Final Thesis

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 PATEL PARESHKUMAR DINESHBHAI PRAJAPATI VIRALKUMAR BABUBHAI
080390119072 080390119059 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 2. Paresh Patel 3. Viral Prajapati 080390119072 080390119059 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 Internal Guide
Prof:- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.
Page 2
Certificate
This is to certify that project work embodied in this report entitled 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 Internal Guide
Prof :- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.
Page 3
Certificate
This is to certify that project work embodied in this report entitled Design of Belt Conveyor was carried out by Mr. Paresh Patel with Enrolment number: 080390119059 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 :- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.
Page 4
Certificate
This is to certify that project work embodied in this report entitled Design of Belt Conveyor was carried out by Mr. Viral Prajapati with Enrolment number: 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:- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.
Page 5
Acknowledgement
The feeling of gratefulness to any ones help directly arises from the bottom of heart. A small but an important and timely help can prove to be a milestone in ones 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
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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 gears 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.
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INDEX
Title page.1 Certificate Pages.2 Acknowledgements.6 Abstract...7 Index....8 List of Figures10 List of Table...12 Chapter: 1 1.1 Introduction...13
Project Summary.....14 1.1.1 Objective of this Project......14 Definition....15 Conveyor.....15 Introduction....16 Main Components of Redler Conveyor..17 Main Function of Redler Conveyor....19 Drawbacks of Redler Conveyor.19 Redler Failure Photos.20 Detail Description of Project...15 1.2.1 1.2.2
1.2
1.3
Redler Conveyor.....16 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5
Chapter: 2 2.1 2.2 2.3 2.4 2.5
Literature Review.........21
Belt Conveyor History...22 Tianjin Chinas Conveyor System.22 Wyodak Mine.23 Metso Rope Conveyors..24 Distributed Power System.25
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Chapter: 3 3.1 3.2 3.3 3.4 3.5 3.6
Belt Conveyors26
Introduction..27 Objective of Belt conveyor...28 Guidelines in selecting material Handling Equipment.28 Advantages of belt conveyor29 Types of materials which is handled by Belt Conveyor...29 Method of Feeding or loading in Belt Conveyor.30 Methodology31 Data available for Belt Conveyor Design Calculation..32 Design Procedure for Belt Conveyor32 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8 Belt Capacity.32 Belt Width32 Belt Tension..........33 Power calculation......34 Idler Spacing.34 Motor RPM calculation.....35 Calculate the Diameter of shaft....35 Pulley Diameter37 Final Design of Belt Conveyor...38
Chapter: 4: 4.1 4.2
Chapter: 5 5.1
Design of Main Components of Troughed Belt Conveyor..39 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 Conveyor Pulley...40 Belt Take-up Devices...46 Frame Structure of Idler Roller....47 Conveyor Belt..51. Final Design of Belt Conveyor55 Conclusions.56
Chapter: 6 6.1
Conclusions......57 Reference58
Chapter: 7 7.1
Reference.59
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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 China23 Fig. 2.2: Wyodak Coal23 Fig. 2.3: MRC straight section24 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 Hopper30 Chapter: 4 Methodologies Fig. 4.1: Bending Moment Diagram..36
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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 Pulley40 Fig. 5.3: Design photos of Crown Face type of Pulley.41 Fig. 5.4: Location of Snub Pulley42 Fig. 5.5: Design Sheet of Roller type idler with rolling bearing..43 Fig. 5.6: Design Photos of Roller type idler with rolling bearing44 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 Series51 Fig. 5.18: Conveyor Belt Components52 Fig. 5.19: Design of Steel cord Belt53 Fig. 5.20: Design of Belt and Feeder Mechanism...54 Fig. 5.21: Final Design Photos of Troughed Belt Conveyor Mechanism...55
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List of Tables
Table 4.1 Table 4.2 Material factor for Plies, K1 ...37 Belt Tension and arc of Contact Factor K2 37
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CHAPTER: 1 INTRODUCTION
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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 conveyors 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, etcby 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...
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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
S.P.B.PATEL ENGINEERING COLLEGE Page 15
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
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(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 cant transfer properly. (7) Cant 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
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CHAPTER: 2 LITERATURE REVIEW
Page 21
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 Chinas 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 manmade 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 todays technology allows designers to accommodate these curves relatively easily.
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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.ODonovan & 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
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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.
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CHAPTER: 3 BELT CONVEYOR
Page 26
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
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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
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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 Like: Corrugated cartons, plastic boxes, wooden boxes, drums, etc
4. Packages:
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
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Chapter 4 METHODOLOGY
(Calculate the Dimensions of Belt Conveyor Parts)
Page 31
4 METHODOLOGY 4.1 Data available for belt conveyor system:

Input data used for designing of belt conveyor are: Material Density =1600kg/m Belt Speed (v) = 0.1 m/s Length of Conveyor (L) = 32m,80m,145m Height of Conveyor (H) =2m Inclination angle = 3 Material size = 850250 mm Material temperature = 40-80C
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] T1 Belt width(w)

Live Load =
Belt Strength(kg inch)
(2)
= 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 T1
= = =
Effective Belt Pull T1 Factor(Taking From Table) 5212.14 1.42 7401.24 kg
From material Temperature (40 - 80C) 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) =

w = 1200mm
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 10
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 10 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 10
For horizontal and elevating conveyor, Ft = 0.025 Load fraction = 18.86 KN Load slope Tension = 9.81 10 = 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 = Take Sag = 0.02 (2%)
. (5)
Idler Spacing Si = 1 Meter
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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 + w g)
Where, D = 0.630 meter (From table of bulk material handling handbook) And = 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 , Kb Combined shock and fatigue factor applied to bending moment, Mb maximum bending moment, Kt combined shock and fatigue factor applied to tensional moment
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Fig 4.1: Bending moment Diagram
From above calculation we can find the Diameter of shaft, d = 28.37mm 25 to 35mm
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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, Duck, Duck in Combination with Capron and Lavsan Material factor 1.25 1.4 1.6 2.0 2.5 Anide High Tensile Combination of Duck with Lavsan Capron High Tensile Capron
for plies, K1
Table 4.2: Belt tension and arc of contact factor, K2 Belt Tension as Percentage of F
Arc of Contact, deg 100 240-180 110-70 30-15 Under 15 100 80 63 50
75 80 63 50 40
50 63 50 40 32
25 50 40 32 25
12 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)
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5. 5.1
FINAL DESIGN OF BELT CONVEYOR 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. ii. Crown-face type pulley 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. iii. iv. Changing the path of carrying run of the belt; Changing the path of return run of the belt; and 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.
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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
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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. i. ii. iii. iv. Limit the belt
Types of belt take-up Devices: Vertical gravity type take-up Screw type take-up Horizontal gravity type take-up 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
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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
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Fig. 5.14: Design of Frame Structure of Idler Roller without & with Return Idler
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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
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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.
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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
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6.1 Conclusion:
Belt conveyor is capable for completely eliminating drawbacks of Redler Conveyor. Belt Conveyors Design is easy compare to Redler Conveyor so we can easily modify the Belt Conveyor Mechanism. Also Belt Conveyors 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%.
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CHAPTER: 7 REFERANCE
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7.1 References:
(1) Fenner Mathews Dunlop Belt Conveyor conveyor, FKI Handbook Logistex conveyor publication, belting, Cincinnati, Australia (June 2009) (pp 1- 32). (2)
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, (PartII), 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) (7) (8) (9) (10) ZKL, Rolling Bearings catalogue, Czech Republic (2001) (pp 6-234). http://en.wikipedia.org/wiki/Chain_conveyor http://en.wikipedia.org/wiki/Belt_conveyor#History http://fennerdunlopconveyorservices.com/ www.sciencereserchonbeltconveyor.com
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Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

S.P.B.PATEL ENGINEERING COLLEGE, LINCH

PATEL VISHALKUMAR BHARATBHAI PATEL PARESHKUMAR DINESHBHAI PRAJAPATI VIRALKUMAR BABUBHAI

080390119072 080390119059 080390119073

SHAILESH PRAJAPATI (B.E.MECHANICAL)

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

Prof :-Shailesh Prajapati Internal Guide

Prof:- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

Prof :- Shailesh Prajapati Internal Guide

Prof :- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

Prof :- Shailesh Prajapati Internal Guide

Prof :- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

Prof :- Shailesh Prajapati Internal Guide

Prof:- Taushif Shaikh HOD, MECHANICAL DEPARTMENT.

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

VISHAL B. PATEL PARESH D. PATEL VIRAL B. PRAJAPATI

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

Redler Conveyor.....16 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5

Chapter: 2 2.1 2.2 2.3 2.4 2.5

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

Chapter: 3 3.1 3.2 3.3 3.4 3.5 3.6

Chapter: 4: 4.1 4.2

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor

S.P.B.PATEL ENGINEERING COLLEGE

Gokul Refoil & Solvent Ltd.

Design of Belt Conveyor