Thesis 0

A PROJECT
REPORT ON
“ AUTOMATIC PALLET CARRIER FOR SMALL WORKSHOPS ”
Submitted as per requirement of

Savitribai Phule Pune University
Towards partial fulfillment of Bachelor degree of Mechanical Engineering
By
Mr. Pawar jivan keshavrao [B120750891] Mr.

Shaikh Nausherwan Adil [B120750907] Mr.
Wayal Vishal Radheshyam [B120750937] Mr.
Zende Kiran Ashok [B120750939]
Under the Guidance of
Prof. Malave A. C.
DEPARTMENT OF MECHANICAL ENGINEERING
S. B. Patil College of Engineering, Indapur

2015 - 2016
S.B.PATIL COLLEGE OF ENGINEERING
VANGALI, INDAPUR-413106
DEPARTMENT OF MECHANICAL ENGINEERING
C E RTIFIC A T E
This is to certify that Project report entitled
“ AUTOMATIC PALLET CARRIER FOR SMALL WORKSHOPS ”
Submitted by
Mr. Pawar jivan keshavrao Mr.

Shaikh Nausherwan Adil Mr.
Wayal Vishal Radheshyam Mr.
Zende Kiran Ashok
is in partial fulfillment for the award of Degree of Bachelor of Engineering in Mechanical

Engineering of Savitribai Phule Pune University . This Project report is a record of the
student’s own work carried out by him under my supervision and guidance.
[Prof. Malve A. C.] [Prof. S. R. Kshirsagar]

Guide HOD
External Examiner [Dr.P. D. Nemade]

Principal
Date :
Seal :
ABSTRACT
In small workshops there are workstations which are at distance of 5 meter and
large time is spent on transmission of product from one workstation to another work-
station .To transfer product, the conventional transfer medium such as conveyor belt,
automated guided vehicle (AGV) are used. These methods consume electricity as well
as they are costlier. So this paper is important for transmission of product from one
workstation to another without use of any electricity .The project is operating on weight
of the product. There are arrangement such as Lever, gears, spring and wheels which
operates this machine, there is arrangement such as when lever is pressed due to weight
of product then gears rotates and there motion is transmitted to the wheels and ma-
chine moves from one workstation to another workstation. spring arrangement is used so
that when weight is lifted then spring gets contracted and wheel move in reverse direction.
KEYWORDS:-Pallet Carrier, lever, spring, Propulsion.
i
Contents
1 INTRODUCTION 1
1.1 Problem Statement . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Ob jectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 LITERATURE REVIEW 4
3 CONVENTIONAL MATERIAL HANDLING SYSTEMS 18

3.1 Types Of Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1.1 Belt Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1.2 Screw Conveyor . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1.3 Roller Conveyor . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.4 Live Roller Conveyor . . . . . . . . . . . . . . . . . . . . . 21
3.1.5 Minimum Pressure Conveyor . . . . . . . . . . . . . . . . 21
3.1.6 Zero Pressure Conveyor . . . . . . . . . . . . . . . . . . . 23
3.1.7 Pallet Conveyor . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1.8 Overhead Conveyor . . . . . . . . . . . . . . . . . . . . . . 24
3.1.9 Table Top Chain . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1.10 Magnetic Slide Conveyor . . . . . . . . . . . . . . . . . . . 24
4 TERMINOLOGY OF GEARS 25
4.1 Introduction To Our Engineering Design Process . . . . . . . . 25
4.2 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2.1 Design consideration of the gear driver:- . . . . . . . . . 29
4.2.2 The following requirement must be met in the design
of a gear drive:- . . . . . . . . . . . . . . . . . . . . . . . . 29
5 RESEARCH DEVELOPMENT 30
5.1 Drawing, Fabrication, . . . . . . . . . . . . . . . . . . . 30
WorkingInvolved . . . . . .
5.2 Process . . . . . . . . . . . . . . . . . . . . . . 31
5.2.1 Design:- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.2 Drawing:- . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.3 Getting material:- . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.4 Cutting material:- . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.5 Drilling:- . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ii
5.2.6 Bending process:- . . . . . . . . . . . . . . . . . . . . . . . 33
6 DESIGN 34
6.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2 System Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.1 System Selection Based on Physical Constraints:- . . . . 35
6.2.2 Arrangements of Various Components:- . . . . . . . . . . 35
6.2.3 Components of System:- . . . . . . . . . . . . . . . . . . . 35
6.2.4 Mechanical Design- . . . . . . . . . . . . . . . . . . . . . . 36
6.3 Fabrication Method . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.3.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.3.2 Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7 DESIGN OF AUTOMATIC PALLET CARRIER 40

7.1 Design Of Welded Joint . . . . . . . . . . . . . . . . . . . . . . . . 40
7.2 Design of shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Design of Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4 Selection Of Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.4.1 Advantages of bearing 6304 . . . . . . . . . . . . . . . . . 49
7.5 Design Of Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.6 Design Of Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.6.1 Types of Springs . . . . . . . . . . . . . . . . . . . . . . . 52
8 PROCESS SHEET 55
8.1 Analysis of each element . . . . . . . . . . . . . . . . . . . . . . . 56
8.1.1 Frame:- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.1.2 Helical Tension Spring:- . . . . . . . . . . . . . . . . . . . 56
8.1.3 Spring Supporting Rod:- . . . . . . . . . . . . . . . . . . . 56
8.2 Component Cost Estimation . . . . . . . . . . . . . . . . . . . . 57
8.2.1 Cost Estimation:- . . . . . . . . . . . . . . . . . . . . . . . 57
9 ADVANTAGES, DISADVANTAGES AND APPLICATION 58

9.1 Advantages of Automatic pallet carrier for small workshop:- . . 58
9.2 Disadvantages of Automatic pallet carrier for small workshop:- 58
9.3 Application of automatic pallet carrier for small work shop:- . 59
10 FUTURE SCOPE 60
11 CONCLUSION 61
REFERENCES 62
iii
List of Figures
3.1 belt Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2 Screw Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 Roller conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Live Roller Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Minimum Pressure Conveyor . . . . . . . . . . . . . . . . . . . . . 22
3.6 Zero Pressure Conveyor . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Involute Form Of Gear Tooth . . . . . . . . . . . . . . . . . . . . 26

4.2 20o full Depth Involute system . . . . . . . . . . . . . . . . . . . 27
4.3 Meshing Of Spur Gear . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 3D view Automatic pallet Carrier . . . . . . . . . . . . . . . . . . 30

5.2 Gear Arrangement Of Automatic pallet Carrier . . . . . . . . . 31
5.3 2D View of Automatic pallet carrier . . . . . . . . . . . . . . . . 32
5.4 Actual Image Of Automatic pallet carrier . . . . . . . . . . . . . 33
7.1 Gear and shaft arrangement . . . . . . . . . . . . . . . . . . . . . 42

7.2 Loading Diagram Of shaft . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Vertical Bending Moment Diagram . . . . . . . . . . . . . . . . . 44
7.4 Nomenclature of Ball Bearing . . . . . . . . . . . . . . . . . . . . 48
iv
List of Tables
7.1 Combined Shock and Fatigue factor for bending and torsion . . 41
7.2 Lewis form factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.3 dimensions and static and dynamic load capacities of single row
deep groove ball bearings . . . . . . . . . . . . . . . . . . . . . . . 47
7.4 basic load rating for bearing . . . . . . . . . . . . . . . . . . . . . 49
8.1 Manufacturing Of Parts . . . . . . . . . . . . . . . . . . . . . . . . 55

8.2 Process Sheet of Frame . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Costing Of Frame and transportation . . . . . . . . . . . . . . . . 56
8.4 Costing of Helical Tension Spring . . . . . . . . . . . . . . . . . . 57
8.5 Total Material Cost . . . . . . . . . . . . . . . . . . . . . . . . . . 57
v
LIST OF ABBRIVATIONS
Abbreviation Definitions
TPH Tonnes Per Hour
P Pitch Point
M Module
Dp Diametral Pitch
D Pitch Diameter
φ Diameter
P Load
S Size Of Weld
L Contact Length
Ft Tensile Force
Syt Yield Tensile Strength
Te Equivalent Twisting
Moment
Km Combined Shaft And
Fatigue Factor For
Bending
Kt Combined Shaft And
Fatigue Factor For
Tor- sion
M Moment
vi
Abbreviation Definitions
T Torque
Sut Ultimate Tensile Strength
Π Pie=3.14
N Revolutions Per Minute
R Radius
F Summation Of Forces
M Summation Of Moments
Tmax Maximum Torque
Pb Bearing Pressure
t Tensile Stress
K Stiffness
P Load
D Outer Diameter
D Wire Diameter
Rs Rupees
vii
ACKNOWLEDGEMENT
We have great pleasure in presenting this report on AUTOMATIC

PAL- LET CARRIER FOR SMALL WORKSHOPS. We take this
opportunity to thank all those who have contributed in successful completion
of this report.
This Pro ject has helped us to express extracurricular knowledge with

incredible help and inspiring guidance from Principal, Dr. P. D. Nemade.Our
special thanks to Prof. Malave A. C. who at very discrete step in studies of
this seminar contribution their valuable guidance to solve every problem
that arose.
We wish to thank our Pro ject Co-Guide Prof. K. M. Kare and

H.O.D. Prof. S. R. Kshirsagar for opening the door of department towards
the re- alization of Pro ject report. Not to forget the contribution of my
classmates who gave invaluable suggestions for making improvements in the
report. Once again, we would like to thank all those who directly or
indirectly made a contribution to this report.
Mr. Pawar jivan keshavrao Mr.

Shaikh Nausherwan Adil Mr.
Wayal Vishal Radheshyam Mr.
Zende Kiran Ashok
Place:Indapur
Date:
viii
Chapter 1
INTRODUCTION
Material handling is movement and storing of goods. Material handling

activity includes picking up material, transporting material and setting down
material.
Out of total production time 20 percent time is spent on actual process.

Remaining time is spent in movement, waiting etc. Thus proper arrangement
of material handling system can improve means of faster production, higher
plant capacity, lower stock is process and less damage to product in all
stages. It is observed that out of total production time, 20 percent time is
spent on actual process. Remaining time is spent in movement, waiting etc.
Thus proper arrangement of material handling system can achieve faster
production, Uti- lizes higher plant capacity, and lower work in process. The
working principle of this pro ject is Propulsion of pallet carrier using self
weight of the ob ject. The weight w is kept on lever, due to its gravitational
force, the upper shaft gets rotated gear also be rotated which is keyed on
shaft. By increasing gear ratio, power is transmitted to wheel pallet carrier
can run from one station to other station.
When the weight is removed, the lever comes back to its initial
position, due to the spring tension and due to which pallet carrier also
comes back to its initial position. By this process we can transport work in
progress from one place to other at fixed distance by means of Mechanical
Energy.
This material handling system does not need any electricity or other
power sources for its operation. It solely performs due to the weight of the
product/material and spring for forward and backward motion of the pallet
carrier. It may be very effective in organizations where there is large amount
of material handling systems and so much money is spent on material trans-
portation with conventional material handling systems.
1
1.1 Problem Statement
In general all industry has time is main factor so if it proper consumes any
condition it help to the increase the overall efficiency industry so in industry
overall production only 20 percent time is only for actual working on that
ob ject and remaining time is spend in transportation of material from one
station to another work station. So the any how we can proper consume the
time of production it help to overall output of that company.
So to minimizing the drawback of this we can used the various

transportation device .in our pro ject we are used automatic pallet carrier
are used for transportation of object in that pro ject we can used input is self-
weight of the object which is to be place on that pallet carrier and due to
the gravity it works automatically without any human interfere.
1.2 Ob jectives
[ 1 ]To achieve a travel up to 8.5 meter due to weight (gravitational force).
[ 2 ]To give definite path to the pallet carrier by means of using guide ways.
[ 3 ]Auto stop mechanism after travelling particular distance by using

stoppers in guide ways.
[ 4 ]To increase travelling distance by increasing gear ratio.
[ 5 ]To Design Pallet carrier for Weight carrying capacity of about 35
kg. [ 6 ]Pallet carrier requires less space compare with other conveyors.
[ 7 ]Use the Pallet carrier wherever the space limitations.
[ 8 ]Noiseless and smooth in operation.
1.3 Scope
Automatic pallet carrier has a large scope in the field of material handling
system as it does not need electricity or other power sources for its operation.
As other material handling systems are costlier and need power source like
electricity to run, the overall cost of material handling system becomes
uneco- nomical and failure of power source may halt the material
transportation viz. from store department to workstations, from one work
station to the other etc. And this is where the automatic pallet carrier
comes into effect as its operation is solely based on the weight of the
product/material and does not require any power source to run. It may be
very effective in organizations where there is large amount of material
handling systems and so much money
2
is spent on material transportation with conventional material handling sys-
tems.
1.4 Methodology
The working principle of this pro ject is “Propulsion of pallet carrier using
self weight of the object.
The weight w is kept on lever. Due to which the upper shaft gets
rotated due to weight. The shaft is keyed with gear which is meshing with
other gear. By increasing gear ratio power is transmitted to wheel.
Wheel rotate up to 8.5m in a length. When lever goes at final position,

weight is removed and the weight gets displaced from one place to
another place. The tension spring is attached on lever. As soon as the
weight is removed the lever moves to initial position due to which
conveyor comes back to initial position. When lever goes down due to
weight the energy stored in tension spring. The energy is used to return the
pallet carrier to its original position.
3
Chapter 2
LITERATURE REVIEW
The Current State And Future Trends In The Use Of Pallets In

Distribution Systems By Javad MokhlesiSaman Lohrasebi (University Of
Bors School Of Engineeringse-50190borstelephone +46 033 435 4640)
The main idea behind developing such a research is to demonstrate the

situation of pallet utilization in industries and related affecting factors. Pallet
plays a very important role in Logistics chains or Distribution systems. Re-
gardless of the application purposes of pallets there are a lot of other factors
in pallet usage that draw a great attention for the users and also producers
of pallet. These factors can be considered from so many different aspects.
Pallet is a part of a cargo carrier concept. This concept is broadly taken into
account since individual transportation and handling of materials is costly.
It can also reduce the speed of handling process to a very low level. It also
decreases the efficiency of the desired logistics chain. To overcome the
stated obstacles creating a desired large unit configuration is of interest.
When it comes to larger scales then mechanical handling becomes vital.
One of the most important aspects that brought a lot of heat on pallet
industries in the recent years is Environmental issues along with the strict
associated policies and regulations. Due to the limited number of natural
resources for instance Forrest and water there have been a lot of debate
around roles and regulations regarding resource conservation and so forth.
These factors directly or indirectly affect the pallet utilization in any

kinds of business sectors which leads this industry to a new futuristic trends
and changes. These trends can be classified in many different ways and from
several points of views. Many experts believe that, these likely changes
and trends have been started quite a while ago and they are just in the
process of evolving for the predicted needs of the future.
Some of the argued trends are about the recycling, repairing and re-
using of pallets. As mentioned earlier these facts demonstrate the importance
of the pallet in distribution systems and related industries. Such characteris-
tics of this device talk for the other dimensions of importance. This attitude is
4
widely discussed in this report and will be explained in details in the provided
chapters. This thesis report is mostly around the current situation of pallets
and the used raw materials for producing them also create guideline for pos-
sible future trends and changes both in structure, design and used materials.
S. Mahendran, K.M.Eazhil ,L.Senthil Kumar-On General Spur Gear
The gear stress analysis, the transmission errors, and the prediction of
gear dynamic loads, gear noise, and the optimal design for gear sets are always
ma jor concerns in gear design. The polymer gear wear rate will be increased,
when the load reaches a critical value for a specific geometry. The gear
surface will wear slowly with a low specific wear rate if the gear is loaded
below the critical one. The possible reason of the sudden increase in wear
rate is due to the gear operating temperature reaching the material melting
point under the critical load condition. Actual gear performance was found
to be entirely dependent on load. A sudden transition to high wear rates was
noted as the transmitted torque was increased to a critical value. This is to
be associated with the gear surface temperature of the material reaching its
melting point. That is for a given geometry of actual gear, a critical torque
can be decided from its surface temperature calculation. [K. Mao, 2006].
The detailed analysis of the flash temperature for polymer general gears
and the heat partition between gear teeth problem is treated as an unsteady
one where the intensity distribution and velocity of heat source changes as
meshing proceeds. A numerical approximation is adopted using finite differ-
ent method and the results are shown to be close to those found using semi-
analytical method assuming no internal hysteresis and the material properties
are constant. steady approximation that is for mean flash temperature esti-
mation. A numerical method has been developed in the current paper for
polymer general gear flash temperature prediction. [K. Mao, 2007] Load car-
rying capacity and occurring damages of gears which are made of PC/ABS
blends were investigated. PC is hard material and ABS is soft material. The
usage of materials limits these drawbacks. However PC and ABS polymers
combine each other, the PC/ABS blends have suitable mechanical proper-
ties for gear applications in the industrial areas. In this study, usability of
PC/ABS general plastic materials as spur gear was investigated. PC/ABS
gears were tested by applying three different loading at two different
numbers of revolutions on the FZG experiment set. [R. Yakut, 2009]
Pandiyara jan.R, Starvin.M.S, Ganesh.K.C (2011)[Singh, 3(7): July,

2014] ISSN: 2277-9655 Scientific Journal Impact Factor: 3.449(ISRA),
Impact Fac- tor: 1.852
5
There are some papers which have been studied and referred on my
work. A bearing may have to sustain severe static as well as cyclic loads
while serving reliably in difficult environments. An angular contact thrust
ball bearing better supports combined loads (loading in both the radial and
axial directions). The larger the contact angle, the higher the axial load sup-
ported, but the lower the radial load. It can take greater thrust load than
maximum capacity of the ball bearing from only one direction.
There are lots of researches developed to study the contact mechanics

problems due to its nonlinear properties. This analysis used to study the
failure behavior at the contact zone and improving the contact behavior to
increase its service life. Basically the study starts with the components
failures static contact also to simplify the Hertzian contact problems the
frictional effects in the analysis are not considered. The commercial
numerical analysis packages like ANSYS, Abacus, etc. are strongly proven
its ability to predict the failure of component and the results can be
justified through relevant experimental or mathematical models. The failure
initiation, maximum load carrying capacity, life of components can be
approximately predicted. Espe- cially fatigue analysis to predict the
minimum service life on bearing is carried out by various researchers and the
load carrying capacity and corresponding service life are the important area
of research to understand.
EL HAD Khalid1,2, HACHIM Abdelilah1,2, EL AMRI Abdelhamid1, ABOUE-

LAZ Ahmed3, EL GHORBA Mohamed1, Analytical Approach and Mechani-
cal Estimate of Vibration Behavior in Presence Of Ball Bearings, Research In-
venty: International Journal of Engineering And Science, Vol.4, Issue 7 (July
2014), PP 65-76, Issn (e): 2278-4721, Issn (p):2319-6483, www.researchinventy.com
Whether for industrial, transportation or complex systems, ball bearing

are considered as ma jor factor in kinematics rotating systems. Apart from
their strategic role in the drive assemblies, these mechanical components can
require an increased rate of reliability.Bearings turbines and rotating
machines are primordial in most mechanical components which contribute
directly to the performance of automotive and aerospace engines through
reliability. Due to their role as liaison between fixed and moving parts, any
failure could have catastrophic consequences such as loss of engine use. This
research is aimed to develop the analytical fundamentals details of new
model which is dedicated to the dynamic behavior of rotating ball bearings.
Theoretical research will be detailed enough to provide a simple model that
lends easily to programming, but powerful enough to incorporate the effect
of a maximum of influential parameters on the vibration of bearings. The
essence of this work is to present an analytical model of a specific type
single of row effect balls (SKF 6004). This study is a first step dedicated
to define the geometric characteristics, and in second time to determine the
equations governing the distribution of
6
responsibilities within the ball bearing.
Even if the geometry of a ball bearing is perfect, it will still produce

vibrations. The vibrations are caused by the rotation of a finite number of
loaded rolling contacts between the balls and the guiding rings. Because these
contacts are elastic, the bearing stiffness becomes explicitly dependent on
time.In general, a time varying stiffness causes vibrations, even in the
absence of external loads. Since the stiffness can be regarded as a system
parameter, the variable stiffness leads to a so-called parametric excitation.
It is one of the ma jor sources of vibration in ball bearings. The first
systematic research on this sub ject was conducted by (Perret, 1950) and
(Meldau, 1951).
(Dowson and Higginson, 1977) have proposed the first analytical solu-
tions to EHD in case of cylinder/plane contact. Then, in the middle of 1970s,
digital solutions contact ellipsoid/ maps have been proposed by (Hamrock
and Dowson, 1977). Thus, using these procedures, we can go back to the
thicknesses of lubricant in contact and we can realize that these thicknesses
vary between a few nanometers.From the viewpoint of contact fatigue in
the presence of indentation, (Wang and al., 2007) exhibit a work based on
the introduction of a ceramic rolling element (Si3N4) from the rolling ones
in steel. This study demonstrates a smoothing effect created by the passage
of ceramic rolling element which generates strong plastic deformation of
bead. This smoothing effect makes it possible to reduce the height of
beads and, at the same time, local overpressure. This suggests that the
addition of ceramic allows increasing number of cycles to chipping
adjacent indents. In addition, the work presented by (Jacq, 2001) shows
a smaller effect of the load on damage by chipping in vicinity of the with
respect to sliding.(Cheng,
1997) present a model including contact fatigue crack initiation in slip bands
formed in the grains of the material. The slip bands are modeled by two
stacks of dislocations of opposite signs, of which the length is equal to that of
the grains. Accumulation of dislocations occurs during the cyclic loads due
to irreversibility of dislocations movement. This type of analytical study is
actually based on the work of (Tanaka and Mura, 1981), together with its
collaborators studied crack initiation in a crystalline material sub jected to
cyclic loading.Moreover, the modeling of the propagation of cracks in contact
fatigue was studied by many other authors.
Niranjan Singh, on helical tension spring, International Journal of Ad-

vanced Engineering Research and Studies E-ISSN22498974
A few papers where discussed about the different types of mechani-

cal springs used in the suspension system of automobiles. Also the different
modes of spring failure and modifications were developed and validating the
procedures for predicting the fatigue stress analysis. James M. Meagher et
7
al. (1996) the author presented the theoretical model for predicting stress
from bending agreed with the stiffness and finite element model within the
precision of convergence for the finite element analysis.
CONCLUSION: The literature review discussed above depicts that the

design of mechanical springs used in automobiles is quite necessary to do
its deign analysis which involves stress distribution analysis, maximum dis-
placement and different mode of failure. The springs undergo the fluctuating
loading over the whole span of service life. In addition, various Design soft-
wares like ANSYS, Solid Works, Pro-E, CATIA, Autodesk Inventor, etc.,
have been used for performing the stress analysis of mechanical springs.
Almost in all of the above cases, fatigue stress, shear stress, maximum
displacement calculation, play significant role in the design of mechanical
springs. This study shows that shear stress and deflection equation is used
for calculating the number of active turns and mean diameter in helical
compression springs. Comparison of the theoretical results obtained by the
shear stress equation and Finite Element Analysis (FEM) of springs provides
the better solution of the problems arises in the existing design of the
mechanical spring. In future, it will help the designers for predicting the safe
design of mechanical springs used in the automobiles to get better and
comfortable ride.
YogeshMaha jan, A. Y. Vyavahare, D. RPeshwe, on Failure Analysis

of Tension Spring, International Journal of Engineering Research
Technology (IJERT) ISSN: 2278-0181 Vol. 3 Issue 5, May 2014
A spring is an elastic ob ject and performs many functions. The basic

function of a spring is to store mechanical energy, as it is elastically deformed,
and then recover this energy, at a later time as the spring recoils [1]. There
are various types of springs such as Leaf springs, Coil springs, etc and has dif-
ferent applications in different areas. Among various types of springs, helical
tension springs are designed to absorb and store energy as well as create a
resistance to a pulling force [2]. These are metal wire coiled around in loops.
In the manufacturing process, an initial tension is incorporated to pull the
coils tight against each other. It is initial tension that determines how
tightly together a tension spring is coiled. This initial tension can be
manipulated to achieve the load requirements of a particular application.
The initial tension is equal to the minimum force required to separate
adjacent coils. Small springs can be wound from pre-hardened stock, while
larger ones are made from annealed steel and hardened after fabrication.
There are varieties of ends that can be put on tension springs. It may
include threaded inserts, reduced and expanded eyes on the side or in the
centre of the spring, extended loops, hooks or eyes at varying positions or
distances from the body of the spring. These ends are very critical and
generally made
8
with standard tools in one operation. As the space occupied by the machine
loop is shortened, the transition radius is reduced and an appreciable stress
concentration occurs. This contributes greatly to shortened spring life and
premature failure. Often the spring is one of the last parts designed in an
assembly. This means there is often limited geometry and high expectations
of part life [3]. Most tension spring failures occur at the hook as the design
of the end hook impacts the stress concentration. Fig.1 indicates the part of
tension spring and spring design. Often stresses are higher in the spring ends
than in the spring body. Hook stresses can be reduced by using forming
radii, not to exceed one-half the I.D. and by reducing the end coil diameter
relative to the body coils. The hook stress in torsion should not exceed 40-45
percent of tensile strength, while hook stress in bending should not exceed 75
percent of tensile strength. Earlier failure analysis reports indicated the
criticality of the hook design. A typical raw material defect is the
existence of a foreign material inside the steel, such as non-metallic
inclusions [4]. Surface defects, tool marks and other stress concentrations
were found to be the main source of the failure of springs. In the present
studies, detailed metallurgical inves- tigations carried out on the fractured
spring samples, which included visual examination, optical microscopy and
scanning electron microscopy. Fracture characteristics of a tension spring
are obtained by the observations and the reasons why the tension springs
fracture are concluded.
Conclusions:(1) From the above observations we can conclude that the

presence of surface irregularities and presence of inclusions are the potential
sites for the crack initiation and subsequent failure. (2) It is a shear type of
failure originated in the bending region where tensile stress generated
exceeds the fractured strength of material. (3) Spring fails from a location
of maximum bending stress which may have subsequently exceeded the
fractured strength of material during assembly. Following precautions can
minimize the chances of premature failure- 1. Stress reliving operations will
minimize the failure. 2. Increasing stress reliving time will help in reducing
the stress level and subsequent failure. 3. The elimination of above crack
pone sites leads decrease in the failure in future. 4. Reducing surface
irregularities will decrease the chances of failures.
Ra jeev Ranjan, Parametric Optimization of Shielded Metal Arc Welding

Processes by Using Factorial Design Approach, International Journal of Sci-
entific and Research Publications, Volume 4, Issue 9, September 2014, ISSN
2250-3153.
Abstract:The Shielded Metal Arc Welding (SMAW) process is an arc

welding process which produces coalescence of metal by heating them with
an arc between a covered metal electrode and the work. Shielding is
obtained from decomposition of the electrode covering. Pressure is not
used. Filler metal
9
is obtained from the electrode. The prediction of the optimal weld deposit
area is an important aspect in shielded metal arc welding (SMAW) process
as it is related to the strength of the weld. The goal of this research work
is to optimize various parameters for Shielded Metal Arc Welding process,
including welding voltage, welding current and welding speed by developing a
mathematical model for sound weld deposit area of a mild steel specimen. Fac-
torial design approach has been applied for finding the relationship between
the various process parameters and weld deposit area. The study revealed
that the weld deposit area varies directly with welding voltage and welding
current and inverse relationship is found between welding speeds with
weld deposit area.
Welding is a process of joining different materials. It is more economical

and is a much faster process compared to both casting and riveting [1]. The
weld deposition area is the maximum area of the weld metal deposited. It
in- fluences the flux consumption rate and chemistry of the weld metal and
hence determines the mechanical properties of the weld [2]. SMAW input
process parameters like welding current, welding speed; open circuit voltage
and external magnetic field are highly influencing the quality of weld
joints. [3]. A precise means of selection of the process variables and control
of weld bead shape has become essential because mechanical strength of weld
is influenced not only by the composition of the metal, but also by the weld
bead shape. The weld bead width is an important factor of the shape of
the weld. The weld quality can be achieved by meeting quality requirements
such as bead geometry which is highly influenced by various process
parameters involved in the process. Inadequate weld bead dimensions will
contribute to failure of the welded structure [4]. Among all the welding
processes, SMAW is very important. The advantages of this method are
that it is the simplest of the all arc welding processes. The equipment is
often small in size and can be easily shifted from one place to the other.
Cost of the equipment is very less. This process finds a number of
applications because of the availability of a wide variety of electrodes which
makes it possible to weld a number of metals and their alloys.
The welding of the joints may be carried out in any position with
highest weld quality and therefore the joints which are difficult to be welded
because of their position by automatic welding machines can be easily welded
by shielded metal arc welding. Both alternating and direct current power
sources could be used effectively. Power sources for this type of welding
could be plugged into domestic single phase electric supply, which makes it
popular with fab- rications of smaller sizes [5]. However, non equilibrium
heating and cooling of the weld pool can produce micro-structural changes
which may greatly affect mechanical properties of weld metal. To get
the desired weld quality in SMAW process, it is essential to know
interrelationships between process parameters and bead geometry as a
welding quality. Many efforts have been
10
done to develop the analytical and numerical models to study these relation-
ships, but it was not an easy task because there were some unknown,
nonlinear process parameters. For this reason, it is good for solving this
problem by the experimental models. These results showed that arc
current has the great- est influence on bead geometry, and that
mathematical models derived from experimental results can be used to
predict bead width accurately. Nearly
90 percent of welding in world is carried out by one or the other arc welding
process; therefore it is imperative to discuss the effects of welding
parameters on the weldability of the materials during the arc welding.
Mild steel was selected for work-pieces to be welded because it is the most
common form of steel as its price is relatively low while it provides material
properties which are acceptable for many applications.
For this research work, after conducting the related literature survey
we found that among the most important parameters were welding voltage,
welding current, and welding speed. So these three variables were used as
treatment variables for the model.
CONCLUSIONS:Based on the experimental work and the Factorial

design approach the following conclusions are drawn:
1. A strong joint of mild steel is found to be produced in this work by using

the SMAW technique.
2. Results indicate that processes variables influence the weld deposition

area to a significant extent.
3. If amperage is increased, welding deposition area generally increases.
4. If voltage of the arc is increased, welding deposition area generally in-

creases.
5. Welding voltage was found to be most influencing variable to WDA.
6. If travel speed is increased welding deposition area generally decreases.
7. The two level fractional half area fractional designs is found to be very
effective tool for quantifying to main and interaction effects of variable
on weld bead area.
R. A. Gujar1, S. V. Bhaskar2, Shaft Design under Fatigue Loading By

Using Modified Goodman Method, R. A. Gujar, S. V. Bhaskar / Interna-
tional Journal of Engineering Research and Applications (IJERA) ISSN: 2248-
9622www.ijera.com Vol. 3, Issue 4, Jul-Aug 2013, pp.1061-1066
In this paper, shaft employed in an Inertia dynamometer rotated at

1000rpm is studied. Considering the system, forces, torque acting on a shaft
11
is used to calculate the stresses induced. Stress analysis also carried out by
using FEA and the results are compared with the calculated values. Shaft
is having varying cross sections due to this stress concentration is occurred
at the stepped, keyways ,shoulders, sharp corners etc. caused fatigue failure
of shaft. So, calculated stress concentration factor from which fatigue stress
concentration factor is calculated. Endurance limit using Modified Goodman
Method, fatigue factor of safety and theoretical number cycles sustained by
the shaft before failure is estimated and compared results with FEA.
A shaft is a rotating member, usually of circular cross-section for trans-

mitting power. It is supported by bearings and supports two flywheels. It is
sub jected to torsion, and bending in combination. Generally shafts are not of
uniform diameter but are stepped, keyways, sharp corners etc. The stress on
the shaft at a particular point varies with rotation of shaft there by introduc-
ing fatigue. Even a perfect component when repeatedly subjected to loads of
sufficient magnitude, will eventually propagate a fatigue crack in some highly
stressed region, normally at the surface, until final fracture occurs.
Extensive work has been carried out by failure analysis research community
investigating the nature of fatigue failures using analytical, FEA and
experimental methods [1]. According to Osgood all machine and structural
designs are problems in fatigue [2]. Failure of an elevator shaft due torsion
bending fatigue was given in [3]. The failure of a shaft due improper
fastening of support was explained in [4]. Accurate stress concentration
factors for shoulder fillet in round and flat bars for different loading
conditions are given in [5]. Failure analysis of a locomotive turbocharger
main-shaft and rear axle of an automobile was discussed in [6,7]. Celalettin
Karaagac and M.Evren Toygar considered an agitator shaft with a
circumferential groove forwhich the fatigue life has been estimated [8].
Michele Zappalorto, FilippoBerto and Paolo Lazzarin predicted the notch
stress concentration factors of round bars under torsion.
Emmanuel Adeleke Fagbemi1, *, Agbolahan Okeeseni2, Baldwin Omonigho2,

Ebike Iseru3, Teddy Akpovwovwo3, Emmanuel Kayode Awolola4 literature
review on shaft.
Mechanical Shaft (A drive shaft, driven shaft, driving shaft, propeller

shaft (prop shaft), or Cardan shaft) is a mechanical component used in agri-
cultural machineries for transmitting torque and rotation, usually used to
connect other components of a drive train that cannot be connected directly
because of distance or the need to allow for relative movement between
them [2,5]. A shaft is a rotating or stationary component which is normally
circular in section and designed to transfer torque from a driving device to
a driven device [5]. If the shaft is rotating, it is generally transferring
power and if the shaft is operating without rotary motion it is simply
transmitting torque and is probably resisting the transfer of power or relative
movement between
12
them. Drive shafts are carriers of torque: they are sub ject to torsion and
shear stress, equivalent to the difference between the input torque and the
load. They must therefore be strong enough to bear the stress, whilst avoid-
ing too much additional weight as that would in turn increase their inertia
[1,
2]. To allow for variations in the alignment and distance between the driv-
ing and driven components, drive shafts frequently incorporate one or more
universal joints, jaw couplings, or rag joints, and sometimes a splined joint
or prismatic joint. Shafts are sub ject to combined loading including torque
(shear loading), bending (tensile compressive loading), direct shear loading,
tensile loading and compressive loading. Therefore, the design of a shaft must
include consideration of the combined effect of all these forms of loading. The
design of shafts must include an assessment of increased torque when start-
ing up, inertial loads, fatigue loading and unstable loading when the shaft is
rotating at critical speeds.
Conclusion:In developing countries today, machines and equipment are

designed and fabricated locally for processing agricultural products and
manufacturing purposes, such machineries or equipment to mention but
view are; Oil Expeller, Seed Sheller, Dehulling Machines, and Hammer Mill.
All these machines and equipment has shaft as ma jor component to
transmit power, torque and accommodate members like gear, bearing and
pulley. Types and area of applications of different shafts has been explained in
this paper to help engineers in designing an efficient machines or equipment
and as well increases life span of these equipment.
P.A. Ioannou, H. Jula, C.-I. Liu, K. Vukadinovic and H.

Pourmohammadi University of Southern California research paper on
Advanced Material Han- dling: Automated Guided Vehicles
An automated guided vehicle (AGV) is a vehicle that is driven by an

automatic control system that serves the role of the driver. Sensors on the
road or infrastructure and onboard the vehicle provide measurements about
the location and speed of the vehicle which are used by the automatic control
system to generate the appropriate commands for the throttle/brake
actuators in order to follow certain position and speed tra jectories. AGVs
are considered to be the most flexible type of material handling system.
Their size ranges from small load carriers of a few kilograms to over 125-ton
transporters. The vehicles working environment ranges from small offices
with carpet floor to huge harbor dockside areas [43]. The AGV system
consists of the vehicle, onboard controller, management system,
communication system, and navigation system.
The onboard controller is responsible for initiating start-up and shut-

down procedures. It manages the propulsion, steering, braking, and other
13
functions of the vehicle. It also monitors and detects any error and issues the
necessary commands for error correction. The management system deals with
planning, scheduling, and traffic control. It is responsible for optimizing the
vehicle utilization, giving transport orders such as dispatching and routing,
and tracking the material in the manufacturing environment.
AGVs have been in use since the 1950’s. A U.S. company, the Cravens
Company at Mercury Motor Express in Columbia, S.C., installed the first
AGV in 1954. However, the use of AGVs did not take off in the U.S. By the
early 80’s, the entire investment by U.S. firms in AGVs was less than 70 Mil-
lion. Meanwhile, several European companies grabbed hold of the idea and
rapidly evolved it [2]. In 1986, the California Department of
Transportation (Caltrans) initiated a large program at PATH (Partners for
Advanced Tran- sit and Highways) to support research in automated
vehicles and automated highways [51]. The activities at PATH were later
increased to nationwide programs on automated highway systems supported
by the Federal Highway Administration. A demonstration that took place on
I-15 north of San Diego in August of 1997 involved platoons of fully
automated vehicles guided at speeds of 65 mph and at distances a few
meters from each other [51]. Similar demonstrations took place in Europe
and Japan. Currently PATH and Cal- trans are planning Demo 2002 where
full automation of trucks on a highway will be demonstrated. The research
on vehicle and highway automation led to the development and testing of a
wide range of sensor technologies. These include embedded magnetic nails in
the middle of the lane to provide a reference as to the location of the vehicle
relative to the lane by sensing the magnetic field of the nails using
magnetometers on board of the vehicle. Low cost radar sensors are developed
for providing measurements of relative speed and distance between the
vehicle and any obstacle or other vehicle ahead. Similarly, vehicle-to-vehicle
communications and Differential GPS (DGPS) systems have also been tested
successfully as sensors for providing the appropriate measurements for the
automatic guidance of the vehicle at high speeds and with great accuracy
[51], [55].
In container terminals, AGVs could be used to replace the manually

driven trucks that transport containers within the terminal. In this appli-
cation, AGVs are automated industrial trucks, which could be powered by
electric motors and batteries or by the conventional diesel engine. Modern
AGVs can be equipped with robot arms and grippers and perform robotic
handling functions. AGVs could also be used as storage machines equipped
with forks, handling loads in storage racks up to 10 meters in height or more.
While the automation of vehicles and trucks on highways does not have
strong support of manufacturers due to liability issues and the complexity of
the environment in which they have to operate, the use of automated
trucks at low speeds in a restricted environment such as a terminal is a
completely
14
different story. The low speed characteristics of AGVs together with the re-
stricted area they have to operate in makes the overall problem much simpler
to solve. Therefore, the use of AGVs as container handling devices in termi-
nals is feasible from the point of view of technology and has a strong potential
to improve efficiency and reduce labor cost.
Suman Kumar Das, M.K. Pasan (Department Of Mechanical Engineering,

NIT Jamshedpur, INDIA) 2(Professor, Department Of Mechanical Engineer-
ing, NIT Jamshedpur, INDIA
INTRODUCTION:-0
Material handling is defined by MHIA (MATERIAL HANDLING IN-
STITUE OF AMERICA) as The movement, storage, protection and control
of material throughout the manufacturing and distribution process includ-
ing their consumption and disposal. Effective material handling is the most
important part of manufacturing and distribution operation without it final
product cannot turn into profit. The handling of material must be performed
safely, efficiently, at low cost in timely manner, accurately without damage
to the material. The cost of material handling is a significant portion of total
production cost estimating average around 20-25 percent of total
manufacturing cost, so direct cost of material handling cannot be measured.
The main factor attributing the material handling cost is wasted time. The
second ma jor cost added to material handling is labour cost. In addition
increasing labour and time compensation costs make material handling
alternative more desirable. The purpose of this paper is to inform the reader
about alternative material handling solution that include different type of
AGV and autonomous mobile robot with different application of colored
tape type AGV. An Automated guided vehicle is a programmable mobile
vehicle used in industrial application to move materials around a
manufacturing unit. The first AGV developed by A.M.Barnet (1953) who
used overhead wire to navigate the vehicle in gro- cery shop. The use of
AGV has grown enormously since their introduction, the number of area of
application and variation type has increased signifi- cantly. Recently AGV
extended their popularity to other application. Depak punithe (IJRAS
august 2013) developed an AGV to betterment public health care system.
AGV can used as serving robot in hotel, material handling robot in
warehouse and improve the health care system. At manufacturing area
AGV are capable to transport all type of material related to manufacturing
process. According to Gotte (2000)[5] the usage of AGV will pay off for man-
ufacturing environment (like distribution ,transportation, and transshipment
) with repeating transpiration pattern. He described different available
technology for automation in container terminal.
CONCLUSION:-
There are several possible directions for further research. We can im-
proved the guided tape type AGV utilizing better navigation technique. It
15
can be adopted any environment and cheap among autonomous robot. There
is significant amount of difference between theoretical and practical work
cy- cle value of time which can be optimized by adopting different
methodology. In addition, one could think of a relaxation of the token-
holding requirement in the traffic control scheme so that multiple vehicles
can leave different at- crossing zones simultaneously, and hence the
performance of the AGV system can be improved.
Michael G. Kay Fitts Dept. Of Industrial And Systems Engineering North
Carolina State University
Design of MH Systems:-
A common approach to the design of MH systems (MHSs) is to consider
MH as a cost to be minimized. This approach may be the most appropriate
in many situations because, while MH can add real value to a product, it
is usually difficult to identify and quantify the benefits associated with MH;
it is much easier to identify and quantify the costs of MH (e.g., the cost of
MH equipment, the cost of indirect MH labor, etc.). Once the design of a
production process (exclusive of MH considerations) is completed, alternate
MHS designs are generated, each of which satisfies the MH requirements of
the production process. The least cost MHS design is then selected.
The appropriateness of the use of MHS cost as the sole criterion to se-
lect a MHS design depends on the degree to which the other aspects of the
production process are able to be changed. If a completely new facility and
production process is being designed, then the total cost of production is the
most appropriate criterion to use in selecting a MHSthe lowest cost MHS may
not result in the lowest total cost of production. If it is too costly to even
consider changing the basic layout of a facility and the production process,
then MHS cost is the only criterion that need be considered. In practice, it is
difficult to consider all of the components of total production cost simultane-
ously, even if a new facility and production process is being designed. Aspects
of the design that have the largest impact on total cost are at some point
fixed and become constraints with respect to the remaining aspects of the
design.
16
Chapter 3
CONVENTIONAL MATERIAL
HANDLING SYSTEMS
3.1 Types Of Conveyors

Gravity or powered devices commonly used for moving uniform loads,
continuously from point-to-point over fixed paths, where the primary func-
tion is conveying, Conveyor is a material handling devices used for moving
material over a fixed path in factory. The advantages of conveyor are that it
generally moves the material without the use of labor.
3.1.1 Belt Conveyor

Belt conveyors are substituted for roller conveyors when the parts are
smal- lAnd are required to be transferred separately, from one station to
another. For handling bulk material such as iron ore, Coal, Sand, Gravel,
Bauxite etc. Belt conveyors are economical in operation in operation and
longer life.
17
Figure 3.1: belt Conveyor
3.1.2 Screw Conveyor

Screw Conveyors for handling Grain, Wood chips etc. Ranging from 5 TPH
to 50 TPH capacity and 100mm to 500mm screw diameter range. Screw
conveyors are available in different material of construction to suit
conveyors are available in different material requirement. We have supplied
screw conveyors for industrial like chemical, Food, Starch etc. We offer
you trouble free, advance designed screw conveyors. It can operate
horizontal, vertical and in- clined direction.
It is not used for material which gets damaged by crushing. It is

suitable for transmitting material like paste or powder.
Figure 3.2: Screw Conveyor
18
3.1.3 Roller Conveyor
Roller conveyor may be gravity aided or powered and employed for trans-
porting products having flat bottom. Bigger jobs can be handled as they are,
whereas small items are put in boxes, tins or pallets before being transferred.
Roller conveyors can move the material along straight or curved paths. Grav-
ity type conveyors should be preferred as compared to line conveyors
wherever practical.
All types of roller conveyors for handling hard board, Fruit Boxes,
Mould box etc. Roller Conveyors is general transport conveyor with the ca-
pabilities of minimum back pressure of accumulating products quite operation,
versatile design, are standard feature of our roller conveyors.
Figure 3.3: Roller conveyor
19
3.1.4 Live Roller Conveyor
It is typically used in general transport when product accumulation is not
required. It is also used in package handling applications and is ideal for light-
to medium-product loads.
Figure 3.4: Live Roller Conveyor
3.1.5 Minimum Pressure Conveyor

It is used in short sections of accumulation, general transport of product,
and is ideal for medium to light loads such as package handling applications.
20
Figure 3.5: Minimum Pressure Conveyor
21
3.1.6 Zero Pressure Conveyor
It is commonly found in distribution centers where there is a wide variety
of product width and weight. Applications include buffering of product prior
to sortation, packaging, kitting, or shipping areas. It is also ideal for
picking areas and palletizing areas. This conveyor is used in high throughput
systems.
Figure 3.6: Zero Pressure Conveyor
3.1.7 Pallet Conveyor

• Drag Chain-
It is typically used for handling extremely heavy loads, special pallet
configurations, and extremely low- to high-temperature areas.
• Roller-
Roller pallet conveyor is typically used for handling extremely heavy
loads and is ideal for accumulation zones in pack out areas.
22
3.1.8 Overhead Conveyor
It is typically used in paint and finishing lines, trash removal, food
packing, and assembly lines. These are some of the oldest conveyors still
used in the industry today because they are very reliable and require little
maintenance.
3.1.9 Table Top Chain

It is used in accumulation, package handling, filling, labeling, and wash-
down applications.
3.1.10 Magnetic Slide Conveyor

is used in metal stamping, chip removal, and small part transport applica-
tion.
There are many types of material handling technologies out there, but
no matter what automation system you install, there will more than likely
be conveyor to support the efforts. Do your due diligence or consult with
an industry expert to ensure youre choosing the right conveyor typefor
your application. By selecting the right conveyors, youll ensure your entire
manufacturing or distribution facility runs at peak performance.
23
Chapter 4
TERMINOLOGY OF GEARS
4.1 Introduction To Our Engineering Design Process

Gears are machine elements used to transmit rotary motion between
two shafts, normally with a constant ratio. The pinion is the smallest gear
and the larger gear is called the gear wheel.A rack is a rectangular prism with
gear teeth machined along one side- it is in effect a gear wheel with an infinite
pitch circle diameter. In practice the action of gears in transmitting motion is
a cam action each pair of mating teeth acting as cams.Gear design has evolved
to such a level that throughout the motion of each contacting pair of teeth
the velocity ratio of the gears is maintained fixed and the velocity ratio is
still fixed as each subsequent pair of teeth come into contact. When the
teeth action is such that the driving tooth moving at constant angular
velocity produces a proportional constant velocity of the driven tooth the
action is termed a conjugate action.
The teeth shape universally selected for the gear teeth is the involute
profile. Consider one end of a piece of string is fastened to the OD of one
cylinder and the other end of the string is fastened to the OD of another
cylinder parallel to the first and both cylinders are rotated in the opposite
directions to tension the string(see figure below). The point on the
string midway between the cylinders P is marked.
As the left hand cylinder rotates CCW the point moves towards this
cylinder as it wraps on. The point moves away from the right hand
cylinder as the string unwraps. The point traces the involute form of the
gear teeth. The lines normal to the point of contact of the gears always
intersects the center line joining the gear centers at one point called the
pitch point.For each gear the circle passing through the pitch point is
called the pitch circle.The gear ratio is proportional to the diameters of the
two pitch circles.For metric gears (as adopted by most of the worlds
nations) the gear proportions are based on the module.
24
Figure 4.1: Involute Form Of Gear Tooth
25
m = (Pitch Circle Diameter (mm)) / (Number of teeth on gear).
In the USA the module is not used and instead the Diametric Pitch dpis
used.
d p = (Number of Teeth) / Diametrical Pitch (inches)
Figure 4.2: 20o full Depth Involute system
Profile of a standard 1mm module gear teeth for a gear with Infinite
radius (Rack ). Other module teeth profiles are directly proportion.
e.g. 2mm module teeth are 2 x this profile.
Many gears trains are very low power applications with an ob ject of
transmitting motion with minimum torque e.g. watch and clock mechanisms,
instruments, toys, music boxes etc. These applications do not require
detailed strength calculations.
26
Figure 4.3: Meshing Of Spur Gear
27
4.2 Gears
We have discussed earlier that the slipping of gear is a common
phenomenon in the transmission of motion or power between two shafts. The
effect of gear is to reduce the velocity ratio of the system. In precision
machines. In which a definite velocity ratio is of important (as in watch
mechanism) the only pos- itive drive is by gears is by or toothed wheels. A
gear drive is also provided when the distance between the driver and the
follower is very small.
4.2.1 Design consideration of the gear driver:-

• The power is transmitted.
• The speed of the driving gear.
• The speed of the driven gear or velocity ratio.
• The center distance.
4.2.2 The following requirement must be met in the design of

a gear drive:-
• The gear tooth should have sufficient strength so that they will not fail
under static loading or dynamic loading during normal running condition.
• The gear tooth should have wear characteristics so that their life is sat-
isfactory.
• The use of space and material should be economical.
• The alignment of the gears and deflections of the shaft must be

considered because they effect on the performance of the gears.
28
Chapter 5
RESEARCH DEVELOPMENT
5.1 Drawing, Fabrication, Working
Figure 5.1: 3D view Automatic pallet Carrier
29
Figure 5.2: Gear Arrangement Of Automatic pallet Carrier
5.2 Process Involved

The fabrication process starts from dimensioning the raw material until
finished desired product is obtained. The processes that are involved are:
5.2.1 Design:-
Deciding which components to be used standard and which need to be de-
signed.Design of components like shaft, bearing selection etc.
5.2.2 Drawing:-
Drawing of all the components using CAD software Solid edge thus
creating the Following drawings:
• Part drawings
• Assembly drawing
• Layout of machine
5.2.3 Getting material:-

Getting suitable material of gear, shaft, pallet, bolt etc.
30
Figure 5.3: 2D View of Automatic pallet carrier
31
Figure 5.4: Actual Image Of Automatic pallet carrier
5.2.4 Cutting material:-

The process involves cutting the material of required size using suitable
machine.
5.2.5 Drilling:-
Drilling, tapping processes to accommodate bolts.
5.2.6 Bending process:-

The sheet metal used in hopper arrangement undergoes process bending
using bending machine to get true shape for the pro ject.
32
Chapter 6
DESIGN
6.1 Design
Design consists of application of scientific principles , technical information
and imagination for development of new or improvised machine or mechanism
to perform a specific function with maximum economy and efficiency.
Hence an careful design approach has to be adopted. The total design

work, has been split up into two parts;
• System design
• Mechanical Design
System design mainly concerns the various physical constraints and er-
gonomics, space requirements, arrangement of various components on main
frame at system, man + machine interaction, No. of controls, position of
controls, working environment of machine, chances of failure, safety,
measures to be provided, servicing aids, ease of maintenance, scope of
Improvement, weight of machine from ground level, total weight of machine
and a lot more.
In mechanical design the components are listed down and stored on the
basis of their procurement, design in two categories namely.
• Designed Parts
• Parts to be purchased
For designed parts detached design is done distinctions thus obtained

are compared to next highest dimensions which are readily available in mar-
ket. This amplifies the assembly as well as postproduction servicing work.
The various tolerances on the works are specified. The process charts are
33
prepared and passed on to the manufacturing stage. The parts which are to
be purchased directly are selected from various catalogues specified so that
anybody can purchase the same from the retails shop with given specifica-
tions.[1]
6.2 System Design

In system design we mainly concentrated on the following parameters:-
6.2.1 System Selection Based on Physical Constraints:-

While selecting any machine it must be checked whether it is going to be
used in a large scale industry or a small scale industry. In our case it is to be
used by a small scale industry .So space is a ma jor constrain. The system is
to be very compact so that it can be adjusted to corner of a room.
The mechanical design has direct norms with the system design. Hence
the foremost job is to control the physical parameters, so that the
distinctions obtained after mechanical design can be well fitted into that.
6.2.2 Arrangements of Various Components:-

Keeping into view the space restrictions the components should be laid
such that their easy Removal or servicing is possible. More over every
component should be easily seen none should be hidden. Every possible
space is utilized in components arrangements.
6.2.3 Components of System:-

As already stated the system should be compact enough so that it can be
accommodated at a corner of a room. All the moving parts should be well
closed compact. A compact system design gives a high weighted structure
which is desired Man Machine Interaction.
The friendliness of a machine with the operator that is an important

criteria of design. It is the application of anatomical psychological principles
to solve problems arising from Man Machine relationship. Following are
some of the topics included in this section. Design of foot lever Energy
expenditure in foot hand operation Lighting condition of machine.
34
• Chances of Failure-
The losses incurred by owner in case of any failure are important cri-
teria of design. Factor safety while doing mechanical design is kept high
so that there are less chances of failure. Moreover periodic maintenance
is required to keep unit healthy.
• Height of Machine from Ground-

For ease and comfort of operator the height of machine should be
properly decided so that he may not get tried during operation. The
machine should be slightly higher than the waist level, also enough clear-
ance should be provided from the ground for cleaning purpose.
• Weight of Machine-
The total weight depends upon the selection of material components
as well as the dimension of components. A higher weighted machine is
difficult in Transportation in case of ma jor breakdown; it is difficult
to take it to workshop because of more weight.
6.2.4 Mechanical Design-

Mechanical design phase is very important from the view of designer as
whole success of the pro ject depends on the correct design analysis of the
problem.
Many preliminary alternatives are eliminated during this phase Designer

should have adequate knowledge above physical properties of material, loads
stresses, deformation, and failure. Theories and wear analysis. He should
identify the external and internal force acting on the machine parts.
This force may be classified as:-
1. Dead weigh forces
2. Friction forces
3. Inertia forces
4. Centrifugal forces
5. Forces generated during power transmission etc
Designer should estimate these forces very accurately by using design

equations. If he does not have sufficient information to estimate them he
should make certain practical assumptions based on similar conditions. This
35
will almost satisfy the functional needs. Assumptions must always be on the
safer side.
Selection of factors of safety to find working or design stress is another

important step in design of working dimensions of machine elements. The cor-
rections in the theoretical stress value are to be made according in the kinds
of loads, shape of parts service requirements. Selection of material should be
made according to the condition of loading shapes of products environments
conditions desirable properties of material.
Provision should be made to minimize nearly adopting proper lubrica-

tions methods. In, mechanical design the components are listed down stored
on the basis of their procurement in two categories.
• Design parts
• Parts to be purchased
For design parts a detailed design is done designation thus obtain are
compared to the next highest dimension which is ready available in market.
This simplification the assembly as well as post production service

work. The various tolerances on the work are specified. The processes
charts are prepared passed on to the work are specified.
The parts to be purchased directly are selected from various catalogues

specification so that anybody can purchase the same from retail shop with
the given specifications.
6.3 Fabrication Method

There are few types of fabrication methods that are done on the
machine. They are as follows:
• Arc cutting.
• Welding.
• Drilling.
• Turning.
• Grinding.
36
WELDING:-
It is the process, which is used to join two, is more similar materials as
well as dissimilar materials. This is done by gas welding process.
TURNING:- It is used in this pro ject to make the groove on the

both sides of topcover plate. This is done by conventional lathe.
37
• FURTHER OPREATIONS:-
6.3.1 Cleaning
It is the operation to clean the all machined parts without burrs, dustand
chip formals. By meaning the parts they are brightened and goodlooking.
6.3.2 Assembling
It is the operation, its deals with the assembling of various parts produced
by above operations.
38
Chapter 7
DESIGN OF AUTOMATIC
PALLET CARRIER
7.1 Design Of Welded Joint

Checking the strength of the welded joints for safety,The transverse
fillet weld welds all the angle and the edge, The maximum load which the
weld can carry for transverse fillet weld is
P = 0.707 x S x L x ft
Where,
S = size of weld
L = contact length = 35mm .. ( 10 mm for starting stopping of weld

)
The load of shear along with the friction is 200 kg = 1962N
Hence,
1962 = 0.707 x 5 x 35 x ft
Ft=15.8522 N/mm2
Hence let us find the safe value of ft
Ft=Syt/fos
Ft=210/4
39
Ft=52.5 N/mm2
Since the calculated value of the tensile load is very smaller than
The permissible value as ft=52.5 N/mm2. Hence welded joint is safe.
7.2 Design of shaft

The shaft is sub jected to fluctuating Loads, so shaft is under combined Bend-
ing and Torsion.
Therefore,
The equivalent Twisting Moment.
Te = [(km M) 2 + (kt T) 2]
l/2 equivalent Bending Moment.
= [km * M + (km * m) 2 + (kt * T) 2 l/2]
Where,
Km = Combined Shock and Fatigue factor for
bending. Kt = Combined Shock and Fatigue factor for
torsion.
Nature of load Km Kt
Gradually Applied Load 1.5 1.0
Suddenly applied load with 1.5 to 2.0 1.5 to 2.0
minor shock
Suddenly applied load with 2.0 to 3.0 1.5 to 3.0
Major Shock
Table 7.1: Combined Shock and Fatigue factor for bending and torsion
So we consider the load on gear drive maximum 30kg.
Material 45C8- gray cast iron
Sut=600 N/mm2
Syt=380 N/mm2
G= Modulus of rigidity= 80x103 N/mm2

40
Figure 7.1: Gear and shaft arrangement
41
Km=1.5
Kt=1
ASME CODE
all=0.18x Sut
=0.18x600
= 108 N/mm2
Or
all=0.3syt
all=0.3380
=114 N/mm2
The Smaller allowable shear stress for shaft material is the smaller value from
above two shear stresses.
all=114 N/mm2
Diameter Calculation of gear shaft:-
acting on first shaft = T = F r
= 309.81590
= 173637 N-mm
d=20 mm
Diameter calculation of wheel shaft:-

Calculation of Total torque acting on wheel shaft
Torque on first shaft=T1= Force9.81
=309.81590
=173637 N-mm
42
Figure 7.2: Loading Diagram Of shaft
Figure 7.3: Vertical Bending Moment Diagram
43
=38677.436 N-mm
=8615.353 N-mm
=8615.353/8731.5
T=T4=3119.351 N-mm
Now, to find reaction at both ends RA AND RB
Taking moment about point A
MA=0
13050+130510-RB560=0
RB=130 N
RA+RB=260 N
RA=RB=130 N
To find maximum bending moment, M
MCV=RAV50
=13050
=6500 N-mm
MDV=RDV50
=13050
=6500 N-mm
Maximum Bending Moment=M=6500 N-mm
The equivalent Twisting Moment.
Te = [(km M) 2 + (kt T) 2] l/2
44
Te = [(1.5 6500) 2 + (1 3119.351) 2] l/2
=10236.837 N-mm
Now, To Find diameter of the wheel shaft, d,
d=7.844 mm
Diameter of shaft=d=7.844 mm = 8 mm
Actual diameter of shaft taken= 25 mm
7.3 Design of Spur Gear

While the designing of spur gear first of all we have to determine the
torque on that system.
Thus, power developed by arm on the shaft is calculated as follows-
We know that
= 18.36 watt
Effective load on gear tooth (mt), therefor,

Thus check for Design
Y factor to be calculated by interpolation method

The gear has 127 no. of teeth. So, Lewis form factor to be calculated by
interpolation method.
No of teeth Y
100 0.466
150 0.458
Table 7.2: Lewis form factor
By Interpolation,
Y=0.4515
The tangential component is given by (Pt),
Diametral pitch (Dp),
45
Where, is the pitch line velocity in m/s
Pitch Line Velocity is given by,
For ordinary and commercially cut gears made with cutters and width
(¡10 m/s),
The effective load between two meshing teeth is given
by, Beam Strength (Sb),
Where,
Sb=Beam Strength of gear tooth (N)
=Permissible bending stress (N/mm2)
=Lewis form factor
For gray cast iron FG 200(Sut=20 n/mm2 )
The beam strength is lower than wear strength therefore,
Factor of Safety,
Hence the design is satisfactory the module should be 1.58 mm.
7.4 Selection Of Bearing

As load acting on bearing consist of two components Radial Thrust.
So we have used single row deep groove bearing. This bearing has high
load carrying capacity suitable for high running speed.
Bearing no. Bore dia. D1 Outside Width B C0(KN) C(KN)

(mm) dia.D2 (mm)
(mm)
6302 15 42 13 5.40 11.40
6303 18 47 14 6.55 13.50
6304 22 52 15 7.80 15.90
Table 7.3: dimensions and static and dynamic load capacities of single row deep groove
ball bearings
46
Figure 7.4: Nomenclature of Ball Bearing
47
Since, our principal dimension of internal diameter d is 22 mm we chose
bearing
no.6304
a= 15mm
B = 35 mm
C= 9mm
Principle Di- Basic load Designation

mension rating in N
D1 = 22 C = 15.90 6304
D2 = 52 Co = 7.80
B = 15
Table 7.4: basic load rating for bearing
Where, d = Inner diameter of bearing in mm
D = Outer diameter of bearing in mm
B = Axial width of bearing in mm
C = Dynamic load capacity in N
Co = Static load capacity in N
7.4.1 Advantages of bearing 6304

• Deep groove geometry for high speeds and supporting both radial and
axial loads.
• Chrome steel for durability and resistance to deformity under heavy

loads.
• Metal shields on both sides of the bearing to keep lubricant in and con-
taminants out.
48
• Lubricated at manufacturer for no additional lubrication required.
7.5 Design Of Nut

To minimize friction, material used for nut is weaker than screw
material. So material of nut is cast iron.
Bearing Pressure = 120 Kg/cm —-(PSG 7.87)
= 12 N/mm
Pb=
N= 9.03
= 10
Number of threads in contact with screwed spindle = 10
Thus Height of nut = H = n p = 10 5
= 50 mm
For FG 200 ;
ut = 200 N/mm ( Ultimate tensile strength )
Tensile Stress =t
(For C.I Nut and at Steady load f.o.s. = 5) Page 88 K and G)
considering failure of nut as C/S 1-1
Considering tearing strength of nut.
Considering tearing strength of nut.
W =Π/4(D1 − do)t
W here
49
D1 = outerdiameterof nut
Π/4D1 − 26)40 = 20000
Dt = 36.23mm
Outerdiameterof nut = 36.23mm = 40mm.
Byconsideringcrushingof collarwehave
Π/4(D2 − d1)xf c = load
Π/4(D2 − 40)xf c = 20000
W hereD2 = outerdiameterof collar
uc for FG 200 = 720 N/mm (Bhandari 16)(Ultimate compressive

strength)
Compressive stress =
Π/4(D2 − 40)x144 = 20000
D = 42.15mm Outerdiameterof
collarD2 = 50mm F orf
ittingsetscrewM 7
T husP C D = D1 + 12
= 40 + 12
= 52mm
Considering shearing of collar we have
us =
t1 d1 (fs) = load
t1 * 37 * 23 = 2000
50
t1 = 7.5 mm
Hence thickness of collar = 10 mm.
Checking for shear stress in nut :-

s(act) = W/nd2t
= 20000/* 14 * 50 * 10
= 0.91 N/mm ¡ 23 N/mm
Hence design is very much safe.
Thickness of thread P/2 = 5/2 = 2.5 mm
7.6 Design Of Spring

7.6.1 Types of Springs
Though there are many types of the springs, yet the following,
according to their shape, are important from the sub ject point of view.
• Helical springs:-
The helical springs are made up of a wire coiled in the form of a helix and
is primarily intended for compressive or tensile loads. The cross-section of the
wire from which the spring is made may be circular, square or rectangular.
The two forms of helical springs are compression
• Tension helical spring:-
The helical springs are said to be closely coiled when the spring wire is
coiled so close that the plane containing each turn is nearly at right angles
to the axis of the helix and the wire is subjected to torsion. In other words,
in a closely coiled helical spring, the helix angle is very small, it is usually
less than 10. The ma jor stresses produced in helical springs are shear stresses
due
51
to twisting. The load applied is parallel to or along the axis of the spring.
In open coiled helical springs the spring wire is coiled in such a way
that there is a gap between the two consecutive turns, as a result of which
the helix angle is large. Since the application of open coiled helical springs are
limited, therefore our discussion shall confine to closely coiled helical springs
only.
The helical springs have the following advantages:
1. These are easy to manufacture.
2. These are available in wide range.
3. These are reliable.
4. These have constant spring rate.
5. Their performance can be predicted more accurately.
6. Their characteristics can be varied by changing dimensions.
We have used helical tension spring for returning action. This spring
is attached between tray arm and top edge of the pallet carrier. When the
load is removed from the tray and job is placed at its required place then
the tension spring comes into action. When load is removed at that time the
arm is at lower side after that the tension spring gets contracted i.e.
comes at its original position due to the potential energy stored in the
spring due to weight and the pallet carrier starts to move to its original
position because of contraction of spring.
D = Mean diameter of the spring
coil, d = Diameter of the spring wire,
and C = Spring index = D/d.
Since the spring is to be enclosed in a casing of 25 mm diameter, therefore

the outer diameter of the spring coil (Do = D + d ) should be less than 25
mm.
We know that deflection of the spring We have select diameter of

spring as per space in given below.
D = 28mm
d = 3 mm
52
n=58
53
c= D/d.
=28/3
=9.33
We have select load of spring as per space in given below
P=30*9.81
=294.3 N
=0.2943 KN
Deflection = (8PD*3n)/Gd*4
= (8*0.2943*28*3*58)/(207*103 )
= 0.055
K = P /Def lection
K = 0.2943/0.0555
K = 5.35N/mm
54
Chapter 8
PROCESS SHEET
Manufacturing of the machine part:-
The manufacturing procedure for various parts of the dish washer is lid
in the form of process chart which is given below.
• Fabricated stand.
• Shaft (key way)
• Tray (Sheet metal)
• MANUFACTURING OF PARTS
NAME OF JOB :-FABRICATION OF STAND
Measuring instrument Measuring tape /scale
SR.NO. OPERATION M/C. TOOL and TIME

EQUIPMENTS
1 Fabrication Welding electrode, 120 min.
Arc Welding ma-
chine
2 Drilling Twist Drill, Drill 45 min.
machine
3 Turning Turning tool, 180 min.
lathe m/c, 4 jaw
Chuck
4 Cutting Power hack saw 60 min.
5 Fitting - 240 min.
Total time 645 min.
Table 8.1: Manufacturing Of Parts
55
8.1 Analysis of each element
8.1.1 Frame:-
Raw material required
Total weight = 20kg.
Raw material rate = 25 Rs. 1kg.
Cost of raw material = 20 *25 = 500Rs
PROCESS TIME REQUIRE- COST PER TOTAL

MENT HOUR COST
CUTTING 60MIN 40RS 10RS.
WELDING 120MIN 90RS 90RS.
3 HOURS TOTAL COST 100RS.
Table 8.2: Process Sheet of Frame
Element Amount
Frame cost 500 Rs
Material trans- 100 Rs
port cost
Total 600 Rs
Table 8.3: Costing Of Frame and transportation
8.1.2 Helical Tension Spring:-

Material = oil tempered spring
Quantity = 1
Standard rate = 200/-
Nut and bolt and washer
Material mild steel
Transport Rs. 10/-
Total amount = 282 + 10 = 292/-
8.1.3 Spring Supporting Rod:-

Material = 18 * 600mm M.S.
Quantity = 2
Standard rate = 25Rs.
1pcs. Total amount = 50Rs.
56
PARTICULARQUANTITY RATE AMOUNT
122*3 nut 6pcs. 15/- 90/-
and bolt
7116*3 nut 6pcs. 18/- 108/-
and bolt
7116 washer 12pcs. 2/- 24/-
112 washer 12pcs. 5/- 60/-
total 282/-
Table 8.4: Costing of Helical Tension Spring
8.2 Component Cost Estimation

8.2.1 Cost Estimation:-
SR.NO COMPONENT MATERIAL QUANTITY RATE TOTAL

COST
1 Frame M.S. 1 600/- 600/-
2 Spindle 1 M.S. 1 90/- 90/-
3 Spindle 2 M.S. 1 90/- 90/-
4 Spindle 3 M.S. 1 90/- 90/-
5 Wheel axle M.S. 1 110/- 110/-
6 Mo teeth gear 127 C.I. 2 150/- 300/-
7 30 teeth gear C.I. 2 60/- 120/-
8 45 teeth gear C.I. 1 70/- 70/-
9 100 teeth gear C.I. 1 90/- 90/-
10 U.P.B.19mm - 6 100/- 600/-
11 U.P.B.25mm - 4 125/- 500/-
12 Nut 112*3 - 4 15/- 90/-
13 Nut, bolt 7116*3 - 6 18/- 108/-
14 Washer 112*3 - 6 2/- 24/-
15 Washer 7116*3 - 12 5/- 60/-
16 Big washer - 12 10/- 120/-
17 Leaver - 1 100/- 100/-
Table 8.5: Total Material Cost
Total material cost : = material cost + Miscellaneous cost

= 3717/- + 258/-
Hence, total cost of machine =Rs. 3975/- approximately.
= 4000/-
57
Chapter 9
ADVANTAGES,
DISADVANTAGES
AND APPLICATION
9.1 Advantages of Automatic pallet carrier for small

workshop:-
• It saves electrical power.
• It easy to operate.
• Optimal use of site supply.
• Simple installation anywhere.
• Optimize result and economy.
• Space required is more.
9.2 Disadvantages of Automatic pallet carrier for small

workshop:-
• Noise due to mechanical components.
• Low speed.
• Less vibration is created during operation.
• Maintenance required time to time.
58
9.3 Application of automatic pallet carrier for small
work shop:-
• Workshop:- In many workshop, it can be used to transport raw material,
jobs from one location.
• Small industries-material transportation from one station to other station

through fixed distance.
59
Chapter 10
FUTURE SCOPE
Improvement in any pro ject is development of pro ject efficiency. By

developing also can be increased. The operating of pro ject can be simple.
• By increasing gear ratio, the weight of equipment can be increased. The

travel distance can also be increased.
• By adjusting the lever, we can adjust the distance to be traveled.
• By providing rails, we can give definite path or way to conveyor.

Circular distance can also be traveled.
• Use of electronic devices such as sensors, transducers circuits etc can be

made so that we can make ROBO.
• By use of mechatronics we can make more development in this pro ject.
60
Chapter 11
CONCLUSION
By this process we can transport work in progress from one place to other
at fixed distance by means of Mechanical Energy. As well as it has high
amount of power saving. It saves the money and time. It reduces labor
work in workshop. Less human intervention required.
61
REFERENCES
[ 1 ] Science and Engineering, An Introduction, John Wiley and Sons, Inc.,

New York, USA, 1997.
[ 2 ] S.V. Nadkarni. Modern Arc Welding Technology, Oxford IBH

Publish- ing Co. Pvt. Ltd., 1988.
[ 3 ] M.I. Khan and A.K. Gupta. A study of Hard Facing under Magnetic
Field, ASME Conference, I.I.T. Delhi, 174-176, 1989.
[ 4 ]W. Robert Messler. Principles of Welding Processes, Physics, Chem-

istry and Metallurgy, Wiley, VCH VerlagGmbh and Co.
KgaAWeinheim,
2004.
[ 5 ]Chien-Yi Lee. A study of an Automatic Welding System, Dissertation of

Ph.D., Institute of Mechanical Engineering at National Central
Univer- sity. Jhongli City, Taoyuan County, Taiwan, Republic of
China, 2007.
[ 6 ] Deepak Punetha, Neera j Kumar, Vartika Mehta Development and

Appli- cations of LineFollowing Robot Based Health
CareManagementSystem , IJARCET volume 2 issue 8 2013
[ 7 ] Ra jeev K piyre,Member; LAENG, and Ravinesh Singh. Wireless Con-

trol of an Automated Guided Vehicle. In Proceeding og the Interna-
tional Multiconference of Engineering and Computer Scientists 2011 Vol
II IMECS 2011, March 16-18, 2011, Hong Kong, China.
[ 8 ]M. ZafriBaharuddin, Izham Z. Abidin, S. SulaimanKa jaMohideen, Yap

KeemSiah, Jeffrey Tan Too Chuan Analysis of Line Sensor Configuration
for the Advanced Line Follower Robot.
62
[ 9 ] K KishorDesgine Of Automated Guided Vehicel , IJARC Volume 3, Issue
1, January- April (2012).
63

Thesis 0

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Thesis 0

Uploaded by

Copyright:

Available Formats

A PROJECT

“ AUTOMATIC PALLET CARRIER FOR SMALL WORKSHOPS ”

Submitted as per requirement of

Mr. Pawar jivan keshavrao [B120750891] Mr.

Under the Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

S. B. Patil College of Engineering, Indapur

This is to certify that Project report entitled

“ AUTOMATIC PALLET CARRIER FOR SMALL WORKSHOPS ”

Mr. Pawar jivan keshavrao Mr.

is in partial fulfillment for the award of Degree of Bachelor of Engineering in Mechanical

[Prof. Malve A. C.] [Prof. S. R. Kshirsagar]

External Examiner [Dr.P. D. Nemade]

KEYWORDS:-Pallet Carrier, lever, spring, Propulsion.

3 CONVENTIONAL MATERIAL HANDLING SYSTEMS 18

7 DESIGN OF AUTOMATIC PALLET CARRIER 40

9 ADVANTAGES, DISADVANTAGES AND APPLICATION 58

3.1 belt Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.1 Involute Form Of Gear Tooth . . . . . . . . . . . . . . . . . . . . 26

5.1 3D view Automatic pallet Carrier . . . . . . . . . . . . . . . . . . 30

7.1 Gear and shaft arrangement . . . . . . . . . . . . . . . . . . . . . 42

8.1 Manufacturing Of Parts . . . . . . . . . . . . . . . . . . . . . . . . 55

We have great pleasure in presenting this report on AUTOMATIC

This Pro ject has helped us to express extracurricular knowledge with

We wish to thank our Pro ject Co-Guide Prof. K. M. Kare and

Mr. Pawar jivan keshavrao Mr.

Material handling is movement and storing of goods. Material handling

Out of total production time 20 percent time is spent on actual process.

So to minimizing the drawback of this we can used the various

[ 3 ]Auto stop mechanism after travelling particular distance by using

[ 4 ]To increase travelling distance by increasing gear ratio.

[ 5 ]To Design Pallet carrier for Weight carrying capacity of about 35

[ 7 ]Use the Pallet carrier wherever the space limitations.

[ 8 ]Noiseless and smooth in operation.

Wheel rotate up to 8.5m in a length. When lever goes at final position,

The Current State And Future Trends In The Use Of Pallets In

The main idea behind developing such a research is to demonstrate the

These factors directly or indirectly affect the pallet utilization in any

S. Mahendran, K.M.Eazhil ,L.Senthil Kumar-On General Spur Gear

Pandiyara jan.R, Starvin.M.S, Ganesh.K.C (2011)[Singh, 3(7): July,

There are lots of researches developed to study the contact mechanics

EL HAD Khalid1,2, HACHIM Abdelilah1,2, EL AMRI Abdelhamid1, ABOUE-

Whether for industrial, transportation or complex systems, ball bearing

Even if the geometry of a ball bearing is perfect, it will still produce

Niranjan Singh, on helical tension spring, International Journal of Ad-

A few papers where discussed about the different types of mechani-

CONCLUSION: The literature review discussed above depicts that the

YogeshMaha jan, A. Y. Vyavahare, D. RPeshwe, on Failure Analysis

A spring is an elastic ob ject and performs many functions. The basic

Conclusions:(1) From the above observations we can conclude that the

Ra jeev Ranjan, Parametric Optimization of Shielded Metal Arc Welding

Abstract:The Shielded Metal Arc Welding (SMAW) process is an arc

Welding is a process of joining different materials. It is more economical

CONCLUSIONS:Based on the experimental work and the Factorial

1. A strong joint of mild steel is found to be produced in this work by using

2. Results indicate that processes variables influence the weld deposition

3. If amperage is increased, welding deposition area generally increases.

4. If voltage of the arc is increased, welding deposition area generally in-

5. Welding voltage was found to be most influencing variable to WDA.

6. If travel speed is increased welding deposition area generally decreases.

R. A. Gujar1, S. V. Bhaskar2, Shaft Design under Fatigue Loading By

In this paper, shaft employed in an Inertia dynamometer rotated at

A shaft is a rotating member, usually of circular cross-section for trans-

Emmanuel Adeleke Fagbemi1, *, Agbolahan Okeeseni2, Baldwin Omonigho2,