Gaikwad, et al.

, International Journal of Advanced Engineering Technology E-ISSN 0976-3945

Research Paper
STATIC ANALYSIS OF A ROLLER OF GRAVITY ROLLER
CONVEYOR FOR STRUCTURAL STRENGTH & WEIGHT
OPTIMIZATION
1
S.S. Gaikwad, 2E.N. Aitavade
Address for Correspondence
1
PG student, 2Prof, Mechanical Engineering Department, Tatyasaheb Kore Institute of Engineering and
Technology, Warananagar, Tal.-Panhala, Dist.Kolhapur-416113, India
ABSTRACT
In the present work, an attempt is made to reduction in weight of existing roller conveyor by optimizing the critical parts of
(e.g. Roller,) conveyor without hampering its structural strength. The existing Roller conveyor designed is considered for
this project work. The dimensions being 2200 mm length, 30 inch above ground and inclined at 2 to 4 degree with the
ground and the weight to be carried by the conveyor - 280Kg (350 kg with added factor of safety). This is the weight of the
largest component to be transported over the conveyor. The conveyor would normally encounter gradually applied loads
while the components are lowered by hoist. For reasons of safety, a `sudden load’ is already considered during its design
phase. Static analysis of roller of existing conveyor is carried out find out maximum deflection & stress. Then Optimization
is carried out by modifying the dimensions of roller .Then analysis of optimized roller are carried out to find out maximum
deflection & stress. As such, the existing roller conveyor structure is tested for mechanical strength over the shop-floor while
a trial is taken using optimized designed rollers of assembly and with the real-time components of the excavator. Upon
completion of the experimentation, the assembly is observed for any visible damage to the conveyor units. The units are
measured for their height, especially at the central region along the length of the unit with a general purpose retractable
measuring tape. The recorded measurement does not highlighting any sag induced in the unit during the experimentation
phase. As the roller in which changes are made in existing design are standard (the weight of the physical model is slightly
more than the optimized model values). So made easily available in market.
KEYWORDS- Structural strength, factor of safety, weight, maximum stress.
I. INTRODUCTION pipe to be used as roller. While evaluating the
Conveyor is used in many industries to transport existing design options, there appears to be a scope
goods and materials between stages of a process. for weight reduction of the entire assembly (through
Using conveyor systems is a good way to reduce the weight optimization).
risks of musculoskeletal injury in tasks or processes The problem is taken up for study and execution for
that involve manual handling, as they reduce the need evolving alternatives to design while targeting weight
for repetitive lifting and carrying. Conveyors are a optimization for the critical components like roller in
powerful material handling tool. They offer the the assembly. Structural analysis of the rollers in
opportunity to boost productivity, reduce product conveyor should offer insights into the problem at
handling and damage, and minimize labour content in hand. The FEA methodology would be adopted to
a manufacturing or distribution facility. Conveyors solve the problem while finding out the structural
are generally classified as either Unit Load strength of the rollers and addressing the reduction in
Conveyors that are designed to handle specific weight without compromising on the strength of raw-
uniform units such as cartons or pallets, and Process material handling member parts in the assembly.
Conveyors that are designed to handle loose product Gravity roller Conveyor has to convey 350 kg load,
such as sand, gravel, coffee, cookies, etc. which are 30 inch above ground and inclined at 4 degree.
fed to machinery for further operations or mixing. It
is quite common for manufacturing plants to combine
both Process and Unit Load conveyors in its
operations. Roller conveyor is not subjected to
complex state of loading still we found that it is
designed with higher factor of safety. If it is redesign
critical parts e.g. Roller, Shaft, and Bearing& Frame
etc. then it is possible to minimize the overall weight
of the assembly. Powered belt conveyors are
considerable long (9000 meter to 10000 meter) as Figure No.1-Roller Conveyor
compared to roller conveyor. So we can achieve Components of conveyor are as follows-
considerable amount of material saving if we apply Table no.1- Components of conveyor
above study related to roller conveyor to this belt
conveyor.
With the past experience of the Service provider in
analysis field, Solidwork appear as a competent tool
to pursue Analysis for this Project Work. The roller
conveyor assembly has to be installed over varying
lengths in the assembly line area for multi-national Design of roller:
company manufacturing excavators (client of Material – MS
sponsoring company).The transportation can cause a E = 2.10*105 Mpa,
problem if such assemblies are made as one-piece ρ= 7850 Kg/m3,
units. The roller conveyor assembly normally yield stress=260 Mpa
involves the use of channels, rollers and /bars that are Considering uniformly distributed load & FS = 1.5
heavy by virtue of their structure and the material Allowable Stress (σall) = Syt / Fs =260/1.5
used (steel).The amount of material is needed (kg) is =173.34 Mpa
directly dependent on the thickness of the channel or
Int J Adv Engg Tech/IV/IV/Oct-Dec.,2013/27-30
 Gaikwad, et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945

In principle at least three rollers must always sit STATIC LINEAR ANALYSIS OF ROLLER-
under the material to be transported in order to ensure A static analysis calculates the effect of steady
that it is conveyed smoothly. In this calculation four loading condition on a structure, while damping
rollers are considered. effects, such as those caused by time varying loads. A
Maximum Stress Calculation for given condition – static analysis can, however, include steady inertia
W= 350/4= 87.5kg (Load act on 4 rollers at a time) load (such as gravity and rotational). Design and
D1= Outer diameter of roller = 70 mm analysis of roller conveyor for weight optimization &
D2 = Inner diameter of roller = 50 mm material saving (velocity) [2, 6, 8] and time varying
w = Width of roller = 500 mm load that can be approximated as static equivalent
y = Distance from neutral axis = 0.07/2 = 0.035m loads (such as static equivalent wind and seismic
Considering uniformly distributed load, loads commonly defined in many building codes).
Maximum Moment Select element and apply material properties. Static
(Mmax) = W*L/8 analysis determines the displacements, stresses,
= (87.5*9.81*0.5)/8 strains, and forces in structures or components caused
Mmax = 53.64 Nm by lodes that do not induce significant damping
Moment of Inertia (I) effects. Steady loading and response conditions are
=П (D14 – D24)/64 assumed; that is, the loads and the structure’s
= П (0.074 – 0.054)/64 response are assumed to vary slowly with respect to
I = 8.7179*10-7 m4 time.
Maximum bending stress Material Properties-
σb = Mmax * y/ I =53.64*0.035/ 8.7179*10-7
σb = 2.153 Mpa
Checking Factor of Safety for design-
Fs = σall / σb
= 173.34/2.153
Fs =80.5
As Calculated Fs is greater than assumed Fs, Selected
Material can be considered as safe. Loads-
Maximum Deflection (ymax) Gravity load-
= 5*W*L3/384EI Reference: Top Plane
Values: 0 0 -9.81
= (5*87.5*9.81*0.53)/ (384*2.10*1011* 8.7179*10-7) Units: SI
ymax = 7.631*10-3mm
As compared to length 500 mm deflection of
7.631*10-3mm is very negligible. Hence selected
channel can be considered as safe.
Weight of Rollers –
=cross-section area*width*mass density* number of
rollers
= П (0.072 – 0.052) *0.5*7850*14/4
=103.57 Kg
Figure No.2-Gravity load
Weight of Shafts -
Force load-
Cross-section area*width * mass density* number of
shafts
= П (0.012) *0.56*7850*14
= 19.33 Kg
Total weight of Bearings -
= 28*0.2494 = 6.982 kg (standard mrc CONV-4SF
bearing)
Weight of C-frame –
Cross-section area*length of frame* mass density
= (11.70*10-4 *2.2*7830) Figure No.3-force load
= 20.15kg / per frame
= 2*20.15 = 40.30kg
Weight of Channels-
Cross-section area*length * mass density* number
Mesh Information
of Channels
= (835.26*10-6*0.762*7830*4)
= 19.93Kg
Total Weight of Existing Conveyor Assembly-
Table No.-2-Total Weight of Existing Conveyor
Assembly

Figure No.4-Mesh information

Int J Adv Engg Tech/IV/IV/Oct-Dec.,2013/27-30

 Gaikwad, et al., International Journal of Advanced Engineering Technology
Table no.3-mesh information
Study results-
Minimum von mises stress is 1276.35 N/m^2 &
maximum is 4.75994e+007 N/m^2
Figure No.5-Stress plot
Minimum resultant displacement is 0 mm &
maximum resultant displacement is 0.0318847 mm
Figure no.-6-deflection plot
II. MODIFICATION
As factor of safety Rollers is very high there is scope
of weight reduction in this component.
Selection of Critical Parameter –
• Roller Outer diameter
• Roller thickness
For optimisation purpose selected Roller Outer
diameter is 60 mm and roller thickness 5 mm.
Design of roller after optimisation:
Material – MS
E = 2.10*105 Mpa,
ρ= 7850 Kg/m3,
Yield stress=260 Mpa
Considering uniformly distributed load & FS = 1.5
Allowable Stress (σall)
= Syt / Fs =260/1.5=173.34 Mpa
In principle at least three rollers must always sit
under the material to be transported in order to ensure
that it is conveyed smoothly. In this calculation four
rollers are considered.
Maximum Stress Calculation for given condition –
W= 350/4= 87.5kg (Load act on 4 rollers at a time)
D1= Outer diameter of roller = 60 mm
D2 = Inner diameter of roller = 50 mm
w = Width of roller = 500 mm
y = Distance from neutral axis = 0.06/2 = 0.03m
Considering uniformly distributed load,
Maximum Moment
(Mmax) = W*L/8= (87.5*9.81*0.5)/8
Int J Adv Engg Tech/IV/IV/Oct-Dec.,2013/27-30
E-ISSN 0976-3945
Mmax = 53.64 Nm
Moment of Inertia (I)
=П (D14 – D24)/64 = П (0.064 – 0.054)/64
I = 3.29*10-7 m4
Maximum bending stress σb
= Mmax*y/ I = 53.64 * 0.035/ 3.29*10-7
σb = 2.153 Mpa
Checking Factor of Safety for design-
Fs = σall / σb = 173.34/4.89=35.44
As Calculated Fs is greater than assumed Fs, Selected
Material can be considered as safe.
Maximum Deflection (ymax)
= 5*W*L3/384EI
= (5*87.5*9.81*0.53) / (384*2.10*1011* 3.29*10-7)
ymax = 20*10-3mm
As compared to length 500 mm deflection of 20*10-3
mm is very negligible. Hence selected channel can be
considered as safe.
Weight of Rollers –
= cross-section area*width * mass density* number
of rollers
= П (0.062 – 0.052) *0.5*7850*14/4
=47.47 Kg
Total weight of optimized assembly-
Table no.4-Total weight of optimized assembly
STATIC LINEAR ANALYSIS OF OPTIMIZED
ROLLER-
Minimum von mises stress is 0 N/m2 & maximum
von misses stress is 1.23409e+008 N/m2.The yield
stress for selected material of roller is 2.5 e+008
N/m2. Hence design is safe.
Figure No.7-Stress plot after optimization
Minimum resultant displacement is 0 mm &
maximum resultant displacement is 0.0685024 mm
Figure No.8-Deflection plot after optimization
III. RESULT COMPARISION
Effect of Optimized Design Compared with Existing
design-
 Gaikwad, et al., International Journal of Advanced Engineering Technology
Table no.5-Effect of Optimized Design Compared with
existing design
Weight reduction due to Optimization-
Table no.6- Weight reduction due to Optimization
Stress Analysis-
Table no.7- Stress analysis before optimization & after
optimization
IV. EXPERIMENTATION
Experimentation-
For experiments, the existing Roller conveyor
designed by the Sponsoring Company for vendors is
putted to test. The conveyor would normally encounter
gradually applied loads while the components are
lowered by hoist. For reasons of safety, a `sudden
load’ is already considered during its design phase.As
such, the existing roller conveyor structure is tested for
mechanical strength over the shop-floor while a trial is
taken using optimized designed components of
assembly and with the real-time components of the
excavator. Components in all shapes and sizes with a
maximum of 280Kg are rolled over the conveyor
during its transit from one end of the conveyor to the
other. For trials, the roller conveyor is grouted in the
floor with nuts and bolts as has been designed for the
full scale implementation. All other conditions of
loading and the method of use to remain the same as
per the real-time application at the shop-floor. A
minimum of 30 nos. passes of the component from end
to end are carried during the experimentation phase.
Validation-
Upon completion of the experimentation, the assembly
is observed for any visible damage to the conveyor
units. The units are measured for their height,
especially at the central region along the length of the
unit with a general purpose retractable measuring tape.
The recorded measurement does not highlighting any
sag induced in the unit during the experimentation
phase. The maximum deflection value that is measured
with retractable type tape is 4.4 mm. Sag of about 8
mm is permissible per the brief shared by the client.
As the parts in which changes are made in existing
design are standard (the weight of the physical model
is slightly more than the optimized model values). So
made easily available in market and are assembled for
testing on which 350 kg load is applied and safety is
checked.
V. CONCLUSIONS
• Existing design calculation shows the factor
of safety is very greater than requirement
and there is a scope for weight reduction.
• Critical parameter which reduces the weight
is roller outer diameter and roller thickness.
Though value of deflection, stress is more in
Int J Adv Engg Tech/IV/IV/Oct-Dec.,2013/27-30
E-ISSN 0976-3945
case of Optimized design, but it is
allowable.
• 29.54 % of weight reduction is achieved due
to Optimized design.
• 56.18 Kg. weight reduction achieved by
optimized design than existing design.
• Actual physical model is done for validation
using optimized design parameters and it is
found that the design is working safely
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