, Sarah Kasi, Jon Ko Note: All work documented by team scribes or individual task owner Plan Date Act. Date Start Comp Start Comp Who's Responsible Task 21-Mar 22-Mar 21-Mar 23-Mar Jon Start and finish timeline 21-Mar 21-Mar 20-Mar 20-Mar Courtney Group development and team constitution 21-Mar 21-Mar 20-Mar 21-Mar Sarah Problem Statement 21-Mar 21-Mar 21-Mar 21-Mar Sarah Background 21-Mar 21-Mar 21-Mar 21-Mar Courtney Customers 21-Mar 22-Mar 21-Mar 21-Mar Courtney Scope 21-Mar 21-Mar 21-Mar 21-Mar Sarah Deliverables 21-Mar 21-Mar 21-Mar 21-Mar Team Brainstorming 22-Mar 25-Mar 19-Mar 6-Apr Team Research and Generate Ideas 22-Mar 24-Mar 19-Mar 25-Mar Sarah Overall & Aluminum Can Bin 22-Mar 24-Mar 19-Mar 25-Mar Courtney Lever & Base 25-Mar 25-Mar 5-Apr 6-Apr Sarah and Courtney Can Crusher Calculations 22-Mar 22-Mar 21-Mar 22-Mar Kartikey Criteria and Constraints 28-Mar 29-Mar 24-Mar 29-Mar Team Explore Possibilities 28-Mar 29-Mar 24-Mar 29-Mar Team Select an Approach 2-Apr 12-Apr 28-Mar 11-Apr Team Develop a Design Proposal 2-Apr 3-Apr 1-Apr 1-Apr Test Plan 2-Apr 5-Apr 14-Apr 14-Apr Build Process 5-Apr 8-Apr 14-Apr 14-Apr Bill of Materials 28-Mar 2-May 28-Mar Jon and Kartikey CAD Drawings 28-Mar 17-Apr 28-Mar 15-Apr Jon and Kartikey Bin with Inclined plane 18-Apr 20-Apr 18-Apr 19-Apr Self-Loading Mechanism 21-Apr 29-Apr Jon Ko Crushing Mechanism 28-Apr 29-Apr 25-Apr 27-Apr Kartikey Frame 28-Apr 29-Apr 21-Apr 25-Apr Jon & Kartikey Make A-Size for Individual Parts of Bin 29-Apr 2-May Make A-Size for Crushing Mechanism & Frame 2-May 13-May Team Prototype 2-May 3-May Bin 3-May 4-May Self-Loading Mechanism 5-May 6-May Frame 6-May 13-May Crushing Mechanism(Lever) 13-May 13-May Prototype section in tech report 16-May 20-May Team Refine 20-May 21-May Team Lessons Learned 20-May 21-May Team Summary 18-Mar 22-May 18-Mar Team Tech Report 22-Mar 22-May 18-Mar Team PowerPoint 25-May Team Presentation Problem Statement Roadrunner Trucking wants us to build a can crusher that will reduce the volume of their aluminum cans.

Background

We work for Alpha Engineering Company, and Roadrunner Trucking has contacted us because they have a lot of aluminum can wastes. In order to reduce the waste, we were asked to create a can crusher that will reduce the volume of the aluminum cans by seventy percent. If they do not find a way to reduce the volume of these cans they will have to pay a fine of $0.05 per can.

Can crushers are primarily used to save space and recycling. Can crushers make it possible to make small stackable piles that save space. There are many designs that can crushers come in. Some of the designs are pneumatic, hydraulic, aluminum, and wood. Jesse M. Wright was the man who invented the aluminum can crusher in 1937, but he did not get it patented until August 30, 1938.

Customers

Our two customers are Mr. Pritchard, our ITC instructor, and Roadrunner Trucking Company.

Our task for this project is to design and create a can crusher that will minimize the volume of aluminum cans by 70%. The can crusher will be made up of various parts including a lever, body, and aluminum bin. Sarah and I will be documenting all of the work we do in the designing and building to create our technical report. We will be composing a Power Point that will be presented during class. We will be turning in our can crusher, technical report, and Power Point presentation to Mr. Pritchard at the close of the project.

We will be utilizing different resources throughout the project to successfully complete our research. We also have the privilege to utilize the following individuals:

 Technical – Mr. Pritchard

 Math Calculations – Miss Hernacki

 CAD Drawings – Mr. Hund The materials that we will be using for this project are wood, PVC, metal brackets, metal hinges, screws, and nails. In addition, we will also use many shop tools including the band saw, claw hammer (to go with nails), drill press / hand held portable electric drill, and sander. The approximate cost of all the material we will need to purchase is $40.

The key constraints given by our customers are:

 Maximum space of 18”×24”×30”

 Minimum of one simple machine

 Aluminum can must fall into the aluminum can bin once crushed

 Aluminum can bin must slide in and out of crusher

 Aluminum can bin must hold 20 uncrushed cans

 Design must be one unit

 Must be manually operated

 All parts must be made not bought

There are a few conflicts we have with meeting outside of class. Kartikey and Jon Ko are in tennis so it will be hard for all four of us to meet after school due to their practices. Another issue we will face is meeting during study hall. Sarah and Jon Ko do not have a study hall throughout the week. Also, Courtney and Kartikey do not have study hall during the same period, so they cannot work together; they can only work by themselves. Other than that,we have no issues in meeting outside of school. Deliverables

At the end of this project we will give our customers 3 different outputs. The 3 outputs are the can crusher, technical report, and PowerPoint presentation. The can crusher will be composed of the lever, body, and aluminum can bin. The technical report will take us through the 12-step design process and it will contain our final CAD drawings. The PowerPoint presentation will be a complete overview of our whole project Brainstorming

 Overall:

o What adhesive should we use? Wood glue? Hot glue? Super glue?

o Will the can crusher be operated by hand or foot?

 Aluminum Can Bin:

o What material should it be made of? (Wood?)

o What size should it be?

o How thick should the material be? (Does it matter?)

o If we can make it hold more than 20 crushed cans, should we? (Or would that be a waste of material?)

o Should it be really tall but narrow? Wide but flat? Square sides like a cube?

o How will it slide in and out of the crusher? (Like a drawer?)

o Will we need a handle in order to slide it out of the crusher?

o Do we need to do anything specifically so that it smoothly slides out of the crusher? (Or would this be a waste of material?)

 Lever:

o What material(s) should it be made of?

o What other parts will we need to get? Metal hinges? Screws?

o How thick should the material be? (Does it matter?)

o How big / long should it be? o The longer the lever is, the less input force is required. Is there a way we can mathematically calculate the length of the lever so that too much input force is not required to crush the can to 30% its original size?

 Base:

o What material should it be made of? (Wood?)

o How big will it be?

o Should we make it so that it could hold something bigger than the size of a standard aluminum can, or would that be a waste of material?

Research and Development

 Overall

o Potential methods of attaching the parts are: wood glue, super glue, hot glue, duct tape, and screw and nails. Hot glue will be messy, and will not be as strong as the other potential solutions. Screw and nails will require the use of a drill. Screws and nails are mess free and do not take drying time. The downside to screws and nails are that if a mistake is made, it is hard to fix since the holes cannot be filled. Wood glue and superglue are both fairly strong and will take around 15second to dry. Wood glue is stronger, and is cheaper. Superglue is strong, but can be messy and costs more for the quantity we will need.

o Manual can crushers can be operated by either hand or foot. There are a variety of different types of can crushers. All of our designs are different, but they are all hand operated. Designs that require more input force are generally crushed by foot, and can crushers that require very little input force (such as crushers with long levers) are operated by hand.

 Aluminum Can Bin o It would be ideal to make it using wood. It can be made of other materials such as metal, but that would be more difficult and cost more.

o The exact size depends on the design. It should be capable of holding 20 crushed cans. (This can be calculated by finding the volume.) But making it so it holds way more than 20 crushed cans would be a waste of material. Also, it should fit in the 18” x 24” x 30” requirement.

o The material thickness will depend on what they have at the store, although, Home Depot has a variety of wood thicknesses. It should be thick enough so that it is sturdy, but not too thick that it is both a waste of material and space. 1/2” to 3/4" thick is acceptable.

o The aluminum can bin can slide out of the base like a drawer, but there do not need to special appliances that help it slide smoothly (that would be a waste of material).

o A handle on the aluminum can bin would be most ideal, to pull the bin out of the base since it is going to slide out like a drawer. However, the handle should be designed big enough to fit an adult’s hand, but also as small as possible so save material. (If using wood, the handle will have to be sanded a lot to prevent splinters.)

o Although not required on the aluminum can bin, metal brackets would make the bin more sturdy. If using metal brackets, we must be careful when dimensioning both the bin and base.

 Lever

o The lever should be made of metal, wood, or aluminum. Plastic would not work because it is not sturdy enough to exert that much pressure. Wood seems to be the best option. It is highly available in a variety of sizes, and our customers will let us use wood. In addition, it will be strong enough and easy to work with. o The material should be thick so it can stand against a lot of force. 3/3” to 1” thick is the minimum. 2” by 4” wood is a potential option.

o The lever should be long, not short, so we can use less input force. Since it is a simple machine, the longer the lever, the less force required.

o Depending on the design, the lever may require other parts such as hinges. Metal hinges, such as the ones that are in doors, are easily available.

 Base

o The materials that we are allowed to use for the base are wood, aluminum, plastic, and metal to construct the base of the can crusher.

o The size of the base will be decided by the group, but the maximum space it can occupy is 18” in length and 24” in height.

o The frame does not need to be too thick, only a ½” to ¾” thickness is necessary if using wood.

o Metal brackets would help the strength of the base. Metal brackets would help prevent the base from falling apart while crushing a can. They will also help align parts when gluing things together. The can be installed using screws or nails.

o We should make the base larger that the size of twenty uncrushed aluminum cans to ensure that it will hold all of the cans. By making the base larger, it allows the cans to fit in a way where they are not closely packed together where they cannot be moved.

 Can Crusher Calculations:

Can Dimensions: 2.625in in diameter (1.3125in in radius), 4.875in in height

Volume – 1 uncrushed can

V = πr2h V = π x 1.31252 x 4.875

V = 26.38in3

Volume – 1 can reduced by 70%

V = πr2h x .3

V = π x 1.31252 x 4.875 x .3

V = 26.38 x .3

V = 7.914in3

Height of a crushed can (height reduced by 70%)

h = 4.875 × .3

h = 1.4625 in.

Volume – 20 uncrushed cans

V = πr2h x 20

V = π x 1.31252 x 4.875 x 20

V = 26.38 x 20

V = 527.66

Volume – 20 cans reduced by 70%

V = πr2h x .3 x 20

V = π x 1.31252 x 4.875 x .3 x 20

V = 26.38 x .3 x 20

V = 7.914 x 20

V = 158.28in3 Criteria and Constraints

 Criteria:

o Self-loading

o Inexpensive

o Reliable

o Not time consuming

o Simple

 Constraints:

o Maximum space the design can occupy is 18”x24”x30”. o Materials that can be used are wood, PVC, metal brackets, metal hinges, screws and nails. o Minimum of one simple machine. o Crushed aluminum can must immediately fall into the aluminum can bin without human intervention. o The aluminum can bin must slide in and out of the crusher. o The aluminum can bin must be sized to hold 20 crushed cans. o All parts of the can crusher must be fabricated. o The design is to be one unit. o Must be manually operated.

Explore Possibilities

Design

Kartikey’s Design Pros(+) Cons(-) Simple Used incline plain wrong Dimensioned well No thickness Self-loading Requires a lot of input force Courtney’s Design

Pros(+) Cons(-) Multi-view and isometric drawings not dimensioned well Follows all size constraints No bin Very neat Lever too complicated and would not work

Sarah’s Design

Pros(+) Cons(-) Aluminum can bin is really tall (all space will Bin may tip over when crushing a can be taken up Follows all constraints complex Very neat Not self-loading Uses a lot of material Jon Ko’s Design

Pros(+) Cons(-) Detailed Confusing Good dimensions Materials used are expensive Followed most constraints Aluminum can bin does not slide in and out Method of Bonding Parts

Wood Glue

Pros(+) Cons(-) Sticks to wood Hard to fix mistakes once glued Strong Dries a yellowish color Inexpensive Dries quickly

Hot Glue

Pros(+) Cons(-) Clear Messy Dries quickly Takes up space when dried Inexpensive Takes time to heat up

Super Glue

Pros(+) Cons(-) Dries quickly Can be messy Strong Expensive for the quantity we need Not as affective on wood Screws and Nails

Pros(+) Cons(-) Reliable Hard to repair mistakes made with nails Works well with brackets and wood Inexpensive and common Easy to repair mistakes with screws

Duct Tape

Pros(+) Cons(-) Does not need to dry Comes off Inexpensive Sticks together Hard to stick edges together Not the best option

Materials

Aluminum Brackets

Pros(+) Cons(-) Strong Hard to find Lightweight Conducts electricity Metal Brackets

Pros(+) Cons(-) Strong Can be costly Many different designs Steel Brackets

Pros(+) Cons(-) Durable Tends to be wide and occupies a lot of space Costly

Iron Brackets

Pros(+) Cons(-) Durable Used more for decoration Easy to use Costly None that would be used for project Rusts easily

Titanium Brackets Pros(+) Cons(-) Very strong Very expensive Lightweight Not always in stock at the store

Select an Approach

Designs:

Potential Designs Criteria Kartikey’s Courtney’s Sarah’s Jon Ko’s Design Design Design Design Self-loading 5 1 1 3 Inexpensive 4 3 3 3 Reliable 4 1 3 5 Quick to 4 3 3 3 build Simple 5 3 3 3 Ease of use 3 2 3 4 Total 25 13 16 21 Scale: 1 -5; 1 being the worst, 5 the best

Although Kartikey’s design scored highest, we will be combining Jon Ko’s design and Kartikey’s design. The reason we will be doing this is because we liked that Kartikey’s design was self-loading and that Jon Ko’s design had a reliable lever that would crush the can effectively. Sarah’s design had a lever similar to Jon Ko’s, but Jon Ko’s dimensions would work better with the design of our crusher.

Method of Bonding Parts:

Potential Adhesives Screw Criteria Duct Wood Glue Hot Glue Super Glue s and Tape nails Dries quickly 4 5 4 5 5 Inexpensive 4 4 3 5 3 Sticks to our material 5 2 4 5 3 Ease of appliance 3 1 3 3 2 Cleanliness 4 1 3 4 1 Reliability 4 2 4 5 3 Total 24 15 21 27 17 Scale: 1 -5; 1 being the worst, 5 the best

We are going to use screws and nails as it scored the highest. Moreover, screws and nails will work well with other materials we may use such as wood and metal brackets. If we run into a circumstance where screws and nails are hard to use, we will use wood glue or duct tape. Materials:

Potential Materials Aluminu Steel Criteria Metal Iron Titanium m bracket brackets brackets brackets brackets s Inexpensive 3 4 2 2 1 Availability in the 4 5 3 1 store 1 Ease of use 2 5 4 3 3 Strength 3 4 4 3 5 Reliability 3 5 4 2 5 Total 15 23 17 11 15 Scale: 1-5; 1 being the worst, 5 the best

We will be using metal brackets because they are inexpensive, reliable, strong, and easy to use. They are highly available in many stores such as Menards, Home Depot, and Lowes. Moreover, they will be easy to attach since we are using screws and nails. Develop a Design Proposal

 CAD Drawings

 BILL OF MATERIALS

PART UNIT TOTAL PART QUANTITY DESCRIPTION PRICE PRICE .75 × 2 ×4 PLYWOOD 1 $1.98 $1.98 WOOD .75 × 2 × 2 PLYWOOD 1 $2.19 $4.38 1 PACK OF 50 SCREWS $5.37 $5.37 2” LONG SCREWS CROWN BOLT 1 PACK OF 40 NAILS $1.30 $1.30 FINISHING NAILS NAILS WOOD TITEBOUND WOOD 8OZ. BOTTLE $2.78 $2.87 GLUE GLUE METAL NARROW UTIITY 1 PACK OF 2 HINGES HINGES 1-1/2” HINGES NUTS 8 $0.70 $5.60 ” HEX NUT ” HEX BOLTS 6 $0.82 $4.92 BOLTS 5 ½ ” HEX 2 $1.23 $2.46 8” HEX BOLTS 1 $ $ SUBTOTAL $29.11 TAX $2.62 TOTAL $31.73  Build Process

 Aluminum Can Bin Outside

o Obtain the wood (.75” thick).

o Trace the outline of Bin outside bottom, Bin outside side, Bin outside short, and Outside top (parts A-D) on the wood. (Preferably larger to give room to sand)

o Cut the wood.

o Sand the wood.

o Assemble pieces to ensure they fit.

o Glue and then nail the pieces together.

 Aluminum Can Bin Inside

o Trace the outline of Bin outside bottom, Bin inside long side, Bin inside short side, and Bin inside handle (parts E-G, I) on the wood (Preferably larger to give room to sand)

o Cut the wood.

o Sand the wood.

o Glue and then nail the pieces together. Inclined plane for inside of bin

o Obtain the wood.

o Trace the outline of the long rectangular piece and the two angular pieces(90°) (part H)

o Cut the wood.

o Sand the wood

o Assemble pieces by placing in the aluminum can bin inside to ensure fitting

o Glue piece into bin. (NO NAILS)

 Crushing Mechanism

o Trace the outline of the Large Frame Side, Small Frame Side, Stable Block, and Frame Bottom (parts N-Q) on the wood. (Preferably larger to give room to sand)

o Cut the wood.

o Sand the wood.

o Drill holes in necessary pieces.

o Glue then nail the pieces together.

Lever o Obtain the wood (.75” and 3”thick).

o Trace the outline of the Crushing block (part J) on 3” thick, Diagonal lever, upright lever part, and Handle (parts K-M) on .75” thick on the wood. (Preferably larger to give room to sand)

o Cut the wood.

o Sand the wood.

o Drill holes,

o Attach pieces together with nuts and bolts

o Attach the lever to the frame with nuts and bolts

 Self-loading Mechanism

o Trace the outline of the part on the wood. (Preferably larger to give room to sand)

o Cut the wood.

o Sand the wood.

o Glue pieces together. (NO NAILS)  Test Plan

Test Criteria How Tested Expected results Actual Results

Reliability Crush a can, The can will be measuring size crushed to 70% of before and after its original height crushed

Durability Crush a can, open The aluminum can and close the bin will slide in and drawer of the bin out with ease that stores aluminum cans

Bin Must Hold 20 Put 20 cans crushed All 20 cans will be Crushed Cans in the bin crushed

Self- Loading Put 3 cans into the The crusher will be self-loading able to self-load mechanism and appropriately crush all three cans without any complications

Can Must End-up Crush a can and see The can will fall In Bin After Being if it falls through through the hole Crushed the appropriate hole into the bin into the bin

Prototype While making our prototype, we identified many changes we had to make as well as many steps and issues in building that the build process did not address.

Test and Monitor

Test Criteria How Tested Expected results Actual Results

Reliability Crush a can, The can will be measuring size crushed to 70% of before and after its original height crushed

Durability Crush a can, open The aluminum can and close the bin will slide in and drawer of the bin out with ease that stores aluminum cans

Bin Must Hold 20 Put 20 cans crushed All 20 cans will be Crushed Cans in the bin crushed

Self- Loading Put 3 cans into the The crusher will be self-loading able to self-load mechanism and appropriately crush all three cans without any complications

Can Must End-up Crush a can and see The can will fall In Bin After Being if it falls through through the hole Crushed the appropriate hole into the bin into the bin Refine

Lessons Learned

We learned to effectively complete a large number of tasks at once without having to re-do them by dividing and assigning the tasks, but also helping each other. We realized that we had to assign people to do certain things, but the person would only be the leader for that task, and other group members would have to help complete that task.

We also learned how to use a lot of hand and power tools. This was the first project for us that required the use of so many tools to build things.

Summary