This paper includes the design of belt conveyor system where the moving roller of the conveyor is powered by a pneumatic cylinder. Pneumatic cylinder will starts reciprocating and by using rack and pinion mechanism the reciprocating motion converts into the rotary motion. These rotary motions further transmit using freewheel-sprocket chain drive to the drive pulley of conveyor. Due to power given by cylinder piston, rack -pinion and freewheel-sprocket chain drives the shaft of pulley starts rotating unidirectional. Hence our belt conveyor is also starts rolling. Keywords: pneumatic Conveyor, Packing, Material Handling, Rack and Pinion

1. PROJECT STAGE-IІ PRESENTATION
ON
“DESIGN OF MATERIAL HANDLING SYSTEM FOR KIT
PACKING MACHINE ”
Presented By
Ganesh Yande EXAM NO.B120610937
Rahul Sanap EXAM NO.B120610896
Shubham Wadekar EXAM NO.B120610929
Mayur N.Nikam EXAM NO.B120610864
Guided By
Prof. P. S. Garudkar
DEPARTMENT OF MECHANICAL ENGINEERING
SANDIP FOUNDATION'S
SANDIP INSTITUTE OF TECHNOLOGY & RESEARCH CENTRE
TRAMBAK ROAD, MAHIRAVANI, NASHIK(MAHARASHTRA) INDIA-422213.
SAVITRIBAI PHULE PUNE UNIVERSITY, PUNE.
(2017-2018)

2. CONTENTS
● Introduction
● Problem Statement
● Objectives
● Expected Solutions/ Methodology
● Work done
● Project Completion action plan
● Conclusion
● References.

3. INTRODUCTION
• A Sharada motor currently packages a variety of bush and
washers into small plastic bag.
• Their means of operation is a group of three men who do the
job manually.
• The men stand around a table and take bush and washer from
hopper. They package an estimated 300 bags of washer and
bush in 8 hours. .

4. PROBLEM STATEMENT
• Time consuming process due to manual work.
• Less production rate.
• More labor work requires.
• The Company has a large demand of parts which the supplier
fails to meet.
• Overall affects the supplier as well as the receiver

5. OBJECTIVE
• To design a material handling system that will automate a
Sharda motors industries packaging process in order to
increase the efficiency of their operation.
• To reduced labor work.
• To increase production rate.
• There should be automation in packing process.
• To reduced overall effects on supplier as well as the
receiver.

6. METHODOLOGY
Controlling of Pneumatic Cylinder
Design of Shaft for Gear And Sprocket
Design of Chain and Sprocket Mechanism
Design of Rack And Pinion Mechanism
Design of Belt Conveyor System

7. Pneumatically operated Belt Conveyor
System
1. Belt conveyor assembly
2. Rack and pinion Mechanism
3. Sprocket chain mechanism
4. Pneumatic cylinder with solenoid valve
5. Control Unit
Components:
Bucket Bucket Bucket
3
1
2
4
3
Control
unit
Solenoid
Fig : Working diagram of pneumatic conveyor

8. Components used
1. Conveyor Belt :
• The conveyor belt is made up of rubber.
• Rubber conveyor belts are commonly used to convey items
with irregular bottom surfaces, and small items.
• Rubber belt conveyors are least expensive.
Figure : Rubber Conveyor Belt

9. 2. Slider and Rack-Pinion Assembly :
• It converts reciprocating motion into rotary motion.
• The rack is placed on the sider and is connected by bolts.
• Slider slide in socket of ball bearing slider.
Figure : Slider and Rack- Pinion
Components used

10. 3. Head and tail pulleys:
• The shaft of head pulley connected to the power drive.
• The tension of conveyor belt is adjusted by adjusting
distance between head and tail pulley.
Figure : Roller
Components used

11. 4. Compressor :
• It can convert the mechanical energy from motors and
engines into the potential energy in compressed air.
• Type – Rotary compressor
• Pressure – 4 bar
Symbol
Components used

12. 5. FRL Unit :
• Filter-Regulator-Lubricator
• Air leaving a compressor is hot, dirty, and wet which can
damage and shorten the life of downstream equipment, such
as valves and cylinders.
• Therefore air can be used it needs to be filtered, regulated
and lubricate.
Figure 3.6 FRL Unit
Symbol
Components used

13. 6. Actuator
• Double Acting Cylinder :
In a double acting cylinder, air pressure is applied alternately to the
relative surface of the piston, producing a propelling force and a
retracting force .
SymbolFigure : Pneumatic Cylinder
Components used

14. 7. Direction Control Valve:
• It is used to control the pneumatic cylinder.
• It is connected to double acting cylinder to control it.
Figure : Directional Control Valve
Components used

15. Design of Belt Conveyor
Data :
Material of washer = Soft Steel
Density = 7.9 × 103 𝑘𝑔/𝑚3
Capacity = Q = 1 kg/sec
Inclination = horizontal
Centre distance = L= 800 mm = 0.8 m
Required belt speed = v= 0.132 m/s
 Specification of material to be Conveyed:

16. Design of Belt Conveyor
CALCULATIONS RESULTS
Calculation of belt width
M= ƍ c [0.9B − 0.05]2 × v
Calculation minimum diameter of roller
Dmin
= k1
× k2
× zp
Calculation of length of belt (L)
L = 2c +
𝜋
2
(D + d) +
D−d 2
4c
Calculation for power required to drive conveyor belt,
Power = Ftight
− Fslack
×
V
1000
B =100mm
𝐃 𝐦𝐢𝐧
= 100mm
L=1914mm
P = 3.5W
 Calculations of Belt Conveyor:

17.  Calculations of No's Plies and Thickness of Belt
CALCULATIONS REF. RESULTS
Max tension in the belt in kgf
T1 = P
𝑒 𝜇𝛼
𝑒 𝜇𝛼−1
T2=T1 – p
Assume µ = 0.25, for steel and rubber
& α =angle of lap = 180o
No. of plies,
𝒁 𝒑 =
𝑇1
𝐵𝐹
Where, T1 = Max tension in the belt in kgf
B = belt width=100 mm
F = friction between idler and belt= 0.02, for
Standard conveyor
Belt thickness = thickness of ply (1.5 to 2.51) x 𝒁 𝒑+
some allowance ( assume 0.5)
PSG 9.18
PSG 9.18
PSG 9.18
T1 = 11.3461
kgf.
T2=0
𝑍 𝑝 = 2.83 ~ 3
Belt thickness
= 5 mm
Design of Belt Conveyor

18. Design of Belt Conveyor
Length of each bucket 70 mm
Width of each bucket 70 mm
Total No. of Buckets 10
packing time per pouch 14 sec
 Selection of size of bucket

19. Design of shaft for head pulley
CALCULATIONS RESULTS
Calculation of Design Of Shaft
1. 𝐹 𝑁 = 𝐹 𝑇 cosΦ
Where, FT =
P
V
2. weight of gear
Wg = 0.00118 × Zg × b × m2
3. Resultant load acting on gear
FR = FN
2
+ Wg
2
+ 2 × FN × Wg × cosΦ
1
2
= 1343.75 N
4.Diameter of shaft
Te =
π
16
× d3 × ζ
Where ζ = shear stress for material = 40 Mpa
FN=137.86 N
Wg=27.52 N
FR = 1343.75 N
d=20mm

20. Bearing selection for head pulley
CALCULATIONS REF. RESULTS
Fr =
T1+T2
2
Fr = 5.67 kgf
Vact =
πDN
60
for long life, Lh = 12000 hrs. [for conveyor Belt]
Lmr =
Lh X N X 60
106
For equivalent load (P),
X=radial factor=1,
Y= Thrust factor
S=service factor=1.2
Fa
= axial load = 0 kgf
Fr= radial load= 5 kgf
P = (X x Fr + Y x Fa
)x S
Dynamic capacity (C),
k=3 (for ball bearing )
C = (Lmr)1/k
P
PSG 4.5
PSG 4.2
PSG 4.12
Fr = 5.67 kgf
N =26.26 ~ 30
rpm
Lmr = 21.6
million
revolution
P = 6 kgf
C = 16.67 kgf
Hence, select
ball bearing
6001

21. Selection of Power drive for head
pulley
 Selection of pinion
Specifications Value
Material C45
Profile 20° Full Depth
Pitch Circle Diameter 108 mm
Number of teeth of pinion 18
Module 6 mm
Tooth Thickness 9.42 mm
Face Width 36 mm
Circular Pitch 17.45 mm

22.  Selection of Rack
Selection of Power drive for head
pulley
Specification Value
Material C35 MN75
Linear pitch 17.45 mm
Number of teeth 18
Length of rack 314 mm
Face width of rack 36 mm

23.  Selection of Chain Drive
Specification Notation Value
Chain number ISO/DIN 06B-1 R957
Pitch p 9.525 mm
Pin body diameter Dp 3.28 mm
Plate depth (max) G 8.15 mm
Overall joint (max) A1 16.40 mm
Diameter of larger sprocket D2 82 mm
Diameter of smaller sprocket D1 163 mm
Exact centre distance a 360 mm
Selection of Power drive for head
pulley

24.  Selection of Pneumatic cylinder
Selection of Power drive for head
pulley
Operating pressure (P) 4 bar
Stroke (S) 100 mm
Piston rod diameter (d) 20 mm
Bore diameter (D) 50 mm

25. Working model of Power drive for
head pulley
Pneumatic cylinder Rack Pinion
Freewheel
Fig. Working model of Power drive for head pulley

26. Front View Side View
2D Sketch of Pinion
Fig. 2D Sketch of Pinion

27. Side View
Top View
Front View
2D Sketch of Rack
Fig. 2D Sketch of Rack

28. Head (Drive) Pulley

29. Base of Belt Conveyor System

30. Material Density Yield Strength
(Material)
Yield Strength
(From Analysis)
FOS
Plane
Carbon
Steel
7800 (kg/m3
) 350 MPA 34.805 MPA 10
 Results
Static Analysis of Base

31. Fig:- Pneumatic Control of cylinder
 Circuit diagram
Controlling of Pneumatic Belt Conveyor
System

32. Fig:- Pneumatic Control of cylinder– Forward Stroke
 Circuit diagram – Forward Stroke
Controlling of Pneumatic Belt Conveyor
System

33. Fig:- Pneumatic Control of cylinder- Backward stroke
 Circuit diagram – Backward stroke
Controlling of Pneumatic Belt Conveyor
System

34. CAD Assembly of Belt Conveyor System
Fig. CAD Assembly of Belt Conveyor System

35. Working model of Belt Conveyor system
Pneumatic cylinder RackPinion Freewheel
Bearing Head PulleyConveyor beltBuckets
Tail Pulley
Fig. Working model of Belt Conveyor system
Chain drive

36. Bill of Material

37. Schedule For Project Work

38. Conclusion
 The design of conveyor belt system and the factors which are to be
considered are totally depending upon Capacity of material conveyed
and center distance between pulley.
 Using rack and pinion mechanism the positioning control of belt
conveyor is easily done by controlling pneumatic cylinder.
 For the belt conveyor which operated by the pneumatic cylinder is
simple mechanism and reduce the additional part required to control
the motion of conveyor belt drive.
 One direction motion of conveyor belt is easily achieved using
freewheel mechanism.

39.  The material carrying capacity is improved by using high strength belt
conveyor.
 Automation is done using PLC can help to increase accuracy.
 By using idlers it can be used to handle material for long distance
Future Scope

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Study of a Low Cost Pneumatic System Controlled By On/Off Solenoid Valves”, Volume 2014 p-
ISSN: 236-250.
[3] Aniket A Jagtap, Shubham D Vaidya, Akash R Samrutwar, Rahul G Kamadiand Nikhil V Bhende
“design of material handling equipment: Belt conveyor system for crushed Biomass wood using v
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[4] Konakalla Naga Sri Ananth, Vaitla Rakesh, “Design And Selecting the Proper Conveyor-Belt ”,
Pothamsetty Kasi Visweswarao International Journal of Advanced Engineering Technology, E-ISSN
0976-3945.
[5] Reference Book, “Design Data “, Compiled by PSG College of Technology, Coimbatore – 641 004
India, Published by Kalaikathir Achchagam.
References

41. Thank You