Hops Baler Project 2013
Created by: Jacob Speed, Matt Gallagher, Sam Ledue, Lloyd Bryant, and Nathan Rocker
Updates from origianl design
Experimental Process
• Measure forces on the mounting brackets as the actuators are extended.
• Measure off-axis displacement of actuator from its original axis when different loads are applied.
• Determine which mounting design most rigidly supports the actuators under full loading and range of movement.
• Determine if additional mounting methods are required to hold the actuators in place.
• We are going to create the chambers out of 3/8” plywood that is donated by ABM Mechanical, Inc.
• To prototype the machine we will need a material similar to hops.
• We plan to test with polyurethane materials such as packing peanuts with varying densities.



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​​​We have come up with a process to do the compression, but we are kind of at a hault with the dimensions. With the setup we have, the total height (to the top of the linear actuator) would be over 7 feet. The total length would be just under 7 feet and the width would be roughly a foot. At 7 feet tall, 36" of that would be the compression chamber, and the rest would be the linear actuator mounted vertically for the compression. Similarly, the length is measured by about 26" for the 2nd compression chamber and 15" for the bag chamber (where the final bale is going to be formed).

The bag chamber is going to be detachable so the length horizontally will decrease. We are trying to think of a detachable mounting method for the actuators so they can easily move the baler around without worrying about the actuators sticking out beyond the baler chambers if needed.

Questions we are dealing with is if we do make something with these dimensions, would that be ok for the company we are building this for? Or would they want something smaller seeing as they are just an up and coming company, which would in turn make us come up with a different compression method.

We also talked to the overseer of the capstone projects and we might be able to give the company the baler we are making, as long as we build another for the University. He would ideally like us to make 2 balers for the University to keep one, but we will see what we can do with the time restraints.

We changed the idea of a hopper, to a fill chute that will fill the vertical chamber while pouring the hops in. We added a bag chute for an easy vacuum sealing operation. The ideal final product will be 5 lb bales of compressed hops. Dimensions of a baler to make 10 lb bales were unrealistic for the work environment for the company. We have decreased the cost for materials, and downsized the stroke length.
Assembly Process
Budget
Design Changes/Final Assembly
Materials​
Materials: 
-Clear 3/8” Poly-carbonate Plexiglass
-12 GA Telestrut Square Tubing & Fittings
-12GA Steel Punched Angle

​Vertical Actuator
• 36” stroke length
•Generatesmaximumof 1500 pounds offorce
• Mounted to the top frame using a Thomson
rear clevis-endmount
•Used asfirst-stage compression

Horizontal Actuator
• 24” stroke Length
•Generatesmaximumof 2000 pounds offorce
• Mounted on plywood blocks with pipe hanger
strapping around the shaft and plywood blocks
at back for support of any deflection during
operation.
•Used assecond-stage compression

Batteries and Controls
• Each Linear Actuator is wired to a separate
12-volt battery and are concealed in a box for aesthetic pleasure
•Double pole-double throw (DPDT) switches are wired between the actuators and batteries to control the actuators’ motion (Extension, retraction, or remain neutral)

Push Plate Mounts
• Push Plates made of 3/8” polycarbonate with a hole drilled in the middle to fit over the clevis mount on the end ofthe actuators
• Two washers and felt also slid over clevis mount with a pin connection for plate stability


Base and Frame
• ¾” Oak Plywood table
• P9200 and P9000 Steel Telestrut Tubing, stainless steel angles, and P9011 Telestrut Post-bases fastened together using 9/16” bolts, washers and nuts which create a strong, durable structure

Compression and Bag Chambers
• 3/8” impact-resistant polycarbonate sealed with weld-on #4 polycarbonate glue
• We created an L-Shaped Compression Chamber that holds and forms the bale during compression


Compression Method
Poly-carbonate plexiglass push plates  are measured to fit ‘snug’ to the internal walls of the chambers.

​The actuators we have chosen are designed to withhold the increase in pressure during the compression. The horizontal chamber is designed to have the actuator extend to its maximum stroke length (24”). We will use the controller to stop the actuator while the horizontal compression is in progress.

For the compression and bag chambers, we chose to use secure it together with 3/8” impact-resistant poly-carbonate sealed with weld-on #4 poly-carbonate glue. We also created an L-Shaped Compression Chamber that holds and forms the bale during compression.

​One 36” Electric Push/Pull Linear Actuator - $449.83

One 24” Electric Push/Pull Linear Actuator - $412.94

One Power Supply Controller - $353.46

Four 12 GA Punched Angles - $52.91

Eight 12 GA Telestrut Postbase - $480.00

Twentyfive 90° Angle Telestrut Fitting - $312.85

One 12 GA Telestrut Square Tubing - $74.00

Two Toggle Clamps - $32.36

Polycarbonate Plexiglass - $380.00

Four Actuator Mounting Brackets - $613.60

Total Budget - $3,161.95


SolidWorks Design of Hops Baler

​Pictures of Materials

​Pictures of Materials