DESIGN AND FABRICATION OF FLEXIBLE GRAVITY CONVEYOR Presented by C.SIVAKUMAR - ( ) K.SIVAPRAKASAM - ( ) G.UDESH KUMAR - ( ) Guided by Mrs.V.HARITHA. ME., AP/Mech

ABSTRACT :  The project aims to the transfer of packages by the difference between the datum lines through the conveyor on the action of gravity force with rollers for the movement of the packages.  The main theme of the project is flexibility, portability and ease of convenience. Since they are flexible, they can be set at angles and the product will convey following the pattern of the conveyor, which allows for moving product between lines or lanes to different truck docks, accumulation conveyor or other operations.

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:  Flexible Gravity Conveyors  Roller Conveyor System  Belt Conveyor System  Screw Conveyors  Trolley conveyor  Reciprocating vertical conveyor  Vertical lift conveyor  Pneumatic conveyor  Vibrating conveyor  Bucket conveyor

Flexible Gravity Conveyors  The flexible gravity conveyor is basically working on a gravity force.  It was flexible and useful for low weights packaged materials.  They can be installed any where, and much safer then forklift or machine to move materials..  The can be transport light weights packaged materials.

WORKING PRINCIPLE  It moves the materials usually on a flat surface along a series of rollers that are evenly spaced.  Gravity roller conveyors are either parallel to the ground or on incline, with the load starting at the upper end of the conveyor and ending at the lower end.  Materials are either moved by gravity along a decline or pushed by a person, who is assisting the rollers in moving the load from one point to another. It reduces man power and more external powers are not required.

PHOTOGRAPHY EXPANDED VIEW

CONTRACT VIEW

COMPONENTS DETAILS ROLLER  Roller is defined as a cylinder that rotates about a center axis. The roller which material is rolled for transport. It is revolving on a fixed axis and is used in various machines and devices to move, flatten spread and something.

WASHER  Washers are usually metal or plastic. High quality bolted joints require hardened steel washers to prevent the loss of pre-load due to Brinelling after the torque is applied.  Washers usually have an outer diameter (OD) about twice the width of their inner diameter (ID).

MILD STEEL  Mild steel also known as plain-carbon steel, is now the most common form of steel because its price is relatively low while it provides material properties that are acceptable for many applications.  Low-carbon steel contains approximately 0.05– 0.15% carbon making it malleable and ductile.  Mild steel has a relatively low tensile strength, but it is very cheap at cost.

BOLT AND NUT  Bolts are threaded lengths of steel rod with heads on one end. They are used with a nut at the other end and sometimes with a washer as well. Most of them have a hexagonal head (6-sided)  Carriage bolts are used to fasten Mild steel strip parts where a smooth finish is required.

DESIGN CALCULATION  Outer diameter d 1 =20 mm  Inner diameter d 2 =18 mm  Width w=370 mm  Mass density ρ=7850 Kg/m 3  young’s modulus E = 2.10×10 5 Mpa yield stress S yt =260 Mpa  W= 30/4= 7.5kg(Load act on 4 rollers at a time)  Distance from nutral axis y =0.02/2=0.01 m  Considering uniformly distributed load & FS = 1.5 Allowable Stress (σ all ) = S yt / Fs =260/1.5 = Mpa

 WEIGHT OF ROLLER: Weight of roller =π (d 1 ²–d 2 2 ) × w × ρ × No. of rollers =9.02 kg.  MAXIMUM MOMENT: Maximum moment (M max ) = (W×L) / 8 = (7.5×9.81×0.37) / 8 = 3.4 Nm.  MOMENT OFINERTIA: Moment of inertia I = π × (d d 2 4 ) / 64 = π × ( ) / 64 = 2.7×10 -9 m 4

 MAXIMUMBENDING STRESS: Maximum bending stress σ b = M max × y/ I =3.4 × 0.01 /2.7×10 -9 σ b = 12.6Mpa  MAXIMUM DEFLECTION: Maximum Deflection (y max ) = (5 × W × L 3 )/384EI = (5 × 7.5 × 9.81 × )/(384 × 2.10 × ×8.7179×10 -7 ) y max = 8.55×10 -5 mm As compared to length 370 mm deflection of 8.55×10 -5 mm is very negligible. Hence design is safe.

ADVANTAGES  Simple to install and maintain.  It is flexible and convenient.  No power consumption.  Reduced noise.  It moving easily anywhere.  We can move a block for our convenience.  Based on requirement compress and expand

COST ESTIMATION S. NO NAME OF THE COMPONENTSQUANTITYCOST 1ROLLERS STEEL BAR COLUMN BASE WHEEL NUT & BOLT 8(SETS)160 6 RIVITS (WELDING &DRILLING) _ 1400 TOTAL4960

LITERATURE REVIEW S.S.GAIKWAD: STRUCTURAL STRENGTH & WEIGHT OF GRAVITY ROLLER CONVEYOR  Using conveyor systems is a good way to reduce the risks of musculoskeletal injury in tasks or processes that involve manual handling, as they reduce the need for repetitive lifting and carrying.  They offer the opportunity to boost productivity, reduce product handling and damage, and minimize labour content in a manufacturing or distribution facility.

H. MASOOD, B. ABBAS, E. SHAYAN, A. KARA: DESIGN AND MANUFACTURING OF MECHANICAL CONVEYORS  This paper presents a application of principles of design for manufacturing and design for assembly, several critical conveyor parts were investigated for their functionality, material suitability, strength criterion, cost and ease of assembly in the overall conveyor system.  The improved design methods and the functionality of new conveyor parts were verified and tested.  Results obtained on a test conveyor system verify the benefits of using the improved techniques. The overall material cost was reduced by 19% and the overall assembly cost was reduced by 20% compared to conventional methods.

APPLICATIONS  It can be used in transportation of luggage from one floor to another on stairs in shopping malls..  It can be used for material handling.  Production, assembly, erection, packing and conditioning lines.  Work - station supply, transport, handling, distribution, storage.  Rail and air freight in-feed, automatic postal package sorting,  hospital logistics, transport and storage of documents and files,

CONCLUSION  Though this project had some limitations regarding the strength and built of the structure, it can be considered to be a small step forward, as far gravity conveyor are concerned.  During the test run of this project, it was realized that it would not be a bad idea to consider this design for carrying heavy loads up the flexible conveyor.  This product can be fully automated and produced at a lower cost the acceptance will be unimaginable. Presently, there are no competitors for such a kind of product in our market

REFERENCES  Suhas M. Shinde “Design and Analysis of a Roller Conveyor System for Weight Optimization and Material Saving” on 1995  Satish Vithoba Gaikwad “dynamic analysis & weight optimization of roller conveyor” on 2003  S.S. Gaikwad “ static analysis of a roller of gravity roller conveyor for structural strength & weight optimization’’ on 1999

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