DESIGN AND MANUFACTURING METHODOLOGY FOR CONVEYOR Sanket Kolte 1, Rohit Khandre 2, U. V. Patil 3 1,2 U. G. Student, Department of Mechanical Engineering, Sandip Foundation s- SITRC, Mahiravani, Trimbak Road, Nashik, Maharashtra (India) 3 Assistant Professor, Department of Mechanical Engineering, Sandip Foundation s- SITRC, Mahiravani, Trimbak Road, Nashik, Maharashtra, Savitribai Phule Pune University, Maharashtra, (India) ABSTRACT The most significant and pristine aim of our project is to apply the principles of engineering to expose their proficiency in industries. Although designed for simplicity, our project consists of one systems working to handle material in industry to complete specific requirements. The material handling by conveyor without energy reflects the combined effort of all the team members who worked hard to come up with optimum design in accordance with the theory knowledge learnt so far. The design focuses towards explaining the procedure and methodology used for designing the conveyor. The design process of this conveyor is iterative and based on several engineering and reverse engineering processes. The main area of this report is about the designing and manufacturing methodology for frame and trolley of conveyor. The frame and trolley of conveyor is designed for its application requirements keeping in mind its feasibility of use and sustainability to various loads. Keywords: Conveyor, Feasibility, Frame, Material Handling, Reverse Engineering, Sustainability, Trolley I. INTRODUCTION A conveyor system is a piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy and light materials. Conveyor systems allow quick and efficient transportation for various materials, which make them popular in the material handling and packaging industries. Many kinds of conveying systems are available, and are used according to the various needs of different industries. Conveyor systems are used widespread across a range of industries due to the numerous benefits they provide. Conveyors are able to safely transport materials from one level to another, which when done by human labor would be strenuous and expensive. They can be installed almost anywhere, and are much safer than using a forklift or other machine to move materials. They can move loads of all shapes, sizes and weights. Also, many have advanced safety features that help prevent accidents [1]. Conveyor systems are commonly used in many industries, including the automotive, agricultural, computer, electronic, food processing, aerospace, pharmaceutical, chemical, bottling and canning, print finishing and packaging. Although a wide variety of materials can be conveyed, some of the most common include food items such as beans and nuts, bottles and cans, automotive components, scrap metal, pills and powders, wood and 188 P a g e
furniture and grain and animal feed. Many factors are important in the accurate selection of a conveyor system. It is important to know how the conveyor system will be used beforehand. Some individual areas that are helpful to consider are the required conveyor operations, such as transportation, accumulation and sorting, the material sizes, weights and shapes [2, 3]. II. HISTORY Primitive conveyor was used since the 19 th century. In 1892. thomos robins he is the first who invented conveyor for carrying coal and other products. In 1901, the man whose name is sandvik invented and started the production of steel conveyor. Then in 1905 richard Sutcliffe invented first conveyor for use in coal mines. Then In 1913, henry ford established conveyor-belt assembly lines at ford motor companys Highland Park, michigan factory. In 1970, the company 'intralox' registered the first patent for all plastic, modular belting [4, 5]. III. DESIGN WORK Design of trolley on CAD Fig. 1 Design of Frame on CAD Fig. 2 Design of Trolley on CAD 189 P a g e
IV. METHODOLOGY 4.1 Manufacturing Processes Used 4.1.1 Cutting The material was first cut into the required dimensions for further processing. Many factors are involved in cutting method decision like squre pipe material, thickness, end conditioning requirements and secondary processes requirement. Other factors that play roll can be production volume, cutting efficiency, overhead cost and special requirement for pipe material [6]. Types of cutting: Abrasive cutting Band saw cutting Cold sawing Laser cutting Lathe cutting Shearing *Band saw cutting: It is fully automatic process and the most common method used for cutting rod, bar, pipe and tubing. This process is excellent for cutting large volumes. Some band saw s can handle large product bundle. The blade is a continuous band of metals, available in various tooth configurations that rotates on two wheels. Depending on the model design, the blades approached to the metal maybe horizontal or vertical. It is a viable method for cutting various sections like squares, rectangles, channels, high beams etc. 4.1.2 Welding Welding is a fabrication or sculptural process that joins materials, usually metals thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in contrast with soldering and brazing, which involve melting a lower-melting-point material between the work pieces to form a bond between them, without melting the work pieces. There are several different ways to weld, such as: Shielded Metal Arc Welding, Gas Tungsten Arc Welding, Tungsten Inert Gas and Metallic Inert Gas. MIG or Metallic Inert Gas involves a wire fed "gun" that feeds wire at an adjustable speed and sprays a shielding gas (generally pure Argon or a mix of Argon and CO2) over the weld puddle to protect it from the outside world. TIG or Tungsten Inert Gas involves a much smaller hand-held gun that has a tungsten rod inside of it. With most, you use a pedal to adjust your amount of heat and hold a filler metal with your other hand and slowly feed it. Stick welding or Shielded Metal Arc Welding has an electrode that has flux, the protectant for the puddle, around it. The electrode holder holds the electrode as it slowly melts away. Slag protects the weld puddle from the outside world. Flux-Core is almost identical to stick welding except once again you have a wire feeding gun, the wire has a thin flux coating around it that protects the weld puddle [7, 8]. 190 P a g e
Types of welding: Arc Welding Oxyfuel Welding Resistance Welding Solid state Welding 4.1.2.1 CO 2 Welding MIG welding was developed in the 1940. MIG welding uses an arc of electricity to create a short circuit between a continuously fed anode ( + the wire fed welding gun) and a cathode ( - the metal being welded). The heat produced by the short circuit, along with a non-reactive (hence inert) gas locally melts the metal and allows them to mix together. Once the heat is removed, the metal begins to cool and solidify, and forms a new piece of fused metal. MIG welding is useful because you can use it to weld many different types of metals: carbon steel, stainless steel, aluminum, magnesium, copper, nickel and etc. Advantages: The ability to join a wide range of metals and thicknesses All-position welding capability A good weld bead A minimum of weld splatter Easy to learn Disadvantages: MIG welding can only be used on thin to medium thick metals. The use of an inert gas makes this type of welding less portable than arc welding which requires no external source of shielding gas. Produces a somewhat sloppier and less controlled weld as compared to TIG (Tungsten Inert Gas Welding) 4.1.3Other process used Grinding Hammering V. CONCLUSION As the project was started with the primary aim of applying many of the engineering principles learnt so far into practice, we could achieve it. While doing so we frequently came across various problems but also could solve them. The project gave us the exposure to the practical world and also we learnt how theoretical principles can practically work. Also while doing entire project, we came across things, where theory and laws are obeyed, but there are some cases where many things violate theoretical principles and sometimes it is impossible to implement those principles and laws into practice. We believe that this is probably the first attempt to manufacture such a low cost conveyor as a project work. 191 P a g e
REFERENCES [1] Static analysis of a roller of gravity roller conveyor for structural strength & weight optimization 1S.S. Gaikwad, 2E.N. Aitavade,E-ISSN 0976-3945 [2] Design and Analysis of a Roller Conveyor System for Weight Optimization and Material Saving,Suhas M. Shinde* and R.B. Patil,,ISSN No. : 0975-8364 [3] Design and analysis of a roller conveyor for weight optimization & material saving,1yogesh Tanajirao Padwal, 2Mr. Satish M. Rajmane, 3Swapnil S. Kulkarni,E-ISSN2249 8974 [4] Conveyor systems. Retrieved 12 September 2011. [5] Conveyors. 005-07-16. Retrieved 2013-03-27. [6] Faculty of materials science and technology in trnava slovak university of technology in bratislava,eva kucharikova, jozef peterka,nov 2009 [7] "Welding Inspection Handbook", 3rd edition, American Welding Society, ISBN 0-87171-560-0, Miami, FL, pp. 10-11 (2000) [8] Design data book; PSG college of Technology Coimbatore, Chennai. 192 P a g e