Modifications in Drive System to Reduce Deflection of Sleepy Bar using ADAMS

IJSRD - International Journal for Scientific Research & Development| Vol. 4, Issue 05, 2016 | ISSN (online): 2321-0613

Modifications in Drive System to Reduce Deflection of Sleepy Bar using ADAMS Pankaj Kulkarni1 Prof. G.E. Kodhalkar2 1,2 Department of Mechanical Engineering 1,2 APCOER, Pune Abstract— Drive system of a counter separator machine, in which slippery bar is subjected to numerous loading condition. About 90-95% of the total conveyor weight is preoccupied by the sleepy bar. Hence correct style of the drive system is extraordinarily important. In present paper work force analysis of the drive system for machine structure is done. In order to scale down deflection of the sliding bar, one of the choices is weight reduction and reduces force performing on it. However, the designer should be aware that so as to scale back the burden, the strength of the machine structure should not be disturbed.

Sleepy bar is the most vital component used to move the conveyors from one location from one location to a different location application. The Drive mechanism in a drive system must conjointly carry the load of the cartons on conveyor.

Key words: ADAMS, Drive system, FEA, Pulleys, timing belt I. INTRODUCTION Design of conveyor system includes belt speed, belt width, motor selection, belt specification, shaft diameter, pulley, gear box selection. The optimum belt speed, the determination of the belt width is largely a function of the quantity of conveyed material which is indicated by the design of conveyed belt [1]. Structural analysis is done on belt conveyor used in the high speed industrial automation and the maximum deformation induced in belt conveyor system in mm near the tail pulley side belt surface in which vertical forces are applied[2]. Authors also dealt with multibody formalisms and finite element modelling. The pulley was modelled as an elastic multibody system.

Neglecting its own internal dynamics, the pair of rocker pins was modelled as one stiff mass less spring acting along the direction of shaft axis. The model was simulated under the conditions of a constant driver pulley speed and a constant driven pulley load torque. Dynamics of axially moving materials, belt drive mechanics, chain drive mechanics are the main studies are discussed [3]. A flat belt drive is designed by limiting the maximum tension. According to the permissible tensile stress specified for the belt material.

Pulley material is generally cast iron or cast steel [4]. The impact analysis of the pre tensioning of timing belt is conducted for real timing belt drive [5].

III. POSSIBLE SOLUTIONS Possible solution to reduce weight of conveyor and machine /reduce deflection 1) Addition of no of sliding bars to distribute the weight of conveyor and reduce deflection but it will increase the weight of machine.

2) By doing changes in drive system – change in type belt, position runs Idlers, return idlers so that it will reduce weight and will transfer maximum force 3) By changes in conveyor design- conveyor mounting plate height and thickness can be reduced but it will reduce the strength of the machine and it is not correct solution considering shipping point of view.

Out of these three solutions, second solution is feasible IV. PRIMARY FUNCTIONS OF SLEEPY BAR The main functions are: 1) To transfer motion of conveyor from along its length 2) To support the vertical mounting frames on the ends of it.

3) To compensate for change in length (as per the distance requirement of conveyors): The length of the sliding shaft must also be capable to support the machine structure as well as to guide the conveyor while matic motors operation starts. Distance changes between right conveyor and left conveyor are required as per the corrugated sheet size. It is located on lower side of the machine structure and is mounted on to main frames.

To carry weight of both the conveyors it includes rollers , bolts ,nuts, pneumatic cylinders, pulley, timing belt, motion sensors, optical sensors (to detect the edge of corrugated sheet) sheet metal bracket , side guide, studs, square tubes, pneumatic cables, power supply cables etc.

Sleepy bar is mounted on OS (operator side) side frame and OOS (opposite operator side) frames at lower side. Lower left conveyor assembly and lower right conveyor assembly is mounted is mounted on it. It provides platform for the conveyors to move along it. Weight of conveyors assembly includes conveyor plate, sheet metal bracket, sensors, belt drive, nut, bolts, studs, pneumatic cylinder, routing cables, Weight of cartons etc. causing bending of sliding bar.

II. PROBLEM STATEMENT It provides platform for the conveyors to move along it.

Weight of conveyors assembly includes conveyor plate, sheet metal bracket, sensors, belt drive, nut, bolts, studs, pneumatic cylinder, routing cables, Weight of cartons etc. causing bending of sliding bar 1) To minimize deflection of sleepy bar -It carries weight of conveyor along its length 2) To reduce weight of the machine 3) To increase force transfer at the drive pulley.

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Modifications in Drive System to Reduce Deflection of Sleepy Bar using ADAMS (IJSRD/Vol. 4/Issue 05/2016/406)

Fig. 1: overview of sleepy bar These kind of machine modules are used in high speed industrial automation. Cartons pass from feeder section to delivery section with the help of flat belt and it is operated by motor fixed at the bottom.

1.At initial point F1=F slack 2. At point 2 F2=F1+€Fp1 (€=0.03) angle of lap is 120 Deg F2=1.03 Fslack, N 3.At point 3 F3=F2+fc (mb+ mri*zr\l1) F3=1.03Fslack+3.45,N F4=1.0619Fslack+3.56,N…….(2) Resistance at loading station FL=m (V-Vi) FL =17.2N F5=F4 +FL =106019Fslack+17.2,N F6=1.0619Fslack+16.94 Ftight =1.1256Fslack+11.4……….(3) Solving (1),(2) ,(3 ) F slack=12.16N, Ftight =49.1264 Effective belt tension in pulley Resistance at unloading station FL FU=(3.1 to3.6)Mm .g .B Final values of forces F1=12.16N, F2=12.54N, F3=15.97N, F4=16.47N, F5=30.11N, F6=29.85N Force on driven pulley =Force on drive pulley –(sum of total resistance forces) Force on driven pulley =150-(134.080) Force on driven pulley =15.9N

Fig. 2: Machine set-up V. MATHEMATICAL MODEL

Fig. 3: Resisting Forces acting on the Drive system are: Force required to move the cartons from inlet section to delivery section along conveyor, frictional resistance due to Idlers, frictional resistance at pulley, resistance at loading station, frictional resistance at unloading of station, bearing resistance to the pulley.

Total material load acting on load carrying belt Fm=(Mm) *( l) *g mass of material x l= distance of loading to unloading station.

Frictional resistance Due to Idlers Wr= (Mm+mb)*g* tc Mm = mass of material carried by conveyors per unit belt Mb=mass of belt per unit length tc =pitch of carrying run idlers tr=pitch of returns run Idlers.

Fig. 4: For proposed system with timing belt Free body diagram of drive and driven pulley with timing belt D=P Zp\π……..(1) D=59.23=60mm D=60mm D= Diameter of drive pulley, Zp= no of teeth of pulley.

Effective Tension Te=T1-T2 M =Te (d\2) Frictional resistance at pulley Resistance at loading station FL Force required to move the mass of carton is Fs Fs =ma Fs=ms+mp+2mi((v-vi)\t) Fs =12.77N ……..(2) Fg=102.5N Ff=frictional force for pulley and bearing Fab =Wb.Lb.a\g……….(3) Fab=5.1N

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Modifications in Drive System to Reduce Deflection of Sleepy Bar using ADAMS (IJSRD/Vol. 4/Issue 05/2016/406)

Ff=7.40N Ff=frictional force for pulley and bearing Idler resisting force

mi= mass of idler of drive system Fai =2.835N F1=12.77N, F2=102.5N, F3=5.1N, F4=7.40, F5=2.835 Force on driven pulley =Force on drive pulley – (sum of total resistance forces) Force on driven pulley = 151.3-(12.77+2.835+102.35+7.40+5.1) Force on driven pulley =20.845 VI. MSC-ADAMS MODELLING AND SIMULATION OF EXISTING DRIVE SYSTEM

Mechanism modelling is done with all standard pulleys and have 1 drive pulley 1 driven pulley, 4 run idlers, and 5 returns idlers with flat belt drive in Adams -advanced

machinery in which corrugated sheets are moving from inlet side to outlet side cross sections at the ends.

1) Cad model prepared in CATIA V5 (R21) and force analysis is done in Adams15-advanced machinery below are steps to be followed during cad.

2) Co-ordinates of pulleys are given driven pulley(0,30,0) ,driven(450,30,0)and belt profile .

3) Type of belt selected is timing belt and carton weight of 85 Kg is applied.

4) Material properties Sut= 300 N/mm2, Young’s Modulus: 210 GPa are given 5) Friction parameters µ1= 0.4, µ=0.34 are applied in Adams –machinery.

6) Rpm 350 (motion) is given all above procedure is done as per machine configuration and operation process.

For force analysis, multi body dynamics. And linear, nonlinear is done using Hypermesh. This computer simulation product provides force elements to model behaviour, and supports material models and equation solvers for a wide range of mechanical design problems.

Function of analysis is to perform and predict more information and gives accurate result of model life before actual testing; it will save valuable time, cost and actual testing.

Fig. 5: A belt drive system co-ordinates modelling in Adams-advanced machinery layout.

Fig. 6: A belt drive system modelling-motion solver with carton weight in Adams-advanced machinery.

Fig. 7: Force Vs time of drive system

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Modifications in Drive System to Reduce Deflection of Sleepy Bar using ADAMS (IJSRD/Vol. 4/Issue 05/2016/406)

VII. MSC-ADAMS MODELLING AND SIMULATION OF PROPOSED DRIVE SYSTEM

Proposed system is modified with changing the flat belt by timing belt New modelling of drive system is done with change in type of belt and pulley and diameter of drive pulley is changed with lighter weight tooth-head pulley with keeping other parameters constant.

PARAMETERS DIMENSIONS Diameter drive pulley 60 (mm) Diameter of driven pulley 66(mm) WEIGHT OF sleepy bar 10.32 (Kg) WEIGHT Of conveyor 109 (Kg) Force on driven pulley 21.35N Table 1: New drive System Parameters

Fig. 8: Timing belt with idler pulley, drive pulley and driven pulley

Fig. 9:

Fig. 10: Joint force on the proposed drive system Vs time Analysis has done by using optistruct solver as per below procedure, 1) Create new file for new project.

2) Create new material file for 27C15 and select material properties.

3) Import igs file of cad data for analysis.

4) Created mesh size as 15mm to complete geometry.

5) Apply point loads and fix constrains to ends of rod.

Update loading condition and select required solutions asTotal Deformation.

Fig. 11 Deflection of sleepy bar of existing system

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Modifications in Drive System to Reduce Deflection of Sleepy Bar using ADAMS (IJSRD/Vol. 4/Issue 05/2016/406)

Fig.12: Deflection of sleepy bar of proposed system determination in serpentine belt drives: influence of tensioner and belt characteristics”, Mech. Mach. Theory VIII. CONCLUSION 44 (2009) 813–821.

1) Existing drive system is using flat belt. Sleepy shaft [9] D. Yu, T.H.C. Childs, K.W. Dalgarno, “Experimental analyzed with this flat belt is showing displacement and finite element studies of the running of V-ribbed 0.69mm. This drive system is replaced with timing belt belts in pulley grooves”, Proc. Inst. Mech. Eng. C J. and deflection observed was 0.484mm.

Mech, Eng. Sci. 212 (1998) 343–355.

2) Hence, proposed design of drive system gives less [10] H. Peeken, F. Fischer, “Experimental investigation of deflection of sleepy bar. Design of conveyors meets the power loss and operating conditions of statically loaded strength requirement. belt drives”, Proceedings of the 1989 International, 3) Proposed system gives 16.45% weight reduction in the Power Transmission and Gearing Conference, Illinois, machine.

1989, pp. 15–24 REFERENCES [1] Rohini N. Sangolkar, Vidhyadhar P. Kshirsagar, “Modelling and analysis of industrial belt conveyor system” International Journal of technical research and application, issn: 2320-8163 [2] W. Chen, C. Shieh, “On angular speed loss analysis of flat belt transmission system by finite element method”, Int. J. Comput. Eng. Sci. 4 (2003) 1–18.

[3] G. Gerbert, On flat belt slip, Veh. Tribol. Ser. 16 (1991) 333–339, “Finite Element Systems”, ; A Handbook; Springer-Verlag; Berlin; 1982.

[4] G. Cepon, L. Manin, M. Boltezar, “Introduction of damping into the flexible multibody belt-drive model: a numerical and experimental investigation”, Journal of Sound Vib. [5] R.R. Senthilkumar, K. Sooryaprakash, “Industrial drive belt tensioning optimization”, International Conference on Current Trends in Engineering and Technology, IEEE-32107, ICCTET, 2013, ISBN 978-1-4799-25858. 304–306 (Coimbatore, India), IEEE Catalogue Number:CFP1300W-POD.76.

[6] C. Zhu, H. Liu, J. Tian, W. Xiao, X. Du, Experimental investigation on the efficiency of the pulley-drive CVT, Int. J. Automot. Technol. 11 (2) (2010) 257–261.

[7] G. Gerbert, “Belt slip-a unified approach”, J. Mech.

Des. 118 (1996) 432s–438s.

[8] L. Manin, G. Michon, D. Remond, R. Dufour, “transmission error measurement to pulley-belt slip

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