Design Of Belt Conveyor to Prevent the failure and many other drawbacks from redler conveyor...

Gokul Refoil & Solvent Ltd. Design of Belt Conveyor

S.P.B.PATEL ENGINEERING COLLEGE, LINCH

“DESIGN OF BELT CONVEYOR TO PREVENT THE FAILURE, BREAKDOWN &
OTHER DRAWBACKS OF REDLER CONVEYOR”

By

PATEL VISHALKUMAR BHARATBHAI 080390119072

PATEL PARESHKUMAR DINESHBHAI 080390119059

PRAJAPATI VIRALKUMAR BABUBHAI 080390119073

GUIDE: SHAILESH PRAJAPATI

(B.E.MECHANICAL)

A Project Submitted To

GUJARAT TECHANOLOGICAL UNIVERSITY

In fulfillment of the requirement for

The degree of bachelor engineering

In mechanical engineering

S.P.B.PATEL ENGINEERING COLLEGE Page 1


Certificate

This is to certify that project work embodied in this report entitled
“Design of Belt Conveyor” was carried out by
1. Vishal Patel 080390119072
2. Paresh Patel 080390119059
3. Viral Prajapati 080390119073

At S.P.B. Patel College of Engineering –Mehsana for partial fulfillment of
B.E. semester 8th to be awarded by Gujarat Technological University. This
project work has been carried out under my supervision and is to my
satisfaction.

Date:

Place:

Prof :-Shailesh Prajapati Prof:- Taushif Shaikh

Internal Guide HOD, MECHANICAL
DEPARTMENT.



Certificate

“Design of Belt Conveyor” was carried out by Mr. Vishal Patel with
Enrolment number: 080390119072 at S.P.B. Patel College of Engineering –
Mehsana for partial fulfillment of B.E. semester 8th to be awarded
by Gujarat Technological University. This project work has been carried out
under my supervision and is to my satisfaction.

Date:
Place:

Prof :- Shailesh Prajapati Prof :- Taushif Shaikh

DEPARTMENT.



Certificate

“Design of Belt Conveyor” was carried out by Mr. Paresh Patel with
Mehsana for partial fulfillment of B.E. semester 8th to be awarded
by Gujarat Technological University. This project work has been carried out
under my supervision and is to my satisfaction.

Date:

Place:

Prof :- Shailesh Prajapati Prof :- Taushif Shaikh

DEPARTMENT.



Certificate
“Design of Belt Conveyor” was carried out by Mr. Viral Prajapati with
Mehsana for partial fulfillment of B.E. semester 8th to be awarded by
Gujarat Technological University. This project work has been carried out under
my supervision and is to my satisfaction.

Date:

Place:

Prof :- Shailesh Prajapati Prof:- Taushif Shaikh

DEPARTMENT.



Acknowledgement

The feeling of gratefulness to any one‟s help directly arises from the bottom of heart.
A small but an important and timely help can prove to be a milestone in one‟s life.

Every human being has such kind of experience. Being human being, we also have,
the same feeling of gratefulness of today we have achieved an important milestone in my life.

This project is dedicated to all the people, whom we met, took guidance, talked,
interviewed and learned something from them. At this occasion we sincerely thank all of
them while submitting this project report. We would like to heartily thank to
Mr. Shailesh Prajapati who has provided us necessary information and guidance for the
success of this project.

Last, we would like to extend thanks to all our classmates also. On this occasion we
would like to thank to Mr. Taushif Shaikh without whom this would have not been possible.
We are thankful to him for giving time-to-time and valuable guidance during the project
period and giving us guidance in taking our curriculum decision and choosing, initiating and
getting on with the project. We always have felt the invisible help from the almighty, without
the blessing almighty, we could not have succeeded.

VISHAL B. PATEL

PARESH D. PATEL

VIRAL B. PRAJAPATI



ABSTRACT

Redler Conveyor is the Material Handling device which is use for material
transferring device, which is transferring mustard and sack from one plant to other plants of
company. Some time failure accurse (like, breakdown of Redler chain or gear‟s teeth) in
Redler conveyor under working time period. So company waste times until repair it. Also
maintenance and repair cost is high for Redler Conveyor.

Eliminates Above drawbacks our team selects Belt Conveyor Mechanism
instead by collecting information about the material handling devices and find out which
device can be use instead of Redler Conveyor Mechanism than finally decided we can use the
Belt Conveyor Instead of Redler Conveyor.

Belt Conveyor has many advantages like: increase efficiency, reduce or
eliminate failure and breaking, and also it has long working life. So finally we will make a
design of Belt Conveyor & of the Belt Conveyor.



INDEX
Title page…………………………………………………………………………………….1

Certificate Pages…………………………………………………………………………….2

Acknowledgements………………………………………………………………………….6

Abstract……………………………………………………………………………………...7

Index………………………………………………………………………………………....8

List of Figures………………………………………………………………………………10

List of Table………………………………………………………………………………...12

Chapter: 1 Introduction………………………………………………………………...13

1.1 Project Summary………………………………………………………………..…...14
1.1.1 Objective of this Project………………………………………...…………...14
1.2 Detail Description of Project……………………………………………..……….…15
1.2.1 Definition…………………………………………………………..………..15
1.2.2 Conveyor……………………………………………………………..……...15
1.3 Redler Conveyor………………………………………………………………..…...16
1.3.1 Introduction……………………………………………………………..…..16
1.3.2 Main Components of Redler Conveyor…………………………………..…17
1.3.3 Main Function of Redler Conveyor………………………………………....19
1.3.4 Drawbacks of Redler Conveyor………………………………………….…19
1.3.5 Redler Failure Photos…………………………………………………….…20

Chapter: 2 Literature Review…………………………………………………….........21

2.1 Belt Conveyor History………………………………………………………..…….22
2.2 Tianjin China‟s Conveyor System……………………………………………….…22
2.3 Wyodak Mine…………………………………………………………………….…23
2.4 Metso Rope Conveyors…………………………………………………………..…24
2.5 Distributed Power System………………….………………………………………25



Chapter: 3 Belt Conveyors……………………………………………………………26
3.1 Introduction……………………………………………………………………..…27
3.2 Objective of Belt conveyor………………………………………………………...28
3.3 Guidelines in selecting material Handling Equipment………………………….…28
3.4 Advantages of belt conveyor………………………………………………………29
3.5 Types of materials which is handled by Belt Conveyor…………………………...29
3.6 Method of Feeding or loading in Belt Conveyor……………………………….…30
Chapter: 4: Methodology………………………………………………………………31
4.1 Data available for Belt Conveyor Design Calculation……………………………..32
4.2 Design Procedure for Belt Conveyor………………………………………………32
4.2.1 Belt Capacity…………………………………………………………….…32
4.2.2 Belt Width…………………………………………………………………32
4.2.3 Belt Tension…………………………………………………………..........33
4.2.4 Power calculation………………………………………………………......34
4.2.5 Idler Spacing……………………………………………………………….34
4.2.6 Motor RPM calculation………………………………………………….....35
4.2.7 Calculate the Diameter of shaft…………………………………………....35
4.2.8 Pulley Diameter……………………………………………………………37

Chapter: 5 Final Design of Belt Conveyor………………………………………...…38

5.1 Design of Main Components of Troughed Belt Conveyor…………………..……39
5.1.1 Conveyor Pulley…………………………………………………………...40
5.1.2 Belt Take-up Devices……………………………………………………...46
5.1.3 Frame Structure of Idler Roller…………………………………………....47
5.1.4 Conveyor Belt………………………………………………………..……51.
5.1.5 Final Design of Belt Conveyor……………………………………………55

Chapter: 6 Conclusions……………………………………………………………….56
6.1 Conclusions……………………………………………………………………......57

Chapter: 7 Reference…………………………………………………………………58
7.1 Reference………………………………………………………………………….59



List of Figures
Chapter: 1. Introduction

Fig. 1.1: Design of Redler Conveyor……………………………………………………..16

Fig. 1.2: Redler Conveyor………………………………………………………………..16

Fig. 1.3: High strength chain……………………………………………………………...17

Fig. 1.4: Casing…………………………………………………………………………...18

Fig. 1.5: Driving end (Sprocket gear)…………………………………………………….18

Fig. 1.6: Breaking tooth…………………………………………………………………..20

Fig. 1.7: Braked Redler tooth…………………………………………………………….20

Fig. 1.8: Failure parts of Redler…………………………………………………………..20

Chapter: 2 Literature Review

Fig. 2.1: Tianjin China……………………………………………………………………23

Fig. 2.2: Wyodak Coal……………………………………………………………………23

Fig. 2.3: MRC straight section……………………………………………………………24

Fig. 2.4: MRC vs. Conventional conveyor……………………………………………….24

Chapter: 3 Belt Conveyors

Fig. 3.1: Simple Mechanism of Belt Conveyor…………………………………………..28

Fig. 3.2: Feed by Hopper…………………………………………………………………30

Chapter: 4 Methodologies

Fig. 4.1: Bending Moment Diagram……………………………………………………..36



Chapter: 5 Final Design of Belt Conveyor

Fig. 5.1: Components of Belt Conveyor………………………………………………..39

Fig. 5.2: Design Sheet of Crown - Face type of Pulley…………………………………40

Fig. 5.3: Design photos of Crown – Face type of Pulley……………………………….41

Fig. 5.4: Location of Snub Pulley………………………………………………………42

Fig. 5.5: Design Sheet of Roller type idler with rolling bearing………………………..43

Fig. 5.6: Design Photos of Roller type idler with rolling bearing………………………44

Fig. 5.7: Design Sheet of Return idler………………………………………………….45

Fig. 5.8: Design Photo of Return idler………………………………………………….45

Fig. 5.9: Vertical gravity type take-up………………………………………………….46

Fig. 5.10: Frame Structure of Idler Rollers……………………………………………..47

Fig. 5.11: Design Sheet of Frame Structure of Idler Rollers…………………………...48

Fig. 5.12: Design Sheet of Frame Structure of Idler Rollers with Return Idlers……....49

Fig. 5.13: Frame Structure of Idler Rollers with Return Idlers………………………...50

Fig. 5.14: Design of Frame without & with Return Idler……………………………....51

Fig. 5.15: Front view of Frame Structure of both Idler Rollers………………………...50

Fig. 5.16: Design Photos of Frame Structure of Idler Rollers in Series………………...50

Fig. 5.17: Design Photos of Frame of Idler Rollers with Return Idlers in Series………51

Fig. 5.18: Conveyor Belt Components…………………………………………………52

Fig. 5.19: Design of Steel cord Belt……………………………………………………53

Fig. 5.20: Design of Belt and Feeder Mechanism……………………………………...54

Fig. 5.21: Final Design Photos of Troughed Belt Conveyor Mechanism……………...55



List of Tables
Table 4.1 Material factor for Plies, K1 …………………………………………...37

Table 4.2 Belt Tension and arc of Contact Factor K2 ……………………………37



CHAPTER: 1
INTRODUCTION



1. INTRODUCTION
1.1 Project summary:

“Design of Belt Conveyor to Prevent the Failure, Breakdown & Other drawbacks of

Redler conveyor.”

Redler conveyor is one type of material handling equipment which is use for
transfer primary material (mustard), raw material (sack), final products from one plant to
other plant by means of electric power an mechanical equipments.

But many failures and breakdowns occur in Redler Conveyor during working
time period because some factors are affected on Redler conveyor equipments like, Materials
properties, working condition, load of materials, environmental condition, etc…

First of all we focused on the Redler conveyor‟s failures and breakdowns and
know some reason from these questions like…. How occurs? Where occurs? How can be
eliminating? What will we do for eliminate?

1.1.1 Objective of this Project:

Our main objective is to reduce or eliminating problems which occure in
Redler conveyor like, failures & breakdown, high friction between materials and Redler
components, etc… increase the efficiency, reduce the friction, maintenance, cost, etc…by
using the Belt Conveyor instead of Redler Conveyor.

Because of Belt conveyor has many advantages which are capable to eliminate
the redler drawbacks. Like, less failure & breakdown, less friction, high efficiency, low hp
motor required, long life, less maintenance, etc...



1.2 Detail Description of Project

1.2.1 Definition:
“Design of Belt conveyor to prevent the failure, breakdown, and other drawback of
the Redler conveyor.”

1.2.2 Conveyor:
1.2.2.1 Introduction to Conveyor:
The industrial development has led to the growth of the factory or plant sizes. The
growth of the factory or plant sizes has created hung demand for the material
handling systems.
Any Conveying process consists of three activities:
(1) Picking up the load
(2) Transporting the load
(3) Setting the load down.

1.2.2.2 Definition:
Conveyors are used to moving the loads in horizontal or inclined direction along
affixed path in a continuous flow.
The conveyors are mainly used for handling of bulk loads. In addition, Conveyors
are also used in processing lines in production units. For example conveyors are
used in raw material transferring.

1.2.2.3 Types of Conveyors:
Redler Conveyor
Flat Belt Conveyor,
Trough Belt Conveyors,
Blanket Belt Conveyors,
Chain Conveyors,
Screw Conveyor etc…



1.3 Redler Conveyor:
1.3.1 Introduction :
The high strength chain moved by electric power inside to casing. This is called a
Redler Conveyor.
Redler conveyor is also material handling device which is used to transfer materials,
raw materials, final product, etc... From one plant to other plant.
Redler conveyor is operated by electric power with high hp motor for drive the
conveying system.
Redler conveyor has main components are high strength chain, casing, driving end
(sprocket gear).
Redler Conveyor Design photo Shown in below Fig. 1.1:

Fig. 1.1: Design of Redler Conveyor

Fig.1.2 Redler Conveyor



1.3.2 Main Components of Redler Conveyor:
Redler Conveyor has mainly,
(1) High strength chain
(2) Sprocket
(3) Casing
(4) Electric motor (20Hp to 45Hp)

(1) High strength chain:

Fig.1.3: High strength chain

- Versatile welded steel design
- Riveted construction
- High tensile strength
- Welded flight attachments
- Extensive flight range available
- Engineered chain



(2) Casing:

Fig.1.4: Casing

- Heavy duty & dust tight construction
- Bolted wear strips & return runner supports
- Weatherproof „Viewports‟ at each casing Joint enabling quick inspection for
wear and runner alignment
- Laser profiled end flanges to connect conveyor supports

(3) Driving End (Sprocket Gear):

Fig.1.5: Driving End (Sprocket Gear)



- Fully bolted segmented drive sprocket
- Assembly for rapid replacement
- Multi directional sprocket shaft removal
- Heavy duty robust sprocket stripper
- Positive landing for pedestal bearing
- Mountings facilitating easy change out

1.3.3 Main Function of Redler Conveyor:

Redler Conveyor has main function is to transfer the materials or product or waste from
the one plant to another plant without require any worker & other equipment.

- Transfer the mustard form the godown to the silo.
- Transfer the mustard form 1st silo to 2nd, 3rd & 4th silo.
- Transfer mustard from silo to the plant. (Kohlu plant & Chillex Plant.).Kohlu &
Chillex plant are the crushing plant which is produces the oil by means of crushing
the mustard.
- Transfer the wastage which produces from the kohlu & Chillex Plant to Solvent Plant.
- Transfer the wastage from the Solvent Plant to the D.O.C. go-down.
- Transfer the coal from the go-down to the boiler plant.
- Transfer the product (small oil bottle) to the product go-down.

1.3.4 Drawbacks of Redler Conveyor:
(1) High Capital & installation cost.
(2) High maintenance required.
(3) Erosion problem occurs in casing.
(4) High friction occurs between casing & high strength chain when increase quantity of
transfer materials.
(5) High HP Motor required because high friction & high tensile force produced between
casing & high strength chain.
(6) Efficiency of Redler conveyor is less because some materials can‟t transfer properly.
(7) Can‟t use for material transfer in long distance.



1.3.5: Redler Failure Photos:

Fig 1.6: Breaking tooth Fig 1.7: Braked Redler Tooth

Fig1.8: Failure Parts of Redler



CHAPTER: 2
LITERATURE
REVIEW



2. LITERATURE REVIEW
2.1 Belt Conveyor History:[8]
Primitive conveyor belts were used since the 19th century. In 1892, Thomas
Robins began a series of inventions which led to the development of a conveyor belt used for
carrying coal, ores and other products.
In 1901, Sandvik invented and started the production of steel conveyor belts.
In 1905 Richard Sutcliffe invented the first conveyor belts for use in coal mines which
revolutionized the mining industry. In 1913, Henry Ford introduced conveyor-belt assembly
lines at Ford Motor Company's Highland Park, Michigan factory. In 1972, the French
society REI created in New Caledonia the then longest straight-belt conveyor in the world, at
a length of 13.8 km.
In 1963-64, First Indian Small Scale Industrial Unit with Japanese Plant for
Rubber Belts for Conveyor / Elevator / Transmission was installed near National Capital
Territory of Delhi and its Mr. Belts Conveyor Belting has been widely used in Steel, Cement,
Fertilizer, Thermal Power, Sponge Iron Plants and Coal / Mineral establishments / Mines,
Port Trusts and similar material handling applications of Industry for the last over 4 decades.
Hyacinth Marcel Bocchetti was the concept designer In 1957, the B. F.
Goodrich Company patented a conveyor belt that it went on to produce as the Turnover
Conveyor Belt System.

2.2 Tianjin China’s Conveyor System:[10]
Of course the most efficient way to transport material from one point to the
next is as directly as possible. But as we continue to transport longer distances by conveyor,
the possibility of conveying in a straight line is less and less likely as many natural and man-
made obstacles exist.

The first horizontally curved conveyors were installed many years ago, but
today it seems just about every overland conveyor being installed has at least one horizontal
change in direction. And today‟s technology allows designers to accommodate these curves
relatively easily.



Fig. 2.1: Tianjin China
Fig. 2.1 shows an overland conveyor transporting coal from the stockpile to
the ship loader at the Tianjin China Port Authority installed this year. Designed by
E.J.O‟Donovan & Associates and built by Continental Conveyor Ltd of Australia, this 9 km
overland carries6000 mph with 4x1500 kW drives installed.

2.3 Wyodak Mine:[10]
The Wyodak Mine, located in the Powder River Basin of Wyoming, USA, is
the oldest continuously operating coalmine in the US having recorded annual production
since1923.
It currently utilizes an overland (Figure 2.2) from the new pit to the plant
756m long (2,482 ft) with a 700m (2,300 ft) horizontal radius. This proves a conveyor does
not need to be extremely long to benefit from a horizontal turn.

Fig. 2.2: Wyodak Coal



2.4 Metso Rope Conveyor: [10]

Another variation from conventional is the Metso Rope Conveyor (MRC) more
commonly known as Cable Belt. This product is known for long distance conveying and it
claims the longest single flight conveyor in the world at Worsley Alumina in Australia at 30.4
km. With Cable Belt, the driving tensions (ropes) and the carrying medium (belt) are
separated (Below Figure 2.3).

Fig. 2.3: MRC- Straight Section

Fig. 2.4: MRC vs. Conventional Conveyor in Horizontal Curve



2.5 Distributed Power System:
One of the most interesting developments in technology in the recent past has
been the distribution of power along the conveyor path. Is has not been uncommon to see
drives positioned at the head and tail ends of long conveyors and let the tail drive do the work
of pulling the belt back along the return run of the conveyor. But now that idea has expanded
to allow designers to position drive power wherever it is most needed. The idea of
distributing power in multiple locations on a belt conveyor has been around for a long time.
The first application in the USA was installed at Kaiser Coal in 1974. It was
shortly thereafter that underground coal mining began consolidating and long wall mines
began to realize tremendous growth in output. Mining equipment efficiencies and capabilities
were improving dramatically.
Miners were looking for ways to increase the size of mining blocks in order to
decrease the percentage of idle time needed to move the large mining equipment from block
to block. Face widths and panel lengths were increasing.
When panel lengths were increased, conveyance concerns began to appear.
The power and belt strengths needed for these lengths approaching 4 -5 km were much larger
than had ever been used underground before. Problems included the large size of high power
drives not to mention being able to handle and move them around. And, although belting
technology could handle the increased strength requirements, it meant moving to steel
reinforced belting that was much heavier and harder to handle and more importantly, required
vulcanized splicing.
Since long wall panel conveyors are constantly advancing and retreating
(getting longer and shorter), miners are always adding or removing rolls of belting from the
system. Moreover, since vulcanized splicing takes several times longer to facilitate, lost
production time due to belt moves over the course of a complete panel during development
and mining would be extreme.
Now the need surpassed the risk and the application of intermediate drives to
limit belt tensions and allow the use of fabric belting on long center applications was actively
pursued. Today, intermediate drive technology is very well accepted and widely used in
underground coal mining.
Many mines around the world have incorporated it into their current and future
mine plans to increase the efficiency of their overall mining operations.



CHAPTER: 3
BELT CONVEYOR



3. BELT CONVEYOR
3.1 Introduction:

The belt is moved by electric power. This is called a Belt Conveyor. Belt
conveyor mechanism improving the working efficiency also prevents the drawback of the
Redler conveyor mechanism. So our team gets solution and use the Belt Conveyor instead of
Redler Conveyor.

A Belt conveyor consists of two or more pulleys, with a continuous loop of
material - the conveyor belt - that rotates about them. One or both of the pulleys are powered,
moving the belt and the material on the belt forward.

The powered pulley is called the drive pulley while the unpowered pulley is
called the idler. There are two main industrial classes of belt conveyors; Those in general
material handling such as those moving boxes along inside a factory and bulk material
handling such as those used to transport industrial and agricultural materials, such as mustard,
sack, grain, coal, etc... generally in outdoor locations.

Generally companies providing general material handling type belt conveyors
do not provide the conveyors for bulk material handling.

In addition there are a number of commercial applications of belt conveyors
such as those in grocery stores. The belt consists of one or more layers of material they can
be made out of rubber.

Many belts in general material handling have two layers. An under layer of
material to provide linear strength and shape called a carcass and an over layer called the
cover.

Belt conveyors have many different types like Flat belt conveyors, Troughed
belt conveyor, Blanket belt conveyor, etc…



Fig. 3.1: Simple mechanism of Belt Conveyor

3.2 Objective of Belt Conveyor:
1. Accuracy in transporting Loads to Destination
2. Precision in pick-up of Loads
3. Transporting Loads in Scheduled Time
4. Transporting Loads of Required Quantity
5. Transporting Loads without Damage
6. Automation with minimum manpower
7. Low initial and operational costs
8. Simplicity and Easy Maintenance
9. Operational Safety

3.3 Guidelines in Selecting Material Handling Equipment:
1. Direction of Load Travel
2. Length of Load Travel
3. Type and Properties of Loads to be Handled
4. Required Load Moving Capacity of Unit
5. Characteristics of Production Processes
6. Methods of Stacking Loads at Initial and Final Points
7. Local Conditions
8. Initial and Operational Costs



3.4 Advantages of Belt Conveyor:
1. Due to Continuous flow, Belt Conveyor ensures steady and sufficient supply of
material at processing units or sites.
2. Belt Conveyors can transfer the material at extremely high rates. Hence, the capacity
of conveyor is much higher than the other conveyor system.
3. By changing the speed of the Belt conveyor, the rate of material flow can be changed
so as to suit the requirements at processing units or sites.
4. The Belt conveyor can be started or stopped within shortest time. Hence, with
conveyors the material flow can be started or stopped within the shortest time.
5. Belt Conveyors can be placed at floor level, at work station level or at higher level as
per requirement. Therefore, Belt Conveyors need not occupy valuable floor space and
they can utilize the air-space of the plant.
6. Belt Conveyors carry material along fairly direct routes, and hence require minimum
time for transferring the material.
7. The Belt Conveyors can take the material to the locations where manual loading is not
possible due to extreme operating conditions.
8. When properly designed and installed, conveyors are very reliable in operation and
require minimum maintenance.

3.5 Types of Materials which is Handled by Belt Conveyors:
1. Bulk Material:
Bulk materials are in the form of granules or cakes of different sizes and shapes.
The different bulk material handled by belt conveyors are: cake, mineral ores, coal,
sand, stone, clay, cement, powdered materials such as flours, slurries, etc…
2. Hazardous Material:
The explosive substances or mixtures which cannot be handled by hoists or elevators
or Redler Conveyor due to potential risk of explosion under impact, can be handled
by conveyors.
3. Loose Material:
Small parts like: Nuts, bolts, castings, forging, plastic parts, etc…
4. Packages:
Like: Corrugated cartons, plastic boxes, wooden boxes, drums, etc…

Note: Our Design of Belt Conveyor is used for Bulk Material Handling.


3.6 Methods of Feeding or Loading to Flat Belt Conveyor:
1. By Hooper
2. By Preceding Conveyor
3. By Process Equipment
4. By Travelling Machine

Note: In our Design we selecting the Feeding or Loading by Hopper

1. By Hopper:

Fig.3.2: Feed by Hopper



Chapter 4
METHODOLOGY

(Calculate the Dimensions of Belt Conveyor Parts)



4 METHODOLOGY

4.1 Data available for belt conveyor system:
Input data used for designing of belt conveyor are:
Material Density =1600kg/m³
Belt Speed (v) = 0.1 m/s
Length of Conveyor (L) = 32m,80m,145m
Height of Conveyor (H) =2m
Inclination angle = 3°
Material size = 850×250 mm
Material temperature = 40°-80°C
4.2 Design Procedure for Belt Conveyor system:
Most of the formulas are in MKS units and for better understanding, convert into SI units.
The Following procedure is followed to design present belt conveyor system:

4.2.1 Belt capacity (c): [2]
c = 3.6 × load cross section are perpendicular to belt × belt speed ×material
density ……………………………………………………………… (3)

c = 300 ton/hr (Daily conveying material by Redler Conveyor)

4.2.2 Belt width (w): [3]
…………………………………………………… (2)

Live Load = = 700 kg/m

Total Live load (A) = live load × Conveyor Length
= 26901.55 kg

Dead Load (B): This Load consists of weight of roller, belting and drive pulley.
So, Dead Load (B) = 1419.5 kg

Belt Pull = (A+B) × Coefficient of friction
For Roller Belt Conveyor Coefficient of friction = 0.05
So, Belt Pull (C) = (26901.55 + 1419.50) × 0.05
= 1416.35 kg

Additional Belt Pull = Total Live load × Sine of angle
=1408 kg
Also, Additional Belt Pull = Average live load × Rise in elevation
= 700 × 2 =1400 kg



Maximum of above two is consider, D = 1408 kg
Other Additional Belt Pull (E) = Total live load × Coefficient of friction
= 1345.3 kg

Effective Belt Pull = Total Belt Pull (C+D+E) × 1.25
= 5212.14 kg

Now, T1 = Effective Belt Pull × T1 Factor(Taking From Table)
= 5212.14 × 1.42
T1 = 7401.24 kg

From material Temperature (40° - 80°C) Heat resistant belt required. Therefore
Pyroshield belt (KEP 800/4) is selected having the properties like high tensile
strength, longer working life, robust construction, corrosion resistance, wear and tear
resistance. Therefore, Belt Strength = 167.37 kg/inch.

So finally Substitute the value of Belt Strength & T1 in equation (2);

Belt Width (w) = = 1200mm

w = 1200mm

4.2.3 Belt tension: [2]

Effective tension Te = Total empty friction + Load friction + Load slope
tension………………………………………………….(3)
Return side Tension = Fe × W × L × 0.4 × 9.81× 10ˉ³
For Horizontal and Elevating Conveyor, Fe = 0.020
W = Weight of material + Weight of belt, kg/m

Weight of material, Wm =

Weight of belt Wb = 16.6 lbs/ft
So, W = Wm + Wb = 780.88 kg/m
Substitute the above value in equation….. (3)
Return Side Tension = 1.978 KN

Total empty friction = Fe × (L + tf ) × W × 9.81 × 10ˉ³

Standard edge distance = 0.055b + 0.9inch = 0.0899 m

For standard edge distance 0.0899 tf = 60m



Total empty friction = 14.13 KN
Carring side empty friction = Total empty friction – Return side tension = 12.15 KN

Load fraction = Ft × (L + tf ) × × 9.81 × 10ˉ³

For horizontal and elevating conveyor, Ft = 0.025
Load fraction = 18.86 KN

Load slope Tension = × 9.81 × 10ˉ³ = 14.91 KN

From above value we can use in equation…. (3) For finding the effective tension
Te = Total empty friction + Load friction + Load slope tension

Te = 47.908 KN

4.2.4 Power Calculation: [5]

Power = ……………………………………... (4)

Substituting the values in equation …. (4)

Power = = 7HP

Power = 7 HP

4.2.5 Idler Spacing: [2]

Idler Spacing Si = …………………………………. (5)
Take Sag = 0.02 (2%)

Idler Spacing Si = 1 Meter



4.2.6 Motor RPM Calculation: [6]

Motor RPM, N = ………………………….. (6)

Here Torque is not known and hence it can be calculated by following method. For belt
conveyor application,
Mt = 0.5 × D × (F + µ w g)

Where,
D = 0.630 meter (From table of bulk material handling handbook)
And µ = 0.35 (According to CEMA)
Subsisting values in above equation,
Mt = 47990.334 Nm = 47990334 Nmm

Now Substituting the Torque and Power values in equation …. (6)
Motor RPM = 1500 RPM

4.2.7 Diameter of Shaft: [9]

Diameter of Shaft (d) =

Where,
Shear stress τ,
Kb Combined shock and fatigue factor applied to bending moment,
Mb maximum bending moment,
Kt combined shock and fatigue factor applied to tensional moment



Fig 4.1: Bending moment Diagram

From above calculation we can find the Diameter of shaft,
d = 28.37mm≈ 25 to 35mm



4.2.8 Pulley Diameter:
The minimum diameters of drive pulley and tail pulley are given by,
Dmin = K1 K2 Zp

Where, Dmin = minimum diameter of drive pulley and tail pulley, mm
Zp = Number of plies
K1 = Material factor for plies
K2 = Belt tension and arc of contact factor

Table 4.1: Material Factor for Plies, K1
Material of plies Reyon, Anide High Tensile Capron High
Duck, Duck Combination Tensile
in of Duck with Capron
Combination Lavsan
with Capron
and Lavsan
Material factor
for plies, K1 1.25 1.4 1.6 2.0 2.5

Table 4.2: Belt tension and arc of contact factor, K2

Belt Tension as Percentage of ∑ F
Arc of
Contact,
deg
100 75 50 25 12
240-180 100 80 63 50 40
110-70 80 63 50 40 32
30-15 63 50 40 32 25
Under 15 50 40 32 25 16

Note: ∑ F is the Vector sum of belt tension on tight side & slack side.
D min = 646.93mm ≈ 500 to 650 mm



CHAPTER: 5
FINAL DESIGN
OF
BELT CONVEYOR
(In Autodesk Inventor 2012)



5. FINAL DESIGN OF BELT CONVEYOR
5.1 Design of Main Components of Troughed Belt
conveyor:
Belt conveyor has main parts are Conveyor Belt, Pulley, Ball Bearing, Electric motor,
Idler roller, chain ,sprocket, etc…

Fig. 5.1: Components of Belt Conveyor



5.1.1 Conveyor Pulleys:
1. Drive Pulley & Tail Pulley
2. Snub Pulleys
3. Idlers
1. Drive Pulley & Tail Pulley:
The ply separation due to the repetitive bending over the pulleys is the most common
cause of the belt failure.
The larger the pulley, the less the belt is strained and larger is its life.

Types of Drive and tail pulleys:

i. Crown-face type pulley
ii. Wing-type pulley

Note: In our Design we selected Crown-face Type Pulley.

i. Crown-face type pulley:

Fig. 5.2: Design sheet of Crown-face Type Pulley



Fig. 5.3: Design photos of Crown-face type pulley



2. Snub Pulley:
In belt conveyors, it is necessary to change the direction of belt for various
reasons like:
i. Increasing the angle of lap on drive and tail pulleys;
ii. Changing the path of carrying run of the belt;
iii. Changing the path of return run of the belt; and
iv. Facilitating the loading and unloading operations.

Fig. 5.4: Location of Snub Pulley

3. Idlers:
Purpose of using idlers:
i. To support the conveyor belt along with the load on upper run, with
minimum resistance to belt-motion.
ii. To support the conveyor belt on lower run, with minimum resistance to
belt motion.
iii. To provide support to belt at loading point with minimum wear and tear to
belt.
iv. To align the belt on the pulleys. The idlers should automatically try to
bring the belt centre line close to conveyor centre line.
v. To give the trough profile to the belt in case of troughed belt conveyor.



Types of Idlers:

(1) Roller type idlers with ball bearings
(2) Roller type idler with roller bearing
(3) Impact idlers
(4) Rubber covered idlers
(5) Disc-type idlers
(6) Spring idlers

Note: In our Design we can use Roller type idlers with ball bearing or
Roller type idlers with roller bearing.

Fig. 5.5: Design sheet of Roller type idler with rolling bearing



Fig. 5.6: Design photos of Roller type idler with rolling bearing



Fig. 5.7: Design Sheet of Return Idler

Fig. 5.8: Design photo of Return Idler



5.1.2 Belt Take-up Devices:
Belt take-up device is used in belt conveyors to maintain adequate tension in belt so
as to:
i. Transmit the mechanical power from drive pulley to belt without slip under all
operating conditions; and
ii. Limit the belt

Types of belt take-up Devices:
i. Vertical gravity type take-up
ii. Screw type take-up
iii. Horizontal gravity type take-up
iv. Winch operated take-up

Note: In our Design we can take Vertical gravity type take-up Devices.

Fig. 5.9: Vertical gravity type take-up



5.1.3 Frame Structure of Idler Roller :

Fig. 5.10: Frame Structure of Idler Roller

Fig. 5.11: Design Sheet of Frame Structure of Idler Roller



Fig. 5.12: Design Sheet of Frame Structure of Idler Roller with Return Idler

Fig. 5.13: Frame Structure of Idler Roller with Return Idler



Fig. 5.14: Design of Frame Structure of Idler Roller without & with Return Idler



Fig. 5.15: Front view of Frame Structure of Both Idler Rollers

Fig. 5.16: Design photo of Frame Structure of idler Rollers in Series



Fig. 5.17: Design photo of Frame Structure of Idler Rollers with Return Idlers in Series

5.1.4 Conveyor Belt:

Belt is an important component of a conveyor system due to the following reasons:

i. Belt is actually responsible for conveying material.
ii. Belt is in contact with material and is taking all the punishment from material, such as
impact, abrasion, etc…
iii. It is the costliest item.
Requirements of good belt:
1. Adequate strength;
2. Good longitudinal and lateral flexibility;
3. High wear resistance;
4. Freedom from ply separation due to repeated bending;
5. Low elastic and permanent elongation;
6. Low water absorption;
7. Least affected by moisture.



Components of conveyor belts:
The conveyor belt primarily consists of two parts:

Fig. 5.18: Conveyor Belt Components

1. Carcase:
Carcase is the body of belt, which provides basic strength to take care of all
forces acting on belt during conveyor operation.
2. Rubber Covers:
The carcase is encased all around by rubber. This is done by incorporating
rubber layer on top side of carcase as well as on bottom side of carcase.

Types of Conveyor Belt:
1. Steel Cord Belts:
2. Fabric Ply Belts:

Note: In this design only Steel Cord belts are suitable for transporting materials.

1. Steel Cord Belts:

The Steel Cord Belt consists of a load carrying carcase made up of steel cords running
parallel along the length of belt.

The steel cords are reinforced by transverse textile strings at top and bottom and
are impregnated with rubber.
The carcase is covered at the top and bottom by rubber covers providing
protection against damage.
The thickness of rubber cover at top is between 10 mm to 15 mm, while at the
bottom it is 5 mm to 10 mm.



Fig. 5.19: Design of Steel Cord Belt



Fig. 5.20: Design of Belt & Feeder Mechanism



5.1.5 Final Design of Belt Conveyor:

Fig. 5.21: Final Design Photos of Troughed Belt Conveyor Mechanism



CHAPTER: 6
CONCLUSION



6.1 Conclusion:
Belt conveyor is capable for completely eliminating drawbacks of Redler
Conveyor. Belt Conveyor‟s Design is easy compare to Redler Conveyor so we can
easily modify the Belt Conveyor Mechanism. Also Belt Conveyor‟s construction is
simple compare to Redler Conveyor so we can easily install in factory or industries.
Redler Conveyor installation cost is very high compare to Belt Conveyor
because of the all components are made from iron metal and these metal is very costly
in today life, so Belt Conveyor is the best option for eliminating this problem.
Belt Conveyor installation cost is 40% less compare to Redler Conveyor
installation. Also Belt Conveyor has High efficiency of Material handling
(Transferring) we can say 100%.



CHAPTER: 7
REFERANCE



7.1 References:
(1) Fenner Dunlop “Conveyor Handbook” conveyor belting,”
Australia (June 2009) (pp 1- 32).
(2) Mathews “Belt conveyor,” FKI Logistex publication, Cincinnati,
ohio (2001) (pp 10-16).
(3) CEMA (Conveyor Equipment Manufacturers Association)
“Belt Conveyors for Bulk Materials,” Chaners Publishing Company, Inc.
6thedition. (pp 218-230).
(4) J.B.K. Das and P. L. Srinivas Murthy, “Design of Machine Element,” (Part-
II), Sapna Book House, Bangalore, third edition (2007) (pp 251-255).
(5) V.B.Bhandari “Design of Machine Element,” Tata McGraw Hill publishing
company, eighth edition (2003) (pp 234-282).
(6) ZKL, “Rolling Bearings catalogue,” Czech Republic (2001) (pp 6-234).
(7) http://en.wikipedia.org/wiki/Chain_conveyor
(8) http://en.wikipedia.org/wiki/Belt_conveyor#History
(9) http://fennerdunlopconveyorservices.com/
(10) www.sciencereserchonbeltconveyor.com


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