CHENDHURAN

POLYTECHNIC COLLEGE
PUDUKKOTTAI – 622507

AUTOMATIC POWER SAVING CONVEYOR

PROJECT WORK 2023-2024

Done by

NAME REG NO
GANGESWARAN M 22209611
HARIHARA SUBRAMANIAN S 22209612
HARIHARA SUDHAN S 22209613
IYYAPPAN V 22209615
JAGATHEESH S 22209616
MADHAVAN A 22209618

Report Submitted in partial fulfillment for the award of the

“Diploma in Mechanical Engineering” of the
Directorate of technical education,
Government of TamilNadu

Under the Guidance of

Mr.S.BALAGANESH BE.,
LECTURER

DEPARTMENT OF MECHANICAL ENGINEERING

CHENDHURAN POLYTECHNIC COLLEGE

PUDUKKOTTAI – 622507

1
 BONAFIDE CERTIFICATE

This is to certify that the report titled

AUTOMATIC POWER SAVING CONVEYOR

is a Bonafide record of work done by

Register Number: of the Department of

Mechanical Engineering in partial fulfillment for the Directorate of Technical

Education, Government of Tamil Nadu during the academic year 2023-2024

PROJECT GUIDE HEAD OF THE DEPARTMENT

Mr. S. BALAGANESH B.E., Dr.SG.SHELVARAJ, M.E, Ph.D.,

(LECTURER/MECH) HOD/MECH and PRINCIPAL

Submitted for the Board Examination held on

Internal Examiner External Examiner

2
 ACKNOWLEDGEMENT

At the outset, we express our thanks to our esteemed chairman. Thiru

AVM SELVARAJ and beloved CEO Dr. AVM.S.KARTHICK B.E.,MBA.,
Ph.D for their dynamic role and for elevation of our institution to greater heights
by providing us with all the infrastructure and other essential facilities.

Also we would like to extend our thanks to our principal & also HOD of
Mechanical Engineering Department Dr. S.G.SHELVARAJ M.E.,Ph.D for his
constant effort in helping us by providing the necessary equipment and
materials that were used to build the project.

Not the more formality but from the depth of our heart, we extend our
sincere thanks to our project guide Mr. S. BALAGANESH B.E., lecturer in
Department of Mechanical Engineering for his valuable suggestions, motivation,
and constant support.

We are really indebted to our parents, faculty members and our friends
for their timely help, and for the mental and moral support. Along with their
blessing of the almighty, we will continue to feel the success.

We would like to submit our special thanks to our Department Staff

Members and Lab Instructors and other non teaching staff for their valuable
suggestions to improve the content and quality of the project.

We also exhibit our thanks to one and all who had constantly supported
us either directly or indirectly to complete in completing this project
successfully.
 CONTENTS
CHAPTER
TITLE PAGE NO
NO

ABSTRACT 01

I INTRODUCTION 02

II LITERATURE REVIEW 09

III METHODOLOGY 12

IV WORKING PRINCIPLE 16

V DIAGRAM 18

VI COST ESTIMATION 20

VII FEATURES 23

VIII CONCLUSION 25

IX REFERENCES 27
 ABSTRACT
The paper presents an effective solution for conventional packaging system in
industries to reduce the manual efforts. The simplest version for automation in the
field of transportation & packaging is the result of our research. The main idea of
our research is to fabricate a small and simple conveyor belt system and automate
the process of packaging small cubic piece of wood into small paper box. A low
cost IR sensor, is used to detect the object. Electric DC motor used as output
actuator for the system to move the conveyor belt after getting the orders from the
control system. The efficiency of the approach confirmed by the results of
theoretical & experimental research of control system based on industrial
controllers. The result obtained show that the system able to decrease product
packaging time and increase product packaging rates compared with conventional
manual system.
INTRODUCTION
 CHAPTER I
INTRODUCTION
Automation is the use of control system for handling different processes and
machineries to replace human efforts. Nowadays, more and more companies are
switching to automation. The implementation of advanced automatic control
system on the basis of industrial controllers enable us to programmatically perform
a main handling system effectively. This paper will focus on the implementation of
requirements to control the belt conveyor. The use of automatic control on all parts
of the machine system; which will play a major role in controlling all the parts of
the system. Our research is about to fabricate an automated packaging machine
system. Electrical DC motors control were used as actuators for the entire process
to move the upper & lower conveyor belts and the sensor used to feed the conveyor
system by system information. Conveyor belt used for transporting samples from
one location to another, which would be packaged into a specific paper boxes later.
Automated system reduces the labor cost and the production time with reduction of
product packaging rate.

Conveyor Belt

A conveyor belt is one of many types of conveyor systems. The belt is a

loop of flexible material as shown in Figure 1(a) used to mechanically link two or
more rotating shafts, most often parallel. A belt conveyor system consists of two or
more pulleys (sometimes referred to as drums), with an endless loop of carrying
medium that rotates about them. 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.

Packaging

Packaging is the technology of using conveyor belts for enclosing or

protecting products (food, wood, and material) for storage, pack objects together
into containers, sale, and use. Packaging also refers to the process of design,
evaluation, and production of packages. Packaging can be described as a
coordinated system of preparing goods for transport, warehousing, logistics, sale,
and end use. Packaging contains, protects, preserves, transports, informs, and sells.

Why this Machine

The conveyor belt changed the face of the industrial economy around the
world. Today, it has applicable for Material Handling based on LDR 11 uses in
countless industries, such as transportation and food services. According to the
survey performed 85% industrial units face difficulties in handling bulk material
packaging. Conventional ways are responsible for material wasting, time wasting
& above all a poor management. In order to overcome those drawbacks not only
Belt & sensors are combined but also artificial intelligence brought in use.
Efficiency & accuracy of the system were ensured using the sensor.

Primitive conveyor belts were used since the 19th century. In 1892, Thomas
Robins began a series of inventions which led to the development of a conveyor
belt used for carrying coal, ores and other products. In 1901, Sandvik invented and
started the production of steel conveyor belts. In 1905 Richard Sutcliffe invented
the first conveyor belts for use in coal mines which revolutionized the mining
industry. In 1913, Henry Ford introduced conveyor-belt assembly lines at Ford
Motor Company's Highland Park, Michigan factory. In 1972, the French society
REI created in New Caledonia the longest straight-belt conveyor in the world, at a
length of 13.8 km. Hyacynthe Marcel Bocchetti was the concept designer. In 1957,
the B. F. Goodrich Company patented a Möbius strip conveyor belt, that it went on
to produce as the "Turnover Conveyor Belt System". Incorporating a half-twist, it
had the advantage over conventional belts Conveyors are durable and reliable
components used in automated distribution and warehousing, as well as
manufacturing and production facilities. In combination with computer-controlled
pallet handling equipment this allows for more efficient retail, wholesale, and
manufacturing distribution.

It is considered a labor-saving system that allows large volumes to move

rapidly through a process, allowing companies to ship or receive higher volumes
with smaller storage space and with less labor expense. Belt conveyors are the
most commonly used powered conveyors because they are the most versatile and
the least expensive. Products are conveyed directly on the belt so both regular and
irregular shaped objects, large or small, light and heavy, can be transported
successfully. Belt conveyors are also manufactured with curved sections which use
tapered rollers and curved belting to convey products around a corner. These
conveyor systems are commonly used in postal sorting offices and airport baggage
handling systems. Belt conveyors are generally fairly similar in construction
consisting of a metal frame with rollers at either end of a flat metal bed. Rubber
conveyor belts are commonly used to convey items with irregular bottom surfaces,
small items that would fall in between rollers (e.g. a sushi conveyor bar), or bags
of product that would sag between rollers. The belt is looped around each of the
rollers and when one of the rollers is powered (by an electrical motor) the belting
slides across the solid metal frame bed, moving the product. In heavy use
applications the beds which the belting is pulled over are replaced with rollers. The
rollers allow weight to be conveyed as they reduce the amount of friction generated
from the heavier loading on the belting. The exception to the standard belt
conveyor construction is the Sandwich Belt conveyor. The Sandwich Belt
conveyor uses two conveyor belts, instead of one. These two conventional
conveyor belts are positioned face to face, to firmly contain the items being carried
in a "sandwich-like" hold.

BRIEF CLASSIFICATION OF CONVEYORS

A wide variety of related conveying machines are available, different as regards

principle of operation, means and direction of conveyance, including vibrating

1. Screw conveyors

2. Pneumatic conveyors

3. The moving floor system, which uses reciprocating slats to move cargo, and

4. Roller conveyor system, which uses a series of powered rollers to convey boxes
or pallets.

CONSTRUCTION

One typical layout of BCS is the conventional troughed belt conveyor

(Figure 1.1 and Figure 1.2). The length of a belt in such a system may vary from 10
m to 20,000 m. The velocity can reach up to 9 m/s and the width can vary from
about 0.3 m to 3.2 m. Today's the highest capable belt conveyors carry up to
40,000 tons/hour of lignite at the RWE lignite mines in Germany (Küsel, 2004). A
troughed belt conveyor normally consists of an endless rubber belt reinforced in
the warp or longitudinal direction by a polyester or nylon fabric or steel cords. The
belt is supported along its length by rotating idler rolls and suspended between
pulleys at either end. A drive pulley is powered to rotate the belt and Figure-2 -
Construction of Conveyor belt move the materials on the belt forward. A
tensioning device, also called a take-up, applies pre-tension on the belt to limit belt
sag and to allow drive power transmission (Figure 1.3). The belt can be stopped by
means of an operational stop utilizing the motors or an emergency stop utilizing
brakes if the BCS has brakes.

The configuration and applied components of the system can vary based on
design requirements. Taking the assembled elements into account, a belt conveyor
can be considered as a system that consists of a number of components. Such a
system is as reliable as the combined reliability of its components. The malfunction
of one of the components may lead to expensive downtime if it causes a total
shutdown of the system. The downtime of one of the conveyors in a sequential
conveying system may result in a stop of the production process. Increasing the
reliability of the components of a BCS, and therefore of the BCS itself, is a direct
way to minimize system downtime and to reduce the cost of downtime for the
companies using belt conveyors. Since a BCS cannot be designed to be 100%
reliable and the reliability of BCS components decreases with aging and when
wear occurs, proper maintenance techniques are required to maintain the reliability
of the various components and the system.

THE USE OF IR-SENSORS

An infrared sensor is an electronic device, that emits in order to sense some

aspects of the surroundings. An IR sensor can measure the heat of an object as well
as detects the motion. These types of sensors measure only infrared radiation,
rather than emitting it that is called a passive IR sensor. Usually, in the infrared
spectrum, all the objects radiate some form of thermal radiation. These types of
radiations are invisible to our eyes, that can be detected by an infrared sensor. The
emitter is simply an IR LED (Light Emitting Diode) and the detector is simply an
IR photodiode that is sensitive to IR light of the same wavelength as that emitted
by the IR LED. When IR light falls on the photodiode, the resistances and the
output voltages will change in proportion to the magnitude of the IR light received.

TYPES OF IR SENSORS:

Active IR Sensors: Active IR Sensors are the type of IR Sensors that employs an
IR source & IR detector (emitter & receiver). They operate by transmitting energy
from either a light emitting diode (LED) or a laser diode. A phototransistor is used
as an active IR detector. In these types of IR sensors, the LED or laser diode
illuminates the target, and the reflected energy is focused onto a detector.
Photoelectric cells, Photodiode or phototransistors are generally used as detectors.
The measured data is then processed using various signal-processing algorithms to
extract the desired information. Active IR detectors provide count, presence, speed,
and occupancy data.

Passive IR Sensors: These are basically IR detectors; they don't use any IR
source. These form the major class of IR sensors/detectors. A passive infrared
system detects energy emitted by objects in the field of view and may use signal-
processing algorithms to extract the desired information. It does not emit any
energy of its own for the purposes of detection. Passive infrared systems can detect
presence, occupancy, and count.

IR SENSOR REQUIRED FOR ENERGY SAVING CONVEYOR

 Obstacle Sensing Circuit or IR Sensor Circuit A typical IR sensing circuit is
shown below. It consists of an IR LED, a photodiode, a potentiometer, an IC
Operational amplifier and an LED. IR LED emits infrared light. The Photodiode
detects the infrared light. An IC Op -Amp is used as a voltage comparator. The
potentiometer is used to calibrate the output of the sensor according to the
requirement. When the light emitted by the IR LED is incident on the photodiode
after hitting an object, the resistance of the photodiode falls down from a huge
value.

One of the inputs of the op -amp is at threshold value set by the

potentiometer. The other input to the op-amp is from the photodiode's series
resistor. When the incident radiation is more on the photodiode, the voltage drop
across the series resistor will be high. In the IC, both the threshold voltage and the
voltage across the series resistor are compared. If the voltage across the resistor
series to photodiode is greater than that of the threshold voltage, the output of the
IC Op -Amp is high. As the output of the IC is connected to an LED, it lightens up.
Therefore, if we adjust the threshold voltage according to the load then at a specific
minimum load, conveyor starts moving until the load is unloaded and once
unloaded it stops automatically. Basically, we see a part of this in conveyors of
escalator but those sensors are single starter that is if it starts, even after unloading
it does not stop at the moment and takes time to stop and load detection is for a
certain range around 5- 15 m maximum. But if we are looking to incorporate it
within a standard industrial conveyor which spreads over kilometres then those
sensors must be fitted at regular intervals and must be powerful enough and along
with it there should other sensors to monitor there functioning. And to advantage if
we properly design it through simulation to make it variable speed mechanism that
is different speeds for varied loads then a massive amount of power consumption
can be compromised.

The threshold voltage can be adjusted by adjusting the potentiometer

depending on the environmental conditions. The positioning of the IR LED and the
IR Receiver is an important factor. When the IR LED is held directly in front of the
IR receiver, this Figure 4a -IR sensor Circuit setup is called Direct Incidence. In
this case, almost the entire radiation from the IR LED will fall on the IR receiver.
Hence there is a line of sight communication between the infrared transmitter and
the receiver. If an object falls in this line, it obstructs the radiation from reaching
the receiver either by reflecting the radiation or absorbing the radiation. 2.3-
WORKING PRINCIPLE OF IR SENSOR An infrared sensor circuit is one of the
basic and popular sensor module in an electronic device. This sensor is analogous
to human's visionary senses, which can be used to detect obstacles and it is one of
the commonapplications in real-time. This circuit comprises of the following
components • LM358 IC 2 IR transmitter and receiver pair • Resistors of the range
of kilo-ohms. • Variable resistors. • LED (Light Emitting Diode). Figure 4(b)- IR
Sensor Circuit In this project, the transmitter section includes an IR sensor, which
transmits continuous IR rays to be received by an IR receiver module. An IR
output terminal of the receiver varies depending upon its receiving of IR rays.
Since this variation cannot be analyzed as such, therefore this output can be fed to
a comparator circuit. Here an operational amplifier (op-amp) of LM 339 is used as
comparator circuit.

When the IR receiver does not receive a signal, the potential at the inverting
input goes higher than that non-inverting input of the comparator IC (LM339).
Thus, the output of the comparator goes low, but the LED does not glow. When the
IR receiver module receives signal to the potential at the inverting input goes low.
Thus, the output of the comparator (LM 339) goes high and the LED starts
glowing. Resistor

12 R1 (100), R2 (10k) and R3 (330) are used to ensure that minimum 10 mA

current passes through the IR LED Devices like Photodiode and normal LEDs
respectively. Resistor VR2 (preset=5k) is used to adjust the output terminals.
Resistor VR1 (preset=10k) is used to set the sensitivity of the circuit Diagram.
Read more about IR sensors.

DC motor that operated at 12(v)/24(v) DC supply. The voltage depends upon

speed require for the process. This conventional method of conveyor control is
further mobilized by use of dimmers. They were better option in the case of on off
control they can be operated in full load condition also. But the main problem with
them is stoppage of conveyors. the pneumatic stoppers were used which did not
stop the belts completely but use to stop materials on it. This leads to wear and tear
of the belts as well as the product also the rejection ratio is increased.
Computerized conveyor belt system issued. In this the control of these belts is
achieved by the use of the pc interface and embedded system based. These lead to
better option of conveyor control in today's industrial environment. It is very
difficult for those to maintain them at constant or through variable speeds.
Recently single shop conveyor belt systems are modified to become multiple type
i.e. instead of single conveyor multiple conveyors are used in series, parallel and
speed is controlled using remote monitoring. Also, the recent trend is3 emerging
towards controlling the speed of these conveyors by the use of computer
technology.
Conveyors are used in a broad range of industries and applications to move
packaged goods, assemblies, process byproducts, or any material from one place to
another. A process designer will typically look for opportunities to use the force of
gravity to accomplish product movement. Electric motors are commonly used
when gravity cannot be employed or when the speed of a gravitational fall needs to
be controlled. Airports, mines, cement plants, distribution facilities, assembly, and
food processing plants all utilize conveyors. Conveyors are typically constant
torque loads, meaning the required torque to drive a conveyor is independent of
speed. A fixed amount of torque is also required to overcome the frictional, or
machine drag, portion of the total load. Conveyors can have nominal amounts of
friction and machine inertia for which to compensate. Material flowing over the
belt may be weighed in transit using a belt weigher.
LITERATURE REVIEW
 CHAPTER II

LITERATURE REVIEW

Ghazi Abu Taher, Yousuf Howlader, Md. Asheke Rabbi, Fahim Ahmed
Touqir, Automation of Material Handling with Bucket Elevator and Belt
Conveyor, International Journal of Scientific and Research Publications, Volume
4, Issue 3, March 2014 1 ISSN 2250-3153: 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. 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. On account of
this, a machine and its physical description is covered here with some basic
calculation.

Abhijit Gaikwad , Yogesh Raut , Jitendra Desale , Akshay Palhe, Govinda

Shelar, Prof.Shreekant Pawar, Design and Development of Automated Conveyor
System for Material Handling, IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320- 334X, PP 31-34: In the process
or manufacturing industry, raw materials and products need to be transported from
one manufacturing stage to another. Material handling equipment are designed
such that they facilitate easy, cheap, fast and safe loading and unloading with least
human interference. For instance, belt conveyor system can be employed for easy
handling of materials beyond human capacity in terms of weight and height. This
project discusses the design calculations and considerations of belt conveyor
system for press machines, 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 well as its maximum loading capacity in
order ensure fast, continuous and efficient movement of material. The successful
completion of this project work is help to the development of an automated belt
conveyor system which is fast, safe and efficient. It is aimed to reduce human
effort and at the same time increase the productivity & accuracy levels that cannot
be achieved with manual operations.

Alhade A. Algitta, Mustafa S., Ibrahim F., Abdalruof N. and Yousef M

Automated Packaging Machine Using PLC, IJISET - International Journal of
Innovative Science, Engineering & Technology, Vol. 2 Issue 5, May 2015.
www.ijiset.com ISSN 2348 – 7968: This paper presents final year project
prototype with the use of programmable logic controller in automation industry for
packaging process. The main idea of the project is to design and fabricate a small
and simple conveyor belt system, and automate the process for packaging small
cubic pieces (2 × 1.4 × 1) cm3 of wood into small paper box (3 × 2 × 3) cm3 .
Inductive sensor and photoelectric sensor were used to provide the information to
the controller. Electrical DC motors used as output actuators for the system to
move the conveyor belts after get the orders from the control system.
Programmable logic controller Mitsubishi FX2n- 32MT was used to control and
automate the system by ladder logic diagram software. The experimental result of
the prototype was able to fully automate the packaging system. This results show
that the machine were done to package 21 boxes in one minute. In addition, the
results obtained show that the system able to decreases product time, and increase
product rate as compared with traditional manual system .

Konakalla Naga Sri Ananth , Vaitla Rakesh , Pothamsetty Kasi

Visweswarao, DESIGN AND SELECTING THE PROPER CONVEYOR-BELT,
Ananth et al., International Journal of Advanced Engineering Technology E-ISSN
0976-3945: 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.

Harshavardhan A. Kadam , Nilesh S. Hyalij ,Design and Analysis of Belt

Conveyor Roller Shaft, International Journal of Engineering Trends and
Technology (IJETT) – Volume 36 Number 1- June 2016: For the continuous
transportation of material a belt conveyor are used in the transport of coal and
mineral International Journal of Mechanical And Production Engineering, ISSN:
2320-2092, Volume- 5, Issue-11, Nov.-2017 http://iraj.in Fabrication of
Automated Conveyor System for Material Handling based on LDR 12 powder it
gives high efficiency and environmental protection. In some cases according to
requirement if we 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 within few month. An analysis of stress and impact creates on roller
shaft with the help of Hypermesh and to develop design of shaft for 170 to 180
create model Analysis using hyperwork. By using design failure modes and effects
Analysis (DFMEA) for systematic, proactive method for identifying where and
how it might fail.

Imran S.Khan , Prof. Ravindra Gandhe, STUDY AND ANALYSIS OF

ROLLER CONVEYOR IN MATERIAL HANDLING, Khan,4(8): August, 2015]
ISSN: 2277-9655 (I2OR), Publication Impact Factor: 3.785 In industries, it is very
necessary to move the components from one area to the other in a regular basis
making it desirable to minimize the workers involved in it. In this work we have
designed a conveyor which can be used in industries. It is very necessary to send
material from one place to another in an industry in a convenient manner and
hence a need to find a way to transmit the materials and hence in this work we
have made a conveyor model which is used for the material transformation from
one end to another. The main objective of this study is to explore the analysis of a
roller. This has entailed performing a detailed static analysis. The study deals with
static analysis. A proper Finite Element Model is developed using Cad software
Pro/E Wildfire 4.0.
METHODOLOGY
 CHAPTER III

METHODOLOGY

PROJECT PLANNING

Our project is based on the handling of bulk material and its packaging
process. It is a combination of mechanical and electrical logics including conveyor
and the packaging process is controlled automatically by using sensors. At first we
thought about the design of this machine. Though we build a prototype we had to
be careful about the design and dimension. After surveying on various industries
we cleared our concept and designed our machine with proper dimension. To build
this project we distributed our work in two parts which included the mechanical
part and the electrical part. First we decided to build the mechanical part which
included the belt conveyor. All the works had done in our departmental workshop.
After completing the mechanical part we worked on the electrical part. We set up
the IR sensor which is connected through the Circuit board so that it could sense
the presence of material and the belt starts moving. For building this project
completely necessary work had done on the workshop.
BELT CONVEYOR

A conveyor belt (or belt conveyor) consists of two or more pulleys, with a
continuous loop of material - the conveyor belt - that rotates about them. 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. 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 industrial and agricultural
materials, such as grain, coal, ores, fines and lumps material. Conveyors are
durable and reliable components used in automated distribution and warehousing.
In combination with computer controlled pallet handling equipment this allows for
more efficient retail, wholesale, and manufacturing distribution. It is considered a
labor saving system that allows large volumes to move rapidly through a process,
allowing companies to ship or receive higher volumes with smaller storage space
and with less labor expense
SELECTION OF
MATERIALS
 CHAPTER IV

SELECTION OF MATERIALS

1.Properties:

The material selected must possess the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface finish,
rigidity, ability to withstand environmental attack from chemicals, service life,
reliability etc. The following four types of principle properties of materials
decisively affect their selection

 Physical

 Mechanical

 From manufacturing point of view

 Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,
electrical conductivity, magnetic purposes etc. The various Mechanical Properties
Concerned are strength in tensile, Compressive shear, bending, torsional and
buckling load, fatigue resistance, impact resistance, elastic limit, endurance limit,
and modulus of elasticity, hardness, wear resistance and sliding properties. The
various properties concerned from the manufacturing point of view are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage

2. Manufacturing Case

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtainable by the application of suitable coating substances may demand
the use of special materials.

3. Quality Required

This generally affects the manufacturing process and ultimately the material.
For example, it would never be desirable to go casting of a less number of
components which can be fabricated much more economically by welding or hand
forging the steel.

4. Availability of Material

Some materials may be scarce or in short supply, it then becomes obligatory

for the designer to use some other material which though may not be a perfect
substitute for the material designed. The delivery of materials and the delivery date
of product should also be kept in mind.

5. Space Consideration
 Sometimes high strength materials have to be selected because the forces
involved are high and space limitations are there.

6. Cost

As in any other problem, in selection of material the cost of material plays

an important part and should not be ignored. Sometimes factors like scrap
utilization, appearance, and non-maintenance of the designed part are involved in
the selection of proper materials.
COST ESTIMATION
 CHAPTER V

COST ESTIMATION

S.No Component Qty Price

1 Base frame - Rs.650

2 Sensor Kit 1 Rs.1200

3 DC Motor 1 Rs.200

4 AC Adaptor 1 Rs.600

Total Rs.2650

LABOUR COST

 welding
  Grinding

 Power hacksaw

OVERGHEAD CHARGES:

The overhead charges are arrived by ”manufacturing cost”

Manufacturing Cost = Material Cost +Labour Cost

= Rs.2650 + Rs.1200

= Rs.3850

Overhead Charges = 20%of the manufacturing cost

= Rs.770

TOTAL COST

Total cost = Material Cost +Labour Cost +Overhead Charges

= Rs.2650 + Rs.1200 + Rs.770

= Rs.4620

Total cost for this project = Rs.4620

DIAGRAM
CHAPTER VI

DIAGRAM
WORKING PRINCIPLE
 CHAPTER VII

WORKING PRINCIPLE

Most industrial conveyor systems have continuous operation without stopping for
the reason of avoiding high power consumption during starting and stoppage of the
system. High starting power will result high starting torque and shock loads giving
rise to problems of short belt life due to more tension and also leads to more
energy costs. In order to reduce these negative effects there should be a power
controlling system and design of a belt with good strength qualities.

This design will have significance for the industry as its goal is to reduce power
consumptions thus reducing energy cost. Low power consumption and low starting
torque will result in reduction in shock loads and abnormal belt tensions hence the
average belt life will be increased. The system will have speed control therefore for
any load the speed will be adjusted to its safe speed that matches with its power
demanding. The researchers automated the system and this reduces accidents since
there will be less human interference
FEATURES
 CHAPTER VIII

FEATURES

ADVANTAGES

 The Conveyor Automation is more effective in the specialized field

 Quick reaction is accomplished
 Simple in development
 Easy to keep up and repair
 Cost of the unit is less when contrasted with different mechanical technology
 No fire risk issue due to over stacking
 Comparatively the task cost is less
 Continuous task is conceivable without ceasing
APPLICATION

 The Conveyor Feed has a wide application in ease computerization

enterprises. It can be utilized as a part of robotized mechanical production
systems to convey up the completed item from workstation and place them
in canisters. It can likewise be utilized to pick crude material and place them
on the transport lines..
CONCLUSION
 CHAPTER IX

CONCLUSION

The main purpose for building this machine is to automate the handling of bulk
material and its packaging. We are trying to build a prototype for expressing our
motive on this project. Though we have some mistakes caused by human error but
we believe that we can clear our concept by our work. The total process is
controlled by a control system automatically. We mainly focus on the packaging
system. The control system helps to package the right amount of material in
several packets. It stops the machine for a certain time between two packaging
process. So once it is set the requirement of skilled operator is also reduced as
compared to a manual system.
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