Design and Fabrication
The SunSieve system's design and construction are essential phases that turn creative ideas into working devices. During the design phase, a thorough comprehension of the project's objectives informs the development of a blueprint that incorporates environmental sustainability, operational efficiency, and cost efficiency. Engineers and designers carefully delineate the technical characteristics, taking into consideration the intended use of the system in the agricultural industry. Individuals choose suitable specifications for solar panels, battery storage, motor needs, and the size of the physical extractor, in addition to comprehensive schematics that depict the connections between the electrical and mechanical parts.
Power Demands
The power consumption requirements of the SunSieve system are determined by the total energy needs of its various components. These requirements are essential for determining the appropriate capacity of solar panels and for battery storage. The extractor motor is the primary energy user and requires 746 watts to operate. On the other hand, the Arduino Uno R3, which handles the control logic of the system and manages the sensors and UV light, has a very low power consumption of just 0.29 Watts. Furthermore, the UVC lamp, which is crucial for sterilizing tomato juice to guarantee its safety during ingestion, requires 4 watts of power. Collectively, these constituents contribute to a cumulative power consumption of 750.29 Watts in the system.
The total load is the primary determinant of the size of the solar power generating and storage system. The solar panel array must have the capacity to generate sufficient power to meet or surpass this need during most sunny periods of the day. In addition, to maintain uninterrupted functioning, particularly in the absence of sunshine, it is essential that battery storage has sufficient capacity to provide power to the system, taking into consideration any inefficiencies or energy losses. It is crucial to slightly exceed the specified capacity of solar panels and batteries to account for inefficiencies and fluctuations in the solar energy supply. Furthermore, factors such as the motor's duty cycle, the frequency of UVC light activation, and the Arduino's runtime will impact the total energy consumption throughout the operating cycle of the SunSieve system. Hence, the design should include a reserve in energy estimates to guarantee dependability and continuous functioning, irrespective of external circumstances.
Panel and Battery Sizing
Accurate sizing of solar panels and batteries is essential for the functioning of the SunSieve system, particularly due to its 6-hour daily operation and total load of 750.29 Watts. To begin with the size of the solar panel, the daily energy need of the system is determined to be 4501.74 Watt-hours (Wh), taking into account its 6-hour operation. Accounting for common system inefficiencies, which are expected to be approximately 25%, the revised daily energy demand increases to approximately 6002.32 Wh. To achieve this requirement, the solar array would need a capacity of approximately 1200.46 Watts, assuming an average of 5 peak sunshine hours each day. Based on the use of conventional 250-Watt solar panels, this computation indicates that approximately 5 panels would be required to provide sufficient electricity.
The process of determining the appropriate battery size follows a similar methodical approach. The daily energy storage demand remains constant at 4501.74 Wh. To maximize the lifespan of the batteries and take into consideration the depth of discharge (DoD), which is normally set at 50% for deep-cycle batteries, the total battery capacity needed is effectively increased to 9003.48 Wh. In the case of a 24 V system, which is often used in medium-scale solar projects, it is necessary to have batteries with a combined capacity of approximately 375.15 ampere-hours (Ah). To accommodate the usage of ordinary 12 V 100 Ah batteries, approximately 8 units are needed. When interconnected to create a 24 V configuration, these components provide enough capacity to fulfill the operating requirements of the SunSieve system, even in the absence of sunshine.
The calculations for the solar panels and batteries provide a fundamental understanding of the energy generation and storage capacity needed for the efficient functioning of the SunSieve system. Nevertheless, it is important to acknowledge that these numbers are approximations. Geographic location, local weather trends, and operating hours might impact the ultimate size of a city. Hence, guidance from a solar energy expert is advised to fine-tune these figures, thereby guaranteeing the optimal performance and dependability of the system in real-world scenarios.
The Sunsieve System
Figure 5 depicts the concrete design of the SunSieve system, showcasing its many components, each carefully crafted and manufactured based on precise measurements to enhance the efficiency of collecting tomato seeds, pulp, and juice. The skeletal structure serves as the fundamental underpinning of the system, providing crucial support and stability to all other elements. The extractor, an essential element of the system, is connected to this skeleton structure and has a width of 45 cm. The product consisted of a well-planned 7 cm blade connected to a tubular construction measuring 25 mm × 50 cm. The blade is designed to function at a speed of 800 rpm, efficiently separating the tomato seeds from the pulp. Its alignment and angle are carefully determined to guarantee optimal performance.
The seeder, positioned just below the extractor, has an internal spiral blade plane sheet. This component is essential for directing isolated seeds toward seed output, enabling seamless and effective processing. The hopper, strategically placed to optimize the transfer of tomatoes into the extractor, serves as the primary point of entry for the unprocessed fruit. After the extraction process, the pulp was sent to the juicer. The juicer, measuring 16 cm in length and 5 cm in diameter, is skillfully engineered to efficiently extract juice from the pulp, leaving no portion of the tomato unused.
In addition, the SunSieve system utilizes tailor-made bearings and pulleys that are essential for its mechanical operation. These components are crucial for facilitating the seamless transmission of motion and functioning of the system's mobile sections, hence enhancing the overall efficiency and effectiveness of the process.
Figure 5 not only displays the physical configuration of the components of the SunSieve system but also emphasizes the meticulous engineering and design considerations involved in developing an effective, solar-powered agricultural processing system. Every individual component is designed to serve a distinct purpose within the process, together contributing to a system that is characterized by both ingenuity and practicality in its approach to sustainable agriculture.
Integrated Control System for the SunSieve Solar-Powered Extractor
The Arduino UNO R3 microcontroller is crucial in the SunSieve system since it automates and enhances the juice extraction process, with a specific emphasis on ensuring high-quality control and food safety. The system's program is specifically developed to oversee two essential functions: sterilization of tomato juice using UV light and continuous monitoring of its pH.
UV light, renowned for its powerful germicidal capabilities, is triggered by a float sensor that detects the presence of juice in the container. This guarantees that UV light functions only when needed, efficiently eliminating a broad spectrum of microbiological pathogens, such as viruses, bacteria, and fungi, to improve the safety and longevity of the juice. The effectiveness of UV light in lowering microbial flora and prolonging the shelf life of orange juice products with minimum nutritional loss was emphasized in a study performed by Syed et al. (2019) on orange juice preservation.
Concurrently, the incorporation of a pH sensor is essential for preserving the quality of tomato juice. The sensor is configured to trigger upon detecting the presence of juice in the container and then consistently monitors the pH until the juice is no longer present. It is crucial to note that the pH level of tomatoes generally falls between 4.05 and 4.65. Tomato juice, in particular, tends to have a pH level similar to that of nonacidic dietary items. Ensuring that the juice remains within the ideal pH range is essential for both its flavor and safety.
The programming and debugging procedure included optimizing the Arduino UNO R3 to guarantee smooth and precise activation of both the UV light and pH sensors. This procedure involves conducting tests on the system under different operating circumstances, fine-tuning the sensitivity of the float sensor, calibrating the pH sensor to ensure precise measurements, and optimizing the length and intensity of the UV light. The objective is to develop a resilient, automated system that not only improves the performance of the SunSieve extractor but also guarantees the highest quality and safety requirements for the tomato juice produced.
Test the Functionality of the SunSieve Machine
The effectiveness of the SunSieve tomato processing system's extraction process is shown in Fig. 6. The technology separates tomatoes into three different components: pulp, seeds, and juice. The picture depicts three containers, each containing a distinct result of the tomato processing.
To the left, there is a receptacle containing tomato pulp, which refers to the dense and fibrous material that remains after the extraction of seeds and juice. The vibrant hue of orange‒red indicates that the pulp of the tomato plant still contains a significant amount of natural pigments, which are abundant in lycopene, an antioxidant. The pulp has various uses in the culinary field, such as being used to create sauces or pastes or as a foundational component for soups and stews. This utilization not only enhances the nutritional content but also contributes to the overall taste.
The central container contains tomato seeds immersed in gelatinous material, a common occurrence when extracting seeds from the locular jelly of tomato plants. The distinct segregation of seeds suggested that the system was meticulously calibrated to safeguard the integrity of the seeds for potential cultivation or for the production of tomato seed oil, which may be useful for its health-promoting properties or as a high-quality culinary oil.
Finally, the container on the right contains tomato juice, a transparent liquid that has been strained to remove seeds and pulp. The vibrant crimson color of the juice implies little oxidation, indicating that a recently produced item preserved the majority of its nutrients and taste. This juice may be drunk as it is or undergo further processing to create goods such as bottled juices or concentrates or to serve as a foundation for drinks and cocktails.
The orderly configuration shown in Fig. 6 not only showcases the effective functioning of the SunSieve system in segregating the various constituents of tomato plants but also underscores the possibility of achieving waste-free manufacturing. Every byproduct is prepared for further processing or immediate use in accordance with sustainable techniques that enhance the value of each component of the produced crop. Efficiency plays a vital role in the food processing industry, where the primary focus is on maximizing production and minimizing waste. The SunSieve system, shown in this diagram, is a sophisticated method for agricultural processing that uses renewable energy to produce top-notch food products.
Table 1
Performance Evaluation of the SunSieve System across Multiple Trials: pH Monitoring, UV Sterilization Efficiency, and Processing Times
Trial No. | pH Level | UV Light Sensor | Yield of Juice (Liters) | Seed Processing Time (s) | Pulp to Juice Processing Time (s) | Juice Processing Time (s) | Tomato Pulp and Skins Processing Time (s) |
1 | 4.0-4.50 | ON with juice, OFF without | 1.3 | 110 | 120 | 150 | 180 |
2 | 4.0-4.50 | ON with juice, OFF without | 1.3 | 110 | 120 | 150 | 180 |
3 | 4.0-4.50 | ON with juice, OFF without | 1.3 | 110 | 120 | 150 | 180 |
4 | 4.0-4.50 | ON with juice, OFF without | 1.3 | 110 | 120 | 150 | 180 |
5 | 4.0-4.50 | ON with juice, OFF without | 1.3 | 110 | 120 | 150 | 180 |
6 | 4.0-4.50 | ON with juice, OFF without | 1.3 | 110 | 120 | 150 | 180 |
Table 1 provides a comprehensive assessment of the efficiency and efficacy of the SunSieve system across several operating parameters in six trials. This cutting-edge technology combines solar power and an Arduino microcontroller to automate the process of extracting Solanum lycopersicum (tomato) seeds, pulp, and juice. The system's design prioritizes eco-friendliness, operating efficiency, and the production of high-quality juice via the integration of modern technology for pH monitoring and UV sterilization.
The uniform pH values found in all the experiments, ranging from 4.0 to 4.50, demonstrated the system's capacity to keep the juice within the ideal acidity range for tomatoes. Ensuring the safety and flavor quality of the juice is of paramount importance. ScienceDirect states that tomatoes typically have a pH range of 4.05 to 4.65. This finding aligns with our data and highlights the efficiency of the system in maintaining the natural acidity of tomato juice without requiring additional acidification (Kosters et al. (2009)).
An automatic ultraviolet (UV) light sensor is crucial for guaranteeing food safety and prolonging juice shelf life. When juice is detected in a container, UV light is triggered to sterilize the juice, efficiently eliminating a wide range of microbiological pathogens, including viruses, bacteria, fungi, and yeasts. The efficiency of UV radiation in maintaining fresh orange juice has been established by the research of Kosters et al. (2009), which supports this technique of sterilization. Research has emphasized the capacity of UV radiation to diminish microbial flora while causing low nutritional degradation and small changes in juice characteristics, thereby prolonging its shelf life. The SunSieve device exemplifies the adaptability and efficacy of UV sterilization in preserving juice.
The consistent juice production of 1.3 liters in all the experiments, together with the accurate processing times for seed separation, pulp-to-juice conversion, juice processing, and handling of tomato pulp and skins, clearly showcased the operational effectiveness of the system. The results are noteworthy, as they demonstrate both the system's efficiency in processing tomatoes and its constant performance. The specific durations—110 seconds for seed processing, 120 seconds for pulp-to-ju conversion, 150 seconds for juice processing, and 180 seconds for handling tomato pulp and skins—offer a comprehensive understanding of the system's operation and effectiveness.
To summarize, the SunSieve system signifies notable development in agricultural processing technology. The use of solar energy and the incorporation of intelligent technology for quality assurance present a sustainable, highly effective, and secure method for tomato processing. The system's design and operational principles are validated by the consistent performance observed in multiple trials, as shown in Table 1. This performance not only confirms the system's potential to revolutionize the food processing industry but also demonstrates its ability to enhance food safety, sustainability, and the efficient utilization of renewable energy sources.