Video Excluded Final Ics

PROJECT WORK PRESENTATION
INTELLIGENT CONVEYOR SYSTEM FOR

PUMP ASSEMBLY
BATCH - 2
STUDENT NAMES
Mugesh R (18M230)
Nafees Abdul Azeez Z (18M231)
Nanta Gopal C (18M232)
Guided by
Dr. N. Ganesh Kumar
Associate Professor
Mechanical Engineering, PSGCT
Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING
23/07/2022 PSG COLLEGE OF TECHNOLOGY
15M820 1
INTRODUCTION
• A proper material handling is mandatory for any workshop or industry in order
to ensure the movement of products is done in a well-defined manner.
• In PSG Industrial institute , especially in the pump assembly, the assembly of

multi-stage pump requires many parts including impellers, to be moved to the
assembly section.
• This Process is carried out by mini-trolleys or manually carried by a labour ,

which may cause human error, economical loss, loss of productivity, and
damage to the parts.
15M820 2
• These problems can be solved by replacing them with a conveyor system

which is IoT enabled. This repetitive process in the video shows that the
assembling needs a lot of parts to be transported.

15M820 3
PROBLEM STATEMENT
Currently, the pump assembly is made at PSG Industrial institute in
workshop mode. Since all the material handling process are manual, this
manual transportation leads to
 Loss of productivity(In general,80% of time is spent for material handling).

 Economical loss(In general,20% of total cost is material handling cost)
 Damage to the parts which will lead to rejection of components.

15M820 4
OBJECTIVES
1. To design and develop conveyor system for pump testbed demonstrator.
2. Design and transform conveyor system into IoT enabled that automates the
material handling process and prevents the damage to the parts. Enable it
either using HMI or Laptop to stop/start conveyor.
Figure 1- view of Figure 2

existing test bed
15M820 5
LITERATURE REVIEW
Design of belt for conveyor system

 Abhijit Gaikwad et al., 2014
 The diameter of the driver and the driven pulley is determined by the
type and dimension of conveyor belting.
 Belt length is dependent on both the pulley diameters and
centre distances(Belt basic length = 2 × conveyor along the route)

15M820 6
LITERATURE REVIEW
A review of Automatic conveyor system

 Avinash L.Nandivale et al., 2018
 Different types of conveyor belts have been created for conveying
different types of materials available in PVC and rubber materials.
 Types of conveyors include Belt , Plastic belt, Wire mesh, Bucket ,
Spiral , Pneumatic, Screw conveyor.

15M820 7
LITERATURE REVIEW
Material handling based on LDR

 Hirendra Kumar Verma et al., 2017
 The Usage of LDR(Light Dependent Sensor) to automate the process
by using the exposure of light.
 Usage of Chain Sprocket Mechanism for the conveyor system .

15M820 8
LITERATURE REVIEW
Automatic Packaging Machine

 Alhade A. Algitta et al., 2018
 Programmable logic controller Mitsubishi FX2n-32MT was used to
control and automate the system by ladder logic algorithm software.
 As a result of automation, there is a decrease in product time and
increase in product rate as compared with traditional manual system.

15M820 9
LITERATURE REVIEW
Auto Separation System for Oil Packaging Industry
 Mr.Akshay K Naphade et al., 2017
 Design Calculations for proposed systems including motor,
chain drive ,bearing.
 This proposed system gives the convenient approach of automatically
detecting the weight of product on the conveyor system using a
Microcontroller for high reliability and fast operation without
interruption.
15M820 10
LITERATURE REVIEW
PALLET CONVEYOR SYSTEM APPLICATION

 Pratik P Gandhi & G.S. Sharma et al., 2019
 Chain conveyors can be a great solution for handling GMA type pallets
with the 40inch dimension.
 Vertical lifts are applied in pallet handling systems where loads are
transported between floors or levels of a system.

15M820 11
LITERATURE REVIEW
CONVEYOR BELT FAULT DETECTION USING IOT

 Ms. Jayshree, C.Phad , Ms.Kajal et al., 2019
 Arduino is a single board microcontroller meant to make the
application more accessible.
 The conveyor belt has enough friction between it and the rotor that it
sticks to the rotor.

15M820 12
LITERATURE REVIEW
Automatic Mini-Conveyor System
J. E. Bassey , K. C. Bala et al., 2018
 Sensors distance analysis is based on power transmitted and/or power
density across sensors and magnitude of the incident current
generated at the photodiode.
 The result gives a guide as to how far apart the sensors must be
positioned in order to obtain optimum sensitivity.

15M820 13
LITERATURE REVIEW
Industrial Automation based on IOT

Apurva S Zope, Mayuri S Jambhale et al., 2017
 L293D is a typical Motor driver or Motor Driver IC which allows DC
motor to drive on either direction.
 The L293D can drive small & quite big motors as well.

15M820 14
SUMMARY OF LITERATURE
 Various types of conveyor systems and their function are studied.

 The theoretical calculation for motor power and cycle time of the conveyor
are observed
 Usage of LDT sensors , Proximity sensors and their respective
implementation are noted.

15M820 15
METHODOLOGY
Problem definition YES
Literature survey
Compare
NO analytical value
Calculation of motor power Experimental setup
with numerical
and belt parameters
value for
equivalency Comparison of results
Modelling of the system
Results and discussion
Validating the model using
numerical analysis
Conclusion

15M820 16
2D SKETCH OF TEST BED
ALL DIMENSIONS ARE IN mm

15M820 17
SELECTION OF MOTOR
 The objective of selection is to select a motor that has a ,
• Precise Control
• High Torque
• Easy Speed Control
• Capable of driving high load.

15M820 18
DC motor has high initial cost ,converters are required to supply power,
cannot maintain the required torque.
Servo motor is most preferable for positional control applications like
automatic sanitizer dispenser.
Stepper motor has an exact control over speed and torque and can drive
heavy load.

15M820 19
CHOICE OF SELECTION
MOTOR SELECTED : SERVO MOTOR
REASON FOR SELECTION: 1. PRECISE CONTROL

2. HIGH TORQUE
3. EASY SPEED CONTROL
4. CAPABLE OF DRIVING HEAVY
LOAD

15M820 20
SELECTION OF SENSORS
 The objective of the sensors is to detect when an object is conveyed to the

end of the conveyor mechanism setup.
 The sensors which detect the motion of the objects include,
• Proximity Sensor
• Light Dependent Sensor
• Photoelectric Sensors

15M820 21
Among these sensors, Proximity sensor is considered to be the most

suitable sensor for our application.
Since, the objective of the sensor is to detect the object and return the
signal to relay then Proximity sensor is best choice for selection.
LDR sensors has disadvantages like narrow spectral response and
Hysteresis effect and hence not suitable
In, Photo electric sensors, sensing range may be affected due to the
colour and reflectivity of the target.

15M820 22
SELECTION OF CONVEYOR SYSTEM
 The objective of selection is to select a conveyor that ensures,
• High load carrying capacity

• Faster belt speed
• Easy machinability and installation
• Safe transportation of the components.

15M820 23
SELECTION OF CONVEYOR SYSTEM

• There are different types of conveyor system that helps to transport
the materials. Some of them are ; bucket conveyor, spiral conveyor,
pneumatic conveyors , chain and flat belt conveyor system.
• Bucket conveyor system: They are suitable for transportation of coal ,
perishable items preferably. So, they are not suitable for the
transportation of large sized and heavy weight Pumps.
• Spiral conveyor systems: Spiral conveyor systems cannot
accommodate lengthy and large sized pumps and the path of travel is
in a spiral manner which makes the transportation of the pumps even
more difficult.
15M820 24
• Pneumatic conveyor systems: The pneumatic conveyors are operated

by gases under pressure , they preferably transfer powdered materials
which is not suitable for our application.
• Flat belt conveyor system: The flat belt conveyor system is simple and
can accommodate the pumps that are to be transported through the
conveyor system. But they come along with slip and creep which
greatly affects the efficiency of power transmission.
• Chain conveyor system: They are effective for horizontal
transportation over a long distance. No slip and creep during the
power transmission. It has High transmission efficiency other than
friction drives. So, Chain conveyor system is the most suitable type of
conveyor for our application.

15M820 25
CHOICE OF SELECTION
Conveyor Selected : Chain conveyor system
Reason for selection : 1. Can withstand high load

2. Can be easily installed.
3. Can be driven faster.
4. Materials can be safely transported.

15M820 26
TIME STUDY OF MATERIAL HANDLING INSIDE

PSG INDUSTRIAL INSTITUTE
S.No From To Trial No Time taken Average time
I 114s
1 Assembly Testing II 107s 114.33s

III 122s
I 134s
Submersible Incoming II 140s

2 pump assembly inspection 137s
III 137s

15M820 27
PALLET SYSTEM
ADVANTAGES OF PALLET SYSTEM DISADVANTAGES OF PALLET SYSTEM
They ensure efficient and stable flow of goods Belt can be difficult to clean and generally does not
leave a very successful result.
Ensure consistent , smooth flow for end of line Fabrication of the system is a complex process.
stacking , labeling etc..,
Since the belt system is rigid , they are capable of Not as flexible with what types of items it handle.
handling the load in a better manner.

15M820 28
CHAIN SYSTEM
ADVANTAGES OF CHAIN SYSTEM DISADVANTAGES OF CHAIN SYSTEM
High load capacity High capital cost of all components relatively.
The possibility of replacing individual chain links The return path that is difficult to clean
instead of replacing the entire chain incase of an error.
An optional number of branches of according the Chain system is a complex system when compared to
material being transported other belt systems.

15M820 29
BUCKET SYSTEM:
ADVANTAGES OF BUCKET SYSTEM DISADVANTAGES OF BUCKET SYSTEM
They can handle various types of materials It is not suitable for carrying large sized components
It can handle materials at low temperatures and can The conveying materials are limited to small elements
maan that can be carried with in a bucket space.
It can move materials vertically upwards unlike belt High installation costs
conveyors

15M820 30
FLAT BELT SYSTEM:

ADVANTAGES OF FLAT BELT SYSTEM DISADVANTAGES OF FLAT BELT SYSTEM
One of the cheapest conveyors The simplicity means very limited features
Simple and easy to use. To maintain correct velocity ratio is difficult
Can be loaded from any place along the belt Slip and creep will be higher and both will result in
loss of power and efficiency of belt drive

15M820 31
ROLLER CONVEYOR SYSTEM

ADVANTAGES OF ROLLER CONVEYOR SYSTEM DISADVANTAGES OF ROLLER CONVEYOR SYSTEM
Effective horizontal transportation over a long distance Noisier than many other conveyors
If a motor stops, it will only stop one zone More expensive than other conveyors
The speed and also the process can be easily It is not as flexible to what type of items it can handle.
controlled and the risk for damage is reduced as the
parts never touch

15M820 32
DESIGN FOR FABRICATION OF SPROCKET AND SHAFT:
• Objective: To select a design for transmission of motion from shaft to

the sprocket.
• Based upon the objective, there are two designs that are finalized .
We have to select the best design from these two.
• The First Design is manufactured with a key in shaft and whereas in
the second design, the shaft and sprocket are locked with a nut and
bolt in a through hole which passes through the sprocket and the
shaft.

15M820 33
DESIGN 1:
• This design perfectly suits our required demand. The motion that is
transferred from motor – coupling – shaft – sprocket .
• The main problem with the design is that the manufacturing of shaft
with key is difficult. The shaft may get misaligned during
power transmission from the keyway.
DESIGN 1 WITH KEY

15M820 34
• The sprocket also needs to be designed with the keyway and

fabricated with keyway
• The location of the key in the shaft and keyway in the sprocket may
get mislocated causing improper mating of the components.

15M820 35
DESIGN 2: (DESIGN WITH HOLE JOINED WITH

PIN)
• This design comprises two holes in shaft i.e.., totally four holes in two
shafts and with a single hole per sprocket i.e.., four sprockets.

15M820 36
• The two sprockets are set on the shaft and they are fixed with the nut
and bolt through the holes.
• The horizontal position of the shaft is fixed , So that the sprockets will
not get released from the shaft during the functioning of the conveyor
• A hole of about 6mm is drilled in each sprockets and shafts i.e.., 4
sprockets and two shafts.
• They are joined with a M6 nut bolt together in order to fix the
horizontal position of the sprocket and to ensure the power
transmission is done from shaft to sprocket without any
discrepancies.

15M820 37
CHOICE OF SELECTION
DESIGN SELECTED: DESIGN 2
REASONS FOR SELECTION: 1. Simple design
2. Easy to fabricate
3. Horizontal axis is fixed
firmly.

15M820 38
COMPONENT SPECIFICATIONS:
• Sprocket: 7 inch Diameter i.e.., 177.8mm with 43 teeth
• Shaft : 15 mm shaft with 1m length
• Nut and Bolt : M6
FABRICATION:
• The sprockets are drilled with a hole of 6mm and the shafts with
6mm holes and they are joined with a M6 bolt.

15M820 39
LIST OF OPERATIONS DONE:

1) Initial cutting of raw shaft from 1m to 85cm length.
2) Boring with hole of 6mm diameter in 4 sprockets
3) Boring two holes in two shafts at two locations.
4) Final cutting of shaft to 65 cm length on the either side
symmetrically.
5) Cutting the two side chains to from 9m to 8.2m and linking them
with chain link.

15M820 40
FUCNTIONING OF THE MECHANISM:

• The mechanism is manually rotated and checked for the correctness .
• The chain implemented correctly mates with the sprocket and runs
without any discrepancies.
• This indicates that we can successfully connect the motor and
automate the mechanism.

15M820 41
2D SKETCH OF COUPLING:

15M820 42
FABRICATION OF PALLET:
• The pallet fabricated must fit inside the space of the conveyor bed .
So a wood pallet with a size of 56x25 dimension in cm is selected
• They are fixed with the 4 rollers in total having a load capacity of
about 80kg each sharing 20kg load.
• A steel plate with M6 nut and bolt is fixed to hold the chain and pallet
together.
• The chain is also locked with nut and bolt in the chain conveyor
system with which we can move the pallet on the conveyor .

15M820 43
IMAGES OF PALLET:

15M820 44
EMBEDDED SYSTEM FOR CONVEYOR:

• The embedded system is the most important electronic component
that decides the dedicated functions with in a mechanical system.
• The embedded system selected for the conveyor system is, Arduino
UNO.
• The conveyor system is driven with a PMDC motor. The motor is
controlled by connecting an Arduino to it.

15M820 45
• The objective of using embedded system is to control the clockwise

and anticlockwise motion of the motor along with the immediate stop
function whenever the pallet reaches the sensor.
• These requirements are achieved by connecting the Arduino with a
relay and a sensor. The relay turns ON/OFF the motor at any time
whenever the Arduino triggers a signal.
• The dual direction of the motor is achieved by using dual relay. When
one is OFF and other is ON motor runs in Clockwise direction. Vice
versa for the anticlockwise direction.

15M820 46
CIRCUIT CONNECTION:

15M820 47
WORKING:
• Whenever we start the conveyor from HMI i.e.., Laptop, the Arduino
triggers a signal to the relay. The relay starts the motor to rotate in
clockwise direction. The components are loaded
• Whenever the conveyor reaches the sensor, the sensor triggers a
signal to the Arduino . As a result the Arduino makes the relay OFF .
Finally, conveyor stops. The components are assembled.
• Again , the relay is triggered by the Arduino signal and then conveyor
again reaches the end. Then the components are unloaded

15M820 48
WORKING OF IoT ENABLED

CONVEYOR SYSTEM:

15M820 49
S.NO PROBLEM DEFAULT MATERIAL MATERIAL DISCUSSION

HANDLING INSIDE PSG HANDLING
INDUSTRIAL INSTITUTE WITH
CONVEYOR
SYSTEM
1 TIME LOSS 134 seconds 85 seconds About 36% of time
is saved by using
conveyor system
2 DAMAGE TO THE YES NO Since the conveyor
PARTS safely transports all
the components, it
eliminates damage.
3. ECONOMICAL LOSS HIGH REDUCED Since the economical
loss caused by the
damage and time
loss is eliminated,
it is reduced

15M820 50
CONCLUSION:
• The Conveyor bed is altered and the Chain conveyor mechanism is
successfully implemented
• The IoT is successfully implemented in the conveyor system.
• The overall material handling process is improved.

15M820 51
INDIVIDUAL CONTRIBUTION:
ROLL NUMBER NAME CONTRIBUTION
18M230 Mugesh R • CAD modelling

• Pallet fabrication and
implementation.
18M231 Nafees Abdul Azeez Z • Bed alteration and chain

implementation
• Machining of coupling
18M232 Nanta gopal C • Fabrication of shaft

• Drilling the holes in Sprocket for
power transmission.

15M820 52
COURSES REFERRED:
S.NO COURSES FINDINGS
1 KINEMATICS OF MACHINERY • Studied the functioning of Conveyors and studied about

the slip and creep that happens in conveyors
2 DESIGN OF MACHINE ELEMENTS • Studied about the design of sprocket and studied about
the basic construction of the mechanism

15M820 53
JOURNALS REFERRED:
S.NO TEXTBOOKS/JOURNALS AUTHOR(S)
1 Design of belt for conveyor system Abhijit Gaikwad et al., 2014
2 A review of Automatic Conveyor system Avinash L.Nandivale et al., 2018
3 Material Handling Based on LDR Hirendra Kumar Verma et al.2017
4 Automatic Packaging machine Alhalde A.Algitta et al., 2018
5 Auto Seperation System for Oil Mr.Akshay K Naphade et al., 2017

Packaging Industry

15M820 54
JOURNALS REFERRED:
S.NO TEXTBOOKS/JOURNALS AUTHOR(S)
6 Pallet conveyor system Prathik P Gandhi and G.S.Sharma et al., 2019
7 Conveyor Belt Fault Detection using IoT Ms. Jayshree C.Phad,Ms.kajal et al., 2019
8 Automatic mini-conveyor system J.E.Bassey , K.C.Bala et al., 2018
9 Industrial Automation Based on IoT Apoorva S Zope, Mayuri S Jambhale et al., 2017

15M820 55
HARDWARE/SOFTWARE :
S.NO HARDWARE/SOFTWARE APPLICATION
1 SOLID WORKS • CAD model of the conveyor system is fully

designed.
2 PM DC SERVO MOTOR • To drive the conveyor system, the motor is

used.
3 ARDUINO UNO • To configure the embedded system for the

motor control

15M820 56
GANTT CHART
Feb Mar Apr May
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Selection of Drive system
Fabrication of Sprocket and shaft
Alteration of the existing test bed and Fixing the drive

elements
Implementation of Chain system
Connection of motor with IoT
Report preparation

15M820 57
REFERENCES
 Avinash L.Nandivale, Omkar D.Kumbhar ,Aniket R.Kherade ,Amar
V.KolekarShubham ,D. Hankare(2018).“A Review of Automatic Conveyor
System”.
 Hirendra Kumar Verma, Sakshi Dewangan, Praveen Kumar Thakur,

Dharmendra Sahu , Rinkey Sahu(2017).“Fabrication Of Automated Conveyor
System For Material Handling Based On Ldr”.
 Abhijit Gaikwad, Yogesh Rauttendra Desale, Akshay Palhe,Govinda,

Shelar(2014).“Design and Development of Automated Conveyor System for
Material Handling”.

15M820 58
REFERENCES
 Nasif Hassan Khan , Deb Kumar Sarkar, Asif Siddique ,M.d. Mamunur
Rahman,Swarup Chakraborty.(2017).“Fabrication of a Conveyor Belt with
Object Sorting and Counting Facility”.
 Mr. Akshay K. Naphade, Prof. Manish J. Deshmukh(2017).“Improved

Automated Conveyor With Auto Separation System For Oil Packaging
Industry”.
 Pratik P Gandhi & G.S. Sharma (2019). “Pallet conveyor system application”.
 J. E. Bassey* , K. C. Bala (2018). “Development of an Automatic Mini-

Conveyor System for Product Monitoring”.

15M820 59
REFERENCES
 Apurva S Zope, Mayuri S Jambhale, Nimisha M Korde, Hajra A Khan,
Prof.Akansha Bhargav (2017).“Iot Based Industrial Automation”
 Xiang Yang, Hui-hong Wang (2011): The design and implement of embedded
M2M Smart Home System

15M820 60

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PROJECT WORK PRESENTATION

INTELLIGENT CONVEYOR SYSTEM FOR

• In PSG Industrial institute , especially in the pump assembly, the assembly of

• This Process is carried out by mini-trolleys or manually carried by a labour ,

• These problems can be solved by replacing them with a conveyor system

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

 Loss of productivity(In general,80% of time is spent for material handling).

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Figure 1- view of Figure 2

Design of belt for conveyor system

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

A review of Automatic conveyor system

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Material handling based on LDR

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Automatic Packaging Machine

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

PALLET CONVEYOR SYSTEM APPLICATION

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

CONVEYOR BELT FAULT DETECTION USING IOT

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Industrial Automation based on IOT

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

 Various types of conveyor systems and their function are studied.

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

2D SKETCH OF TEST BED

ALL DIMENSIONS ARE IN mm

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

 The objective of selection is to select a motor that has a ,

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

MOTOR SELECTED : SERVO MOTOR

REASON FOR SELECTION: 1. PRECISE CONTROL

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

 The objective of the sensors is to detect when an object is conveyed to the

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Among these sensors, Proximity sensor is considered to be the most

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

SELECTION OF CONVEYOR SYSTEM

 The objective of selection is to select a conveyor that ensures,

• High load carrying capacity

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

SELECTION OF CONVEYOR SYSTEM

• Pneumatic conveyor systems: The pneumatic conveyors are operated

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Conveyor Selected : Chain conveyor system

Reason for selection : 1. Can withstand high load

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

TIME STUDY OF MATERIAL HANDLING INSIDE

1 Assembly Testing II 107s 114.33s

Submersible Incoming II 140s

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

High load capacity High capital cost of all components relatively.

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

FLAT BELT SYSTEM:

Simple and easy to use. To maintain correct velocity ratio is difficult

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING

ROLLER CONVEYOR SYSTEM

Course code Slide number DEPARTMENT OF MECHANICAL ENGINEERING