Multimedia

In November 2024, our group decided that this traditional conveyor system would be most effective in creating the desired cleaning system.  However, as time went on, problems arose... 

The initial design required 4 key components, which included a brush system, a conveyor system, a liquid misting system, and an offloading system. We went as far as to prototype the beginning stages of the brush system and spec'ing out conveyor systems and spraying systems. 

Iteration 1: FAILED

Although the original project showed promise, it ultimately failed due to overengineering, excessive complexity, and time and space constraints. However, the experience provided valuable engineering insights and reinforced the importance of staying focused on the project's core objectives. As a result, the team redefined its major goals, prioritizing the inefficiencies of manual cleaning, with a particular emphasis on improving ergonomics and time efficiency. 

As the project neared critical stages, it became clear that the original design was too complex, impractical, and constrained by time and space limitations. Forced to pivot late in the timeline, the team had to scramble for new solutions, quickly refocusing on ergonomics and efficiency to address manual cleaning challenges. With limited time, they explored alternative designs, including a Caged Mechanical System, a Tilting Table, and a Handheld Device, each balancing automation and feasibility. The rushed shift demanded rapid prototyping, iterative testing, and efficient decision-making, pushing the team to adapt under pressure while salvaging key insights from the initial concept. 

After multiple design iterations, the team prioritized feasibility and ergonomics, selecting a semi-autonomous top-down cleaning system. Inspired by the movie Dune, the sandworm presents a similar mechanism of cleaning the sides of the barrel through linear actuation. This design integrates adjustable brushes, built-in sprayers, and bottom cleaning within conveyor transport, balancing automation with practicality.

 Proof-of-concept tests validated the lead screw brush movement, PVC material durability, and sprayer efficiency, with the Arduino-controlled system ensuring seamless operation. Key decisions remain on brush locking, nozzle placement, and automation levels, while ongoing refinements address cleaning effectiveness and water management. With these improvements, the project is advancing toward a functional, ergonomic, and efficient final design. 

Side Brush System:

Bottom Brush & Transport System:

Misting System:

Top Brush System:

Controls

In the assembly process, there were several changes that facilitated with the system.

Since the hoop caused a forward tilt to the linear actuator, a provisional weight was added to the back to balance the slider on the lead screw. This succeeded as an 18lb steel block was added, and the motor had fewer issues.

Since the original spec'd motor was rated for 80lbs, we changed the original motor into a better torque motor with a gear ratio of 1:50! This allowed for better success with our system.

The controls had some wire noise and filtering issues, so more testing will be done before they are implemented into the Genentech workflow. Since the misting system would compromise the current configuration, the system cannot run without proper waterproofing.

The speed of the top brush system was lowered to fit the system better.

On March 10, 2025 the team went to the Genentech site in Oceanside and presented our project to the group. We received positive feedback about the system and can't wait to continue working with Genentech to improve it!

Some of the improvements include more testing and safety features, however, the system worked wonderfully for a proof of concept project.