Final Design

In the final design, the team decided on a top-down cleaning system that consists of 3 main subsystems:

1. Top Brush Subsystem

2. Side Brush Subsystem

3. Bottom Brush and Transport Subsystem

Top Brush Subsystem:

The Top Brush Cleaning System is designed for efficient and adjustable cleaning, featuring replaceable brush cores and adjustable arm positioning to accommodate various cleaning needs. The system also is fit with a misting subsystem that will loosen debris. The system is still in development, with tasks including machining arm bars, creating an adjustment mechanism, assembling the system, and integrating a sprayer. The inclusion of 3D-printed brush cores enhances cost-effectiveness and ease of maintenance.

Misting Subsystem:

        The misting system is designed to automate the external spraying of barrels, reducing the need for manual labor. It features serviceable, low-cost misting nozzles, quick-connect fittings for easy customization and installation, an external liquid reservoir, and a low-noise diaphragm pump. These elements enhance efficiency and ease of use while maintaining a cost-effective and adaptable solution. 

Side Brush Subsystem:

The proposed design incorporates key features to improve stability, adaptability, and ease of use in the cleaning process. It includes a slider with caster wheels to stabilize the system, a lead screw vertical actuator with a coupler to accommodate various barrel heights, and a 27-inch modular hoop with 6-inch bristles for a serviceable fit across different sizes. These features provide ergonomic benefits by eliminating manual scrubbing, reducing wrist and back strain, and enabling effortless operation with a simple load-and-push-button mechanism. 

Bottom Brush & Transport Subsystem

The Bottom Cleaning & Material Transport system facilitates seamless movement from the pallet to the cleaning zone without manual lifting or tilting, improving efficiency and reducing strain. It is designed to clean hard-to-reach areas at the bottom of barrels using a structured platform. The remaining tasks include finishing the milling of brush pockets, assembling the plates, and testing the system for effectiveness.

Control

The control system for the cleaning setup is managed via Arduino using analog controls. The next steps include replicating the control system for the top and side brush mechanisms as needed. A demonstration showcases a motor spinning via hand control, with future plans for computer integration facilitated by a transistor. This system aims to streamline automation and enhance the efficiency of the cleaning process.

Performance & Results: 

The Material Transfer Cleaning System testing demonstrated effective cleaning across all major subsystems. Using a flour-based visibility test, the sprayer system successfully coated barrel surfaces (excluding the bottom). The top brush effectively removed debris, though some flour clumped near the rim. The side brush achieved near-complete cleaning after five cycles and withstood stress tests without deformation. The bottom cleaner and ball roller conveyor facilitated smooth barrel movement, though minor wobbling occurred due to uneven bearings. Control system improvements reduced signal noise, preventing erratic motor behavior. Compared to initial performance requirements, the system successfully cleaned the top, sides, and bottom of barrels, supported sizes 15–21 inches (with a planned attachment for smaller sizes), and efficiently transported barrels, with minor adjustments needed for smoother operation.