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IMPROVEMENT OF MECHANISM OF CONVEYOR SYSTEM PART 5
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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.
IMPROVEMENT OF MECHANISM OF CONVEYOR SYSTEM PART 5
M.A.MUDA*, F .I .MALEK, M.MUAZ, S. RUBIAH, M.N. MANSOR
Faculty of Mechanical Engineering, Universiti Malaysia Pahang,

26600 Pekan, Pahang, Malaysia,
Phone: +0129501907
*Email : asyrafmuda@gmail.com
ABSTRACT
A conveyor system is a common piece of mechanical handling equipment that moves

materials from one location to another. Many kinds of conveying systems are available, and
are used according to the various needs of different industries. The purpose of this project is
to improve the existing conveyor machine that located at the methodology lab in University
Malaysia Pahang. The current design of the conveyer machine used timing belt that
connected at the motor to move the shaft. The problem of the current design is the timing belt
disheveled and shaft was slipping. For the improvement we use sprocket and chain as drive
mechanism. Beyond the above improvement the conveyor system is expected to work. This
project also helps student to utilize their engineering information and improve the skill of
student in solving the mechanical problems.
Keywords: conveyer system; design of conveyer; CAD.
INTRODUCTION
A conveyor system is a common piece of mechanical handling equipment that moves
materials from one location to another. Conveyor systems allow quick and efficient
transportation for a wide variety of materials, which make them very popular in the material
handling and packaging industries [1]. Many kinds of conveying systems are available, and
are used according to the various needs of different industries. There are chain conveyors
(floor and overhead) as well[2]. Chain conveyors consist of enclosed tracks, I-Beam, towline,
power & free, and hand pushed trolleys [3] . Conveyor systems are used widespread across a
range of industries due to the numerous benefits they provide [4].Conveyor systems are
commonly used in many industries, including the automotive, agricultural, computer,
electronic, food processing, aerospace, pharmaceutical, chemical, bottling and canning, print
finishing and packaging [5]. Although a wide variety of materials can be conveyed, some of
the most common include food items such as beans and nuts, bottles and cans, automotive
components, scrap metal, pills and powders, wood and furniture and grain and animal feed
[6]. Many factors are important in the accurate selection of a conveyor system. It is important
to know how the conveyor system will be used beforehand. [7].
1
Conveyers have many kind of benefits, it can almost can be installed anywhere. Besides,
using conveyer as transportation to move load are much safer than using forklift or other
machines. It also can move loads of all sizes and shapes [8]. There are many types of
conveyer machines such as gravity conveyer system, power belt conveyer systems, vibration
conveyer systems, flexible conveyer systems and live roller conveyer system [9]. The design
capacity of the conveyor belt system was calculated from the information collected using
different methods of calculation [10]. Three different methods of calculation were used to
determine the design capacity of the conveyor belt system [11]. The design of the belt
conveyor must begin with an evaluation of the characteristics of the conveyed material and in
particular the angle of repose and the angle of surcharge. The angle of repose of a material,
also known as the “angle of natural friction” is the angle at which the material, when heaped
freely onto a horizontal surface takes up to the horizontal plane [12].
The conveyer belt installations have been used for moving a wide variety of goods and
materials for many decades [13]. They continue to provide the fastest, safest, most effective
and economical method of transportation over relative long distance often in areas where
space is limited an operating under some of the most adverse conditions imaginable [14]. The
conveyer belt plays an integral role in the efficient operation of every conveyer system and
has to be able to cope with an enormous variety of stresses and demands [15]. Every
conveying installation and the conditions that are required to operate in are of course different
[16]. This means that the correct choice of belt type and cover quality is crucial [17]. There
are several important technical rules, values and calculations involved when selecting a
conveyer belt. This is also applies to installing new belts, so that they operate at maximum
efficiency [18]. A belt conveyor consists of an endless and flexible belt of high strength with
two end pulleys (driver and driven) at fixed positions supported by rollers. In this work, 3 roll
idlers are required for adequate support of materials transported and protection of the belt
along its length [19]. Pulleys are used for providing the drive to the belt through a drive unit
gear box powered by an electric motor [20]. It also helps in maintaining the proper tension to
the belt. The drive imparts power to one or more pulleys to move the belt and its loads [21].
Roller conveyor chains are generally used in production or assembly lines where individual
large objects need to be conveyed [22]. Roller conveyor chains differ from transmission roller
chains such as a bicycle chain, which is used to transfer torque instead of conveying goods
[23]. Conveyor chains have a large pitch which is efficient in bridging large distances with
fewer shackles, they generally have thicker side plates and rollers with large diameter [24].
Therefore they can withstand higher tensile and shock loads than transmission chains.
Furthermore they can bear large amounts of wear before breakage occurs [25]. On the other
hand, roller conveyor chains have a necessary clearance that easily becomes contaminated
with particles from the conveyed material [26]. A typical conveyor chain is constructed with
two different types of shackles, the roller link (or inner link) and the pin link (or outer link),
see Figure 1 [27]. The roller link consists of two steel bushings who are press-fitted inside the
roller link plates, while the pin link consists out of two steel pins press-fitted inside the pin
2
link plates. To prevent disengaging of plates and pins, riveted pins or t-pins (as shown) are
used [28].
Stochastic Design Improvement (SDI) is a fast and efficient method for improving the
performance of a system [29]. 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 [30].
Conveyor chains can be loaded in two ways which is the force can be applied on the side
plates by use of attachments which are connected to the side plates, see Figure 1. Alternately
the force can be applied on the pins. Therefore hollow pins and axles instead of solid pins (as
shown) are used [31]. The rollers transfer the normal force, due to the weight of the conveyed
objects, to the track. The driving sprocket exerts a force on the chain to pull the load, this
results in a tensile force inside the chain which must be large enough to overcome the sliding
friction between roller/bushing and the rolling friction between roller/track [32]. Additionally
the chain is restressed by the sprocket this will result in a raise of tensile force [33]. To
transfer this tensile force from one shackle to another, bushing and pin will act together as a
bearing [34]. A chain is a machine component that comes with a series of a connected links.
It can be used to transmit power or conveyance systems [35]. Usually, there are five types of
chains that are cast iron chain, cast steel chain, forged chain, steel chain and plastic chain
[36]. The advantages, conveyor chain had been applied widely in coal mining, food
processing, sewage treatment, timber harvesting, agricultural, bakery, harvesting, and textile
machines, car, cement, and chemical plant, and sorting, handling, and material conveyors
[37].
Sometimes failure of the conveyers also could happen. Failure mean is not meeting a
desirable or intended objective [38]. There are five general failure categories that are fracture
(full section), cracking (partial section), distortion (bending, elongation, and plastic collapse),
corrosion (pitting, through wall perforation) and wear (material wastage). All the failure
caused by defect in designing, manufacturing, operating and environment[39]. There are two
types of defects that are generally observed in material. The first one is inherited defects
where the origin is in the ingot and the other one is generated defects that are introduced in
the material during various metal working operations and thermal treatments [40].
3
METHODOLOGY
A conveyor belt having a cover layer is disclosed and a core layer [41]. A conveyor belt is
described, which has a support fabric, which is provided with at least one thermoplastic
material coating and is characterized in that onto its cutting edges is welded a thermoplastic,
strand-like profile material, preferably a round cord so as to constitute an edge protection
[42]. The conveyor belt further has a migration-proofing layer provided between the cover
layer and the core layer for preventing migration of the adhesion-proofing agent in the cover
layer to the core layer [41]. A conveyor belt is to be provided with a practice-proven anti-
adhering surface which is permanent and resistant to wear [43]. The inventive method makes
it possible to economically provide individual endless and finite conveyor belts with an edge
protection when this proves necessary [44]. A dimensionally stable synthetic internal support
conveyor belt which comprises [45] at least one homogeneous, flat tape of a molecularly
oriented plastic with a modulus of elasticity of 15,000 to 25,000 kp/cm2
The basic idea of the subject matter of the invention comprises preventing the baking-on
and dirtying of conveyor belts during the transport of the most different goods, especially
mass goods [43]. When the belt reaches a point of transition between the helical path section
and the preceding straight path section, the links at the inner lateral edge of the belt slide
towards each other so as to present a reduced pitch, while the links at the outer lateral edge of
the belt either retain the same pitch or expand by sliding away from each other to a greater
pitch than along the preceding straight path section [46]. The conveyor belt according to the
present invention is composed of a cover layer having at least one layer in which an
adhesion-proofing agent is contained, a core layer and a migration-proofing layer for
preventing migration of the adhesion-proofing agent to the core layer, and though it requires
no such application of specific adhesion-proofing liquids such as kerosene at each service, the
conveyor belt is free from adhesion of tacky materials such as oil sand, resulting in reduction
of conveying cost, no fear of fire, facilitation of maintenance and others [44]. Conveyor belts
having a sliding action between the links at both lateral edges of the belt experience
collapsing or contraction of the links along the inside lateral edge of the belt in the helical
path section [46].
The sprockets are mounted on the ends of a shaft that is adapted to be driven by
motor[47]. To chain link conveyors formed of a plurality of chain links assembled by pivot
means so that adjacent chain links can turn in a hinge like manner around the pivot means
holding them together, with means being provided for position ably securing the pivot means
[48]. A chain conveyor formed from a plurality of modules or links hinged together by pins
which are inserted through holes present in said modules or links and are prevented from
escaping by axially counteracting elements mounted in seats also present in said modules or
links [49]. The invention comprises respective sprocket means for driving the opposite edges
of 'a belt, and a differential for coupling the sprockets to a drive motor. Additionally, floating
idler sprockets are associated with the drive sprockets, and are coupled to a weight [50].In a
4
chain link track of the aforementioned type, at least the chain link sides which face towards
an adjacent chain and opposite the pivot bores of the chain links, a groove is provided in
which the locking dowel can be inserted before insertion of the pivot, with the locking dowel
having a central bore for the pivot and being arranged for simultaneous engagement with the
grooves in two chain links which abut each other on the same pivot thereby coupling these
chain links together [48].
Figure 2 : Flow Chart of the project

5
Design of Work
The flow of our project design is by identifying the problem of the current design in order to
make some improvement. The original drive system of the conveyer is using v-belt pulley
system. The problem that occur from this system is that it did make the conveyer belt running
but instead only the motor of the system is running. Therefore, to make an improvement
some research and planning need to be done in order to recognize the main issues need to be
improve in this conveyer system.
After done planning for improvement, some machining process and replacement of the
original equipment need to be done in order to improve the conveyer drive system.
Machining process such as milling process of using face mill are done in order to create a
pocket for the shaft that connect to the pulley. The purpose of the pocket is to hold the
sprocket from slipping during power transmission process. The second machining process
done is drilling the plate holder to widen the motor holder. The third machining process is
welding sprocket onto cylindrical rod to connect the sprocket into the shaft.
After machining process is done, a test run is to be conducted in order to make sure that the
idea giving can improve the conveyer drive system. If the idea is still need to be fixed, then
we need to repeat the machining process in order to satisfy the need of improvement to the
conveyer drive system.
Lastly, result obtains from the test run need to be further discussed in order to obtain a
satisfying result.
6
RESULT & DISCUSSION

This project is mean to improve the current conveyor system which has been not
working for quite a long time. The current conveyor uses a belt conveyor system. A belt
conveyor system is one of many types of conveyor systems. A belt conveyor system consists
of two or more pulleys with an endless loop of carrying medium. One or both of the pulleys
are powered, moving the belt and the material on the belt forward. The powered pulley is
called the drive pulley while the unpowered pulley is called the idler pulley. There are two
main industrial classes of belt conveyors. Those in general material handling such as those
moving boxes along inside a factory and bulk material handling such as those used to
transport large volumes of resources and agricultural materials, such as grain, salt, coal, ore,
sand, overburden and more.
Today there are different types of conveyor belts that have been created for conveying
different kinds of material available in PVC and rubber materials.
The belt consists of one or more layers of material. Many belts in general material handling
have two layers. An under layer of material to provide linear strength and shape called a
carcass and an over layer called the cover. The carcass is often a woven fabric having a warp
& weft. The most common carcass materials are polyester, nylon and cotton. The cover is
often various rubber or plastic compounds specified by use of the belt. Covers can be made
from more exotic materials for unusual applications such as silicone for heat or gum rubber
when traction is essential. As for the current conveyor it is used to transport tray with
components.
7
Figure 1: Conveyor under commissioning
Next, the current conveyor uses conveyor pulley to move the conveyor belt .A
conveyor pulley is a mechanical device used to change the direction of the belt in a conveyor
system, to drive the belt, and to tension the belt. Rubber lagging is applied to pulley shells in
order to improve the friction between the pulley and the belt. Conveyor drive pulleys are
often supplied with diamond grooved lagging as indicated in the adjacent sketch. 'Diamond
grooved lagging' refers to the pattern in the lagging and this pattern, like with vehicle tyres,
enhances the grip or friction even if the belt surface is dirty. Pulleys are used on conveyors to
support and deflect the belting through the conveyor structure. Pulleys also provide a
mechanism whereby the conveyor belt can be trained to run (track) true along the conveyor
idlers .Generally, pulleys are located at the ends of the conveyor structure and at the take-up
arrangement. Pulleys are used to transmit the drive power into the conveyor belt and as such,
are subjected to the dynamic belt tension forces in a conveyor.
Figure 2: Pulley
8
Next, we analyse the drive mechanism for the conveyor. The current conveyor system are
using a AC motor and v-belt as the drive pulley to drive the conveyor. The most common
systems for transmitting power from a drive to a driven shaft are belt, gear, and chain drives.
Figure 3 : V belt
V belts solved the slippage and alignment problem. It is now the basic belt for power
transmission. They provide the best combination of traction, speed of movement, load of the
bearings, and long service life. They are generally endless, and their general cross-section
shape is trapezoidal (hence the name "V"). The "V" shape of the belt tracks in a mating
groove in the pulley (or sheave), with the result that the belt cannot slip off. The belt also
tends to wedge into the groove as the load increases—the greater the load, the greater the
wedging action—improving torque transmission and making the V-belt an effective solution,
needing less width and tension than flat belts. V-belts trump flat belts with their small center
distances and high reduction ratios. The preferred center distance is larger than the largest
pulley diameter, but less than three times the sum of both pulleys. Optimal speed range is
1,000–7,000 ft/min (300–2,130 m/min). V-belts need larger pulleys for their thicker cross-
section than flat belts.
V-belts may be homogeneously rubber or polymer throughout, or there may be fibers

embedded in the rubber or polymer for strength and reinforcement. The fibers may be of
textile materials such as cotton, polyamide (such as Nylon) or polyester or, for greatest
strength, of steel or aramid. But V-belt drive systems, also called friction drives because
power is transmitted as a result of the belt's adherence to the pulley are an economical option
for industrial, automotive, commercial, agricultural, and home appliance applications. V-belt
drives are also easy to install, require no lubrication, and dampen shock load.
Standard friction drives can both slip and creep, resulting in inexact velocity ratios or
degraded timing precision between input and output shafts. For this reason, it is important to
select a belt appropriate for the application at hand.
9
Unfortunately it has some minor setbacks. The V-belt does not provide enough tension to
drive the conveyor. There are few reason for this to happen. First, the v belt has become old
and reduce in friction as it cannot provide enough tension to move the conveyor.
Figure 4 : Drive timing belt
Improvement
After observing all the main parts of the conveyor system and analysing which and where to
be optimized we start our improvement process. First we analyse the drive mechanism of the
conveyor in which the drive pulley that uses V belt is not in a good condition. The first
optimization that were suggested is to change the drive pulley that drive the mechanism by
using chain and sprockets.
10
Figure 5: Drive mechanism
A sprocket is a profiled wheel with teeth, cogs, or even sprockets that mesh with
a chain, track or other perforated or indented material. The sprocket use in this project acting
as gear that move the pulley with the help of motor. The 17-tooth sprocket is attach to the
motor while the 15-tooth sprocket is attach to pulley.
Figure 6 : 17-tooth and 15-tooth sprocket
First the sprocket should be welded to a cylinder metal made from mild steel so that the
sprockets can be fitted to the motor shaft and pulley.
11
Figure 7 : Connecting cylinder metal
Conveying Materials
Chain drives are used in many types of industries to move, slide, carry, push and pull a
variety of materials. These drives can be used to move objects directly by attaching pockets,
buckets, frames, or meshes to the chains. They can also be used indirectly, such as turning
rollers, which, in turn, move a conveyor belt.
After that we start assembling all the modified and improved parts and starts the conveyor
into action. This is our first test run for our project .As expected the conveyor starts to move.
Unfortunately there are some slippage happened to the conveyor belt. This is because of the
chain slippage and the chain is not tight enough. Hence, we start to think about tightening the
tension of the belt. There are few improvement were done to the plate that holds the motor
shaft and other pulley.
Figure 8 : Improvised drive mechanism
12
Finally, we run again the conveyor into action and it run smoothly without any difficulties.
Calculation
Next we move on to the calculation of the motor.
Figure 23 : AC motor specification
40
Torque( N .m) 
2  1300r / min
 0.298N.m
Torque  RPM
Horsepower 
5255
0.298  1300

5252
13
 0.074hp
As the conveyor need full speed of motor to run , thus it need minimum 0.3 N.m torque and
0.074hp to work efficiently.
Future Improvement
From our discussion, further improvement can still be done in this project to further increase
the success rate for the conveyer drive system. During this project we manage to make the
conveyer belt move with the current equipment of the drive system to run normally but from
our observation the motor that run the conveyer can still be improvise to a more powerful
motor for example from figure below.
Figure 24: Asynchronous motor
Product Name Asynchronous motor

Technology Three Phase
Power 1kW-675kW
Voltage 230-400V
Table 5: Asynchronous motor specification
Other improvement that still could be made for the conveyer drive system is to replace chain
system with a high efficiency system.
CONCLUSION
The conveyor system is successfully improvised using drive chain. The conveyor move
without causing any slippage although the conveyor need a regular maintenance to avoid any
casualties in the future. This project also helps student to utilize their engineering information
and improve the skill of student in solving the mechanical problems.
ACKNOWLEDGEMENTS
14
We would like to thank to our supervisor and other lecturers that helps us in finishing our
project. Also we would like to be obliged to University Malaysia Pahang for providing
laboratory facilities.
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16
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IMPROVEMENT OF MECHANISM OF CONVEYOR SYSTEM PART 5

Article · January 2016

Asyraf Muda Nasiruddin Mansor

SEE PROFILE SEE PROFILE

The user has requested enhancement of the downloaded file.

IMPROVEMENT OF MECHANISM OF CONVEYOR SYSTEM PART 5

M.A.MUDA*, F .I .MALEK, M.MUAZ, S. RUBIAH, M.N. MANSOR

Faculty of Mechanical Engineering, Universiti Malaysia Pahang,

A conveyor system is a common piece of mechanical handling equipment that moves

Figure 2 : Flow Chart of the project

RESULT & DISCUSSION

Figure 1: Conveyor under commissioning

V-belts may be homogeneously rubber or polymer throughout, or there may be fibers

Figure 4 : Drive timing belt

Figure 5: Drive mechanism

Figure 6 : 17-tooth and 15-tooth sprocket

Figure 7 : Connecting cylinder metal

Figure 8 : Improvised drive mechanism

Figure 23 : AC motor specification

Figure 24: Asynchronous motor

Product Name Asynchronous motor

28. DEMATIC, Conveyor Systems. Retrieved 2013 Jan, 1, , 2012.

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