ETM 499C Senior Project

FALL 2017

Dr. K. Jenab

Final Proposal

Title:Design the calibration gauge

Students Name:Ahmed Brnawi

Date: September 8, 2017

Problem Statement

Need was felt to design the calibration gauge that will be fixed to the conveyor

belt so that calibration can be done as required. Calibration of the conveyor belt is

required from time to time to ensure that the efficiency of the production unit is

optimized by the reduction of faults. The manufacturing units may find defects if the
conveyor belt finds a shift in the zero calibration. The automation in the

manufacturing process may suffer due to this error in the calibration. Attaching a

gauge assembly will help in determining the condition where the belt has considerably

shifted from the acceptable range and will be used to trigger the zero calibration. This

process which ensures that the conveyor belt is properly calibrated will reduce the

amount of waste in the manufacturing process.

The object and intent of this project is to design and prepare a prototype of one

cost effective calibration gauge assembly unit which will let the staff to quickly and

accurately adjust the zero calibration. Several steps are required in the design of this

prototype and each step in the design and making process will be addressed offering

blueprint, material required, and components required to purchase to fulfill this

project. Also the cost - benefit analysis would be presented in order that management

can assess feasibility of producing more units to deploy at each conveyor belt.

Chief steps required for fulfilling the object of this project and completion of the

prototype are as follows:

1. Literature Review and Research: Primary and secondary research data and

information would be gathered to ascertain the need of the manufacturing engineer.

(ETM Option(s): Engineering Technology Fundamentals. Week 1)

2. Conceptual Design: Various candidate solutions will be considered, evaluated and

most appropriate will be proposed. (ETM Options(s): Engineering Design. Week 2)

3. Calibration Gauge Assembly: Software Tools like Siemens product life

management (PLM) software is used to prepare model and blueprint of the assembly.

(Engineering Design and CAD, Weeks. 3 & 4)

4. Raw Material Selection: Raw Materials used to make assembly and calibration base

unit will be specified.(Materials Science. Week 5)

5. Prototype Development Process: Technique used to make each component would

be discussed at length. (Manufacturing Processes and Engineering Design. Week 6)

6. Actual Prototype creation: First the pre-production prototype will be made.

(Manufacturing Processes and Engineering Design. Week 7 & 8)

7. Prototype Testing: Test plan would be made to test the prototype. (Manufacturing

Processes and Engineering Design. Week 9)

8. Cost benefit Analysis: Cost benefit analysis will be undertaken and presented.

(Engineering Economic Analysis.Week 10).

Solution Approach

Literature Review and Research

Often there are errors in the assembly line of products and this causes defects

and delays due to faulty calibration of the conveyor belt. There are errors if the

conveyor belts are not in motion for periods of time like few hours and so zero setting

may be required. With the manual or other calibration systems, this calibration is

generally done prior to 15 minutes before the new transportation initiation. This is

done so that the system is supported and the belt is enabled to have the optimal

position. Normally, in the existing assemblies additional hardware & software is used

for controlling the auto belt weigher. However, correct display of value is constrained

and requires a stable temperature to be reached (Aleksandrovi and Jovi, 2008).

In some systems, the setting the zero is accomplished when the conveyor belt

is still not loaded or is in a motion with constant speed. So there is a lot of scope of
error. It is proposed that the weighers must not affect too much and the new system to

be designed is much lighterin weight than the existing versions. The new system has

to be more robust and reliable. Need of hour is to adhere to the green environment and

related issues. These issues must be addressed beforehand so as to encourage

sustainable development. The carbon footprint has to be reduced and greener methods

to be adopted for the new development. Before adopting the final version, various

types of candidate solution will be vetted and most appropriate solution will be

adopted based on the specified criteria like accuracy and stability of design (Knapp,

1989). (ETM Option(s): Engineering Technology Fundamentals. Week 1).

Research on existing design Principles

The calibrators for the conveyor belt need both hardware and software combo

to control the precise calibration process. Here the actual design principles will be

considered. As far as the hardware methods are concerned we can consider the

existing Tape Dosing - Functional Principle. This is represented in the below figure:

Figure 1: Weighing Belt Feeder Design (Process Automation, nd).

In a weighing belt feeder, the product is supplied on a continuous belt on a

conveyor belt, by an inlet sash valve or an automatic pre-doser. A load sensor located
under the web continuously measures the weight of the products over a defined length

of the web. This load sensor can be useful in providing the inputs the software which

can then control the calibration, as required. The control device continuously

compares the actual weight with the target weight and automatically adjusts the

engine speed either to increase or reduce the speed of the belt in order to maintain a

constant flow rate. Any variation in the density of the material is reflected as a change

in the load of the web, which is compensated by an adjustment of the web speed

(Process Automation, nd)..

The weighing belt feeders are placed directly under a silo, making them

suitable extraction devices. The ideal inlet valve has an adjustable width, so that the

profile (and therefore the volume) of the discharged materials can vary to suit the

application requirements. For inventory management or measurement, the Intelligent

Weighing Strip is placed in a constant speed configuration to measure or total the

amount supplied in the process.

Figure 2: Intelligent Weighing Strip (Process Automation, nd).

The Intelligent Weighing Strip has the following advantages:

It comes with a relatively lower price for high mass flow rates

No filling required
 The compactness of the device makes it possible to install it even in rooms

with low free height.

The values can be supplied to the calibration device for calibration

adjustments

Coperion K-Tron Weighing Machine Models for Medium and High

throughput Applications

Two Sizes of Medium Flow Stripe Weigher are available with 300 mm and

600 mm band widths, with or without center element, for medium dosage or

gravimetric measurement. A continuous calibration option reduces downtimes for

calibration and maintenance. As it was highlighted that the values can be supplied

directly to the calibration device, so following expression is used for the estimation:

SWB-300/600 flow rates: 10 - 80,000 dm 3 / h (0.4 - 2,800 ft 3 / h)

The output from the above expression provides the continuous feed for calibration, so

there is no downtime required for actual calibration process. An Open Reinforced

(OF) version may be proposed to allow direct unloading on the surface of the

strip. This characteristic can be an important advantage for fragile materials such as

crisps, when easy access is required, or when dosing very hot or very cold materials

(Process Automation, nd).

The dosing belt dosers must be regularly inspected and revised. They must

also be regularly cleaned since the materials that stick to the weighing surface or the

weighing strip prevent the balance from zeroing properly through the calibrators or

may cause problems with the web travel. The Coperion K-Tron Medium-Flow Smart
Weigher is the first weigher-in-line weigher to offer a solution with its optional in-line

self-calibration compensation.

The autotare option uses two Smart Force Transducer (SFT) weighing

units. The first SFT measures the actual weight of the web before receiving the

material, but includes the weight of the material stuck on the web. The second SFT

determines the gross weight after the material is received on the web. The dispenser

compensates for the difference and the speed control of the belt ensures long-term

dosing stability and high accuracy.

Even in the case of sticky materials, better accuracy and reduced downtime

for cleaning, maintenance and calibration are achieved. The new tare technology also

offers an automatic cleaning indicator and increases the dosing range of the weigh

feeder, allowing it to perform dosing operations of less than 50 lb / min.

High-speed intelligent weight loss belt feeders are available in three sizes,

with open or closed casing, for feeding or gravimetric dosing.

Figure 3: High-speed intelligent weight loss belt feeders (Process Automation,

nd).
 Supply speeds for the SWB-650/800/1000: 2,000 - 120,000 dm 3 / h (70 -

2,800 ft 3 / h). These are then fed to the intelligent calibration software device.

All K-Tron Coperion Intelligent Weighing Batchers use digital load cells

instead of analog load cells, with the following advantages:

High resolution (1: 4,000,000)

Unaffected by electrical noise during data transfer

Directly feed the inputs to the intelligent calibration software device

On-board microprocessor to linearize the weight efficiency and compensate

for temperature fluctuations.

Automatic calibration

Suppression of low-frequency vibrations without reduction of resolution

Conceptual Design

So far the recommended designs for the calibrators in the technical manual

arethe minimal zero testing time. This is achieved through auto zero settings and the

control intervalsis for aboutthree minutes or time it takes to compete the full rotation

for the conveyor belt. Conceptually it should be based on how the control intervals

amount to, three minutes or time it takes to complete the full rotation for conveyor

belt, whichever is longer. The tests for the reliability of the zero weigherconsist of set

of control procedure. This control procedure repeats consecutively for 3 times. The

object is to reduce the error to less than 0.06 per cent of the capacity of weigheror

capacity of belt weigher, whichever is smaller. Since this is going to be hardware and
software controlled gauge so basic sketch & drawingis required. Tools like Visio are

good to complete drawing processas software is also involved. Sketches will help to

visualize the conceptual design and have a better understanding. Information collected

at this stage will help to ascertain the calibrator architecture (Aleksandrovi and Jovi,

2008). (ETM Options(s): Engineering Design. Week 2).

Conveyor Belt Calibration Process Automation

The conveyor belt process automation requires that the minor adjustments are made

directly to the belt. Some of the design concepts were discussed which help to get the

inputs directly to the software module. The design of the conveyor belt is also such

that it assists in the automation. For instance it was discussed that even in the case of

sticky materials, better accuracy and reduced downtime for cleaning, maintenance and

calibration are achieved with the new tare technology. This technology also offers an

automatic cleaning indicator and increases the dosing range of the weigh feeder,

allowing it to perform dosing operations of less than 50 lb / min. The intelligent

design systems as well as the digital, rather than the analog technology allows to feed

the values directly to the calibrator device.

One line diagram of the automation process is represented below:

The figure shows the line design of the conveyor belt and the process automation of

the calibration system. This will be used for the exact design of the calibration device.

The direction of the conveyor belt and the separate detector is shown. The detector

will provide all the inputs for the calibration. This system will be automatic and

would not require any down time for the calibration process (Process Automation,

nd).

Calibration Gauge Assembly

The sketches and drawing of both hardware and software to control the

calibrating system will help to create the actual assembly design. The 3D designs

helps to visualize the architecture of the equipment, especially the hardware portion. It

will reveal the spatial arrangement and the interconnections / interface with conveyor
belt and the software. At this stage proper Computer Aided Design (CAD) software

would be required to complete the design process. The tools needed at this stage are

like Siemens Product Life Management (PLM) software, which is CAD software

which would help in designing the calibration based prototype. PLM software helps in

generation of the solid model as required to design the fixtures. Any subsequent

design changes can be incorporated in the prototype available (Knapp, 1989).

(Engineering Design and CAD, Weeks. 3 & 4).

Raw Material Selection

Main raw material which would be required here is the alloy of aluminum and

steel. This will make the assembly robust as well as pliable. Robustness properties

like desired hardness are attributable to the percentage of steel used and suitable

conductivity and pliability of the material comes from the mix of aluminum in the

composition. Apart from this the necessary connectors, screws, bolts and other

material like fasteners and springs will be required from a branded supplier.

(Materials Science. Week 5)

Prototype Development Process

To make a blue print of the design, first step is to conceptualize a prototype.

As highlighted CAD software helps in the prototype design process. Software tools

like Siemens Product Life Management (PLM) software assists in the design process.

PLM can be used to generate the solid model. Other fixtures and the inventory used to

complete the design is also listed in the blueprint. As the software model is saved as a

file, it is easy to incorporate the future changes (Schenck, 2002). (Manufacturing

Processes and Engineering DesignWeek 6).

Actual Prototype creation

Again, once PLM software based design of is complete, the software lets the

change of parameters. The design changes are effected based on the parameters input

to the system. Quality and design standards are entered in the design. The model is

finally created which adheres to the design standards, specifications and follows the

given quality standards. Finally PLM helps to create the solid model of the prototype.

Any changes to the solid model can be effected by changing the specifications, quality

standards and the design parameters (Schenck, 2002). (Manufacturing Processes and

Engineering Design.Week 7 & 8).

Prototype Testing

Test cases are designed to test the accuracy of the calibrator. Since the

specifications are already entered to the system, test cases allow the testing of the

design through PLM. Once the design passes all the test cases, the prototype can be

taken to the next stage where the actual operational tests can be simulated. Some

changes will come-up if the prototype design fails a test. The design changes can

again be entered in the model creation process. Once the changes are incorporated in

the new prototype then the testing process is re-initiated (Schenck, 2002).

(Manufacturing Processes and Engineering Design.Week 9).

Cost benefit Analysis

Cost benefit analysis will be undertaken and presented. Basically the CBA

tests the financial feasibility of the prototype and also computes the cost saving

achieved through a quality calibrator. The calculation process is done through the

excel sheet and the reports is generated and presented through the software

(Engineering Economic Analysis. Week 10).

Project Timeline

Following is a tentative project timeline: (Around 12 weeks. There is a slack / buffer

period of 1 week as shown in the last segment: 13th week).

References

Aleksandrovi, S. and Jovi, M. (2008). Automatic Conveyor BeltScale Accuracy

Verification, Proc. 7th InternationalSymposium On Mine Haulage And Hoisting,

Belgrade 115-119

Knapp, K. (1989). Installation and Alignment of Conveyor Belt Scales,Technical

Publications Of The National Industrial Scale Association (NISA).

Process Automation. (nd). Process Automation Technical Data.

Schenck.(2002).Measuring and process systems, Multibelt beltweighers - Installation

and operating instructions.