Peanut Processing Belt
Peanut Processing Belt
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Solving a major challenge in peanut conveyance for automated treatment of peanuts.
Company was able to pivot based on this work. Unlocked a new vertical, earned 25% raise.Solving a major challenge in peanut conveyance for automated treatment of peanuts.
Year: 2022
Role: Project Lead
Collaborators: Head Plasma Scientist, (1) Junior Engineer
Problem
Problem
Needed to solve a core material transport problem blocking progress of all R&D work: how to move peanuts through plasma (gas ionized with high voltage electricity),
The solution needed to be feasible at industrial scale, eventually be made from food-safe materials, without stainless steels, and reasonably waterproof for washdown procedures, resistant to ozone, peroxides, UV, oxygen super-oxides, nitric acids and also flame resistant. Previous prototypes all suffered various failures due to electrical arcing, melting, static build-up and out of spec variance in feedrate.
Strategy
Strategy
The Solution: aluminum metal food-grade conveyor belting.
A New Problem: this doesn't exist. (read; immense cost and lead time)
The New Solution: apply a plating of aluminum to surplus (eBay) polymer conveyor belting with aircraft flush rivets. This would simulate a 100% metal belt, for experimental purposes. If this prototype was successful, we could justify the expense of having 100% aluminum conveyor belting made.
It is usually worth using as much of a pre-engineered system as possible, in this case we avoided engineering a chain belt from scratch, and could be more confident it would hold up at an industrial scale.
Prototyping
Prototyping
Since this belting isn't typically stocked by suppliers or manufacturers, we began with spare lengths sourced from eBay. I selected a belt with a flat(ish) top and wide links, as we would have to cut fewer aluminum plating panels.
Plasma intensifies at prominent conductors, so we needed a flush, robust, repeatable, and precise attachment for an aluminum skin. Naturally, this meant aircraft tooling. I sourced aircraft flush-riveting tools (also eBay), so we could countersink blind rivets (see inset illustration).
It was also necessary to machine the surface of the links flat. Food grade belting isn't made with precision finishes.
Blind countersunk rivets
Milling the the belt flat on our cnc
Applying each link plating with a hole drilling template, countersink tool, dimple die press, and pop-riveter
Finished links and high voltage cabling
Static belt test under plasma, before starting work on the conveyor mechanism
Final Build, Testing
Final Build, Testing
After a successful test under plasma, we set about making a basic frame to hold the belt and it's driving and support mechanism.
First static belt test. Quick frame was constructed with belt runners, cog-wheels, a small electric motor and chain drive, and a passive adjustable hopper with vibrator. To minimize electrical arc-over, all components were made out of insulators - fiberglass structural channel frame and polymer pillow block bearings, Kevlar drive rod and polymer chain and gearing.
Complete prototype conveyor
Complete prototype conveyor with peanut hopper, rear
Complete prototype conveyor with peanut hopper, front
Complete prototype conveyor with peanut hopper, side
Results:
Results:
For the first time, peanuts were transported through an active plasma field with none of the previous failure modes. Overall, successfully demonstrated concept, resulting in an order of custom aluminum belting from a manufacturer for full-scale testing.
Overall: demonstrated feasibility of conductive metal belting, avoiding high cost and lead time for custom manufacture, despite tight material constraints and lack of commercially available product which met all the requirements.
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