Professional Documents
Culture Documents
UNIT - I
Introduction, Definition of Material Handling, its relationship with Plant Layout. Type of
industries, related material handling Equipment. Design of Plant Layout, Site selection for Plant.
INTRODUCTION :-
Material Handling involves the movement of material, manually or mechanically in
batches or one item at a time within the Plant. The movement may be horizontal, vertical or
combination of horizontal or vertical.
Material Handling is concerned with motion, time, quantity and space. The
Material Handling Institute describes this as follows,
(1) First, Material Handling is MOTION. Parts, material and finished products
must be moved from store to location. Material Handling is concerned with moving them in the
most efficient manner.
(2) Second, Material Handling is TIME. Each step in any manufacturing process
requires that it supplies are on hand the moment it needs them. Material Handling must assure that
no production process or customer need will be hampered by moving material arranged of location
too late or too early.
(3) Third, Material Handling is QUANTITY. Rate of demand varies between
steps in the manufacturing process. Material Handling has the responsibility of being sure that
each location continually receive the correct quantity of parts.
(4) Fourth, Material Handling is SPACE. Storage space, both active and
dormant, is a major consideration in any building as space costs money. Space requirement are
greatly influenced by the Material Handling flow pattern.
Put these four elements together and you have the basics of Material Handling. It
should be noted that this element are not treated independently. They must be integrated and there
composite performance determines the quality of Material Handling systems.
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In the classic sense, Material Handling is the act of creating Time and Place utility,
as distinct from Manufacturing, which creates form utility. The proper application of Material
Handling knowledge will result in the smooth integration of all the process in an enterprise into
one efficient Production Machine.
2) BY J.R. BRIGHT:
Material Handling is a system designed in order to get the materials. At right place
b) at right time c) in right quantity d) in good condition e) at minimum cost.
3) BY HENRY FEYOL :
It is a system of auxiliary equipment that improves flow of material which intern
reduces stoppage in production machines and thus increases productivity of machine. These
equipment are designed in order to supplement the production machines.
4) BY JAMES APPLE :
It is that branch of Engineering concerned with development of special Machinery
for transporting goods through various manufacturing stages to finished product stage. It is
systematic physical movement of material.
5) BY NATIONAL PRODUCTIVITY COUNCIL :
It is a system which forms the single factors of movement, transfer, warehousing, in
process handling and shipping into one interdependent cycle considering the most economical
solution for the respective plant.
If we look at the cost for Material Handling formed to a cost circle there are the
following cost factors (fig 1) :
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The goal, therefore, is to get control over these costs to be able to reduce them with effective
Material Handling.
Briefly, Material Handling is the moving of materials from the raw stage through
Production to ultimate Customer with the least expenditure of time and effort so as to produce
maximum Productive Efficiency at the lowest Material Handling cost.
PLANT LAYOUT :
Plant Layout means the physical arrangement of the various Industrial facilities
(equipment, material, manpower, etc.) within the plant. This arrangement includes the spaces
needed for material movement, storage, indirect labourers and all other supporting activities or
services as well as operating equipment and Personnel.
Plant Layout is the basis of industrial activity since it determines the efficiency.
Generally what is being achieved is arrangement of work areas and equipment which is the most
economical and at the same time safe and satisfying employees.
Plant Layout is concerned with the analysis, planning, and design of the physical
facilities utilized in the production of goods and services. Material Handling deals with that phase
of the operations which involves the movements of the material used in carrying on the activities
of the enterprises. No two aspects of industrial activity are more closely related. Actually,
Material Handling is a Major part of nearly all Plant Layout work. This close relationship is
emphasized in the following definition of Plant Layout :
Plant Layout may be defined as planning and integrating the paths of the
component parts of a product to obtain the most effective and economical inter relationships
between men, equipment and the movement of material from receiving, through fabrication, to the
shipment of the finished product.
TYPES OF PLANT LAYOUT AND FUNCTION :-
1) PROCESS LAYOUT OR FUNCTIONAL LAYOUT :
It is characterized by keeping similar machine or similar operations at one location
(place). In other words, all lathes will be at one place, all milling machine at another and so on,
that is machine are to be arranged according to their function. This type of layout is generally
employed for industries engaged in job order production and non-repetitive kind of maintenance or
manufacturing activities.
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6) FLEXIBILITY:
In automotive and other industries where models of products change
after some time, it is better to permit all possible flexibility in the layout. The machinery is
arranged in such a way that the changes in the production processes can be achieved at the least
cost to disturbance.
PROCEDURE FOR DESIGN OF PLANT LAYOUT :
The ideal procedure for a plant layout, is to build the layout around the
productive process and then design the building around the layout.
This may not be possible always, because the plant building may already be
existing or the shape of plant site may not permit the construction of building to house the
productive process, etc.
Ultimately, one has to strike to balance between the two approaches. However
various procedural steps involved in plant layout have been listed below
a. Accumulate basic data,
b. Analyse and coordinate basic data,
c. Decide the Equipment and Machinery required.
d. Select the material handling system.
e. Sketch plan of plot for making factory building,
f. Determine a general flow pattern,
g. Design the individual work stations,
h. Assemble the individual layout into the total layout,
i. Calculate the storage space required.
j. Make flow diagram for workstations and allocate them to areas on plot plan,
k. Plan and locate service areas,
l. Make master layout,
m. Check final layout, and
n. Install the approved layout.
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less costly material handling equipment. It permits, material handling without any loss of time,
with minimum delays and least back tracking. The total number of movements and the distances
moved in one movements are also considerably reduced in a properly designed plant layout. In a
poorly planned layout, the aisle's s/sub aisle's widths or ceiling heights may not be sufficient to
accommodate efficient material handling equipment; even if used somehow or rather, the back
tracking or duplication of material movements may not permit the material handling system to be
economical.
On the other hand, an efficient material handling system helps building an effective
plant layout around itself. Various departments are located such that the material handling is
minimised. Space requirements are considerably reduced. Material movements are much faster and
more economical. Bottlenecks and points of congestion are removed. Machines and workers do
not remain idle due to lack of material. Production line flow becomes smooth.
The place of material handling in industry
It has been said that for manufacturing activity of any kind, whether it is a single
machine or a group of machine or an entire plant, it is possible to identify three basic function
which define the total activity. The functions are work performing, handling, and control. This
function is shown in figure 2.
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2) Storage:
It includes storage of material and tools and supplies between and around all of the
above location, including finishing good, warehousing, and the other storage related activities that
lie between the producer and consumer.
3) Selection
a. To choose production machinery and assist in plant layout so as to eliminate as far as possible
the need of material handling; and
b. To choose most appropriate material handling equipment which is safe and can fulfill material
handling requirement at the minimum possible overall cost.
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g. Reducing the amount of subsidiary materials such as packaging materials and other protective
devices such as trays, racks and special containers.
2) INCREASED CAPACITY
Material handling improvements can increase capacity in the following ways,
a) Better space utilization
Modern storage systems, make use of "AIR RIGHTS" by means of racks or
containers that stack upon each other when full and nest completely when empty, e.g.
Handling systems, particularly cranes and conveyor can operate in unused space above production
activities. They can be arranged to operate outside buildings in unnecessary stairways, through
underground passage-ways, or other unusable space. This can release prime space for production
and storage. The net result is a great increase in space utilization and handling efficiency.
b) Improving the layout to reduce travel or excessive waste of spaces
By analysing the flow of materials between operations, the volume involved in the
flow paths, and the timing of material movement, it is usually possible to reduce travel time and
space needs. Rearranging equipment and providing handling systems that reduces the distance
material must travel are usual practices.
c) Higher equipment utilization
Many pieces of expensive production equipment do not operate at their potential
capacity because are limited by the rate at which materials are supplied to, or removed from,
the equipment or the work area. A proper handling system, or efficient control of an existing
handling system can greatly increase production equipment utilization.
d) Faster loading and discharge of common carriers:
The adaptation of portable conveyor systems & cranes to the loading of motor
carriers greatly reduces loading time. Thus the transportation unit can spend more time moving
and less time sitting the loading dock. This not only lowers operating cost but reduces the number
of docks or terminal spaces required, with a corresponding reduction in loading crews (workers)
and of supervision.
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The reduction in packaging or packing materials and their cost is some times
obtained through unit load techniques. This may enable the vendor to cut his cost to the
customer. Also, the use of materials by the purchaser may be simplified by proper unit load design
thereby reducing the cost of unpacking and disposing of the packaging material. Unitizing by
the vendor may be done at the end of his assembly lines, or other final operations.
C) Sales value of an outstanding installation :
While it might be hard to prove that a handling system is justified in promotional
value alone, a tremendous amount of publicity can accrue to a truly outstanding system. Several
managers have been heard to argue vigorously that by taking prospective customers through their
new factories, the visitors have become so impressed that an order was obtained because of the
impression of efficiency, quality and service conveyed by the installation. An outstanding plant is
admired by employees as well as customers.
To say again in brief, the primary objectives are;
1. To save money
2. To save time
3. To save men
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time loss must be included in the evaluation, or it must be shown that the investment will be
satisfactorily recovered before the proposed handling system will require modification.
3) Vulnerability to downtime;
Since a handling system is a composite of mechanical and electrical machinery and
controls, it must be recognised that it may break down at any times. What happens than how long
will it take to get back to service and what will be done when repairs are being made. If this is
serious-, the handling system must be re-design to provide for better reliability, for alternate
handling techniques in event of breakdown or for in-process- storage that can feed subsequent
operations while be system is being repaired. All of these can result in additional costs that must
be charged against the handling system.
4) Maintenance
If it is planned to install additional handling mechanization, almost surely it will
be necessary to take on more maintenance. This may mean the addition of new maintenance
skills, or a provision for obtaining them when needed. It may be that extra pieces of handling
equipment should be provided for use during downtime or breakdowns. It may be necessary
to plan for periodic overhauls by skilled technicians. It may be necessary to carry a large supply
of repairs parts, or a new or enlarged maintenance facility and staff may be required.
5) Auxiliary equipment costs
Frequently a new handling system carries with it requirements that involve hidden
or unrecognized costs for auxiliary equipment or service, e.g. adopting a fork lift truck means more
than taking on the mobile equipment, its power supply, and its maintenance.
The point of identifying this drawbacks is neither to discourage nor disparage the
adaptation of modern handling methods, but to emphasize that a careful balance of the total
benefits and limitations is required before wise decisions can be reached.
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engine assembly, engine block, gearbox, etc. Motor trucks are employed for inter department
transporting of heavy components. Overhead cranes are used in machine shop, engine shop,
assembly shop & degreasing plant etc. Recovery van may be used for moving breakdown vehicles.
(D) Big steel plant
In a big steel plant almost all types of handling devices are employed.
Locomotive is used to carry laddles of molten pig from blast Furnaces to steel shop or to open
hearth furnaces. They are used to Pull the hot ingots of steel shop or to open hearth furnaces.
They are used to pull the hot ingots of steel of steel shop or to open furnaces,. They are used
to pull the hot ingots of steel to rolling mills for Production of various steel sections. They are
employed for bringing in Iron ore and other huge materials. Belt Conveyor is employed to
transport coke oven to blast oven to blast Furnace. Belt conveyor is employed to transport coke
from coke oven to Blast oven to blast furnace. Belt conveyor is also used for- Transporting sand
in huge casting foundry shop.
Roller conveyor is used in rolling; mills- to move the hot Billets of iron along the
bed to various processes.
Huge cranes are employed to transport machinery and iron ore for storing and processing.
Overhead cranes are installed almost in every shop.
(e) Cement factory :
In dry process of cement manufacture, the various stepwise Processes are
(1 ) crushing of raw materials, (2)drying, (5)grinding, (4) Proportinating, (5)pulverizing of raw
material, (6) Burning, (7) Cooling and storing the Clinker, (8) Adulteration of related set,
(9)reduction of clinker to an impalpable powder, (10)seasoning of cement, (11) bagging.
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highway trailers and unit load containers, pallets and skids to eliminate the necessity for hauling
excess weight.
11. " The most economical motive force is gravity"
One of industry's highest priced items is the cost of power to run its processes.
Therefore, when nature's free, bountiful supply of gravitational pull can be put to use the very
essence of economy is Practiced.
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(1) SPACE
(2) TIME
(3) QUANTITY
(b) Suggest suitable layout for the following industries & justify your answer.
(i) Ship building industry.
(ii) Pharmacutical industry.
(iii) Bottling plant for cold drink.
Q.No.26. (a) Write the advantages and disadvantages of rural site ?
(b) Explain line layout with its advantages & disadvantages.
(c) Explain the principle of cubic space utilization with suitable example ?
60724- 453117
VISIT DEPARTMENT OF PRODUCTION ENGINEERING ON WEB AT
http://coeta-production.tripod.com
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UNIT II
Principles of Mechanical Handling, Types of Material Handling Equipment and
their field of applications. Selection and Specification of Equipment's.
SCREW CONVEYOR :- Introduction , Calculation of H.P. of Motor used , Characteristics
and field of Application of Screw Conveyor , Determination of Application of Screw
conveyor, Salient Dimensions and Power Requirement.
PRINCIPLES OF MATERIAL HANDLING :-
The principle presented here represent an accumulation of experience
equivalent to untold years of practice. They are adapted from those stated in the literature, with
certain changes made for clarification and with several new one added to round out the coverage
of the field. In reviewing the principles it will be found that nearly every one applies to several
aspects of Material Handling and aids in accomplishing one or more objectives.
In presenting the principle's, each is stated and briefly described. Next,
suggestions for putting the principle into used are spelled out- often in explicit details - to facilitate
their prompt convenient application. Then , at the end of the presentation of the principles, some
general suggestion are given on their use in analyzing and solving Material Handling problems.
1. PLANNING PRINCIPLE :-
STATEMENT:
All Handling activities should be planned.
DESCRIPTION:
If there is one principle on which all should agree, it is that Handling activities
should be planned, and not left to chance. Remember , Handling may account for 25 to 80
percent of all the productive activity. Management most certainly deserves to have this sizable
portion of total activity planned - not left to chance.
SUGGESTIONS FOR CARRYING OUT THE PLANNING PRINCIPLE :
a) Avoid placing material directly on the floor, without a pallet or other support underneath.
b) Assure adequate storage space at the workplace for the proper amount of material , both ahead
of and following the operation being planned.
c) Plan to use the same container throughout the system ; avoid frequent changes of containers.
d) Consider floor Load capacities , ceiling heights, truss capacities , column spacing , etc.
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2 .SYSTEMS PRINCIPLE :-
STATEMENT:
Plan a system integrating as many Handling activities as is possible and
coordinating the full scope of operations (receiving , storage , production, inspection
packaging, warehousing, shipping, and transportation.)
DESCRIPTIONS
Each Handling activity should be considered a portion of the whole Handling system, and planned
as an integral part of the system.
SUGGESTION FOR CARRYING OUT THE SYSTEMS PRINCIPLE :
a) Consider the entire scope of the handling activity, i.e., beyond the area under immediate
consideration.
b ) Plan flow between work areas.
c) Integrate operations into the handling system, such as : processing , inspect ion , packaging , etc
d) Arrange for alternative Handling Methods - in case of emergency.
e) Move material directly to production whenever practical, rather then an intermediate storage
area- to avoid re-handling.
f) Work closely with suppliers, customers and carriers.
g) Be aware of future requirement changes in product, process, volume, etc. - and allow for
necessary flexibility.
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3. MATERIAL-FLOW PRINCIPLE :-
STATEMENT:
Plan an operation sequence and equipment arrangement to optimize material flow.
DESCRIPTION :
As has been previously suggested. Material Handling and Plant Layout are
intimately interrelated. The Material-flow pattern is actually the backbone of most production
facilities, and one of the first steps in Planning a Material Handling systems is the design of the
Material— flow pattern. This may be largely determined by operation sequence , which in turn
will determine the pattern of equipment arrangement.
SUGGESTION FOR CARRYING OUT THE MATERIAL PLOW PRINCIPLE :
a ) Avoid crowded conditions.
b ) Eliminate obstacles from Material flow.
c) Carefully observe building and carrier restrictions.
d) Plan movement in direct path.(Avoid backtracking, zig-zag flow, crooked paths .
e) Arrange for alternate path, in case of difficulty.
i) Be aware of cross traffic and take necessary precautions. Avoid traffic Jams.
g) Keep related work areas close together.
h) Use Product-type layout when possible
i) Plan proper location of subassembly and feeder lines.
j) Comb inc operations to eliminate handling between times.
k)Plan for definite pick up and delivery locations.
l)Minimize moves between Floors, Buildings.
m)Process Heavy, bulky materials close to receiving
n) Move the greatest bulk and/or weight the least distance.
4.SIMPLIFICATION PRINCIPLE :-
STATEMENT:
Reduce, combine, or eliminate unnecessary movements and /or equipment .
DESCRIPTIONS :
Simplification is one of the by-words of efficiency, motion economy, and
many other aspects of industrial operation. .It should likewise be a goal in Material
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DESCRIPTION :
Wherever practical, individual items should gathered and made up into loads.
SUGGESTIONS FOR CARRYING OUT THE UNIT SIZE PRINCIPLE :
a) Examine every move of one item for possibility of making up unit loads.
b) Purchase materials in unit loads.
c) Work with vendors towards design of larger unit loads.
d) Use containers to consolidate items.
e) Use uniform, standardized containers.
f) Design pallet pattern to efficiently utilize pallets and storage space.
g) Design load size to make optimum use of handling equipment.
8. SEFELY PRINCIPLE :-
STATEMENT :
Provide for safe handling methods and equipment.
DESCRIPTION :
It should be obvious that all handling activities in operations or being planned -
should be safe, since an objective of material handling is to improve working conditions by
providing safer work situations. A high proportion of all industrial accidents is in the material
handling aspects of the production activity.
GENERAL CAUSES OF INDUSTRIAL ACCIDENTS :
I) Unsafe Conditions, Environmental Causes.
a) Inadequate guarding ( of Conveyors, Trucks, etc )
b) Unguarded (equipment.)
c) Defective condition (of equipment ).
d) Hazardous arrangement (stacks of material, pallet loads, arrangement of trucks,
etc._
II) Unsafe Acts of Persons.
a) Operating without authority ( trucks, etc.)
b) Operating at unsafe speed.
c) Making safety devices inoperative (governors, etc.)
d) Using unsafe equipment (needing repairs)
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9 .MECHANISATION/AUTOMATION PRINCIPLE :-
STATEMENT:
Use mechanized or handling equipment when practicab1e .
DESCRIPTION:
Used judiciously, mechanized or automated handling devices and equipment can
be of extreme value in increasing material handling efficiency. However, handling operations
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should not be mechanized for the sake of ,mechanization alone, nor should they be over -
mechanized in terms of the function to be performed.
SUGGESTION FOR CARRYING OUT THE MECHANIZATION/AUTOMATION PRINCIPLE :
a) Consider use of mechanization for :
i) Large quantities or volume of materials
ii ) Frequent , repetitive moves, even though short
iii ) Long moves
iv) High - effort , hazardous, difficult moves.
v ) Two - man lifting/moving tasks.
vi) Replacing excess manual handling
vii) Feeding and removing materials from machine
viii) Moving heavy containers.
ix ) Handling and done by direct labour .
x ) Scrap removal .
xi) Reducing Handling time.
b) Do not over mechanize.
c) Design or select containers suitable for Mechanical Handling.
d) Use equipment that is self controlled and self programmed when practicable .
e) Consider mechanization of people flow and equipment movement as well as material
movement.
f) Mechanize communication to facilitate material movement.
g) Utilize automatic couplings, switches transfer, etc.
h) Move heavy Jigs, Fixtures, Tools, etc by mechanical means.
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12.FLEXIBILITY PRINCIPLE :-
STATEMENT:
Use methods and equipment that can perform a variety of tasks and application.
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DESCRIPTION :
Equipment that can perform a wide range of handling tasks and which has a
variety of uses and application can often be more fully utilized than single purpose, specialized
units. Since industry requirements are subject to frequent change, flexibility should be
carefully considered as an important characteristics of any Handling Equipments.
SUGGESTION FOR CARRYING OUT THE FLEXIBILITY PRINCIPLE :
a) Buy flexible equipment -lift trucks, roller and wheel conveyor etc:,
b ) Specify adjustable speed drives.
c) Make use of attachment and accessories (for lift Trucks, etc.)
d) Use gasoline-powered equipment.
e) Use four way pallets, skids, containers
f) Utilize trucks, etc. (mobile) in favour of conveyors (which may be fixed).
g) Carefully weigh use of special purpose equipment.
h) Consider adjustable racks.
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14.MOTION PRINCIPLE :-
STATEMENT:
Equipment designed to transport materials should be kept in motion.
DESCRIPTION:
This Principle implies; that mobile equipment should be keep moving i.e.,
performing the function for which it was designed. It should not be tied up for unduly long
periods of time for loading an unloading.
SUBGESTIONS FOR CARRYINB OUT THE MOTION PRINCIPLE :-
a) Plan to reduce load/unload time to decrease turn-around time.
b) Use mechanized loading and unloading equipment.
c) Maintain equipment properly to minimize down time.
d) Use self-loading equipment- lift trucks, straddle carriers, etc.
e) Consider 2-way radio on vehicles to permit quicker stacking.
f) Plan return loads for equipment.
g) Return mobile equipment promptly for re-use.
h) Study carefully use of load-carrier and platform-type trucks where carrying devices are attached
to motive unit.
i) Plan to haul loads, rather than carry them.
j) Utilize pallets, skids, etc to hasten loading of trailers.
k) Use pallets or skids in place of "stationary", four-wheel hand
trucks-which should be kept moving.
15 .IDLE-TIME PRINCIPLE :-
STATEMENTS :
Reduce idle or unproductive time both handling equipment and manpower.
DESCRIPTION:
Idle time is undesirable in nearly any industrial or commercial activities and
especially so in the use of Material Handling equipment or manpower. Equipment- and manpower
are "Making Money" when fully utilized. Therefore, every effort should be made to plan methods
and scheduled equipment to permit full use of both resources.
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This Principle is very closely re1afed to the Motion Principle and many suggestions
made there are equally applicable here.
SUBOESTION FOR CARRYING OUT THE IDLE-TIME PRINCIPLE:
A. Manpower
a) Deliver materials at the proper rate.
b) Use indirect labour for material handling.
c) Install handling equipment to permit direct labour operators to spend full time on production.
d) Combine jobs i.e. one man, 2 machine or jobs--load one while other is eye cycling.
e) Be sure that operator is supplied with material-not waiting.
B. Equipment
a) Scheduled use of Handling Equipment.
b) Use radio for dispatching .
c) Transfer Equipment to other areas where it can be utilised more fully .
16.MAINTAINCE PRINCIPLE :-
STATEMENT :
Plan for preventive maintenance and scheduled repair of all handling equipment.
DESCRIPTION:
The suggestion for application of several of the previous principles have
implied the importance of preventive maintain and scheduled repairs to the effectiveness of
Material Handling activities. Probably very few phases of the Material Handling program can
contribute more to overall plant efficiency then well-organized maintenance and repair
function.
SUGGESTION FOR CARRYJNB OUT THE MAINTENANCE PRINCIPLE:
a) Anticipate repairs in order to avoid breakdowns that will take equipment out of service
unexpectedly.
b) Require operators to make daily inspections of equipment and report findings.
c) Plan for detailed, major inspection and reporting on equipment condition at regular intervals.
d) Set up a regular lubrication schedule covering all Handling Equipment, using chart to assure
adequate lubrication.
e) Establish a preventive maintenance program.
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f) Provide adequate maintenance and repair facilities and personnel to handle normal requirement.
g) Work out a schedule and work load for repair work to its being done when equipment can
be spared and at convenient times.
h) Maintain an adequate supply of repair parts and maintenance supplies .
i) Keep number of makes and models to minimum to reduce inventory of parts & simply
maintenance.
j) Paint all equipment on a scheduled basis to keep up appearance and promote care of equipment.
k) Require Driver training for all mobile equipment operators.
l) Provide adequate instruction in proper operation of all non- mobile equipment .
m) Fix responsibility and delegate authority for the maintenance and repair function .
n) Send maintenance mechanics' to factory training programs.
o) Check with manufacturers on required periodic maintenance, instructions etc.
p) Alter maintenance schedules when production schedules change.
q) Avoid "over - maintenance".
r) Keep floor clear.
17.OBSOLESCENCE PRINCIPLE :-
STATEMENT:
Replace obsolete handling methods and equipment when more efficient
methods or equipment will improve operations.
DESCRIPTION:
As with any other type of physical equipment, Material Handling devices are
subject to obsolescence, as well as depreciation. And, in a similar sense, so are handling methods.
New ideas, techniques, methods and equipment are reported every day, and the Material.
Handling engineer must be continuously alert to be sure he is aware of the latest developments.
SUGGESTIONS FOR CARRYING OUT THE OBSOLESCENCE PRINCIPLE:
a ) Establish a definate replacement policy.
b) Set a replacement program and budget.
c) Be aware of old equipment that still works.
d) Carefully study all alternatives.
e) Rent or lease new equipment for a try out period.
f) Established a planned, periodic equipment evaluation program.
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18 .CONTROL PRINCIPLE :-
STATEMENT :
Use material handling equipment to improve production control, inventory control and order handling.
DESCRIPTION:
Since Material Handling equipment is used to move materials through the plant and
the production process, its use can have a great effect on the control of the items being moved. In
many cases, Handling Equipment provides a direct Mechanical path for the movement, and
thereby facilitates the control of the material.
SUGGESTIONS FOR CARRYING OUT THE CONTROL PRINCIPLE :
a. Provide Mechanical Path for materials movement.
b) Move materials in lots, batches, containers of a predetermined quantity and size.
c) Store, or pack, materials in containers holding a specific number of pieces.
d) Use containers (wire mesh) through which contents can be identified and /or counted.
e) Utilize 2-way radio or TV to expedite movement and control of materials .
f) Make optimum use of Mechanical Handling in order picking, automation, loading.
g) Pace production with Mechanical Handling Equipment.
h) Build production, inventory, and accounting control features in to the Material Handling
Systems.
i) Move material on a schedule and in lots to match production, to avoid rush delivery, partial
loads, duplicate moves.
j) Coordinate handling program (schedule) with purchasing, Manufacturing
19. CAPACITY PRINCIPLE :-
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STATEMENT:
Use Handling Equipment to help achieve full production capacity.
DESCRIPTION:
In many ways, this principle is a summation of all the preceding ones, in
that major objective of material handling is to increase production capacity. Nearly every one
of the foregoing principle will contribute in some way to higher production levels. However,
the emphasis here is on those facets, of operation and the other principles that are directed
specially towards increasing or- making full use of production capacity.
SUGGESTIONS FOR CARRYING OUT THE CAPACITY PRINCIPLE:
a) Use Mechanical Handling Equipment to assure a uniform, paced rate of flow.
b) Operate Equipment at optimum rate.
c) Plan to utilize return runs of Handling Equipment.
d) Fully Load or use container, vehicle, conveyors.
e) Make full use of Building cube and floor load capacity to obtain additional square foot.
f) Reduce time between operations and departments with Mechanical equipment.
g) Efficiently utilise carrier capacity by judicious combination of load, weight, and volume.
h) Change size, shape of unit loads to utilise space, equipment capacity, manpower .
i) Use area over Aisles (balconies) for additional storage space make use of rented storage
facilities during peak season to free own space for production.
k) Use outdoor storage space for materials not requiring protection from weather- or easily
protected.
l) Pool Handling Equipment for better utilization.
m) Establish one- way aisle to easy traffic congestion.
n) Widen aisles to speed Materials Movement.
o) Utilize automatic door openers, dock levelers, couplings, etc.
p) Eliminate storage areas by using overhead space, moving storage processing during movement etc.
q) Use additional safety devices -bo permit, greater speed of movement.
20 . PERFORMANCE PRINCIPLE :-
STATEMENT:
Determine efficiency of handling performance in terms of expense per unit
handled.
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DESCRIPTION:
As pointed out above, there are many objectives of Material Handling. However ,
an effective Handling Method may achieve one or several of these objective. The primary
criterion for measuring the efficiency of a handling technique is Dollars. Although efficiency can
be measured in terms of total cost or equipment performance, the most effective means of
measuring efficiency is in terms of dollars per unit handled .
It should be pointed out that there are cases where maximum economy is not the
overall goal. Some Material Handling devices may be installed to provide higher production rats,
safer working conditions, or reduced physical effort. Time or effort saved may be the primary
criteria and the cost of handling may be of little or no interest.
SUGGESTIONS FOR CARRYING OUT THE PERFORMANCE PRINCIPLE:
a) Carefully study all characteristics of the material to identify all possible units which could be
used as a basis for comparison.
b) Select a common, convenient, standard unit,
c) Use the same unit for as many control purposes as possible,
d) Avoid changing the unit from department to department, time to time, etc.
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released will retained its initial arrangement for subsequent movement. It is implied that single
initial arrangement for subsequent movement. It is implied that single objects too large for manual
handling are also regarded as Unit Loads
In summarizing the Unit Load concept, Johnson has stated that it should:
1. Perform a minimum number of handlings and eliminate Manual handling.
2. Assemble materials into a Unit Load for economy of Handling and storage.
3. Assemble materials into Unit Load as soon as possible and keep n that form as soon as possible.
4. When necessary, redesign packages and cartoons for better assembly into unit loads and retain
the unit load form to use all possible cube and prevent product damage.
5.Make the Unit Load as large as possible considering the imitations of building, Handling
Equipment, Production areas, volume of material required, and common carrier dimensions and
capacities .
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18) Production Operators need not waste valuable time in helping to move materials.
17) Items themselves need not be uniform as unitizing medium provides uniformity.
18) Irregular items can become stable load.
19) Provide basis for overall handling system within physical distribution cycle .
20) Provide basis for handling systems within plant.
21) Unitized load stabilize stacks of materials.
22) Unitizing Medium can provide uniform temperature and moisture control of goods.
23) Unitizing Medium can protect loads from foreign elements.
24) Maximum accessibility of stored goods
25) Reduces Handling of individual items.
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Equipment. Therefore, one of the major task of Material Handling Engineer is to become
acquainted with the large and overgrowing field of handling equipment, although it would
be next to impossible for an individual to become intimately acquainted with all the types.
THE PLACE OF EQUIPMENT IN THE HANDLING SYSTEM :-
As implied several times previously, equipment is not always required in order to
solve a Handling problem. Usually the simplest and most economical method should be
utilized, which may not require any equipment In fact, the work simplification approach
suggests the following general procedure :
1. Eliminate the move .
2 . Combine the move with some other function processing , inspection, storage, etc.
3. Change the sequence of activities to shorten, eliminate, and after the move requirement.
4.Simplify the move to reduce the scope, extent, distance, method, equipment, etc.
Then-after having accomplished the above -the equipment would selected if necessary.
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b . Multi-plane.
c. Level to level.
d . Variable profile.
e. Complex path.
f. Working height.
g . Complicated move .
6 . Move Characteristics
a. Short distances
b. Infrequent
c. Low rate
d .Non-uniform rate
e . Variable speed
f. Irregular
g. Intermittent
h . Variable
i. Low percentage of Handling
j .Variable sequence.
7. Move Type
a. Maneuvering
b. Positioning
8. Handling Unit-same as items 1 & 2
9. Equipment
a. Probab1y none
b. Operator controlled
10. Manpower
a. Relatively small amount of operator time required
b. Low hourly rate.
11. Physical Restrictions
(As implicit by other characteristics of the problem,
above : otherwise , not applicable.)
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It should be pointed out that all the above characteristics do not imply only
manual methods. Some of them, usually in combination with other characteristics or because of
the nature of the nature of the material, will require Mechanical devices. Only after it has been
proved that Manual Handling is more costly, too dangerous., too slow, etc .should the analyst
turn his attention to Mechanical Equipment.
NON-POWERED EQUIPMENT: -
Included with the several hundred types of Material Handling Equipment are
a number of non powered or manually operated or controlled, i.e., not "mechanized".
The following list indicates the situations in which non-powered or manual equipment may
fit into handling system.
1 .Where handling volume is limited, or handling activity can be extended over a long
period of time.
2. Where building limitations preclude use of heavier or bigger devices.
3. Where service conditions, such as confined areas, explosive atmosphere, or quiet
surroundings necessitate the advantage of non- powered equipment.
4. Where equipment is used not only for handling but for storage or display .
5. When investment capital is limited.
6. When the required Flexibility, utility, mobility, arid portability can only be obtained in a
non-powered floor device .
7. Where the maintenance facility are minimal or non-existence
8. Where the mobile equipment must be tailored to the production need.
9. Where the operating efficiency of non-powered equipment higher than that of other type.
10.When loads are relatively light and equipment .is to be manually moved.
11. For stand-by use.
12. For durable, low cost operation.
The above possibility should be checked before Mechanized or Powered Equipment
is seriously considered.
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specific requirement or the condition an industry. Naturally, the best equipment will be
the one which permits smooth and continuous production flow, involves less accidents, reduces
production cycle time, promotes better working condition, incurs less fatigue to the operators and
brings down the Material Handling Costs .
The following factors may be considered while selecting a Material Handling
Equipment ;
MATERIAL TO BE HANDLED:
The size of the material, it's shape, weight, delicacy, nature (solid, liquid, gases,)
and its chances of getting damaged during handling, etc, should be considered.
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9) Amount of care and maintenance required for the Material Handing equipment.
10 ) Safety of equipment.
11 ) Equipment Reliability.
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Classification:
A. Belt Conveyor
a. Flat
b. Trough
c. Portable
B. Bucket
a. Gravity Discharge
b. Pivoted Bucket (Bucket Elevator)
C. Chain or Cable
a. Apron
b. Arm
c. Car Type
d. Drag
e. Flat-top
f. Flight
i. Power and Free
j. Slat
k. Tow
i) Overhead
ii) Flush
iii) Under-floor
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l. Trolley
D. Chute
E - Pneumatic conveyor
a. Pipeline
b. Air activated gravity
c. Tube
F. Roller Conveyor
a. Gravity
b. Line
c. Portable
d. Rack
G. Screw Conveyor
a. Screw attachment
i) Ribbon Conveyor
ii) Paddle Conveyor
b. Movement of Material
i) Horizontal Screw Conveyor
ii) Vertical Screw Conveyor
H. Vibrating
I. Wheel
Uses:
Conveyors are generally useful when:
a. Loads are Uniform
b. Material moves continuously
c. Route does not vary
d. Load is constant
e. Movement rate is relatively fixed
f. Conveyors can By-pass Cross traffic
g. Path to be followed is fixed
h. Movement is from one point to another
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screw feeder or a Horizontal Screw Conveyor which serve to create thrust at the foot of the lifting
screw as shown in figure 4,
In general there are three types,
1. HELICOID SPIRALS : Use for Dry Materials ranging in size from powder to medium lumps.
2. RIBBON SPIRALS : Adopted to handle coarsely-broken and sticky loads.
3. PADDLE SPIRAL AND CUT FLIGHTS : Utilize to convey flow-resistant solids tending to
cake. This type is also employed in installations combining transportation with processing
(mixing, crushing, wetting, etc.).
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LIMITATIONS :
1. Screw Conveyors invite difficulties when the load is abrasive, coarsely broken, or sticky.
2. Commonly made in 10-12 feet section.
3. Certain amount of degradation of material.
4. Length limited by torque capacity of shaft and drive.
5. Operate at 10-120 feet per minute.
6. Handle upto 10,000 cu. ft per hour.
7. Not recommended for handling materials which are degraded due to breakage.
APPLICATION :
1. Oil Refineries. 2. Chemical Industries.
3. Sugar Mills. 4. Soap Industries etc.
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In designing short screw conveyors which have no inner bearings, the above values
can be increased by factor of 1.5 to 2. On the other hand, they must be reduced by 10 to 15
percent when the Conveyor is intended to handle free-flowing materials.
The hourly capacity of a Helicoid Spiral Conveyor by tonnage can be estimated by
the formula.
Q = 3600 S v γk
where k is a factor introduced in designing inclined conveyors, for their capacity is always less
than that of horizontal ones. Approximate values on the angle of rise are given below :
β, deg . . . 0 5 10 15 20
k.......1 0.9 0.8 0.7 0.65
= 4 > ϕ γ t n D2 k
In capacity calculation, the speed is adopted from practical experience at
n = 60 / √ D , for light non-abrasive loads
n = 45 / √ D , for heavy non abrasive materials
n = 30 / √ D , for heavy abrasive stock
where D is the screw diameter in m.
The Power requirement in kw referred to the drive shaft can be determined for
Horizontal Conveyors from
Q L
Nh = Co
367
and for sloping installation from,
QH QL
Ns = + Co
367 367
In the above formulas, the friction factor, Co, is adopted from the following
tabulation based on experimental data :
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= 0.006892
We know ,
Q = 3600 Sv ϒk
Since β = 0 deg therefore k = 1
Q = 3600 x 0.006892 x 0.1506 x 1.46
= 5.45 tons/hr
Q L
Nn = Co
367
5.45 × 6
= 2.55
367
= 0.2272 kw
NOTE : If the Power required is in H.P., than the conversion factor is 1 H.P. = 0.736 kw
REVIEW QUESTIONS :-
Q.No.1 : What are the different principles of material handling ? Explain Gravity Principles with
application ?
Q.No.2 : List various material handling equipment and give their field of application ? Explain the
selection criteria for the material handling equipment.
Q.No.3 : Explain the principles the unit load ?
Q.No.4 : What handling situation and problem characteristics suggest (a) No material handling
equipment (b) Manual equipment (c) Mechanized equipment (d) Automated equipment ?
Q.No.5 : Classify and explain the various type of material handling equipment ?
Q.No.6 : Explain different type of conveyors ? You relative merits & demerits ?
Q.No.7 : Explain working principle of screw conveyor ? Give characteristics and field of
application screw conveyor ?
Q.No.8 : What are the different type of screws used in screw conveyor ? Explain with application
? When will you select ribbon type of screw ?
Q.No.9 : Give the complete design procedure for a screw conveyor ?
Q.No.10 : Calculate the amount of dry powder conveyed in one hour by the screw conveyor,
which is used for conveying the material through a distance of 8 metre. Diameter of screw is 15
cm. Specific weight of the powder material is 1.46 ton/m3 , Specific friction factors 2.55,
Capacity factor 0.39. Also find the power required to drive the conveyor.
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Q.No.11 : A screw conveyor is to be used in chemical plant for conveying some powder through a
horizontal distance of 12 meter. The diameter of screw is 30 c.m. and reduction ratio is 1:20.
Calculate the quantity of powder handled per hour and power required for paint.
Pitch of the screw t = 0.78 D, Specific weight r = 1.2 ton/m3 , Specific friction factor Co=2,
Capacity factor ϕ = 0.32 ?
Q. No.1 : (a) Explain following principles of material handling
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Q.No.7 : (a) What are the various types of screws used in screw conveyor ? When will you select
ribbon type screw ?
(b) A screw conveyor is to be used in chemical plant for conveying some powder through a
horizontal distance of 12 meters. The diameter of screw is 30 cm and reduction ratio1:20.
Calculate the quantity of powder handled per hour and power required for plant
pitch of screw , t = 0.78 D, specific weight , r = 1.2 ton/m3 , specific function factor Co = 2,
capacity factor φ = 0.32
Q.No.8 : (a) Give complete design procedure for screw conveyor ?
(b) Calculate the amount of dry powder conveyed in the hour by screw conveyor which is
used for conveying the material through a distance of 8 meter. Diameter of screw is 15 cm sp
weight of powder material is 1.46 t/m3 , specific friction factor 2.55, capacity factor 0.39. Also
find out the powder required to drive the conveyor.
Q.No.9 : (a) Explain different types of conveyor. Give their merit and demerit ?
(b) Explain selection criteria for material handling equipment ?
Q.No.10 : (a) Give different principles of material handling. Explain ‘Gravity principles’ and its
application.
(b) What do you understand by equipment specification ? Describe the specification of
screw conveyor ?
Q.No.11: (a) What handling situation and problem characteristic suggest.
(b) no material handling equipment.
(c) Manual equipment.
(d) Mechanized equipment.
(e) Automated equipment.
Q.No.12 : (a) Design the screw conveyor to find out
(i) conveying capacity.
(ii) Power required for horizontal and inclind screw conveyor.
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60724- 453117
VISIT DEPARTMENT OF PRODUCTION ENGINEERING ON WEB AT
http://coeta-production.tripod.com
notice- if you find any error or printing mistake please bring to our notice. Any suggestion to
improve these notes will be most welcome.
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UNIT - III
BELT CONVEYOR :- Introduction Types of Drives used for Belt Conveyor. Methods of
maintaining belt Tension Optimization of Cross Sectional Area of Belt Conveyor supported on (a)
Two Roller System (b) Three Roller System, Determination of Salvant Dimensions and Power
Requirement.
BELT CONVEYOR :-
In Belt Conveyor, the belt made up of plain fabric, rubber, plastic, leather, metal,
etc., operating over suitable drive, is used as the conveying medium. Belt Conveyors can be
operated over a long distances, being easily adapted the natural counter of the ground.
The belt Conveyor consist of a driving traction element 2 in the form of an endless
belt also giving support to the load, a drive linked up with a drive pulley 1, a take-up with a pulley
6 and a counterweight 7 arranged at the foot end, belt-carrying idler rollers 4, return-run idlers 8, a
load in device 6, an unloading arrangement 3, a snub pulley 10, and a belt pleaner it. On some
installations, a slider trough in metal or timber is used as the roadbed over which the belt travels
instead of idlers. All conveyor components are supported by a metal frame 9. (Figure 6)
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ADVANTAGES :
1. High handling capacities.
2. Simple construction.
3. Light weight.
4. Operational reliability and convenience.
5. Comparatively Low power consumption.
6. Belt Conveyor appear, as the practice proves, to be more economical than
railways and automotive transport over distances of 25 km and even 100 Km when the tonnage to
be hauled amounts to 25 million tons per year.
APPLICATION :
Belt Conveyors enjoy wide-spread application in various fields for moving diverse
loads and bulk materials. They cope with hauling loads from one location to another within the
process in inline production, deliver foundry sand, are employed in mining operations, at coal-
handling plants, granaries, etc.
LIMINATION :
1. Conveyor belting is, however, a costly material with a comparative short life. To
spare it, limitations are imposed on the use of belt conveyors at elevated and sub-zero temperature.
2. The loss of light weight bulk material carried away as dust or spilled from the
belt along its path is another objectionable feature.
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fα (e f α − 1)
Pmax = Tslack (e - 1) = Ttight
e fα
The requirement enabling the drive to function is that the actual pull should be less
than the maximum value, i.e.,
P < P max
The coefficient of friction f is a function of the belt type, the material of pulley
face, and ambient conditions. For the fabric ply-constructed belting it is as follows :
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Pulley
Cast-iron :
dry . . . . . . . . . . . . . . . . . 0.3
moist . . . . . . . . . . . . . . . . . 0.2
wet . . . . . . . . . . . . . . . . . 0.1
Wooden :
dry . . . . . . . . . . . . . . . . . 0.35
wet . . . . . . . . . . . . . . . . . 0.15
Rubber-lagged :
dry . . . . . . . . . . . . . . . . . . 0.4
moist . . . . . . . . . . . . . . . . . . 0.15
Fabric ply constructed belting with PVC covers display a reduced coefficient of
friction, amounting to 0.2 for plain pulleys and to 0.28 for lagged ones.
Wire belts call for adopting the following values of the coefficient of friction :
On Steel Pulley :
in humid surroundings .. . . . . . . . . 0.15
in dry room . . . . . . . . . 0.20
On rubber lagging in dry room . . . . . . . . . 0.35
On wooden lagging in dry room . . . . . . . . . . 0.30
For a steel band conveyor with plain pulleys, f = 0.10; for rubber or wood-lagged
pulleys, f = 0.27.
The driving traction can be boosted by increasing either the coefficient of friction or
the angle of wrap of the belt.
There are basically two types of drives used for belt Conveyor,
1. SINGLE DRIVE WITH SNUB PULLEY :
In most of the conveyors, α > 180 deg by virtue of snub pulleys.(fig 9a)
2. TANDEM DRIVE :
Long-center Conveyors for handling heavy loads are frequently equipped with a
dual or tandem drive in which the belt is snubbed in excess of 2 Π (390 to 430 deg) to provide for
high driving traction. Tandem drives, apart from being complicate, are a source of high belt wear
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and fatigue as well as ply separation resulting from reverse bends. These factors should be given
due consideration in point of economy before adopting a tandem drive for use.
A non-uniform circumferential speed of drive pulleys resulting from non-uniform
belt wear brings about belt slip. This is another limitation inherent in the tandem drive with a rigid
pulley link-up. On high-power installations this may be overcome for dependable performance by
using an equalizing tandem drive with a planetary gear or fluid motors which serve to distribute
the motor torque between the pulleys in a certain proportion depending on the estimated
traction.(fig 9b)
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are mechanically operated devices (screw, rack-and-pinion, gravity types) maintaining a constant
tension. Serving the same purpose automatically, though by means of extra controls, are compact
pneumatic and Hydraulic cylinders gaining now popularity.
The take-up is located in a place where belt tension is a minimum, necessitating a
minimum is chief consideration in sitting the Take-up. There are two types of take-up as follows,
1. SCREW TAKE-UP :
Referring to Figure 10a, the take up pulley shaft is supported by bearings contained
in housings 1 capable of displacing along guide 2. When the bearing are accommodated in the
pulleys hubs, the shaft is fitted to the housing directly. In a Screw-type take-up, the housings are
connected to screw 3, operating as compression members when the belt is arranged as indicated by
solid lines or as tension ones with the belt operating as shown in dash lines. Long compression
screws should be proportional to resist the load bending or replaced by screws subject to tension.
The take-up travel, adopted on the center distance and path of the conveyor, must
offset the belt elongation due to load, temperature, and wear. It must also provide for unobstructed
maintenance and repair. Standard take-up travel of Horizontal Conveyors is commonly 1/100th of
the belt length or 400 mm, whichever is greater, and that of inclined installations is 3/200th of the
length. A belt stretch exceeding the above values is taken care of by replacing the belt.
Screw-type take-ups require careful attention and adjustment to offset belt stretch.
On the other hand, it may produce an excessive tension in the belt, overloading it. Taking into
account these limitations, their use is confirmed to short-center conveyors operating under the
conditions of practically stable ambient temperature.
At the same time, Screw-type take-ups are attractive owing to their compactness. A
preferable arrangement is when the screws are not geared to each other. This enables a non-
uniform belt stretch set up across the width to be taken care of individually so as to prevent the belt
from running off the pulley. The possibility of non-uniform belt stretch set up across the width to
be taken care of individually so as to prevent the belt from running of the pulley. The possibility
of non-uniform loading of the screws is allowed for by introducing a load factor of 1.5 to 1.8 into
the strength calculations. On some installations, the screw-type take-up is provided with means of
balancing the screw loads.
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2. GRAVITY TAKE-UP :
A more advanced kind providing for an automatic belt stretch control and constant
belt tension is the Gravity-Type Take-up illustrated in Figure 10b. By analogy with the screw-
type, the take-up pulley travels along guides being attached to housings. Alternately, it can be
displaced by means of a trolley acted upon by a weight, G, attached to a rope or chain, which
produces constant belt tension T1 and T2. The weight can be applied directly as shown in Figure
10c in which case the take-up dispenses with the rest of the parts save the take-up pulley.
Excessive trolley travel and weight displacement are checked by limit switches. Gravity take-ups
are rather bulky and therefore find application on stationary conveyors only.
The force applied by the take-up should equal the geometrical sum of the tensions
in the belt runs at the drive pulley during starting the conveyor plus the effort required to displace
the take-up pulley along the guides or trolley along the rails. A tension factor of 1.2 to 1.5 is
introduced in calculating the force.
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Qt = Qm x γ tons/hr
where,
γ = Specific weight or bulk weight of material in tons/m3
The width of the belt depends on the material handled. For individual loads free
margins between 50 to 100 mm wide must be provided on either side of the belt. For a Bulk
material, the width is calculated by the formula,
B= Qt / Kv γ
where,
K = flowsbility factor
= 0.85 to 0.95 --- Plain belt
= 0.75 to 0.85 ---- Cleated belt
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F = F1 + F2
= 0.122 ( 0.9B - 0.05 )2 m2
CONVEYING CAPACITY
Volumetric Capacity,
Qm = 440 x V x (0.9B - 0.05)2 m3/hr
Conclusion
The capacity of Troughed Belt Conveyor is nearly double the capacity of Flat Belt Conveyor.
We can increase the capacity of Trough belt by increasing angle of material
inclination ϕ but as ϕ increases the life of belt decreases. ϕ = 200 is the most economical angle
used in actual practice.
Actual Capacity Q = Qm x K m3/hr
where,
K = Sliding back factor of the material. It depends upon the inclination of the belt.
For dry powder or granular material K is given by,
Angle of Inclination ( β 0 ) K
20 1
40 0.99
60 0.98
80 0.97
100 0.95
120 0.93
0
14 0.91
160 0.875
180 0.85
200 0.81
220 0.76
240 0.71
0
26 0.66
280 0.61
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300 0.52
The Belt inclination angle β 0 is seldom kept more than 302. It is normally between
120 and 220. Above this it is not economical to use the conveyor.
Capacity in tons/hr
Qt = Q x γ
where,
γ = Specific weight of material tons/m3
MATERIAL γ (tons/m3 )
Coal 0.8 - 0.9
Concrete 1.8 - 2.2
Coke 0.4 - 0.5
Lime stone 1.6 - 2.0
Sand 1.4 - 1.5
Iron ore 2.1 - 3.1
NOTE : For an unsized material the minimum width of the belt is B = 2 x amax + 200 mm and for
a sized one B = 3.3 x amax + 200 mm, where a = average lump size in mm.
POWER REQUIREMENT OF BELT CONVEYORS :-
The Power requirement of a belt conveyor consist of the power required to lift the
load to a given height and that for moving the load horizontally.
When a Conveyor with a capacity Qt in tons/hr lifts the load to the height H, the
required power in KW is given by,
Qt × 1000 × H
N vertical = (KW )
3600 × 102
Qt × H
= (KW )
367
where,
H = height to which material is raised.
In moving the load horizontally the power requirement depends on the frictional
resistance to the movement of the belt which varies directly with the capacity Qt and the belt
length L. Hence the Power in KW can be determined from,
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Qt × 1000 × L ⊂ ×Co
N horizontal = (KW )
3600 × 102
Qt × L ⊂ × Co
= (KW )
367
where,
Lc = corrected length = 1.08 x L
Co = Specific friction factor Indicating the frictional resistance which has to be
overcome in moving 1 ton through 1 meter.
Type of Belt Co
i) Flat Belt slider type 0.15
ii) Plain Belt 0.02
iii) Average antifriction bearing 0.065
iv) High Grade bearing 0.050
⇒ N = Nvertical + Nhorizontal
Qt × H Qt × Lcx Co
= + (KW )
367 367
NOTE : If the Power required is in H.P., than the conversion factor is
1 H.P. = 0.736 KW
Qt × 1000 × H
⇒ N vertical = (H .P .)
3600 × 75
Qt × H
= ( H .P.)
270
Qt × 1000 × L ⊂ × Co
⇒ N horizontal = ( H .P .)
3600 × 75
Qt × L ⊂ × Co
= ( H .P.)
270
therefore,
⇒ N = N vertical + N horizontal
Qt × H Qt × L ⊂ × Co
= + ( H .P.)
270 270
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Material fs
1) Cotton 5.4 – 11
2) High Grade Cotton 15 – 30
3) Nylon, Rayon 30 – 100
4) Teflon 125
5) Steel Wire 150 - 300
PROBLEM :-
Design a Flat belt Conveyor for conveying concrete from concrete mixing plant. Site
distance between two ends is 100m. Capacity required is 30 ton/hr.
Take, Co = 0.065 , f = 0.25 , a = 265 o ,
Velocity of conveying should not exceed beyond 20 m/sec.
SOLUTION :
Given,
Co = 0.065 , f = 0.25 , a = 2650 ,
L = 100 m , Q = 30 ton/hr , v = 20 m/sec.
We know,
Qt × 1000 × Lc × Co
⇒ Nhorizontal = ( H .P .)
3600 × 75
30 × 1000 × (1.08 × 100) × 0.065
=
3600 × 75
= 0.78
T tight
= e fα
T slack
ƒα
T sight = T slack e
= e0.25 x (265 x π /180) x T slack
T tight = 3.177 x T slack ……………….. (I)
Also,
T tight −T slack
H. P. = ×V
75
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T tight −T slack
0.76 = × 20
75
T tight – T slack = 2.92 ------------- II
Eqn. I & II ⇒
T tight = 4.26 kg
T slack = 1.36 kg
Since,
T max = T tight
= t x b x ƒs
4.26 = 1 x b x 6 (assumed )
⇒ b = 0.71 m
But we know that,
b = 0.9B – 0.05
Qm = 240 V ( 0.9B – 0.05 )2
= 240 x 20 x ( 0.71 )2
= 2419.68 m3 / hr.
Qt = Qm x γ
= 2419.68 x 2.0
= 4839.36 tons/hr
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Q.No.8 : What are the different arrangements used to provide the troughed shape to belt in
Belt Conveyor ?
Q. No.9 : How Conveying Capacity of Belt Conveyor can be calculated ?
Q.No 10: A Belt Conveyor system is to be used for conveying coal in Thermal Power
station through a distance of 15 meter. The quantity of coal to be handled is 12 t/hr. Take Drive
factor = 0.54, Specific friction factor = 0.025, Reduction ratio = 1:20. Determine, (I) Motor HP
required (II) Effective tension in Belt (III) Tension in Tight and Slack side ?
Q. No.11 : (a) Explain the types of belt conveyors ?
(b) Design a belt conveyor for conveying coat from mine site to the railway loading
station which is situated at 75 meters from source capacity required is 35
tonnes/hour. And conveying velocity should be up to 15 m/sec. Consider
Co = 0.09 φ = 2650 and µ = 0.25
Q.No.12 : (a) Explain working of three different types of take ups used in belt conveyor ?
(b) Classify belt conveyor in detail ?
Q.No.13 : (a) Find out actual conveying capacity of the throughed belt conveyor used for
conveying coal A of a specific weight of 1.2 tonnes ? /m3 width and velocity of belt
is 400 mm and 1.5 m/sec respectively.
Sliding back factor = 0.85
(b) What are different drives used for belt conveyor ?
(c) What are different arrangements of providing the trough shape to the flat belt ?
Q.No.14 : (a) Explain in detail the screw conveyor with reference to
(i) construction
(ii) Typical screw configuration
(iii) Characteristics
Q.No.15: (a) Explain any one method of maintaining belt tension ( Belt take up ) with neat sketch.
(b) Explain construction and working of belt conveyor with neat sketch ?
Q.No.16: (a) Compare Flat belt conveyor with trough belt conveyor ?
(b) How conveying capacity of belt conveyor can be calculated ?
(d) A belt conveyor system is to be used for conveying coal in thermal power station
through a distance of 15 meter. A quantity of coal to handled is 12 tones/hr. Take
drive factor = 0.54 specific friction factor = 0.025 Reduction ratio = 1.20.
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Determine (I) Motor HP required (II) effective tension in belt (III) tension in light
and slack side.
Q.17: (a) What are different method of maintaining belt tension ?
(b) How will you optimize cross sectional area of belt conveyor supported on two roller
system ? How cross sectional area is calculated in case of three roller systems ?
On what factor it depend ?
(c) Explain fields of application of belt conveyor ?
Q.18 : (a) Why hold back devices are necessary in horizontal and inclined belt conveyor ?
(b) Explain working of two roller belt conveyor system and give its application ?
Q.19 : (a) Discuss the importance of proper belt tension in different types of conveyors.
(b) Describe the procedure for determining the power requirement and salient dimension of
belt conveyor ?
Q.20 : (a) Find out the conveying capacity of troughed belt conveyor used for conveying wheat
having a specific weight of 1-1 tonnes/m3. Actual width of belt is 600 mm and speed should not
exceed 2.8 m/sec. Sliding back factor is 0.85.
Q.21 : (a) A belt conveyor is used for conveying the raw material to a mixing plant in a cement
factory. The distance between the raw material store a mixing plant is 120 metre and material is to
be conveyed at an inclination of 10. The width of belt is 100 cm and the rate of conveying
required is 40 tonnes/hour. Calculate
(1) H.P. required to drive the conveyor.
(2) Tight side belt tonsion
Slack side belt tension.
Effective belt tension.
Assume Specific friction factor = 0.065
Coefficient of friction = 0.25
Angle of wrap = 2100
Angle of repose format = 180
Q.22 : (a) Explain limitation and application of belt conveyor ?
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SECTION-B
UNIT – IV
Types of Cranes and their application.
Electric Overhead Traveling (E.O.T.) cranes.
Types of E.O.T. Cranes and their application, Design of Mechanical System used for,
a) Cross Travel of the Crane.
b) Longitudinal Travel of the Crane and
c) Hoisting and Lowering motion of the Crane load.
Design of Breaking System for various of E.O.T. Cranes, functions of limit Switches used in E. O.
Cranes. ( 13 Marks )
CRANES :-
CRANES are employed for lifting and lowering bulky items and packages or cases. They
provide overhead movements. The crane hook can move in a rectangular area (Overhead Bridge
Crane) or a circular area (Jib Crane). An Overhead Bridge Crane finds application in most of the
industries, making engines, compressors, pressure vessel, foundries, steel mills, Power House,
Chemical Plants, etc. A Jib Crane (FIG 12) is preferred where lifting of the jobs is required in a
few locations only or where bridge cannot be erected; for example, outside near the wall of
building. In a jib crane the hoist unit may be mounted on an I – section Jib which is in turn
supported on a column. A Gantry crane (FIG 13) acts as am auxiliary to Bridge Crane. It is on
wheels and can be moved at the place of use.
bracket
HINGE
wall bracket
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the trolley is placed on a Bridge. The bridge is located suitably at elevated distance. The Crane
hook is suspended towards ground which can move in a rectangular area. Since Overhead Bridge
Cranes travel on elevated tracks, they occupy no shop floor area and are consequently very
convenient in operation.
Overhead Bridge Crane of Push-type are operated by hand, other cranes of this kind are
operated electrically.
General purpose Overhead Bridge Crane manufactured, have a capacity ranging from 5 to
300 ton, and Special purpose 600 ton have been developed to handle erection work at sites of big
nuclear and hydro-power projects.
Depending on the mounting of Hoisting Mechanism and Trolley, E.O.T. Cranes are
classified as,
A.UNDER-RUNNING BRIDGE CRANE (FIG 14) :
In this type of Crane, the lifting element is suspended on a I-beam or it is mounted at the
bottom of the bridge.
Under-Running Bridge Crane can be operated in buildings of a height less than would have
been required for Top-Running Cranes. Another advantage is that Under-Running Bridge Crane
can transfer loads from bay to bay.
Under-Running Bridge Crane are weightless and required less held room as compared to
the Top-Running Bridge Cranes. They also permit better space utilization. However lifting
capacity is limited in this Crane. Normally Under-Running Bridge Crane are used up to 5 to 6 tons
of load or maximum 10 tons load.
Under-Running Bridge Crane are controlled from the cab which is suspended from either
the bridge or the trolley. Low speed Crane are Crane control is selected in each particular cases
taking in to account shop equipment layout, crane traveling speed and the availability of means for
the transfer of loads from bay to bay.
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I-BEAM
WHEEL
TROLLEY
+
HOISTING MECHANISM
ROPE
HOOK
WHEEL
TRACK RAILS
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They are suitable for heavier load and are available in wide range of capacity up to 1000
tons. If the trolley of the Crane is supported on the bridge having one horizontal girder it is known
as Single Girder Crane. Single Girder Cranes are used for 10 tons load. For heavier load bridge
with two girder is used and it is known as Double Girder Crane.
COMPARISON :
Under-Running Bridge Cranes compares favorably with Top-Running ones in point of
mass. So a 5 ton capacity Under-Running Crane weights 4.3 tons against 8.5 tons of Top-Running
Crane having the same capacity.
CHARACTERISTICS :
1. Covers any spot within the rectangular area over which the Bridge travels.
2. Can be provided with “cross-over” to adjacent bay.
3. Provides three dimensional travel.
4. Hoist may be top or bottom running.
5. Bridge propelled by hand, chained gearing or power.
6. Two hoist (light and heavy duty) can be mounted on one Crane.
7. Usually designed and built by special companies,
8. Does not interfere with work on floor.
9. Can reduce axile Aisle space requirement.
10. Can reach area otherwise not easily accessible.
11. Crane ways can extend out of the buildings.
USES :
Overhead Bridge Crane can be used for,
1. Low to medium volume.
2. Large, heavy and awkward objects.
3. Machine shops, foundries, steel mills, heavy assembly and repair shops.
4. Intermittent moves.
5. Warehousing and Yard storage.
6. With attachments such as magnets, strings, grabs, buckets, etc.
LIMITATIONS :
1. Capacities to 1000 tons.
2. Spans to 125 fts.
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D. Plate Clamp
This Handling Attachment is an eccentric clamp used for handling steel sheets and plates in
the vertical position suspended from the Hook.
E. Vaccum Lifters
These end of line attachements offer a convenient means of handling sheet stock of various
kind (steel, non-ferrous metals, glass, etc.) along with cartoons, boxes, etc.)
F. Grabbing Attachment for Bulk Material
a. Ladles
b. Buckets
c. Grab Buckets or Clamp Shell Buckets
Automatic picking up of the loads, high-tonnage loads in particular, is affected through the
use of Automatic Handling Attachments called Grab Buckets or Clam Shell Buckets.
G. Special Grip
Wire, ropes and chains for Hoisting and Haulage.
PARTS OF E.O.T.CRANE :-
A. BRIDGE :
Bridge is made up of standard rolled section or by handling steel plate in bar section.
Bottom of the Bridge is provided generally with four wheels which moves over the track rails. At
the top portion of the bridge, trolley is mounted.
B.TROLLEY :
It is structure on which lifting mechanism of the crane is mounted. Accommodated on the
trolley frame are the main and auxiliary hoists along with the cross traverse mechanism. Trolley
moves on the bridge by means of wheels. Separate motor is provided for movement of the trolley
on the bridge i.e. Cross travel of the crane.
C. DRUM AND SPROCKET ASSEMBLY :
It is mechanism mainly responsible for lifting the load. It is mounted on trolley drive
transmission system. It consist of various transmission element used for achieving different
movements of the crane. Overhead Cranes have got three important movements viz, system of
load, movement of bridge i.e. longitudian travel, movement of trolley i.e. Cross travel. First drive
is for providing power to rope drum, second one is for bridge movement, and the third one for
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trolley movement. Next is hook and rope. Hook is suspended from rope by means of flexible wire
rope, which is generally made of steel.
D. BRAKE :
It is very essential part of the Crane used for restricting various movements of the Crane
like brake for rope drum, brake for movement of trolley.
Types of Brakes :
1. According to construction
a. Block Brake
b. Band Brake
c. Disc Brake (Thrust Brakes)
d. Cone brake (Thrust Brakes)
2. According to Principle of operation
a. Automatic Brake
b. Controlled Brake
3. According to function
a. Stopping Brake
b. Regulating Brake
4. Method of applying Brake Force
a. Normally set Brakes
b. Normally release Brakes
c. Combination Brakes
FUNCTION AND TYPES OF LIMIT SWITCHES USED IN E.O.T.CRANES :-
FUNCTION :
i) Excessive Trolley travel are checked by Limit Switches.
ii) Weight Displacement are controlled by limit switches.
iii) Limit Switches are used for breaking the power supply.
TYPES :
Limit Switches are classified as,
A. Inductive type of Limit Switch
B. Controlling type of Limit Switch
a. Stopping
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b. Starting
c. Reversing
C. Interlock type limit switch
Limit Switches can be further classified as,
D. Mechanical
E. Electrical
F. Pneumatic
TRANSMISSION LINK
DRIVE PULLEY
ROPE
FIG NO.16
It consist of following parts.
a) Prime Mover
b) Transmission link between driving and driven pulley of shaft
c) Drum for collecting rope
d) Flexible hoisting equipment like rope or chain
e) Brakes
f) Load Handling Attachments like Hooks, grabs, etc.
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Hoisting Mechanism may be Hand operated or Power operated, but in E.O.T. Crane it is
normally Power operated.
1. Calculation of Power required :
Q ×V
H −P=
75 × η
2. Calculation of Torque :
2Π NT
H −P=
4500
H .P. × 4500
⇒T=
2Π N
3.Calculation of speed ratio :
N motor
SPEED RATIO =
N drum
4.Calculation of Linear Velocity :
ΠDN
v= m / sec
60
where,
Q = Load to be lifted, T = Torque.
V = Velocity in m/sec, Nmotor = Speed of Motor shaft.
η = Efficiency of mechanism, Ndrum = Speed of Rope Drum.
N = Speed in R. P. M. , D = diameter of Rope drum.
B. DESIGN OF CROSS TRAVEL OF E.O.T. CRANE (FIGURE 17)
TROLLEY
BRIDGE
HOOK
FIG NO. 17
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Go Q
P max = +
4 4
2) The hoisting mechanism may be at eccentric position
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F
FIG NO.17b
When wheel is traveling in horizontal direction it has to overcome certain resistance owing to
the weight of the trolley and friction taking place. Take friction of wheel contact and surface as ω-
Moment of Resistance ,
M=ωR
µd
= (Q + Go) + (Q + Go) K
2
therefore,
Resistance to motion.
(Q + Go ) ( µ d + 2K)
ω=
2R
C. POWER REQUIRED :
F ×V ωv
H −P= =
75 × η 75 × η
D. SPEED RATIO :
N motor
SPEED RATIO =
N trolley
60 V
& Ntrolley =
ΠD
where , V = Linear velocity of the trolley
D = diameter of Trolley wheels
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E. TORQUE REQUIRED :
2ΠNT
H.P. =
4500
H .P. × 4500
⇒T=
2ΠN
NOTATION,
Go = Weight of the Trolley & Hoisting equipment etc.
Q = Load to be lifted
Pmax = Maximum load on each wheel
d = diameter of axis
D = diameter of wheel
R = radius of wheel
K = coefficient of rolling friction at wheel contact
ƒ = Coefficient of friction for bearing
ω = frictional forge or resistance to motion of the wheel
C. DESIGN FOR LONGITUDINAL TRAVEL OF E.O.T. CRANE (FIG NO.18) :-
a. CALCULATION OF MAXIMUM LOAD ON THE WHEEL :-
G / 4 + (Go + Q) ( L − e)
P max =
2L
b. RESISTANCE TO MOTION OF WHEEL :
(Q + Go + G ) (fd + 2K)
ω =
2R
HOISTING EQUIPMENT
TROLLEY
WHEEL
RAILS
FIG NO.18
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c.POWER REQUIRED :
ω ×v
H.P. =
75 × η
d. TORQUE REQUIRED :
2ΠNT
H .P. =
4500
H .P. × 4500
⇒T=
2ΠN
Nmotor
e. SPEED RATIO =
Nwheel
NOTATIONS
Go = Weight of Trolley
G = Weight of Crane or Bridge
Q = Weight to be lifted
L = Span or Length of the Bridge
e = Maximum extreme possible position of the trolley
V = Linear velocity if the Bridge
D = diameter of wheel of Bridge
µ = Coefficient of friction at bearing i.e. at wheel shaft and bearing
k = Coefficient of friction between wheel of bridge & Rails.
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REVIEW QUESTION :
Q.No.1: How will you design the Hoisting Mechanism of Crane ?
Q.No.2 : Explain the constructional detail of E.O.T. Crane and it’s working with
neat sketch ?
Q.No.3 : Sketch and explain the system used for longitudinal travel of
E.O.T.Crane ?
Q.No.4 : Explain Limit Switches and its function in E.O.T. Crane?
Q.No.5 : Explain with the help of neat sketches the material handling attachments
used in E.O.T. crane for handling the liquid metals ?
Q.No.6 : What do you mean by E.O.T. crane ? Giving classification specify their
field of application ?
Q.No.7: What are the precautions to be taken while operating E.O.T. crane?
Q.No.8 : Give advantages and application of E.O.T. crane ?
Q.No.9 : (a) Sketch the mechanical system used for longitudinal travel of the crane and explain its
working.
(b) Explain different types of E.O.T. Cranes and give at list two application of each of
them.
Q.10 : (a) Design a cross trolley mechanism of a E.O.T. crane for lifting the load of 7 tones where
weight of trolley is 1.2 tones velocity required for cross traverse is 12 m/min. When the
dia.of wheel is 12 cm. Take coefficient of friction for bearing is 0.01, coefficient of
friction for bearing is 0.01, coefficient of friction between wheels and rails is 0.05.
Diameter of axel is 25 mm. Assume efficiency of mechanism as 75 %.
(b) Explain construction and working of overhead crane in a foundary shop to handled
heavy castings ?
Q.11 : (a) What is breaking of E.O.T. crane ? Why it is necessary ?
(b) Explain in details various parts of E.O.T. crane ?
Q.12 : Explain with neat sketches various load handling attachments used in E.O.T. crane ?
Q.13 : (a) Explain in details the working of under running bridge crane ?
(b) Explain in details the working of top running bridge crane ?
Q.14 : (a) Explain the design procedure for
(i) hoisting and lowering mechanism of crane
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UNIT – V
Introduction , Working Principles, and field of application of the following Mechanical Handling
Equipment ( No. Mathematical treatment is contemplated )
a) Pneumatic Conveyors.
b) Hydraulic Conveyors.
c) Escalators.
d) Robots in Material Handling.
(13 Marks)
PNEUMATIC CONVEYORS :-
Pneumatic Conveying is a method of transporting bulk materials in the form of powder,
short fibre and granules over a pipeline as a mixture with air or due to a pressure of air. In either
case a high-velocity air stream is used to impart motion to the material. Such an installation will
convey over more than 2 km at a rate of up to 400 tons per hour. It is capable of lifting loads to a
height of 100 metres.
Three basic system are used to generate, the high-velocity air stream :
1. SUCTION OR VACUUM SYSTEMS : (FIG 19a)
It utilizes a vacuum created in the pipeline to draw the material with the surrounding air.
Referring to Fig, a positive pressure exhauster 6 causes material to flow through a nozzle 1 and a
duct 2 into a cyclon collector 3 where it is separated from the conveying air. The exhaust air is fed
to a filter collector 5 for complete recovery of fine material, leaving then through the exhauster
into the atmosphere. The material is discharged from the collectors through rotary air-lock feeders
4 preventing in leakage of air. Vacuum conveying eliminates the dust problem and is most
successfully applied for unloading material at a number of points, using a network of pipes, and
delivering it to a single point. The system operates at a low pressure, which is practically 0.4 to
0.5 atm below atmosphere, and is utilized mainly in conveying light free-flowing materials over
short distances ( e.g., bulk carrier unloading ).
2. PRESSURE-TYPE SYSTEMS : (FIG 19 b)
In this, a positive pressure is used to push material from one point to next. Material is
introduced into a pipeline 2 (FIG ) through a rotary air lock feeder 10 to be conveyed by
transport air fed by a blower 7 through a receiver 8 and a moisture trap 9. At the destination, the
air stream enters a cyclon collector 3 for the recovery of material and the exhaust air is passed
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through a filter collector 5 for dust separation before leaving into the atmosphere. The system is
ideal for conveying material from one loading point to a number of unloading ones. It operates
under a pressure of 6 atm and upwards and is capable of handling heavy pulverized and lumpy
materials over considerable distances.
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its turn, is a velocity at which the aerodynamic forces acting on a particle are at balance with its
force of gravity so that the particle is capable of soaring in the pipeline. The soaring velocity
depends on the weight and shape of the particle and is determined experimentally, taking into
account the form drag.
ADVANTAGES :
Pneumatic conveying enjoys wide-spread application, apparently due to the
following advantages offered :
1. Delivery of materials over a path capable of changing its direction in any plane as
required,
2. Processing of the material simultaneously with its conveying,
3. An almost limitless number of loading and unloading points served by a single system,
4. Air and gas tightness eliminating dust nuisances and dust hazards ,
5. An almost totally automated conveying
6. Considerable reduction in of losses of material.
7. Improved labour conditions,
8. Minimum of Human attendance.
LIMITATIONS :
1. High Power requirement,
2. Rapid wear of equipment,
3. The problem of dust recovery from the exhaust air before this leaves into the
atmosphere,
4. Inability to convey wet, caking and sticky loads.
HYDRAULIC CONVEYORS :-
Coming under the category of pipeline conveying are Hydraulic Conveyors in
which bulk material in the form of slurry is transported over tubes. In existence are three methods
of conveying :
A SLUICING :
In this slurry is conveyed over sluiceways at a slight down gradient ( 0.02-0.06) due
to gravity.
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B. PUMPING (FIG 20 a) :
When a solid pump 3 draws slurry from a mixing pit 1 and delivers it over a
pipeline 4. At the destination, the material is recovered from the stream by means of a mesh filter
6, being then dumped into a hopper 7, and the water is drained into a settling tank 8 from which it
is returned to the mixing pit by a recirculating pump 5. The systems operates at inclines of up to
90 deg as well as on horizontal sections.
C. SLUICING AND PUMPING (FIG 20 b) :
When the slurry is Gravity-fed over a shop sluiceway 10 into the collecting hopper
12, of a jet pump 13 which introduces it into a pipeline 9 through a diffuser by means of a high-
velocity jet of water supplied by a pump 11.
Hydraulic conveying has firmly gained ground in conjunction with Hydraulic
stripping and is of particular value when wet concentration is employed.
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eliminates exposure to radioactivity. However, the robot does not become radioactively
contaminated once it is exposed and then must be handled as a radioactive object.
Another example of a dangerous operation is loading material into a forge or punch
press. A Robot can put the part into the press and remove the finished part automatically. Even if
an accident to the robot occurs, replacement of the robot part is easy and no human worker is
injured.
4. Moving Heavy Objects
Robots can be built to move heavy objects that weigh more than the limit
considered acceptable for a human worker. If it has the capacity to handle the weight, the robot
can function indefinitely without fatigue or back strain.
5. Loading and Unloading
Robots can be used for general loading and unloading if the motion patterns are
within the robot’s capabilities. A major limitation is the area covered and the distance the robot
must move the product. Thus, a robot would have difficulty loading a railroad gondola car unless
either the car or the robot were repositioned periodically while the robot filled the section within
its reach.
This work is seldom sought by a manual worker. It is heavy, boring, dull, and
seldom leads to a better job.
6. Packaging
A recent application is the use of robots in packaging a product.
7. Inspection
A robot can be used to move product as part of an inspection operation. The robot
can pick a unit from a moving assembly line, transfer it to the inspection station, turn it over if
necessary, and then put it back on the line if it is good or in the reject pile if it fails to pass
inspection.
APPLICATION :
In this section, we shall look at a few specific examples of material handling
systems that use robots.
1. Press Work
Interest in removing the operator from exposure to injury from punch presses goes
back at least 30 years. At that time, some major companies adopted the policy that the press
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operator should put hands into the press to feed or remove the parts. Various transfer mechanisms
and guards were developed. However, many were unsatisfactory and led to reduced productivity.
Now, a robot can be used to put the material into the press and remove the complete
part. Since most of the material is sheet metal, which is stiff and solid, the robot has no difficulty
grasping and moving the parts. Furthermore, the robot’s function can be synchronized with the
press strokes to improve productivity.
2. Forging
A robot has an additional advantage handling forging billets and parts. It is not
affected as much by heat as the human operators. With properly designed grippers, the robot can
pick up and carry hot forgings with no trouble or damage. It also has good repeatability, so it can
accurately place the billet in each cavity. This reduces scrap losses due to misalignment.
3. Die Casting
Robots can be used to remove the completed die casting from the casting machine.
Again they are not bothered by heat.
4. Assembly
A Robot can be used to put and place parts and components in an assembly
operation. If the operation is high-volume mass production, the robot can replace the human
operator with resulting increase in productivity.
5. Flexible Manufacturing System
The role of robots in a flexible manufacturing system (FMS) is different from its
function in most applications. In a typical FMS, many different parts are produced in small
batches. Consequently, the robot must be programmed to handle many different items on their
way through FMS.
TRENDS :
Several trends exist in Material Handling by Robots. Among them are ;
1. Increasing gap between the cost of using a robot and that of a manual worker. The
economics of scale, competition, and technological improvements are holding down the
cost of robots while their efficiency goes up. On the other hand, the hourly wage increases
have exceeded productivity improvement, so that unit cost of manual material handling
keeps rising.
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2. Increased used of robots to load and unload machine tools, Not only do costs go down,
accidents decrease.
3. The use of vision sensing will expand. Although present applications are relatively crude,
research is producing improvements regularly.
4. The use of electricity for powering robots is increasing at the expense of hydraulic power.
REVIEW QUESTIONS :
Q.No.1: Compare Pneumatic and Hydraulic Conveyors on the basis of their working and
application.
Q.No.2: Explain working of one Hydraulic Conveyor with neat sketch?
Q.No.3: What are Escalators ? Explain the working principle of Escalator? Also state its
application.
Q.No.4: Explain the role of Robot in Material Handling ?
Q.No.5: Sketch and explain in detail the three basic systems used to generate the high-velocity air
stream in Pneumatic Conveying ?
Q.No.6: What is “Industrial Robots”? Give advantages of Robots?
Q.No.7: How you find Robots useful in material handling system in mordern industries ? Brief out
with suitable examples ?
Q.No.8: Describe working principle of hydraulic conveyor. State its application ? (Any one)
Q.No.9: (a) Explain in details the suction or vaccume systems of pneumatic conveying.
(b) Write short notes on escalators ?
Q.No.10: (a) Explain in details the pumping system of hydraulic conveyor ?
(b) List out the field of applications of ‘Industrial Robot’.
Q.No.11: Explain in details the various types of Pneumatic conveyors with neat sketches ?
Q.No.12: Define robots. Give advantages, disadvantages and classification of robots ?
Q.No.13: (a) Explain construction and working of Pneumatic conveyor with neat sketches ?
(b) What is robot ? What are its general characteristic ?
Q.No.14: (a) What are requirement of a satisfactory pneumatic handling system ?
(b) What are the different causes of accident ?
Q.No.15: (a) Explain preventive measures requires for pneumatic conveying system ?
(b) Where and why use conveyor ? What types of material that can be handled
by conveyor ?
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Q.14 : (a) Explain the fig the pressure type system of pneumatic conveying ?
(b) What is pneumatic conveying ? What are different method used ?
Explain them is details with neat sketches?
Q.15 : (a) List down the application in robot in industries ?
(b) What are limitation of Hydraulic Conveying ?
60724- 453117
VISIT DEPARTMENT OF PRODUCTION ENGINEERING ON WEB AT
http://coeta-production.tripod.com
NOTE : IF YOU FIND ANY MISTAKE OR PRINTING ERROR PLEASE BRING TO
OUR NOTICE . ANY SUGGESTION TO IMPROVE THESE NOTES WILL BE MOST
APPRECIATED.
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UNIT -VI
A) Introduction, Working Principle and field of application of following mechanical Handling
Equipment. (No. Mathematical treatment is contemplated)
1) Ladle Crane
2) Electric lifts.
3) Skip Hoists.
4) Fork Lift Trucks.
5) Winches.
B) Repairs and Maintenance of Material Handling Equipment’s and Hazards with Material
Handling Equipment.
(13 Marks)
LADLE CRANE (TEEMING CRANE) (FIG 22) :-
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m/s, being consequently equipped with a two-speed drive. The cars of lifts installed in very tall
buildings shuttle at speeds ranging between 1.5 to 3.5 m/s depending on the height.
An increase in the effective handling capacity of lifts is achievable either by
increasing their speed or by shortening the periods of starting and retarding. Yet, these periods
cannot be shortened beyond a certain limit taking into account that rapid acceleration and sudden
retardation are likely to cause passengers discomfort. This is the reason why modern lifts are rated
to operate at accelerations and declarations not in excess of 1.5 m/s2.
Lift operating at a speed of 1.5 m/s or less are equipped with geared motor drives,
but high speed lifts have their traction-type driving sheave linked directly (without a reduction
gearing) to the shaft of a low-speed D.C. motor.
Unattended freight lift differ from passenger lifts and attended freight lifts by a
simplified construction and a less number of safety gadgets. The speed of unattended freight lifts
is between 0.1 and 0.3 m/s and that of attended ones, up to 1 m/s.
The so-called ropeless lift, developed in recent years, is used to hoist men, tools,
and supplies to the top of oil well derricks, very tall buildings, radio and TV towers. The car of a
ropeless lift travels along guide rails due to traction between drive rollers and the flanges of guide
rails. Alternatively, a drive of the rack-and-pinion type is used to set the car into motion.
The passenger lift illustrated in Fig 23 essentially consists of a car 6 traveling over a
set of rigid guide rails 5 which keep the car restrained laterally and provide support for it with the
aid of special safety devices 10 should the hoisting rope 3 rupture. A hoisting machine 1 is
arranged at the top or bottom of hoistway, with the top arrangement preferred in passenger
installations. To reduce the load on the hoisting machine, counterweight 7 is commonly
employed. Running along a separate set of guide rails 4 it offsets the car’s mass and half the duty
load. The safeties are adjusted to operate when the descending speed of the car becomes
excessive, a governor 2 operated from a separate rope 9 being provided in the machine room for
the purpose of regulating the speed. Buffers 8 are arranged at the bottom of the hoistway, and lift
control 11 (commonly magnetic switches) are found in a cubicle next to the hoisting machine.
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HOISTING MECHANISM
CAR
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The skip hoist of the third type is arranged to operate unbalanced (Figure 24 c), the
load on the winding machine being in this case the equivalent of the mass of duty load plus that of
skip. They are ideal in light and medium capacity installations operating from time to time at a
moderate daily running.
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USES :
1. Relatively light loads.
2. Intermittent moves.
3. Varying loads.
4. Serving a machine or work place.
5. High volume.
6. Long distances.
7. Varying routes.
LIMITATIONS :
1. Must allow space for chain to clear corner.
2. Need smooth surface.
FORK LIFT TRUCK (FIG 24) :-
COLUMN
DRIVER SEAT
PALLET LOAD
FORK
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Material handling operations inside a shop and between shops are taken care of by compact
hoisting Winches. These are also used for deliveries to in line production and automatic transfer
lines, and to machine tools as well.
REPAIRS AND MAINTENANCE OF MATERIAL HANDLING EQUIPMENT :-
The proper maintenance of material handling equipment’s is extremely essential for
preventing the occurrence of bottlenecks or points of congestion’s. Production line flow can be
maintained only if the material handling equipment is in the proper working order.
Preventive maintenance is by far one of the best maintenance techniques suggested for
material handling equipment.
By Preventive Maintenance, the equipment can be kept running thereby minimizing costly
interruptions in the production schedule. A little periodic inspection and minor adjustments may
be enough to prevent equipment breakdown. Preventive maintenance consist of frequent
inspection and examination of material handling equipment’s, with special attention to the
components requiring it. The aim is to uncover conditions leading to breakdown or harmful
depreciation. Preventive maintenance also includes lubrication, adjustment, or repair while the
equipment is still in a minor stage of defect.
Three stages of Preventive Maintenance are :
1. Inspection,
2. Repair, and
3. Overhaul.
The Maintenance system for a few material Handling Equipment’s like Hoist, cranes, and
Conveyors have been discussed below :
A. HOISTS AND CRANES
a.Inspection : All parts, open or covered are inspected for wear and tear. Worn out or unworkable
components like wire ropes, wheels, bearings, bolts, etc., are removed. Brakes are adjusted and
lubrication is provided wherever necessary.
b.Repair: The repairable parts of the system, after inspection are corrected for small repairs and
minor defects are rectified, Systems like open gear transmission, couplings, riverted, and bolted
joints, trolley, brakes, guards, etc., may be repaired.
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c.Overhaul: Overhauling involves dismantling the complete mechanism and replacing all
damaged components. Crane structure, buffers, rails, open gear transmission, pulley blocks, etc.,
may be replaced and various sub-mechanisms may be aligned and adjusted.
B. CONVEYORS:
a. Inspection : Belts and roller are inspected for tensions and wear and tear. Gear box is
properly lubricated, various fasteners are tightened and safety guards are checked.
b.Repairs : Rollers and Belt are checked, adjusted or repaired. Couplings, packing, safety
guards, steel structures, gear transmission, bearings, fastener joints, threaded components, etc.,
are adjusted or repaired as per their conditions.
c. Overhaul : The conveyor system is completely dismantled. Components, worn out and
beyond repair like belts, bearings, packings, oil seals, rollers, drums, fasteners, and couplings are
replaced. Structure, safety guards, etc., may be repaired as per their conditions.
HAZARDS WITH MATERIAL HANDLING EQUIPMENT :-
There are accident causes by moving machinery or equipment in the materials handling
function in industry. This section will discuss some of this causes.
1.Fork lift trucks accident are important not only in frequency but in severity among
Industrial Accidents. Following are the 10 most common types of Fork lift truck accidents,
a) Worker struck by Fork Lift Truck.
b) Worker struck by object.
c) Operator struck by falling object.
d) Other worker struck by object.
e) Mounting or dismounting Fork lift truck.
f) Fork-lift truck overturns.
g) Collision with other vehicle.
h)Fork-lift Truck falling of the dock.
i) Body part struck by object.
j) Parts falling back on the operator.
1. Fork-lift operating on Gas are noisy and produces fumes which create Health Hazard.
2. The chief hazard from Conveyors is a worker coming in contact with the moving
conveyor or its load. Accident may result from broken parts and component failure of
conveyors.
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3. The potential for serious accidents from cranes and Hoists is high. Most involve running
into workers or dropping loads which strike a worker. In ladle Crane, due to the failure
of Auxilairy hoist, molten metal may falls on the operator resulting in serious accidents.
Due to the failure of Limit Switches Excessive trolley travel and weight displacement
may occur resulting in serious hazard.
4. The average person seldom thinks of a small container such as a tote box as a accident
source. However, one can cause an accident. A common type is muscle or back strain
through improperly lifting of a loaded tote box. Another type of accident is dropping a
loaded tote box on a worker’s foot.
5. Tripping and falls are two common types of industrial accidents in American Industry.
The failing of the load may occur due to excessive lubrication and faulty installations of
the parts of the equipment. Although most accidents are minor, they can be serious,
causing disability and even a fatality.
6. Inefficient Braking is one of the causes ofr the hazards in the Material Handling
Equipment. Due to the inefficient braking, the Material required at a specified or desired
location will not be available there. There will not be any control over the speed with
which the Material is to be moved, e.g. If the load is of amorphous type it will flew away
because of the excessive speed. If the Material is to be carried from higher location to
the lower location, the speed must be controlled and for this reason only efficient braking
is required.
7. In Pnuematic Conveyors, due to the choking of the Ducts or Nozzle, conveying
becosdmes impossible. Also in Hydraulic Conveyors the leakage of pipeline may loose
the pressure head.
8. Accidents may result in the passenger lift operated on rope due to the breakdown of the
rope.
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REVIEW QUESTIONS :-
Q.No.1: Explain the working of ladle crane with its advantages ?
Q.No.2: Discuss any two types of winches, with neat sketches?
Q.No.3: What are different causes of accident?
Q.No.4: Brief out preventive maintenance required for a screw conveyor, in general?
Q.N0.5: Explain working of fork Lift truck with neat sketch? Mention it’s wide use in Industry?
Q.No.6: How electric lift plays its roll in material handling systems?
Q.No.7: What are the hazards associated with overhead material handling systems?
Q.No.8: (a) Describe the operation flexibility of facts lift trucks ?
(b) Compare passenger safety between escalators and passenger lift ?
(c) What is winch ?
Q.No.9: (a) How accidents associated with belt conveyor can be prevented ?
(b) Explain the construction, working and application of ladle cranes ?
Q.No.10: (a) Explain various hazards related with material handling equipments ?
How they are eliminated ?
(b) Describe the working principle and give advantage of following & application.
(i) Ladle crane. (ii) Skip hoists.
Q.No.11 : (a) Give general safety rules for material handling equipments ?
(b) Describe how fork truck is versatile ?
Q.No.12 : (a) Explain in details working of fork truck with neat sketches with characteristic uses
and limitations ?
(b) Explain in details repair and the maintainances of conveyor ?
Q.No.13 : Explain the working of electric lift with neat sketch. State its application ?
What is its limitation ?
Q.No.14 : (a) Explain any two types of winches with neat sketches. State their uses ?
(b) What are limitation of winches ?
Q.No.15 : (a) Write a short note on ‘ ladle crane ?
(b) Explain special features of fork lift truck . Give its application ?
Q.No.16 : (a) How electric lift plays its role in material handling system ?
(b) What are the different types of causes of accident ?
Q.No.17: What are the types of repairs normally occure in automatic
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CHEMICAL TECHNOLOGY
1. Emerging role of the paint industry in improving human health
2. Role of software in Chemical Engg.
3. Xylitol Technology
CIVIL ENGINEERING
1. Advanced composite materials an alternative to reinforcement, tendons and cables
2. Drainage problems related to irrigation in Maharashtra
3. Fly ash sand lime brick - an alternative walling material
4. Latex modified SFRC beam-column joints subjected to cyclic loading
5. Reinforced earthwork approach embankment using kologrid for rob at Murtijapur
6. Reinforcement detailing in non engineering and engineering earthquake resistant structures
7. Simplified CPM/PERT simulation model
8. Vaastu-shastra & its importance in residential building
COMPUTER ENGINEERING
1. Groupware technology
2. Parallel processing in LINUX
ELECTRICAL ENGINEERING
1. Application of superconductivity in electric power system
2. Cardiac pace-maker
3. Design of voltage regulator
4. Eco-friendly energy sources for rural development
5. Electric earthing and shock
6. Emission levels of a two-stroke S.I. Engine with in-cylinder fuel injection
7. Energy conservation in industry
8. Energy saving in home lighting
9. Future trends in technology for locomotive traction
10. HVDC transmission lines
11. Hydrostatic transmission for shunting locomotives
12. Internet & netsurfing
13. MHD-power generation
14. Mini Romag generator
15. Recycling of plastics
16. Selecting transformers for hydro power plants
17. Solar energetics in space
18. Substation
ELECTRONICS ENGINEERING
1. Computer numerical control
2. Electronic multipoint fuel injection system
3. Fibre optical sources & detectors
4. Logic analyzer
5. Operation & temperature maintenance of Xerox Machine
6. Programmable logic controller
7. Radar system
8. Remote control system
9. Satellite tracking system
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