Faculty of Engineering and Materials Sciences

German University in Cairo

Compactor and Shredder Machine

Bachelor Thesis

Author: Rita Samy Milad.

Supervisor: Dr. Hisham ElSherif.
Reviewer: Dr. Saad Kassem.
Submission Date: 15-07-21
This is to certify that:
(i) the thesis comprises only my original work towards the Bachelor Degree

(ii) due acknowledgement has been made in the text to all other material used

Rita Samy Milad

Name of the Author
Date:15/07/2021
Abstract
This thesis research project focuses on providing an implementable solution to the problem
of Aluminum CANs and PET Bottles waste management in Egypt. This issue causes pollution,
high health problems, and global climate changes. The aim of this thesis research project is to
design and control a hydraulic based Compactor and Shredder Machine that crushes empty
beverage Cans and shreds empty PET Bottles. The crushed Cans and the shredded Bottles then
return to the industry to assist in rapid recycling, feasible transportation of both materials, reduce,
and prevent health issues.

To model the design of the Compactor and Shredder Machine, SolidWorks was used. A
Programmable Logic Controller (PLC) controls the Machine using a Sequential Function Chart
Programming. The research consists of the Wiring diagrams of the actuators and the controller.

This thesis incorporates various simulations and analysis, which test the design of the
Compactor and Shredder Machine. An implemented lab simulation of the hydraulics tested and
ensured the functionality of the hydraulic system. Analyzing the Von Mises stress distribution,
strain analysis and displacement deformation, evaluated the maximum deformation that could
occur on the machine and assessed the forces on the machine. The performance evaluation of the
machine gave a result of an efficiency of approximately four compacted bales per hour forming
up a total weight of 20 kilograms per hour and the shredder produces 5 kilograms of shredded
plastic per hour using this proposed design.

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Contents
Chapter 1 Introduction............................................................................................................... 12
1.1 Motivation ..................................................................................................................... 12
1.2 Waste Compaction Management in Egypt ................................................................ 16
1.3 Waste Management in Egypt ...................................................................................... 19
1.4 Aim of the Project ........................................................................................................ 22
Chapter 2 Literature Review ................................................................................................... 23
2.1 Background ................................................................................................................... 23
2.2 Previous Designs and Research ................................................................................... 23
2.3 United States Patents ................................................................................................... 24
2.4 Inventions’ System of Operation ................................................................................ 27
Chapter 3 Mechanical Design .................................................................................................. 28
3.1 Introduction .................................................................................................................. 28
3.2 General Machine Design.............................................................................................. 28
3.2.1 Compactor and Shredder Machine Setting and Formation ............................. 34
3.2.1.1 Aluminum CANs Compartment ...................................................................... 34
3.2.1.2 Plastic Compartment ........................................................................................ 35
3.2.1.3 Shredder and Compactor Machine Views ...................................................... 36
3.2.2 2-D Dimensional Sketches with Detailed Explanation ...................................... 37
3.2.2.1 Aluminum CANs Compartment ...................................................................... 37
3.2.2.2 Aluminum CANs Compactor’s Base ............................................................... 37
3.2.2.3 Inlet Door ........................................................................................................... 39
3.2.2.4 Outlet Door ........................................................................................................ 40
3.2.2.5 Cylinder A .......................................................................................................... 41
3.2.2.6 Cylinder B .......................................................................................................... 42
3.2.2.7 Plastic Shredder Compartment ....................................................................... 43
3.2.2.8 Safety Box........................................................................................................... 43
3.2.2.9 Shredder ............................................................................................................. 44
3.2.2.10 Shredder’s Box ............................................................................................... 44
3.2.2.11 Shredder’s Motor .......................................................................................... 45

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 3.2.2.12 Shredder’s Outlet Box ................................................................................... 46
3.2.2.13 Shredder’s Body Structure ........................................................................... 47
3.2.2.14 Blades .............................................................................................................. 48
3.2.2.15 Spacers ............................................................................................................ 48
3.2.2.16 Shaft ................................................................................................................ 49
3.2.2.17 Bearings .......................................................................................................... 50
3.2.2.18 Gears ............................................................................................................... 50
3.2.2.19 Supports .......................................................................................................... 51
3.3 Design Calculations and Analysis ............................................................................... 51
3.3.1 Results of Design Calculations ............................................................................. 53
3.4 SolidWorks Analysis .................................................................................................... 53
3.4.1 Stress Analysis ....................................................................................................... 54
3.4.2 Strain Analysis ...................................................................................................... 55
3.4.3 Displacement Analysis .......................................................................................... 55
3.4.4 Analysis Conclusion .............................................................................................. 56
3.5 Performance Evaluation of the Compactor and Shredder Machine ....................... 56
3.5.1 Compaction Mode Efficiency ............................................................................... 56
3.5.1.1 Compaction Efficiency Calculations................................................................ 57
3.5.2 Shredding Mode Efficiency .................................................................................. 57
3.5.2.1 Shredder Efficiency Calculations .................................................................... 58
Chapter 4 Hydraulic Design ..................................................................................................... 59
4.1 Introduction .................................................................................................................. 59
4.2 Hydraulic Components ................................................................................................ 59
4.2.1 Double Acting Hydraulic Cylinder...................................................................... 60
4.2.2 4/2 Way-Solenoid Valve........................................................................................ 61
4.2.3 Pressure Relief Valve ............................................................................................ 61
4.2.4 Hydraulic Flexible Hoses ...................................................................................... 62
Chapter 5 Controller Design .................................................................................................... 63
5.1 Introduction .................................................................................................................. 63
5.2 Hydraulic and Electro-Mechanical Circuit Lab Simulation .................................... 63
5.3 General Block Diagram ............................................................................................... 65
5.4 Operational Flow Chart............................................................................................... 68
5.4.1 Compaction Mode ................................................................................................. 68

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 5.4.2 Shredding Mode .................................................................................................... 69
5.4.3 Compaction and Shredding Mode ....................................................................... 69
5.4.4 Operational Flow Chart ....................................................................................... 70
5.5 List of Components of the Compactor and Shredder Machine ............................... 76
5.6 Controller Description ................................................................................................. 80
5.6.1 Capacitive Sensor .................................................................................................. 80
5.6.2 Magnetic Reed Switch .......................................................................................... 81
5.6.3 Power Supply......................................................................................................... 82
5.6.4 Electro-mechanical Relays ................................................................................... 83
5.6.5 Main Circuit Breaker ........................................................................................... 84
5.6.6 Motor Contactor ................................................................................................... 85
5.6.7 Analog Pressure Sensor ........................................................................................ 86
5.6.8 Oil Level Sensor .................................................................................................... 87
5.6.9 Magnetic Door Lock ............................................................................................. 88
5.6.10 Optical Sensor ....................................................................................................... 88
5.6.11 Motor Circuit Breaker ......................................................................................... 89
Chapter 6 Control Panel ........................................................................................................... 91
6.1 Introduction .................................................................................................................. 91
6.2 Control Panel SolidWorks Design and Location ....................................................... 91
6.3 Control Panel Face Plane ............................................................................................ 92
6.4 Machine Wiring Diagram ............................................................................................ 95
6.4.1 Motor Wiring Diagram ........................................................................................ 95
6.4.2 Power Supply Wiring Diagram ........................................................................... 96
6.4.3 Digital Inputs Wiring Diagram............................................................................ 96
6.4.4 Relays Interface Wiring Diagram ....................................................................... 97
Chapter 7 Conclusion and Future Work .............................................................................. 100
7.1 Conclusion ................................................................................................................... 100
7.2 Future Work and Recommendations ....................................................................... 100
References… .............................................................................................................................. 102

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List of Terms

B.Sc. Bachelor of Science

PLC Programmable Logic Controller
RPM Revolutions per minute
PET Bottles Polyethylene Terephthalate bottles

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List of Figures
Figure [1.1]: Annual municipal solid waste generated per capita (kilograms/capita/day) .. 12
Figure [1.2]: Wastes dump sites................................................................................................. 13
Figure [1.3]: Global Primary Plastics Waste Generation, 1950-2015 .................................... 14
Figure [1.4]: Data from “Plastic waste inputs from land into the ocean” ............................. 15
Figure [1.5]: Paper and Paperboard Waste Management: 1960-2017 .................................. 16
Figure [1.6]: Total Municipal Solid Waste (MSW) by Material, 2015 .................................. 16
Figure [1.7]: Cairo Streets drowning in waste. ........................................................................ 17
Figure [1.8]: Wastes in Egypt. ................................................................................................... 17
Figure [1.9]: Waste Generation in Egypt Provinces. ............................................................... 18
Figure [1.10]: MSW Composition in Egypt (2012). ................................................................. 18
Figure [1.11]: “Sell your Garbage” Kiosks in Cairo. .............................................................. 20
Figure [1.12]: Waste Prices. ....................................................................................................... 20
Figure [1.13]: Egyptian-German Cooperation and GIZ ......................................................... 22
Figure [2.1]: The Trash compactor side-elevated view ........................................................... 24
Figure [2.2]: The Trash compactor Schematic Wiring Diagram ........................................... 25
Figure [2.3]: Design of the Compactor and the Mechanism used .......................................... 25
Figure [2.4]: Front and side view the compactor ..................................................................... 26
Figure [2.5]: Hydraulic operating circuit and the electrical control circuit of the compactor
....................................................................................................................................................... 26
Figure [3.1]: Compactor and Shredder Machine..................................................................... 28
Figure [3.2]: Aluminum CANs Compaction Process into Facilitated Steps .......................... 29
Figure [3.3]: Plastic Shredding process into facilitated steps ................................................. 30
Figure [3.4.a]: Compactor and Shredder Machine.................................................................. 30
Figure [3.4.b]: Compactor and Shredder Machine ................................................................. 31
Figure [3.4.c]: Compactor and Shredder Machine .................................................................. 31
Figure [3.5] Exploded View of the Aluminum CANs Compartment ..................................... 34
Figure [3.6]: Exploded View of the Shredding Machine Compartment ............................... 35
Figure [3.7]: Top View of the Machine ..................................................................................... 36
Figure [3.8]: Front View of the Machine .................................................................................. 36
Figure [3.9]: Rear View of the Machine.................................................................................... 37
Figure [3.10.a]: Aluminum CANs Compactor’s Base 2-Dimensional Sketch ....................... 38
Figure [3.10.b]: Compactor’s Base ............................................................................................ 38
Figure [3.11.a]: Compactor’s Inlet Door 2-Dimensional Sketch ............................................ 39
Figure [3.11.b]:Compactor’s Inlet Door ................................................................................... 39
Figure [3.12.a]:Compactor’s Outlet Door 2-Dimensional Sketch .......................................... 40
Figure [3.12.b]:Compactor’s Outlet Door ................................................................................ 40
Figure [3.13.a]:Cylinder A 2-Dimensional Sketch ................................................................... 41

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Figure [3.13.b]:Cylinder A ......................................................................................................... 41
Figure [3.14.a]:Cylinder B 2-Dimensional Sketch ................................................................... 42
Figure [3.14.b]:Cylinder B ......................................................................................................... 42
Figure [3.15.a]:Shredder’s Safety Box 2-Dimensional Sketch ................................................ 43
Figure [3.15.b]:Shredder Safety Box ......................................................................................... 43
Figure [3.16.a]:Shredder 2-Dimensional Sketch ..................................................................... 44
Figure [3.16.b]:Shredder ............................................................................................................ 44
Figure [3.17]:Shredder 2-Dimensional Sketch ......................................................................... 45
Figure [3.18.a]:Shredder’s Box 2-Dimensional Sketch ........................................................... 45
Figure [3.18.b]:Shredder’s Box ................................................................................................. 45
Figure [3.19.a]:Shredder’s Motor 2-Dimensional Sketch ....................................................... 46
Figure [3.19.b]:Shredder’s Motor ............................................................................................. 46
Figure [3.20.a]:Shredder’s Outlet Box 2-Dimensional Sketch................................................ 46
Figure [3.20.b]:Shredder’s Outlet Box...................................................................................... 46
Figure [3.21.a]:Shredder’s Body Structure 2-Dimensional Sketch ........................................ 47
Figure [3.21.b]:Shredder’s Body Structure .............................................................................. 47
Figure [3.22.a]:Blades 2-Dimensional Sketch........................................................................... 48
Figure [3.22.b]:Blades ................................................................................................................. 48
Figure [3.23.a]:Spacers 2-Dimensional Sketch......................................................................... 49
Figure [3.23.b]:Spacers ............................................................................................................... 49
Figure [3.24]:Shaft’s 2-Dimensional Sketch ............................................................................. 49
Figure [3.25]:Ball Bearings’ 2-Dimensional Sketch ................................................................. 50
Figure [3.26]:Gears’ 2-Dimensional Sketch ............................................................................. 50
Figure [3.27]:Supports 2-Dimensional Sketch ......................................................................... 51
Figure [3.28]:SolidWorks Stress Analysis of the Compactor Machine ................................. 54
Figure [3.29]:SolidWorks Strain Analysis of the Compactor Machine ................................. 55
Figure [3.30]:SolidWorks Displacement Analysis of the Compactor Machine..................... 55
Figure [4.1]:Hydraulic Circuit ................................................................................................... 59
Figure [4.2]:Double Acting Hydraulic Cylinder ...................................................................... 61
Figure [4.3]:4/2 Way-Solenoid Valve ........................................................................................ 61
Figure [4.4]:Pressure Relief Valve............................................................................................. 62
Figure [4.5]:Hydraulic Flexible Hoses ...................................................................................... 62
Figure [5.1.a]:Hydraulic and Electro-Mechanical Control Circuit Shredding Mode .......... 64
Figure [5.1.b]:Hydraulic and Electro-Mechanical Control Circuit Compaction Mode ...... 64
Figure [5.1.c]:Hydraulic and Electro-Mechanical Control Circuit Compaction and
Shredding Mode .......................................................................................................................... 65
Figure [5.2]:General Block Diagram of the Compactor and Shredder Machine ................. 66
Figure [5.3]:Operational Flow Chart for Compaction Mode ................................................. 73
Figure [5.4]:Operational Flow chart for Shredding Mode ..................................................... 74

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Figure [5.5]:Operational Flow Chart for Compacting and Shredding Mode ....................... 75
Figure [5.6.a]:Capacitive Sensor Schematic ............................................................................. 80
Figure [5.6.b]:Capacitive Sensor Internal Construction ......................................................... 80
Figure [5.7]:Magnetic Reed Switch working principle ........................................................... 81
Figure [5.8]:AC/DC Power Supply Operation ......................................................................... 82
Figure [5.9]:Schneider Electric Power Supply Wiring ............................................................ 83
Figure [5.10.a]:Electro-Mechanical Relay Circuit ................................................................... 83
Figure [5.10.b]:Shneider Electro-Mechanical Relay Wiring Diagram .................................. 83
Figure [5.10.c]:ISO-View of Shneider Electro-Mechanical Relay.......................................... 83
Figure [5.11.a]:Main Circuit Breaker Wiring .......................................................................... 85
Figure [5.11.b]:ISO-View Main Circuit Breaker ..................................................................... 85
Figure [5.12.a]:Shneider Electric Motor Contactor Wiring ................................................... 85
Figure [5.12.b]:Motor Contactor Wiring Circuit .................................................................... 86
Figure [5.13.a]:Analog Pressure Transducer ........................................................................... 87
Figure [5.13.b]:Analog Pressure Transducer Structure ......................................................... 87
Figure [5.14]:Float Level Sensor ............................................................................................... 87
Figure [5.15]:Magnetic Door Lock Installation ....................................................................... 88
Figure [5.16]:Different Types of Optical Sensors .................................................................... 89
Figure [5.17]:Optical Sensor Detection Process ....................................................................... 89
Figure [5.18.b]:Motor Circuit Breaker Wiring ........................................................................ 90
Figure [5.18.b]:ISO-View Motor Circuit Breaker ................................................................... 90
Figure [6.1]:Control Panel ......................................................................................................... 92
Figure [6.2.a]:Control Panel Face Plane 2-D View .................................................................. 93
Figure [6.2.b]:Control Panel Face Plane 3-D View .................................................................. 94
Figure [6.2.c]:Control Panel Face Plane 3-D View .................................................................. 94
Figure [6.3]:Motor and Pump Wiring Diagram ...................................................................... 95
Figure [6.4]:Power Supply Wiring Diagram ............................................................................ 96
Figure [6.5]:Inputs Wiring Diagram ......................................................................................... 97
Figure [6.6.a]:Interface Relays Wiring Diagram ..................................................................... 98
Figure [6.6.b]:Interface Relays Wiring Diagram ..................................................................... 98
Figure [6.6.c]:Interface Relays Wiring Diagram ..................................................................... 99

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List of Tables
Table 3.1: Machine Components and Parts ............................................................................. 32
Table 4.1: Hydraulic Components............................................................................................. 60
Table 4.2: Function of each Hydraulic Component ................................................................. 60
Table 5.1: Block Diagram Contents .......................................................................................... 66
Table 5.2: List of Components and Actuators.......................................................................... 76
Table 5.3: Technical Specifications of the Capacitive Sensor ................................................. 82
Table 5.4: Technical Specifications of the Power Supply........................................................ 84
Table 5.5: Technical Specifications of Electromechanical Relay ........................................... 84
Table 5.6: Technical Specifications of the Main Circuit Breaker .......................................... 86
Table 6.1: Control Panel Face Plane Components .................................................................. 94

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 Chapter 1
Introduction
1.1 Motivation
According to the World Bank, Global Waste could rise by 70% by the year 2050.
Researches stated that countries could benefit both environmentally and economically from
better collection, disposal, and recycling of waste products such as Aluminum CANs, Plastic,
and Paper. One-third of the mentioned waste products occupy an open environment without
treatment. [1]

Figure 0.1.1: Annual municipal solid waste generated per capita (kilograms/capita/day).
Lower-income countries, that need sufficient waste removal and waste treatment plans
and offices, include 90% of the waste products. This executed action results in severe obstacles
affecting the global health, global climate changes, and global disease(s) spreading. [2]

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Figure 1.2: Wastes dump sites.

Aluminum CANs are widely used in packaging in the industry of food and beverages due
to their advantages that include a high level of corrosion resistance, optimal protection from
ultra-violet rays, water vapor, oxygen and microorganisms, oil and fats. Aluminum CANs
recycling feasibility leads their advantages; however, their disadvantages harm the environment
as they highly donate the pollution of earth imposing health risks to the public. [3]
Container Recycling Institute states that 50% of all aluminum jars end up in incinerators
or landfills - bringing about the requirement for extra jars produced using new materials.
Aluminum refining radiates sulfur dioxide and nitrogen dioxide, which can produce and result in
both smog and acid rain. According to the British Medical Journal, not only that aluminum
CANs could cause pollution and health problems to the public, but also it arises in injuries of
being cut from sharp edges and could result in the need for stitches and the use of antibiotics.
Thirty-three percent of all aluminum fabricating plants use coal when they produce aluminum
jars. Another 10 percent depend on other petroleum derivatives, for example, oil and flammable
gas. Coal, oil, and flammable gas form from rotting natural issues underneath the world's surface
more than a great many years. When the earth uses up its inventory of petroleum derivatives,
making more is not an alternative. [4]
For over 50 years, Plastic usage in the industry increased rapidly. The industry utilizes
plastic in packaging, in bottles manufacturing, and containers manufacturing as well. In 2013,
studies estimated that the industry produces 299 million tons of plastic, which shows an increase
of 4% more than that of 2012 and it is still increasing up to this date. [5]

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Figure 1.3: Global Primary Plastics Waste Generation, 1950-2015.
Industrial consumers prefer plastic when it comes to packaging processes. Relatively
cheaper than other packaging products, Plastic offers flexibility, and lightweight. Plastic provides
high resistance to moisture as well.
Beside the mentioned plastic favors to the industrial sector, plastic disadvantages
overweigh the mentioned advantages as it forms up the main reasons of pollution. Plastic, often
thrown to the public, degrade slowly and lasts due to its durability. According to the World Bank,
plastics can debase conduits and environments for a large number of years, include 12 percent of
all waste. Around 8 million metric tons of plastics are currently in the oceans. The shown
statistics prove that the amount of plastic in the oceans irritates the marine nature and exposes it
to severe danger. [6]

14
Figure 1.4: Data from “Plastic waste inputs from land into the ocean.”
Paper, produced from trees and one of the most widely used product, forms up more than
5000 products in the industrial sector. Although they include various utilizations, Papers harm
the environment. Manufacturing paper takes double the energy used to deliver a plastic bag.
Paper manufacturing process requires cutting down trees, which is the main oxygen provider on
earth and carbon dioxide absorber. The mentioned process destroys animal habitats and causes
deforestation.
Although very useful in our everyday life, paper forms up 25% of landfill environmental
wastes. It causes pollution as the production of paper releases greenhouse gases to the
atmosphere.

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Figure 1.5: Paper and Paperboard Waste Management: 1960-2017.

Figure 1.6: Total Municipal Solid Waste (MSW) by Material, 2015.

1.2 Waste Compaction Management in Egypt

In Egypt, waste and lack of proper management of it pose serious health and
environmental problems for the country and its population. There have been some governmental
attempts to better the system of waste management since the 1960s, but those have not proven

16
sufficient until now. In the last 10 years, focus on this issue and solutions to it has increased both
from the government and civil society. Some attempts at recycling are present, and growing in
the country.

Figure 1.7: Cairo Streets drowning in waste.

Both formal and informal groups recycle and dispose about 60% of the generated solid
wastes. The remaining 40% scatters along the city avenues, streets, river, lakes, drainage
channels and illegal dumpsites. The illegal disposal of solid wastes in the water contaminated the
water in many Egyptian cities. The high level of air pollution decreased the life expectancy in
Egypt by 1.85 years, where also an estimation stated that the Ischemic coronary illness caused by
air pollution results in 67,283 deaths annually.
A report on recycled dry waste covers plastics, paper, and metals as solid waste which is
in the recycling process. However, a bulk of problems are created by not collecting wet organic
waste forms which constitute 60 percent of the total waste in Egypt.

Figure 1.8: Wastes in Egypt.

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 By March 2018, 80 million tons of garbage are collected in Egypt each year. An estimated
55.2 percent household's solid waste is collected by private companies, while 44.8 percent of the
households dispose their waste by dumping it onto the street. [7]

Figure 1.9: Waste Generation in Egypt Provinces.

Figure 1.10: MSW Composition in Egypt (2012).

Cairo has a waste problem that is too big for its public funding agencies and the
Zabbaleen waste pickers to solve by themselves. It is one of the largest cities in the world of over
17 million inhabitants, producing more than 15,000 tons of waste every day.

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 According to the World Bank, only 60% of all trash is properly collected, leading to a 0.4
– 0.6% loss of gross domestic product to the Egyptian economy as a result. A combination of
private, public and informal (Zabbaleen) collection techniques has not been able to keep up with
the growth of municipal waste, and as a result, the city is facing an environmental, health, safety,
and economic crisis that cannot be resolved through this current approach. [8]

1.3 Waste Management in Egypt

The activities involved in the management of waste from the point of generation to final
disposal can be grouped into six main phases:
1. Waste Identification
2. Handling, separation, and storage at the source
3. Collection
4. Transfer or transport
5. Processing and transformation
6. Disposal

However, a proper management of solid waste is achieved through the development and
implementation of a variety of tools such as legislations, enforcement procedures, capacity of
waste recovery and recycling, as well as the presence of infra-structures and facilities for safe
handling, treatment, and disposal of such waste.
There are basic management options that can be identified for an integrated waste
management system:
Source reduction: Reduction includes any action that reduces the volume or toxicity of
waste prior to treatment or disposal.
Waste recovery: Recycling and reuse of materials concern the recovery of certain waste
types to be used in new products, in addition to the conversion of certain types of waste into
energy.
I. Reuse
Reusing products delays the need for producing new products and land-filling the
existing ones. When reuse is possible, it is sometimes a better strategy than recycling.
Recycling requires additional energy and machinery to separate, process, and
manufacture existing products into new ones.

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 II. Recycling
Recycling refers to the removal of items from the waste stream to be used as raw
materials in the manufacture of new products. Although recycling can be profitable
and benevolent in most cases, a cost/benefit analysis must be conducted before the
recycling option is chosen, as costs of recycling versus those of land-filling greatly
vary from one place to another.

In 2017, the Government of Cairo launched a new project, “Sell your garbage” in to
reduce pollution and waste problems. The project instigated by placing 2 kiosks in Heliopolis,
Cairo, and expanded throughout the government. This inspired and encouraged people to sell
their solid wastes of Aluminum CANs, Plastic bottles, and Papers. [9]

Figure 1.11: “Sell your Garbage” Kiosks in Cairo.

Figure 1.12: Waste Prices.

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 CAIRO - 7 February 2021: In fulfillment of the directives of Egypt’s President Abdel-
Fattah El-Sisi to the government to take urgent steps to implement the new system for managing
municipal solid waste in the various governorates; ministers of environment, local development,
and planning met recently to discuss the latest developments in the municipal solid waste system.
In coordination between the governorates and the Arab Organization for Industrialization,
accumulations of garbage and waste are being lifted from 38 sites in 4 governorates, namely
Behera, Sharkia, Aswan, and Gharbia, with a total of 447,000 tons, as the accumulation of 402
has been completed with an achievement rate of 90%, and 5 has been completed. Moreover, five
fixed intermediate stations were completed in the governorates of Cairo, Beni Suef, and Beheira,
and all equipment for the intermediate stations in the first phase was 100% managed.

Regarding waste recycling factories, three production lines are being established with the
knowledge of the Ministry of Military Production in Dar Al-Salam in Suhag and Tuna Al-Jabal
in Minya, and the completion rate is about 70%. It was also agreed to develop the factories of
Mahalla and Dafra in Al-Gharbia and raise all the accumulations in the factories and establish a
new line In Mahalla, its total capacity reaches 640 tons/day and the construction of two lines in
Dafrah with a capacity of 1200 tons/day.

The Minister of Local Development also presented the plan for the system during the
current fiscal year regarding the construction of fixed and mobile intermediate stations, new
recycling lines, and sanitary landfills that will be established. The government is racing against
time to accelerate the implementation of the executive plan for the waste system at the highest
level to bring about a major change in the level of cleanliness on the Egyptian street, to achieve
the satisfaction of citizens, and to overcome all problems and challenges related to garbage and
its safe disposal through a new system for integrated waste management. [10]

The Egyptian government achieved an agreement of a project with the German Federal
Ministry for Economic Cooperation and Development (BMZ) for the period of 2019 to 2022.
The project aims to support the development of waste infrastructure in four governments, aiding
of financial cooperation and achieving structures needed. The program supports the foundation
of the Egyptian Waste Management Regulatory Authority (WMRA), which offers new types of
assistance for the waste division in participation with existing entertainers. These incorporate
approach and methodology advancement, support for and supervision of the governorates, and
the production of practical financing models. This cooperation resulted in generous commitment
to the foundation of the structure for the usage of waste segment change. This has also opened
the investment in the waste industry and resulted in plans for the Egyptian Ministry of

21
Investment and International Cooperation. This also promoted various methods of effective use
of resources, recycling and collection of waste. [11]

Figure 1.13: Egyptian-German Cooperation and GIZ.

1.4 Aim of the Project

The main objective of this thesis is to design, develop and introduce a fully
automated PLC-controlled (Aluminum Cans Compactor, and Plastic Bottles shredder)
Machine to the Egyptian industry. The desired compactor will be with one inlet port of
fixed volume to digest the required amount of compaction.
The designed machine includes a fully automated control panel that gives the
user the diversity to choose which operation to start. The operation could be compacting
Aluminum, shredding Plastic Bottles, or it can be both operations at the same time,
which will save a lot of time working on the two operations in parallel.
Saving time is one of the main objectives of the waste compactor as the fully
automated compactor saves time compared to any other method. The applied utility of
automated compactor reduces greenhouse emissions as the process of compacting
aluminum Cans, and Plastic Bottles facilitates the recycling process; therefore, carbon
dioxide emissions are eliminated which is extremely harmful for the environment. Just as
any other compactor, the fully automated PLC-controlled compactor reduces fulfilled
and occupied spaces resulting in free volume for further applications and utilities.
Saving energy is a main advantage of using a fully automated compactor as the
process of compacting and recycling the already mined aluminum saves 90% of the
energy used in extracting aluminum from the cores.

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 Chapter 2
Literature Review
2.1 Background
As stated in the previous chapter, divergent nations suffer from the waste problem.
Technology introduced smart fixations to the waste problem such as the trash compactors. This
chapter reviews and displays various previously concluded researches in the trash compactor
machines sector.
A trash compactor aims to compact Aluminum CANs and shred plastic to reduce the size
by at least 70%, which would improve recycling in Egypt. Recycling improvement results in the
reduction of pollution, and the improvement of the waste management system.

2.2 Previous Designs and Research

In the city of Kolkata, India, engineers designed a trash compactor for the same purpose
of this project. The process included placing bountiful number of compactors in the city for the
civilian’s usage. Upon the accomplishment of the compaction process, transportation transfer the
compacted bale to the dumpsite for further processing including decompression, separation, and
recycling. The drawback of this system results because of the mixed wastes, regardless of the
material, so the compressed pack of waste requires another stage of decompressing. [11]
Haswell Technology Ltd. constructed a self-trash system. The machine uses a rack pinion
mechanism that causes the pneumatic cylinder to move down and up precisely. It has a simple
system for the public to use. Although very useful and does the job quite well; however, the
mechanism requires a while to be compacted as high strength is compulsory, and the waste is
blended together unfit for recycling. [12]
Another specialized company in the manufacturing and designing of exclusive houseware
equipment, Dial Industries developed a Can Ram by applying the famous Mechanism of Crank
Rocker functions in the machine. Simply, the vertically aligned Cans fit in the space, and then
the operator compresses the Cans by using the handle. [13]
In a recent study conducted by J. Becker, C. Ponce, J. Rodríguez, D. Vázquez and H.
Ponce (2017), they proposed an automatic waste compactor system, that distinguishes when a
can is in a specific container thus is then reduced in size using a small cylinder and could then be
shut down automatically when there are no Cans available. The system is also equipped a feature
that knows when the container is stocked thus stops any further operation in expectation of
unfilled again.

23
 The essential inputs of the system include an electric power feeding the full system, and
the Cans. The outputs are the packed processed waste. In case the system output is full, the
system controller receives an alert signal. At first, the system begins with observing the can in
the feeder then crushing by the compactor. This sequence repeats itself until the controller
receives a signal stating the fulfillment of the container. [14]
Although some limitations and problems took place while testing, such as the random
blockage of Cans at the feeder after compressing the Cans next in the line. This was occurring, as
the last put can had no pressure above to advance it to the correct position at the instance of
insertion to the compression chamber. Successfully, the study accomplished the desired aim and
the machine operated flawlessly as expected. The machine reduced the original-uncrushed Cans
volume by 70%. [15]

2.3 United States Patents

Since 1970s, the United States Patent and Trademark Office issued numerous patents of
Trash compactor designs.
The inventors of a design, Dario J. Moriconi, Bloomfield Hills, and Mich designed a
trash compactor that aims to cut down transportation costs and to manage waste problem. Their
design included a simplified design of the compactor along with a schematic diagram for the
electrical circuit. [16]

Figure 2.1: The Trash compactor side-elevated view.

24
Figure 2.2: The Trash compactor Schematic Wiring Diagram.

A level sensitive waste compactor was introduced in 1999 by James Ernest Gawley,
Bowmanville; Charlotte Mary-Anne May; Glenn, Emile Rochon, both of Keswick, all of (CA).
A sensor opens the inlet door when the signal is processed. Another sensor measures the gauge
level of the waste in the compactor. When enough waste is collected, the compression begins to
compress the waste. The compression unit uses the mechanism of scissors having a side of the
scissor’s mechanism held on one plane. [17]

Figure 2.3: Design of the Compactor and the Mechanism used.

25
 Richard W. Steinberg; Samuel B, McClocklin; Clarence L. Kostelecky, all of Owatonna,
Minn, have also implemented a waste compactor. Their target was to produce a new compactor
with enhanced results to the industry of compactors with the addition of several unique features.
The compactor uses a motor, which applies fixed force to the waste. The compactor has a case
and is accessible from the front receiving the waste. The compactor uses both hydraulic and
electrical control for safety measures of the machine with a determined force that is applied to
the waste for a specific period. [18]

Figure 2.4: Front and side view the compactor.

Figure 2.5: Hydraulic operating circuit and the electrical control circuit of the compactor.

26
2.4 Inventions’ System of Operation
The basic idea behind any hydraulic system is very simple: Force, applied at one point,
flows to another point using an incompressible fluid such as hydraulic oil. Hydraulic fluid
molecules are able to resist compression under heavy load hence the experience minimal energy
loss and directly transfers work applied to the actuating surfaces. As opposed to pneumatic
system, which uses air, a leakage in a hydraulic system is easier to spot during ground
maintenance operations. Hydraulic fluid operates very well in a very hot working environment, it
is able to sustain its airworthiness viscosity, density & fluid temperature even if it subjected
under extreme heat. Hydraulic systems allow operators to accurately huge amounts of power
with little input force. They also provide constant force, according to the National Fluid Power
Association. [19]
Hydraulic system is susceptible to contaminations & foreign object damage (FOD).
Mishandling and constant exposure to hydraulic fluid and its gas fumes without proper
equipment and precautions is a health risk. If disposed improperly, a hydraulic fluid is an
environmental risk. Hydraulic systems contain highly pressurized fluid. This can cause burns,
bruises or the accidental injection of fluid into the body, according to Colorado State University.
Hydraulic systems require periodical checks for leaks and lubrication, and filters require regular
change. Removing solids from the power fluid is very important for positive displacement pumps.
[20]
From the proposed mechanisms, the most suitable system of operation is the hydraulic
system, as it is the best fitting system to the trash compactor. As it produces large enough power
to compress the garbage with small input, and with a high ratio of power to weight, which gives
a chance to have a lighter machine. Also, the high torque to mass and high force to inertia ratio,
which result in high acceleration capability and a rapid response of the hydraulic motors. The
ability to apply a simple protection against overloading is one of the major advantages of the
hydraulic system, which gave it competitive edge against the other systems, as it is a huge safety
consideration in compacting garbage. Incompressible items within the garbage at the compacting
chamber could cause some serious damage to the machine if not dealt with correctly. This also
applies to the safeguarding against explosion using the valves and sensors that sense the increase
in pressure inside the system and then relives the extra pressure, to prevent explosion. [21]

27
 Chapter 3
Mechanical Design
3.1 Introduction
This chapter elaborates the general proposed mechanical design of the hydraulic
Compacter and Shredder Machine. It offers a detailed explanation of each of the two machines’
sequence, and a precise description of the components and parts that created the Compactor and
Shredder. It offers 2-Dimensional sketches for all the machine parts. The chapter conducts some
calculations in order to define various mechanical and fluid features. The calculations are done
for the compaction compartment letting the operator know the amount of Aluminum CANs that
can be loaded into the chamber.
In order to achieve the desired stability of the system, the stability of the design required
several analysis including Stress, Strain and Deformation tests. The calculations analyzed both
stress analysis and axial forces applied on the compactor surface and the compaction plate.
Calculations identified the required system pressure of operation and the required hydraulic
cylinders diameters as well. The calculations help define the Compactor’s efficiency and
Shredder’s efficiency.

3.2 General Machine Design

The Machine consists of two main compartments. The first compartment is the
Aluminum CANs Compartment, where the cans’ inlet is located as well as the compacting
chamber and the compaction unit. The hydraulic power unit, also known as hydraulic power
pack, includes a motor, and a pump to apply the hydraulic pressure required for the designed
hydraulic system. The second compartment is the Plastic Shredding Compartment, where the
plastic shredder and the outlet box are located.

Figure 3.1: Compactor and Shredder Machine.

28
 First of all, the operator loads the Aluminum CANs into the compacting chamber until the
proximity level sensor emits a signal that the determined compacting volume inside the chamber
is reached. Second, the process begins by the automatic extension of the compacting cylinder
attached to the compacting plate. As the compacting cylinder on the compacting plate applies
axial force, any external vibrations or misalignment may result in the failure of the compacting
unit including both the compacting cylinder and the compacting plate. Upon the accomplishment
of the compaction process, the compacting cylinder retracts, and the outlet door opens. Last but
not least, located beneath the Shredding Compartment is the delivery cylinder. The cylinder
extends to deliver the compacted bale outside of the chamber.

Figure 3.2: Aluminum CANs Compaction Process into Facilitated Steps.

The Plastic Compartment, located next to the aluminum CANs compartment, consists of
a Plastic Shredder to shred PET Bottles of different sizes. Firstly, the operator will start loading
the plastic bottles into the safety box that then fall on to the shredder. When the capacitive sensor
on the shredder detects a plastic bottle, the motor will start working, causing the shafts that have
the blades on them to rotate. The shredder will outset shredding the plastic bottles and
immediately upon accomplishing shredding, when the proximity sensor inside the outlet box
detects that the determined volume is reached. The system will stop operating and the operator

29
will remove the outlet box with the shredded plastic inside of it. The box has a detachable base
that will be removed in order for the shredded plastic to fall into the delivery box, that is placed
below the outlet box.

Figure 3.3: Plastic Shredding Process into Facilitated Steps.

30
Figure 3.4.a: Compactor and Shredder Machine.

Figure 3.4.b: Compactor and Shredder Machine.

31
Figure 3.4.c: Compactor and Shredder Machine.

Table 3.1: Machine Components and Parts

Component Number Component Description

1 Inlet

2 Outlet Door

3 Pump

4 Cylinder A

5 START Button

6 STOP Button

32
7 Shredder Motor

8 Outlet Box

9 Machine’s Base

10 Shredder

11 Optical Sensor S3

12 Inductive Sensor A1
13 Inductive Sensor A2

14 Inductive Sensor B1

15 Cylinder B

16 Capacitive Sensor S4

17 Oil Level Sensor S1

18 Pressure Sensor S0

19 Emergency Push Button

20 Optical Sensor S2
21 Magnetic Door Lock

33
3.2.1 Compactor and Shredder Machine Setting and Formation

3.2.1.1 Aluminum CANs Compartment

The aluminum CANs compartment includes the aluminum CANs inlet, where the
operator will load the aluminum CANs through in order to fill the compacting chamber
until the determined volume is reached.
End of Cylinder A piston rod is the Compressing plate, as the cylinder extends
allowing the initiation of the compacting process and retracts automatically once the
process is accomplished.
At the accomplishment of the compacting process, the operator accesses the
outlet door after the automatic release of the magnetic lock, this process is followed by
the extension of cylinder B to displace the compacted ballet out of the compacting
chamber for further recycling processes.

Figure 3.5: Exploded View of the Aluminum CANs Compartment.

34
3.2.1.2 Plastic Compartment
The mechanical design of the shredder consists of a safety box that aims to secure the
operator when he or she throws a bottle into the shredder. The shredding compartment connected
to a motor that starts operating when a plastic bottle is detected. There exists an outlet box where
the shredded plastic falls. The outlet box’s detachable base opens for the shredded plastic to fall
into the delivery box.

Figure 3.6: Exploded View of the Shredding Machine Compartment.

35
3.2.1.3 Shredder and Compactor Machine Views

Figure 3.7: Top View of the Machine.

Figure 3.8: Front View of the Machine.

36
Figure 3.9: Rear View of Machine.

3.2.2 2-D Dimensional Sketches with Detailed Explanation

3.2.2.1 Aluminum CANs Compartment

The compartment contains:
• Aluminum CANs Compactor’s Base.
• Inlet Door.
• Outlet Door.
• Cylinder A (Compacting Cylinder).
• Cylinder B (Delivery Cylinder).

3.2.2.2 Aluminum CANs Compactor’s Base

The Aluminum CANs Compacting Machine includes the machine’s base, located inside
the compaction chamber. It is the seat where the cans are thrown into through the inlet before the
compaction process and also where the cans stay after they become a compacted bale waiting for
the delivery cylinder to deliver them out of the chamber.

37
 (b)

(a)

Figure 3.10: (a) Aluminum CANs Compactor’s Base 2-Dimensional Sketch. (b) Compactor’s
Base.

38
3.2.2.3 Inlet Door
The inlet is located on left side of the machine, where the operator fills the
compaction chamber with Aluminum CANs through for the compaction process.

(b)

(a)

Figure 3.11: (a) Compactor’s Inlet Door 2-Dimensional Sketch. (b) Compactor’s Inlet Door.

39
3.2.2.4 Outlet Door

This door is known as the outlet door or else known as the delivery door, where after the
compacting process comes to an end the magnetic door lock is deactivated and the operator
becomes capable of opening the door that leads to the automatic extension of the delivery
cylinder that pushes the compacted cube out of this door.

(b)

(a)

40
Figure 3.12: (a) Compactor’s Outlet Door 2-Dimensional Sketches. (b) Compactor’s Outlet Door.

3.2.2.5 Cylinder A
Cylinder A, also known as the compacting cylinder, is attached to a compacting plate.
It operates as follows after Aluminum CANs fill the chamber with the required volume. Cylinder
A extends and compresses the cans into a compacted cube.

(b)

(a)
Figure 3.13: (a) Cylinder A 2-Dimensional Sketches. (b) Cylinder A.

41
3.2.2.6 Cylinder B
Cylinder B, also known as the delivery cylinder, is located below the shredder’s
compartment. The cylinder is normally retracted and operates as follows. After the retraction of
Cylinder A, the magnetic door lock deactivates and the outlet door opens. Then the cylinder
automatically extends is to deliver the compressed cans’ cube outside of the compacting chamber,
but the cylinder retracts manually by pressing on the retraction button located on the control
panel.

(b)

(a)

Figure 3.14: (a) Cylinder B’s 2-Dimensional Sketch. (b) Cylinder B.

42
3.2.2.7 Plastic Shredder Compartment
The compartment contains:
• Safety Box.
• Shredder.
• Shredder’s Box.
• Shredder’s Motor.
• Shredder’s Outlet Box.
• Shredder’s Body Structure.
• Blades.
• Spacers.
• Shaft.
• Ball Bearings.
• Gears.
• Supports.

3.2.2.8 Safety Box

This safety box is used to prevent the operators from harming themselves by being in
very close contact with the shredder. It is located above the shredder. The operator throws a
Plastic Bottle into the safety box and then the bottle falls into the shredder.

(b)

(a)

43
Figure 3.15: (a) Shredder’s Safety Box 2-Dimensional Sketch. (b) Shredder’s Safety Box.

3.2.2.9 Shredder
The shredder is the main part of the whole process. This is where the whole
operation takes place. As the PET bottles fall on to the shredder, the motor receives a
signal to start operating leading to the shafts’ movement that cause the shredding of the
plastic into pieces and for it to be ready for recycling.

(b)

(a)
Figure 3.16: (a) Shredder’s 2-Dimensional Sketch. (b) Shredder.

3.2.2.10 Shredder’s Box

This is the compartment where the shredder lies inside. Figure [3.16] below shows a normal
rectangular sheet metal that is found on both sides of the shredder, while Figure [3.17] shows
another sheet metal that has two circular holes in it, which are used for the shafts to be placed
through and the for the gears to be located at.

44
Figure 3.17: Shredder’s Box Sides 2-Dimensional Sketches.

Figure 3.18: Shredder’s Box Sides 2-Dimensional Sketches.

3.2.2.11 Shredder’s Motor

The motor is responsible to start the whole operation. When the sensor found on the
shredder senses the plastic bottles, it sends a signal to the motor and the motor starts operating.

45
 The motor causes the shafts’
rotation which leads to the
motion of the blade cutters that
shred the PET Bottles.

(b)

(a)
Figure 3.19: (a) Shredder Motor 2-Dimensional Sketch. (b) Shredder Motor

3.2.2.12 Shredder’s Outlet Box

After the plastic is shredded in the previous step inside the shredder, the plastic falls through
a hole created beneath the shredded that finds its way down into the outlet box. The box has a
sensor located on it that tells when the desired volume is reached and that the whole operation
should come to an end.

46
 (b)

(a)
Figure 3.20: (a) Shredder’s Outlet Box 2-Dimensional Sketch. (b) Shredder’s Outlet Box.

3.2.2.13 Shredder’s Body Structure

The shredder’s body structure is base, where the shredder and the motor sit on.
The outlet box is located inside this body. The structure has a hole designed in it ,
located beneath the shredder, so the plastic can fall through it directly into the outlet box.

(b)

(a)
Figure 3.21: (a) Shredder’s Body Structure 2-Dimensional Sketch. (b) Shredder’s Body Structure

47
3.2.2.14 Blades
The blades are also known as the teeth, that make the shredding of the PET
Bottles possible, are found inside the shredder. The blades lay on the shafts. They start
shredding the plastic based on the rotation of the shafts. The shafts start rotating when
the motor starts operating.

(b)

(a)

Figure 3.22: (a) Blades 2-Dimensional Sketch. (b) Blades.

3.2.2.15 Spacers
Each tooth on the rotating shaft is separated by spacers and are at an offset angle that
prevents the teeth from interlocking with one another.

48
 (b)

(a)
Figure 3.23: (a) Spacers 2-Dimensional Sketch. (b) Spacers.

3.2.2.16 Shaft
The shaft carries the gears, blades and spacers to transmit rotary motion. The rotary motion of
the shafts relies completely on the start of the motor’s operation.

49
Figure 3.24: Shaft 2-Dimensional Sketch.

3.2.2.17 Bearings
They are used to reduce the friction and allow smoother rotation. In other words, this will help
prevent friction that will occur in between the shaft and the gear box hole.

Figure 3.25: Ball Bearings’ 2-Dimensional Sketch.

3.2.2.18 Gears
The shredder has two main counter-rotating shafts on which the shredding elements called
knives are attached. Each element is independently controlled by a gear unit.

50
Figure 3.26: Gears 2-Dimensional Sketch.

3.2.2.19 Supports
Aids or in other words supports the blades to tighten their clamping on the plastic to shred it
into smaller pieces.

Figure 3.27: Supports 2-Dimensional Sketch.

3.3 Design Calculations and Analysis

There were several conducted calculations to find several unknowns required for the
design of the Compactor and Shredder Machine. The calculations mainly focused at the
Aluminum Compactor.

51
 The most commonly utilized Aluminum CAN in the Egyptian industry comes with a
height of 0.145 meters and a radius of 0.0325 meters. The nominal volume of the Cans is 330 ml.
Both parameters determine the volume of the can using the equation:

(m3) meter cube. (Equation 4.1)

As shown in Chapter 3.2, the compaction process occurs in a cuboid shaped chamber.
The length, width and height calculate the area of the compaction chamber. The following
equation determine the values of the length, width, and height.

(m3) meter cube. (Equation 4.2)

Using both, equations 4.1 and 4.2 determine the values of both volumes. Dividing the
results of (equation 4.1) and (equation 4.2) results in another equation that determines the
maximum number of aluminum CANs inside the chamber.

(Equation 4.3)

The next required variables are the diameters of both the bore and the rod. Based on a
previous Trash Compactor Design, the Piston Bore Diameter was 0.1016 meters [m] and the
Piston Rod Diameter was 0.05 meters [m].
(Piston Diameter/Piston Rod - Stroke) defines the size of a cylinder in meter[m].

A= d2= = 8.107×10-3 m²

d= ((4×A/ +d2)1/2 = ((4×8.107×10-3)/ +0.052)1/2= 0.1132 m²

The working pressure as well as the maximum pressure of the system are important
parameters of any system. Most of Trash Compactors operate with a pressure of 130 bars, along
with a maximum pressure of 150 bars. The proposed Trash Compactor utilizes both parameters.
The next equation finds the force exerted on the hydraulic cylinders.

(N/m2) newton per square meter. (Equation 4.4)

Rearranging (equation 4.4) for Force, the cross-sectional area of contact must be
multiplied by the maximum pressure of the system to determine the maximum force on the
system. AISI 317 Stainless Steel builds the compacting plate. This material has a plate weight
per unit area of 410.092882 Kg/m2 for a thickness of 0.05 meters. The area of compacting plate
is 0.25 m2, resulting in a weight of 100 N for the compacting plate.

52
Based on a research, the average force required to crush an aluminum CAN is 250 N.

(m3/s) meter cube per second (Equation 4.5)

The pump utilized in the Trash Compactor Machine provides a flowrate of 25 liters per minute.
Another hydraulic system data is the Power, obtained by solving the following equation.

(W) Watts (Equation 4.6)

3.3.1 Results of Design Calculations

2
Using (Equation 4.1): Volume of Can= ×0.145= 4.81×10-4 m3
Using (Equation 4.2): Volume of Compaction Chamber= 0.5×0.5×0.8= 0.2 m3
Using (Equation 4.3): Number of Cans= 0.2 / 4.81×10-4= 415*
Force Required to Crush all cans = 250 N × 300 Cans = 87500 N
Using (Equation 4.4):

5
Maximum Force for Extension= 150 × =169050 N

Using (Equation 4.4):

5
Maximum Force for Retraction= 150 × =74105.9 N

Using (Equation 4.6):

Velocity of Cylinder ( ) = 4.16×10-4/ = 0.0413 m/s

Q=( ) A = 0.0842 = 6.82x10-4 m3/s

Using (Equation 4.7): Total Power during extension= 169050 ×0.0413 = 6987.5 W
Using (Equation 4.7): Total Power during Retraction= 92157.4 ×0.0842 = 7759.6W

*For safety measures and volume losses, the number of Cans will be 350*.

3.4 SolidWorks Analysis

This section shows the Compactor and Shredder Machine design on the SOLIDWORKS
software to run a simulation to determine whether the design is stable when applying the

53
maximum force and pressure required and to examine the deformation happening on the
structure of the design using stress analysis studies.
Examining stability of the design required several analysis including Stress, Strain and
Deformation tests. Alloy Steel serves as the material of the Compactor Machine. It has an Elastic
Modulus of 210000 N/mm2, Tensile and Compressive Strength of 723.8256 N/mm2, and a Yield
Strength of 620.422 N/mm2.

3.4.1 Stress Analysis

Stress, calculated using dividing the Force by Area and has the units of Pascal, is the pressure a
material is sensing in response to an applied load. This load scatters throughout the material
based on the stiffness. Figure [3.28] shows the stress analysis done on the body of the waste
compactor machine due to the acting force on the cross-sectional area. The maximum

stress based on Von Mises on the body is 2.589 10-9 N/m2 on the shown area in the figure.

Figure 3.28: SolidWorks Stress Analysis of the Compactor Machine.

54
3.4.2 Strain Analysis
Strain, which is calculated by and defined to be the Change in Length from Applied
Force divided by the Original Length and is unit less, is strain is a measure of geometric response
and the change in shape due to applied forces. Figure [3.29] shows the strain analysis done on
the body of the waste compactor machine due to the acting force on the cross-sectional area. The
maximum strain on the body is 7.99 10-2 ESTRN (Equivalent strain) on the shown area in the
figure.

Figure 3.29: SolidWorks Strain Analysis of the Compactor Machine.

3.4.3 Displacement Analysis

The machine has a maximum deformation is 2.14687 meters shown in Figure 3.29.

55
Figure 3.30: SolidWorks Displacement Analysis of the Compactor Machine.

3.4.4 Analysis Conclusion

Based on all three conducted tests above, the results of the tests prove that the material
chosen for the waste compactor is compatible with the machine parameters of forces, pressure
and areas chosen.

3.5 Performance Evaluation of the Compactor and Shredder Machine

This section shows the calculated efficiency of the machine for both the compaction and
shredding modes. The calculations included various assumptions to get a closer value to the
realistic working efficiency of the Compactor and Shredder Machine.

3.5.1 Compaction Mode Efficiency

Based on the performed calculations, a maximum number of 350 Aluminum Cans can fit
inside the compaction chamber and assuming that it would consume approximately 700 seconds
to entirely fill the chamber with Aluminum Cans through the inlet of the aluminum compaction
chamber.
The average weight of one empty aluminum Can is 0.0149 kilograms. This means that a
compacted bale contains average of 4.47 kilograms of compacted aluminum.
Upon the fulfillment of the compaction chamber, pressing the START button and the
selection of the compaction mode, the hydraulic piston responsible of the compaction of the
Cans will extend. Based on previous calculations, the process of the extension consumes 10
seconds until reaching the pressure relief value, and 5 seconds to retract back to its initial
position.

56
 Followed by 10 seconds of extension of the bale delivery piston to empty the chamber,
and six more seconds to retract the bale delivery piston. The total time of one cycle of the
compaction process is 646 seconds. For safety measures and any errors that might occur,
calculations approximated the time value must to 800 seconds. If it takes 800 seconds for
producing one bale of compacted aluminum Cans, the following equation approximately finds
the number of bales produced per hour.

(Equation 4.8)

The next equation finds approximately how many produced kilograms of compacted aluminum
per hour.

(Equation
4.9)

3.5.1.1 Compaction Efficiency Calculations

Using (equation 4.9): Number of bales per hour= = 4.5 ≈ 4 bales

Using (equation 4.10):

Weight of compacted aluminum per hour = = 20.1 kilos

3.5.2 Shredding Mode Efficiency

Assuming the most commonly used plastic bottle, the efficiency calculations of the
shredder examine the 0.5 liters plastic bottles. On average, the 0.5 liters plastic bottles weigh
approximately 0.0099 kg.
The following equations and analysis determine and conclude the efficiency of the shredder.

(Equation 4.10)

(Equation 4.11)
If the time it takes for one complete cycle of the shredding process appears, we can then evaluate
the time needed for the complete shredding cycle if we determine the number of bottles required.
The shredding time, defined to be the maximum seconds it would take the shredder to
shred each plastic bottle, consumes 5 seconds, which is the average time it takes to shred a 0.5
liters plastic bottle.

57
Since each 0.5 liters bottle weigh 0.0099 kg, and the analysis require 5 kg for the cycle to be
completed, then we can approximately conclude how many bottles we require for the cycle to be
completed.

(Equation 4.12)

Using all the above equations estimates the efficiency of the shredder to evaluate the
performance and the approximate output.

(Equation
4.13)

3.5.2.1 Shredder Efficiency Calculations

Using (equation 4.10): Total Shredding Process Time= = 250 seconds

Using (equation 4.11): Time of 1 cycle = = 150 seconds ≈ 250 seconds

Using (equation 4.12): Number of bottles = = 303.03 bottles ≈ 310 bottles

Using (equation 4.13):

Weight of shredded plastic per hour = = 43.2 Kilograms

58
 Chapter 4
Hydraulic Design
4.1 Introduction
This chapter focuses on the detailed overview of the Trash Compactor Machine
Hydraulic System as it provides a comprehensive explanation for all the utilized hydraulic
components including features and specifications. Since the shredding process doesn’t require
hydraulic components, the focus will be on the compaction’s hydraulic components.

4.2 Hydraulic Components

Figure 4.1: Hydraulic Circuit.

The designed hydraulic circuit of the Compactor and Shredder Machine includes a total
number of two hydraulic double acting cylinders used on the compacting compartment of the
machine. One of the hydraulic cylinders forms the compaction unit in accompany with the
compaction plate. This cylinder is used to compact the Aluminum CANs found inside the

59
compaction chamber. Following the sequence of operation, the bale delivery hydraulic cylinder
extends to transfer the compacted bale outside of the compaction chamber upon the
accomplishment of the operation.

Table 4.1: Hydraulic Components

Component Number Label Quantity

1 Double Acting Cylinder 2
2 4/2-Way Valve Solenoid 2
3 Pump Unit 1
4 Pressure Relief Valve 1
5 Tank 1

Table 4.2: Function of each Hydraulic Component

Quantity Component Function
1 Compacting Cylinder Compaction of Aluminum Cans
1 Bale Delivery Cylinder Transferring the bale outside of the compacting chamber

4.2.1 Double Acting Hydraulic Cylinder

A hydraulic cylinder is a linear actuator powered by hydrostatic energy. A linear actuator
is a mechanical device engineered to create force in a straight line, either extending or retracting.
Hydrostatic energy is the motivation generating the cylinder’s ability to create linear force, and
the hydraulic pump generates the hydrostatic energy. Hydraulic energy is a combination of
pressurized fluid and the volume or rate the fluid moves at, expressed as pressure and flow
respectively.
A double-acting cylinder is a cylinder in which the active fluid acts on both sides of the
piston depending on the mode of operation wither extension or retraction. It has a port at each
end, equipped with hydraulic fluid for both the extension and retraction of the piston. Double-
acting hydraulic cylinder must have ports at the head and rod ends. Pumping oil into the head
end moves a piston to extend a rod while any oil in the rod end flows out and returns to the
reservoir. Reversing the operation results in retracting the rod. Oil from a pump goes into a rod
end, and a connected head-end port returns the flow. The flow direction to and from a double-
acting cylinder can be controlled by a double-acting directional valve or by actuating a control of
a reversible pump.

60
Figure 4.2: Double Acting Hydraulic Cylinder.

4.2.2 4/2 Way-Solenoid Valve

A 4/2-Way Directional Control Solenoid Valve consists of two switching positions for
controlling the flow rates. A DC solenoid coil directly actuates the valve. If the left sided
solenoid is activated, the left chamber will be the activated chamber, if the right sided solenoid is
activated, the right chamber will be the activated chamber. The initial position of the Valve
depends on the application and whether the hydraulic piston status; normally extended or
retracted.

Letters identifying the Valve ports:

• A, B Working Ports.
• P Supply Port.
• T Return-Line Port (Tank Connection).

Figure 4.3: 4/2-Way Solenoid.

4.2.3 Pressure Relief Valve

A Pressure Relief Valve is a safety valve that functions in controlling or limiting the
maximum pressure reached in the fluid power system; pressure could otherwise build up and
might result in a failure in the hydraulic system or even the destruction of hydraulic components.

61
Pressure relieving occurs by rerouting all or some of the output flow of pump back to the
reservoir alternatively than allowing it to advance to flow into the system.
In many systems, pressure relief valves in combination with a pump provide a source of
flow at constant pressure. The pressure Relief Valve must open at a predetermined set pressure,
flow a rated capacity at a specified overpressure, and close when the system pressure has
returned to a safe level. Designed with materials compatible with many process fluids, Pressure
Relief Valves operate in a consistently smooth and stable manner on a variety of fluids and fluid
phases.

Figure 4.4: Pressure Relief Valve.

4.2.4 Hydraulic Flexible Hoses

A hydraulic hose conveys hydraulic fluid to or among hydraulic components, valves,
actuators, and tools. It is typically flexible, often reinforced, and usually constructed with several
layers of reinforcement since hydraulic systems frequently operate at high or very high pressures.
Hydraulic hose applies in a variety of industrial hydraulic systems. Dimensions, performance
specifications, construction options, and features are important parameters to consider when
searching for hydraulic hose.

Figure 4.5: Hydraulic Flexible Hoses.

62
 Chapter 5
Controller Design
5.1 Introduction
This chapter explains the controller of the Compactor and Shredder Machine. Divided into
five main sections, the controller includes hydraulic and electro-mechanical circuit lab
simulation, general block diagram of the machine, a flow chart that demonstrates the different
cycles of operation, a list of components and actuators of the Trash Compactor Machine, and a
comprehensive explanation for all the utilized components mentioned in the list.

5.2 Hydraulic and Electro-Mechanical Circuit Lab Simulation

Connecting with the designed automated system of the Compactor and Shredder
Machine, the Electro-Mechanical Circuit, shown in Figure [5.1], contains both electrical and
mechanical parameters of the designed system. The circuit contains thirty electrically controlled
relays transmitting signals to each corresponding solenoid valve, sensors, key switch, push
buttons and pump. The Electro-Mechanical Circuit includes normally open and normally closed
switches to eliminate overlapping of operations on each other; for example, when pressing the
retraction push button during the operation of extension, the extension operation will be
deactivated first then the operation of retraction will occur.

63
 BOX PLASTIC_DETECT
START E.STOP RESET SHRED PLASTIC_LEVEL

K1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
+24V

3 3 3 3 3
3 3 3 4 3 3 3 3 3 1
3 3 K5 K6 3 K11
K1 K3 K5 K12 K13
K2 K11
K1 K2
4 4 4 4 4
4 4 4 4 4 4 4 2
4 4 4 3

K13

K13
1 1 3 1 1
4
K18 K11
K2 K3 3 K11

2 2 K1 4 2 2

Shred. Motor
3

E.Stop

Reset
K12

Start

Shred
4
A1 A1 A1 A1 A1 A1 A1

K1 K2 K3 K5 M K11 K12 K13

A2 A2 A2 A2 A2 A2 A2

0V

2 1 4 3 13 9 15 17 8 8
6 12 14 19 19 17
8 21 21
11

Figure 5.1.a: Hydraulic and Electro-Mechanical Control Circuit of the Shredding Mode.

A2 B1
CAN_LEVEL A1
START E.STOP RESET COMP OIL DOOR EXTENSION_B
PRESSURE
K1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
+24V

3 3 3 3 3 3 3 3 3 3 3
3 3 3 4 3 3 3 3 3 3 1 BN 3 3 3 3 3 3 3 1 3 3
3 3 K4 K6 K8 K9 3
K1 K2 K3 K7 K14 K15 K19 K16 K17 K18
K4 K8 BK K14 K15 K15 K16 K17 K19 K20 K17
K1 K2 K12
4 4 4 4 4 4 4 4 4 4 4 4
4 4 4 4 4 4 4 4 2 4 4 1 4 1 4 1 4 1 4 1 2 4 4
4 4 4
BU
K16 K17 K17 K16 K13
3
2 2 2 K19 3 2 2
1
3 K9
K19 4
1 4
3 K4 32
1 1
4 K15
K10 K10 K14
K20
2
43 4
12 BE BR 2
1 1
K8 AE AR
K10
K17 K17
43
1 1 1 1 3 2 3
2 2
K7 K4 3
K2 K3 K7 K17 K9 K5
3
4 4
2 2 2 2 4 4
1 3 3 1 K4

K17 K4 K10 K10 4

23 4 4 2

K1
E.Stop

Reset
Start

Co mp

DOOR-LOCK
4

Retraction B
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1

K1 K2 K3 M K7 K8 K9 K10 K14 K15 K19 K16 K17 K18 K20

K4
A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2

0V

2 1 4 3 13 9 15 8 15 8 21 32 8 40 24 24 27 25 29 27 32 8 35 38 32 41
6 12 14 17 19 24 34 25 25 28 39 33 35 33 17 36
8 15 32 27 30 19 42
11 24 21
27 29
39 32

Figure 5.1.b: Hydraulic and Electro-Mechanical Control Circuit of the Shredding Mode.

64
 A2 B1
CAN_LEVEL BOX PLASTIC_DETECT A1
START E.STOP RESET COMP SHRED OIL DOOR PLASTIC_LEVEL EXTENSION_B
BOTH PRESSURE
K1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57
+24V

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
3 3 3 4 3 3 3 3 3 3 3 3 3 3 1 1 BN 3 3 3 3 3 3 3 1 3 3
3 3 K4 K6 K5 K6 K8 K9 K11 3
K7
K6 4 K1 K2 K3 K4 K5 K6 K11 K8 BK K12 K13 K14
K14
K15
K15
K19
K15
K16
K16
K17
K17
K18
K19 K20 K17
K1 K2 K12
4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4
4 4 4 4 4 4 4 4 4 4 4 4 2 2 4 4 1 4 1 4 1 4 1 4 1 2 4 4
4 4 3 4
BU
K16 K17 K17 K16 K13
K13
3
2 2 2 K19 3 2 2
4 1
3 K9
K19 4
1 4
3 K4 32
1 1
4 K15
K10 3 K10
K20 K14
K13 2
43 4
12 BE BR 2
3 1 1
K8 43 AE AR
K13 K10
K17 K17
43 K12
1 1 3 1 1 1 1 3 2 3
4 2 2
K7 4 K11 K4
K2 K3 K18 K7 K17 K9 3 K5
3 K11
3
4 4
2 2 K1 4 2 2 2 2 4 4
1 3 3 1 K4
3
K17 4 K4 K10 K10
Shred. Motor

K9 4

23 3 4 4 2
4
3
K1
E.Stop

K12
Reset

DOOR-LOCK
Start

Shred
Co mp

Pu mp
Bo th

K1
4 4

Retraction B
A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1
4
K1 K2 K3 K5 K6 M M K7 K8 K9 K10 K11 K12 K13 K14 K15 K19 K16 K17 K18 K20
K4
A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 A2

0V

2 1 4 3 18 9 12 10 23 8 23 8 14 46 8 22 32 11 52 11 54 38 38 41 39 43 41 46 8 49 22 46 55
6 17 19 20 13 25 27 29 48 39 34 14 14 39 42 53 47 49 47 25 50 52
8 23 51 15 38 41 36 34 32 44 27 56
11 38 21 46 51 36 29
14 41 43
16 53 46

Figure 5.1.c: Hydraulic and Electro-Mechanical Control Circuit of the Compaction and
Shredding Mode.

5.3 General Block Diagram

The general block diagram of the Trash Compactor Machine analyzes the different input
devices, transmitted signals to the controller, as well as the output devices connected to the
controller. Consisting of 18 different inputs and 43 outputs, the general block diagram of the
Compactor and Shredder Machine is capable of sensing the level of Aluminum CANs inside the
compacting chamber, the operating pressure inside the compacting chamber, plastic bottles
placed into the shredder, the weight of the box that receives the shredded plastic parts. The
general block diagram can also determine the extension and retraction positions of the hydraulic
cylinders. The input devices include 8 sensors, 1 switch key, 1 magnetic door lock, 2 magnetic
reed switches and 6 pushbuttons, each having a specific function. The output devices include 7
LEDs, one electric motor, one pump and electrically controlled solenoid valves. The applied
controller processes and saves the input data. The controller operates the different output devices
through a relay interface circuit, the relays sum up to a total of 30 relays.

65
Figure 5.2: General Block Diagram of the Compactor and Shredder Machine.
The following table 5.1 explains all the symbols included in the general block diagram of the
Compactor and Shredder Machine.

Table 5.1: Block Diagram Contents

Label Type Function

Start Switch Key Initiates the selected mode of operation.
E-Stop Push Button Stops the machine in case of emergency.
Reset Push Button Resets the machine after an emergency occurs.
Compact Push Button Initiates the selected Compaction mode.
Shred Push Button Initiates the selected Shredding mode.
Both Push Button Initiates both the Shredding and Compaction mode.

66
Retract-B Push Button Retracts the delivery cylinder, Cylinder B, after it
delivers the compacted bale.
Door-Lock Magnetic Door Lock Used on the outlet door to keep it closed and makes it
impossible for the door to be opened during the
compaction process.
S0 Analog Pressure Detects if the pump’s pressure increases or decreases
Sensor than the normal pressure of the system.
S1 Oil Level Sensor Detects if the oil level inside the tank decreases that the
determined level.
S2 Optical Sensor It is the CAN-LEVEL sensor. The operator fills the cans
through the inlet door, the sensor is responsible to detect
when the cans reach their required volume and by then
the operator will stop filling the chamber.
S3 Optical Sensor It is the PLASTIC-LEVEL sensor. It is responsible to
detect when the shredded plastic reaches its desired
volume inside the outlet box. Sending a signal to
S4 Capacitive Sensor It is the PLASTIC-DETECT sensor. It is responsible to
detect when a plastic bottle reaches the shredder and
then it emits a signal to the motor to start working
making the shredder starts shredding the plastic bottle.
S5 Inductive Sensor Placed on the compaction cylinder’s extension port to
detect if the extension occurs.
S6 Inductive Sensor Placed on the compaction cylinder’s retraction port to
detect if the retraction occurs.

S7 Inductive Sensor Placed on the delivery cylinder’s extension port to detect

if the extension occurs.
Door Magnetic Reed Switch Detects if the outlet door is closed or opened.
Box Magnetic Reed Switch Detects if the outlet box is closed or opened.
LED-1 Indicator Lights up when the START push button is pressed.
LED-2 Indicator Lights up in case of an emergency occurring.
LED-3 Indicator Lights up when RESET button is pressed on.
LED-4 Indicator Lights up when Compaction Mode is chosen.
LED-5 Indicator Lights up when Shredding Mode is chosen.

67
LED-6 Indicator Lights up when both Compaction and Shredding Mode
are chosen.
LED-7 Indicator Lights up when the RETRACT-B push button is pressed
on.
AE Solenoid Signal Solenoid signal of the extension port and it allows the
extension of the cylinder of the compaction unit.
AR Solenoid Signal Solenoid signal of the retraction port and it allows the
retraction of the cylinder of the compaction unit.
BE Solenoid Signal Solenoid signal of the extension port and it allows the
extension of the hydraulic bale delivery cylinder.
BR Solenoid Signal Solenoid signal of the retraction port and it allows the
extension of the hydraulic bale delivery cylinder.
C1 Contactor 1 Controls the Plastic shredder’s motor.
C2 Contactor 2 Controls the Pump.
M Motor Plastic shredder’s three-phase motor.
P Pump Fixed Displacement Pump.

5.4 Operational Flow Chart

This section shows the operational flowchart of the Compactor and Shredder Machine in
all modes of operation. As mentioned in the previous section (5.3), the START push-button
powers the Machine ON. On the actuation of the push-button, the Machine waits until the certain
sensors send signals and then the operator either chooses to select the Compaction Operation,
Shredding Operation, or both the Compacting and Shredding Operations. Figure [5.3] shows the
operational flowchart of the machine.

5.4.1 Compaction Mode

To initiate the compaction mode, the operator should turn the START switch key on and
select the compaction mode by pressing on the Compactor Push Button; built in the control
panel; this will then switch on the hydraulic power unit. In order for the compaction process to
begin, a few things must happen first. The pressure sensor and the oil level sensor must send
signals that both the pump’s pressure and tank’s oil level are normal. In parallel, the optical
sensor known as the CAN-LEVEL sensor, which detects that the operator fully loaded the
compaction chamber with Aluminum CANs through the can’s inlet, emits a signal that the
compaction chamber is fully loaded with Aluminum CANs. The magnetic reed switch, which is

68
found on the outlet door that is used to deliver through the compacted bale, emits a signal that
the outlet door is closed.
After the compaction mode is chosen, the magnetic door lock on the outlet door gets
activated, so no matter what happens the outlet door could not be opened once the magnetic door
lock is activated. Then the compaction hydraulic cylinder along with the compacting plate,
known as Cylinder A, extends to compact the Aluminum CANs inside the chamber. On reaching
the specified pressure, the compaction hydraulic cylinder and the compacting plate will retract to
its initial position.
Once the hydraulic cylinder and the compacting plate reach its initial position, the
magnetic door lock and the magnetic reed switch found on the outlet door will deactivate. After
they are deactivated, the operator will be capable of opening the outlet door manually. When
those two conditions are satisfied, the extension of the delivery cylinder, known as Cylinder B, to
push the bale outside of the compaction chamber. After the accomplishment of the bale
transferring process, the rear delivery cylinder retracts to its initial position by pressing on the
EXTENSION-B push button. Cylinder B, unlike Cylinder A, extends automatically but retracts
manually; finalizing the compaction cycle.

5.4.2 Shredding Mode

To initiate shredding mode, the operator should turn the START switch key on and select
the shredding mode by pressing on the Shredder Push Button, built in the control panel. The
Shredding process would not begin unless two things take place. First of all, the capacitive
sensor found on the shredder, known as PLASTIC-DETECT, is responsible for the operating of
the motor. Meaning that the motor would not start working, until the operator firstly places a
Plastic Bottle into the safety box which falls into the shredder and the sensor has to detect this
plastic bottle for the motor to start working. Second, the magnetic reed switch found on the outlet
box, known as BOX, detects that the outlet box is closed.
After the two conditions take place, the shredding process starts. The Shredded Plastic
starts falling into the outlet box. For the operation to come to an end, one thing must take place
and that is the optical sensor, also known as PLASTIC-LEVEL sensor, found inside the outlet
box should emit a signal when the shredded plastic reaches its maximum capacity inside the
outlet box the whole operation should stop completely. The operator then moves the outlet box
out of the shredding compartment. Sliding open its detachable base, the shredded plastic will fall
right into the delivery box; finalizing the shredding cycle.

5.4.3 Compaction and Shredding Mode

Compaction and shredding mode provide the ability to perform both operations
simultaneously. To initiate the compaction and shredding mode, firstly the operator should

69
follow the initial instructions mentioned in both subsections 5.3.1 and 5.3.2 then the operator
should select the compaction and shredding mode by pressing on the push button known as
BOTH built in the control panel after turning the Switch Key known as START on.

5.4.4 Operational Flow Chart

Aluminum CANs Compaction Mode
• The actuation of the START switch initiates the operation
• If the E-STOP (Emergency Stop) button is pressed, the machine halts operating.
• The operator should start filling the compaction chamber with Aluminum CANs through
the inlet, until the optical sensor detects that the determined can level is reached.
• The pressure sensor should detect that the pressure of the pump is normal.
• The oil level sensor should detect that the oil level inside the tank is normal.
• The magnetic reed switch on the outlet door should detect that the door is closed.
• The operator presses on the Compaction Mode Push Button, which will not start
operating if the conditions above were not successful.
• The magnetic door lock on the outlet door should be activated, so the outlet door could
not be opened during the operation.
• Then the compaction cylinder, Cylinder A, extends to compact the aluminum CANs
inside the compaction chamber until achieving the desired pressure.
• The compaction cylinder then retracts to its normal position.
• Following the retraction of the compaction cylinder, the magnetic reed switch and the
magnetic door lock on the outlet door should deactivate.
• When the above condition happens, this allows the operator to be capable of opening the
outlet door.
• Then the delivery cylinder, Cylinder B, extends to transfer the bale outside of the
chamber.
• The operator then presses on a push button that is responsible for the retraction of the
delivery Cylinder. The cylinder then retracts to its normal position.
• The machine waits again for the compaction mode button signal for another cycle of
operation.
Plastic Shredding Mode
• The actuation of the START button initiates the operation.
• If the E-STOP (Emergency Stop) button is pressed, the machine halts operating.
• The operator should place a Plastic Bottle into the Safety Box that then falls into the
shredder.
• The capacitive sensor found on the shredder, also known as the PLASTIC-DETECT
sensor, detects the Plastic Bottle.

70
 • The magnetic reed switch found on the outlet box should detect that the box is closed.
• When the above conditions happen, the operator then presses on the Shredding Mode
Push Button.
• The motor starts operating, which causes the shredder to start shredding the plastic bottles.
• When the optical sensor, also known as PLASTIC-LEVEL sensor, detects that the
shredded plastic reached its maximum capacity inside the outlet box the operation comes
to an end.
• The operator slides open the detachable base of the outlet box allowing the shredded
plastic to fall into the delivery box.
• The machine waits again for the shredding mode button signal for another cycle of
operation.
Compaction and Shredding Mode
• The actuation of the START button initiates the operation.
• If the E-STOP (Emergency Stop) button is pressed, the machine halts operating.
• The operator should select the Compaction and shredding Mode by pressing on the
BOTH push button on the control panel.
• While the operator should load the compaction chamber with the Cans through the inlet
until the chamber is fully loaded, the shredding mode is simultaneously operating.
• The pressure sensor should detect that the pressure of the pump is normal.
• The oil level sensor should detect that the oil level inside the tank is normal.
• The magnetic reed switch on the outlet door should detect that the door is closed.
• The operator presses on the Compaction Mode Push Button, which will not start
operating if the conditions above were not successful.
• The magnetic door lock on the outlet door should be activated, so the outlet door could
not be opened during the operation.
• Then the compaction cylinder, Cylinder A, extends to compact the Aluminum CANs
inside the compaction chamber until achieving the desired pressure.
• The compaction cylinder then retracts to its normal position.
• Following the retraction of the compaction cylinder, the magnetic reed switch and the
magnetic door lock on the outlet door should deactivate.
• When the above condition happens, this allows the operator to be capable of opening the
outlet door.
• Then the delivery cylinder, Cylinder B, extends to transfer the bale outside of the
chamber.

71
• The operator then presses on a push button that is responsible for the retraction of the
delivery Cylinder. The cylinder then retracts to its normal position.
• Simultaneously, the operator should place a Plastic Bottle into the Safety Box that then
falls into the shredder.
• The capacitive sensor found on the shredder, also known as the PLASTIC-DETECT
sensor, detects the Plastic Bottle.
• The magnetic reed switch found on the outlet box should detect that the box is closed.
• When the above conditions happen, the operator then presses on the Shredding Mode
Push Button.
• The motor starts operating, which causes the shredder to start shredding the plastic bottles.
• When the optical sensor, also known as PLASTIC-LEVEL sensor, detects that the
shredded plastic reached its maximum capacity inside the outlet box the operation comes
to an end.
• The operator slides open the detachable base of the outlet box allowing the shredded
plastic to fall into the delivery box.

72
Figure 5.3: Operational Flow Chart for Compaction Mode.

73
Figure 5.4: Operational Flow Chart for Shredding Mode.

74
Figure 5.5: Operational Flow Chart for Compacting and Shredding Mode.

75
5.5 List of Components of the Compactor and Shredder Machine
This section shows the list of the required input and output devices of the Compactor and
Shredder Machine. The list includes sensors and actuators to function as explained and desired.
Table 5.2 displays the required devices for operating the machine.

Table 5.2: List of Components and Actuators

Item Description Quantity Photo

1 Capacitive Proximity Sensor 1

2 Inductive Sensor 3

3 Optical Sensor 2

4 Reed Switch Surface Mount 2

5 Oil Level Sensor 1

6 Pressure Switch 1

76
7 START-green 4

8 RESET-red 1

9 Emergency Stop Push Button 1

Normally Closed

10 Switch Key-START 1

11 LED indicator-green 7

12 4/2-Way Solenoid Valve-24Volts 2

13 Panel Sheet Metal-Control Panel 1

(70x50x20)

77
14 Panel Board Rails 3mt

15 Fuses-4A 2

16 Panel Terminals 3mm 80

17 PVC Wire Terminals 1mm-Red and 1 pack

Blue each

18 Electric wire 0.5mm-Red, 100mt

each
White and Black

19 PVC Electric Ducts-2mmx2mm 3mt

20 Nylon Cable Tie Wraps Pack 1 pack

100x2.5

21 Industrial Relay 24VDC with base 30

78
22 Power supply 220VAC / 24VDC - 1
5A

22 Power Circuit Breaker 32amps 1

23 DIN Fuse Holder 2

24 Contactor 3 Phase 24 Volts 2

25 Hydraulic Hoses 2

26 Magnetic Door Lock 1

27 Plastic Shredder Motor 1

79
28 Hydraulic Double Acting Cylinder 1

5.6 Controller Description

This section provides a detailed explanation of the control components, including sensors
and actuators, mentioned in the list of components of the Compactor and Shredder Machine in
the previous section, (5.5).
5.6.1 Capacitive Sensor
A capacitive sensor acts like a simple capacitor. A metal plate in the sensing face of the
sensor, connected electrically to an internal oscillator circuit, acts as the first plate and the
subjected target to be sensed acts as the second plate of the capacitor. Unlike an inductive sensor
that produces an electromagnetic field, a capacitive sensor produces an electrostatic field. The
external capacitance between the target and the internal sensor plate forms a part of the feedback
capacitance in the oscillator circuit. As the target approaches the sensors face, the oscillations
increase until they reach a threshold level and activate the output. [22]

Capacitive sensors have the ability to adjust the sensitivity or the threshold level of the
oscillator. The sensitivity adjustment can be made by adjusting a potentiometer, using an
integral teach pushbutton or remotely by using a teach wire. If the sensor does not have an
adjustment method, then the sensor must move physically for sensing the target correctly. Table
5.10 shows the technical specifications of the capacitive sensor. [23]

(a) (b)

80
Figure 5.6: (a) Capacitive Sensor Schematic. (b) Capacitive Sensor Internal Construction.

5.6.2 Magnetic Reed Switch

Magnetic reed switch, an electromagnetic switch, controls the flow of electricity in a

circuit. Magnetic reed switches, made from two or more ferrous reeds encased within a small
glass tube-like envelope, magnetize and move together or separate when a magnetic field moves
towards the switch. The switch effectively works like a gate, or a bridge. In an electric circuit
when the two reeds are in contact, electricity can flow around the circuit operating a device.
Unlike mechanical switches, they do not require something or someone to actuate them ON or
OFF; invisible magnetic field controls them completely. [24]

There are two fundamental types, ‘normally open’ and ‘normally closed’. In a normally
open switch, the two reeds do not touch each other. When a magnet moves close to the switch, it
pull one of the reeds towards the other so that they touch, and therefore completing the circuit. A
normally closed switch works in the opposite way, when no magnetic field is present the reeds
are in full contact, the electric circuit is complete and the device is ‘ON’. When a magnet moves
close to a switch, or the switch close to a magnet, the reeds repel one another and split apart,
breaking the circuit. [24]

Figure 5.7: Magnetic Reed Switch working principle.

81
5.6.3 Power Supply
The function of the power supply is to provide the DC power to operate the PLC.
Supplied by single-phase 120 or 240 V/AC line power, the power supply powers the PLC system.
The Power Supply is a module located in the PLC system module rack. It provides power the
other modules in the rack, such as the CPU, Co-processor Modules, and I/O Modules. The line
power provided to the PLC system also powers the I/O Field Devices. To protect the PLC
module or field device against malfunctions, the control system includes safety fuses. Table 5.5
shows the technical specifications of the power supply. [25]
This technique replaces the big transformers used in power supplies which have many
windings in order to attain the needed reduction ratio, as the switch power supplies does not
depend on windings so a smaller transformer can be used instead. Once the smaller transformer
reduces the voltage as mentioned, a rectifier that uses four diodes in form of a bridge converts
the AC waveform to a DC format, during each half cycle each two opposing diodes conduct and
therefore provide a complete AC waveform at the end of a full cycle. After the AC voltage
conversion to a DC voltage form, a filter, which is capacitor, removes any remains of the AC
voltage known as ripples. [25]

Table 5.3: Technical Specifications of the Power Supply

Maximum Operating Single- 240 Volts AC

Phase Input Voltage
Output Current 6.2 amperes
Operating Frequency Range from 47 to 63 hertz
Efficiency >80%
Output Voltage Range from 21.6 to 26.4 Volts DC
Rated Power 150 watts
Ambient Air Temperature for from 0 to 60°C
Operation
Weight 0.97 kg

82
Figure 5.8: AC/DC Power Supply Operation.

Figure 5.9: Schneider Electric AC/DC Power Supply Wiring.

5.6.4 Electro-mechanical Relays

The relay, electromechanical switch, protects and as a controls various circuits,
equipment, and electrical networks in a power system. The electromechanical relay, defined as
an electrically operated switch, completes or interrupts a circuit by physical mating of electrical
contacts with each other. The flow of current through an electrical conductor causes a magnetic
field at right angles to the current flow direction. If the current flowing through the conductor
increases, then the magnetic field strength also increases (and vice-versa). The typical
applications of electromechanical relays include motor control, electrical fuel pump control,
industrial applications where control of high-powered voltage and currents takes place, and large
power loads control. Table 5.12 shows the technical specifications of the electromechanical relay
provided by Schneider Electric. [26]

(a) (b) (c)

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Figure 5.10: (a) Electromechanical Relay Circuit. (b) Schneider Electromechanical Relay Wiring
Diagram. (c) ISO-View of Schneider Electromechanical Relay.

Table 5.4: Technical Specifications of Electromechanical Relay

Rated Operational Current 12A

Control Circuit Voltage 24V/DC
Rated Operational Voltage 26V/DC
Max. Switching Voltage 400V/DC
Contact Opening Time 4ms
Contact Closing Time 9ms

5.6.5 Main Circuit Breaker

A circuit breaker, an automatically operated electrical switch, protects operating
electrical circuits from damage caused by excess current from an overload or short circuits
occurrence. Its basic function is to interrupt current flow after detecting a fault. Unlike a safety
fuse, which operates once and then must be replaced, a circuit breaker can reset (either manually
or automatically) to resume normal operation. Circuit breakers comes in varying sizes, from
small devices that protect low-current circuits or individual household appliance, up to larger
switching gears designed to protect high voltage circuits feeding an entire city. OCPD (Over
Current Protection Device) defines the generic function of a circuit breaker as an automatic
means of removing power from a faulty system. Table 5.13 shows the technical specifications of
the main circuit breaker provided by schneider electric.[27]

Table 5.5: Technical Specifications of the Main Circuit Breaker

Rated Operational Current 40A

Rated Operational Voltage 220-240V AC
Rated Operational AC Work Frequency 50/60 Hertz

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 (a) (b)

Figure 5.11: (a) Main Circuit Breaker wiring. (b) ISO-View Main Circuit Breaker.

5.6.6 Motor Contactor

A contactor is an electrically controlled switch used for switching a power circuit,
similar to a relay except with higher current ratings. A circuit controls the contactor, which has a
much lower power level than the switched circuit. Contactors come in many forms with varying
capacities and features. Unlike a circuit breaker, a contactor does not intend intended to interrupt
a short circuit current. Contactors range from those having a breaking current of several amperes
and 24 V DC to thousands of amperes and many kilovolts. Table 5.15 shows the technical
specifications of the motor contactor provided by Schneider Electric. [28]

Figure 5.12.a: Schneider Electric Motor Contactor Wiring.

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Figure 5.12.b: Motor Contactor Wiring Circuit.

Table 5.6: Technical Specifications of the Motor Contactor

Rated Operational Current 25A

Control Circuit Voltage 24V/DC
Rated Operational Voltage 115-600V/DC
Min. Switching Current 5mA
Contact Opening Time 16-32ms
Contact Closing Time 55-75ms

5.6.7 Analog Pressure Sensor

Analog pressure sensors convert the detected operating pressure inside a compartment
for example, into an electrical signal. Mainly utilized for pressure readings, analog pressure
sensors contain a sensing element of a constant area. The sensing element responds to the applied
force on its surface resulting in detecting the operating pressure on the surface area. A pressure
sensor, also known as a pressure transducer, includes a diaphragm that builds up its internal
structure. The sensing element measures the deflection of the internal diaphragm resulting from
the applied pressure and then converts it into electrical signal. This allows microprocessors,
programmable controllers and computers along with similar electronic instruments to read the
pressure. [29]

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 (a) (b)

Figure 5.13: (a) Analog Pressure Transducer. (b) Analog Pressure Transducer Structure.

5.6.8 Oil Level Sensor

Use ultrasonic level sensors for non-contact level sensing of highly viscous liquids, as
well as bulk solids. The sensors emit high-frequency (20 to 200 kilohertz) acoustic waves that
are reflected back to and detected by the emitting transducer.
When the level of lubricant or other monitored liquid drops, the circuit closes (in some
cases, it opens on the contrary) and an alarm is triggered. Calibration of the device should not be
carried out on a cold engine. At this point, the oil level will generally be at maximum or within
acceptable limits. When the engine starts, some of the grease will surely go away.

Figure 5.14: Float Level Sensor.

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5.6.9 Magnetic Door Lock

A magnetic door lock is a lock that uses an electric current to produce the magnetic force.
Due to the increased strength because of the current, the doors can withstand pressure, so they
can’t be forced open without use of the confirmed access method. Magnetic door locks use an
electromagnetic force to stop doors from opening, so they are ideal for security. The door can be
unlocked remotely and allow entry in two main ways: by pushing the buzzer switch which cuts
off the power to the magnet, or using an access control system. With a keypad, card reader
or biometric scanner, an access control system verifies the identity of each person and unlocks
the door for authorized operators. Some access control programs also have smartphone apps with
remote locking and unlocking capabilities.

Power is required to keep the door locked. This means that electromagnetic locks are fail-safe by
default. Fail-safe locks automatically unlock when the power goes out, enabling people to leave
the building safely in case of fire or an emergency. For high-security doors, a backup power
supply or battery can be used to ensure that the door remains securely locked even during a
power outage. [30]

Figure 5.15: Magnetic Door Lock Installation.

5.6.10 Optical Sensor

Optical sensors are a broad class of device for detecting light intensity. This can be just a
simple component for notifying when ambient light levels rise above or fall below a prescribed
level, or a highly sensitive device for detecting single photons. Most optical sensors produce an
electrical output.

88
 Optical Sensors are used for contact-less detection, counting or positioning of parts.
Optical sensors can be either internal or external. External sensors gather and transmit a required
quantity of light, while internal sensors are most often used to measure the bends and other small
changes in direction. [31]

Figure 5.16: Different Types of Optical Sensors.

Figure 5.17: Optical Sensor Detection Process.

5.6.11 Motor Circuit Breaker

Thermal-magnetic circuit breakers contain two different switching mechanisms, a
bimetal switch and an electromagnet. Thermal-magnetic breakers are often employed where it is
important to quickly limit short-circuit current. This is because the electromagnet in these
devices can extinguish the arc between breaker contacts in as little as four msec. This compares
favorably to the speed of interruption available from other types of breakers, such as hydraulic-
magnetic, which generally energize a solenoid to interrupt short-circuit currents. It may take
hydraulic-magnetic breakers 10 msec or more to completely stop current flow. One point to note
is that thermal-magnetic breakers are sensitive to temperature. In sufficiently warm ambient,

89
their normal current-handling capacity must berate according to manufacturer recommendations.
[32]

(a) (b)

Figure 5.18: (a) Motor Circuit Breaker Wiring. (b) ISO-View Motor Circuit Breaker.

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 Chapter 6
Control Panel
6.1 Introduction
This Chapter provides a detailed explanation of the control panel including both the
SolidWorks design and the location of the control panel on the Compactor and Shredder
Machine. The chapter provides a precise explanation of the face plane of the control panel
including the design and the components utilized. Moreover, it explains and illustrates with
figures the wiring diagram of the control panel of the Machine.
The control panel contains all the electric components to control and function the
electromechanical system.
The enclosure contains essential components to form up the assembly of the control panel
enclosure, as shown and explained in the previous Chapter 5, such as:
❖ DIN-Rails
❖ Block Terminals
❖ Wire Ducts
Other electrical components, as shown and explained in Chapter 5, such as:
❖ Programmable Logic Controller (PLC)
❖ DC Power Supply
❖ Circuit Breakers
❖ Contactors
❖ Relays
❖ Fuses
The control panel includes the controller that controls the Compactor and Shredder Machine,
the Programmable logic controller (PLC) that controls the system, the drivers that control the
motors, the electromechanical industrial relays, the electrical terminals blocks, the wire ducts, a
AC/DC power supply, a main circuit breaker, and a group of fuses. The DIN rails hold all of the
previously mentioned components.

6.2 Control Panel SolidWorks Design and Location

The control panel is mounted on the main housing unit above the Aluminum CANs
compaction compartment, where it is accessible for the operator.

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Figure 6.1: Control Panel.

6.3 Control Panel Face Plane

The face plane of the control panel includes all the utilized electrical control components
of the Compactor and Shredder Machine’s control panel. The following table 6.1 explains each
component.
A control panel, designed and used to control an electromechanical system, consists of all
electric components that control and operate the electromechanical system of the Compactor and
Shredder Machine. The control panel’s cabinet contains DIN rails that hold the electrical
components and wiring ducts, where system wires enter through for further connections.
The control panel includes the main circuit breaker of the system, and a group of fuses to
protect the control panel. For the controller level, the control panel includes a PLC controller to
control the system as desired along with a power supply that supplies power for both the
controller and to the controller input and output devices. The panel consist of a group of
electromechanical Relays interface to control the outputs of the system. For the wiring level, the
control panel includes AC and DC Terminal blocks, input terminal blocks, output terminal
blocks, and wiring ducts that receive wires from inside the control panel for further connections.

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Figure 6.2.a: Control Panel Face Plane 2D-View.

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 (b) (c)
Figure 6.2: (b)Control Panel Face Plane 3D-View. (c)Control Panel Face Plane 3D-View.

Table 6.1: Control Panel Face Plane Components

CB Circuit Breaker
PLC PLC Controller
PS AC/DC Power Supply
C1 Shredder Motor Contactor
C2 Pump Contactor
B1 Shredder Motor Circuit Breaker

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B2 Pump Circuit Breaker
K (1-30) Electro-Mechanical Relays
X1, X2 AC Terminal Blocks
X3, X4 DC Terminal Blocks
X5 Input Terminal Blocks
X6 Output Terminal Blocks

6.4 Machine Wiring Diagram

6.4.1 Motor Wiring Diagram

A Circuit Breaker (CB), located inside the control panel, prevents current flow to the
system when there is an overload in the current. C1, and C2 connected to the circuit breakers, are
the motor contactor and the pump contactor. Upon the transmission of a signal from the PLC,
the normally open contacts close resulting in the connection between the Motor M, Pump P and
the circuit breakers.

Figure 6.3: Motor and Pump Wiring Diagram.

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6.4.2 Power Supply Wiring Diagram
The AC/DC power supply receives 220V/AC from the main electric suppliers (L1, L2, L3,
and N) through the AC terminal blocks (X1, X2) of the control panel. The cables transmit
220V/AC to the power supply once connected to its input pins. The power supply contains two
output cables each connected to a fuse. These cables, moving into the cable ducts inside the
control panel, transmits direct current two the DC terminal blocks (X3, X4). The AC/DC power
supply connects the first cable, carrying 24V/DC, to the first DC terminal block (X3) and the
second cable, carrying 0V/DC to the second DC terminal (X4). The two direct current terminal
blocks provide power to the different input and output devices of the control system.

Figure 6.4: Power Supply Wiring Diagram.

6.4.3 Digital Inputs Wiring Diagram

The input devices present in figures [6.5.a], of the system, sensors, magnetic reed switches,
magnetic door lock and push buttons, are supplied with 24 volts DC through the DC and AC
Terminal Blocks (X3 and X4). All inputs to the system, connected to the PLC controller and
transmit signals to the PLC in case the current state of the sensor has changed.

96
Figure 6.5: Inputs Wiring Diagram.

6.4.4 Relays Interface Wiring Diagram

Firstly, the terminal block X6 receives the transmitted signals and then connects directly
to the interface relays.
The stages of the wiring connections are:
1. Input devices are connected to the AC and DC Terminal Blocks (X1 and X3)
2. Signals from the Output Terminal Blocks are then connected to the interface relays
3. The interface relays energize and then close their contacts.
4. The contacts establish a direct connection to the output devices.

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 Figure 6.6.a: Interface Relays Wiring Diagram.

Figure 6.6.b: Interface Relays Wiring Diagram.

98
Figure 6.6.c: Interface Relays Wiring Diagram.

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 Chapter 7
Conclusion and Future Work
7.1 Conclusion
The purpose of the research focuses on providing a medium level solution to solve the
problems of indiscriminate dumping of solid wastes (mainly Aluminum CANs and Plastic
Bottles), and identifying the reasons behind Solid Waste Management failure in Egypt since the
2000s. Research concluded that that Cans and plastic bottles both contribute in the negative
impact of the solid waste issue on citizens’ health and on the environment. An Aluminum CAN
crusher and a Plastic Shredder, designed and assembled into one body, construct a Compactor
and Shredder Machine to help in collecting, transporting, and recycling activities. The proposed
design on the Waste Compactor and Shredder Machine went through both design and simulation
on SolidWorks to predict the behavior while during operation. A Programmable logic controller
controls the Compactor Machine through the coded sequential function charts. The study
includes the machine’s performance and the efficiency for both modes of operations.

The design gained inspiration form the idea of manufacturing a fully automatic can
crusher machine, which will make the product durable for the long time as well as make it
efficient. Thus, with the help of this design we can fabricate an automatic Can crusher machine
and a plastic shredder to reduce the volume of cans and plastic bottles as well as to reduce the
human fatigue. The Compactor and Shredder Machine will meet the demand for solid waste
management problems in Egypt when commercialized.

7.2 Future Work and Recommendations

• Automated loading for both the Aluminum CANs and the Plastic Bottles.
• Operating all the modes of operation at a faster rate.
• Adding sensors to shut down the machine, if a operator moves closer to the machine.
• Adding a standing lifting conveyor for space reduction.

100
• Trying to implement the idea of this Compacting and Shredding Machine inside garbage
bins, so it can be accessible to pedestrians on the streets of Egypt and to increase
awareness of garbage recycling.

101
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