MODELING AND FABRICATION OF BELT CONVEYOR SYSTEM PROJECT REPORT

INTRODUCTION

A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries. Many kinds of conveying systems are available, and are used according to the various needs of different industries. There are chain conveyors (floor and overhead) as well. Chain conveyors consist of enclosed tracks, I-Beam, towline, power & free, and hand pushed trolleys.

1.1 INDUSTRIES THAT USE CONVEYOR SYSTEMS
A line shaft roller conveyor conveys boxed produce at a distribution center. A conveyor belt conveys papers at a newspaper print plant roller conveyor for carton transport in the apparel industry. Conveyor systems are used widespread across a range of industries due to the numerous benefits they provide. Conveyors are able to safely transport materials from one level to another, which when done by human labor would be strenuous and expensive. They can be installed almost anywhere, and are much safer than using a forklift or other machine to move materials.

They can move loads of all shapes, sizes and weights. Also, many have advanced safety features that help prevent accidents. There are a variety of options available for running conveying systems, including the hydraulic, mechanical and fully automated systems, which are equipped to fit individual needs.

Conveyor systems, as shown in fig:1.1, are commonly used in many industries, including the automotive, agricultural, computer, electronic, food processing, aerospace, pharmaceutical, chemical, bottling and canning, print finishing and packaging. Although a wide variety of materials can be conveyed, some of the most common include food items such as beans and nuts, bottles and cans, automotive components, scrap metal, pills and powders, wood and furniture and grain and animal feed.

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 help full 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 care and maintenance of conveyor systems.

A conveyor system is often the lifeline to a company’s ability to effectively move its product in a timely fashion. The steps that a company can take to ensure that it performs at peak capacity include regular inspections and system audits close monitoring of motors and reducers, keeping key parts in stock, and proper training of personnel.

Increasing the service life of conveyor system involves choosing the right conveyor type, the right system design and paying attention to regular maintenance practices.

A conveyor system that is designed properly will last a long time with proper maintenance. Here are six of the biggest problems to watch for in overhead type conveyor systems including I-beam monorails, enclosed track conveyors and power and free conveyors. Overhead conveyor systems have been used in numerous applications from shop displays, assembly lines to paint finishing plants and more.

1.2 LACK OF LUBRICATION
Bearings require lubrication in order to reduce friction. The chain in the drives experiences the double the force of transmission in the case of bearings are poorly lubricated. This can cause the system to overload by either its mechanical or electrical overload protection. Fig: 1.2 shows failures occurred in the case of poor lubrication in bearings.

1.3 CONTAMINATION
Paint, powder, acid or alkaline fluids, abrasives, glass bead, steel shot, etc. can all lead to rapid deterioration of track and chain. Ask any bearing company about the leading cause of bearing failure and they will point to contamination. Once a foreign substance lands on the raceway of a bearing or on the track, pitting of the surface will occur, and once the surface is compromised, wear will accelerate. Building shrouds around your conveyors can help prevent the ingress of contaminants. Pressurize the contained area using a simple fan and duct arrangement. Contamination can also apply to belts (causing slippage, or in the case of some materials premature wear), and of the motors themselves. Since the motors can generate a considerable amount of heat, keeping the surface clean is an almost-free maintenance procedure that can keep heat from getting trapped by dust and grime, which may lead to motor burnout.

1.4 PRODUCT HANDLING
In conveyor systems that may be suited for a wide variety of products, such as those in distribution centers, it is important that each new product be deemed acceptable for conveying before being run through the materials handling equipment. Boxes that are too small, too large, too heavy, too light, or too awkwardly shaped may not convey, or may cause many problems including jams, excess wear on conveying equipment, motor overloads, belt breakage, or other damage, and may also consume extra man-hours in terms of picking up cases that slipped between rollers, or damaged product that was not meant for materials handling. If a product such as this manages to make it through most of the system, the sortation system will most likely be the affected, causing jams and failing to properly place items where they are assigned. It should also be noted that any and all cartons handled on any conveyor should be in good shape or spills, jams, downtime, and possible accidents and injuries may result.

1.5 DRIVE TRAIN
Notwithstanding the above product handling, involving take-up adjustment, other parts of the drive train should be kept in proper shape. Broken O-rings on a Line shaft, pneumatic parts in disrepair, and motor reducers should also be inspected. Loss of power to even one or a few rollers on a conveyor can mean the difference between effective and timely delivery, and repetitive nuances that can continually cost downtime.