DESIGN AND FABRICATION

OF AUTOMATIC CONVEYOR

Presented by

U.DINESH BABU - (510812114025)

R.DINESH KUMAR - (510812114026)

M.DURAIMURUGAN- (510812114027)

Guided by

Mr.V.SIVAKUMAR. ME.,

AP/Mech

ABSTRACT:

• This project works at the design, development and testing of working model entitled Automatic Conveyor Controller.The model of Conveyor controller is designed by using 8051microcontroller, IR sensors to avoid the unwanted motion.

• By employing the automatic Conveyor control at the level crossing the arrival component is detected by the sensor placed near Roller.

• This fabrication system is used to reduce the power consumption and also to neglect the unwanted motion of the conveyor. Saving of labour and also time.

OBJECTIVE • To avoid unwanted motion and power

wasteage.

• To increase the life time of the Conveyor and its drives

INTRODUCTION

A conveyor system is a common piece of

mechanical handling equipment that moves materials

from one location to another. Conveyors are especially

useful in applications involving the transportation of

heavy or bulky materials. Conveyor systems allow

quick and efficient transportation for a wide variety of

materials, which make them very popular in the material

handling and packaging industries

TYPES OF CONVEYORS:

Belt Conveyor System

Flexible Gravity Conveyors

Roller Conveyor System

Screw Conveyors

Trolley conveyors

Reciprocating vertical conveyor

Vertical lift conveyor

Pneumatic conveyor

Vibrating conveyor

Bucket conveyor

Belt Conveyor

Belt Conveyor

• A Belt is a looped strip of flexible material, used to mechanically link two or more rotating shafts. They may be used as a source of motion, to efficiently transmit power , or to track relative movement. Belt conveyor are the most versatile and widely of the all conveyor.

WORKING PRINCIPLE

Belt conveyor is composed by two endpoint pulleys and a closed conveyor belt. The pulley that drives conveyor belt rotating is called drive pulley or transmission drum; the other one–only used to change conveyor belt movement direction–is called bend pulley.

Drive pulley is driven by the motor through reducer, and conveyor belt dragging relies on the friction drag between the drive pulley and the conveyor belt.

The metal detecting sensor is placed at the two ends of the conveyor. It helps to detect the components and materials.

By detecting the components the sensor helps to activate the motion of the conveyor, because it is connected to the motor.

Compared with other transport equipment, such as

Motorcycle, belt conveyor is the best efficient continuous coal

transportation equipment with advantages of long transmission

distance, large volume, continuous conveyor, etc., and operate

reliably, easy to implement automation and centralization control;

especially for high yield and efficient mine, belt conveyor has

become the key equipment for coal mining and mechtronics

technology.

Coding • $MOD51

• ORG 0000H

• clr p2.0

• clr p2.1

• LOOP1:

• clr p2.0

• clr p2.1

• setb p2.3

• setb p2.4

• open: jb p2.3,open

• setb p2.0

• setb p2.1

• ACALL DELAY1

• ACALL DELAY1

• ACALL DELAY1

• ACALL DELAY1

• ACALL DELAY1

• ACALL DELAY1

• clr p2.0

• clr p2.1

• ACALL LOOP1

• begin: sjmp begin

• DELAY: MOV R6,#50

• HERE2: MOV R7,#255

• HEREW: DJNZ R7,HEREW

• DJNZ R6,HERE2

• RET

• DELAY1: MOV TMOD,#01H

• MOV R3,#25D

• Z3:MOV TL0,#08H;

• MOV TH0,#01H;

• SETB TR0

• BACK3: JNB TF0,BACK3

• CLR TR0

• CLR TF0

• DJNZ R3,Z3

• RET

• END

Component

• Motor

• Micro controller(AT89s52 Microcontroller)

• Relay

• Pulley

• Belt

• Pillow head ball bearing

PHOTOGRAPHY

TOP VIEW

Cad view

DESIGN CALCULATION

• 6.1 MOTOR:

• 1. 60 RPM 12V DC motors with Gearbox2. 6mm Shaft Diameter With Internal Hole3. 125gm weight

• 4.1.2kgcm torque (T = 0.12 N-M)5. No-load current = 60 mA(Max), Load current = 300 mA(Max)

BELT

• Material is rubber

• Diameter of the driver (D1) : 60 mm

• Diameter of the follower(D2) : 60 mm

• Center distance of the drive(C) : 600mm

• Width of Belt : 80mm

• Thickness of Belt : 5mm

• Speed of the driver : 60 rpm

• Angle of contact : 180

• D1 = 60mm =0.06m• D2= 60mm = 0.06m• C =0 .6m• N1 = 60 rpm• Velocity ratio = D1/D2• R = 1• Arc Of Contact = 180•• Velocity Of Belt = π DN/60• V = 0.1885m/s•

• Length of the Belt ( L) =2C+ П / 2 (D1+ D2) + (D1-D2) / 4C• L= (2x0.6) + П / 2 (0.06+ 0.4) + (0.2+ 0.4) / 4x2• L= 1388mm• Power • P =( 2πNT)/60• P = (2 × 60 × 60 × .12)/60• P = 14.4 W•

• 6.3 BEARING

• Material isCAST IRON

• Speed of shaft N = 60rpm

• Life of the bearing Lh = 10,000 hrs

• Service factor S = 1.5

• Refer Psg data book 4.12

• Deep groove ball bearing D = 20mm

• Select the bearing is SKF 6004

• co = 4500

• c = 7350N or c = 735kgf

• Refer Psg data book 4.6 for find C/P value

• Speed and life of bearing

• C/P =3

• C = 7350

• P= 2025N (OR) 202.5KGF

• DYNAMIC CAPACITY

• C = P(L/L10)^1/K

• C = 2025(28.8/1)^1/3

• C = 6207N OR 620.7KGF

• Since, The Dynamic Load Rating Of Skf 6004 Is More

Than The Required Dynamic Load Capacity , THE SELECTED

BEARING IS SAFE

COST ESTIMATIONMATERIALS QUANTITY COST

Motor 2 500

Pillow head Bearing 4 600

Sensors 2 600

Micro controller 1 200

Adaptor 1 260

Frame - 400

Pulley 2 400

Belt 2 400

Shaft 4 40

Nut and Bolt 8 100

Relay and Wire - 500

Total - 4000

LITERATURE REVIEW

Design Improvements and Fabrication of Conveyor Belt Cleaner and Washing System at Westports MalaysiaTasnim F. Ariff, Muhd. Fahmi B. Jusoh, Malek Parnin and Mohd. Hanif Azenan

• Conveyor belts at ports are used worldwide to carry and transport various materials ranging from fertilizers to foods items such as corn, barley and soy beans from the cargo ship to the packaging site. A serious spillage and carryback problem existed at DB2 terminal, Westports Malaysia where lots of chemical fertilizers (ammonium sulphate) were wasted to some extent and extra manpower was needed to shovel the spillage into the container.

• The floor was highly corroded due to improper washing and drainage system. The main aim of this research was to eliminate if not reduce spillage and solve the corroded floor issue. The primary and secondary belt cleaners were designed using CATIA software. These newly improved cost effective and simple designs of the primary and secondary belt cleaners together with a spray shaft and proper washing box were fabricated, tested and implemented successfully. The spillage was reduced tremendously and the washing system can prevent corrosion from happening in the future.

Design And Optimization Of Idler For Belt ConveyorHitesh J Soni1, Mr. Ronak R Patel 2.

The work present in this paper focuses on the reduction of cost of idler as belt conveyor consist of many idler and reducing running cost of conveyor system by optimizing by.

i ) Selecting optimum diameter of shell, ii) selecting optimum diameter of shaft. iii) Thickness of shell. iv) Distance between two bearings. Modeling and Analysis of parts of idler is done by using ‘Finite Element Method.

APPLICATIONS• Vegetable , furit and potato processing industry

• Sugar industry

• Meat and poultry processing / abattoirs / rendering industry

• Fish and Shellfish processing industry

• Brewing , malting and beverage industry / distilleries

• Horticulture industry

• Paper and pulp industry

• Chemical and petrochemical industry

• Mining and Minerals industry

• Exhaust gas cleaning

• Waste recycling industry

• Spent catalyst recycling

• Bio Energy Industry

• Air port

CONCLUSION

• By employing the automatic conveyor control at the level crossing the arrival component. We can reduce the consumption, neglect the unwanted motion of the conveyor and to avoid the wastage on life duration of the conveyor and its equipments.

REFERENCES

• Design And Selecting the Proper Conveyor-belt By KLU Guntur. Vol. 3

April 13, 2012

• Design Optimization For Modification Of Trough Belt Conveyor To

Reduce Material Spillage Used In Clinker Transport In Cement Plant By

Shalom Akhai , Harpreet Singh.Vol. 2, Issue 04, 2014 |

• Design Improvements And Fabrication Of Conveyor Belt Cleaner And

Washing System At Westports Malaysia By Tasnim F. Ariff, Muhd.

Fahmi B. Jusoh, Malek Parnin and Mohd. Hanif Azenan.Vol. 1 No.

10 October 2013

• Design and Analysis of a Roller Conveyor System for Weight

Optimization and Material Saving By Suhas M. Shinde and R.B.

Patil.25 April, 2012

• Design Of A Material Handling Equipment: Belt Conveyor System For

Crushed Limestone Using 3 Roll Idlers By I. A. Daniyan , A. O.

Adeodu And O. M. Dada on January 16, 2014.

THANK YOU