ROHIT KUMAR SINGH-19ETEC004063

Assignment-1
19ETEC004063 Part-A ROHIT KUMAR SINGH
“Renewable energy sources will replace fossil fuels in near future”
“The fact that oil is a “finite” material is not a problem…Every material is finite. Life is all about taking the
theoretically finite but practically limitless materials in nature and creatively turning them into useful resources. The
fossil fuel industry does it, the “renewable”—actually, the “unreliable”—energy industry doesn’t. End of story.” Alex
Epstein

COULD RENEWABLE ENERGY COMPLETELY REPLACE FOSSIL FUELS?

To know the answer of this question we need to think about usefulness of fossil fuels in industries as well
as transportation. We know that fossil fuels comes in the later few year back it has so many types; coal and
then oil and then natural gas. These energies are useful in industries as well as for vehicles. Coal was
initially used for running trains , industries in various parts of our countries.

Fossil Fuels (coal, oil, petroleum, and natural gas) formed from decay of plants and animals that lived
hundreds and millions of years ago and became buried deep inside the Earth’s surface. These then
collectively transformed into the combustible materials that we use today for fuel. The earliest known
fossil fuel deposits are from about 500 million years ago, when most of the major groups of animals first
appeared on Earth. The later fossil fuels, such as peat or lignite coal (soft coal), began forming from about
five million years ago.

Now-a-days, we are largely dependent on fossil fuels to run our cars, power our offices, industry and
manufacturing. Nearly all of the energy needed to meet our demands – 80 percent of global energy –
comes from burning fossil fuels. At the current rate of global energy demands, fossil fuels cannot replenish
fast enough to meet these growing needs. The (over)consumption of these non-renewable fuels has been
linked to the emission of greenhouse gases and pollutants into the atmosphere – the leading cause of
global warming and climate change.

For example, our energy consumption from fossil fuels was 89% in 2013. Our highest demand for fossil
fuel energy over the last 51 years was experienced during the period of high growth under the ‘Celtic Tiger’
(2004), where we required 93.39%. The lowest energy consumption value (67.24%) was in 1960, more than
half a century ago! Ireland is ranked 46th out of 136 countries in its fossil fuel consumption. That’s higher
than the UK (52nd) and the US (56th)!
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Renewable energy is energy that is coming from natural processes (e.g. sunlight and wind). Solar, wind,
geothermal, hydropower, bioenergy and ocean power are sources of renewable energy and in small
industries also . Currently, renewables are utilised in the electricity, heating and cooling and transport
sectors. Renewable energy collectively provides only about 7 percent of the world’s energy needs. This
means that fossil fuels, along with nuclear energy — a non-renewable energy source — are supplying 93%
of the world’s energy resources. Nuclear energy (a controversial energy source among public opinion)
currently provides 6% of the world’s energy supplies.

PROBLEMS DUE TO THIS ENERGY SOURCES:

Burning fossil fuels creates carbon dioxide, the main greenhouse gas emitter that contributes to global
warming, which hit its peak in 2012. In the last 30 years, temperatures have risen to the warmest since
records began. If we continue to pump greenhouse gases into our environment the average global
temperature could increase by 1°C to 4°C by 2100. Even if we changed today to using more renewable
resources instead of fossil fuels for example, increases could be between 1 to 2.5°C.

The 20th century saw the most prolific population growth and industrial development, which was and
remains totally dependent on the use of fossil fuel for energy.
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Many scientist of our country estimates that due to fossil fuel reserves their is depletion range from
between 50-120 year. This shows that peoples are heavily dependent on energy to meet our basic human
needs – needs that keep growing.

Scientists maintain that the impact of global warming on the environment is widespread. In the Arctic and
Antarctica, warmer temperatures are melting ice, which leads to increases in sea levels and alters the
composition of the surrounding sea water. Rising sea levels impacts on settlements, agriculture and fishing
both commercially and recreationally. Air pollution is also a direct result of the use of fossil fuels, resulting
in smog (see in China and India), and the degradation of human health and plant growth. There is the
negative impact on natural ecosystems that result from collecting fossil fuels, particularly coal and oil.
There is also the continuing threat of oil spills that devastate ecosystems and the impact of mining on land
vitality.

IN COMMING TIMES:

The discussions around climate change and energy problems today centre around the potential for
technical solutions to energy demands that are cost effective. So far, the alternative to fossil fuels has been
around renewable energy sources, which are expected to play an increasingly vital role in the mix of power
generation over the next century. The demands on these alternative energy sources are inordinate – they
will need to not only keep up with the increasing population growth, but needs to go beyond these
demands by contributing to the replacement of fossil fuel energy production in order to meet future
energy needs and consider the natural environment.

However, the argument from governments, oil, coal and natural gas companies is that until renewable
energy sources become more viable as major energy providers, the only alternative in meeting the
increasing demands for energy from a growing global population that requires more and more energy, is to
continue to extract fossil fuel reserves.

Part-B

B.1
A centre punch is used to mark the centre of a point. It is usually used to mark the centre of a hole
when drilling holes. A drill has the tendency to "wander" if it does not start in a recess. A centre punch
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forms a large enough dimple to "guide" the tip of the drill. The tip of a centre punch has an angle between
60 and 90 degrees.[1] When drilling larger holes, and the web, that is the centre of the drill tip, is wider than
the indentation produced by a centre punch, the drilling of a pilot hole is usually needed.
An automatic centre punch operates without the need for a hammer.

AUTOMATIC CENTRE PUNCH

An automatic centre punch is a hand tool used to produce a dimple in a workpiece (for example, a piece of
metal). It performs the same function as an ordinary centre punch but without the need for a hammer.
When pressed against the workpiece, it stores energy in a spring, eventually releasing it as an impulse that
drives the punch, producing the dimple. The impulse provided to the point of the punch is quite
repeatable, allowing for uniform impressions to be made.

DETAILED DIAGRAM OF A CENTRE PUNCH

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PARTS OF A CENTRE PUNCH

The most common mechanism is based upon the Sweet patent. Within the body of the punch, there are
three principal moving parts arranged in line:

 The punch
 The intermediate rod (tumbler)
 The hammer (hammer mass)
The hammer mass is spring-loaded from the back of the punch by a large spring. (The spring's preload
compression can usually be adjusted by loosening or tightening the end cap at the back-most portion of
the punch, to decrease or increase the force of the punch.) A stopped hole drilled in the front centre
portion of the hammer mass facing the tumbler acts as a receiver for the rod, and as an anvil for the punch
action.
The tumbler provides the automation. When reset, a provision is made such that the tumbler rod is cocked
slightly, so that its resting position is skewed, and the tip contacts the hammer mass on the face of the
hammer slightly offset to the hole. This is commonly done by using a special bent end on the tumbler
spring or using an out-of-flat face on the bottom end of the pin or top of the punch. It bears on the
hammer mass and pushes it back against its spring as the punch is pressed, storing energy in the hammer
spring.
As the punch is further pressed against the workpiece, the tumbler travels back until the point where its
tapered midsection begins contacting the surface of the guide hole in the body of the punch. As it
continues back, it is pushed into alignment with the centre axis of the tool. When the tip of the tumbler is
nearly centred, it slips into the receiving hole in the hammer mass and releases the hammer. The hammer
mass is then allowed to move forward, propelled by the rear spring. Because the hole in the hammer mass
does not go through the mass and is less deep than the end section of the tumbler, the tip of the tumbler
bottoms out in the hole in the hammer, and the impulse of the hammer mass is transmitted through the
tumbler, through the punch, and to the workpiece.
Taper Turning Methods in lathe machine
There are four methods.
1. Form Tool Method
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2. Tailstock set over method
3. Compound rest method
4. Taper turning attachment method
Form tool method
This is one of the simplest methods to produce short taper. This method is shown in the above figure. To
the required angle the form is grounded. The tool is fed perpendicular to the lathe axis, when the work
piece rotates.
The tool cutting edge length must be greater than the taper length. Since the entire cutting edge removes
the metal, it will produce a lot of vibration and hence a large force is required. It is done in slow speed.

Tailstock set over method

Generally, when the angle of taper is very small this method will be employed. The work piece be placed in
the live centre and live centre. Now, the tailstock will be moved in a cross wise, that is perpendicular to the
lathe axis by turning the set over method. This process is known as tail stock set over method.

TAPER TURNING BY TAILSTOCK METHOD

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Hence here the job is inclined to the required angle. When the work piece rotates the tool is moved
parallel to the lathe axis. So that the taper will be generated on the work piece.
Compound rest method
Generally short and steep taper will be produced will be produced using this method. In this method the
work piece will be held in the chuck and it will be rotated about the lathe axis. The compound rest is
swivelled to the required angle and then it will be clamped in position.

TAPER TURNING BY COMPOUND REST METHOD

The angle is determined using the formula, tanα = (D-d)/2L.
Then by using the compound rest hand wheel the tool will be fed. Both the internal and external taper can
be done using this method. The important feature is that the compound rest can be swivelled up to 45° on
both sides. Only with the help of the hand the tool should be moved.
Taper turning attachment method
In this method by using bottom plate or bracket, a taper turning attachment is attached to the rear end of
the bed. It has a guide bar which is usually pivoted as its centre. The guide bar can swing, and it can be set
in any required angle. It has graduations in degrees. On either side, the guide bar can be swivelled to a
maximum angle of 10°. It has a guide block which connects to the rear end of the cross slide and it moves
on the guide bar. The binder screw is removed, before connecting the cross slide, hence the cross slide is
free from the cross-slide screw.
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Usually during taper turning, the job will be held in the chucks or in the centres. To the required angle the
guide bar turned.
The angle is calculated using the formula, tanα = (D-d)/2l.
When the division is given in mm instead of degree, then the angular distance of the guide bar to be tilted
is given by
Using the compound rest hand wheel, the depth of cut will be given. At a half taper angle, the guide will be
set. Using this method any taper turning method can be done.

Calculation of taper turning angle

Taper Degree is the central angle of the taper measured in degrees. It can be calculated from the taper %
or it can be calculated with the number of the different type of tapers.
Formula:
Taper = (dl - ds) / Length Taper Angle = a tan (0.5 x Taper)
where, dl = Large End Dimension, ds = Small End Dimension
E.g.A 20-inch taper with small and large diameter as 5 inch and 10 inch has a taper length of 0.25 inch.
What is the angle formed by a 0.25-inch taper?
= atan (0.5 x 0.25)
= atan (0.125)
Taper angle=0.124 radians,7.125 in degrees.
ALTERNATIVE METHODS FOR TAPER TURNING

Facing
Facing in the context of turning work involves moving the cutting tool at right angles to the axis of rotation
of the rotating workpiece. This can be performed by the operation of the cross-slide, if one is fitted, as
distinct from the longitudinal feed (turning). It is frequently the first operation performed in the production
of the workpiece, and often the last—hence the phrase "ending up".
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Parting
This process, also called parting off or cut-off is used to create deep grooves which will remove a
completed or part-complete component from its parent stock.

Grooving
Grooving is like parting, except that grooves are cut to a specific depth instead of severing a
completed/part-complete component from the stock. Grooving can be performed on internal and external
surfaces, as well as on the face of the part (face grooving or trepanning).

B.2
Refrigeration is a process that removes heat from a space, substance, or system to lower and/or maintain
its temperature below the ambient temperature. In other words, refrigeration is artificial (human-
made) cooling Energy in the form of heat is removed from a low-temperature reservoir and transferred to
a high-temperature reservoir. The work of energy transfer is traditionally driven by mechanical means, but
can also be driven by heat, magnetism, electricity, laser, or other means. Refrigeration has many
applications, including household refrigerators, industrial freezers, cryogenics, and air conditioning. Heat
pumps may use the heat output of the refrigeration process, and may be designed to be reversible, but are
otherwise like air conditioning units.
Industrial refrigeration isn’t air conditioning—it goes beyond that, both in scale and in the little details.
Industrial refrigeration can be defined as the equipment and accessories projected to remove heat from
large-scale processes or materials, lowering the temperature to a desired value. Depending on different
parameters like the production scale, temperature difference, accuracy or expected temperature, there
are multiple methods used to apply industrial refrigeration.
Industrial refrigeration has been of paramount importance since the early years of the twentieth century.
Historically, industries like Food and Beverages, Pharmaceuticals or Petrochemicals, achieved important
developments thanks to systems indicated for reducing the temperature of their products or processes, or
conserving them in optimal conditions to avoid safety issues.
In industries where bioprocesses are involved, products and processes must be developed and stored in
ideal conditions to achieve the maximum yield in reactions, or to avoid the decay of products. Sometimes
refrigeration is necessary to maintain safe conditions in the process or product to avoid accidents or chain
reactions, e.g. in compounds with a low boiling point. In addition, cooling may be applied to have an
adequate environment for people or machines to work, like in industries where high amounts of heat are
produced or for equipment that needs to dissipate the heat generated.
Refrigeration and cooling systems are designed to fulfil determined requirements based on the specific
characteristics of each industry. One of them is data centres.
DATA CENTRES
A data centre is a building, dedicated space within a building, or a group of buildings used to
house computer systems and associated components, such as telecommunications and storage systems.
Since IT operations are crucial for business continuity, it generally includes redundant or backup
components and infrastructure for power supply, data communications connections, environmental
controls (e.g. air conditioning, fire suppression) and various security devices. A large data centre is an
industrial-scale operation using as much electricity as a small town.
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DATA CENTRES
DATA CENTRE COOLING TECHNOLOGIES DEFINED

Given the importance of data centre cooling infrastructure, it’s worth taking a moment to examine some
commonly used and new data centre cooling technologies.

Calibrated Vectored Cooling (CVC)

A form of data centre cooling technology designed specifically for high-density servers. It optimizes the
airflow path through equipment to allow the cooling system to manage heat more effectively, making it
possible to increase the ratio of circuit boards per server chassis and utilize fewer fans.
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Chilled Water System

A data centre cooling system commonly used in mid-to-large-sized data centres that uses chilled water to
cool air being brought in by air handlers (CRAHs). Water is supplied by a chiller plant located somewhere in
the facility.

Cold Aisle/Hot Aisle Design

A common form of data centre server rack deployment that uses alternating rows of “cold aisles” and “hot
aisles.” The cold aisles feature cold air intakes on the front of the racks, while the hot aisles consist of the
hot air exhausts on the back of the racks. Hot aisles expel hot air into the air conditioning intakes to be
chilled and then vented into the cold aisles. Empty racks are filled by blanking panels to prevent
overheating or wasted cold air.

Computer Room Air Conditioner (CRAC)

One of the most common features of any data centre, CRAC units are very similar to conventional air
conditioners powered by a compressor that draws air across a refrigerant-filled cooling unit. They are quite
inefficient in terms of energy usage, but the equipment itself is relatively inexpensive.

Computer Room Air Handler (CRAH)

A CRAH unit functions as part of a broader system involving a chilled water plant (or chiller) somewhere in
the facility. Chilled water flows through a cooling coil inside the unit, which then uses modulating fans to
draw air from outside the facility. Because they function by chilling outside air, CRAH units are much more
efficient when used in locations with colder annual temperatures.

Critical Cooling Load

This measurement represents the total usable cooling capacity (usually expressed in watts of power) on
the data centre floor for the purposes of cooling servers.

Direct-to-Chip Cooling

A data centre liquid cooling method that uses pipes to deliver coolant directly to a cold plate that is
incorporated into a motherboard’s processors to disperse heat. Extracted heat is fed into a chilled-water
loop and carried away to a facility’s chiller plant. Since this system cools processors directly, it’s one of the
most effective forms of server cooling.

Evaporative Cooling

Manages temperature by exposing hot air to water, which causes the water to evaporate and draw the
heat out of the air. The water can be introduced either in the form of a misting system or a wet material
such as a filter or mat. While this system is very energy efficient since it doesn’t use CRAC or CRAH units, it
does require a lot of water. Data centre cooling towers are often used to facilitate evaporations and
transfer excess heat to the outside atmosphere.
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Free Cooling

Any data centre cooling system that uses the outside atmosphere to introduce cooler air into the servers
rather than continually chilling the same air. While this can only be implemented in certain climates, it’s
a very energy-efficient form of server cooling.

Immersion System

An innovative new data centre liquid cooling solution that submerges hardware into a bath of non-
conductive, non-flammable dielectric fluid.

Liquid Cooling

Any cooling technology that uses liquid to evacuate heat from the air. Increasingly, data centre liquid
cooling refers to specifically direct cooling solutions that expose server components (such as processors) to
liquid to cool them more efficiently.

Raised Floor

A frame that lifts the data centre floor above the building’s concrete slab floor. The space between the two
is used for water-cooling pipes or increased airflow. While power and network cables are sometimes run
through this space as well, newer data centre cooling design and best practices place these cables
overhead.

NEED OF DATA CENTRE REFRIGERATION

Data centres store groups of servers used to process and distribute data. The servers naturally produce
heat during operation, and if the heat is not removed, the temperature rises. Unfortunately, this can
adversely affect the functioning of the servers. To prevent this problem, powerful air-cooling systems are
usually placed in these data centres, dissipating the heat produced and minimizing maintenance
operations. These cooling systems are commonly air-based or liquid-based, depending on exterior
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conditions. Furthermore, new cooling systems are starting to be more environmentally friendly, using
seawater as a refrigerant.

BLOCK DIAGRAM OF THE DATA REFRIGERATION SYSTEM

The two main refrigerants used in data centre cooling systems today are R410A, used in small to medium-
sized data centres that require about up to 300-400kW of cooling capacity per unit, and R134a, used in
larger systems.

R410A

R-410A, sold under the trademarked names AZ-20, EcoFluor R410, Forane 410A, Freon 410A, Genetron
R410A, Puron, and Suva 410A, is a zeotropic but near-azeotropic mixture of difluoromethane (CH2F2, called
R-32) and pentafluoroethane (CHF2CF3, called R-125) that is used as a refrigerant in air
conditioning applications. R-410A cylinders are coloured rose.

R410a is a high-pressure refrigerant with a low critical temperature used mainly in ac compressor. With
proper system design, it has been shown to give equivalent or better performance than R407C.

Many air conditioning suppliers switched to R410a from R22, especially for direct expansion-type systems
where an added advantage is the use of smaller pipe sizes.
R32 is a possible longer-term alternative. It is already a 50% component of R410a, but alone it is flammable
to a limited extent.

R134A
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R134a is an HFC refrigerant used on its own as a pure refrigerant and as a component in many blends. It is
widely used in automotive air conditioning and medium temperature refrigeration in applications where
R12 would have previously been used.

R134a is capable to be at temperatures of -28°Cat room temperatures of 38°C, its performance being very
similar to that of an R12. However, the compressor must use a synthetic polyester lubricating oil.

Key properties of the main refrigerants are given in together with their typical application ranges.

Low Temperature −25℃ to –40°C

Refrigerant

Medium Temperature −5℃ to –25°C

Refrigerant

High Temperature +10 to –5°C

Refrigerant

The key to a refrigeration system is to transfer heat energy from the evaporator to the condenser.

In order to achieve this, the compressor circulates refrigerant around the system which changes state as it
receives and rejects heat.

Data centres technology is quite complex and advanced, and this has as a result to require huge amounts
of energy. Therefore, data centres need to be as efficient as possible and data environmental control has a
significant role to this issue.
The recommended temperature for a data centre is estimated between 21°C and 24°C. In addition to,
some studies regarding the desired temperature in a data centre shown that maybe it is not so optimal
(money-wise) for firms to keep the temperature below 21°C. Furthermore, typical data centre limit
temperatures have been estimated to be 85°C for processors and DIMMs, while disk drives can usually
work in stricter conditions, at a maximum of 45°C.
It is also remarkable that, while the conventional heating, ventilation and air conditioning systems (HVAC)
for similar size rooms deal with heat fluxes in the order of 40-90 W/m2, cooling systems in data centres
work with extremely higher heat loads: modern data centre infrastructures can need to refresh apparatus
that produces 6-10kW/m2 as power density. In the next few years, it is estimated that the power density
consumption will still raise up to 15 kW/m2.
Google for instance mentions the significance of taking serious action to reinforce energy efficiency in case
of either running a small data centre or a huge service. According to Google, many manufactures construct
the suitable equipment to be used at temperatures higher than the standard 21°C we aforementioned.
This may lead to next generation servers having the ability of performing at higher temperatures, fact that
can make data centre using less equipment and therefore save money. So for an effective management
and control data centres should be able to perform accurate temperature analysis by measuring the
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amount of energy spent for processes that concern cooling. Nevertheless, the best solution may be
consulting the corresponding equipment manufacturer so with his expertise can point out the suitable
approach.
Many opinions of experts about this subject point out that data centres could have better performance if
they could adopt a mixture of cooling methods. Another important factor that could drastically contribute
to an optimal performance is the location where data centres are placed. Constructing data centres either
in places with cooler climates or near to sources of cold water not only could increase energy efficiency in a
high level but also could reduce costs by deploying the external environment.

B.3
Belt Drives are a type of frictional drives used for transmitting powers from one shaft to another by means
of pulleys which rotate at the same speed or at the different speed.

FLAT BELT DRIVE

A belt drive is shown in the figure. consists of two pulleys over which an endless belt it passed over them.
The mechanical power or rotary motion is transmitted from the driving pulley to the driven pulley because
of the frictional grip that exists between the belt and the pulley surface.

The portion of the belt which is having less tension is called slack side and the one which has higher
tension is called tight side. The effective pulling power of the belt that causes the rotation of the driven
pulley is the difference in tension on the slack and tight side.

The tensions in the tight and slack sides of the belt depend on the angle of contact, the belt drives must be
arranged such that the slack side comes above, and the tight side comes below the pulleys.

BELT DRIVE APPLICATION: CONVEYOR BELT

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A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt conveyor). A
belt conveyor system is one of many types of conveyor systems. A belt conveyor system consists of two or
more pulleys (sometimes referred to as drums), with an endless loop of carrying medium—the conveyor
belt—that rotates about them. One or both pulleys are powered, moving the belt and the material on the
belt forward. The powered pulley is called the drive pulley while the unpowered pulley is called the idler
pulley. There are two main industrial classes of belt conveyors; Those in general material handling such as
those moving boxes along inside a factory and bulk material handling such as those used to transport large
volumes of resources and agricultural materials, such as grain, salt, coal, ore, sand, overburden and more.

CONVEYOR BELTS

Conveyors are durable and reliable components used in automated distribution and warehousing, as well
as manufacturing and production facilities. In combination with computer-controlled pallet handling
equipment this allows for more efficient retail, wholesale, and manufacturing distribution. It is considered
a labour saving system that allows large volumes to move rapidly through a process, allowing companies
to ship or receive higher volumes with smaller storage space and with less labour expense.
Belt conveyors are the most used powered conveyors because they are the most versatile and the least
expensive. Products are conveyed directly on the belt so both regular and irregular shaped objects, large or
small, light and heavy, can be transported successfully. Belt conveyors are also manufactured with curved
sections which use tapered rollers and curved belting to convey products around a corner. These conveyor
systems are commonly used in postal sorting offices and airport baggage handling systems.
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DETAILED SKETCH OF A CONVEYOR BELT

Rollers to wind up conveyor belt are attached at the tip of frame. This is called a head pulley or a head
roller. Conveyor belt moves forwards as the roller/pulley rotates.
Roller which wind up conveyor belt is also attached at the end of conveyor, which is opposite side of the
tips. This roller is called tail pulley or tail roller. Conveyor belt is wound up by both of rollers above.
Normally, rollers are attached under side around the head pully as well. This is called snap pulley / snap
roller, or snub pulley / roller. This snap pulley is attached to prevent the belt wound up at the head pulley
from slipping by making winding angle larger.
A side where objects are being carried is called carrier side, and a side where belt returns is called return
side.
The carrier side holds belt which is carrying object. There are two ways for holding which are holding with
steel plates and holding with rollers. The steel plate is called by several different names such as sliding
plate, conveyor plate, etc. In case that rollers are used, it is called carrier roller. Belts are held by rollers in
return side where belt return. This roller is called return roller.
CALCULATION OF LENGTH OF THE CONVEYOR BELT

BELT LENGTH REQUIRED FORMULA

L= 2C+ π((D+d)/2)+ (D-d)2/4C
where L= belt length in inches
C= centre length between two pulleys in inches
D= pitch diameter of second pulley in inches
d= pitch diameter of first pulley in inches
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In this, C=16 in, D=12 in and d=6 in
Hence,
L= 2*16 + 3.14((12+6)/2)+(12-6)2/4*16
= 32 + 3.14(18/2)+36/64
= 32+(3.14*9)+0.5625
= 32+28.26+0.5625=60.8225 in [Ans]
Of all the components in a conveyor system, the drive mechanism is the most expensive. It can account for
as much as two-thirds the cost of the entire system, as well as 80% of the maintenance and repair costs.
It’s no surprise, then, that many engineers put the drive mechanism at the top of the list when spec’ing out
a conveyor system.

External chain and V-belt drive mechanisms are the traditional choice, but motorized pulleys — an old idea
reborn with new technology — are beginning to live up to earlier promises. With integrated electronic
intelligence, today’s self-propelled pulleys are reliable, efficient, and virtually maintenance-free in many
applications.

WHAT IS A MOTORIZED PULLEY?

A motorized pulley is simply a drum motor in which the outer shell rotates around a stationary shaft. The
revolving member serves as a traction pulley, gripping and driving the conveyor belt. Electrical power leads
pass through the stationary shaft to terminals within the pulley housing. Since the shaft end does not
rotate, there is no need for slip rings to deliver electrical energy to the motor windings.

The entire internal mechanism — including motor, gears, and bearings — is completely sealed and
protected by the outer metal drum. Oil inside the drum continuously lubricates the bearings and gears, and
acts as a heat-transfer fluid by dissipating heat away from the motor windings. This keeps the motor cool,
extends service life, and reduces maintenance. It also means designers can put pulleys in hot environments
(up to 120°F) and in non-conventional applications such as sprocket drives and kick rollers.

By bringing the drive mechanism inside, a motorized pulley is much more compact than a conventional
drive system with all its external components. This dramatically reduces space requirements and allows for
the installation of more conveyor in less floor or overhead space. And since all moving parts and electrical
connections are completely enclosed in steel, external safety hazards are virtually eliminated.
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MOTORIZED PULLEY

Typically, the only service required on a motorized pulley is a simple oil change every 20,000 hours. To put
this in perspective, that’s nearly 10 years of service (40-hour week) without maintenance.

Self-propelled pulleys are also quiet. Most designs — because gears and other moving parts are enclosed
within a sealed, oil filled chamber — operate in the 57 to 62 dB range, the sound intensity of normal
conversation. At this level, there is no need for workers to wear ear protective devices, as specified by
OSHA guidelines and requirements.

Another advantage for motorized pulleys is efficiency. They typically transfer about 95% of the input
horsepower to the conveyor belt. In today’s cost-conscious plant, that can help a system pay for itself in
short order.

Motorized pulleys are not without problems, however. One has been oil escaping through the end seals.
Earlier designs put end seals in contact with the shaft, causing both components to wear. The more the
conveyor was used, the less time it would take the oil to find a leak path to the outside world.

New sealing technology corrects this problem by inserting a hardened, ground stainless steel sleeve
between the main shaft and double-lip oil seal. The new design works so well that pulleys often perform
reliably without leaking for many years — even after repeated washdowns with scalding water, caustic
solutions, and steam at pressures to 1,200 psi.

APPLICATIONS FOR MOTORIZED PULLEY CONVEYOR BELTS

It would be an oversimplification to say that any conveyor system can be driven by a self-contained
motorized pulley, although the statement is certainly true. There are, however, several conveyor
applications that can realize significant benefits from self-contained motorized pulleys.
ROHIT KUMAR SINGH-19ETEC004063

MOTORIZED CONVEYOR BELTS

Chief among these are in the food processing and handling industry. Because foods for human
consumption are involved, the FDA has stringent rules governing cleanliness. Conveyor systems and
associated equipment must be washed down daily with high-pressure steam, hot water, and/or caustic
chemical solutions. Sealed pulleys are impervious to these harsh cleanings and remain so for years.
Package handlers — from shippers, to package-forwarding organizations such as Airborne Express, to
companies receiving hundreds of parcels daily — are also benefiting from the simplified design and space-
saving features offered by motorized pulleys. This includes airlines that handle a variety of items inside
terminals every day, and the truck mounted conveyors that carry parcels in and out of cargo hold on parked
aircraft.The foundry industry is also benefiting as sealed, enclosed drives reduce the potential for
shutdowns caused by airborne dust and dirt fouling bearings, gears, and other exposed parts.

END