DESIGN AND FABRICATION

OF AUTOMATIC CONVEYOR
Presented by
Guided by
U.DINESH BABU - (510812114025)
Mr.V.SIVAKUMAR. ME.,
AP/Mech
R.DINESH KUMAR - (510812114026)
M.DURAIMURUGAN- (510812114027)

ABSTRACT:
This project works at the design, development and testing
of working model entitled Automatic Conveyor
Controller.The model of Conveyor controller is designed
by using 8051microcontroller, IR sensors to avoid the
unwanted motion.
By employing the automatic Conveyor control at the level
crossing the arrival component is detected by the sensor
placed near Roller.
This fabrication system is used to reduce the power
consumption and also to neglect the unwanted motion
of the conveyor. Saving of labour and also time.

OBJECTIVE
To avoid unwanted motion and power
wasteage.
To increase the life time of the
Conveyor and its drives

INTRODUCTION
A conveyor system is a common piece of
mechanical handling equipment that moves materials
from one location to another. Conveyors are especially
useful in applications involving the transportation of
heavy or bulky materials. Conveyor systems allow
quick and efficient transportation for a wide variety of
materials, which make them very popular in the material
handling and packaging industries

TYPES OF CONVEYORS:
Belt Conveyor System
Flexible Gravity Conveyors
Roller Conveyor System
Screw Conveyors
Trolley conveyors
Reciprocating vertical conveyor
Vertical lift conveyor
Pneumatic conveyor
Vibrating conveyor
Bucket conveyor

Belt Conveyor

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

WORKING PRINCIPLE

Belt conveyor is composed by two endpoint pulleys

and a closed conveyor belt. The pulley that drives
conveyor belt rotating is called drive pulley or
transmission drum; the other oneonly used to
change conveyor belt movement directionis called
bend pulley.

Drive pulley is driven by the motor through reducer,

and conveyor belt dragging relies on the friction drag
between the drive pulley and the conveyor belt.

Compared with other transport equipment, such as

Motorcycle, belt conveyor is the best efficient continuous coal
transportation equipment with advantages of long transmission
distance, large volume, continuous conveyor, etc., and operate
reliably, easy to implement automation and centralization control;
especially for high yield and efficient mine, belt conveyor has
become the key equipment for coal mining and mechtronics
technology.
The metal detecting sensor is placed at the two ends of the
conveyor. It helps to detect the components and materials.
By detecting the components the sensor helps to activate the motion
of the conveyor, because it is connected to the motor.

Coding

$MOD51
ORG 0000H
clr p2.0
clr p2.1
LOOP1:
clr p2.0
clr p2.1
setb p2.3
setb p2.4
open: jb p2.3,open
setb p2.0
setb p2.1
ACALL DELAY1
ACALL DELAY1
ACALL DELAY1

ACALL DELAY1
ACALL DELAY1
ACALL DELAY1
clr p2.0
clr p2.1
ACALL LOOP1
begin: sjmp begin

DELAY: MOV R6,#50

HERE2: MOV R7,#255
HEREW: DJNZ R7,HEREW
DJNZ R6,HERE2
RET
DELAY1: MOV TMOD,#01H
MOV R3,#25D

Z3:MOV TL0,#08H;
MOV TH0,#01H;
SETB TR0
BACK3: JNB TF0,BACK3
CLR TR0
CLR TF0
DJNZ R3,Z3
RET
END

Component

Motor
Micro controller(AT89s52
Microcontroller)
Relay
Pulley
Belt
Pillow head ball bearing

PHOTOGRAPHY
TOP VIEW

Cad view

DESIGN CALCULATION
6.1 MOTOR:
1. 60 RPM 12V DC motors with
Gearbox
2. 6mm Shaft Diameter With
Internal Hole
3. 125gm weight
4.1.2kgcm torque (T = 0.12 N-M)
5. No-load current = 60 mA(Max),
Load current = 300 mA(Max)

BELT
Material is rubber

Diameter of the driver(D1) : 60 mm

Diameter of the follower(D2) : 60 mm

Center distance of the drive(C) :
600mm

Width of Belt
: 80mm

Thickness of Belt : 5mm

Speed of the driver

: 60 rpm

Angle of contact
: 180

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

Length of the Belt ( L) =2C+ / 2 (D1+ D2) + (D1-D2) / 4C

L= (2x0.6) + / 2 (0.06+ 0.4) + (0.2+ 0.4) / 4x2
L= 1388mm
Power
P =( 2NT)/60
P = (2 60 60 .12)/60
P = 14.4 W

6.3 BEARING
Material isCAST IRON
Speed of shaft
N = 60rpm
Life of the bearing
Lh = 10,000 hrs
Service factor
S = 1.5
Refer Psg data book 4.12
Deep groove ball bearing D = 20mm
Select the bearing is SKF 6004
co = 4500
c = 7350N or c = 735kgf
Refer Psg data book 4.6 for find C/P value
Speed and life of bearing
C/P =3
C = 7350
P= 2025N (OR) 202.5KGF

 DYNAMIC CAPACITY
C = P(L/L10)^1/K

C = 2025(28.8/1)^1/3

C = 6207N OR 620.7KGF

Since, The Dynamic Load Rating Of Skf 6004 Is More

Than The Required Dynamic Load Capacity , THE SELECTED
BEARING IS SAFE

COST ESTIMATION
MATERIALS

QUANTITY

COST

Motor

500

Pillow head Bearing

600

Sensors

600

Micro controller

200

Adaptor

260

Frame

400

Pulley

400

Belt

400

Shaft

40

Nut and Bolt

100

Relay and Wire

500

Total

4000

LITERATURE REVIEW

Design Improvements and Fabrication of Conveyor Belt Cleaner and

Washing System at Westports MalaysiaTasnim F. Ariff, Muhd. Fahmi B.
Jusoh, Malek Parnin and Mohd. Hanif Azenan
Conveyor belts at ports are used worldwide to carry and transport various
materials ranging from fertilizers to foods items such as corn, barley and
soy beans from the cargo ship to the packaging site. A serious spillage and
carryback problem existed at DB2 terminal, Westports Malaysia where lots
of chemical fertilizers (ammonium sulphate) were wasted to some extent
and extra manpower was needed to shovel the spillage into the container.
The floor was highly corroded due to improper washing and drainage
system. The main aim of this research was to eliminate if not reduce spillage
and solve the corroded floor issue. The primary and secondary belt cleaners
were designed using CATIA software. These newly improved cost effective
and simple designs of the primary and secondary belt cleaners together with
a spray shaft and proper washing box were fabricated, tested and
implemented successfully. The spillage was reduced tremendously and the
washing system can prevent corrosion from happening in the future.

Design And Optimization Of Idler For Belt

ConveyorHitesh J Soni1, Mr. Ronak R Patel
2.
The work present in this paper focuses on
the reduction of cost of idler as belt conveyor
consist of many idler and reducing running cost
of conveyor system by optimizing by.
i ) Selecting optimum diameter of shell, ii)
selecting optimum diameter of shaft. iii)
Thickness of shell. iv) Distance between two
bearings. Modeling and Analysis of parts of idler
is done by using Finite Element Method.

APPLICATIONS
Vegetable , furit and potato processing industry
Sugar industry
Meat and poultry processing / abattoirs / rendering
industry
Fish and Shellfish processing industry
Brewing , malting and beverage industry / distilleries
Horticulture industry
Paper and pulp industry
Chemical and petrochemical industry
Mining and Minerals industry
Exhaust gas cleaning
Waste recycling industry
Spent catalyst recycling
Bio Energy Industry

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

REFERENCES

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

3 April 13, 2012
Design Optimization For Modification Of Trough Belt Conveyor To
Reduce Material Spillage Used In Clinker Transport In Cement Plant By
Shalom Akhai , Harpreet Singh.Vol. 2, Issue 04, 2014 |
Design Improvements And Fabrication Of Conveyor Belt Cleaner And
Washing System At Westports Malaysia By Tasnim F. Ariff, Muhd.
Fahmi B. Jusoh, Malek Parnin and Mohd. Hanif Azenan.Vol. 1 No.
10 October 2013
Design and Analysis of a Roller Conveyor System for Weight
Optimization and Material Saving By Suhas M. Shinde and R.B.
Patil.25 April, 2012
Design Of A Material Handling Equipment: Belt Conveyor System For
Crushed Limestone Using 3 Roll Idlers By I. A. Daniyan , A. O.
Adeodu And O. M. Dada on January 16, 2014.

THANK YOU