DEPARTMENT OF MECHANICAL ENGINEERING

COLLEGE OF ENGINEERING

MESB4013 – ELECTRO-MECHANICAL SYSTEMS

SEMESTER 2, 2020/2021

MINI PROJECT

GROUP NUMBER : 1

MOTOR SELECTION FOR SUPERMARKET

PROJECT TITLE :
CHECKOUT CONVEYOR BELT

MOHAMED ANSARI MOHAMED NAINAR,

LECTURER :
ASSOC. PROF. DR.

TEAM MEMBERS ID SECTION

Muhammad Syukri Bin Mohd Shabre ME0104956 01B
Muhamad Shahid Ammar Bin Shahanaz ME0104902 01A
Shaquille Rashuan Bin Mohamed Napi ME0105264 01A
Nik Farith Ridzwan Bin Roslam ME0104927 01B
Muhammad Syafiq Bin Mohd Sujak ME0105247 01B
Muhammad Haikal Bin Sazali ME0104933 01B

1
 Table of Contents

Chapter 1: Introduction ....................................................................................................................... 3

1.1 Summary................................................................................................................................ 3
1.2 Literature review .................................................................................................................. 4
Chapter 2: Methodologies .................................................................................................................... 6
2.1 Design of the checkout counter system ............................................................................... 6
2.2 Specification and operating condition ................................................................................. 7
2.3 Electrical circuit .................................................................................................................. 11
Chapter 3: Discussion ......................................................................................................................... 14
Chapter 4: Conclusion ........................................................................................................................ 16
Reference ............................................................................................................................................. 17
Appendix .............................................................................................................................................. 19
Appendix 1 ........................................................................................................................................ 19
Appendix 2 ........................................................................................................................................ 20
Appendix 3 ........................................................................................................................................ 21
Appendix 4 ........................................................................................................................................ 22

List of Figures

Figure 1 - Supermarket checkout counter ............................................................................................... 3

Figure 2 - Three Phase AC induction motor ........................................................................................... 5
Figure 3 - Structural drawing of checkout conveyor’s components ....................................................... 6
Figure 4 - Equivalent circuit of the induction motor............................................................................. 11

List of Tables

Table 1 - Motor comparison ................................................................................................................... 5

Table 2 – Structural specification ........................................................................................................... 7
Table 3 – Mechanical data of 80S-SMP induction drum motor [Appendix 3] ..................................... 11

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Chapter 1: Introduction

1.1 Summary

The checkout conveyor belt is the conveyor belt most consumers are most familiar with. It can
be found in the supermarket when the customer wants to pay for their groceries which located
at the checkout counter. A conveyor system is a fast and efficient mechanical handling
apparatus for automatically transporting groceries within an area. This system lowers
workplace risks and reduces labour. They are useful in helping to move customers items from
one point to scan station. A conveyor system may use a belt, rollers, chain and a motor to
transport objects [1].

For conveyor belt applications, it required certain type of motor with a fixed or constant
speed applications, for example AC motors & gear motors are well suited. For this project, it
required the conveyor systems to operate continuously in one direction. Therefore, the AC
induction motors were chosen. There are many circumstances need to figure out when
structuring and designing a motor-drive system [2]. Before selecting the motor, it is important
to ensure that the mechanical design should be determine. After acquiring it, the efficiency of
the motor needs to be calculated before presenting the design factors and design procedure.

This design proposed the selection of motor that will drive a conveyor belt of checkout
station such as the one that is available in the supermarket. The conveyer belt that connected
to the rollers will create a motion mechanism that allow the groceries items to move from end
to end of the belt. This action is caused by the rotation of motor.

Figure 1 - Supermarket checkout counter

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1.2 Literature review

As we all known, a conveyor system is a mechanical handling device that automatically

transports load and material from one location to another location. In this project, the Interrolls
drum motor 80 S-SMP have been used to move the conveyor which is similarly function as the
AC induction motor. An AC induction motor is also known as asynchronous motor. It is so
called because it never runs at synchronous speed [3]. Conveyors with the AC motor can
improve the performance of the conveyor belts and other mechanical equipment by providing
smooth and precise control of motor speed and torque, reduces the operating and maintenance
cost of the conveyor. Furthermore, if a conveyor joint needs to be repaired, the AC motor will
enable the user to precisely transfer the belt into it place [4].

AC induction motor are suitable to be used for the conveyor to run continuously in one
direction. AC induction motor can be referred as an AC electric motor where the electric current
in the rotor used to generate torque is obtained by electromagnetic induction from the magnetic
field of the stator winding. As a consequence, an induction motor can be produced without any
electrical connections to the rotor [5]. The sinusoidal distribution, which can be defined as the
flow of electric current through a single wire and rotates within a stationary magnetic field,
will be produce from the distribution of stator windings, which is comes from AC Induction
motor following Michael Faraday laws. Stator winding means the windings that have been
installed on the stator, which is a stationary part of induction motor.

There are three phases of AC Voltage that are needed to apply to stator windings in order
to produce a rotating magnetic field. Three phase power usually used to power high-power
loads which is the current is distributed over three wires instead of one, making for smaller and
therefore less costly wiring [6]. Also, there is an existence of windings in the rotor of induction
motion, or also known as a squirrel cage made of a copper with iron lamination embedded
around it. A magnetic field is produced from an induction of electric current in the rotor bars.
The rotor is dragged by the rotating magnetic field produced by the stator, but it doesn’t always
manage to catch up with this rotating magnetic field as it usually slips as the field rotating. For
example, for one cycle of magnetic field rotation. The rotor only manages to catch up only
third quarter of the cycle [7].

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 Figure 2 - Three Phase AC induction motor

Table 1 is the comparison between various type of motor that available that explained with the
help of various factors, like the characteristics of the motors.

Table 1 - Motor comparison

Characteristics Stepper DC DC Asynchronous

Motor Brush Brushless AC
Low Cost Yes Yes Yes No

Smooth operation (minimal No Yes Yes No

noise, vibration)
High Speed No Yes Yes No

High Power No No Yes Yes

High Torque to Size Ratio Yes No Yes Yes

Ease of Use Yes No No No

Simplest Control Circuitry No Yes No No

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Chapter 2: Methodologies

2.1 Design of the checkout counter system

Designing for the checkout counter system is an important part of the product development
cycle as it optimizes the design for its manufacturing and assembly process, merging the design
requirements of the product with its production method. Implementing the designing for
manufacturing (DFM) tactics can reduces the cost and difficulty of producing a product while
maintaining its quality [8].

Figure 3 - Structural drawing of checkout conveyor’s components

As per our design, we the conveyer system is reversible conveyer with head drive. The head
drive (discharge end) is the most common and preferred option for reversible conveyors and is
ideal because it is simple to design and easy to install. Furthermore, most of the belt tension is
on the top carrying side and allows the drum motor to transfer its full torque to the belt.
Compared to the tail drive (loading or receiving end), it is not the ideal drive position as the
drum motor is pushing the top carrying side of the belt and more tension is applied to the return
belt, therefore the full torque of the drive may not be applied.
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2.2 Specification and operating condition

For this part is to decide the motor technology to use. After a long research, we found the
desired motor that match our project specification which is to use AC induction motors. The
product that we found is Drum Motor 80S-SMP which is brand of Interroll. This brand is one
of the world‘s leading manufacturers of key products for unit load handling systems, internal
logistics and automation. It also has been dedicated to being supermarket solutions as it makes
supermarkets goods moving most efficiently by its drum motors and conveying system. Table
below show the structural specification that obtained from the product Interroll drum motor
general catalogue [9] and there are some of the elements were assumed according to the Low-
Speed Synchronous Motors [10].

Table 2 – Structural specification

Motor type = Asynchronous squirrel cage Frictional coefficient of sliding surfaces,

motor 𝜇 = 0.04

Available power supply: 3 φ, 115 V, 60 Hz Belt and pulley efficiency, η = 0.9

Total mass of belt and work, 𝑚1 = 5 kg Velocity of the shell: 0.05 to 0.88 m/s

Mass of roller, 𝑚2 = 1 kg Intermittent operation, 12 hours per

day/continuous operation.
Roller diameter, D = 81.5 mm

Gear material: Techno Polymer

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Analysis and calculation:

i. Required torque, 𝑇𝐿
𝐹∙𝐷
Load Torque = 2∙η

Here, Frictional coefficient of sliding surfaces, 𝜇 assumed to be 0.04

• The frictional coefficient of sliding surfaces assumption is based on the motion of two
surfaces in contact to the normal force pressing the two surfaces together. In this particular
project, the coefficient of friction for rubber conveyer belt is against the steel roller.

Total mass of belt and work, 𝑚1 assumed to be 5 kg

Acceleration of gravity, g = 9.81 m/𝑠 2 [standard numerical value]
Frictional coefficient of sliding surfaces, F = 𝜇 × 𝑚1 × 𝑔 = 0.04 × 5 × 9.81 = 1.962 N
Roller diameter, D = 81.5 mm
Belt and pulley efficiency, 𝜂 assumed to be 0.9

1.962∙(81.5×10−3 )
Load Torque, 𝑇𝐿 = = 88.84 × 𝟏𝟎−𝟑 N∙m
2∙0.9

ii. Load inertia, 𝐽𝐿

Load inertia of belt and work, 𝐽𝑚1

2
𝜋∙𝐷 2 𝜋∙(81.5×10−3 )
𝐽𝑚1 = 𝑚1 × ( 2∙𝜋 ) = 5× ( ) = 8.303 × 10−3 kg∙ 𝑚2
2∙𝜋

Load inertia of roller, 𝐽𝑚2

1 1
𝐽𝑚2 = 𝑚2 × 8 × 𝐷2 = 1 × 8 × (81.5 × 10−3 )2 = 0.830 × 10−3 kg∙ 𝑚2

Load inertia, 𝐽𝐿 = 𝐽𝑚1+(𝐽𝑚2 × 2) = 8.303 × 10−3 + (0.830 × 10−3 × 2) = 𝟗. 𝟗𝟔𝟑 × 𝟏𝟎−𝟑 kg∙ 𝒎𝟐

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iii. Acceleration torque, 𝑇𝑎

𝜋∙𝜃𝑠 ∙𝑓2
𝑇𝑎 = (𝐽𝑜 + 𝐽𝐿 ) × 180∙𝑛

Here, rotor inertia, 𝐽𝑜 assumed to be 1400× 10−7 kg∙ 𝑚2 as stated according to the Low-Speed
Synchronous Motors [11]

𝜃𝑠 = 7.2°

Frequency of power supply, f = 60 Hz (on request)

n = 3.6°/𝜃𝑠 = 3.6°/7.2° = 0.5

Acceleration torque, 𝑇𝑎 = (1400 × 10−7 + 9.963 × 10−3 ) × 904.78 = 9.14 N∙m

iv. Required torque, 𝑇𝑚 (look for a margin of safety of 2 times)

Required torque, 𝑇𝑚 = (𝑇𝐿 + 𝑇𝑎 ) × 2 = ( 88.84 × 10−3 + 9.14) × 2 = 18.46 N∙m

v. Permissible load inertia, 𝐽𝐺

𝐽𝐺 = 𝐽𝐿 × 𝑖2

Here, gear ratio, i is given to be 78.55 for the 3-phase with 2-poles motor [Appendix 3]

Permissible load inertia, 𝐽𝐺 = 9.963 × 10−3 × 78.552 = 61.47 kg∙ 𝒎𝟐

When the required torque is calculated, 𝑇𝑚 is obtained as 18.46 N∙m<19.5 N∙m, which is
below the rated torque of drum motor, 𝑀𝐴 [Appendix 3]. Next, since the load inertia, 𝐽𝐿
calculated as 𝟗. 𝟗𝟔𝟑 × 𝟏𝟎−𝟑 kg∙ 𝒎𝟐 < 61.47 kg∙ 𝒎𝟐 , which is also below the permissible load
inertia, 𝐽𝐺 , 3-phase of Interroll Drum Motor 80S-SMP can be used for this project.

9
vi. Speed
a. Belt speed
𝜋∙𝐷∙𝑁𝐺
𝑣𝑏𝑒𝑙𝑡 = 60
𝑉∙60 115 ×60
Which, 𝑁𝐺 = = = 26.95 (𝑟/𝑚𝑖𝑛)
𝜋∙𝐷 𝜋 × 81.5
𝜋 ×81.5× 26.95
∴ 𝑣𝑏𝑒𝑙𝑡 = = 115 𝑚𝑚/𝑠 = 0.115 m/s
60

b. Motor speed
𝐴𝑐𝑡𝑢𝑎𝑙 𝑚𝑜𝑡𝑜𝑟 𝑠𝑝𝑒𝑒𝑑, 𝑛𝑟 = 𝑟𝑎𝑡𝑒𝑑 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟 × 𝑔𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜

= 35.6 × 78.55

= 2796.38 𝑟𝑝𝑚

𝑛𝑟 ∙ 𝜋 ∙ 𝐷 2796.38 × 𝜋 × 81.5
∴ 𝑣𝑚𝑜𝑡𝑜𝑟 = = = 151.92 𝑚𝑚⁄𝑠 = 0.151 m/s
60 ∙ 𝑖 60 × 78.55

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2.3 Electrical circuit

Table 3 – Mechanical data of 80S-SMP induction drum motor [Appendix 3]

Elements Value
Available power supply 3φ, 115V, 60 Hz (on request)
Rated power 0.085 kW
Motor frequency 50 Hz
Number of Poles 2
Gear stages 3
Gear ratio 78.55
Rated velocity of the shell 0.15 m/s
Rated revolutions of the shell 35.6 per minute
Rated torque of drum motor 19.5 Nm
Rated belt pull of drum motor 479 N
Maximum belt tension 2000 N
Minimum shell length 270 mm

Figure 4 - Equivalent circuit of the induction motor

Circuit assumption:

A 3φ, Y-connected, 115V, 60Hz, 2-pole induction motor has the following parameter values
in Ω/phase referred to the stator circuit:

𝑅1 = 0.056, 𝑅2 = 0.08, 𝑋1 = 0.21, 𝑋2 = 0.37, 𝑋𝑚 = 6.0

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i. Slip, s
𝑛𝑠 −𝑛𝑟
s= , where 𝑛𝑠 = motor speed and 𝑛𝑟 = actual motor speed
𝑛𝑠
120∙𝐹
𝑛𝑠 = , where Motor frequency, F = 50 Hz and number of poles, P = 2
𝑃
120∙50
𝑛𝑠 = = 3000 rpm
2

𝑛𝑟 = rated revolution of motor × gear ratio = 35.6 × 78.55 = 2796.38 rpm

𝑛𝑠 −𝑛𝑟 3000−2796.38
s= = = 0.068
𝑛𝑠 3000

ii. Input power, 𝑃𝑖𝑛

𝑃𝑖𝑛 = 𝑉𝑇 ∙ 𝐼𝐿 ∙ 𝑐𝑜𝑠𝜃

𝑉𝑇 = 115V

𝑉
Stator current, 𝐼𝐿 = 𝑍 φ ,
total

115
𝑉φ = = 66.4 ∠ 0°
√3

𝑍total = 𝑍stator + 𝑍f

𝑍stator = 𝑅1 + 𝑗𝑋1 = 0.056 + j0.21

1
𝑍f = 1/𝑗𝑋
m +1/𝑍2

𝑅2 0.08
where rotor impendence, 𝑍2 = + j𝑋2 = 0.068 + j0.37 = 1.176 + j0.37 = 1.23 ∠ 17.46°
𝑠

1 1 1 1
𝑍f = 1 1 = −𝑗0.16+0.85−j0.37 = 0.85−𝑗0.53 = 1∠−31.94° = 1∠ 31.94°
+ −𝑗0.37
𝑗6 1.173

𝑍total = 𝑍stator + 𝑍f = 0.056 + j0.21 + 0.84 + j0.52

𝑉 66.4 ∠ 0° 66.4 ∠ 0° 66.4 ∠ 0°

𝐼𝐿 = 𝑍 φ = 0.056 + j0.21 + 0.84 + j0.52 = 0.896+j0.73 = 1.15∠39.17° = 57.74 ∠ -39.17° A
total

𝑃𝑖𝑛 = 115 ∙ 57.74 ∙ cos 39.17 = 5147.91 W

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iii. Output power, 𝑃𝑜𝑢𝑡

The total rotational losses can be assumed to be constant at 480 W, independent of load.

𝑃𝑜𝑢𝑡 = 𝑃𝑐𝑜𝑛𝑣 − 𝑃𝑟𝑜𝑡

Here, total rotational losses, 𝑃𝑟𝑜𝑡 (friction and windage losses) assumed to be 480 W

𝑃𝑐𝑜𝑛𝑣 = (1 − 𝑠)𝑃𝐴𝐺

𝑃𝐴𝐺 = 𝑃𝑖𝑛 − 𝑃𝑆𝐶𝐿 = 5147.91 − 3 ∙ 𝐼𝐿 2 ∙ 𝑅1 = 5147.91 − 3 ∙ (57.74)2 ∙ 0.056 = 4587.81

𝑃𝑐𝑜𝑛𝑣 = (1 − 0.068)(4587.81) = 4275.83 W

𝑃𝑜𝑢𝑡 = 4275.83 − 480 = 3795.88 W

iv. Motor efficiency, ƞ

𝑃𝑜𝑢𝑡 3795.88
Ƞ= × 100% = 5147.91 × 100% = 73.74%
𝑃𝑖𝑛

∴ the motor efficiency is 73.74% which is rate as a good motor (70% ∼ 95%)

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Chapter 3: Discussion

From this project, we can see that the AC Induction Motor plays an important part in
the Conveyor System. This is because, the AC Induction Motor it can produce torque and also
it can improve the performance of the conveyor and other mechanical equipment. The
importance of this project are to determine the suitable motor to be used in the conveyor
through calculation so that it can works better and lasts longer, can help to reduce cost, time
and maintenance services, reduce manual handling of goods as well as reduce manpower and
automate the system and increase efficiency as well as productivity. There are several
advantages of using the motor, first, it is robust and can operate in any environmental condition.

Moreover, induction motors are cheaper in cost due to the absence of brushes,
commutators, and slip rings. They are maintenance free motors unlike dc motors and
synchronous motors due to the absence of brushes, commutators and slip rings. Induction
motors can be operated in polluted and explosive environments as they do not have brushes
which can cause sparks 3 phase induction motors will have self-starting torque unlike
synchronous motors, hence no starting methods are employed unlike synchronous motor.
However, single-phase induction motors do not have self-starting torque, and are made to rotate
using some auxiliaries. For this project, we have list down to 4 motors that are potentially be
used in our system which are Stepper Motor, DC Brush, DC Brushless and Asynchronous AC.

Based on the 4 motors, we decided to choose the Asynchronous which is 80S-SMP for
a few reasons. The reasons are it has high power and torque to size ratio. With this, it will make
the system to run smoothly and precise control of the motor speed. For the calculation part, it
is divided into two parts. For the first part, we have calculated torque, load inertia, acceleration
torque and speed. From the calculation, we have managed to get the value by using the formula
that have been learned in class. The value that we assumed for this part is the coefficient of
friction, which are assumed based on the motion of 2 surfaces in contact to the normal force
pressing the 2 surfaces together.

14
 The values that obtained are suitable to be used in our system. For the second part of
our calculation, we calculated values that are regarding to the system circuit. The values that
we calculate are, slip s, input power, output power and motor efficiency. The values that we
assumed are X1, X2, R1, and R2 which are based on the suitability with the voltage provided by
the motor. Throughout the calculation, we manage to get the efficiency which is 73.74% which
is good. This is because it is in the range of 70% to 90%. The use of AC Induction Motor on
conveyor system gives more reliable operation, reduces maintenance, and helps save energy.
The smooth operation that AC Induction Motor conveyor motors provide reduces the strain on
both the mechanical and electrical systems. There are several ways of improving the system.
This can be done by improving the reliability and control.

Moreover, by saving which is can be made by eliminating reactive power

compensation, which is not necessary when using an AC drive. Energy can be also saved by
running the conveyor at reduced speed when full speed is not required. Lastly, simplify the
conveyor design. AC Induction Motor also help to simplify the conveyor drive system,
potentially reducing the investment costs as well as the maintenance needs. With the motor
speed adjusted for the application, the gear ratio can be optimized, and a simpler gearbox can
be used. In some cases, it may be possible to eliminate the gearbox altogether, improving the
efficiency of the system. The simple asynchronous motor requires minimal maintenance.

15
Chapter 4: Conclusion

This project describes the scope and viability of motor that will be used in the conveyor
system at supermarket. Throughout this project, the purposes are to identify the suitable motor
that can be used in the conveyor system using calculation so that it can work better and last
longer which can also help to reduce the cost, time and maintenance services, reduce manual
handling of goods as well as reduce manpower, and automate the system and at the same time
increase efficiency as well as productivity have been successfully achieved. Based on the result
obtained above, student managed to calculate all the required data using formula of motor. The
results indicate that, the final efficiency for the motor is 73.74% which is considered as high
efficiency.

Furthermore, the calculation and type of motor that were selected are based on the
motor selection catalogue in order to get the suitable and optimum design for conveyor system
with the desired load applied. Thus, the type of AC motor was used in this project because it
required the conveyor system to operate continuously in one direction. From this project, the
students can realize the used of Electromechanical Systems in daily life based, such as the
motor in the conveyor system. Additionally, future suggestion that can be obtained from this
project are to calculate the load precisely, to choose the suitable material for the conveyor and
type of motor efficiently because the absence detailed of information of load and type of
material used usually will affected the performance efficiency. Last but not least, to understand
the load factors of the system. Therefore, this will reduce and avoid common issues that usually
occurred in the market of the conveyor system which are the maintenance and specification
errors.

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Reference

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[8] “The Importance of Design for Manufacturing,” Markforged, 2021.

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[9] “Material Versions Component Version Material Product Description Technical Data
Compact premium drive for small light-duty conveyors,.” Accessed: May 16, 2021.
[Online]. Available:
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18
Appendix

Appendix 1

19
Appendix 2

20
Appendix 3

21
Appendix 4

22