DESIGN AND FABRICATION OF A BELT CONVEYOR

500 LEVEL GROUP D 2024/2025

ANENE DIVINE FAVOUR 2020125017
OKPALA MICHEAL. E 2020125001
OKOLI CHIDIOGO .M 2020125063
NNAMEMZIE CHINAGOROM. J 2021125050 D.E
IBEGBU SHADRACH. S 2020125096
NWANKWO MMADUABUCHI .K 2020125065
AHGAONU CHIJIOKE 2020125067
OKONKWO YAHNEDU OBED 2020125044
OKOYE TOCHUKWU EMMANUEL 2020125092
NNAEBUE KOSISOCHUKWU .V 2020125054
OKPEKE CHIDIEBERE ONYEDIKACHUKWU 2020125056
OBIAKOR EMEKA FREDRICK 2020125016
CHUKWUEBUKA DAVID NNAEMEKA 2020125040
ONYEACHONAM KOSISOCHUKWU 2020125074

SUBMITTED
IN PARTIAL FULFIMENT OF THE COURSE APPLIED DESIGN
(MCE 511)
SUPERVISOR: ENGR DR. IFEANYICHUKWU U. ONYENANU & ENGR.
EGBOKA

DEPARTMENT OF MECHANICAL ENGINEERING

TO
FACULTY OF ENIGNEERING
CHUKWUEMEKA ODUMEGWU OJUKWU UNVERSITY, ULI
ANAMBRA STATE

JANUARY, 2025

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Table of Contents
TABLE OF FIGURE ............................................................................................................... iii
DEDICATION .......................................................................................................................... iv
ACKNOWLEDGEMENT ......................................................................................................... v
ABSTRACT .............................................................................................................................. vi
CHAPTER ONE ........................................................................................................................ 1
INTRODUCTION ..................................................................................................................... 1
1.1. BACKGROUND TO THE STUDY ........................................................................... 1
1.2 PROBLEM STATEMENT .......................................................................................... 3
1.3 AIM AND OBJECTIVES OF BELT CONVEYORS ................................................. 3
1.4 SCOPE OF THE STUDY .......................................................................................... 4
1.5 SIGNIFICANCE OF THE STUDY........................................................................... 4
CHAPTER TWO ....................................................................................................................... 5
CONCEPTUAL FRAMEWORK .............................................................................................. 5
2.1. CONVEYOR SYSTEM.............................................................................................. 5
2.1.1 TYPES OF CONVEYOR SYSTEMS ...................................................................... 7
 Slat Conveyor:........................................................................................................... 10
 Power And Free Conveyor: ....................................................................................... 10
2.1.2 THE CHARACTERISTICS OF A CONVEYOR SYSTEMS ............................... 11
2.1.3 THE WORKING PRINCIPLE OF A CONVEYOR SYSTEM ............................. 11
2.1.4 APPLICATIONS OF CONVEYOR SYSTEMS .................................................... 12
2.2 THORETICAL FRAMEWORK ............................................................................... 13
2.3 EMPIRICAL REVIEW ................................................................................................. 20
SUMMARY GAP ................................................................................................................ 23
CHAPTER THREE ................................................................................................................. 24
METHODOLOGY .................................................................................................................. 24
3.1 DESIGN FABRICATION PATHWAY ........................................................................ 24
3.1.1 CONCEPT 1 ........................................................................................................... 24
3.1.2 CONCEPT 2 ........................................................................................................... 25
3.1.3 CONCEPT 3 ........................................................................................................... 25
3.2 Design Considerations and Requirements for Belt Conveyors ...................................... 26
3.3 Material Selection ...................................................................................................... 28
.............................................................................................................................................. 29
3.3.1 Design Calculations for a Belt Conveyor ................................................................... 29
3.4 CAD DRAWING ....................................................................................................... 36

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 3.4.1 Our Design .............................................................................................................. 36
3.4.2 How it works ............................................................................................................... 37
3.4.3 Fabrication Process ..................................................................................................... 38
3.5 DESIGN CALCULATION Our Design specification ................................................. 39
Chapter Four ............................................................................................................................ 47
Result and Analysis.................................................................................................................. 47
4.1 Color Code ................................................................................................................. 47
CONCLUSION .................................................................................................................... 49
CHAPTER FIVE ..................................................................................................................... 50
WORK SCHEDULE AND ENGINEERING BILL OF MATERIAL .................................... 50
5.2 BILL OF MATERIAL ................................................................................................... 50
CONCLUSION ................................................................................................................ 51
REFERENCE ........................................................................................................................... 52

TABLE OF FIGURE
Figure 1: flat belt conveyor system ............................................................................................ 5
Figure 2: flat belt conveyor system .......................................... Error! Bookmark not defined.
Figure 3:folk Lift........................................................................................................................ 7
Figure 4robotic arm.................................................................................................................... 7
Figure 5:chain conveyor ............................................................................................................ 7
Figure 6: screw conveyor ........................................................................................................... 7
Figure 7:shows a roller conveyor ............................................................................................... 7
Figure 8........... Belt Conveyor ................................................................................................... 8
Figure 9 ........ Gravity Roller Conveyor ......... .......................................................................... 8
Figure 10 Chain Driven Live Roller .......................................................................................... 9
Figure 11...… Live Roller Conveyor ...... ................................................................................. 9
Figure 12…. Motorized Roller Conveyor ….. ......................................................................... 10
Figure 13…….. Slat Conveyor ……… ................................................................................... 10
Figure 14 …… Power and Free Conveyor …….. ................................................................... 11
Figure 15 ………Over under Conveyor ……… .................................................................... 11
Figure 16.... Shows Free body diagram ..... ............................................................................. 14
Figure 17….. Label Inner figure of Idler …... ......................... Error! Bookmark not defined.

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 DEDICATION
This group report is dedicated to almighty God, who made it possible
for report and project to be a success

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 ACKNOWLEDGEMENT
This product is the outcome of thorough and in-depth research, which
at various stages of its development, benefited greatly from the
contributions of individuals and groups to whom the researchers are
deeply appreciative. The researchers express their gratitude to God
Almighty for His boundless wisdom and knowledge, which played a
vital role in the success of this project. We extend our heartfelt thanks
to our project supervisor, Engr. Dr. Ifeanyi and Engr. Egboka, for his
invaluable guidance, as well as to all the faculty members and non-
academic staff in the department. Special thanks are also due to our
colleagues for their various contributions that helped ensure the success
of this project. We are also deeply thankful to our parents for their
financial support throughout the course of this work.

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 ABSTRACT
This project focuses on the importance of the conveyor belt as a critical working element in
transport systems, where damages to the belt can lead to costly downtimes. This Belt
conveyor study is used for the transportation of cement, design and easy maintenance with
high reliability of operation. The Geometrical model is an inclined type belt conveyor system
for Cement loading application. This work shows design calculations of conveyor, trajectory
of the consideration to have a Conveyor capacity at 200 TPH and analysis of pulley due to
belt tensions at the slack and tight side. The results and its effect. This Belt conveyor, used
for Cement processing industry load carrying capacity, has a large length of conveying path,
simply done using Solid Works and finite element analysis is done.

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 CHAPTER ONE
INTRODUCTION
1.1. BACKGROUND TO THE STUDY
Throughout the history of production and economic crises, transportation has been a critical
challenge, often hindering large-scale production in industries such as engineering and
industrial operations. Reliance on manual labor, which required significant human effort,
eventually gave way to the use of heavy-duty machinery, revolutionizing transportation and
elevating it to its current state. From mining and agriculture to manufacturing and logistics, the
efficient movement of goods and raw materials over short and long distances has become
essential for ensuring productivity and operational success. Among the advancements, the belt
conveyor has emerged as one of the most reliable, cost-effective, and widely used methods for
material transportation. The efficiency and economic viability of material transport are
influenced by the quality and optimized design of the transport system. For conveyor systems
used in transport and technological processes, key optimization criteria include minimizing
resistance and friction, which are closely linked to conveyor speed and the physical and
mechanical properties of the materials being transported. Challenges such as friction and
surface resistance at the interface between the conveyor and the material must be addressed to
ensure smooth, reliable, and economical operation. These considerations are critical across
industries, where conveyors play a pivotal role in enhancing productivity and streamlining
material handling processes.(Martin Žídek a et al., 2021)

Cellular Conveyors was introduced in the year 1892 manufacturer and 1innvented by Thomas
Robb in which was originated to transport Coal for Thomas Edison’s Ore Milling company

According to (Wheeler, 2019) On a global scale, hundreds of billions of tons of bulk materials
are transported over varying distances annually. These distances range from tens to hundreds
of kilometers, dictated by operational needs such as moving raw materials from mines to
processing plants, power stations, or export terminals. The selection of a bulk handling system
depends on factors such as transportation distance, throughput requirements, and terrain. In
most cases, these systems rely heavily on belt conveyors, often working in combination with
haul trucks and railway systems. The rising cost of fossil fuels and the global push to reduce
greenhouse gas emissions, alongside an increasing demand for minerals, have intensified the
need to enhance the efficiency and economy of bulk material transportation. Belt conveyors,
as continuous transportation systems, provide significant advantages over batch systems,
offering economic, operational, and maintenance benefits. Recent advancements in low rolling
resistance conveyor belting have further reduced energy consumption, allowing for longer
installations that are increasingly competitive with railway systems in terms of cost and
efficiency.

Historically, significant developments in conveyor technology have shaped modern material

handling. For example, in 1905, the Swedish engineering company Sandvik revolutionized the
field by introducing steel conveyors for mining aggregates and coal. These innovations laid the
groundwork for contemporary conveyor systems, which remain indispensable across
industries.

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Interestingly, the concept of conveyors extends beyond industrial applications into biological
processes. Cellular conveyor belts are described as systems within biological organisms where
processes such as cell proliferation, differentiation, and spatial organization occur along a
defined polarity axis. In these systems, stem cells and actively dividing progenitors are
localized at one end, while differentiated cells occupy the opposite pole. Such configurations
are ideal for studying mechanisms that regulate cell proliferation, differentiation, and tissue
growth. These biological conveyor belts have been observed in the intestinal crypts of
mammals, the retinas of teleost fishes and amphibians, and the optic tectum of developing fish,
as well as in non-vertebrates such as the optic lobes of flies and cerebral ganglia of snails. Both
industrial and biological conveyor systems demonstrate the importance of efficient, organized,
and optimized movement—whether in transporting materials across vast distances or
facilitating cellular processes critical for growth and development. This parallel underscore the
versatility and relevance of the conveyor concept across disciplines.

Conveyor systems play a critical role in enhancing warehouse efficiency and optimizing
operational workflows. They are highly versatile, capable of transporting materials across
varying distances and accommodating a wide range of material types. Conveyors are
particularly valuable in applications that involve moving heavy or bulky items, offering a
reliable and efficient solution for material handling. In recent years, researchers have focused
extensively on optimizing conveyor belt designs to improve performance, increase efficiency,
and develop safer, more reliable mechanisms. These advancements aim to minimize
operational risks while maximizing the system’s durability and productivity, ensuring
conveyors remain a cornerstone of modern industrial and logistical operations.(Halepoto et al.,
2016)

Belt conveyors are mechanical systems designed to transport materials over distances using
continuous belts. These systems are widely used in industries such as mining, steel, and cement
for moving bulk materials like ores, coal, and industrial products. Modern belt conveyors
feature high-speed, high-capacity, and durable designs, minimizing human intervention and
improving efficiency. The system consists of pulleys and idlers that move materials, with
powered pulleys driving the belt. While highly efficient, challenges like design inefficiencies
and maintenance remain, motivating the development of more reliable and tailored conveyor
solutions to meet specific operational needs. (Subba Rao, 2021)
A belt conveyor is a straightforward piece of machinery and one of the most common methods
for moving bulk materials. It can handle a wide variety of products at speeds of thousands of
tons per hour, maintaining a continuous and steady flow over long distances more effectively
than other types of mechanical conveyors that operate continuously. The basic design of a belt
conveyor includes two drum pulleys connected by a continuous loop of material, referred to as
the conveyor belt. The belt loops around the pulleys and is supported by troughing idlers on
the carrying side and return idlers on the return side. One of the pulleys, called the drive pulley,
is powered by an electric motor to move the belt and the materials on it. The other pulley,
located at the far end, is unpowered and is known as the tail pulley. Modern conveyors include
numerous additional components, each specifically engineered to handle different types of
materials efficiently.(Iqbal & Uddin, 2022)

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A belt conveyor is a mechanical system used to transport materials or products from one
location to another. It consists of two or more pulleys with a continuous loop of material that
forms the conveyor belt. The belt moves over the pulleys, driven by a motorized pulley, and
can carry a wide range of materials, including bulk solids and packages. Belt conveyors are
used in industries such as mining, agriculture, manufacturing, logistics, and food processing
due to their efficiency, versatility, and ability to handle large volumes over varying distances
and inclines. The system includes components like the belt, pulleys, motor, idlers, and frame,
working together to automate material handling and improve operational efficiency

1.2 PROBLEM STATEMENT

Efficient material handling is a critical factor in industrial productivity, yet many industries
still rely on outdated, poorly designed conveyor systems or manual processes, leading to
operational inefficiencies. These challenges include delays in material movement, increased
labor costs, and heightened risks of workplace accidents. In industries such as mining,
agriculture, and manufacturing, where the transportation of bulk materials is vital, the lack of
properly designed equipment often results in conveyors that are either underutilized or
overburdened. This causes frequent breakdowns, higher energy consumption, and reduced
overall productivity.

Belt conveyors are widely used for bulk material transport due to their simplicity, cost-
effectiveness, and versatility. However, common operational issues, such as belt misalignment,
slipping, excessive elongation, and belt damage, are frequent in poorly optimized systems,
further impacting performance and increasing maintenance costs. These problems stem from
factors such as improper load distribution, misalignment of rollers, inadequate belt tension, and
the accumulation of debris, leading to inefficiencies that affect material handling and
production.
The absence of customized, efficient conveyor designs specifically suited to the target
application presents a significant challenge. Addressing issues like improper material selection,
insufficient load capacity, and inadequate system tension is crucial for reducing downtime,
enhancing safety, and improving energy efficiency. This project aims to design an optimized
belt conveyor system tailored to effectively transport bulk materials, reduce reliance on manual
labor, and increase production efficiency. By incorporating industry best practices, advanced
engineering principles, and modern computational tools, the design will ensure improved
operational performance, reduced maintenance, and cost savings, ultimately advancing the
efficiency of industrial material handling systems.

1.3 AIM AND OBJECTIVES OF BELT CONVEYORS

Aim: The aim of this project is to design a belt conveyor system.
To achieve this aim, the following specific objectives have been outlined:

 This includes understanding the nature of the materials to be transported, the required
load capacity, conveyor speed, and the environmental conditions under which the
system will operate.
 To select appropriate materials and components, this involves choosing materials for
the belt, rollers, and supporting structures that ensure durability, reliability, and
resistance to wear and tear.
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  To develop a comprehensive design using Solid works. The design process will include
creating detailed technical drawings, specifying dimensions, and calculating key
parameters such as belt tension, motor power, and roller spacing.

1.4 SCOPE OF THE STUDY

Much research work has been done concerning the belt conveyor, its management, and
utilization. Thus, this study will be limited to the use of conveyor belt mechanisms for
transporting goods [maximum load =50N] from one place to another

1.5 SIGNIFICANCE OF THE STUDY

 This study aims to address challenges in industrial material handling by designing an
efficient, reliable, and customized belt conveyor system.
 The project focuses on improving operational efficiency, reducing costs, and enhancing
workplace safety by optimizing conveyor systems for industries such as mining,
agriculture, and manufacturing.
 The design process will incorporate advanced engineering principles, providing
valuable insights for future research and development in material handling. By reducing
maintenance costs, energy consumption, and labor requirements, the proposed system
offers significant economic benefits, contributing to more sustainable and efficient
operations.
 The findings can serve as a foundation for future conveyor design projects, fostering
innovation and improving material handling systems across various industries.

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 CHAPTER TWO

CONCEPTUAL FRAMEWORK
2.1. CONVEYOR SYSTEM
The conveyor system can be considered as a mechanical device used to transport materials
from one location to another. A conveyor system is a fast and efficient mechanical handling
apparatus that automatically transports loads and materials within an area (Waje et al., 2017). It
is commonly used in material handling and packaging industries to move bulky or heavy items,
minimizing human error and reducing labor costs. Its presence makes the process easier, faster,
and more convenient. In various industries, conveyors are essential. This system is designed to
withstand heavy workloads and extreme weather conditions. Its ability to adjust to specific
angles helps in the efficient transfer of materials. The conveyor system can be considered a
mechanical device used to transport materials from one place to another. The primary benefit
of the conveyor system is the reduction in operational labor costs and the significant time
savings it offers during production processes.

Figure 1 Figure 0-2: flat belt conveyor system

Conveying goods is a critical part of modern industrial and manufacturing processes, allowing
for the efficient movement of materials, components, and finished products within a facility.
Over time, a wide range of conveying systems has been developed, each suited to specific types
of goods and operational requirements. These systems not only improve productivity and safety
but also reduce the need for manual labor, optimizing workflows across industries such as
automotive, food processing, logistics, and more.

One of the most basic yet essential material handling systems is the human workforce, often
seen in small-scale operations or for tasks requiring flexibility. Humans can carry, stack, or
move goods manually, but this process is typically slow, labor-intensive, and prone to human
error. To overcome these limitations, more automated systems have been introduced, ranging
from forklifts to sophisticated robotic solutions.

Forklifts are one of the most common and widely used machines for moving heavy goods
across warehouses and factories. These vehicles are equipped with a fork-like structure that
can lift, transport, and stack goods, making them invaluable in environments where large and
bulky materials need to be moved quickly and efficiently. Though highly effective, forklifts
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still require operators and are limited by the space and layout of the facility. According to (Erel
et al., 2023) A forklift is a material-handling vehicle designed to transport loads using its forks
or other attachments.

In addressing the need for continuous, automated material handling, conveyor systems have
become essential. These systems use belts, rollers, or chains to move goods along a fixed path,
making them perfect for high-volume production lines. Chain conveyors, for example, are
particularly useful in industries where heavy or bulky items, such as automotive parts or pallets,
need to be transported across a facility. These systems are highly durable and can handle loads
that would be too heavy for traditional belt conveyors. According to (Živanić & Ilanković,
2023) Plate conveyors are used for transporting bulk and piece material under very difficult
working condition abrasive materials, material at high temperatures, casting, heavy machinery,
etc. they are also used in technological processes where in addition to transportation, certain
technologies operations are performed (heating in furnaces, cooling, drying, tempering, dyeing
etc.) buckets conveyor is used transport bulk materials. The pulling elements of these
conveyors are two lamellar chains. Unlike elevators, they can also transport material
horizontally, that is to have complex route with a close contour in the vertical plane. Another
type of conveyor, the screw conveyor, uses a rotating helical screw to move materials, typically
in bulk form.

Screw conveyors offer distinct advantages over belt conveyors, especially in handling fine
powders, dusty, or toxic materials. Their enclosed design allows for better throughput control
and provides an environmentally clean solution. Screw conveyors are more versatile, occupy
less headroom, and are cost-effective and easy to install. They are widely used in industries
such as agriculture, food processing, pharmaceuticals, chemicals, mining, and construction.
Screw conveyors excel in transporting materials like grains, powders, and fine particles, which
are difficult to handle with other systems. Their simple design allows for horizontal or inclined
transport, making them ideal for various applications. Additionally, robots equipped with
conveyors or robotic arms are becoming increasingly common in material handling tasks,
offering enhanced precision in sorting, picking, and placing items.

Robots equipped with conveyors or robotic arms can handle tasks such as sorting, picking, and
placing items with precision.

Robotic arms, for example, are commonly used in the automotive and electronics industries
for assembling parts, while automated guided vehicles (AGVs) move goods around large
facilities, following predetermined paths and communicating with central control systems to
optimize workflows. All of these systems forklifts, conveyors, and robots work together to
enhance the efficiency and accuracy of material handling. Each type of conveying system has
its own strengths and is selected based on the specific needs of the operation. The ongoing
evolution of these systems reflects the growing demand for automation, flexibility, and speed
in manufacturing and logistics, ultimately improving the competitiveness of industries
worldwide.

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 Figure 0-3:folk Lift Figure 0-4robotic arm

Figure 0-5:chain conveyor Figure 0-6: screw conveyor

Figure 0-7:shows a roller conveyor

2.1.1 TYPES OF CONVEYOR SYSTEMS

Conveyor systems are essential in modern industrial operations, providing efficient and
automated transport of materials across different stages of production, packaging, and
distribution. There are various types of conveyor systems designed to handle different types of
materials, weights, and operational environments. Below are some of the most common types
of conveyor systems used in industries today:

 Belt Conveyors: Belt conveyors are one of the most widely used types of conveyors.
They consist of a continuous loop of flexible material (usually a rubber or fabric belt)
that moves over rollers or pulleys. Belt conveyors are ideal for transporting bulk

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 materials (like coal, grain, and sand) or unit loads (such as boxes or pallets). They are
commonly used in manufacturing, mining, and logistics due to their simplicity and
ability to transport a variety of products.

Figure 0-1........... Belt Conveyor

 Roller Conveyors: Roller conveyors also known as Gravity Roller Conveyor use a
series of rollers mounted in a frame to transport goods. They are often gravity-powered,
meaning products move along the conveyor due to their weight and inclination, though
powered versions are also available. Roller conveyors are commonly used for moving
boxed or palletized goods and are ideal for warehouse or distribution center
environments. The key benefit of roller conveyors is their ability to handle a variety of
load sizes and weights.

Figure 0-2 ........ Gravity Roller Conveyor .........

 Chain Conveyors: Chain conveyors utilize a chain to carry heavy loads through a series
of rollers or pallets. These systems are typically used for transporting heavy or bulky
items, such as automotive parts, large crates, or heavy machinery components. Chain
conveyors are often used in automotive manufacturing or material handling for goods
that require more rugged handling. They can be powered or gravity-driven, depending
on the application.

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 Figure 0-3 Chain Driven Live Roller

 Live Roller Conveyor or Chain Driven Live Roller (CDLR):

Various numbers of time people are found using the acronym CDLR in the industries.
In case anyone is found combining the rollers from a gravity conveyor along with the
chains of any chain driven system then the rollers can be linked. To construct a live
roller conveyor or chain driven live roller system, there is a need to add a motor and a
gear box and it’s done.

These are the members of the floor conveyor and are found having heavy duty
material handling systems. These are the mechanical instruments which are used to
transport the pallets, seats, tires, containers etc.

Figure 0-4...… Live Roller Conveyor ......

 Motorized Roller Conveyor:

Motorized roller conveyors are referred to as those conveyors which are found having
motor inside the rollers and these are not just the normal motors, these are the
modern motors with higher capacity and higher speeds of around 200 feet per minute
or even more. These types of conveyors use mostly one or more number of motors
which are driven roller per zone in order to create a series of zones along with the
conveyor.

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 Figure 0-5…. Motorized Roller Conveyor

The motorized roller gets connected to the other rollers in the same manner by plastic
or reinforced belts. The photo eyes present are responsible for turning the motors on
and off, and the parts are found moving to the next zone wherever the space is
available.

 Slat Conveyor:
A slat conveyor is referred to as that conveyor which is simply a two-strand chain
system along with slats which are connected to the chain and a guiding system for the
slats. This is responsible for creating a smooth surface in which the tooling details or
fixtures are found to be mounted. These are the conveyors which are used to hold
parts in any specific position.

At time the fixtures can also found to be the part in order to rotate at an angle of either
90 degrees or 180 degrees which is similar to that required in various airplanes. So,
the user can use the slat conveyors as a working surface for the assembly operations
where positioning of the part is also required to be accurate.

Figure 0-1…….. Slat Conveyor ………

 Power And Free Conveyor:

Power and free conveyor are referred to as those conveyors which also belong from
the overhead family. These conveyor systems are like a regular motorized overhead
system, except that it is found having two tracks. The first track has the chain which
moves continuously whereas in the other track, the trolleys are found moving along
with the chain by using pusher mechanisms also termed as pusher dogs. These are the
systems which are mounted at regular intervals on the chain.

Whenever the two trolleys are pressed against each other, the pusher dog gets slide
over the top. Similarly, there is a stop blade which is used with a pneumatic cylinder

10
 in order to replicate this geometry which allows the trolley to start or stop the virtual
movement anywhere in the entire system.

Figure 0-1 …… Power and Free Conveyor ……..

 Over Under Conveyor:

An over under conveyor is referred to that conveyor system which is similar to the
overhead configurations, except one factor which is that the track is on the ground and
the load is above the track. These types of conveyors are usually found useful in the
paint finishing applications in order to avoid dust or oil dripping onto parts. These
types of conveyors are widely used in the automotive final assembly operations.

Figure 0-2 ………Over under Conveyor ………

2.1.2 THE CHARACTERISTICS OF A CONVEYOR SYSTEMS

A conveyor system is designed for transporting materials efficiently and reliably. It operates
continuously and handles diverse materials, from lightweight goods to heavy industrial loads.
These systems can be tailored with straight, curved, inclined, or declined pathways and are
constructed from durable materials like rubber, metal, or fabric, depending on the material
being transported. They are energy-efficient, often integrated with automation technologies
like sensors and PLCs for tracking and sorting. Conveyor systems are designed for low
maintenance, with safety features such as emergency stops and guards. They are versatile and
find applications in industries like manufacturing, logistics, food processing, and mining.

2.1.3 THE WORKING PRINCIPLE OF A CONVEYOR SYSTEM

In general, conveyor systems are included with a belt that is stretched over 2 or more pulleys.
As the belt surrounds the pulleys, it forms a closed ring so that the pulleys will be continually
rotated in the loop. One of these pulleys is termed a drive pulley which pulls the belt and moves
the items between different locations. Many of the conveyor system designs consist of a rotor
where this supplied power to the belt and drive pulley. The belt has a continuous attachment to
the rotor through the fiction which exists between both surfaces. For the efficient movement of

11
the belt, the idler and drive pulley should function in similar directions which means either
both operate in clockwise or anticlockwise directions.
Whereas in the case of some conveyor systems like movable walkways and grocery store
conveyor systems, these are straight, and the sections have to be turned for delivery of items to
the specified location. To these turns, they have cone shape of wheels or rotors where these
wheels allow the system to turn or bend without tangling. This is the basic working principle.
2.1.4 APPLICATIONS OF CONVEYOR SYSTEMS
1. Manufacturing and Assembly Lines

 Automotive: Transport car parts during assembly processes.

 Electronics: Move delicate components with precision for assembly.
 Food Processing: Carry raw or processed food items for packaging or further
processing.
2. Warehousing and Distribution
 Order Fulfillment: Streamline picking, sorting, and packaging in e-commerce
operations.
 Cross-Docking: Move goods directly from inbound to outbound transportation without
storage.
 Storage and Retrieval: Integrate with automated storage and retrieval systems
(AS/RS).
3. Mining and Quarrying
 Bulk Material Handling: Transport heavy materials like coal, ore, or gravel.
 Overburden Removal: Move large volumes of soil or rock efficiently.
 Crushing and Screening: Feed materials into crushers or sorters.
4. Food and Beverage Industry
 Sorting and Grading: Sort fruits, vegetables, or beverages by size or quality.
 Cooking and Cooling: Move items through ovens, fryers, or cooling tunnels.
 Sanitary Handling: Ensure hygienic transport of perishable goods.
5. Airports
 Baggage Handling: Transport luggage through check-in, security, and loading areas.
 Cargo Movement: Move freight efficiently for air cargo services.
6. Retail and Supermarkets
 Checkout Counters: Transport items at point-of-sale terminals.
 Stock Movement: Move inventory from back rooms to sales floors.
7. Pharmaceutical Industry
 Packaging and Inspection: Handle medicines or medical devices with precision and
cleanliness.
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  Sorting: Separate and arrange items for packaging or further processing.
8. Recycling and Waste Management
 Sorting Facilities: Separate recyclables like paper, plastics, and metals.
 Waste Transport: Move waste materials for disposal or processing.
9. Logistics and Ports
 Container Handling: Move containers in shipping yards.
 Bulk Goods Transport: Handle grains, fertilizers, or other bulk goods in ports.
10. Agriculture
 Crop Handling: Transport harvested crops like grains, vegetables, or fruits.
 Processing: Feed crops into processing machinery for cleaning, sorting, or packaging.
11. Custom and Specialized Applications
 Theme Parks: Move people or equipment in amusement rides.
 Medical Facilities: Transport medical supplies or samples in large hospitals.
Benefits of Conveyor Systems
 Efficiency: Faster and continuous material movement.
 Automation: Reduces reliance on manual labor.
 Safety: Minimizes workplace hazards by reducing physical handling.
 Cost Savings: Long-term operational savings through efficient material handling.

2.2 THORETICAL FRAMEWORK

The design of belt conveyors typically relies on standards like DIN 22101, CEMA, and ISO
5048 to calculate driving forces and startup times, but these do not consider the belt's dynamic
properties. This oversight can lead to operational problems, particularly in high-capacity, long-
distance systems. To address this, the Estimation-Calculation-Optimization (ECO) method is
proposed. It consists of three steps:
 Estimation: Calculates the minimum speed adjustment time, assuming the belt is rigid.
 Calculation: Simulates the belt’s dynamic behavior, including hysteresis, using finite
element methods.
 Optimization: Improves the system’s performance to avoid risks like belt over-tension.
This method helps ensure safe and efficient conveyor operations by factoring in both the
dynamic behaviors and potential risk.

13
 Figure 0-1.... Shows Free body diagram ....

According to (X. Liu et al., 2019) A belt conveyor with a single sheaved gravity take-up.
“a”: conveyor belt; “b”: idler; “c”: drive pulley; “d”: take-up pulley; “e”: take-up mass;
“Lconv”: length of the conveyor; “Ls”: horizontal distance between the drive pulley and the
take-up pulley.
As regards the risk of belt breaking at the splice caused by over-tension, the belt tension
along the conveying route must be maintained in a safe level. In cases as shown in figure, the
maximum belt tension generally occurs right before the drive pulley.
The tension T1 before the drive pulley in a steady state can be approximated by
T1=T2 + Fd (1)
where Fd is the driving force and T2 is the belt tension after the drive pulley.
As shown in figure, if the horizontal distance between the drive pulley and the gravity take-
up device with mass mT is small, the belt tension T2 after the drive pulley can be
approximated by
T2=1/2mTg (2)
where g is the gravity acceleration.
According to Eq. (3), the permitted belt tension T1,max before the drive pulley can be
estimated by
T1,max = kNB/SA,min (3)
Then the combination of Eqs. to HYPERLINK
"https://www.sciencedirect.com/science/article/pii/S0032591018300020?via%3Dihub" \l
"fo0030"(2) gives the maximum permitted driving forces
Fd, max, tension = kNB/SA,min – 1/2mTg (4)
in respect of the risk of belt over-tension.
Belt slippage is another major risk in acceleration operations. As stated by Euler and
Entelwein belt slippage occurs whenever the driving force exerted on the drive pulley
exceeds the maximum available frictions.
Fd, max,slip = Ff, max = T2(eμα−1) (5)
to prevent the risk of belt slippage.
The rated motor torque is the maximum continuous torque available at the design speed that
allows the motor to do work without overheating. In the practical accelerating operations, the
maximum service torque is allowed to be slightly larger than the rated torque τmotor,nom for a
few seconds. The ratio of the maximum service torque and the rated torque is defined as
14
service factor (isf). Then in an acceleration operation, the permitted maximum motor service
torque τmotor,max is
τmotor,max = isfτmotor,nom (6)
and the maximum driving force Fd, max,heat onto the drive pulley is
Fd,max,heat = irfτmotor,max/Rd = irfisfτmotor,nom/Rd (7)
in which irf is the gearbox reduction ratio and Rd is the drive pulley's radium.
Then taking these three risks in acceleration operations into account, the permitted maximum
driving forces Fd,max in transient operations are
Fd,max = min (Fd,max,tension,Fd,max,slip,Fd,max,heat) (8)
According to HYPERLINK "https://www.sciencedirect.com/topics/engineering/newtons-
second-law" \o "Learn more about Newton's Second Law from ScienceDirect's AI-generated
Topic Pages" Newton's Second Law, the acceleration is the net result of any and all forces
acting on belt conveyors. Then in acceleration operations, the permitted acceleration is
aac,max = (Fd,max−Ff)/m (9)
where Ff is the total motional resistances, and m is the total lump mass of the belt, rollers and
the bulk material on the belt. According to the German Institute for Standardization, the
motional resistances along the conveying route can be estimated by
Ff =CfgL(m′roll+2m′belt+m′bulk) cosδ) +m′bulkgH (10)
and the total mass is
m=L(m′roll+2m′belt+m′bulk) (14)
in which
C= the coefficient of secondary resistances

F= the artificial HYPERLINK

"https://www.sciencedirect.com/topics/engineering/coefficient-of-friction" \o "Learn more
about coefficient of friction from ScienceDirect's AI-generated Topic Pages" coefficient of
friction resistances
L= the conveying length of conveyor
m′roll = the mass of rollers in unit length
m′belt = the linear density of belt
m′bulk = the linear density of bulk material
δ = the inclination angle of a belt conveyor
H = the height difference between the loading and unloading areas of a belt conveyor

FOR THE IDLER AND ROLLERS

Rolling Resistance

The force due to rolling resistance Fr is given by:

15
Fr = Cr x NF
Where:

Cr: Coefficient of rolling resistance (dimensionless, typically between 0.001–0.01 for

steel rollers).
NF: Normal force exerted by the load on the roller (in Newtons)

Load Distribution on Rollers

The maximum load a roller can handle W depends on the spacing s between rollers and the
distributed load per unit length q
W=q x s
Where:
q: Load per unit length (N/m).
s: Spacing between consecutive idlers (m).

Belt Sag and Tension

The sag ratio δ is related to the belt tension T and the load q per unit length:

δ=q⋅s2/8⋅T
Where:
 δ: Belt sag (m).
 T: Tension in the belt (N).
 s: Roller spacing (m).

This ensures the belt does not sag excessively, which can damage the system or increase
energy consumption.

Rotational Motion of Rollers

The torque τ required to rotate a roller depends on frictional forces in the bearings:

τ = Fr × r
Where:
 Fr: Rolling resistance (N).
 r: Radius of the roller (m).
The angular velocity ω relates to the belt speed v:
ω = v/r
Power Consumption
The power P required to overcome rolling resistance for a single roller is:
P = Fr × v
16
For n rollers:
Ptotal = n × Fr × v
Vibration and Resonance
The natural frequency fn of a roller is derived from its stiffness k and mass m:
1 𝑘
fn = (2𝜋) √ (𝑚)

This must be designed to avoid resonances with operational frequencies of the system.
Heat Dissipation in Bearings
The heat Q generated due to friction in the bearings is:
Q = μb × Fb × v
Where:
 μb: Coefficient of friction in the bearing.
 Fb: Force on the bearing.

Capacity formula:
Q=3600×A×v×γ×S
Q=3600×A×v×γ×S
Where:
 Q: Capacity (tons/hour)
 A: Material cross-sectional area
 v: Belt speed (m/s)
 γ: Material density (kg/m³)
 S: Inclination factor
Motor Power
The motor output power (shaft) is given by PM = PA/η
Where:
η=Overall efficiency by taking the power losses of gear-box and coupling into account = 0.94
PA=Absorbed power i.e. Power required for drive pulley after taking pulley loss into account
CRITICAL SPEED OF THE SHAFT
Critical speed of the shaft plays a vital role in the determination of the efficiency of the
machine. Thus, the critical speed of the machine was determined as reported by
48ɛ𝑙
Ꞷs = 𝑚𝐿

Where:
Ꞷ = The critical speed of the shaft,

17
ɛ = The modulus of elasticity of steel,
m = The mass of the shaft,
L = The length of the shaft
DETERMINATION OF THE MACHINE SHAFT DIAMETER
Determination of the shaft diameter is necessary to ensure a satisfactory strength and rigidity
when the shaft is transmitting power under various operating and loading conditions. This was
obtained using the conventional formula reported by
16
D3= 𝜋𝑆𝑎(KbMb)2(KtMt)2
Where:
Mb = The bending moment,
Mt = The torsional moment,
Kb = The combined shock and fatigue factor applied to bending moment,
Kt = The combined shock and fatigue factor applied to torsional moment,
Sa = The allowable stress

L= Belt length (IN)

C= Center-to-center distance (IN)

𝜋 = 3.1416

D= 𝑙𝑎𝑟𝑔𝑒 𝑝𝑢𝑙𝑙𝑒𝑦 ′ 𝑠 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(𝐼𝑁)

d= small pulley diameter (IN)

TORSIONAL DEFLECTION OF THE SHAFT

This is calculated to know the angle of deviation of the shaft in degrees and to make sure this
angle of deviation is at its minimum as reported by
584𝜏𝐿
α= 𝐷4 𝐺

α = Angular shaft deflection in degrees

L = Length of the shaft
G = Modulus of elasticity of steel

D = 2.26 × 4√𝜏

18
BELT SPEED: A conveyor belt's speed can be calculated using different approaches
depending on the available parameters. One commonly used formula involves the motor's
RPM (revolutions per minute), the diameter of the drive pulley, and the gear ratio:

Formula:
Belt Speed (m/s) = Motor RPM × Pulley Diameter (m)×π/60
Where:
 Motor RPM is the revolutions per minute of the motor driving the conveyor.
 Pulley Diameter is the diameter of the conveyor's drive pulley.
 π\piπ is the mathematical constant (~3.1416).
 60 converts minutes to seconds.

BELT LENGTH: To avoid the coming up short or having belt that extends beyond use by
using calculation based on conveyor’s pulleys

When the head and tail pulley are the same size: L= (D +d)/2 ×3.1416+ 2C

When one pulley is larger than the other: L= (D +d)/2× 3.1416 +2C+(D− d) ^2/4C
BELT LOAD: In order to prevent too much pressure to the conveyor belt system.

When the load is per square foot: P = G1 ×C (in feet) ×W (in feet)

When the load is pounds per hour: P = G2/ (S ×60) ×C (in feet)

HORSEPOWER: Level conveyors: HP = F ×S ×(P+ M)/33,000

Inclined conveyors: HP = ((P ×B) (P +M)× F× S)/33,000

EFFECTIVE TENSION: It is the pull needed to move the belt and load horizontally. it’s
measured by E=F× (P +M)

SLACK AIDE TENSION: Any additional tension to prevent slippage is represented by

E1=E ×K

TIGHT SIDE TENSION: The total tension needed to move the belt and the load horizontally
is expressed by E2=E+E1

OPERATING TENSION: Operating tension determines the working strength of the belt on
a per inch of width basis. T= E2/W

B: Sine angle of incline

C: Center to center distance(inches)
D: Diameter of drive pulley
d: Diameter of tail pulley
E: Effective Tensions (Ibs.)
E1: Slack side tension (Ibs.)
19
E2: Tight side tension (Ibs)
F: Coefficient of friction
G1: Load per square ft.(Ibs.)
G2: Load per hours (Ibs)
HP: Horsepower
K: Drive factor
L: Belt length(inches)
M: Overall belt weight
P: Product weight (Ibs.)
RPM: Revolutions per minute
S: Conveyor speed (feet per minute)
T: Operating tension PIW (Ibs)
W: Belt weight

According to (ISHWAR G. MULANI, 2017)

Wear resistance on the belt is given by

3.6 ×𝑣×𝑣𝑆𝑤×𝑡
W= ----(1)
200×𝐿
Where v= is the conveying belt speed in meter/sec
Sw = factor for abrasion in mm related 106 revolution (cycles)
T = cover life in operating hours (actual)
L = conveyor center to center length, meters

2×𝑒𝑛𝑒𝑟𝑔𝑦
Lump velocity at chute exits along axis = √𝐿𝑢𝑚𝑝 𝑚𝑎𝑠𝑠 -----(2)
𝐵−𝑎
Belt width resting on slide roller (L) = −𝐷
2

2.3 EMPIRICAL REVIEW

According to (X. Liu et al., 2019) worked on “Integrated decision making for predictive
maintenance of belt conveyor systems” they proposed a framework for making integrated
maintenance decisions by utilizing data from operational conditions, theoretical reliability
estimations, and condition monitoring of belt conveyor systems. This framework facilitates the
interaction between theoretical reliability predictions and real-time monitoring data, allowing
for continuous updates to the predicted failure rates of components like rollers. Additionally,
it enabled adjustments to maintenance thresholds. Simulation results, as reported, demonstrate
that the approach improves the ability to predict roll bearing failures and enhances the accuracy
of failure diagnosis.

According to (Gładysiewicz et al., 2018) worked “Measurements of loads on belt conveyor

idlers operated in real conditions” the tests conducted in their study were aimed at collecting
data on the loads acting on the idlers, which could be used for future improvements and to
reduce energy consumption in belt conveyor systems. They further noted that a key method for
assessing the changing operating conditions of belt conveyors is through the measurement of
loads on the idler set. The radial forces acting on the idlers, as they explained, are critical in
20
determining the rolling resistance between the belt and the idlers. The principle behind the
method is to use special measuring bolts.

According to (Qiao et al., 2022) worked on “Dual-field measurement system for real-time
material flow on conveyor belt they proposed a dual-field measurement method for material
flow on a conveyor belt, aimed at minimizing the effects of belt deformation. This method uses
two binocular cameras to simultaneously capture the contours of the material and the lower
surface of the carry-side belt. A dual-field visual algorithm is then applied to accurately
measure the volume flow of material. The approach utilizes line light sources to support the
binocular cameras, capturing laser line images from two distinct fields at the measurement
position. As the thickness of the conveyor belt remains relatively constant under load, two light
sources are used to illuminate both the upper and lower surfaces of the belt, creating two laser
lines that are perpendicular to the direction of belt motion.

(Homišin et al., 2019) worked on “Removal of systematic failure of belt conveyor drive by
reducing vibrations” highlighted Kuľka et al. investigated the reliability and safety conditions
of the steel support structure of belt conveyors, using both experimental measurements and
calculations to evaluate their performance. Honus et al. conducted significant research on how
the number of conveyor belt carrying idlers affects the failure of the impact zone and He
developed a dynamic model of a belt conveyor and performed its analysis using virtual
prototype technology, offering a new approach for assessing the safety and structural integrity
of belt conveyors. The goal is to enhance the existing conveyor drive system through dynamic
modeling and to validate its performance under real-world operating conditions.

According to (He et al., 2018) worked on “Healthy speed control of belt conveyors on
conveying bulk materials” with the increasing economic and social pressures to enhance energy
efficiency and reduce carbon emissions, there is a significant demand for improvements in the
energy performance of belt conveyors. One promising strategy to achieve this is through speed
control, which adjusts the conveyor speed to match the actual material flow, thereby
minimizing energy consumption. By optimizing speed, the energy usage of the conveyor
system can be substantially reduced. In addition to energy savings, speed control offers other
benefits, such as reduced maintenance requirements and an extended system lifespan. He
explores a method to ensure effective speed control, particularly under dynamic and transient
operational conditions. To address this, they propose an Estimation Calculation-Optimization
(ECO) method. The ECO method, consisting of three key steps, is designed to determine the
optimal minimum speed adjustment time while also considering potential risks. associated with
transient operations and the dynamic behavior of the conveyor system. This approach is
specifically tailored for ensuring the reliable and efficient operation of long-distance, high-
capacity belt conveyors used in the transport of bulk solid materials.

(X. Liu et al., 2019) presented a new approach to maintenance decision-making for belt
conveyor systems, combining data on operational conditions, reliability estimates, and
condition monitoring. The framework integrated theoretical reliability predictions with real-
time monitoring data, enabling continuous updates to the predicted failure rates of rolls and
adjustments to threshold parameters. A simulation was conducted to demonstrate the
effectiveness of the framework. The results indicated that the proposed approach enhanced the
ability to predict roll bearing failures and improved the accuracy of diagnosing these failures.
21
According to (Loveikin et al., 2024), In the presented article, the variational problem of
optimizing the starting mode of a belt conveyor is formulated and analytically solved. To
address this, the conveyor was modeled as a dynamic system consisting of three masses
connected in a chain-like manner with elastic elements. Based on the equations describing their
motion, an optimization criterion was established. This criterion is defined as the root mean
square value of the driving force during the starting mode. The problem involves minimizing
this optimization criterion (integral functional) while satisfying the motion boundary
conditions, which characterizes the essence of the variational problem. To solve this, the Euler-
Poisson equation was employed.

According to (Polishchuk et al., 2024) worked the “Justification for choosing the type of belt
drive” This study aimed to address the issue of the transition segment in pipe belt conveyors.
By analyzing the formation mechanism of the transition segment conveyor belt, the theoretical
maximum positions of additional deformation and stress in the transition segment were
determined. A 3D simulation model of the transition segment was then developed. Using finite
element analysis, the model underwent mechanical simulation to assess the equivalent elastic
deformation and stresses under various scenarios. Mathematical modeling was employed to
estimate the curves of key influencing factors, followed by multiple linear regression analysis.
Finally, the model's reliability was mathematically verified and analyzed. The results provided
valuable insights for solving practical challenges in the transition segment of pipe belt
conveyors and established a theoretical foundation for their design.

According to (Iqbal & Uddin, 2022) researched on “Belt conveyor” The aim of this research
was to investigate conveyor belts, including the types of damage they sustain, the causes of
such damage, as well as the methods of belt repair, gluing, and splicing. The research was
conducted directly at PT SEMEN BATURAJA (PERSERO). The analysis of the belt conveyor
was carried out by gathering historical data, making visual observations using cellphone
cameras, and reviewing literature on conveyor belts.
Based on the analysis, the following conclusions were drawn, the types of damage found on
the conveyor belts at PT SEMEN BATURAJA (PERSERO) included belt wear, belt breakage,
belt peeling, and belt tearing. The causes of damage to the conveyor belts at PT SEMEN
BATURAJA (PERSERO) were identified as, misalignment of the belt, bulk material falling
from the hopper, friction with side rubbers, coal material accumulation on the pulley, stuck
idler bearings, incomplete idler conditions, failed belt repairs, and the presence of material
lodged on the V-plough.

According (Luciano S et al., 2024) who worked on “On-device Anomaly Detection in

Conveyor Belt Operations” conveyor belts play a crucial role in mining operations by enabling
the continuous and efficient movement of bulk materials over long distances, which directly
influences productivity. While much research has been conducted on detecting anomalies in
specific components of conveyor belts, such as idlers, pulleys, and belt surfaces, identifying
the root causes of these failures remains a challenge. This is due to factors such as changing
production conditions and operator errors. Continuous monitoring for anomaly detection in
mining conveyor belt work cycles is still in its early stages and requires more robust solutions.
This study presented two distinct pattern recognition approaches for real-time anomaly
detection in the operational cycles of mining conveyor belts, combining feature extraction,
22
threshold-based cycle detection, and small machine learning classifiers. Both methods
outperformed a state-of-the-art technique in terms of F1-scores on two datasets used for duty
cycle classification. The first approach achieved F1-scores of 97.3% for normal cycles and
80.2% for abnormal cycles on the first dataset, while the second approach performed better on
the second dataset, with F1-scores of 91.3% and 67.9%, respectively. Implemented on two low-
power microcontrollers, the methods demonstrated efficient, real-time performance with
energy consumption of 13.3μJ and 20.6μJ during inference. These findings provide valuable
insights for identifying sources of mechanical failure, supporting targeted preventive
maintenance, and optimizing production cycles.

According to (Y. Liu et al., 2021) worked on “Research on the fault analysis method of belt
conveyor idlers based on sound and thermal infrared image features” Detecting faults in idlers,
which were widely distributed and operated in complex environments, was challenging. This
study introduced a method to identify faults in belt conveyor idlers using sound and thermal
infrared images. Data from 18 types of idler sounds and thermal images were analyzed. The
sound signals were studied in terms of time, frequency, and time-frequency features, with
statistical methods and Fisher’s linear discriminant used to simplify and process the data.
Thermal images were analyzed to identify temperature changes. The results showed that sound
frequency features and temperature rise at specific parts of the idler detected critical faults,
while time-frequency sound features identified common bearing defects. This method proved
to be reliable, cost-effective, and easy to implement.

According to (He et al., 2020) on his work “Sustainable belt conveyor operation by active speed
control” This study presented an active speed control algorithm for multi-belt conveyor
systems. The Delft Systems Approach was used to model both the operation and control
systems. The ECO method was applied as part of the algorithm to determine the best timing
for speed adjustments. A simulation was conducted on a dual-belt conveyor system, leading to
the following conclusions:
The ECO method was effective for finding the best timing for speed changes because it
considered the dynamics of the conveyor system. Active speed control helped improve the
system's performance by increasing the belt's filling ratio. Active speed control also saved
energy in multi-belt conveyor systems.

SUMMARY GAP
However, gaps remain in areas like real time anomaly detection in complex operational
conditions, further integration of data-driven decision making with predictive models, and
optimization of conveyor belt dynamics under various conditions. The studies almost highlight
the need for advanced methods to ensure the reliability of conveyor system under diverse
environmental and operational factors.

23
 CHAPTER THREE

METHODOLOGY
3.1 DESIGN FABRICATION PATHWAY
Review of literature
Developing a concept
CAD Drawing
Running Analysis

Development of Conveyor System

Testing

The process outlined in Figure above begins with brainstorming and progresses through idea
selection, during which unused concepts from brainstorming are identified. These concepts are
then refined and integrated into a unified solution. The chart systematically breaks down the
project execution process step by step. Design development is a structured decision-making
process that follows a logical sequence, starting with conceptual design and moving through
sketching alternative concepts, evaluating design considerations, conducting design analysis,
fabricating components, assembling parts and sub-assemblies, completing the final assembly,
assessing performance, and validating the design. The CAD modeling phase emphasizes the
purpose behind each step of the production process. CAD modeling facilitates tasks such as
sketching, assembly, design analysis, fabrication, and sub-assembly, ensuring a more efficient
and precise workflow.

3.1.1 CONCEPT 1
The image below shows a belt conveyor, an essential piece of equipment in material handling
systems. It features a flat moving belt stretched across a frame supported by rollers, allowing
materials to be transported efficiently. Powered by a motor and drive pulley, the system moves
the belt continuously, enabling steady transport of goods or materials from one point to another.
This type of conveyor is often used in industries like manufacturing, warehousing, and
logistics, as it is ideal for moving lightweight to moderately heavy items over short or long
distances. The simplicity and efficiency of this design make it a staple in various operations.

CONCEPT ONE
24
3.1.2 CONCEPT 2
This image displays an inclined belt conveyor, which is designed to move materials or goods
from one level to a higher elevation. It is commonly used in industries requiring the transport
of items along an upward slope, facilitating efficient and continuous movement without manual
effort. The system's inclined layout makes it suitable for applications where materials must be
transferred to elevated areas, such as storage platforms, processing stations, or trucks. Its
compact and sturdy design ensures reliable operation in industrial, manufacturing, and
logistical settings. The conveyor is powered by a motorized drive mechanism, maintaining a
consistent flow of materials even at an angle.

3.1.3 CONCEPT 3
This image shows a cleated inclined belt conveyor, designed for transporting materials or
products along an upward slope. The conveyor includes raised cleats on the belt, which help
secure items during transport, preventing slippage or rolling back due to gravity. The inclined
conveyor design offers several advantages from an engineering standpoint, making it an
optimal choice for conveying a 50 kg weight from one height to another. Its inclined structure
provides a mechanical advantage by reducing the force required to elevate the load, thereby
improving efficiency. The robust frame ensures structural stability and evenly distributes the
weight, minimizing stress on individual components and enhancing durability. The design
incorporates features that ensure smooth and controlled material handling, reducing the risk of
slippage or damage to the conveyed items. Its modular construction allows for customization
to meet specific operational requirements, such as varying heights or load capacities. The open-
frame design simplifies maintenance and inspection processes, ensuring consistent
performance and reduced downtime. Furthermore, the simplicity of the design contributes to
cost-effectiveness, as it minimizes material usage and manufacturing complexity without
compromising functionality. This combination of structural integrity, operational efficiency,
and ease of maintenance makes this inclined conveyor design a professional and practical
solution for the given application.

This design is particularly effective for moving bulk materials, loose items, or packaged goods
at an incline. It is commonly used in food processing, agricultural operations, and
manufacturing industries where efficient vertical or angled transport is required. The
conveyor's lightweight yet durable structure ensures reliability, making it suitable for small to
25
medium-scale operations. This fits our design because it can be used to convey bulk materials
and it has good inclination also cost effective.

3.2 Design Considerations and Requirements for Belt Conveyors

Designing an efficient and reliable belt conveyor system requires careful consideration of
various factors. Each of these factors impacts the performance, durability, and cost-
effectiveness of the system. They include: Material to Be Conveyed, Conveyor Capacity,
Conveyor Length and Elevation, Belt Design, Power and Drive System, Environmental
Factors, Safety Features, Maintenance and Durability.
1. Material to Be Conveyed:
 Type of Material: The characteristics of the material being transported (e.g., bulk,
packaged, granular, or powdery) influence the choice of belt, speed, and the conveyor's
incline angle.
 Size and Weight: The size and weight of the materials affect the required motor power,
belt tension, and conveyor dimensions.
 Fragility: Delicate or fragile materials may require slower speeds and gentler handling,
influencing the design of the system.
 Moisture or Temperature Sensitivity: If the material is sensitive to moisture or high
temperatures, specific types of belts and idlers may be required to prevent damage.
2. Conveyor Capacity:
 Flow Rate: The capacity of the conveyor should be designed to handle the required
throughput (e.g., tons per hour, cubic meters per hour) based on the material’s bulk
density and load characteristics.
 Speed: The conveyor's speed should be determined to ensure efficient material transfer
without overloading the system. The speed must align with the capacity requirements.
3. Conveyor Length and Elevation:
 Horizontal and Vertical Distance: The length of the conveyor is crucial in
determining the motor size, pulley design, and overall cost. If the conveyor needs to
carry material over long distances, the motor's power and the system's structural
integrity must be enhanced.
 Incline and Angle: For inclined conveyors, the angle of inclination should be
optimized to prevent material slippage, excessive wear, and unnecessary power
consumption. Generally, angles up to 18-20 degrees are used for most materials, but
some may require specialized designs for steeper inclines.
26
4. Belt Design:
 Material of the Belt: The belt material (rubber, PVC, fabric, or steel) must be selected
based on the material type, temperature, and environmental factors (abrasion, moisture,
etc.).
 Belt Width and Thickness: The belt width and thickness must be adequate to support
the intended load while maintaining the proper tension to prevent slippage or damage.
 Cleats or Sidewalls: For inclined conveyors, cleats or sidewalls are often added to the
belt to prevent materials from sliding back.
5. Power and Drive System:
 Motor Power: The power requirement depends on the conveyor length, load, and belt
speed. Proper motor sizing ensures efficient operation without overloading.
 Pulley and Idler Design: Pulley diameter and idler spacing need to be optimized for
smooth belt movement and to reduce friction and wear.
 Drive System Type: The type of drive (e.g., direct, gear-driven) should be selected
based on cost, efficiency, and reliability factors. A correctly sized and powered motor
is key for optimal performance.
6. Environmental Factors:

 Temperature: Conveyor systems operating in extreme temperatures (hot or cold) must

be designed with materials that can withstand these conditions, such as heat-resistant
belts or cold-resistant rollers.
 Dust and Moisture: Conveyors used in dusty or wet environments require appropriate
sealing, weatherproofing, and cleaning systems to prevent clogging and degradation of
the system.
 Corrosion Resistance: In environments where the conveyor will be exposed to
chemicals or moisture (such as food processing or mining), materials and coatings that
resist corrosion must be selected for the structure and components.
7. Safety Features:

 Guards and Covers: Protective guards are necessary to prevent personnel from
coming into contact with moving parts, such as pulleys and drive systems.
 Emergency Stops and Warning Signals: Conveyor systems must be equipped with
emergency stop mechanisms and appropriate warning signals in case of malfunctions.
 Speed Monitoring and Overload Protection: Safety systems that monitor belt speed
and load to prevent system overloads and damage.
8. Maintenance and Durability:

 Ease of Access: Conveyor systems should be designed with maintenance in mind,

ensuring easy access to components like pulleys, belts, and motors for routine checks
and repairs.
 Wear Resistance: The design must account for wear from the movement of materials.
High-wear components such as the belt surface and rollers must be made from durable
materials, and systems should be planned for regular maintenance.
27
  Life Span: The selection of durable materials for components ensures that the conveyor
can operate for long periods with minimal downtime.
9. Cost Considerations:

 Initial Installation Costs: Design choices such as belt type, motor power, and
supporting frame materials can significantly impact the initial investment.
 Operating Costs: Ongoing operational costs include power consumption,
maintenance, and potential repairs. An energy-efficient design can lower long-term
expenses.
 Life-Cycle Costs: Consideration of maintenance, replacement parts, and overall
durability is essential for assessing the total cost over the conveyor's life span.
3.3 Material Selection

For our belt conveyor prototype, our group has chosen hardwood, specifically oak, as the
material for fabrication. Oak was selected for its strength and durability, ensuring it can support
the weight of materials on the conveyor and withstand continuous use without warping. While
oak is more expensive than softwoods, its long-term durability makes it the most suitable
choice for this prototype. It’s also manageable for cutting and shaping, which will help us create
an accurate and professional-looking frame. Oak is widely available, and its natural resistance
to moisture makes it ideal for environments where exposure to humidity or water may occur
during testing. Though oak is heavier than softwoods, its stability and sturdiness are essential
for maintaining the conveyor’s structural integrity during operation. Additionally, we’ll ensure
that the wood is sustainably sourced to align with environmental considerations. By
considering strength, cost, availability, moisture resistance, and sustainability, oak meets the
performance and practical requirements for our belt conveyor prototype.

The Materials used are listed below

 Hard wood (oak)

 Motor
 Glue
 Wires

Here’s a table outlining the components of the belt conveyor prototype, their materials, and
selection criteria

This table summarizes the components, materials, and selection criteria, ensuring that each
part of the belt conveyor system meets the necessary functional, durability, and cost
requirements for the prototype.

Component Material Selection Criteria

Support Legs Hardwood (Oak) Stable and sturdy, providing

proper elevation and support for
the conveyor system.

28
Frame Hardwood (Oak) Strong, durable, easy to work
with, stable, moisture-resistant,
sustainable sourcing.

Tensioning System Steel/Metal Adjustable, durable, and reliable

for maintaining proper belt
tension.
Belt Rubber/Cloth Flexible, durable, able to carry
materials efficiently, resistant to
wear and slippage.

Idler Rollers Steel/Metal Durable, smooth rotation,

resistant to wear.
Support Legs Hardwood (Oak) Stable and sturdy, providing
proper elevation and support for
the conveyor system.
Rollers Hardwood (Oak) Strong and durable for
supporting the belt’s movement,
resistant to wear and tear.

Pulleys Steel/Metal Strong, able to withstand stress

and maintain belt tension.

Shafts Steel/Metal High strength, able to support

rotating components without
bending or breaking.

3.3.1 Design Calculations for a Belt Conveyor

Designing a belt conveyor involves several steps, where key calculations ensure the system
operates efficiently and safely. Below are the basic components and the calculations involved
in the design process:
ACCORDING TO (YOGOHAMA, 2020)

Design Specifications
Transport Capacity, Qt = 2400kg/h
Material Bulk Density, y = 1.80kg/m3
Surcharge Angle = 20 degree
Belt Trough Angle= 30 degree
Belt Speed, v=2.5m/s
Horizontal length, L=250m
Vertical Height, H = 35m
Gravity Take-up Distance from head pulley=10m

29
Carrier Roller Spacing, Ic=1m\Return roller Spacing, Ir = 3m
Drive Pulley wrap angle, 210 degrees
Friction Coefficient of idler roller, f = 0.022
Friction Coefficient between drive pulley surface and conveyor belt, u=o.3
Drive unit efficiency n=85%

BELT WIDTH

35
Conveyor inclination angle a = tan-1(250) 𝛼 = 7.97𝑑𝑒𝑔𝑟𝑒𝑒

Inclination angle 𝛼 = 8𝑑𝑒𝑔𝑟𝑒𝑒

Capacity Reduction rate, i= 0.97

From the table below
Table 1

Inclination angle 2 4 6 8 10
Reduction rate 1.0 0.99 0.98 0.97 0.95

The trough angle is 30 degree and material surcharge angle are 20 degrees

Coefficient of section area, K= 0.1488

TABLE 2

Surcharge angle 10 20
𝑇𝑟𝑜𝑢𝑔ℎ 𝑎𝑛𝑔𝑙𝑒
0(flat) 0.0292 0.591
20 0.0963 0.1245
25 0.1112 0.1285
30 0.1248 0.1488
Transport capacity, Qt = 60 × 𝐴 ×𝑦×𝑣×𝑖

30
Qt = Transport Capacity(ton/h) = 2400ton/h

A = loaded cross sectional area of conveying material(m3)

V= belt linear speed (m/min) 150m/min

i= capacity reduction rate = 0.97

loaded cross sectional area, A = (0.9𝐵 − 0 − 05)2

k= coefficient of section area = 0.1488

B = Belt width (m)

Then Qt =60 × 𝑘 × (0.9𝐵 − 0.05)2 × 𝑦 × 𝑣 × 𝑖

B = 1000 × (√

𝑄𝑡 2400
= 1000 × (√60×0.1488×1.8×150×0.97
60×𝑘×0.1488×1.8×150×0.97

Fig 3.1

1.063
Belt width B = 1000 × ( ) = 1181𝑚𝑚 𝑟𝑜𝑢𝑛𝑑𝑒𝑑 𝑢𝑝 𝑡𝑜 1200
0.9

K = (0.9𝐵 − 0.05)2 = (0.1488) × ((0.9 × 1.2) − 0.05)2

A – 0.1579m2
Maximum Transport capacity
𝑘𝑔
Qmax = 60 × 0.1579 × 1.80 × 150 × 0.97 = 2481 > 𝑄𝑡 = 2400𝑘𝑔/ℎ
ℎ

For the selected belt width =1200mm

For the weight W1= 26kg/m
Table 3

Belt Width Belt Weight W1

(mm) (kg/m)
400 4.5

31
 450 7

500 7.2

600 9

750 13

900 15.5

1050 23

1200 26

For belt width=1200mm

Weight of moving part (carrier side), Wc= 23.6kg/set
Weight of moving Part (return side), Wr = 21.1kg/set

Table 4

Belt width Idler Diam 3-equal-roll Flat Type Return-

Troughing idler
idler

(mm) (mm) Idler (kg/set) (kg/’set)

400 89.1 6.6 5.0
450 89.1 7.1 5.4
500 89.1 7.5 5.9
600 89.1 8.3 6.8
750 114.3 13.2 11.6
900 114.3 15.1 13.4
1050 139.8 21.3 18.9
1200 139.8 23.6 21.1
BACK STOPE TORQUE
Pr = 𝑃3 − (0.7) × (0.06 × 𝑃1 + 𝑃2)
Pr = Backstop Power (Kw)
P1 = horizontal No Load power (Kw) = 14.08kw
P2 = Horizontal Load Power (Kw)= 45.46kw
P3 = Vertical Lifting Power(kw) = 228.88kw

Backstop power, Pr = (228.88) − (0.7) × (14.08 + 45.46) = 187.20𝐾𝑤

If Drive pulley Diameter,∅ 𝐷 = 630𝑚𝑚

32
 𝑣 150
Drive Pulley Speed, N= 𝜋𝐷 = 𝜋×0.63 = 75.79𝑟𝑝𝑚

Backstop Torque Service Factor, Sf = 1.5 (for backstopping several times a day)
9550×𝑃𝑟 9550×187.20
Backstop Torque, T = × 𝑆𝑓 = × 1.5 = 35383𝑁𝑚
𝑁 75.79

Use this Torque Data to select Back stop size from

TSUBAKI BACKSTOP CAM CUTH CATALOG

Table 5

Sf Service Condition
1.5 Backstoping: Several times a day
2.0 Backstopping: More than several times a day

Calculate the backstop power, (Pr)

Pr= P2 – 0.7(P1+Pr) (kw)
Calculate the Backstop Torque: (T)
9550×𝑃𝑟
T= × 𝑆𝑓
𝑁

CALACULATION OF BELT TENSION

FROM DRIVE PULLEY

1
Drive Factor, R= 𝑒𝑢𝜃−1

𝜇 = 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 𝑏𝑡𝑤 𝐷𝑟𝑖𝑣𝑒 𝑝𝑢𝑙𝑙𝑒𝑦 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑛𝑑 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟𝑏𝑒𝑙𝑡 = 0.3

1
R = 𝑒(0.3×3.665)−1 = 0.4993

33
𝜃
= 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 𝑎𝑛𝑔𝑙𝑒(𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 𝑏𝑒𝑙𝑡 𝑤𝑟𝑎𝑝)𝑜𝑓 𝐷𝑟𝑖𝑣𝑒 𝑝𝑢𝑙𝑙𝑒𝑦 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑛𝑑 𝑐𝑜𝑣𝑒𝑦𝑜𝑟 𝑏𝑒𝑙𝑡 210 𝑑𝑒𝑔𝑟𝑒𝑒𝑜𝑟 3.665
6120×𝑃
Effective Tension(kg), Fp = 𝑣

P = Require Power(kw) = 288.42kw and v= belt Speed(m/min) = 150m/min

6120×288.42
Fp = = 11767𝑘𝑔
150

Sag-Slide (Tension)kg

F2 = Fp × 𝑃 = 11767 × 𝑜. 4993 = 5875𝑘𝑔

Tight side (Tension) kg

𝐹1 + 𝐹2 = 11767 + 5875 = 17643𝑘𝑔

6120×288.42
Effective torsion(kg) Fp= = 11,767𝑘𝑔
150

Slag-side tension(kg), F2 = Fp + R = 11,767 × 0.4993 = 5,875𝑘𝑔

Tight-Side Tension(kg) F1 = Fp +F2 = 11,767 + 5875 = 17,642𝑘𝑔

Slope Tension(kg), F3 = 𝑊1 × 𝐻 = 26 × 35 = 910𝑘𝑔( 𝑡𝑒𝑛𝑠𝑖𝑜𝑛 𝑓𝑟𝑜𝑚 𝑏𝑒𝑙𝑡 𝑠𝑒𝑙𝑓 𝑤𝑒𝑖𝑔ℎ𝑡)

Minimum Tension to prevent Belt Sag btw idler roller to much (SAG =2%)
𝑄𝑡
Carrier Side, F4 = 6.25 × 𝐼𝑐 × 1 × (0.06×𝑣 + 𝑊1)

Return Side, F4 =6.25× 𝐼𝑟 × 𝑊1

Qt = transport capacity(ton/h) = 2400ton/h
Ir = Return Roller Spacing(m) = 3m
Ic Carrier Roller Spacing(m)= 1m
W1 Belt Weight(kg/m) = 6kg/m (for belt width 1200mm)
V = Belt Speed (m/min) = 150m/min
2400
Carrier Side, F4 = 6.25 × 1 × (0.06×150 + 26) = 1829𝑘𝑔

Return Side, F4 = 6.25 × 3 × 26 = 487.5𝑘𝑔

Using the larger value of F4 then minimum Tension, F4= 1829kg
𝑊𝑟
Running Resistance of Return Side Belt, Fr = 𝑓 × (𝑙 + 𝑙0) × (𝑊1 + )
𝑙𝑟

21.1
Fr = (0.022) × (250 + 66) × (26 + ) = 230𝑘𝑔
3

BELT TENSION AT THE DRIVE PULLEY

Carrier-Side Tension(kg), T1

34
Case 1: T1= 𝐹𝑝 + 𝐹2 = 11,767 + 5875 = 17642𝑘𝑔

Case 2: T1 = 𝐹4 + 𝐹3 + 𝐹𝑝 − 𝐹𝑟 = 1829 + 910 − 230 = 14276𝑘𝑔

Maximum Tension (kg), T1= 17642𝑘𝑔

Return-Side Tension(kg), T2

Case 1: T2= 𝐹2 = 5875𝑘𝑔

Case 2: T2 = 𝐹4 + 𝐹3 + 𝐹𝑝 − 𝐹𝑟 = 1829 + 910 + 11,767 − 230 = 14276𝑘𝑔

Return-side(kg), T2= 5875kg

Belt Tension at Tail pulley
Return-Side Tensional (kg), T3 Equal to Carrier-side tension(kg), T4
Case 1: T3 = T4= 1829kg
Case 2: T3 = T4 = F2-F3+Fr = 5875+230-910=5195kg
Tail Pulley Belt Tensional(kg), T3=T4= 5195kg
Belt Tension At take up pulley
Weight of counter weight, Wt
𝐿𝑡 10
Case 1: Wt = 𝐹2 + ( 𝐿 ) × (𝐹𝑟 − 𝐹3) = 5875 + (250) × (230 − 910) = 5848𝑘𝑔

𝐿−𝐿𝑡 250−10
Case 2: Wt = 𝐹4 + ( ) × (𝐹3 − 𝐹𝑟) = 1829 + ( ) × (910 − 230) = 2482𝑘𝑔
𝐿 250

L = Horizontal Length(m) = 250

Lt = Gravity take-up Distance from head pulley(m) =10m
Weight OF COUNTER WEIGHT (kg), Wt = 5,848kg
𝑊𝑡 5848
Take-Up pulley Belt Tension(kg), T5= T6 = = = 2924𝑘𝑔
2 2

MAXIMUM BELT TENSION (kg), Tmax =T1= 17642kg

35
BELT CARCASS SELECTION
Conveyor Belt Specification: Polyester fabric Belt
Belt Width, B=120cm(1200mm)/ NO. PLY, n=4PLY/Safety Factor, Sf+12(ordinary)
Maximum Belt Tension, Tmax = 17,642kg
𝑇𝑚𝑎𝑥×𝑆𝑓 17642×12
Breaking Stranght of one PLY FABRIC, TS = = 4×(120−3) = 452.4𝑘𝑔/𝑐𝑚𝑝𝑙𝑦
𝑛×(𝐵−3)

Breaking Strength of POLYESTER FABRIC BELT TYPE EP500= 500kg/cm.ply

Select POLESTER FABRIC BELT TYPE: EP 500 x 4Ply

3.4 CAD DRAWING

3.4.1 Our Design

In our group conveyor design project, we set out with a vision to create an efficient and
durable system that could transport cement over a distance of 50 meters, inclined at a 20-
degree angle. We initially planned to use materials that would have allowed us more
flexibility in design, such as steel or more robust polymers, but we were given the constraint
of using wood for the construction. This limitation significantly influenced our approach,
especially in terms of material properties like strength, wear resistance, and durability.
Our primary goal was to ensure the conveyor could handle the heavy load of cement,
withstand the forces exerted by the incline, and maintain smooth, continuous operation over
the entire distance. Through extensive analysis, we were able to optimize several key design
parameters, even though the material constraint required us to make adjustments and trade-
offs along the way.
3.4.1.1 Belt Width and Speed:
We determined the appropriate belt width and speed based on the required capacity to
transport the cement. Our calculations considered the volume of cement to be moved, the
density of the material, and the required throughput. After factoring in these variables, we
arrived at an optimal belt width and speed, which would ensure that the conveyor could
handle the load efficiently while avoiding excessive wear and tear on the belt. The choice of
wood meant we had to carefully select a belt that would not cause undue friction against the
wooden structure, ensuring longevity of both the belt and the wood itself.
3.4.1.2Motor Selection:
We then moved on to motor selection, carefully choosing one that would provide the
necessary torque and power to drive the conveyor at the required speed. Given the incline and
36
the mass of the cement, the motor needed to be powerful enough to overcome the
gravitational forces pulling the cement back down the incline. At the same time, the motor
had to be energy-efficient, given that our design was constrained by the material's limitations
in terms of weight-bearing capacity.
3.4.1.3 Belt Cross-Section:
The cross-section of the belt was selected based on the weight it needed to carry and the
tensile strength required to transport cement without excessive stretching or sagging. This
was particularly challenging given the wood material's relatively lower strength compared to
metals, so we had to ensure that the belt and its tensioning mechanism were carefully
engineered to avoid putting excessive strain on the wooden components.
3.4.1.4 Drum, Drum Shaft, and Drum Bearings:
The drums, drum shaft, and drum bearings were designed to provide smooth rotation and
minimal friction, while also ensuring that the weight of the cement didn't lead to premature
wear or damage. We were particularly mindful of the fact that using wood for the frame
required us to take additional precautions in the design of these components to avoid
damaging the wooden supports.
3.4.1.5 Idle Roller Selection:
The idle rollers, which play an important role in ensuring the belt runs smoothly without
excessive friction, were also selected carefully. These rollers were designed to help support
the belt as it traversed the 50-meter incline, ensuring a consistent flow of cement and
minimizing the risk of any jamming or belt misalignment. Their material selection had to be
lightweight yet strong enough to support the belt without placing undue stress on the wooden
structure.
Finally, While the material limitation of using wood required us to make some adjustments
and design compromises, our detailed analysis and careful selection of components allowed
us to come up with a well-rounded conveyor system that, despite the constraints, still meets
the required functionality. We are proud of the work we put into designing the system,
especially considering the challenges we faced with the choice of materials. The conveyor
system, inclined at a 20-degree angle and capable of transporting cement over a 50-meter
distance, is now a testament to our adaptability and problem-solving skills in engineering
design.

3.4.2 How it works

The motor generates power and drives the drum at one end of the conveyor. As the drum
turns, it moves the belt along the inclined path. The belt, which is wrapped around the drum,
carries the cement from the starting point to the end over a 50-meter distance. The idle rollers
positioned along the conveyor help support and guide the belt, ensuring it stays aligned and
moves smoothly. The motor’s power and the rotation of the drum work together to overcome
the forces acting on the cement and keep the belt moving at the required speed, while the
belt’s cross-section ensures it can support the load without stretching or sagging. The system
runs continuously, efficiently transporting cement up the 20-degree incline.

37
3.4.3 Fabrication Process

First, we measured and cut the wooden parts of the structure to the required dimensions using
a handsaw. This allowed us to create the framework that would support the conveyor system.
After, cutting the pieces, we marked out the areas for joints and mounting points. This ensured
that all the components would be properly aligned when assembled. We then assembled the
structure by nailing the joints together, securing the wooden components into a sturdy frame
that would support the conveyor system. This provided a solid base for the belt, motor, and
other components. For the shaft driving the drum, we used metal from an electrode. The metal
shaft was crucial for transferring the power generated by the motor to the drum, enabling it to
rotate and move the belt. The electrical setup included a switch, wires, a motor, and a battery.
The motor was connected to the shaft and powered by the battery. The switch controlled the
flow of electricity, turning the motor on and off as needed. The wires connected these
components to ensure the motor operated smoothly. Together, these steps formed the process
of fabricating the conveyor system, from cutting and assembling the structure to wiring the
electrical components for operation. The use of wood for the structure, along with the metal
shaft and electrical components, allowed us to create a functional conveyor system while
adhering to the material constraints.

38
3.5 DESIGN CALCULATION
Our Design specification

Power = force x velocity

Power = belt pull x belt velocity

Belt pull for friction

Now friction btw the material use for the belt and the pulley drums

𝝁 = 𝟎. 𝟐𝟓 𝒇𝒓𝒐𝒎 𝒑𝒔𝒈 𝟗. 𝟏𝟖

𝒇 = 𝟎. 𝟐𝟓 × 𝒍 × (𝟐𝑷𝒏 + 𝑷𝒑𝒓 + 𝑷𝒎 )s--------- (1)

39
Pm = weight of product to handle

Pn = weight of rotating part of the roller

Mass of material = 50kg

Belt width = 800mm

Belt weight = 12kgf = 120N

Length = 50m

40
Height = 30m

For the Belt pull for friction

F = 0.25× 𝟓𝟎 × (𝟐 × 𝟏𝟐𝟎 + 𝑷𝒑𝒓 + 𝑷𝒎 )

From PSG 9.18

𝑾𝒓 𝟏𝟖.𝟔
Ppr = = = 𝟑. 𝟏𝒌𝒈𝒇 = 𝟑𝟏𝑵
𝟐𝒔 𝟐×𝟑

41
Ff = 𝟎. 𝟐𝟓 × 𝟓𝟎 × (𝟐𝟒𝟎 + 𝟑𝟏 + 𝟐𝟎𝟎) = 𝟓𝟖𝟖𝟕. 𝟓𝑵

For Gravity

Belt pull for Gravity

Fg = H x Pm = 30 x 200 = 6000N

Total belt pull (Pf) = Fg + Ff = 5887.5 + 6000 = 11887.5N

Using a speed of 4ms-1

42
Power = 𝟏𝟏𝟖𝟖𝟕. 𝟓 × 𝟒 = 𝟒𝟕𝟓𝟓𝟎𝒘𝒂𝒕𝒕 𝒐𝒓 𝟒𝟕. 𝟓𝟓𝒌𝒘

1HP ------- 745.7watt

xHP -------- 47550

x = 63.765Hp

Density of cement bag

𝒎𝒂𝒔𝒔 𝟓𝟎
= = 𝟏𝟐𝟕𝟏. 𝟑𝟐𝒌𝒈/𝒎𝟑
𝒗𝒐𝒍𝒖𝒎𝒆 𝟎. 𝟕𝟔𝟐 × 𝟎. 𝟓𝟎𝟖

43
Cement Bag dimension

Height = 762mm= 0.762m

Width = 508mm = 0.508m

Thickness = 101.6mm = 0.1016m

M = conveyor capacity

𝝆 = 𝒅𝒆𝒏𝒔𝒊𝒕𝒚

44
V = velocity

B = Belt Width

L = load

M = 1271.3× 𝟐𝟎𝟎 × 𝟒 × 𝟖𝟎𝟎

= 813632000kg/sec

= 813632 ton/sec

= 226 ton/hr

Stress on the ladder like on the belt

45
The area of the slit that experiences stress as result load

𝑭 𝒎×𝒈 𝟓𝟎×𝟏𝟎
Stress = = = = 𝟗𝟔𝟖𝟕. 𝟓𝟏𝟗𝑵/𝒎𝟐
𝑨 𝑨 𝟎.𝟏𝟎𝟏𝟔×𝟎.𝟓𝟎𝟖

𝑡 = (𝑖 × 1) + 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑜𝑝 𝑐𝑜𝑣𝑒𝑟 + 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑜𝑡𝑡𝑜𝑚

+ 𝑟𝑢𝑏𝑏𝑒𝑟 𝑖𝑚𝑝𝑟𝑒𝑔𝑛𝑎𝑡𝑖𝑜𝑛
𝑇
I= 𝐵𝑓1 𝑓𝑟𝑜𝑚 𝑃𝑆𝐺 9.18

𝑒 𝜇𝛼
𝑇1 = 𝑃𝑓 (𝑒 𝜇𝛼−1)----

Pf = the total belt pull

𝛼 = 𝑎𝑛𝑔𝑙𝑒 𝑜𝑓 𝑙𝑎𝑝 𝑜𝑣𝑒𝑟 𝑡ℎ𝑒 𝑝𝑢𝑙𝑙𝑒𝑦 𝑖𝑛 𝑟𝑎𝑑𝑖𝑎𝑛
𝜋
240 × = 4.19𝑟𝑎𝑑
180

Putting the value to get the tension at tight side

𝑒 0.4×4.19
𝑇1 = 11887.5 ( 0.4×4.19 ) = 14623.95𝑁
𝑒 −1

𝑇2 = 𝑇2 − 𝑃𝑓 = 14623.95 − 11887.5 = 2736.45𝑁

14623.95
𝑖= = 1.708
800 × 1.07
F= 1.07 from psg 9.21
𝑖𝑚𝑖𝑛 = 3, 𝑖𝑚𝑎𝑥 = 5
t= 3x1 +3 +2 +3=11mm

46
 Chapter Four

Result and Analysis

Finite Element analysis is a very powerful computation analysis technic that is use solve
problems regarding the effect of load on structures. It can solve the reaction of complex
structures to loads.
4.1 Color Code

Red: High stress (areas most likely to fail or experience significant strain).

Blue: Low stress (regions with minimal load or strain).

Yellow/Orange: Moderate stress (typically represents a middle range of values).

Green/Yellow: Moderate strain.

For Stress, Strain, and Displacement

Figure 4.1 shows the meshing

From the FEA Analysis when a load of when the structure is subjected to a load of 0.1N.
Below is the result of the response. This would be the reaction of the structure. The colors
show the portion that experiences the stress the most. The structure would experience
maximum stress the most at 1.004e+06.

47
the colour variation are as follows from blue to shows minimum staress to the

Figure 4 1. Show the behavior of the structure under load and it reaction

Figure 4.2 shows the displacement reaction

Figure 4.3 shows the strain reactio

48
CONCLUSION
The results of the project showed that the designed conveyor system was effective in moving
objects of various sizes and weights with an average efficiency of 80%. The system was found
to be most effective when moving lighter objects and there was some decrease in efficiency
when heavier objects were used. The system demonstrated high efficiency, with some room
for improvement. The project was successful in meeting its objectives and in demonstrating
the use of conveyor systems.

49
 CHAPTER FIVE
WORK SCHEDULE AND ENGINEERING BILL OF MATERIAL
PROJECT WORK SCHEDULE
TABLE 5.1 CONVEYOR BELT SYSTEM WORK SCHEDULE

Start date End date

Establishment of topic 31/10/2024 31/10/2024
Literature review 01/11/2024 4/11/2024
Market survey 04/11/2024 12/11/2024
Procurement of material 12/11/2024 18/11/2024
Design concept 18/11/2024 28/11/2024
Design calculation 28/11/2024 1/12/2024
Construction of the conveyor 1/12/2024 11/12/2024
belt system
Collation of data 12/12/2024 15/12/2024
Project report 15/12/2024 15/1/2025
writing/preparation
Project defense 26/1/2025 26/1/2025

5.2 BILL OF MATERIAL

For this work to be achieved a proper bill of material and costed bill of material has to
be accurate and detailed. However, below are the associated BOM and CBOM of this
research work.

TABLE 5.2: BILL OF MATERIAL(BOM)/COSTED BILL OF MATERIAL(CBOM)

NO. PART ITEM DESCRIPTION QUANTITY UNIT TOTAL

COST COST
(#) (#)
1 WIRE RUBBER(SILICONE) 2 50 100
2 BATTERY LITHUM (IRON & 2 300 600
POLYMER)
3 ELECTRIC MOTOR VARIES 1 700 700
4 ELECTRIC SWITCH VARIES 1 150 150
5 REXINE SHEET LEATHER 1 550 550
6 SHAFT STAINLESS STEEL 2 200 400
7 ROLLER PLASTIC 2 100 200
8 FRAME WOOD 1 4000 4000
9 SHAFT PULLEY PLASTIC 1 200 200
10 SCREW STEEL 14 20 280
11 LABOUR/TRANSPORT 1 8000
TOTAL #17,700

50
CONCLUSION
The main purpose of this project was to design and test a prototype conveyor system. The
system was designed to move objects of various sizes and weights, and was tested using a
variety of materials. The results of the testing showed that the system was effective in moving
objects and that further research is needed to improve the efficiency of the system.

51
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(https://www.spantech.com) origin of conveyors

(best characterised in the species Pleurobrachia pileus, Alie et al., 2011; Dayraud et al., 2012; Jager et
al., 2013) and the tentacle bulb of the hydrozoan cnidarian medusae (Denker et al., 2008; Jager et al.,
2011; Leclere et al., 2012; Coste et al., 2016)

53