Final Test Mechanical Design and Manufacturing - Intelligent Conveyor System
Precision engineering and robust construction for reliable automated sorting operations.
Introduction
Project Context
This mechanical documentation covers the design and implementation of an intelligent conveyor system for automated waste sorting as part of the TEKBOT Robotics Challenge 2025.
Key Objectives
- Design a 650mm conveyor system for 30mm sorting cubes
- Implement a reliable mechanical sorting mechanism
- Ensure compatibility with electronic and computer systems
- Optimize for 3D printing and rapid prototyping
Material Selection Strategy
Primary Materials Used
PLA Filament
- Main structural material
- 100% infill for critical parts
PVC Conveyor Belt
- 120mm width, 2mm thickness
- Optimal adhesion for cubes
6300-2RS Bearings
- Sealed ball bearings
- 12mm inner diameter
Material Advantages
- Cost Reduction: 60% cheaper than metal solutions
- Production Time: 3 times faster manufacturing
- Maintenance: Simplified part replacement
- Weight: Light but robust structure
Component Specifications
| Component | Material | Dimensions | Quantity | Function |
|---|---|---|---|---|
| Main Frame | PLA | 650×200×150mm | 1 | Primary structure |
| Left/Right Support | PLA | 225×100×12mm | 6 sections | Side frame elements |
| Motor Drum | PLA | Ø60mm | 1 | Motor connection |
| Return Drum | PLA | Ø60mm | 1 | Belt guidance |
| Bearings | Steel | 12×35×11mm | 4 | Rotation support |
| Sorting Guides | PLA | Various | 6 | Object direction |
CAD Modeling and Design
SolidWorks Implementation
Design Features:
- Parametric design for easy modifications
- Motion study for mechanism validation
- Interference detection implemented
- Mass properties analysis
Key Components
Main Frame Structure Modular design inspired by aluminum in PLA with corner reinforcement.
Sorting Mechanism Servo-actuated doors with precise 45° angular control.
Collection System Four separate bins with guided chutes for sorted objects.
Component Gallery
- Support Section A
- Motor Drum
- Sorting Guide
- Bearing Housing
Manufacturing Process
1. 3D Printing
All custom components are 3D printed in PLA filament with 0.2mm layer height and 20-100% infill depending on structural requirements.
Printing Parameters: Nozzle 200°C, bed 60°C, speed 50mm/s
2. Frame Assembly
Modular frame assembly using nested PLA components with M4 stainless steel fasteners for structural integrity.
Tools Used: Hex keys, tape measure, alignment jig
3. Mechanism Integration
Servo mounting with custom brackets, belt system tensioning and bearing installation for smooth operation.
Key Checks: Belt alignment, servo range, sensor positioning
4. Final Assembly and Testing
Complete system integration followed by rigorous testing to ensure reliable operation under various conditions.
Tests: Load capacity, sorting accuracy, endurance
Technical Specifications
Dimensional Specifications
- Total Length: 650 mm
- Belt Width: 150 mm
- Frame Height: 150 mm
- Object Capacity: 20 objects/min
- Belt Speed: 0.1 m/s
Performance Metrics
- Sorting Accuracy: > 95%
- Maximum Load Capacity: 5 kg
- Power Consumption: 12V, 2A
- Noise Level: < 65 dB
- MTBF: > 1000 hours
Validation Results
All mechanical components meet or exceed design specifications with safety margins:
- Structural safety factor: > 2.5 on all PLA components
- Expected bearing life: > 10,000 hours at rated load
- Belt tension maintained within ±10% of optimal range
- All moving parts operate within specified tolerances
Design Files and Documentation
SolidWorks Source Files
Complete CAD project with all parts and assemblies:
- 42 individual part files (.SLDPRT)
- Main assemblies and sub-assemblies
- Technical drawings and specifications
- Motion study simulations
3D Printing Files
STL files ready for printing for all components:
- Optimized for FDM 3D printing
- Pre-supported if necessary
- Printing guidelines included
- Assembly instructions
Important Notes
- Software Requirements: SolidWorks 2025 or compatible viewer for source files
- Printing Recommendations: 20-40% infill for non-structural parts, 80-100% for load-bearing components
- Material: PLA recommended for all printed parts
- Tolerances: Account for 0.2mm printing tolerance in assemblies
Physical Prototype and Testing
Prototype Demonstration
Watch the conveyor system in operation
Test Results
Successful Tests
- Continuous operation for 8 hours without failure
- Accurate sorting of 30mm cubes by color
- Stable belt tracking and tension
- Appropriate servo mechanism response
Areas for Improvement
- Belt slippage at higher speeds
- Noise reduction in gear mechanisms
- Enhanced vibration damping
- Optimized bearing lubrication
Conclusion
The mechanical design of the intelligent conveyor system successfully meets all TRC 2025 requirements, demonstrating robust construction, reliable operation and seamless integration with electronic and computer subsystems.
Key Achievements
- Precision manufacturing using 3D printing technology
- Optimized material selection for cost and performance
- Successful integration of mechanical and electronic systems
- Complete documentation and reproducibility
Future Improvements
- Advanced vibration damping systems
- Modular design for easy scalability
- Enhanced material options for specific applications
- Integration with Industry 4.0 standards
UCAO-TECH - TRC 2025
Innovative Mechanical Solutions for Automated Sorting Systems