Advanced Research Journals of Science and Technology
ADVANCED RESEARCH JOURNALS OF SCIENCE AND TECHNOLOGY
(ARJST)
STRUCTURAL ANALYSIS OF SIDE CONVEYOR FOR BOTTLE INSPECTION MACHINE
2349-1845
Kollipara Gopala Rao1,Ravi Varma Penmetsa 2, 1 Research Scholar, Department of Mechanical Engineering, S.R.K.R. Engineering College, Andhra Pradesh, India. 2 Assistant Professor, Department of Mechanical Engineering, S.R.K.R. Engineering College,Andhra Pradesh, India.
Abstract In this project we considered one of the real time examples of side conveyor mechanism of bottle inspection machine, and many factors are important in designing of a conveyor system. It is important to know which type of conveyor system will be used beforehand. Some individual areas that are helpful to consider are the required conveyor operations, such as transportation, accumulation and sorting, the material sizes, weights and shapes and where the loading and pickup points need to be design. In this project a side conveyor mechanism is chosen which is used to hold and carry bottles to certain distance for carrying inspection a bottle. While the conveyor holds the bottle on sides, the bottom of the bottle will be exposed to the Inspection camera. Inspection section includes the camera, spot light arrangement. This arrangement will help us to detect the manufacturing defects of the bottles that are coming out of the production line. The feedback mechanism from camera will send the feedback to the controller to take necessary action. The side conveyor is arranged on a frame as a cantilever structure. This arrangement made the structure to be unstable and made the structure to get tilted towards center of the main conveyor. The maximum allowable deflection in the structure should be less than one “mm�. So the frame strength also considered as an important parameter in giving proper functionality of the inspection system. In This Project we have designed the conveyor structure as well as the analysis part is carried in SOLIDWORKS software.
*Corresponding Author: Kollipara Gopala Rao , Research Scholar, Department of Mechanical Engineering, S.R.K.R. Engineering College,Andhra Predesh,India. Published: September 08, 2015 Review Type: peer reviewed Volume: II, Issue : II Citation: Kollipara Gopala Rao,Research Scholar (2015) STRUCTURAL ANALYSIS OF SIDE CONVEYOR FOR BOTTLE INSPECTION MACHINE
INTRODUCTION BELT CONVEYOR The belt conveyor is an endless belt moving over two or more end pulleys at fixed positions and used for transporting material horizontally or at an incline up or down. 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 pulley. The belt consists of one or more layers of material. Many belts in general material handling have two layers. An under layer of material to provide linear strength and shape called a carcass and an over layer called the cover. The carcass is often a woven fabric having a warp& weft. The most common carcass materials are polyester, nylon and cotton. The cover is often various rubber or plastic compounds specified by use of the belt. Covers can be made
from more exotic materials for unusual applications such as silicone for heat or gum rubber when traction is essential. 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. 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. Belt conveyors are generally fairly similar in construction consisting of a metal frame with rollers at either end of a flat metal bed. 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. Belt conveyors can now be manufactured with curved sections these conveyor systems are commonly used in postal sorting offices and airport baggage handling systems. A sandwich belt conveyor uses two conveyor belts, face-to-face, to firmly contain the item
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Advanced Research Journals of Science and Technology
being carried, making steep incline and even vertical-lift runs achievable. The main components of a belt conveyor are: 1. The belt that forms the moving and supporting surface on which the conveyed material rides. It is the attractive element. The belt should be selected considering the material to be transported. 2. The idlers, which form the supports for the carrying and return stands of the belt. 3. The pulleys that support and move the belt and controls its tension. 4. The drive that imparts power to one or more pulleys to move the belt and its loads. 5. The structure that supports and maintains the alignments of the idlers and pulleys and support the driving machinery.
structures such as crossing rivers, streets and valleys. 7. The belt conveyor can be adopted for special purposes (fire resistant, wear resistant, corrosion resistant, high angle negotiation etc.) and can be integrated with other equipment. 8. In underground mine transport, belt conveyor can be used in thin seams as it eliminates the rock works that might otherwise be required to gain haulage height. Moreover, belt conveyor can provide continuous haulage service from pit bottom to the surface. The limitations of conveyor belt are: 1.The loading and transfer points need to be properly designed. 2.Numbers of protective devices have to be incorporated to save the belt from getting damaged by operational problems. 3.The belt needs higher initial tension (40-200% of useful pull). 4.The use of belt is restricted by the lump size. If the maximum diagonal of a irregular lump is X then the belt width (B) is approximately given by. Where, B: Belt width, mm X: Longest diagonal of irregular lump, mm a: Factor to account for grading. a is taken as 2.5 for graded material and 3 for un-graded material. However, for particular material these values must be properly estimated. 5.Conveying of sticky material is associated with problems of cleaning and discharge causing poor productivity. 6.Higher elongation of the belt (4% elongation may take place at the working load). INFORMATION REQUIRED TO DESIGN A BELT CONVEYOR
Application of side conveyor belt Conveyor belts are widely used in mineral industry. Underground mine transport, opencast mine transport and processing plants deploy conveyor belts of different kinds to adopt the specific job requirements. The main advantages of conveyor belt system are: 1.A wider range of material can be handled which pause problems in other transportation means. Belt conveyor can be used for abrasive, wet, dry, sticky or dirty material. The lump size of the transported material is limited by the width of the belt. Belts up to 2500 mm wide are used in mining industry. 2. Higher capacity can be handled than any other form of conveyor at a considerably lower cost per tonekilometer. Conveyor belts with capacity of 11000t/h and even higher can be deployed to match with higher capacity mining machinery. 3. Longer distances can be covered more economically than any other transportation system. A single belt conveyor or a series of belt conveyors can do this. Belt conveyors can be adopted for cross-country laying. 4. By the use of many forms of ancillary equipment such as mobile trippers or spreaders bulk material can be distributed and deposited whenever required. 5. Many other functions can be performed with the basic conveying like weighing, sorting, picking, sampling, blending, spraying, cooling, drying etc. 6. Structurally it is one of the lightest forms of conveying machine. It is comparatively cheaper and supporting structures can be used for many otherwise impossible
1. Length of conveyor from centre to centre of end pulleys. 2. Inclination-level or inclined. Either degree of inclination or distance to be lifted or lowered. 3. Average capacity per hour. 4. Maximum capacity per hour. 5. Material to be conveyed, and weight per cubic foot. 6. Average size of material. 7. Size of largest pieces and percentage in feed. 8. (a) Nature of material -dry or wet (moisture content). (b)Abrasive or corrosive? 9. How material is to be fed to the belt and particulars of feed point or points. 10. How material is to be discharged from the belt i.e. overhead pulley or by trippers, and particulars of discharge points. 11. General indication of supporting structure. 12. Power available for driving. If by A.C. electric motor, state voltage, phase and frequency. If D.C. motor state voltage. Design Considerations: 1. The design of the conveyor and selection of the belt should not deform or damage the bottle in any possible way; they should not be sustaining the bottle any way. 2. The bottle must be placed properly on the flat belt conveyor without falling down. 3. Required structural analysis for side conveyor 4. Optimization of the structure of bottle inspection machine.
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Advanced Research Journals of Science and Technology
Details of conveyor system S.No
Name
Value (Specifications)
1
Minimum Size of Bottle
Dia 38mm
2
Maximum Size of Bottle
Dia 75mm
3
Speed of Conveyor
30Meters/min max Linear speed
Motor Position
Fixed directly to pulley
Camera Position
Field of view should be 15% more than bottle dia
Light Position(Spot Light)
5 mm above top of the bottle, height should be adjustable, based upon the bottle presently running.
7
Sensor and reflector position
Sensor should be adjustable as per the bottle Dia and is placed perpendicular to Conveyor and the position of the sensor is such that, the bottle edge is sensed when the bottle is in the center of the camera.
8
Lens
8mm Focal length lens will be used.
4 5 6
PROBLEM STATEMENT In general the conveyors for bottle inspection devices are supported by a frame structure. The frame structure is mounted on the ground by means of a support. The weight of the conveyors and the motors act on the frame structure and make the structure unstable. This arrangement of side conveyor system is heavyand high deflections are observed on the structure.
Objectives of the Equipment: 1. To convey plastic bottles, in such a way that the bottom and top of bottle is exposed. 2. This is required so that a camera can be placed at bottom, looking up to view the bottle base. 3. The conveyor should be adjustable to hold the bottles of different diameter. 4. The conveyor will be mounted on the spot watcher (main bottle inspection machine) such that it will move up & down with the machine. 5. The bottles need to be picked from a flat belt conveyor and also place on the flat belt conveyor. Parameters to be taken in design: • Carrying the bottle through conveyor belts, bottle is travelling from one place to another place. •After that bottle will be in contact between the side conveyor belts within 1mm gap. •Inspection section that means (camera and spot light) is placed in between below the cantilever frame. •Why, cantilever frame was not interlinked from one end to other end? •Because of, inspection section present in between the cantilever frame. In case, interlink the cantilever frame than what will be done? First of all, which place is better to choose for inspection equipment i.e. for example: Either it will be placed above the cantilever frame than it fails, because (In inspection section takes place a bottle irregulaties, whether it withstand the weights, stabilities all those things are inspects) this is the reason, above the cantilever frame condition not detect these elements that’s why, it is not exists the inspection section in other places of these equipment. Finally it will be failure. • Take inspection section in below the cantilever frame condition, client gave the existing dimensions so and so, we have to modify these and then designed. • After that in analysis gives the results i.e. deflections on cantilever frames due to load. • To with stand deflections, we have to give additional supports to the frame than load applied, see the results, variation is observed. SIDE CONVEYOR PARTS & MATERIALS & WEIGHT DETAILS
side conveyor frame with support from the ground
In our inspection system, the side conveyors hold the bottle sideways allowing its base to expose to the inspection camera. The sensor in the device inspects the bottle for any defects. Adding any other supports from the ground is not possible because of the inspection device and other supporting devices for side conveyor mechanism located at the bottom of the conveyor. Hence the frame structure is modified by adding two more frames to the structure without any support from the ground which reduces the high deflection and stresses observed on the frame structure. This gives more strength to the structure. Our objective is to analyze the structural stability of this cantilever frame structure. Based on the results obtained we would identify the critical areas.
SL NO
PART NAME
TYPE
QTY
MATERIALS
WEIGHT Kg
1.SIDE_CYR_LEFT_PLATES_ASM 1
SIDE_CYR_LEFT_ TOP_PLTAE
MNF
1
AL
13
2
SIDE_CYR_LEFT_ BOTTOM_PLATE
MNF
1
AL
13
3
M10_STUD
MNF
2
AL
0.1
4
SUPPORT_FOR_ BEARINGS
MNF
1
AL
0.09
5
GB_T_923_2009_ M10
B/O
8
AL
6
S_C_PULLEY_ SUPPORT_PLATE
MNF
1
AL
V_BELT
B/O
1
7 8
FASTENERS
-
-
-
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Advanced Research Journals of Science and Technology
Designed model:
2. SIDE_CYR_RIGHT_PLATES_ASM 1
SIDE_CYR_ RIGHT_TOP_ PLATE
MNF
1
AL
13
2
SIDE_CYR_ RIGHT_BOTTOM_ PLATE
MNF
1
AL
13
3
M10_STUD
MNF
2
STEEL
0.1
4
SUPPORT_FOR_ BEARINGS
MNF
1
AL
0.09
5
M10_NUT_ GB_T_923_2009
B/O
8
AL
6
S_C_PULLEY_ SUPPORT_PLATE
MNF
1
AL
7
V_BELT
B/O
1
8
FASTENERS
B/O
-
0.2 -
-
-
-
3. SIDE_CYR_ADJUSTABLE_PULLY_ASM 1
ADJUSTABLE_ PULLY_SHAFT
MNF
1
2
DELRIN_PULLEY
MNF
1
3
BALL_BEARING_6004
B/O
2
4
CIRCLIPNFE2216420X175
B/O
1
4.SIDE_CYR_MS_PULLY_ASM
QTY-2
MS DERLIN
0.2 0.4
SKF
-
added frame to with stand weight 60kgs. Standard Profiles used are aluminum 20mmx 20mm. And bottom camera is added for inspection bottle’s bottom side. Existing model images
-
QTY-2
1
MS_PULLY
MNF
1
2
BALL_BEARING_6005
B/O
2
MS_PULLY_ SHAFT
MNF
1
2
DELRIN_PULLEY
MNF
1
3
BALL_BEARING_6004
B/O
2
-
SKF
5. SIDE_CYR_FIXED_PULLY_ASM 1
3
MS
QTY-2 MS DERLIN SKF
0.16 0.4 -
Bottle inspection
Existing model:
SIDE CONVEYOR STRUCTURE USED FOR BOTTLE INSPECTION
Front view of the side conveyor
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Advanced Research Journals of Science and Technology
Side view of the side conveyor Side view of the side conveyor
Top view of the side conveyor Top view of the side conveyor
Isometric view of the side conveyor
New model with additional frame: Isometric view of the side conveyor
Front view of the side conveyor
The above image showing stress
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Advanced Research Journals of Science and Technology
The above image showing strain
Analysis Results of Side Conveyor AFTER adding additional frames
The above image showing strain
CONCLUSION In this project we considered one of the real time examples of side conveyor mechanism of bottle inspection machine, and many factors are important in the accurate selection of a conveyor system. It is important to know how the conveyor system will be used beforehand. Some individual areas that are helpful to consider are the required conveyor operations, such as transportation, accumulation and sorting, the material sizes, weights and shapes and where the loading and pickup points need to be design.
Modifyed model
The side conveyor is arranged on a frame as a cantilever structure. This arrangement made the structure unstable and the structure is tilted towards center of the main conveyor. The maximum allowable deflection in the structure should be less than one “mm” Previously taken side conveyor frame structure gives high deflections of around 90mm. So we have to give additional supports to the side conveyor frame structure that leads to lesser deflection 0.1mm. Since the rnathematical model employed already takes into account other geometrical as well as material and operational parameters, future work will concentrate on achieving further reduction through optimization with respect to these additional design variables.
The above image showing stress
Side conveyor structure is designed and developed to meet the high demands of speed & sensitivity and such a way that it can withstand the weight up to 60kgs. Future scope: •Our client has given a problem in the equipment i.e. the side conveyor is arranged on a frame as a cantilever structure, which gives high deflections. The objective is to overcome this problem by providing additional support on below the side conveyor frame structure.
The above image showing displacement
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Advanced Research Journals of Science and Technology
•The inspection sections like electronic equipments are arranged on the below side conveyor,so that we cannot give any additional supports on the below Side conveyor frame structure. •The entire frame structure of the side conveyor is attached to the side support and this entire frame structure acts as a cantilever structure. This arrangement made the structure unstable and the maximum deflection in the structure is observed , that causes the structure to overhang on the electronic equipment
AUTHOR
Kollipara Gopala Rao, Research Scholar, Department of Mechanical Engineering, S.R.K.R. Engineering College, Andhra pradesh,India.
Shows deflection in side conveyor frame structure.
•To avoid that overhanging, additional frames are added to the side conveyor frame structure to minimize the allowable deflections in the structure. This givesauxiliary strength to the side conveyor frame structure to minimize the overhanging and analyzed the structural strength.
Ravi Varma Penmetsa , Assistant professor, Department of Mechanical Engineering, S.R.K.R. Engineering College, Andhra pradesh,India.
REFERENCES 1. Singh R. Analysis of a vibratory conveyor. Indian Journal of Technology, 1975, 13, pp.500-504. 2. Schofield RE & Yusuf M. The design of a linear 'out of- phase' vibratory conveyor. Journal of Engineering of, Industry, 1973, pp .42-47. 3. Ntlanohar L & Hobe rock LL. Solids conveyance dynamics and shaker performance. SPE Drilling Engineering, 1988, 3, pp.385-392. 4. P. Oscillating Systems (Pty) Ltd, Pretoria. Personal cornrnunication, 1993. 5. Rademacher FJC. Feeders and vibratory conveyors’ for, bulk solids handling, TUNRA Ltd. Department of Mechanical Engineering, University of Newcastle, NSW, Australia, 1974. 6. Snyman JA & Vermeulen PJ. The mathematical modeling of the motion of a horizontal vibratittg screen supported by ROSTA oscillating mountings. R €i D J journal, 1992, 8, pp.25 -33. 7. Snyman JA. An improved version of the original leapfrog dynamic method for unconstrained minirnization: Applied Mathematical Modelling,1983, 7, pp.216-218.
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