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IMPROVEMENT OF MECHANISM OF CONVEYOR SYSTEM, PART 2

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2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

IMPROVEMENT OF MECHANISM OF CONVEYOR SYSTEM, PART 2

M.N. Mansor*, F.I. Malek, M. Muaz, S. Rubiah, M.A. Muda

Faculty of Mechanical Engineering, Universiti Malaysia Pahang,

26600 Pekan, Pahang, Malaysia,
Phone: +60177183834
*Email: nasiruddinmansor93@gmail.com

ABSTRACT

Any conveyor system is a widespread part of hardware controlling products that will techniques
materials derived from one of position to a different. Many varieties of promoting programs
can be purchased, and they are employed using the several wants of diverse industrial sectors.
The intention of this specific challenge is usually to enhance the existing conveyor unit that
will found on the system laboratory in University Malaysia Pahang. The present pattern on the
conveyer unit employed timing belt that will linked on the generator to move the particular
base. The condition on the existing pattern will be the timing belt disheveled as well as base
ended up being slipping. For that advancement most of us make use of sprocket as well as
sequence because get device. Past the above mentioned advancement the particular conveyor
system is actually likely to function. This challenge furthermore allows student to work with
their particular executive facts as well as enhance the proficiency of student in dealing with the
particular hardware difficulties.

Keywords: Conveyor system; timing belt; University Malaysia Pahang.

INTRODUCTION

Some sort of conveyor method can be a widespread part of mechanical controlling products of
which goes supplies from one area to another. Conveyors are especially practical with apps
concerning the travel regarding large as well as bulky supplies. Conveyor programs let speedy
along with useful travel pertaining to a wide variety of supplies, which can make these
individuals quite popular within the materials controlling along with presentation companies
[1]. Numerous sorts of conveying programs can be purchased, and are also used according to
the different wants regarding distinct companies. You will discover sequence conveyors (floor
along with overhead) while well [2]. Chain conveyors include things like surrounded tracks, I-
Beam, towline, electrical power & cost-free, along with side pushed trolleys [3]. Conveyor
programs are employed widespread throughout a variety of companies due to the several
rewards they feature [4]. Conveyor programs can be utilised in quite a few companies, like car,
farm, laptop or computer, electronic, foods digesting, aerospace, pharmaceutical, chemical
substance, bottling along with canning, and printing finishing along with presentation [5].
While a wide variety of supplies could be offered, some of the most widespread include food
items like pinto beans along with nut products, containers along with cans, car parts, refuse
steel, pills along with powders, solid wood along with pieces of furniture along with hemp
along with pet give food to [6]. Numerous factors are important within the precise offering of
any conveyor method. You have to recognize how this conveyor method will probably be used
previously. Some individual areas which can be beneficial to take into account will be the
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

essential conveyor operations, like travel, build up along with selecting, this materials sizes,
weight load along with styles along with the spot that the loading along with collection things
must be [7].
Conveyers have got quite a few form of rewards, it may pretty much could be mounted
wherever. Other than, utilizing conveyer while travel to move heap tend to be very much less
hazardous in comparison with utilizing forklift as well as additional machines. It also can go
loads of many shapes and sizes [8]. There are various forms of conveyer machines like gravity
conveyer method, electrical power belt conveyer programs, vibration conveyer programs,
variable conveyer programs along with reside roller conveyer method [9]. The style capability
on the conveyor belt method was determined from your facts compiled utilizing distinct
strategies of calculation [10]. Several distinct strategies of calculation were being used to
determine the pattern capability on the conveyor belt method [11]. The style on the belt
conveyor must start with an evaluation on the features on the offered materials along with
especially this angle regarding repose and also the angle regarding surcharge. The angle
regarding repose of the materials, also known as this “angle regarding natural friction” would
be the angle when this materials, when heaped freely on any horizontal area takes up for the
horizontal jet [12]. The conveyer belt installs have been employed for moving a wide variety
of items and also products for many people generations [13]. They always provide you with
the speediest, best, reliable and also economical technique of vehicles above relative cross
country generally within areas wherever space is bound a great operating under one of the most
unfavourable problems under the rainbow [14].
The conveyer belt represents an intrinsic purpose inside useful procedure of each and every
conveyer system and has to deal with an enormous number of challenges and also calls for
[15]. Just about every offering installing along with the problems of which must run within are
generally certainly distinct [16]. Because of this the best collection of belt form and also protect
top quality is necessary [14]. There are various significant technological policies, beliefs and
also calculations concerned while choosing a conveyer belt. That is furthermore is true of
installing fresh belts, so they really run on maximum efficiency [17]. A new belt conveyor
involves a great unlimited and also versatile belt regarding excessive toughness having a pair
of stop pulleys (driver and also driven) on repaired jobs supported simply by rollers. In this
operate, 3 roll idlers are expected for adequate assist regarding products sent and also safeguard
in the belt along it is size [11]. Pulleys are widely-used for delivering the actual generate for
the belt via a generate device tools field power simply by an engine [18]. In addition, it aids
within retaining the right pressure for the belt. To generate imparts power to a number pulleys
to relocate the actual belt and a good deal [19]. Roller conveyor organizations are generally
found in manufacturing or assemblage wrinkles exactly where individual significant things
need to be conveyed [20]. Roller conveyor organizations alter from sign roller organizations
for instance a bicycle sequence, that's employed to shift torque rather than promoting goods
[21]. Conveyor organizations possess a significant pitch that's successful in bridging significant
distances using a lesser number of shackles, they often get plumper area clothing and also
rollers using significant dimension [22]. Consequently they can endure larger tensile and also
great shock a lot compared to sign organizations. Additionally they can carry a lot associated
with wear previous to break arises [13]. On the other hand, roller conveyor organizations
possess an essential clearance that easily will become contaminated using allergens through
the conveyed stuff [23]. A regular conveyor sequence can be designed with two different types
of shackles, the roller link (or inside link) along with the pin link (or exterior link) [24]. The
particular roller link contains two material bushings who are press-fitted inside the roller link
clothing, even though the pin link consists away from two material pins press-fitted inside the
pin link clothing. In order to avoid disengaging associated with clothing and also pins, riveted
pins or t-pins are used [25]. Roller conveyor is just not subjected to intricate talk about
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

involving running nevertheless most of us observed that it is fashioned with higher issue
involving safety. If it is redesign important areas example as roller, the whole length, and also
bearing & Frame etc. then it's possible to decrease the overall bodyweight with the putting your
unit together [26].
Conveyor chains can be loaded in two ways which is the force can be applied on the side
plates by use of attachments which are connected to the side plates. Alternately the force can
be applied on the pins. Therefore hollow pins and axles instead of solid pins are used [27]. The
rollers transfer the normal force, due to the weight of the conveyed objects, to the track. The
driving sprocket exerts a force on the chain to pull the load, this results in a tensile force inside
the chain which must be large enough to overcome the sliding friction between roller/bushing
and the rolling friction between roller/track [28]. Additionally the chain is stressed by the
sprocket this will result in a raise of tensile force [27]. To transfer this tensile force from one
shackle to another, bushing and pin will act together as a bearing [29]. A chain is a machine
component that comes with a series of a connected links. It can be used to transmit power or
conveyance systems [30]. Usually, there are five types of chains that are cast iron chain, cast
steel chain, forged chain, steel chain and plastic chain [31]. Chain conveyers include several
advantages when compared with belt conveyer as well as roller conveyer. Many of the positive
aspects tend to be the item ideal to manage large product, very easily incorporated into present
output as well as occupy a little space. The benefits, conveyor chain ended up employed
generally within fossil fuel exploration, meals running, sewage treatment, wood growing,
gardening, bakery, growing, as well as textile products, automobile, bare cement, as well as
chemical substance grow, as well as sorting, controlling, as well as product conveyors [31].
Often failure of the conveyers also can happen. Failure suggest isn't achieving an appealing or
perhaps designed objective [32]. You can find a few basic failure types which might be crack
(full section), damage (partial section), distortion (bending, elongation, and also plastic
collapse), corrosion (pitting, as a result of wall structure perforation) and also wear (material
wastage). All the failure a result of problem with building, creation, managing and also
environment [33]. There are two forms of defects which might be generally seen in materials.
The first an example may be passed down defects the place that the foundation was in the ingot
along with the other an example may be produced defects which might be released from the
materials throughout a variety of metallic working businesses and also winter treatments [34].
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

METHODOLOGY

System flowchart
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Design of Work

The present case study or project aims to improve mechanism of conveyor system. Since we
already have the conveyor machine in the lab there are only a few equipment required in order
to improve the system so that the machine will be functioning. The flow of our project design
is by identifying the problem of the current design in order to make some improvement. The
original drive system of the conveyer is using v-belt pulley system. The problem that occur
from this system is that it did make the conveyer belt running but instead only the motor of the
system is running. Therefore, to make an improvement some research and planning need to be
done in order to recognize the main issues need to be improve in this conveyer system. After
done planning for improvement, some machining process and replacement of the original
equipment need to be done in order to improve the conveyer drive system. Machining process
such as milling process of using face mill are done in order to create a pocket for the shaft that
connect to the pulley.
The purpose of the pocket is to hold the sprocket from slipping during power transmission
process. The second machining process done is drilling the plate holder to widen the motor
holder. The third machining process is welding sprocket onto cylindrical rod to connect the
sprocket into the shaft. After machining process is done, a test run is to be conducted in order
to make sure that the idea giving can improve the conveyer drive system. If the idea is still
need to be fixed, then we need to repeat the machining process in order to satisfy the need of
improvement to the conveyer drive system. Lastly, result obtain from the test run need to be
further discuss in order to obtain a satisfying result.

PROJECT INTEGRATED SYSTEM

Experimental procedure

In order to conduct the experiment, all the equipment must be ready in other words all the
necessary equipment need to be connected together in proper ways. A conveyor belt having a
cover layer is disclosed and a core layer [35]. A conveyor belt is described, which has a support
fabric, which is provided with at least one thermoplastic material coating and is characterized
in that onto its cutting edges is welded a thermoplastic, strand-like profile material, preferably
a round cord so as to constitute an edge protection [36]. The conveyor belt further has a
migration-proofing layer provided between the cover layer and the core layer for preventing
migration of the adhesion-proofing agent in the cover layer to the core layer [35]. A conveyor
belt is to be provided with a practice-proven anti-adhering surface which is permanent and
resistant to wear [37]. The inventive method makes it possible to economically provide
individual endless and finite conveyor belts with an edge protection when this proves necessary
[38]. A dimensionally stable synthetic internal support conveyor belt which comprises [39] at
least one homogeneous, flat tape of a molecularly oriented plastic with a modulus of elasticity
of 15,000 to 25,000 kp/cm2 .The basic idea of the subject matter of the invention comprises
preventing the baking-on and dirtying of conveyor belts during the transport of the most
different goods, especially mass goods [37]. When the belt reaches a point of transition
between the helical path section and the preceding straight path section, the links at the inner
lateral edge of the belt slide towards each other so as to present a reduced pitch, while the links
at the outer lateral edge of the belt either retain the same pitch or expand by sliding away from
each other to a greater pitch than along the preceding straight path section [40]. The conveyor
belt according to the present invention is composed of a cover layer having at least one layer
in which an adhesion-proofing agent is contained, a core layer and a migration-proofing layer
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

for preventing migration of the adhesion-proofing agent to the core layer, and though it requires
no such application of specific adhesion-proofing liquids such as kerosene at each service, the
conveyor belt is free from adhesion of tacky materials such as oil sand, resulting in reduction
of conveying cost, no fear of fire, facilitation of maintenance and others [38]. Conveyor belts
having a sliding action between the links at both lateral edges of the belt experience collapsing
or contraction of the links along the inside lateral edge of the belt in the helical path section
[40].
An endless loop conveyor formed of chain belt placed in differential for driving sprockets
that are carried on separated shafts and engage the ends of the rods that form of the chain links.
The sprockets are mounted on the ends of a shaft that is adapted to be driven by motor[41]. To
chain link conveyors formed of a plurality of chain links assembled by pivot means so that
adjacent chain links can turn in a hinge like manner around the pivot means holding them
together, with means being provided for position ably securing the pivot means [42]. A chain
conveyor formed from a plurality of modules or links hinged together by pins which are
inserted through holes present in said modules or links and are prevented from escaping by
axially counteracting elements mounted in seats also present in said modules or links [43]. A
conveyor chain assembly comprising a multiplicity of rows of chain modules defining a
conveyor surface, the conveyor surface having opposite edges, each chain module having
opposite ends and a plurality of link ends projecting forwardly and rearward from the chain
module with respect to the direction of movement of the conveyor chain [44]. The invention
comprises respective sprocket means for driving the opposite edges of 'a belt, and a differential
for coupling the sprockets to a drive motor. Additionally, floating idler sprockets are associated
with the drive sprockets, and are coupled to a weight [45].In a chain link track of the
aforementioned type, at least the chain link sides which face towards an adjacent chain and
opposite the pivot bores of the chain links, a groove is provided in which the locking dowel
can be inserted before insertion of the pivot, with the locking dowel having a central bore for
the pivot and being arranged for simultaneous engagement with the grooves in two chain links
which abut each other on the same pivot thereby coupling these chain links together [42].

Analysis

This project is mean to improve the current conveyor system which has been not working for
quite a long time. The current conveyor uses a belt conveyor system. A belt conveyor system
is one of many types of conveyor systems. A belt conveyor system consists of two or more
pulleys with an endless loop of carrying medium. 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. There are two main industrial
classes of belt conveyors. Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials, such as grain, salt, coal, ore, sand, overburden and more.
Today there are different types of conveyor belts that have been created for conveying
different kinds of material available in PVC and rubber materials. 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. As for
the current conveyor it is used to transport tray with components. Next, the current conveyor
uses conveyor pulley to move the conveyor belt .A conveyor pulley is a mechanical device
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

used to change the direction of the belt in a conveyor system, to drive the belt, and to tension
the belt. Rubber lagging is applied to pulley shells in order to improve the friction between the
pulley and the belt. Conveyor drive pulleys are often supplied with diamond grooved lagging
as indicated in the adjacent sketch. 'Diamond grooved lagging' refers to the pattern in the
lagging and this pattern, like with vehicle tyres, and enhances the grip or friction even if the
belt surface is dirty. Pulleys are used on conveyors to support and deflect the belting through
the conveyor structure. Pulleys also provide a mechanism whereby the conveyor belt can be
trained to run (track) true along the conveyor idlers .Generally, pulleys are located at the ends
of the conveyor structure and at the take-up arrangement. Pulleys are used to transmit the drive
power into the conveyor belt and as such, are subjected to the dynamic belt tension forces in a
conveyor. Next, we analyse the drive mechanism for the conveyor. The current conveyor
system are using an AC motor and v-belt as the drive pulley to drive the conveyor. The most
common systems for transmitting power from a drive to a driven shaft are belt, gear, and chain
drives.
V belts solved the slippage and alignment problem. It is now the basic belt for power
transmission. They provide the best combination of traction, speed of movement, load of the
bearings, and long service life. They are generally endless, and their general cross-section shape
is trapezoidal (hence the name "V"). The "V" shape of the belt tracks in a mating groove in the
pulley (or sheave), with the result that the belt cannot slip off. The belt also tends to wedge into
the groove as the load increases—the greater the load, the greater the wedging action—
improving torque transmission and making the V-belt an effective solution, needing less width
and tension than flat belts. V-belts trump flat belts with their small center distances and high
reduction ratios. The preferred center distance is larger than the largest pulley diameter, but
less than three times the sum of both pulleys. Optimal speed range is 1,000–7,000 ft/min (300–
2,130 m/min). V-belts need larger pulleys for their thicker cross-section than flat belts. V-belts
may be homogeneously rubber or polymer throughout, or there may be fibers embedded in the
rubber or polymer for strength and reinforcement. The fibers may be of textile materials such
as cotton, polyamide (such as Nylon) or polyester or, for greatest strength, of steel or aramid.
But V-belt drive systems, also called friction drives because power is transmitted as a result of
the belt's adherence to the pulley are an economical option for industrial, automotive,
commercial, agricultural, and home appliance applications. V-belt drives are also easy to
install, require no lubrication, and dampen shock load. Standard friction drives can both slip
and creep, resulting in inexact velocity ratios or degraded timing precision between input and
output shafts. For this reason, it is important to select a belt appropriate for the application at
hand.

Figure 1: Conveyor under commissioning

2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Figure 2: Drive timing belt

RESULT & DISCUSSION

After observing all the main parts of the conveyor system and analysing which and where
to be optimized we start our improvement process. First we analyse the drive mechanism of
the conveyor in which the drive pulley that uses V belt is not in a good condition. The first
optimization that were suggested is to change the drive pulley that drive the mechanism by
using chain and sprockets. A sprocket is a profiled wheel with teeth, cogs, or even sprockets
that mesh with a chain, track or other perforated or indented material. The sprocket use in this
project acting as gear that move the pulley with the help of motor. The 17-tooth sprocket is
attach to the motor while the 15-tooth sprocket is attach to pulley. First the sprocket should be
welded to a cylinder metal made from mild steel so that the sprockets can be fitted to the motor
shaft and pulley. After that we drill a hole to the sprocket to insert the screw which will be then
tighten to the pulley shaft and drive shaft. During the tightening process we face another
difficulties where the shaft of the pulley cannot be screwed. So, we improve by making a
smooth surface by face mill the shaft. The resulting shaft looks like this.

Figure 3: Face mill on shaft

2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

After the milling process we move on to the chain as improvement for the V belt which we
used to drive the pulley. The chain sixe that we use is 428. To modify the chain we use the
special tool for chain cutter to cut our chain into desired length. Chain drives are used to
transmit power from one component to another. Specifically, they transfer speed and torque
through the use of a linked chain and sprockets. Chain drives are well suited for this task
because the sprocket teeth and chain setup results in a positive speed ratio and the ability to
transfer a large amount of torque within a compact space. After that we start assembling all the
modified and improved parts and starts the conveyor into action. This is our first test run for
our project .As expected the conveyor starts to move. Unfortunately there are some slippage
happened to the conveyor belt. This is because of the chain slippage and the chain is not tight
enough. Hence, we start to think about tightening the tension of the belt. There are few
improvement were done to the plate that holds the motor shaft and other pulley.

Figure 4: Motor holding plate

The circled part was drilled about 1.2 cm to the right. By drilling some space we can adjust the
motor shaft and indirectly we can tighten the chain. Finally, we run again the conveyor into
action and it run smoothly without any difficulties.

Figure 5: Improvised drive mechanism

2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

Calculation

40
Torque( N .m) 
2  1300r / min
 0.298N.m

Torque  RPM
Horsepower 
5255
0.298  1300

5252
As the conveyor need full speed of motor to run, thus it need minimum 0.3 N.m torque and
0.074hp to work efficiently.

Future Improvement

From our discussion, further improvement can still be done in this project to further increase
the success rate for the conveyer drive system. During this project we manage to make the
conveyer belt move with the current equipment of the drive system to run normally but from
our observation the motor that run the conveyer can still be improvise to a more powerful motor
for example from figure below:

Figure 6: Asynchronous motor

Table 1: Asynchronous motor specification

Product Name Asynchronous motor

Technology Three Phase
Power 1kW-675kW
Voltage 230-400V
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

CONCLUSION

In a nutshell, this paper is attempt to improve of mechanism of conveyor system. The conveyor
system is successfully improvised using drive chain. The conveyor move without causing any
slippage although the conveyor need a regular maintenance to avoid any casualties in the future.
This project also helps student to utilize their engineering information and improve the skill of
student in solving the mechanical problems.

ACKNOWLEDGEMENT

In performing this mechanical system design project, we had to take the help and guideline of
some respected persons, who deserve our greatest gratitude. A deepest appreciation to all those
who provided us the possibility to complete this project. We would like to show our gratitude
to our MSD supervisor Dr. Ruzaimi bin Mat Rejab, senior lecturer, Faculty of Mechanical
Engineering, University Malaysia Pahang for giving us consultations and not to forget our
MSD coordinator, Dr. Muhamad bin Mat Noor, senior lecturer, Faculty of Mechanical
Engineering, University Malaysia Pahang for his continuous support and good guideline. Last
but not least, to our team members itself for the great cooperation. We also thanks to all the
people for their help directly and indirectly to complete this project. The completion of this
experiment gives us much pleasure. Above all, to the Great Almighty, for his countless love.
2nd Integrated Design Project Conference (IDPC) 2015,
Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

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Faculty of Mechanical Engineering, Universiti Malaysia Pahang, 11 Dec 2015.

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