DEBRE MARKOS UNIVERSITY

INSTITIUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL AND INDUSTRIAL
ENGINEERING
STREAM-MANUFACTURING
HOSTING ORGANAYZATION- AMIMTDE
TITLE OF THE REPORT-INTERNSHIP REPORT
DOURATION OF INTERNSHIP APRIL-JULAY

PREPARED BY: Id/No

1 Benyam Kebede………………………………0075/10
2 Wubetu Berihun……………………………….1114/10
3 Nigusu Mihret…………………………………1181/12
4 Amare Sete……………………………………..0692/10

INDUSTRIAL ADVISER NAME: Mr.Selmon

ACCADAMIC ADVISER NAME: Mr. Mengistu

Date,12/03/2015
Debre markos, Ethiopia
 ACKNOWLEDGMENT

Firstly, we would like to thanks our advisor (Mr. Mengistu) for guiding and helping how to do
this project. Secondly we would like to express our respectful gratitude for AMIMTDE
employees who helped us to obtain various relevant information needed for doing the internship
project and helping us to apply our theoretical understanding to practical experience and the
head of foundry shop department who direct us how to apply and communicate with each other.
Finally, we would like to thanks our friends for their comment and sharing their experience gain
from the company.

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Table of Contents
ACKNOWLEDGMENT.....................................................................................................................................i
ACRONYMUS, SYMBOLS AND ABBRIVATION...................................................................................iv
EXECUTIVE SUMMERY..................................................................................................................................v
1.1 INTRODACTION................................................................................................................................1
1.1.1 Brief history the Company............................................................................................................1
1.1.2 Main product and service..............................................................................................................1
1.1.3 Main customers or end users.........................................................................................................2
1.1.4 Over all organization structure and work flow.............................................................................3
1.1.5 The overall work flow in the company.........................................................................................4
1.2. OVER ALL INTERNSHIP EXPERIENCE.......................................................................................5
1.2.1 our working section of the company.............................................................................................5
1.2.2 The work flow of our working section..........................................................................................9
1.2.3 Our work task we have been executing.........................................................................................9
1.2.4 The procedure to manufacture spur gear and a piece of plate metal...........................................10
1.2.5 challenges you have been facing while performing your work tasks.........................................11
1.3 OVERALL BENEFIT WE GAINED FROM THE INTERNSHIP...................................................12
1.3.1 In terms of upgrading theoretical knowledge..............................................................................12
1.3.2 In terms of upgrading practical knowledge.................................................................................12
1.3.3 In terms of improving industrial problem solving capability.......................................................12
1.3.4 In terms of improving our team playing skills............................................................................13
1.3.5 In terms of improving our leadership skills................................................................................13
1.3.6 In terms of understanding about work ethics issues....................................................................14
1.3.7 In terms of entrepreneurship skills..............................................................................................14
1.4 Conclusion & Recommendation...................................................................................................16
1.4.1 Conclusion...................................................................................................................................16
1.4.2 Recommendation.........................................................................................................................17
2. PROJECT REPORT...................................................................................................................................18
EXCECUTIVE SUMMERY.............................................................................................................................19
2.1. INTRODACTION.............................................................................................................................20
2.1.1 Background of belt conveyor.......................................................................................................20
2.1.2 problem statement and justification............................................................................................21
2.1.3 Objective.....................................................................................................................................22

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2.2 LITRATURE REVIW........................................................................................................................23

2.3 METHODOLOGY.............................................................................................................................26
2.4 DESIGN ANALYSIS OF BELT CONVEYOR................................................................................28
2.4.1 Cost analysis................................................................................................................................40
2.5 RESULT AND DISCCUTION........................................................................................................41
2.5.1 Result...........................................................................................................................................41
2.5.2 Discussion...................................................................................................................................45
2.6 CONCLUSION AND RECOMMENDATION.................................................................................46
Reference...................................................................................................................................................47
Appendix....................................................................................................................................................48

Figure 1 organizational structure of the company..........................................................................................3

Figure 2 over all work flow............................................................................................................................4
Figure 3 CNC lathe machine..........................................................................................................................6
Figure 4 MIG.................................................................................................................................................8
Figure 5 methodology flow chart.................................................................................................................26
Figure 6 belt tension on drive pulley............................................................................................................33
Figure 7 roller ball bearing...........................................................................................................................36
Figure 8 heavy-hex-nuts...............................................................................................................................36
Figure 9 bolt.................................................................................................................................................37
Figure 10 steel cord belt...............................................................................................................................37
Figure 11 push pin type coupling.................................................................................................................38

Table 1 cost analysis....................................................................................................................................39

Table 2 result...............................................................................................................................................41

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ACRONYMUS, SYMBOLS AND ABBRIVATION

AMIMTDE- Amhara Metal Industry and Machine Technology Development Enterprise

EDM -electrical discharge machine

SMAW- Shielded Metal Arc Welding

GMAW- Gas Metal Arc Welding

B=belt width

ρ=specific density

ϴ=inclination

Φ=wrap angle

f =coefficient of friction

p=0.81

𝑞𝑠=weight of the moving parts of the belt

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EXECUTIVE SUMMERY

This project is documented based on the three-month internship program which had been
successfully completed in AMIMTDE. It holds background of the company, main product and
services, organizational structure, work flow, mission, vision, and objectives of the company.
From the project we have also included the section of the company in which the various task has
been performed, the types of tools, methods and techniques used are stated briefly. The project
also includes major problem during performing the work task, their proposed solution, result and
discussion with recommendation for the identified problem. Finally, the project talks about the
overall benefits that have been gained from the internship and then it concludes with
recommendation. The other main points include on this project are state the problem statements
with their justification, main objective within its specification, methodology, analysis for the
equipment which has been designed based upon the mechanical and ergonomic principle. Since
the equipment is new and not exists in the enterprise before, data used for the mechanical and
ergonomic design is obtained from observation. Then give the appropriate proposed solution for
the problem which has been stated and finalize by giving a conclusion with supported
recommendation. The recommendation we forwarded to the company also parts of the paper.
During the overall stay in the company various achievements have been brought. Some of these
are: theoretical knowledge, practical skill, interpersonal skill, leadership skill and team playing
skill. All of these are described briefly inside the paper.

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1. INTERNSHIP REPORT

1.1 INTRODACTION
1.1.1 Brief history the Company
The Amhara Metal Industry and Machine Technology Development Enterprise (here in after
called “AMIMTDE) is an autonomous government development enterprise established by the
Council of Regional Government on November 28, 2004 with the regulation Number 127/2014
intending to create and build up one strong metal engineering centers in the country which
carries out the tasks of manufacturing and commercializing metal and machine technology
products so as to alleviate impediments in technology supply and utilization within the
manufacturing industry and agricultural sector.

The main company is found in Bahir Dar city located at 200m east of Bahir Dar stadium. The
company covers 1.5 hectares at the moment but it has a branch around industry zone that landed
on 55,000 square meter and we had trained on the branch that is Bahir Dar general flexible and
foundry factory. the factory is found at the industry zone almost 1km to the north from the tsehay
paint factory and kokeb paint factory. The factory is landed on 55,000 square meter area and it
have two parts that landed on 14,580 square meter with 202.5*72 square meter area each other.

AMIMTDE works focusing on copping and adapting appropriate technologies. Evaluating each
technology for technical merit, commercial opportunity and state of appropriateness, it
implements the design development, production of prototypes and then harvesting it,
consecutively, for those feasible and selected technologies.

1.1.2 Main product and service

Amhara National Regional State Metal Industry and Machine Technology Development
Enterprise were established to meet the gap of technology requirement among Manufacturing
Industry, Agriculture Sector, Micro and Small enterprise in terms of product and service.
Currently the company produce different product based on reverse engineering techniques. Such
techniques are important for developing country to produce different spare part and machine
components.

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The main current products of the company are:

• Environmental protection equipment manufacturing

• Construction machinery manufacturing example- concrete mixer

• Electrical machinery manufacturing example-transformer

• Agricultural machinery manufacturing example-tractor assembly

• Transportation machinery manufacturing example-light vehicle assembly

• Food processing and packaging materials example-maize Sheller

• Main machinery part manufacturing example-bolt, nut, gear, shaft

1.1.3 Main customers or end users

The com0pany supplies its products to the local markets at reasonable price striving to satisfy the
requirements of its customers. The above products that produced in the company are selling to
local customers. For example

✓ Amhara regional state administration office-car parking and shade

✓ Bahir Dar University-mixer and fish feed Pelletizer machine

✓ Different industries

✓ Universities for research`

✓ Farmers
✓ Researchers
✓ Ministry of health

✓ Federal Defense force

✓ Agricultural research institutes

✓ Different governmental and non-governmental organization

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1.1.4 Over all organization structure and work flow

Amhara metal industry and machine technology development enterprise (AMIMTDE) have
the overall enterprise structure with a single general manager who coordinates the whole
department managers. The structure of the enterprise is as follows.

Figure 1 organizational structure of the company

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1.1.5 The overall work flow in the company

Figure 2 over all work flow

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1.2. OVER ALL INTERNSHIP EXPERIENCE

The university industry linkage program is planned to create a good interaction between
universities and industries to create students that have the capability of facing and solving
practical problems. Because of this reason, Debre markos univrsity institute of technology has
given a great deal attention in helping students starting from searching that are willing to be part
of this program to give essential opportunity.

1.2.1 Our working section of the company

In AMIMTDE there are total of five sections (shops). These are:

 Welding shop
 Machine shop
 Assembly workshop and maintenance
 Electrical shop
 Metal shop

We mainly work in machine shop which is one of the work shop that had different manual, AC
and CNC machines and different machining operation performed. In addition to this we have
been working in the fabrication and welding shop and assembly shop. there are different working
teams in the company, such us, design team, manufacturing team and quality inspection team. so
the company manager made a group, each group have members and there was categorizing all
group members participated in its working sections of the company.

Machine shop

one of the work shop that had different manual, AC and CNC lathe, milling, drilling, bending,
electrical cutting etc. machines and different machining operation performed like facing, turning,
knurling, boring, drilling, cutting, threading etc. and manufacturing different spare parts with
different thickness and dimension for different projects.

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Figure 3 CNC lathe machine

Some of the machine found in this shop

 Radial Drilling machine

Drilling machines are used for drilling operations and mainly designed to make holes in different
materials. Radial Drilling Machines are compatible, well-built, dependable, efficient and durable.

 Lathe machine

A lathe is a machining tool that is used primarily for shaping metal or wood. It works by rotating
the work piece around a stationary cutting tool.

The main use is to remove unwanted parts of the material, leaving behind a nicely shaped work
piece.

The most common lathe operations are turning, facing, grooving, parting, threading, drilling,
boring, knurling, and tapping.

 Milling machine

Milling machines are used mainly for shaping and cutting solid materials such as metal, wood,
plastics or even brass. These machines differ from a lathe in that the tool head itself rotates at
high speed whereas with a lathe the part itself that is being worked on rotates.

The operation of producing keyways, grooves, slots of varying shapes and sizes is called slot
milling operation. Slot milling operation can use any type of milling cutter like plain milling
cutter, metal slitting saw, or side milling cutter.

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 Power hack saw

Power hacksaws are used to cut large sizes (sections) of metals such as steel. Cutting diameters
of more than 10/15mm is very hard work with a normal hand held hacksaw. Therefore, power
hacksaws have been developed to carry out the difficult and time consuming work.

 EDM (electrical discharge machine)

Wire electrical discharge machining (EDM) is a process of metal machining in which a tool
discharges thousands of sparks to a metal work piece. Instead of cutting the material, EDM melts
or vaporizes it, producing comparatively small chips and providing a very accurate cut line.

Fabrication and welding shop

Fabrication is the process of constructing products by combining typically standardized parts

using one or more individual processes. For example, steel fabrication is the production of metal
structures using a range of processes such as cutting, bending and assembling. Welding is one of
the most popular metal fabrication process that involves the joining of two separate metal parts.

There are many types of fabrication techniques where the most common ones are cutting and
machining, punching and drilling, straightening, bending and rolling, fitting and reaming,
fastening, finishing etc. in this shop different machines and techniques exist like rolling machine,
shearing machine, bending machine, arc welding, plasma cutter, submerged arc welding etc…

In welding shop - we saw welding processes. e.g SMAW & GMAW and their respective
working principle.

In Metal workshop (fabrication) - we performed different sheet metal working processes such as
bending, shearing and piercing.

Metal Workshop:
In the metal workshop, different sheet metal working processes such as bending, shearing,
grooving, sheet metal rolling and piercing are performed. Some of the machines in the
AMIMTDE company are hydraulic and mechanical bending machines, hydraulic shear
machines, grooving machines, and rolling machines.

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 Welding workshop:

Welding is a material joining process in which two or more parts are coalesced at their
contacting surfaces by a suitable application of heat and/or pressure. In this shop, there are two
types of welding processes:
1. Shielded Metal Arc Welding (SMAW), and
2. Gas Metal Arc Welding (GMAW)
1. Shielded Metal Arc Welding (SMAW) - It is an arc welding process in which heat for
welding is produced through an electric arc set up between a flux coated electrode and the work
piece.
2. Gas Metal Arc Welding (GMAW) - Metal inert gas arc welding (MIG), or more appropriately
called gas metal arc welding (GMAW), is an arc welding process in which the electrode is a
consumable continuous bare metal wire, and shielding is accomplished by flooding the arc.

figure 4 MIG

Foundry shop

A foundry is workshop in which casting of metal is done. Metals are cast into shapes by melting
them into. a liquid, pouring the metal into a mold, and removing the mold material after the
metal has solidified as it cools. In this process, parts of desired shapes and sizes can be formed.

Assembly workshop and maintenance workshop

An assembly system is a working arrangement where individual components are combined and

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joined to form a unit that may be further integrated with other components to create a final
product.

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Maintenance workshop:

In the maintenance workshop, different machines of the company and different parts of
automobiles are maintained. In this shop, the damaged or worn-out parts are changed (which
might be from the market or one of the AMIMTDE products). The following activities are
performed in the shop: Maintenance of generators, maintenance of automobiles, maintenance of
work shop machines, maintenance of transporting machines In short, it gives repair for all those
requiring maintenance.
All the above activities are performed by the following steps:
Step 1 - Diagnose the problem by inspection
Step 2 - Locating the exact location of the problem
Step 3 - Disassemble the part to repair (if it is needed) by using appropriate tool
Step 4 - Maintaining and assembling
Step 5 - Testing for functionality

1.2.2 The work flow of our working section

MARKETING DESIGN PROCESS PLANNING PATTERN FOUNDRY ASSEMBLY

FINISHING(PAINTING) PACKAGING INSTALLATION AND COMMISSIONING

1.2.3 Our work task we have been executing

We mainly work in machine shop which is one of the workshop that have different manual and
CNC machines and different machine operations are performing.

The tasks we performed in this shop are:

 Drilling various size plates,
 Cutting long shafts
 Gear cutting milling operation
 Threading
 Facing and Turning shafts.

But Mainly we were performing two tasks that are manufacturing spur gear in milling machine
and drilling the holes of the piece of plate metal by using radial drilling machine.

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1.2.4 The procedure to manufacture spur gear and a piece of plate metal
 Spur gear in milling machine:

1. Calculate the gear tooth proportions.

2. The dividing head and the tail stock are bolted on the machine table. Their axis must be
set parallel to the machine table.
3. The gear blank is held between the dividing head and tail stock using a mandrel. The
mandrel is connected with the spindle of dividing head by a carrier and catch plate.
4. The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.
5. Set the speed and feed for machining.
6. For giving depth of cut, the table is raised till the periphery of the gear blank just touches
the cutter.
7. The micrometer dial of vertical feed screw is set to zero in this position.
8. Then the table is raised further to give the required depth of cut.
9. The machine is started and feed is given to the table to cut the first groove of the blank.
10. After the cut, the table is brought back to the starting position.
11. Then the gear blank is indexed for the next tooth space.
12. This is continued till all the gear teeth are cut.

 Plate metal

The process to be manufacturing the piece of plate metal in radial drilling machine.

1. First we cut the plate metal in the gas cutter

2. We find the center of the holes based on the dimension
3. After we get the center of the holes of plate punched the plate
4. Fix the center of plate hole with perpendicular to the appropriate drill bet
5. Adjust the spindle speed and feed rate
6. Finally switch on the radial drilling machine and drill the holes.

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1.2.5 challenges you have been facing while performing your work tasks
Besides the advantages of AMIMTDE, we faced some problems and challenges, like Lack of
independent work Since all the machinists in the shop are engaged full time, there is not enough
time to practice on machines. We didn't get permission to disassemble and assemble the machine
as soon as we finished our practice. Lack of computer access to do individual tasks Lack of
information, like the company’s blue print, was not accessible so as to work on our project. Since
the company did not have enough measuring instruments, all the groups were measuring their
machine components turn by turn. Due to this, there was time lost. Most of the machines were
out of service.

But we managed those challenges as well. Even if the machinists are engaged full time, we
follow all the working processes while they are making different structures like gears, pulleys,
bolts and nuts, treads, slots, etc. like By exchanging measuring tools from one group to another
group, transporting the machine parts from the shop to another shop By dividing tasks and doing
them in groups, by asking for advice from the engineers and workers of the company, and by
asking the mechanics when the machines fail (the mechanics disassemble and reassemble
the machine)

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1.3 OVERALL BENEFIT WE GAINED FROM THE INTERNSHIP

This internship training is very important for our country because of used to generate skill full
generation to create the new technology on the future. This internship is also used to solve the
problems and to improve our practical knowledge. Generally, we improve the following things in
our practice:

1.3.1 In terms of upgrading theoretical knowledge

We have been learning and upgrading our theoretical knowledge. The internship period allowed
us to gather real time activity of industrial systems. So the internship period was our crucial
moment to get theoretical knowledge from the company and upgrading our self with the working
environment. Many of this knowledge were gathered from the manufacturing work. Every
manufacturing activity is done in accordance with the action plan and schedule prepared by the
manufacturing plan expert. The manufacturing plan expert states the action to be taken and list
out all the required spare parts. By reading request sheet the assigned technician will perform its
duty based on the written activity.

1.3.2 In terms of upgrading practical knowledge

This internship training is used to improving our practical skills, But before in this internship
training we haven’t enough practical skill and lab experience, so we didn’t know how to change
the theory of the learning process in to practical process however after this internship training we
gained some the knowledge how to operate some machines, how to change the papers to the
work, how to improved our knowledge in practical work, how to solve the problems, how to
communicate the workers, how to manufacture products like gear, plate, shaft by using and
performing different machines and operations. In general, it was an effective experience in
improving our practical skills in varies aspects during the internship program.

1.3.3 In terms of improving industrial problem solving capability

This was our main aim & is part of our project. Having a problem is very important because it
leads try to solve and read more. We improved our company problem solving capability through
observing and asking where the failure or the problem present and what procedure they consider
to identify the problem and how they solve.

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1.3.4 In terms of improving our team playing skills

This internship training is used to improving team playing skills. Work with our friends, with
worker of company, with the students of other university to shear idea and experience.
Therefore, team play skill has the potential to help us improve skills like:

 To increase self confidence

 Easily control the environment
 Easily solve problems
 To shared knowledge’s
 To give fast decision making
 To interpret the problems and solve the problems
 Giving respect for others

1.3.5 In terms of improving our leadership skills

This internship period was a time of improving our leadership skills. We were trying to develop
our leadership skills by giving comments, sharing ideas, participating in the works, how to lead a
team and how to control the worker.

In general, a leader is a person who has strong principles, courage, dedication of a clear vision,
and decision making ability. Therefore, in this internship program we were able to develop
important leadership skills that play the following roles to us:

 Creating and managing the vision

 Making good decision
 Communicating effective
 Using appropriate style and power
 Leading change
 Motivating and developing others
 Resolving conflicts and issues
 Creating positive culture and climate
 Conducting meaningful evaluation

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1.3.6 In terms of understanding about work ethics issues

Work ethics is the basic behavior one should have in doing his job and fulfilling responsibility.
This involves attitude, behavior, respect, communication and interaction; how one gets along
with others. If one fails to respect the work ethics he will be punished according to the rule of the
company. The company has its own rule and ethics regulation. Strong work ethics is a key to be
productive and effective in any given profession. So that in any working environment, we must
fulfill the following expectations and behaviors:

 Respect the rules and values of the company

 Accountability and responsibility
 Be punctual, motivated, confidant
 Give smooth relation to the partners
 Respect all workers

1.3.7 In terms of entrepreneurship skills

Knowing conditions of factory and types of technologies used in factories helps to identify
required product in the market. Also during the internship ways of processing and mechanisms
used in the factory are observed. Generally, entrepreneurship process is the composition of five
basic things.

 Ability to see work opportunities and recognizing their type.

 Ability to change work opportunities to business
 Persistence to continue in the business
 Ability to work in strategic way
 Ability to understand & accept if there is possibility of loss or any problem

Entrepreneurship success depends on personal behavior, skill & profession. Among

Entrepreneur’s characters: -

 Self-confidence and job creativeness

 Positive response to challenges
 Flexibility and ability to adopt some new technologies
 Knowledge of market
 Performing tasks with plan

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While participating in this internship we have to understand that creativity and problem solving
is basic points of entrepreneurs and motivates we are not to be employee because it enables we
know more about my carrier the real challenges and way of business establishment in this
profession.

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1.4 Conclusion & Recommendation

1.4.1 Conclusion
We conclude that university industry linkage program is planned to create a good interaction
between universities and industries to create students that have the capability of understanding,
facing and solving practical problems. It gave us the chance to review what we have learned for
the past semesters. In this program we have learned: -how we communicate with others, how we
manage our time, how can develop our theoretical knowledge, how can improving our practical
skills in varies aspects. Amhara metal industry and machine technology enterprise is comprising
of machine shop, maintenance shop, fabrication and welding shop and foundry shop and
assembly shop. The factory has been designed to produce different items varying in shape, size,
material, design, and production technology and so on, according to their engineering
application. Generally, those vital internship periods were so helpful and experimental
investigation for the last four years’ theoretical analysis. More importantly it is used as a bridge
between a written sciences and a practical world for mechanical engineering students.

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1.4.2 Recommendation
As we understood, the internship program has mutual benefits for the student and the hosting
company in many ways. So, we want to recommend it to the AMIMTDE and our university (i.e.,
industrial linkage and our faculty) in order to enable this internship program to be provided
continuously for engineering students.

Recommendation for AMIMTDE

AMIMTEDE was a well-established company, and it has good production machines. However,
we would like to recommend it based on our observation while we were conducting the
internship program. Thus, we recommend AMIMTDE. The company should be ready for
internship students by preparing project tasks and motivation to achieve this internship program.
There is no research and development department. This causes the workers to have less sense to
upgrade their knowledge and improve this company. The company should also recognize its
employees' problem-solving abilities and work performance through a variety of activities. As
much as possible, the company's policy should be clear and simple. Even if there were
employees who were eager to demonstrate their knowledge, some were unaware of this
assumption. Even if the company follows reverse engineering, there is a shortage of computers in
the company. As much as possible, the company should have a computer in order to reverse
technology. Finally, we strongly recommend that before working on new machines, operators get
proper operating skills.

Recommendation for DMU

As mentioned above, this internship program offers a lot of advantages to the students. For
instance, it helps us to develop not only practical experience but also theoretical knowledge
related to our academic, social skills, and career goals. Because of this and all the listed
advantages above, we would like to recommend our university to keep giving this great chance
to students.

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2. PROJECT REPORT

TITELE: DESIGN OF INCLIND BELT CONVEYOR

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EXCECUTIVE SUMMERY

In the manufacturing industry, raw materials and products need to be transported from one
manufacturing stage to another. Material handling equipment is designed such that it facilitates
easy, cheap, fast, and safe loading and unloading with the least amount of human interference.
For instance, a belt conveyor system can be employed for easy handling of materials beyond
human capacity in terms of weight, height, and length. This project discusses the design
calculations and considerations of a belt conveyor system for medium loads using roll idlers in
terms of size, length, capacity and speed, roller diameter, power and tension, idler spacing, type
of drive unit, diameter, location and arrangement of pulley, intended application, product to be
handled, as well as its maximum loading capacity in order to ensure fast, continuous and
efficient movement of unit loads while avoiding halts or fatalities during loading and unloading.
The successful completion of this project work has generated design data for industrial use in the
development of an automated belt conveyor system which is fast, safe, and efficient.

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2.1. INTRODACTION
2.1.1 Background of belt conveyor
Belt conveyors are transport equipment, which is also nowadays widely used in various
industries. Most of conveyors are designed to transport bulk materials, but they are often used
also for non- bulk goods. In the cases of larger mines or larger material deposits the long belt
conveyors are implemented. In some cases, the slope of the belt is changing
along its length. In these projects the premises are to design a belt conveyor from some
requirements that will be explained later, from these requirements a reliable design as most
optimized as possible has to be find.

Advantages of belt conveyor

As a consequence of the different energy crises, continuous belts started to get popular in every
kind of material transportation installation. The principal advantages of belt conveyors are listed
below.
1. Low cost of operation and maintenance
2. Electric controlled
3. Good energetic efficiency
4. Big transportation capacity
5. Conveyors are not so affected by climate
6. Easy automation
In the other hand there are some inconveniences that are written bellow
1. Big initial investments
2. Difficulty to adapt to changes and new requirements of transportation
3. A consequence of its way of operation is that it can’t make important direction changes.

Components of belt conveyor

Conveyor frame- It is structure which support and maintains the alignments of idlers, pulleys
and drives. There are several prominent frame design types.
a) Most common is a welded steel frame.

b) Aluminum extrusion frame which is popular for flexibility.

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Drive unit- Which imparts power through one or more pulleys or rollers to move belt and its
loads. Generally, drive unit is electric motor with gearbox.
Belt-The belt, which forms the moving and supporting surface on which the conveyed material
is placed. The belt not only carries material, but also transmit the pull. It is the tractive
element. Types of various belts
• Flat belt
• Modular belt
• Cleated belt
• V belt
• Timing belt

Drive pulley or Drive roller

Driven pulley or Driven roller
Take up unit- The take-up device in a conveyor belt system has three major functions:
a) To establish and maintain a predetermined tension in the belt.
b) Remove the accumulation of slack in the belt at start-up or during momentary
overloads, in addition to maintaining the correct operating tension.
c) To provide sufficient reserve belt length to enable re-splicing, if necessary
Electric control panel- Electrical control panel has all electrical components like MCB’s, on
off switch, and VFD.

2.1.2 problem statement and justification

During the transfer mechanism of chip materials from the machine shop to the foundry was take
long time, less speed, high energy. This is usually done with the help of labors and temporary
materials is fabricated for this like wheel barrow. this process is labor intensive and time taking.
In this project we are undertaking design of material handling system which can supply transfer
chip materials continuously to the needed place. Hence there is a need to design a belt conveyor
material handling system, so we will design the belt conveyor material handling system to
automate this process, to save time and minimize the human effort.

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

2.1.3 Objective
General objective

The general objective of this project work is to provide design data base for the development of a
reliable and efficient belt conveyor system that will develop easy and more efficient chips
transfer mechanism.

Specific objective

To attain the general objective, the following specific objectives are set:

 To select number of parts like belt, pulley, idler, motor

 To select standard parts based on loads and stress.
 To select low cost easily available materials.
 To analysis force and stress caused by the load.
 To develop the machine that decreases effort needed to perform the task in the company.
 To develop easy transfer method to reduce the labour force and time.
 To develop easier, safer, faster, more efficient and cheaper to transport materials from
one processing stage to another.

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2.2 LITRATURE REVIW

Seema S. Vanamane [3] "Design, Manufacture and Analysis of Belt Conveyor System used for
Cooling of Mold" In this paper the study is carried out on DISA pattern molding machine to
meet the requirement of higher weight castings. From the DISA specification the belt conveyor
system is designed by using different standards like CEMA (Conveyor Equipment
Manufacture’s Association) standards, some handbooks of belt conveyor system etc. then this
parameter are verified by using Belt Comp software. The result got from the Belt Comp software
is in close agreement of theoretical results. After the design the manufacturing is done and the
installation is done on the manufacturer’s site. The trials are carried out on the belt conveyor
system successfully and the problems occurs during the trials are overcome in the analysis by
taking proper steps.

Ghazi Abu Taher [4] "Automation of Material Handling with Bucket Elevator and Belt
Conveyor" This paper is mainly based on the combination of Belt & Bucket Conveyers to
perform complex task within a short time and successfully in a cost effective way. Belt conveyor
& Bucket elevator are the media of transportation of material from one location to another in a
commercial space. Belt conveyor has huge load carrying capacity, large covering area simplified
design, easy maintenance and high reliability of operation. Belt Conveyor system is also used in
material transport in foundry shop like supply and distribution of molding sand, molds and
removal of waste. On the other hand, Bucket elevator can be of great use during bulk material
handling. On account of this, a machine and its physical description is covered here with some
basic calculation.

Konakalla Naga Ananth [5] " Design and selecting the proper conveyor belt" Belt conveyor is
the transportation of material from one location to another. Belt conveyor has high load carrying
capacity, large length of conveying path, simple design, easy maintenance and high reliability of
operation. Belt Conveyor system is also used in material transport in foundry shop like supply
and distribution of molding sand, molds and removal of waste. This paper provides to design the
conveyor system used for which includes belt speed, belt width, motor selection, belt
specification, shaft diameter, pulley, gear box selection, with the help of standard model
calculation.

AJAGTAP[6] This paper discusses the design calculations and considerations of belt conveyor
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 INTERNSHIP REPORT AND PROJECT 2015 E.C

system for biomass wood using 3 rolls idlers, in terms of size, length, capacity and speed, roller
diameter, power and tension, idler spacing, type of drive unit, diameter, location and
arrangement of pulley, angle and axis of rotation, control mode, intended application, product to
be handled as

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

well as its maximum loading capacity in order ensure fast, continuous and efficient movement of
crushed biomass wood while avoiding fatalities during loading and unloading. The successful
completion of this research work has generated design data for industrial uses in the development
of an automated belt conveyor system which is fast, safe and efficient.

Dr. Kurt Serpil, et.al [7] "Analysis of belt conveyor using finite element method" Belt conveyors
are the most common material handling conveyor in use today. They are generally the least
expensive powered conveyor and are capable of handling a wide array of materials. Depending
on the type chosen, belt conveyor can carry everything. Today, belt conveyors are in use in many
industries, like mining industry, belt conveyors have an increasing importance and use. They
have important part of mining and cement factories, grain manipulation, etc. For a belt conveyor
longer than one kilometer, viscoelastic properties of the belt is unnegligible and longer-life with
healthy operation for conveyors design require detailed engineering calculation. In this study,
areal conveyor project is taken into account. Wave propagation speeds are calculated. Studied
belt is divided into finite number of beam elements all of which are represented by mass, spring
and a dashpot.

A.W. ROBERTS et.al [8] This paper outlines recent research in the area of belt conveying A
review of design trends associated with long overland conveyors is presented indicating the
influence of economic and technical considerations in the design methodology. Aspects of
conveyor dynamics are discussed and research and development work concerned with specific
subjects including belt drum friction, rolling resistance and bulk solid and conveyor belt
interaction. A test rig for examining stability between bulk solids and conveyor belts during
transportation is described.

Harshavardhan A. Kadam et.al [9] For the continuous transportation of material a belt conveyor
is used in the transport of coal and mineral powder it gives high efficiency and environmental
protection. In some cases, according to requirement if increase conveyor inclination up to 170 to
180 the impact on the whole assembly of shaft occur due to this impact of material on conveyor
shaft it break or bend with in few months. An analysis of stress and impact creates on roller shaft
with the help of Hyper mesh and to develop design of shaft for 170 to 180 create model Analysis
using hyper work. By using design failure modes and effects Analysis (DFMEA) for systematic,
proactive method for identifying where and how it might fail.

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Deepak Gupta [10] Material handling equipment are designed for many advantage such as easy,
cheap, fast and safe loading and unloading condition. Belt conveyor systems are design for easy
handling of materials in terms of weigh: and height. This paper discusses the design and
considerations of belt conveyor system for sample weight, in terms of size, length, capacity and
speed, roller diameter, location and arrangement of pulley, angle and axis of rotation, control
mode, intended application, product to be handled.

LARRY M. STRECKER, et.al [11] This case involves three competing warehouse designs
requiring time study analysis, economic analysis, layout analysis and sensitivity analysis of
business changes to evaluate trade-offs between automated and conventional equipment and
between capital and operating expenses.

Mr. Nasif Hassan Khan Presented paper on “Fabrication of a Conveyor Belt with Object Sorting
and Counting Facility” includes factors and basic component used in conveyor system. In this
paper we studied about how to use factor and basic component in a conveyor system and avoid
accident and defective parts by using control system. In this paper they include design of
mechanical and electrical component and program related to control system.

Mr. Abhijit Gaikwad, et.al are presented paper on “Design and development of automated
conveyor system and material handling” and they discussed about the design for belt conveyor
system. In this review we study about Materials and products need to be transported from one
manufacturing stage to another.

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2.3 METHODOLOGY

Flow chart

The following flow chart is the general procedure for our motor-driven belt conveyor design.

Figure 5 methodology flow chart

This project is performed by some important procedures that each steps cannot be ignored.
Starting from selection of the appropriate material up to final conclusion of the project follows
brief and common procedure as other designs fulfilled. The following will simply show
methodologies we have followed;

 Defining the problem

This is the first basic step of the project in which all the idea to solve begins.

In this instance the question why a belt conveyor should be design is answered and also what
necessary inputs required is also defined.

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 Material selection

Selecting the appropriate materials for each component of the belt conveyor depends on the
transported things. For this reason, the thing being transported is metal work pieces. So, the
selected material for the conveyor should have good heat resistance and enough strength to carry
the metal. To perform the matrix tables, we use the following basic principal procedures:
To use the matrix table follows the following procedures.
Step1: Select the appropriate and available materials that find our surrounding using standard
tables depending on yield and tensile strength of a material related to the calculated one and also
other parameters of a material i.e., cost, environment factor, durability etc.
Step2: Prepare the tables and list the materials into the column and also list the properties of the
material into the row.
From our designed parts of a belt conveyor machine, we select the appropriate materials using
matrix tables. For the following we select the materials:
• Material selection for shaft design
• Material selection for key
• Material selection for supporter.

The physical and mechanical properties of materials are also very essential parameters for
material selection.
 Analysis and optimization
This is the detail body of the project and it may include mathematical analysis of each
part of the tool to be design.
 Result and discussion
This is the final output of the project that a designer gets from the detail analysis.
Discussion also includes whether the design meets the required objective or not.
 Conclusion and recommendation
Conclusion is a sum or a general idea that can be extracted from the whole project. While
recommendation is the expression of displeasure faced during the whole project
performed.

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2.4 DESIGN ANALYSIS OF BELT CONVEYOR

Belt conveyor design calculation
The design of belt conveyor is greatly influenced by the material to be handled.

Basic data requirement

1. The material to be handled

2. Capacity peak or surge rate expressed in ton/hour
3. Path travel
4. feeding and discharge conditions
5. Operating conditions
6. Required life of installation

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Given

B=700mm=0.7m 𝑝1=4kw
.
𝑘𝑔
l =50m ρ=1800
𝑚3

ϴ=200 𝐿𝑡=100m

Φ=1800

f =0.05

p=0.81
𝑘𝑔
𝑞 =46
𝑠 𝑚

ℎ0=0.5m

ℎ1 = 2.5𝑚.

ℎ2=5m

H=ℎ2 − ℎ0=5m-0.5m=4.5m

a =0.11

b=60

D=400mm=0.4m

Π=3.1416

t =0.014m

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solution

1. Capacity of belt conveyor

The material to be conveyed is in bulk, then the capacity Q(ton/hour) is calculated

𝑄 = 3.6ρ ∗ A ∗ V … … . .1 where
𝑘𝑔
ρ= the density of the material== 1800 from table 1.5
𝑚3

A=the cross-sectional area of the material being conveyed

V=velocity of the belt

But the conveyor has an inclination ϭ, then the capacity Q will be reduced by a factor P.

𝑄ϭ = 3.6 ∗ 0.81 ∗ ρ ∗ A ∗ V.......2

First find velocity and area

(𝐵+4)B2
𝐴= ……………………3 Where B=belt width=700mm from table 1.1
110

(𝑂.7+4)0.72
𝐴= . P=0.81 from table 1.3
110

= 0.021𝑚2

p=Q*H*3.75̸1000……………….4 where H is elevation difference

3.6∗1800∗0.021∗4.5∗3.75∗0.81∗𝑉
4𝑘𝑤 = 1000
.
𝑚
𝑉 = 2.15 .
𝑠
𝑚
Take 𝑉 = 2.15 at equation 2
𝑠

𝑄ϭ = 3.6 ∗ 0.81 ∗ ρ ∗ A ∗ V.

𝑄ϭ = 3.6 ∗ 0.81 ∗ 1800 ∗ 0.021 ∗ 2.15.

𝑘𝑔 𝑡𝑜𝑛
= 237 .= 853.2
𝑠 ℎ𝑜𝑢𝑟

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2. Resistance forces
a. Frictional force on the moving parts (belt, idlers, drum etc.)

𝑟1 = 𝑓𝑞𝑠𝑙…………1 where f=coefficient of friction force=0.05 from table 1.2

l=belt length between two extreme drum centers

𝑘𝑔
𝑞 =weight of the moving parts of the belt =46 from table 1.1
𝑠 𝑚
2
(𝑑1−𝑑2)
𝐿𝑡 = 2𝑙 + 1.57(𝑑1 + 𝑑2 ) − 4𝑙
…….2

(0.4−0.4)2
100𝑚 = 2𝑙 + 1.57(0.4 + 0.4) − .
4𝑙

𝑙 = 49.37𝑚.

Take 𝑙 = 49.37𝑚 at equation 1

𝑟1 = 0.05 ∗ 46 ∗ 49.37.

= 113.5𝑁.

b. Frictional force due to material transport

𝑟2 = 𝑓𝑞𝑚𝑙𝑚 … … ….3 Where 𝑞𝑚=weight of material transported of belt

𝑙𝑚=the distance that the material is transported

𝑙𝑚 = 𝑙 − 0.1𝑚 = 49.37 − 0.1 = 49.27𝑚.

𝑞𝑚 = ϭ .............................
4.
3. 6𝑉

337
𝑞𝑚 = 3.6∗2.15.
𝑘𝑔
𝑞𝑚 = 30.6 .
𝑚

Take 𝑘𝑔
= 49.49.27𝑚 and = 30.6 at equation 3
𝑙𝑚 𝑚
𝑞𝑚

𝑟2 = 0.05 ∗ 30.6 ∗ 49.27.

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

𝑟2 = 75.38𝑁.

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

c. Force required to overcome the level difference

𝑟3 = 𝑞𝑚𝐻 … … … 5.

𝑟3 = 30.6 ∗ 4.5.

𝑟3 = 137.7𝑁.

d. Discharging

force Fixed discharge

𝑟4 = 𝑎𝑞𝑚 … … … … .6. a=0.11 and b=60 from table 1.1

𝑟4 = 0.11 ∗ 30.6.

𝑟4 = 3.37𝑁.

Mobile discharge

𝑟5 = 𝑏 = 60𝑁 … … …..6

e. Fixed resistance

The total resistance to motion R, is the sum of the resistance

𝑅 = 𝑟1 + 𝑟2 + 𝑟3 + 𝑟4.....................7. (for fixed discharge)

𝑅 = 113.5 + 75.38 + 137.7 + 3.37.

= 329.95𝑁 = 330𝑁.

𝑅 = 𝑟1 + 𝑟2 + 𝑟3 + 𝑟5......................8. (for mobile discharge)

𝑅 = 113.5 + 75.38 + 137.7 + 60.

= 386.58𝑁.

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

3. Belt tension

𝑅 = 𝑇 − 𝑡 … … 1.

Figure 6 belt tension on drive pulley

The relationship between T and t may be expressed

𝑅 = 𝑇 − 𝑡.

𝑇
= 𝑒𝑓𝜙 … … … .2.
𝑡

𝑇
= 𝑒0.05∗3.1416. where π=1800
𝑡
𝑇
= 1.17. 𝑇 = 1.17𝑡
𝑡

𝑝 = (𝑇 − 𝑡)𝑉.

4𝑘𝑤 = (𝑇 − 𝑡)2.15 Take 𝑇 = 1.17𝑡

4𝑘𝑤 = (1.17𝑡 − 𝑡)2.15

𝑡 = 10944𝑁 = 10.9𝐾𝑁.

𝑇 = 1.17𝑡 = 1.17 ∗ 10944𝑁 = 12804.5𝑁 = 12.8𝑘𝑤.

4. Torque and minimum power

T𝑒=(T-t)r………………...1

𝑇𝑒 = (12804.5 − 10944)0.2.
Pm = P/η=4kw/0.842 = 4.75𝑘𝑤 ∼ 5𝑘𝑤
= 372𝑁_𝑚.

𝐶
𝑡

𝐶
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 INTERNSHIP REPORT AND PROJECT 2015 E.C

5. Th
e
cy
cl
e
ti
m
e
of
co
nv
ey
or

=
2𝑙

…
…
…
…
….
1.
�
�

=
2∗5
0
.=
2*
50/
2.1
5=
46.
5
𝑆−1
2
.
1
5

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

6. The number revolution

𝑉
𝑛=
𝜋∗𝐷 … … … … 1.
2.15
𝑛= =103𝑟𝑝𝑚
3.1416∗0.4

7. Shaft design

Shaft subjected to combined twisting moment and bending moment.

 Shafts Subjected to twisting moment

𝑇
= 𝑟 … … … … .1.
𝜏
𝐽
where T=twisting moment or torque acting up on the shaft

J=polar moment of inertia of the shaft about axis of rotation

r =distance from neutral axis to the outer most fiber

=𝑑 , 𝑤ℎ𝑒𝑟𝑒 𝑑 𝑖𝑠 𝑡ℎ𝑒 𝑑𝑖𝑎𝑚𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡

2

τ=torsional shear stress

for round solid shaft, polar moment of inertia

𝜋∗𝑑4
𝐽= … … … . .2.
32

3.1416∗0.14
= 32 =9.8 ∗ 10−6 𝑚4
𝜋∗𝜏∗𝑑3
𝑇 = … … … … 2. 𝑇 = 372𝑁_𝑚ˍfrom the above
𝑒 16 𝑒

𝑇𝑒∗16
𝜏= = 1.9𝑀𝑝𝑎.
𝜋∗𝑑3

 Shafts subjected to bending moment

𝑀 𝜎𝑏
= … … … … .3. where M=bending moment
𝐼 𝑦

I=Moment of inertia of cross-sectional area of the

shaft about axis of rotation

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

𝜎𝑏=bending stress

y =distance from neutral axis to the outer most fiber

moment of inertia for a round solid shaft

𝜋∗𝑑4
𝐼= … … … … … 3.
64

𝐽
𝐼= 9.8∗10−6
𝑚4= = 4.9 ∗ 10 𝑚4 .
−6
And
= 2
2

𝑑 100
𝑦= = = 50𝑚𝑚 = 0.05𝑚.
2 2

𝜎𝑏 = 84𝑀𝑝𝑎 𝑖𝑠 𝑡𝑖𝑛𝑠𝑖𝑙𝑒.
𝜋∗𝑑3∗𝜎𝑏
𝑀= … … … … … 4.
32

3.1416∗0.13∗84∗106
= 32 .

= 8246.7 𝑁_𝑚.

.Shafts subjected to combined twisting moment and bending moment According to

maximum shear stress theory, the maximum shear stress in the shaft.

𝜏𝑚𝑎𝑥 = 1⁄2 √𝜎𝑏2 + 4𝜏2 … … … … .5.

𝜏𝑚𝑎𝑥 = 1⁄2 √(84 ∗ 106)2 + (4 ∗ 1.9 ∗ 106)2.

= 42𝑀𝑝𝑎.

𝑇𝑒 = √𝑀2 + 𝑇2 … … … … … 6. 𝑇𝑒 = 𝑖𝑠 𝑘𝑛𝑜𝑤𝑛 𝑎𝑠 𝑒𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝑡𝑤𝑖𝑠𝑡𝑖𝑛𝑔 𝑚𝑜𝑚𝑒𝑛𝑡

𝑇𝑒 = √(8246.7)2 + (372)2.

= 8255𝑁_𝑚.

According to the maximum normal stress theory, the maximum normal stress in the shaft.

The equivalent bending moment (𝑀𝑒) is

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

𝑀𝑒 = 1 (𝑀 + √𝑀2
+ 𝑇 2) … … … . .7.
2

1
= (8246.7 + √(8246.7)2
2 + (372)2)

= 16501.7𝑁 − 𝑚

8. Roller ball bearing selection

Figure 7 roller ball bearing

Silver lead deposited due to the following properties. From table 1.6

9. Bolt selection

Select medium carbon steel due to the properties 𝑆𝑝 = 600𝑀𝑃𝑎 𝑎𝑛𝑑 𝑆𝑡 = 830𝑀𝑃𝑎.

From table 1.7

Figure 8 heavy-hex-nuts

 Select M14 Hex-nuts W=24 mm and H=14.3 mm from table 1.8

 Select M14 Hex-nuts, tread pitch=2 mm, W=24 mm and H=9.25 mm from table 1.9
 Select M14 bolt head W=24mm and H=14.3 mm from table 1.10

Bolt length measured under the head, and 𝐿𝑡 = 𝑡𝑟𝑒𝑎𝑑 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑖𝑛 𝑚𝑖𝑙𝑖𝑚𝑖𝑡𝑒𝑟

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

Figure 9 bolt

2𝐷 + 6 𝐿 ≤ 125 𝐷 ≤ 48
𝐿𝑡 = {2𝐷 + 12 125 ≤ 𝐷 ≤ 200 L=bolt length
2𝐷 + 25 𝐿 > 200

Where L and 𝐿𝑡 are in millimeters

𝐿𝑡 = 2 ∗ 14 + 6 = 34 .

𝐿 = 𝐿𝑡 + 60𝑚𝑚 = 34 + 60𝑚𝑚 = 94𝑚𝑚.

10. Flat belt selection

System Requirements – System requirements are also crucial to belt selection, the following are
some considerations that are taken when selecting a drive belt:

 space limitation for operation

 Take-up allowance and take-up design
 Belt construction and service life
 Driver/Driven RPM
 Pulley diameters and center distance
 type of drive required

Figure 10 steel cord belt

Steel cord conveyor belts are highly wear-resistant and used principally for long-haul conveying,
heavy loads and physically demanding applications. They are especially suitable for high-mass
or high-volume flows and for abrasive materials.

11. Flange coupling selection

flexible coupling is widely used for its compact design, easy installation, convenient
maintenance, small size and light weight. As long as the relative displacement between shafts is
kept within the specified tolerance, coupling will operate the best function and have a longer

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

working life. Thus,

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

it is greatly demanded in medium and minor power transmission systems driven by motors, such
as speed reducers, hoists, compressors. conveyers. spinning and weaving machines and ball mills.

Figure 11 push pin type coupling

12. Frame and support

 Frame=0.48m*50m*0.01m
 mild steel sheet metal=0.71m*49.58m*0.01m
 Select square hollow stainless steel with area=0.36𝑚2 means l=60mm
ℎ0 = 0.5𝑚 𝑎𝑛𝑑 ℎ1 = 2.5𝑚 𝑎𝑛𝑑 ℎ2 = 5𝑚
W=730mm

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

Table 1 cost analysis

No Components Material Cost Total cost

1 Belt Steel cord $1.98/m*100m 10098ETB
2 Shaft AISI 4140 $1.8/kg*7.5kg*3 2065.5ETB
03 Support CS 4142 $1.5/kg*50kg 3750ETB
4 Pulley AISI 4140 $1.8/kg*4.85kg*3 1335.7ETB
5 Key Mild steel $0.7/kg*0.9kg *6 306ETB
Chrome Steel
6 Bearing $11/piece *4 2224ETB
- SAE 6320
7 Bolt and nut Steel $0.9/piece*36 1652.4ETB
8 Coupling Cast iron $2.1/kg *2 214.2ETB
permanent
9 Motor magnet servo $200 10162ETB
motor

Total Machining cost=31501.8ETB

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2.4.1 Cost analysis

There are three main costs to be considered
1. Material cost
2. Human power (labor) cost
3. Machining cost

1. Material cost

Material cost is the amount of money invested to buy material is the production of components.

The table below illustrates the amount invested to buy material of each component.

1. Human power (labor) cost

Labor cost is a cost of paid to workers during an accounting period on daily, weekly, or monthly.
It simply means a cost that expense for workers.
The total estimated labor cost for one person to be 1000ETB and it needs 3 labors so
➢ The total cost of labors is 3000ETB

2. Machining cost

Machining cost is a cost that expenses for the production process of components conveyor which
is only shaft of conveyor then the cost for machining of shaft is 2500ETB
Therefore, the total conveyor cost is the sum of the three main costs
Total cost = 31501.8ETB+3000ETB+2500ETB
Total cost = 37001.8ETB (for one conveyor)

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2.5 RESULT AND DISCCUTION

2.5.1 Result

Table 2 result
S/N Part Dimension quantity
Belt Length=100m 1
1. Width=700mm
Thickness=14mm
Support ℎ0 = 0.5𝑚. 2
ℎ1 = 2.5𝑚. 2
2. ℎ2 = 5𝑚. 2
W=730mm 7
L=50m 2
Pulley D=400mm 3
3.
d =182mm
Bearing D=215mm 4
4. d =100mm
w=47mm
5. Shaft D=100mm 2
Keyway W=28mm 6
6. Depth=6.4mm
Radius=0.4mm
Bolt M14 24
7.
M8 6
Nut M14 24
8.
M8 6
Frame L=50m 2
9. t =10mm
w=480mm
10. Coupling D=50mm 2

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2-D and 3-D drawing

1. Belt

2. Frame

3. Shaft

4. Pulley

5. Idler

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 INTERNSHIP REPORT AND PROJECT 2015 E.C

6. Motor

7. Bearing

8. Key

9. Coupling

10. Bolt

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2.5.2 Discussion
The machine was designed to respond to issues that were encountered while working for the
company. This machine was designed by combining several assumptions and practical
measurements. The machine has a capacity of roughly 0.81 KN and is used to determine
component dimensions.
The belt, which forms the moving and supporting surface on which the conveyed material is
placed, not only carries material, but also transmits the pull. It is the tractive element. The
tension on the belt and the small work piece are considered. The length of the belt is 50m, the
𝑡𝑜𝑛
width is 700mm, the speed is 2.15m/s, the thickness is 14mm and the capacity is 853.2 .
ℎ𝑜𝑢𝑟

Conveyor pulleys are used to drive conveyor belts. The torque and tension considered and the
dimensions are diameter 400mm, length of 760 mm.
A shaft that uses a belt as its means of connecting two or more axles and a power source to drive
a driver axle. Bending forces from conveyor belt tensions, torsion from the drive unit, and
deflection are all taken into account during the design. The dimensions are a diameter of 100mm
and a length of 700mm.
The roller supports the belt and makes it easy to clean, as well as allows free rotation of the belt
conveyor in all directions. It has a diameter of 400mm.
To transmit maximum power, we select sleeve or muff coupling and to prevent relative motion
between them we use square sunk key, to support moving machine element we use ball bearing.

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2.6 CONCLUSION AND RECOMMENDATION

2.6.1 Conclusion
Our belt conveyor is meant to move work components (also known as unit loads) from one shop
to another. The load operating on the belt, as well as the torque the belt receives while rotating
with the drive motor, define the tension of the belt. We choose the suitable material for each
component while building the conveyor. The belt, for example, is heat resistant and hence
capable
of transporting hot materials. Each component is examined to determine 0whether it is safe or not.
Generally, we made every effort to design motorized belt conveyors.
2.6.2 Recommendation
We develop belt conveyors to move discrete material using current specifications in these
applications. However, because the company intends to start casting in the future, our conveyor
design is not appropriate in some situations. For the casting shop, the corporation should develop
a new one.

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Reference

[1] Ogedengbe, T. I. (2010). Lecture Note on Applied Techniques of Production Management.

pp. 16-20.

[2] Richardson, J. F., Harker, J. H. and Backhurst, J. R. (2002). Particle Technology and
Separation Process. Vol., 2, 5th Edition, Elsevier publisher, New Delhi, India. Pp. 29-35.

[3] Seema S. Vanamane*, Pravin A. Mane**“Design, Manufacture and Analysis of Belt

Conveyor System used for Cooling of Mould”, Lecturer, Department of Mechanical
Engineering,
Walchand College of Engineering

[4] Ghazi Abu Taher1, Yousuf Howlader2, Md. Asheke Rabbi3, Fahim Ahmed Touqir4
“Automation of Material Handling with Bucket Elevator and Belt Conveyor”, Department of
Industrial Engineering and anagement Khulna University of Engineering & Technology

[5] Konakalla Naga Ananth DESIGN AND SELECTING THE PROPER CONVEYOR-
BELTforMechanical Engineering Departments, KLU Guntur

[6] Aniket A Jagtap, Shubham D Vaidya, Akash R Samrutwar, Rahul G Kamadiand Nikhil V
BhendeDESIGN OF MATERIAL HANDLING EQUIPMENT: BELT CONVEYOR SYSTEM
FOR CRUSHEDBIOMASS WOOD USING V MERGE CONVEYINGSYSTEM

[7] Assoc.Prof. Dr. Kurt Serpil, Assist.Prof. Dr. Gerdemeli I. CengizC.Faculty of Mechanical
Engineering Istanbul Technical University – Turkey ANALYSIS OF BELT CONVEYOR
USING FINITE ELEMENT METHOD

[8] RECENT RESEARCH DEVELOPEMENTS IN BELT CONVEYOR TECHNOLOGY

A.W. ROBERT and A. HARRISON UNIVERSITY OF NEWCASTLE, AUSTRALIA.

[9] Design and Analysis of Belt Conveyor Roller Shaft Harshavardhan A. Kadam, Nilesh S.
Hyalij PG Scholor & Department of Mechanical Engineering MET’s IOE BKC Adgaon Nashik
& SavitribaiPhule Pune University, Pune India.

[10] Study and Performance of Belt Conveyor System with Different Type Parameter Deepak
Gupta
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Appendix

The characteristics and behavior of a variety of materials is given in table

Table 1.1-Characteristics of material

Table 1.2-Frictional force coefficient

Table 1.3. Value of p as a function of σ

Basic d(mm) D(mm) Keyway Keyway Keyway

bearing no length(mm) depth(mm) radius(mm)
6320 100 215 28 6.4 0.4

Table 1.4-Selection of ball bearing

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Table 1.5-Specific weight of bulk material and maximum permissible inclination of belt conveyor

Bearing Fatigue Conform- Embed- Anti - Corrosion Thermal

Material Strength Ability ability scoring resistance conductivity
Tin base Poor Good Excellent excellent excellent Poor
Babbitt
Lead base Poor to fair Good Good Good to Fair to Poor
Babbitt excellent good
Lead Fair Poor Poor poor good Fair
Bronze
Copper Fair Poor Poor to fair Poor to fair Poor to fair Fair to good
Lead
Aluminum Good Poor to fair Poor good excellent Fair
Silver Excellent Almost Poor Poor excellent Excellent
none
Silver lead Excellent excellent Poor Fair to excellent Excellent
deposited good

Table 1.6-The properties of the material to be selected the ball bearing

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Size Min, proof Min, tensile Material

range(mm) strength(106𝑃𝑎) strength(106𝑃𝑎)
M1.6-M16 310 420 Low or medium carbon steel
M5-M24 380 520 Low or medium carbon steel
M1.6-M36 600 830 Medium carbon steel

Table 1.7-Metric steel bolt-property classes

Nominal size D(mm) Width W(mm) Height H(mm)

M12 21 12.3
M14 24 14.3

Table 1.8-Basic dimensions of metric heavy Hex-Nuts

Nominal Thread pitch(mm) type of bolt

diameter(mm) Heavy
W H
M12 1.75 21 7.95
M14 2 24 9.25
M16 2 27 10.75
M20 2.5 34 13.40

Table 1.9-Dimenshion of metric Hex-bolts

Bolt diameter(mm) Head size(mm)

W H
M12 21 12.3
M14 24 14.3
M20 27 17.1

Table 1.10-Dimenshion of metric hex-heads

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