Paper Vending Machine
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Transcript of Paper Vending Machine
1
Chapter 1
Introduction
1.1 Background of the Study
For centuries, paper was a rare and precious commodity. Until today, paper is a
fundamental part of life and its existence is always taken for granted. Each year, the
world produces more than 300 million tons of paper. Since paper comes from plant fibres
and trees, the paper production creates a big sacrifice for our forests. Natural forests are
destroyed at an unsustainable pace with most surviving forests degraded by roads,
agriculture, pollution and invasive species. Also, paper manufacturing requires large
factories with large inputs of fibres, chemicals, machineries and water.
Ultimately, saving our trees will save humanity as all our food, water, livelihood,
medicine and shelter come from the environment. Producing paper from virgin materials
destroys a lot of our forests, efforts has been made to produce paper from other cellulose
materials like banana peels, carrot stalks, onion skins, corn husk, used cloth or any
fibrous materials. This method of creating paper has been adopted by companies like
Papyrus Australia, which uses banana peelings to produce paper products. Not only do
they produce good quality paper, creating paper from these materials also uses a lot less
energy compared to manufacturing paper from virgin materials. If these materials are
widely used, problems arising from paper production can be greatly aided.
The researchers think that one reason for the unpopularity of recycling these
waste materials is due to the arduous process of creating paper. Recycling waste materials
usually takes a lot of effort, as well as time since the procedures are done manually. If
there is an automated way to recycle these waste materials, we believe that more people
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will be encouraged to produce paper from materials like corn husks, banana peels and
those fibrous plants abundant in the country. Since there are a lot of electronic devices
that can replace and mimic the procedures in the manual procedure, creating such
machine is very feasible. And with this information at hand, the researchers have decided
that the automation of the creation of paper proves to be useful to us as it is important to
our environment. The researchers hope that this project will promote consciousness of
conserving the precious resources we still have and pass this through the next generation.
1.2 Objectives
1.2.1 General Objective:
To design and implement a microcontroller-based paper making machine
involving pulp making, paper forming and paper drying using corn husk as a raw
material
1.2.2 Specific Objectives:
To design a paper making machine using a PIC16F877 MCU that is able
to produce a paper material out of corn skin.
To interface a blender to produce the paper pulp, as well as an electronic
heating element to cook the corn husks for 60 minutes.
To create a program for the PIC16F877 MCU using Proton Plus Compiler.
To design a water level detector that will determine the amount of water to
be transferred to the blender cooker and a circuit that controls the blower
to dry the corn husk paper for 30 minutes.
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To interface solenoid valves that would transfer the solution and water to
the blender cooker, and the pulp with water to the mould and deckle.
To test the systems reliability.
1.3 Statement of the Problem
Today the lush forests are long gone, and even though many trees are planted
specifically for the paper industry, they cannot grow fast enough to meet demand. The
ever-increasing demand, especially of the advanced countries has resulted in continued
denudation of forests causing severe environmental imbalances. This phenomenon if not
treated well will result to serious planet degradation. Deforestation or cutting of trees
because of paper production presents multiple societal and environmental problems such
as loss of biodiversity, destruction of forest-based-societies, erosion, flooding and climate
change in the world. These immediate and long-term consequences of global
deforestation are almost certain to jeopardize life on Earth.
Moreover, loss of trees is not the paper industry’s only ecological problem. While
the impact on the world’s forests is undeniable, the industry consumes vast amounts of
energy and water to convert trees into paper. In addition, many chemicals that are used in
the process end up in our air, water, and soil in large amounts, causing serious pollution.
Global deforestation and waste pollution are both major problems the world is
facing right now. And business establishments together with the government in different
areas of the world are having a hard time to solve these problems caused by paper
industries. So in order to eliminate or even reduce this occurring problems an alternative
solution of producing a tree-free paper must be made.
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The group proposed an eco-friendly alternative of producing paper from corn
husks- a discarded agricultural waste which is also noted that if not disposed properly can
cause stubborn drain blockages where fibers get tangled. This material will be processed
automatically in order to minimize the time frame of producing paper to meet the demand
of the consumers. The group’s project promotes method of recycling - producing paper
from waste (corn husks) rather than virgin trees. This method makes use of existing waste
and turns it into something beneficial while saving natural virgin resources such as
hardwood trees and eliminates waste pollution for the purpose of protecting the
environment and human lives while meeting the demand for paper.
1.4 Scope and Delimitation
The study conducted will include the topics discussed but will be limited
to the following conditions:
Though there are many kinds of plant materials that can be recycled, the
study will focus on using corn husks as raw materials. This is due to its
availability in the country as well as in the vicinity of the researchers.
The corn husks that will be used in the study are cleaned and washed. The
stalk or any hard part of the corn husk shall be removed.
Also, the corn husks that will be used in the study is cut into small pieces,
about 0.5 cm x 0.5 cm. Corn husks will be loaded into the cooking section
of the prototype.
The compiler to be used on the PIC16F877 will be Proton Plus Compiler,
which can be easily downloaded from the internet.
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For testing purposes, the size of the paper produced will only be 8’’ x 10’’,
which is estimated to be enough to test the quality of the produced paper.
For the soda ash solution, the ratio to be used will be 1L of tap water for
12.5ml soda ash.
The tanks used for water and soda ash solution will have a capacity of
about 3 litres.
The quality of paper produced has scrapbook material appearance.
1.5 Significance of the Study
One importance of this design is that it imposes and promotes recycling process in
our area. Since the researchers will make an automated way of producing paper from
corn husks, more people will be encouraged to recycle their waste since it is easier to do
so. This project can promote awareness to people as to how important recycling is to us
and our environment. Also, this project can give ideas to other researchers that manual
recycling processes can be made to an automated process.
This project provides an important contribution to saving our environment. Since
the design will produce paper from corn husks as raw materials, there will be a reduction
in waste produced by improper disposal of such materials.
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1.6 Definition of Terms
A
Arduous - demanding great effort or labor
Alkali solution - a basic, ionic salt of an alkali metal or alkaline earth metal element
B
Blender - is a kitchen appliance used to mix ingredients or puree food.
Blow Dryer - is an electromechanical device designed to blow cool or hot air
C
Corn - constitutes a staple food in many regions of the world.
Cellulose - structural component of the primary cell wall of green plants
D
Design - planning that lays the basis for the making of every object or system
Deforestation - occurs for many reasons: trees or derived charcoal are used as, or sold, for
fuel or as a commodity, while cleared land is used aspasture for livestock, plantations of
commodities, and settlements.
Deckle - is a belt used along with a mold to gather up wood pulp from a vat for pressing
and drying into sheets.
F
Fiber – a long thin piece of a natural or artificial substance, similar to a thread or hair in
shape
Float Switch - is a device used to detect the level of liquid within a tank. The switch may
be used in a pump, an indicator, an alarm, or other devices.
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H
Husk - the external covering or envelope of certain fruits or seeds
I
Implement - outsource the new project
Interface - A point at which independent systems or diverse groups interact
Invasive - having to do with invasion
M
Microcontroller - is a small computer on a single integrated circuit consisting internally
of a relatively simple CPU, clock, timers, I/O ports, and memory.
Motor - uses electrical energy to produce mechanical energy, very typically through the
interaction of magnetic fields and current-carrying conductors.
Mould - is a hollowed-out block that is filled with a liquid like plastic, glass, metal,
or ceramic raw materials.
P
Paper - a thin, flexible material made usually in sheets from a pulp prepared from rags,
wood, or other fibrous material, and used for writing or printing on, for
packaging, as structural material, as a fabric substitute, etc.
Pulp - a soft, moist, formless mass that sticks together
Procedure - the act, method, or manner of proceeding in some action; esp., the sequence
of steps to be followed
Proton Plus - is an entry level product written with simplicity and flexibility in mind by
Proton.
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Prototype - the first thing or being of its kind; original; model; pattern
Proximity Detector - Proximity detectors are devices that use mutual capacitance between
itself and object in order to detect its presence.
R
Recycle - to pass through a cycle or part of a cycle again, as for checking, treating, etc.
Relay- is an electrically operated switch. Many relays use an electromagnet to operate a
switching mechanism, but other operating principles are also used.
Reliability - Ability of an equipment, machine, or system to consistently perform its
intended or required function or mission, on demand and without degradation or failure.
S
Solenoid valve - an electromechanical valve for use with liquid or gas; it is a tube like
System - a set or arrangement of things so related or connected as to form a unity
W
Water Detector - is a small electronic device that is designed to detect the presence of
water and alert humans in time to allow the prevention of water damage.
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Chapter 2
Review of Related Literature
The collection of theories, concepts, works and articles that are related to the
study can be found in this chapter. Review of related Literature discusses all the factors
contributing to the study that help in the completion of the design prototype. All the
concepts which are comparison to the study are applied in this chapter which was used as
a reference by the researchers.
2.1 Philippine Agriculture
About one-third of the total land area of the Philippines is classified as arable.
Three-fourths of the cultivated area is devoted to subsistence crops and one-fourth to
commercial crops, mainly for export. Farms tend to be small, and many areas are double-
cropped. Soils are generally fertile, but 30% of the agricultural land is suffering erosion.
In 1973, the Marcos government began a land-reform program that undertook to
transfer landowners to about half of the country's 900,000 tenant farmers. By February
1986, over one- half of the area—about 600,000 ha (1,482,600 acres)—had not been
distributed. The Aquino administration proposed a program in two stages: the first,
covering 1.5 million ha (3.7 million acres) in 1987–89, involved previously undistributed
land and other land held by the state; the second, covering 3.9 million ha (9.6 million
acres) in 1990–92, involved land cultivating sugar, coconuts, and fruits. A more detailed
1990–1995 plan sought to increase productivity of small farms, maintain self-sufficiency
in rice and corn production, and to increase the agricultural sector's role in the trade
balance.
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Roughly half the cultivated land is devoted to the two principal subsistence crops,
palay (unhusked rice) and corn. Production of palay was 11,388,000 tons in 1999; long-
term production has increased, mainly through the use of high-yielding hybrid seeds
under a government development program begun in 1973. The Philippines attained self-
sufficiency in rice in 1974 and became a net exporter of rice for the first time in 1977. A
similar development plan was aimed at raising yields of corn, which is the chief food
crop in areas unsuitable for rice-growing and is increasingly important as feed for use in
the developing livestock and poultry industries. The Philippines has been self-sufficient
in corn for human consumption since the late 1970s, but since production of animal feed
lags behind the demand, imports are still necessary. Corn output in 1999 was 4,643,000
tons. Lesser crops include peanut, mango, cassava, camote, tomato, garlic, onion,
cabbage, eggplant, calamansi, rubber, and cotton. (Retrieved February 03,2010 from
http://www.nationsencyclopedia.com/Asia-and-Oceania/Philippines-
AGRICULTURE.html)
2.2 Philippines Agricultural Geography
In the late 1980s, nearly 8 million hectares--over 25 percent of total land--were
under cultivation, 4.5 million hectares in field crops, and 3.2 million hectares in tree
crops. Population growth reduced the amount of arable land per person employed in
agriculture from about one hectare during the 1950s to around 0.5 hectare in the early
1980s. Growth in agricultural output had to come largely from multicropping and
increasing yields. In 1988 double-cropping and intercropping resulted in 13.4 million
hectares of harvested area, a total that was considerably greater than the area under
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cultivation. Palay (unhusked rice) and corn, the two cereals widely grown in the
Philippines, accounted for about half of total crop area. Another 25 percent of the
production area was taken up by coconuts, a major export earner. Sugarcane, pineapples,
and Cavendish bananas (a dwarf variety) were also important earners of foreign
exchange, although they accounted for a relatively small portion of cultivated area.
Climatic conditions are a major determinant of crop production patterns. For
example, coconut trees need a constant supply of water and do not do well in areas with a
prolonged dry season. Sugarcane, on the other hand, needs moderate rainfall spread out
over a long growing period and a dry season for ripening and harvesting. Soil type,
topography, government policy, and regional conflict between Christians and Muslims
were also determinants in the patterns of agricultural activity. (Retrieved February 15,
2010 from http://countrystudies.us/philippines/60.htm)
2.3 RP Corn Production Up Efforts to raise corn output are paying off
The total corn production of the country has increased by an average of 5.8
percent in the last seven years, an indication that efforts by the government and various
industry stakeholders are paying off, according to Agriculture Secretary Arthur Yap. In a
statement sent to the Sixth National Corn Congress held at the Albay Astrodome here
from April 16 to April 18, Yap said that last year’s national corn production reached 6.93
million tons (MT) which surpassed the 2007, harvest by more than 200,000 tons despite
high-fertilizer prices and the damage wrought by typhoons on corn plantations.
(Retrieved February 03,2010) from http://www.agriculture-ph.com/2009/04/rp-corn-
production-up.html)
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―For 2009, we are looking at anywhere between 7.2 MT to 7.4 MT—which is
admittedly lower than our original target, because we are taking into account a host of
factors including the expected decline in corn yields due to the adverse effect of changing
weather patterns,‖ Yap said. At the core of the Department of Agriculture’s (DA's) corn
sufficiency and security agenda is a stronger focus on the establishment of postharvest
facilities, such as corn-cob dryers, shellers and farm mechanization support in the form of
four-by-four tractors and shallow-tube wells.―For these endeavors, we have earmarked
P400 million or half of the National Corn Programs’ proposed 2009 financial
programming of P817.7 million,‖ he said.
Moreover this allocation reflects a policy shift in favor of investing in
infrastructure development and away from soft interventions in the form of subsidies for
corn seeds and microbial inoculants, Yap said. ―Hence, we have tasked ourselves to
realize the targets of raising the national harvest to 7.4 MT this year and further to 7.69
MT in 2010, and therefore improve sufficiency level from 94- percent en route to total
sufficiency by 2010,‖ he added. Furthermore, to attain those targets, Yap said farmers
should realize an average yield of six tons per hectare in program areas, lower
postharvest losses to 8 percent and boost farm income to at least P10,000 per hectare by
2010. To achieve those goals, the DA will promote the use of organic and microbial
fertilizers, expand farmlands devoted to corn by opening up new corn areas nationwide,
and step up the nationwide inter-cropping program in coconut plantations, he said. And
lastly ―We will also continue to encourage the use of hybrid corn technology among
farmers across the country, reduce postharvest losses by promoting better harvest
practices, continue to increase the production and consumption of white corn particularly
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among the traditional corn-eating population to ease the pressure on our rice
requirements,‖ Yap renounced.
2.4 Philippines Life, Livelihood and Corn
Situation
A Filipino corn farmer earns an average of US$ 535 per hectare each
growing season and plants 1.5 hectares of corn twice a year. They hadn't pursued
alternative sources of income.
Solution
A Pioneer Hi-Bred International community service project in
collaboration with the Corn Husk Association of the Philippines (CHAP) allows
Filipino corn farmers and their families to earn additional income by training
them to create crafts and handiwork utilizing a natural material abundant in their
community - the corn husk.
Impact
More than 15,000 corn farmers have been trained. Now, a family
producing cornhusk handicraft five days per week can double their annual income
enabling farmers to improve their quality of life. (Retrieved February 3,2010 from
http://www.pioneer.com)
2.5 Tree-Free Paper Products
Tree-free paper is one eco-friendly alternative. The fibers from most plants can
be made into quality paper products. Rapidly renewable resources such as flax and hemp
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can create quality paper. Experts believe the most effective and environmentally friendly
resources for tree-free paper can come from otherwise discarded agricultural waste.
Stalks and husks left after harvesting a main crop are perfect; corn, barley, oats, wheat,
rice, rye, coffee bean skins, sugar cane husks, and even tobacco fiber can be made into
paper. This method makes use of existing waste and turns it into something beneficial
while saving natural virgin resources such as hardwood trees.
Some of the most popular alternative materials being used for papermaking today
include the following:
1. Bamboo is being used for everything from flooring to clothing and even paper.
Bamboo paper and rice paper have been made on a small scale in Asia for centuries.
2. Bagasse is the husk and pulp that remains after extracting juice from sugar cane; it
can be processed into paper.
3. Waste bark from banana trees can be made into paper. Banana leaf paper is known as
abaca.
4. Coconut husks can be processed into thick, textured paper.
5. Corn plant stalks, known as corn stover, can be made into excellent paper pulp
comparable to North American hardwood pulp.
6. Cotton paper can be made from old cotton rags and other recycled cotton material,
cotton processing waste, or even fresh organic cotton fibers.
7. Paper can be made from bacteria- and odor-free elephant dung.
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8. Hemp paper is a superior quality product. It is said that Thomas Jefferson drafted the
Declaration of Independence on hemp paper.
9. Jute can be made into high-quality specialty paper.
10. Kenaf is a hibiscus from Africa that has been used to make paper.
11. Mango paper is made from the mango leaf and paper mulberry.
12. Straw fibers are very similar to wood and make great paper. At one time, the United
States produced straw paper, but the industry no longer exists.
13. The petals and leaves from the tamarind tree can be made into paper.
Tree-free paper is not entirely a mainstream product yet, so it may be hard to
come by at your local office supply store or printer. However, as with everything else,
demand pushes supply up. As more people start asking for tree-free paper, mainstream
stores will start supplying it to the general public. Until then, you can search in your local
health food and natural supply specialty stores and online. (Retrieved February 05, 2010
from http://www.everything.com/Eco-InvitesTree-Free-Paper-Products/)
2.6 Making Paper from Plants
Renewable and easy to find fibers like cattail leaves, iris leaves and agricultural
waste like corn husks are perfect for making paper and provide good results for
beginners.
There are several steps to papermaking, the first of which is harvesting. The same
plant can yield fibers that vary in color and consistency depending on when and where
© 1998-2007
Roberta
Lavadour /
Mission
Creek Press
About Mission Creek Press
Handmade Paper Custom
Books
Artist’s Books Printing Upcoming
Exhibitions Workshops
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they are harvested. Next is cooking. Fibers need to be cooked in an alkali solution for
three to twenty hours, depending on the variety. After cooking, the fibers must be
thoroughly rinsed - a process that takes much more time and water than you would think.
After rinsing, the fibers are beaten into a pulp. Because most leaf and grass fibers area
easy to beat by hand, or even with a kitchen blender, they are good choices for
papermakers without access to a Hollander beater. After beating, the fibers are floated in
a vat of water and scooped up onto a papermaking mould in a thin layer. From there, they
are transferred to a cloth or wool sheet and stacked in a ―post‖. The post is then pressed
to squeeze out water and promote bonding between the fibers. For the most simple drying
method, the cloth with the still-damp paper still attached can be hung on a clothes line.
There are any numbers of other drying techniques that yield different surface textures.
(Retrieved March 12, 2010 from http://www.missioncreekpress.com/plants.htm)
2.7 How to Make Cornhusk Paper
A. Removing the husks:
1. Peel cornhusks from corn, making sure to remove the corn silk from the husks as well.
2. Let cornhusks dry out in an airy place overnight. A flat surface near a window is a good
spot that allows the sun to help speed up this process.
B. Making pulp:
To make the PULP, you will need the following: Crock pot (also called ―slow cooker‖)
Blender, Plant fibre and Water
3. Once the husks have dried, cut them into small pieces about 2 cm long. Place them into
a crock pot, cover with water and let them simmer for about 12 hours. This will soften the
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husks and help separate the fibres.
4. Place softened cornhusks into blender with enough water to help the husks move around
while being blenderized. You can add other types of pulp, such as shredded toilet paper, at
this step.
5. When you remove the pulp from the blender and strain it, the fibres will look ―stringy‖.
You can now place these into a large vat or sink full of water.
D. Pulling a Sheet of Paper:
6. Immerse the mold and pull a sheet of paper by lifting the mold in a horizontal position
from the water.
7. Place mold over a pan to catch the water as it drips while the air dries the paper. It can
take up to 2 days to dry this way. If you want it to dry in half the time, you can use a
sponge to dab excess water from the paper every so often.
D. Your Paper is ready to work with!
To finalize the papermaking, you will need: Iron, Clean sheets of paper (letter size is
okay) and Surface covered with thick cloth to iron onto.
8. Remove dried paper from mold by placing the mold upside down onto a flat surface.
Run your fingers over the screen to help the paper separate from the screen. Paper should
release from the mold.
9. When you first remove the paper from the mold, notice that the edges are curled. To
flatten this newly formed paper, place it between 2 sheets of clean paper and press with
hot iron.
10. Transform poem-photograph from white, heavy paper to an antique. Tear edges of
poem-photograph and dab paper completely with a wet teabag. Let it dry and repeat the
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dab-dry process until its color deepens to your liking. Iron it between 2 clean sheets of
paper to flatten it.
11. Glue and iron the poem-photograph onto the cornhusk paper. You can add decorative
items to enhance your new creation your picture is now ready for framing! (Retrieved
February 12,2010 from www.nativeaccess.com/ancestral/corn/CornHuskPaper.pdf)
2.8 “Braided Tapes”, Handmade Paper Scruptural Book
Dennis Yuen, an entrepreneur and an artist at the same time made a new addition
to his repertoire which is a book made entirely out of his own handmade paper. This book
uses 3 sheets of handmade denim plus corn husk paper (the bluish pages) and 1 sheet
with "Angel Wings" botanical elements (the yellowish pages). See the picture below.
Figure 1
Braided tapes
As he mentioned before in his blog (Cailun.info-paper and book making blog),
that he have been making paper recently. He said ―Making paper is generally not an easy
thing to achieve at home, that is, if you want to have an efficient process and good
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result‖. He also added that at home, he don't have a deep vet to hold the pulp, but he has
a big plastic storage container for the purpose. ―By the way, pulp is the basic ingredient
of paper. It's the a mixture of cellulose fibers and water. When the water is drained away,
the left behind fibers is essentially paper‖ he said.
Figure 2
Recycled Paper
In this pulp (and the resulting paper shown here), He added denim cotton (for
indigo the color), corn husk fibers (for the texture) and recycled paper pulp. In place of a
professional beater to break up the fibers, he used—of course, like most paper-makers at
home—a blender. Small batches of fibers are blended and added into the vet to create a
workable amount of pulp. The leftovers pulp is drained and frozen for next time's use.
2.9 Tips for Variations in Paper-Making
Given that the ancient Egyptians used plants to make papyrus paper, it’s only
natural that we consider various plants, as well as other creative sources, in creating our
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own modern paper today. Here are a few tips in creating a look with your own homemade
paper that’s personal, beautiful and unique.
Give it a little color. Add some dye, powdered paint, liquid paint, tea, food
coloring… From henna to smashed berries, coffee grains to cool-aid, there’s
bound to be something creative you can use in your house this very moment.
Experiment to see what colors you like best.
Make it touchy-feely. Adding texture to your paper can give it a very unique
definition. To do this, add the items of your choice to your paper-paste before you
let it dry. Not sure what to add? Anything from tiny seeds to grass, confetti to
pieces of thread to glitter can work.
Write like an Egyptian. Rather than reeds, why not add some flowers to give your
paper a nature look? You can use anything from moss to pieces of grass, full
leaves to flower petals themselves.
Give it an eu de toilette. You may have tried scenting a love letter with some
perfume you had on hand, but scented paper can be even more fun. Use essential
oils, potpouri or spices to give your paper a unique fragrance.
Add your bright and shiny face. You can even put pictures in your paper. Just
smooth a paper copy of a photo onto the paper-paste before draining the water
from it. (Retrieved March 18, 2010 from: http://www.papermaking.net/how-to-
make-paper/tips-for-variations-in-paper-making/#more-18)
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2.10 Homemade Paper to Localize Economy?
From pilfering hotel shampoo bottles to using single squares of toilet paper at a
time, we’ve all heard some pretty interesting, creative, and sometimes slightly unhinged
ways to save money these days. At The Daily Green, handmade paper is considered one
of many ways to re-localize the economy and go green.
They recently featured a piece on Adina Levin, the co-founder of Collab. Collab
is short for collaborators, and is a Manhattan based company that plans on re-localizing
the economy through helping designers, writers, artists, musicians and other creative
people collaborate together to form a more sustainable world.
By enabling these innovative minds with the tools and space that they need to
collaborate together, Collab hopes to get them inspired and working together, which will
hopefully yield environmentally-friendly products and processes to help create localized
economy.
One sustainable practice that Levin advocates–and is knowledgeable in–is making
homemade paper. Levin uses a very similar process to the one posted here at Paper
Making. She also promotes a messy, hands-on approach, often touching the paper pulp
and getting very involved in the process. Her video and instructions are perfect for
anyone who isn’t afraid to get messy and produce some truly amazing results.
Would using handmade paper really support a more local economy and a
sustainable world in general? In a word, probably. By using 50% less energy and 75%
less water–as well as creating up to 90% less wastewater and 70% less air pollution–than
22
paper made from unused fibers, it definitely has less of an environmental impact.
(Retrieved March 18, 2010 from http://www.papermaking.net/)
2.11 Keeping Safety in Mind While Making Paper
Making paper is considered a very safe and enjoyable activity. However, like any
craft, there are some dangers that can always be present. It’s important to take
precautions before embarking on any new activity. Here are a few tips to do that when
making paper.
Use caution when handling your screen. Remember, it’s made of wire and can
cause a cut. If you make your own screen, you might even wish to wear protective
work gloves until its edges are finished. If you cut yourself during construction,
stop the project immediately and apply an antiseptic and a bandage. Be sure that
the bleeding has stopped before continuing. If the cut is deep, seek medical
attention.
Make your paper in a well ventilated area. While most smells are harmless, it’s
always possible to come in contact with harmful chemicals if you’re not certain of
your paper’s origin. Even benign but strong smells, such as those released during
making grass paper, may make some people sick. Wearing a mask can also help
with this. The best bet is to only use paper that you know has not been chemically
treated. Making paper outdoors is also a good option, as it helps minimize the
mess.
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Use caution when handling your water. If you spill water, be sure to clean it up
immediately. It will obviously cause surfaces to become slick, so walk carefully if
you must walk in the water. Be sure to have some towels handy prior to
beginning, and don’t work near anything electrical to avoid water damage and
electric shocks.
Only use mediums that you are comfortable with. If an herb or plant or other item
is a known allergen to you, do not use it. Avoid any materials that may cause
irritation to your skin. You may also wish to wear gloves and eye goggles while
making paper in general. (Retrieved March 18, 2010 from
http://www.papermaking.net/how-to-make-paper/keeping-safety-in-mind-while-
making-paper/#more-91)
2.12 Top Handmade Paper Products
Though making your own paper and using it for personal projects is a fun and
rewarding activity, handmade paper is not just for this purpose. On the contrary,
handmade paper is used in the finest crafts and arts all over the world. From India to the
United States, homemade paper is a staple in many artisan projects.
For your next gift or special purchase, you might consider buying one of these
unique creations made by fine, handmade paper.
Journals: Though all journals are mostly made of paper, handmade paper journals
are highly unique, often displaying cloth or beaded covers that add an artistic style
to the author’s thoughts. Typically quite exotic and bold, they are also often more
24
durable than manufactured journals. The same sentiment applies toward
handmade paper photo albums, photo frames and scrapbooks.
Bags: Rather than wasting brown paper–or even plastic–shopping bags, handmade
paper bags provide a clever, beautiful alternative that is both stylish as well as
eco-friendly.
Candle Holders: This is a very novel function of handmade paper, with it being
such a flammable source. That said, there are some very simple, elegant designs
created for holding and highlighting tea lights.
Clocks: How many of your relatives can say that they own a clock made from
paper? It would surely be a more unique gift than another tie or fruit pie.
Desk Sets: From paper pads to pencil holders, the items on your desk needn’t be
encased within stark cookie-cutter plastics. Why not go for a bold, batik
handmade paper desk set instead?
Gift Boxes: How entertaining it would be to be gifted a handmade paper craft–
within a gorgeous handmade paper box? (Retrieved March 18, 2010 from
http://www.papermaking.net/paper-uses/top-handmade-paper-products/#more-68)
2.13 How to Make Rice Paper
If you’ve been making your own handmade paper now, you might want to try
making rice paper. Rice paper is a beautiful and elegant creation that has been used in
25
writing and art for centuries in China and Japan. Slightly translucent with a unique
texture, it will be a lovely addition to your handmade paper collection.
Though rice paper traditionally means paper made from rice plants, today it can
be made from just about any plant source, such as bamboo.
To make your own rice paper, you will need about a pound and a half of bamboo
leaves, two and a half pounds of wood ash (such as from a fireplace), a big pot, a basin,
water, a couple of towels, some mesh for straining, a mortar and a pestle for grinding, a
wooden spoon, the frame you made for paper-making, any decorations you’d like in the
paper, and some heavy books for pressing your paper.
To begin, shred your bamboo leaves and set them aside. Prepare your ash by
mixing your wood ashes with your water in the pot. Boil the mixture for half an hour and
let it sit overnight.
The next day, strain the mixture through your mesh. Mix your bamboo and the
ash mix in the pot and cook it together for five hours. When it’s finished cooking, strain
the whole mixture once again, and wrap the fiber that’s left in a towel.
Rinse the towel out with fresh water and squeeze out the excess water. Empty the
fibers from the towel into your mortar and grind it into a paper pulp with your pestle.
Next, fill your basin up with water and pour in your pulp. You should have about four
parts of water to one part pulp. Stir it well with your spoon.
26
Follow through with the rest of your paper-making steps, and when you are
finished, lay a piece of cloth over the paper before covering it with your books to flatten
it out. (Retrieved March 18, 2010 from http://www.papermaking.net/how-to-make-
paper/how-to-make-rice-paper/#more-56)
2.14 How to Make Paper with Dryer Lint
With the threat of global warming and other environmental concerns looming
over us these days, more people are turning to reusing and recycling things in their
homes. It’s easy to find a new life for a milk jug, toilet paper rolls or even used clothing
(did you know that you can make insulation out of old jeans?), but some household
wastes are hard to find uses for.
Dryer lint may not have been on your list of things to reuse, but it can actually be
a good base to use for making paper. To make new paper out of your old dryer lint,
gather the items you need to make paper out of any other material–your blender,
preparation frame, sink or basin, etc. You will essentially be performing the same steps–
just with something you may have thought had no use whatsoever rather than your
recycled paper or grass!
Like any other paper base, your lint color will show up in your final product, so
keep that in mind as you collect your dryer lint. Soak your lint in warm water for half an
hour to break it down for blending. If you want a more full-bodied paper, feel free to add
bits of paper as your lint soaks.
27
Next, blend it in your blender as you normally would when making paper. Use
about a cup of lint and fill the rest of your blender with water; then, blend until it’s a
smooth mixture.
Follow through with the rest of your paper-making steps and you’ll have a wholly
homemade creation that’s great for arts and crafts, letters or other paper projects.
(Retrieved March 18, 2010 from http://www.papermaking.net/how-to-make-paper/how-
to-make-paper-with-dryer-lint/#more-44)
2.15 Making Plant-able Homemade Paper
Everyone experiences the conundrum of post-holiday, birthday, and other
seasonal greeting card blues. What are we supposed to do with these lovely cards after
the occasion passes?
While we might save a few for sentimental value, most are fairly generic.
Sometimes we can use them in scrap booking, or creating cool origami crafts or boxes;
but for the most part, we’ve got an extra box of recycling to turn in.
Fortunately, this is a problem that can be easily remedied with plant-able
paper.How cool would it be to enjoy your card–and then plant it into the ground to have a
long-lasting gift of nature in its place? Every time you saw it, you would think of the
person who sent it to you, and be reminded of the earth-friendly, natural gift of beauty
from such a thoughtful friend.
28
While you can buy such paper, it’s also possible to create your own. You can use
all of the steps in creating regular paper to begin with. Why not select some greeting
cards for your paper base? Then they will already be infused with good thoughts and
holiday cheer from past senders.
Now the variation comes in to make your paper plant-able. During the step where
you add your paper ―shake‖ mixture to a sink or basin, be sure to also add plenty of the
seed of the plant you wish to be grown from the paper. Flat seeds work best, such as
tomato, hollyhock, chili pepper, and forget-me-not. Then, follow through with the rest of
the steps and you will have made an incredible gift of plant-able paper!
If you decide to give the paper as a gift in the form of a card, gift tag, stationary or
anything else, be sure to note somewhere that it is plant-able and it can be torn up and
directly deposited into the ground as seeds would be. The paper around the seeds will
naturally disintegrate as the seeds grow. (Retrieved March 18, 2010 from
http://www.papermaking.net/how-to-make-paper/making-plant-able-homemade-
paper/#more-30)
2.16 How to Make Grass Paper
We’ve learned how to make paper, and even how to add a bit of grass to
homemade paper to give it some texture or a nature look. But did you know that you can
actually make paper out of plain old grass? While the smell from making paper out of
grass isn’t for people with weak stomachs, it can still be a fun way to use up your grass
clippings.
29
First, gather up all of your grass clippings. You’ll need between six to ten cups of
them. You may want to do this right after you mow the lawn, which is probably the
easiest way to gather grass.
Add the clippings to a large pot, fill it with enough water to cover the grass, and
mix in a half-cup of washing soda or baking soda. Allow this mixture to cook for an hour.
(If you have plenty of time, letting the grass soak overnight in cold water first can loosen
it up even more, making it easier to work with.)
Like you would do with other paper pulps you might create, pour your mixture
into a blender and blend until it’s of a smooth, uniform consistency. Then you’ll follow
through with the steps you used in making homemade paper from recycled paper.
Remember that you may have to play around with the consistency to get the
thickness that you want. For variation, long prairie grasses and dried straw work as well.
Be sure to clean out all of your instruments and containers immediately, as this project
can start to smell if left to sit for a long period of time! (Retrieved March 18, 2010 from
http://www.papermaking.net/how-to-make-paper/how-to-make-grass-paper/#more-21)
2.17 Solenoid valve: Definition, working principle and common uses
A solenoid valve is an electromechanical valve for use with liquid or gas. The
valve is controlled by an electric current through a solenoid coil. Solenoid valves may
have two or more ports: in the case of a two-port valve the flow is switched on or off; in
30
the case of a three-port valve, the outflow is switched between the two outlet ports.
Multiple solenoid valves can be placed together on a manifold.
A solenoid valve has two main parts: the solenoid and the valve. The solenoid
converts electrical energy into mechanical energy which, in turn, opens or closes the
valve mechanically. A direct acting valve has only a small flow circuit, shown within
section E of this diagram (this section is mentioned below as a pilot valve). This
diaphragm piloted valve multiplies this small flow by using it to control the flow through
a much larger orifice.
Solenoid valves may use metal seals or rubber seals, and may also have electrical
interfaces to allow for easy control. A spring may be used to hold the valve opened or
closed while the valve is not activated.
Solenoid valves are the most frequently used control elements in fluidics. Their
tasks are to shut off, release, dose, distribute or mix fluids. They are found in many
application areas. Solenoids offer fast and safe switching, high reliability, long service
life, good medium compatibility of the materials used, low control power and compact
design.
Solenoid valves are used in fluid power pneumatic and hydraulic systems, to
control cylinders, fluid power motors or larger industrial valves. Automatic irrigation
sprinkler systems also use solenoid valves with an automatic controller. Domestic
washing machines and dishwashers use solenoid valves to control water entry to the
machine. In the paintball industry, solenoid valves are usually referred to simply as
31
"solenoids." They are commonly used to control a larger valve used to control the
propellant (usually compressed air or CO2). In the industry, "solenoid" may also refer to
an electromechanical solenoid commonly used to actuate a sear.
Besides controlling the flow of air and fluids solenoids are used in pharmacology
experiments, especially for patch-clamp, which can control the application of agonist or
antagonist. (Retrieved April 15, 2010 from http://www.wikipedia.com)
2.18 Float Switch: Definition and common uses
A float switch is a device used to detect the level of liquid within a tank. The
switch may be used in a pump, an indicator, an alarm, or other devices. Float switches
range from small to large and may be as simple as a mercury switch inside a hinged float
or as complex as a series of optical or conductance sensors producing discrete outputs as
the liquid reaches many different levels within the tank. Perhaps the most common type
of float switch is simply a float raising a rod that actuates a microswitch.
A very common application is in sump pumps and condensate pumps where the
switch detects the rising level of liquid in the sump or tank and energizes an electrical
pump which then pumps liquid out until the level of the liquid has been substantially
reduced, at which point the pump is switched off again. Float switches are often
adjustable and can include substantial hysteresis. That is, the switch's "turn on" point may
be much higher than the "shut off" point. This minimizes the on-off cycling of the
associated pump.
32
Some float switches contain a two-stage switch. As liquid rises to the trigger point
of the first stage, the associated pump is activated. If the liquid continues to rise (perhaps
because the pump has failed or its discharge is blocked), the second stage will be
triggered. This stage may switch off the source of the liquid being pumped, trigger an
alarm, or both. (Retrieved April 17, 2010 from http://www.wikipedia.com)
2.19 Float Switch Operation
A float switch is an electro-mechanical switch which allows for an electrical
switch to be opened or closed depending on the fluid level in a container. The float
switch allows for automatic operation of devices depending on the level of fluid, such as
the operation of pumps, or the opening or closing of valves. Float switches of numerous
configurations have been used for various marine and industrial applications. Most float
switches contain an electrical switch imbedded within the body of the float switch device.
The electrical switch is actuated upon physical movement of the portion of the float
switch device containing the electrical switch or upon physical movement of another
portion of the float switch device. Such switches typically include a base member having
mounted thereon a buoyant arm or float member. They may be physically integrated with
the devices they control, or physically independent and connected to those devices only
electrically. Electrical circuit and switch means are associated with the arm or member
and are responsive to the angular position thereof, whereby the electrical switch means
opens and closes as the angular position varies. Typically, changes in the angular position
of the arm or member due to changes in water level cause an electrically conductive ball
or fluid, such as mercury, to move between switch ON and switch OFF positions to
33
permit or preclude the flow of current through the electrical circuit means. (Retrieved
April 17, 2010 from http:// www.electronics-manufacturers.com)
2.20 Water Detector
A Water detector is a small electronic device that is designed to detect the
presence of water and alert humans in time to allow the prevention of water damage. A
common design is a small device that lays flat on a floor and relies on the electrical
conductivity of water to decrease the resistance across two contacts. A 9 volt battery then
sounds an audible alarm in the presence of enough water to bridge the contacts. These are
useful in a normally occupied area near any appliance that has the potential to leak water,
such as a washing machine, refrigerator with icemaker, dehumidifier, air conditioner, or
water heater. (Retrieved April 20, 2010 from www.wikipedia.com)
2.21 Unipolar Stepper Motor
A unipolar stepper motor has two windings per phase, one for each direction of
magnetic field. Since in this arrangement a magnetic pole can be reversed without
switching the direction of current, the commutation circuit can be made very simple (eg.
a single transistor) for each winding. Typically, given a phase, one end of each winding is
made common: giving three leads per phase and six leads for a typical two phase motor.
Often, these two phase commons are internally joined, so the motor has only five leads.
A microcontroller or stepper motor controller can be used to activate the drive
transistors in the right order, and this ease of operation makes unipolar motors popular
with hobbyists; they are probably the cheapest way to get precise angular movements.
34
(For the experimenter, one way to distinguish common wire from a coil-end wire
is by measuring the resistance. Resistance between common wire and coil-end wire is
always half of what it is between coil-end and coil-end wires. This is due to the fact that
there is actually twice the length of coil between the ends and only half from center
(common wire) to the end.) A quick way to determine if the stepper motor is working is
to short circuit every two pairs and try turning the shaft, whenever a higher than normal
resistance is felt, it indicates that the circuit to the particular winding is closed and that
the phase is working.
Degree per step is often the most important factors in choosing a stepper motor. It
specifies the number of degrees that the shaft will rotate for each full step. Common
degree/step includes 0.72, 1.8, 3.6, 7.5, 15, and even 90. Degree per step is also known as
the resolution of the motor.
2.22 Relex Case Study: Redesign of a Robot for Improved Reliability
Many product manufacturers realize the need to establish reliability process goals
and commit to continual product improvement in order to meet customer, as well as
internal, quality goals. Oftentimes, companies committed to reliability improvement turn
to Relex Professional Services to aid in their reliability programs. The first step in
improving reliability was to identify points in the system affecting reliability. After that,
test plans were formulated in order to prove that the prototype can obtain the desired
reliability.
To analyze the client’s test coverage, flow charts were created for the processes followed
by both the test robot and a robot in the field. These two flow charts were compared, and
35
all differences were identified. The key differences were in the processes of crating the
robot, transporting the robot to the installation site, de-crating the robot, and installing
the robot. It was suggested here that the product reliability must be between 90-95%
confidence levels.
36
MICROCONTROLLER
Drying Passing through a
conveyor with blower at both ends
Cooking
Blending
Molding
Pouring of alkali solution
Shredded Corn Husk
Draining of Pulp
Draining of solution
Pouring of water
Chapter 3
Research Methodology
This chapter contains the research methodology that the researchers will use
through the course of the study. This section contains the theoretical and conceptual
framework that will be used in the implementation of the design. It will also contain
process flowchart regarding on how the system will work, as well as the proposed
schematic diagram for the design.
3.1 Conceptual Framework
Figure 3
Conceptual Framework
37
Figure 4
Block Diagram of the whole System
38
The figure 3 shows the process of a microcontroller-based recycler. It is
composed of blocks that reflect the process of the machine recycler.
The paper making process will be automatically controlled by our
microcontroller, which is a PIC16F877A. The microcontroller will be activating
necessary devices in order to successfully process the shredded corn husk to corn paper.
The process starts at the cooking, where the user must input the shredded corn
husk. The microcontroller also adds a specified amount of alkali solution to the cooker.
With this, the shredded corn husk will be boiled using a heating element. The cooking
part lasts for about 1 hour, which will be timed by the microcontroller.
After cooking the corn husks in alkali solution, the next process involves draining
the alkali out of the container. Here, a solenoid valve will be used to drain the alkali
solution without draining the corn husks as well. The drained alkali solution will be
passed to the solenoid valve to the container itself. Before blending the corn husks, an
amount of water will be added to aid with the blending process. The blender will now be
activated by the microcontroller. Once the corn husks are fully blended, the paper pulp is
now produced.
The pulp is now transferred to the mould through the use of a solenoid valve. In
order to spread the pulp while in the mould, a brush controlled by 2 motors is used. Once
the pulp is leveled well in the mould and deckle, it can now be passed to the dryer section
of the machine. The dryer is composed of the conveyor belt, a motor controlled lid, with
two hair dryers located at the sides. After the time allotted for drying, the mould will be
now unloaded and the corn paper is now finished.
39
Figure 4 shows the basic processes the machine will go through. It is divided into
two main boxes namely the User and the Machine. The user part tells us where the user is
involved on the process. The machine part tells us the processes where the user has no
intervention.
The user part has start button and a task of putting in the corn. The whole process
depends on the start button which gives the go signal to the machine to start the whole
process. The task of putting the shredded corn husk in the cooker blender container is
done manually by the user.
The machine has many processes in it. The link between the user’s button and the
machine will be the MCU. It will also give orders to what process will take effect next.
The LED display will indicate if the water and soda ash solution source is nearly
depleted.
There are two tanks inside the machine, the soda ash tank and the water tank.
These two tanks supply the liquid necessary on a specific process. The tanks are all
connected to the cooker blender where the cooking and blending process is made. After
this stage, the pulp will be drained to the mould and deckle. The pulp will be flattened or
leveled to the mould. When this is done, the material will be dried and then will be ready
for use.
40
3.2 Design Considerations
3.2.1 Input
The shredded corn husks will be fed into the machine as an input. The
shredded corn husks are pre-determined before being fed into the machine, it must
be in a size of 0.5 x 0.5 cm and weighs 40 grams. It is fed into the hole directly to
the container where it will be cooked.
3.2.3 Water Level Detector
The water level detector will determine how much volume of water to be
poured into the container. In the system, there are two detectors to be used. These
water level detectors are placed into the tanks. There are two tanks in the system,
one is filled with water mixed with soda ash and the other tank is filled with pure
water. The water level detector for the tank with water and soda ash will
determine the volume needed to be poured to the container to cook the corn husks
and the other one will determine the volume the water needed to blend the cooked
corn husks and needed to drain the blended corn husks or pulp to the mold and
deckle.
Both water level detectors will send signal to the microcontroller to
control the operation of the solenoid valves.
This water level detector uses LDR sensors. The sensor is based on a
voltage comparator circuit using LM741. The input to the inverting input will be
the voltage across the LDR that is light dependent. At darkness the resistance of
41
the LDR will be high and so do the voltage across it. The inverting input will be
higher than the reference at non inverting pin and the output of the comparator
will be low. When the LDR is illuminated, its resistance drops and so do the
voltage across it, thus the voltage at inverting input will be lower than that at non
inverting input and the output of the comparator goes high. A potentiometer will
be used as an adjustable reference voltage of the sensor to alter the sensitivity of
the sensor.
Figure 5
LDR
3.2.4 Water Sensor
The system will utilize two water sensors. The first one will detect the
draining of the water from the container where the corn husks are cooked. Once
the draining is done, the water sensor sends signal to the microcontroller to stop
the solenoid valve from draining. The other one will detect the draining of water
with pulp. The sensor will send a signal to the microcontroller to start the motor in
distributing the pulp over the mold and deckle.
42
The water sensor is based on a 2N3904 transistor. It uses the transistor to
act as a switch when the base of the transistor is shorted to the positive of the
supply by the water falling on the sensor. When the transistor saturates, it will
send signal to the microcontroller. The 1 MΩ potentiometer will be used to alter
the sensitivity of the sensor.
2N3904
Figure 6
Water Detector
3.2.5 Relay Circuit
The relay circuit will be used to control the operation of the heating
element in the cooking, the blender to slice the pulp, and the hair dryer in the
heating of the paper. The relay circuit will be controlled by the microcontroller.
Figure 7
Relay
43
This is the circuit that drives the ac components of the prototype as shown
above. It uses a 2N3904 transistor to act as a switch. The microcontroller saturates
the transistor to run the relay. The 1N4001 diode to be putting between the
collector and the power is for the protection of the transistor.
3.2.6 Motors
There are two types of motors that the proponents will use: DC motors,
and stepper motors. There are five DC geared motors to be used move the
components of the system. The first motor will control the replacement of mould
and deckle. There are two motors to be used to spread the pulp to the mould and
deckle. And two other motors will be used in pressing the paper in the heating
process.
Two unipolar stepper motor will be used to transfer the paper and the
mould and deckle to the drying area and to the output area using a conveyor belt.
3.2.7 Motor Driver
For the motor driver for the motors of the prototype, the proponents will
be using L298 IC. The L298 IC is an integrated monolithic circuit. It is a high
voltage, high current dual full-bridge driver designed to accept standard TTL
logic levels and drive inductive loads such as relays, solenoids, DC and stepping
motors.
44
Figure 8
L298 Motor Driver
Figure 9
L298 Pin Configuration
Figure 10
DC Geared Motor Driver
45
Figure 11
Stepper Motor Driver
The circuits above are circuits that drive the motors of the prototype, DC
geared motors and stepper motors using L298. The circuit provides two source
voltages, 5V and 12V for VCC and VS respectively. It uses fast recovery UF202
diode which has 50 ns recovery time as required by the datasheet of L298 which
should not be greater than 200 ns recovery time. The enable pins are at high
condition to enable the Bridge A and Bridge B because both bridges will be used.
A 0.5Ω resistor is connected to sensing pins to control the current of the load.
3.2.7 PIC16F877
The PIC16F877 Microcontroller includes 8kb of internal flash Program
Memory, together with a large RAM area and an internal EEPROM. An 8-
channel 10-bit A/D convertor is also included within the microcontroller, making
46
it ideal for real-time systems and monitoring applications. All port connectors are
brought out to standard headers for easy connect and disconnect.
Figure 12
PIC Microcontroller
In the design, the PIC16F877 will be the system’s main microcontroller. It will
accept all the signals from the detection circuits and will actuate all the motors
and other devices of the system.
Figure 13
PIC16F877 Pin Configuration
47
3.2.8 Power Supply
A dc power supply is used to convert ac voltage at wall outlets into a
constant dc voltage. The circuit is shown below. The power supply will use a
transformer with a rating of 0-110-220V primary and 12-0-12V, 3A secondary.
The rectifier is a Center-Tapped Full Wave Rectifier that provides a full cycle
pulsating dc which leads to produce a smooth and regulated dc signal to the
electronic components. Half-Wave Rectifier and Bridge Rectifier are not
appropriate for the functions of the system because Half-Wave Rectifier produces
a half cycle pulsating DC. Thus, produces a distorted DC signal which can
generate noise causing a delay in the operations of the microcontroller which may
lead to damaging it. The Bridge Rectifier produces a higher voltage and current
rating than Full Wave Rectifier that is not suitable for the functions of the
prototype because it can lead to damaging its electronic components.
The 1N5400 diode will be used in rectifier because this diode suits the
output rating of the transformer t its secondary winding. Though there are other
diodes available such as 1N5401 to 08 but are more expensive. The 2200 µF,
25V capacitor is used to flatten the pulsating output from the Center-Tapped Full
Wave Rectifier.
There are two voltage regulators will be used, L7805 and L7812. The
L7805 voltage regulator has a fixed output voltage of 5V and output current of 1A
that will be used to supply the microcontroller, and detection circuits. Moreover,
the L7812 has a fixed output voltage of 12V and output current of 1A to supply
the motors.
48
Figure 14
Power Supply
49
3.3 Ideal Design of the Prototype
Figure 15
Prototype
Figure 16
Water Tank and Soda Ash Tank with Water Level Detector
50
Figure 17
Cooker Blender
Figure 18
Mould Dispenser
51
Figure 19
Pulp Distributor
Figure 20
Brush
Figure 15 shows the ideal design of the prototype. The whole design is composed
of two tanks, one for soda ash solution and one for water which both contains a water
level detector, input section for shredded corn husk, cooker/blender container for cooking
and blending process, solenoid valves, mould and deckle dispenser, brush for leveling of
the pulp, roller pins for pressing of the excess water, conveyor for moving the mould and
deckle with pulp ,motor controlled lid and two blow dryers used for drying process.
Furthermore, it also contains a LED for indication of errors. It also has a start button for
initializing the machine.
52
3.4 System Flowchart
Figure 21
System Flowchart
53
The process begins when the shredded corn skin is fed to the blender cooker. The
next step involves the pouring of the alkali solution on the blender cooker. This
combination is ready for the next process which is cooking. This process is time bounded
and signaled to start at the moment the right amount of solution is poured. After the given
time is over, the solution on the blender cooker will be drained. A small amount of water
will be introduced to the blender cooker and the blending process will start. Additional
water is supplied to the blender cooker after the process of blending is done. Then, the
water with the pulp will be drained out the blender cooker and then poured out to the
mould and deckle. When all of the pulp is drained out, it will be pressed and distributed
to the mould. After this, the mould with the pulp will be pressed down with a smooth flat
metal and then dried below by blowers or dryers. The finish product is then produced.
3.5 System’s Reliability
To compute for the reliability of the system, consider the equation is shown
below:
R = 1 – Number of Failures
Number of Success/ Trial
To compute the percent reliability of the system, we consider the equation shown
below:
%R = R × 100%
The aimed reliability of 95% was based on a case study provided by the Relex
Company. Their case study focuses on the reliability study of a robot with an automated
54
task. During their test planning, the aimed reliability was 95%. Since the case study
involves a robot already in the industry, we think that having a 95% reliability is enough
for our initial prototype.
3.6 Testing procedures
3.6.1 Error Conditions
Table 1
Error Conditions
Table 1 shows the possible errors that could happen to the prototype machine. The
errors can happen during the input of corn husks, input of alkali solution in the cooker
blender, input of water in cooker blender and the error that could happen in the mould
and deckle. The table also shows the test conditions and the expected result for testing.
55
3.6.2 Test Conditions
Table 2
Testing Conditions
The testing procedure will be done per process. As we see from the table 2, we
consider the five major processes involved in the paper machine recycler such as
cooking, draining, disintegrating, transferring to conveyor belt, drying and cutting.
The testing begins by putting in the shredded corn husk, rice straw or talahib. The
amount of the shredded corn husk, rice straw or talahib is predetermined. The alkali
solution however should be tested in two cases. As the user press the start button, the
machine should start pouring alkali solution and it must stop pouring after the required
56
level is reached. The water level detector operation should be tested depending on the
fluid level in a tank. If pouring soda ash solution reached the desired amount needed for
cooking, the water level detector should be able to detect it and send a signal to the
microcontroller to close the valve then start cooking. Cooking will end upon the specified
time.
There are two stages where draining is involved. Draining 1 is when the alkali
solution is drained from the cooker then replaced with pure water, and the other is the
removal of the pulp with water in the disintegrator. Motor pump is the responsible device
to make this process possible.
The disintegrator function will remove the part not needed in the process. It will
start when the enough water needed is poured to the container. The whole blending
process will end after 5 minutes. At the end, water will be poured into the container and
the second draining process will happen.
In the molding process, a conveyor belt is used to spread the paper pulp. It should
be tested to make an equal spreading. Moreover, once it was finished, the conveyor must
move to the pressing and drying section. It must then be tested that once the pulp is in the
pressing-drying section, it must be then pressed using rolling pins and be dried by an
electronic heating element. After the paper is dried first, it will be brought to the cutting
section. It must be tested that the cutter can cut the paper with its given size. Finally, it
will be air dried for the last time. It will be tested that the dryer will activate for the
specified time.
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3.7 Testing
To thoroughly evaluate the performance of the project, there would be 5 trials to
be used to test each category. The number of trials was determined using the
Fundamental Formula of Gambling: , where
DC = degree of certainty = reliability = 0.95
p = probability of success or failure = 0.5
N = number of trials
Solving for N:
From the formula presented above,
Substituting the values of DC and p, N = 4.322 ≈ 5 trials
Test for Volume of Soda ash Solution
This will test if the volume of 1 liter soda ash solution is transferred for the
cooking of corn husks with five trials.
Table 3
Tabulation for testing the volume of soda ash solution for cooking
TRIAL SUCCESS FAILURE TIME
1
2
3
4
5
AVERAGE
58
Test for Cooking of the Paper Pulp
This will test if the specified time of cooking is achieved with five trials.
Table 4
Tabulation for testing of cooking the paper pulp.
TRIAL SUCCESS FAILURE TIME
1
2
3
4
5
AVERAGE
Test for Disintegration
This will test if the specified time of 5 minutes is achieved in blending the pulp
with five trials.
Table 5
Tabulation for testing of disintegration of the pulp
TRIAL SUCCESS FAILURE TIME
1
2
3
4
5
AVERAGE
59
Test for Volume of Water
This will test if the volume of half liter water is transferred for draining the pulp
with five trials.
Table 6
Tabulation for testing of volume of water for draining the pulp
TRIAL SUCCESS FAILURE TIME
1
2
3
4
5
AVERAGE
Test for Conveyor Belt
This will test if the pulp is transferred to the conveyor belt and distributed equally
with five trials.
Table 7
Tabulation for testing of moulding the paper
TRIAL SUCCESS FAILURE TIME
1
2
3
4
5
AVERAGE
60
Test for Drying of Paper
This will test the quality of paper after the specified time of drying with five trials.
Table 8
Tabulation for drying the paper
TRIAL SUCCESS FAILURE TIME
1
2
3
4
5
AVERAGE
Test for Cutting of Paper
This will test the size of paper after the specified time of drying with five trials.
Table 9
Tabulation for cutting the paper
TRIAL SUCCESS FAILURE TIME
1
2
3
4
5
AVERAGE
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3.8 Error Parameters
This part discusses the possible errors that the group considered to occur during
the development of the prototype. The group clarified that the errors stated below will not
become the limitations of the prototype that may reduce its total reliability. These were
merely consideration that served as guide to minimize such errors and achieve a higher
reliability.
The possible errors that will occur in the system design are the following:
Water Level Detector Reading
- Wrong indication of water level may occur
Draining
- Corn husk, Rice straw or talahib may clog on and in the valve
Dispersion of the pulp in the conveyor belt
- The Pulp may not be dispersed at all sides of the mould and deckle
Drying
- Paper pulp may stick to the rolling pin and in the dryer
3.8 Instruments Used
This study utilizes Internet for gathering information about the study and to site
some articles that is related to the project. The group also conducted further experiments
in making paper from corn husks, rice straw or talahib manually. Such experiment done
is made for the purpose of observing the problem arises or the disadvantages when
making paper done manually and also to test the properties of the finished product paper
62
done manually. The group also made school library visits for the improvement of the
designed project. Through reading books from the library and articles from the internet,
the group was able to get some data that will determine all the required information
needed for the project. Moreover, the group also asked some Electronics Engineers and
concerned citizens for reference regarding the project, the technology given in this
project, the statistics and the parameters to be measured for the project.
63
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65
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