HEATING BELT CONVEYOR DESIGN REPORT

REPORT

ON

DESIGN OF CONVEYOR WITH HEATING SUBSYSTEM

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TABLE OF CONTENTS
S.NO CONTENTS PAGE NO:

1 Abstract 3

2 Introduction 3

3 Belt Conveyor System 4

4 Advantages and Disadvantages of Belt Conveyor System 8

5 Designing Procedure 10

6 Heating Subsystem 16

7 References 19

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ABSTRACT

Belt conveyor is used to transport materials from one place to another and when such a
system is used along with a heating sub-system the system could be used for a wide range of
application. Such systems are used in food industries, cement industries, production
industries, etc. This report deals with the design of a belt conveyer system with a heating
subsystem. The design is made in Solidworks software and the results are presented.

INTRODUCTION

Material handling deals with a vital division of industry, which is extensively devouring the
power supply. Belt conveyors are being utilized to frame the most vital parts of material
taking care of systems in light of their high productivity of transportation (Jyotsna et al,
2015). Conveyors can securely transport materials starting with one level then onto the next,
which when done by human work would be strenuous and costly. They can be introduced
anyplace, and are significantly more secure than utilizing other machineries. They can move
heaps of all weights, sizes and shapes with high safety standards.

There is an assortment of choices accessible for conveying systems including completely

computerized, water powered and mechanical systems which are prepared to fit individual
needs (Padwal et al, 2013). Conveyor systems are generally utilized as a part of numerous
ventures, including packaging, printing, pharmaceutical, aerospace, food processing,
electronic computer, agricultural and so on. Despite the fact that a wide assortment of
materials can be passed on, most regular incorporate sustenance things, like grains and
animal feeds, beans and nuts, pills and powders, containers and jars, car segments, scrap
metal.

Belt conveyers have high efficiency and load carrying capacity. It is widely used in fuel
industry, agricultural industry, coal, mining and waste industries. To guarantee the belt
conveyor system, the streamlining plan of the drum quality and the reinforce utilization of the
drum execution have a critical controlling essentialness to the quality and security of the
system (Yuan et al, 2014). Solid Works software and finite element investigations
demonstrated the impact of ideal plan for improving the production. Conveyer systems fitted
with heating sub-systems are useful in heating applications and is extensively used in food
processing industries.

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BELT CONVEYOR SYSTEM

A belt conveyor comprises of a perpetual belt of a flexible material associated between two
pulleys and moved by pivoting one of the pulleys through a drive unit gearbox, which is
associated with an electric motor.Material is passed on by putting it on the belt, through a
feeder. As the belt turns, the material is conveyed with it on the flip side, where it is then
dropped in the release chute. Stature of conveyor belt is balanced by Pneumatic chamber.
Roller wheel help to turns conveyor system toward all path. Significant Parts of Belt
Conveyor System are frame, bearings,coupling,pneumatic cylinder, conveyor belt auxiliary
container, pulleys, idlers and engine (Bhandari, 2003).

Conveyor belt is comprised of mixes involved normal rubbers, Styrene-butadiene elastic

mixes of normal of crude material in the Hooper, different synthetics, nitrites, butyl, ethylene,
propylene-based polymer, polychloroprene, polybutadiene, polyvinyl chloride, urethanes and
silicones, and so on. Each of those elastomers has particular convenience for different scopes
of properties and working conditions from which producers and end-clients can pick.

Figure : 1 (Steel frame details)

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Frame consists of a lower outline and the upper casing of the belt conveyor are created from
steel sheets and framed in the state of C channel. Four legs are created from steel points. Two
wheels are settled to the front side lower edge to encourage its development in the field and
furthermore utilized lead screw or cylinder chamber course of action for development all over
way to adjust tallness. The upper edge comprises of the belt outline, drums, transmission
system, belt, and cloth cover.

A pneumatic barrel is a gadget with two chambers isolated by a drag. Each chamber has 1
valve and each valve has two opening port and one supply port interfaces the chamber to a
compressor and the other port interfaces the chamber to environmental weight. A little
chamber ordinarily has a drag breadth of 5/16 and a stroke of 2 inches. Bigger, yet run of the
mill barrels have borne distances across of 3” stroke lengths of around 6”.

Engine is a prime wellspring of the vitality to run the entirety belt conveyor system. By
taking current, it creates the mechanical work and this mechanical work is given to head
pulley or tail pulley of the conveyor by methods for equip box drive as talked about above.
We can likewise utilize an enlistment engine with variable speed drive by changing its
recurrence. Some of the engines used are worm equipment box, drive through winding angle
engine, geared drive through parallel shaft, geared drive through primary reduction engine,
direct gear engine drive and so on.

Figure : 2 (Plummer block with bearing)

Bearings are utilized to give bolster the pole of the roller or sit out of gear pulley at the two
closures. They give likewise rotational movement of shaft by giving it bolster with less
erosion. Despite the fact that some grinding is occurred because of the metal to metal contact

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inside the bearing between metal balls and metal housings, it is exceptionally irrelevant as
contrast and the immediate contact of turning shaft and fundamental casing of the conveyor.
Different types of bearings are utilized for different types of applications and some of them
are decreased roller push heading, roller push heading, ball push heading, roller heading,
metal rollers and so on (Daniyan, et al, 2005).

Roundabout sort of Hooper or container is utilized for transferring the crude material from
one conveyor belt to other. Roundabout container help to evade the spillage of material. It is
comprised of mellow steel. Frame segment of round container is connected with flat
conveyor belt structure. Both conveyor belt moves in any direction ,but the material is fall in
the focal point of second belt conveyor.

Figure : 3 (3 piece Idlers)

Pulleys and Idlers are made in an extensive variety of sizes and comprise of a consistent edge
and two end plates fitted with pressure sort centers . In most wide confronted conveyors
pulleys, intermediated hardening plates are welded inside the edge. External pulleys
accessible are self-cleaning wing sorts, which are utilized at the tail, take up or reprimand
areas where materials have a tendency to developed on the pulley confront, and attractive
sorts which are utilized to expel tramp press from the material being passed on. The
requirements for Idlers are to give appropriate help to conveyor and furthermore to the
Material to conveyor. An interminable conveyor belt in a conveyor structure is dragged from

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the tail pulley where material is stacked onto the conveyor, to the head pulley or drive pulley
where the material is released.

Figure : 4 (Head & Tail pulley)

Between a conveyor’s tail and head pulleys, regardless of whether the separation is various
kilometres or only a couple of meters, the conveying and return strand belting is upheld on
idler sets. The rolls are fitted with antifriction heading with seals and with sufficient oil
stuffed into it. The grating between the roller surface and the belt makes the rollers to turn
and in this manner material is exchanged starting with one point then onto the next through
belt conveyor.

Figure : 5 (Pin Bush coupling)

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Couplings are the gadget used to couple or associate two shafts; this is a standout amongst the
most essential parts of any drive system. Since it is difficult to keep up co linearity between
two shafts couplings are intended to give better adaptability to permit starting or running
shaft misalignment. Some of the adaptable couplers are geared coupling, grid coupling, chain
coupling, fluid coupling, all-inclusive coupling and so on.

ADVANTAGES AND DISADVANTAGES OF BELT CONVEYOR

SYSTEM

The primary component of the Belt conveyor is fuselage can be anything but difficult to
adjust, with a capacity distribution center, that the tail can be with the coal mining face to
advance extension or shortening. The rack is light and simple to dismantle. At the point when
the transmission limit and separation are bigger, outfitted with middle of the road drive to
meet the necessities (Padwal, 2013). As indicated by the necessities of the transportation
procedure, it can be transported by remain solitary or multi-unit engineered level or slanted
transportation system to transport the material, and it is extremely advantageous to utilize and
broadly utilized as a part of different modern endeavors, for example, underground mine
roadway and mine ground transportation systems, open pit and concentrator (Jagtap, 2015).

Belt Conveyor is the best proficient ceaseless transportation gear for coal mine, contrasted
and other transport hardware, (for example, trains), it has the benefits of long transport
remove, substantial transport limit and nonstop transportation. What's more, it is solid, simple
to mechanize and unify control. Particularly for high-yielding and effective mine, belt
conveyor has turned into the coal mining mechanical and electrical joining innovation and
gear key hardware. These days, the household belt conveyor goes into a fast advancement
arrange, with a tremendous request. In a few ranges belt conveyors have bit by bit started to
supplant trains and engine transport.The advantages and disadvantage of a belt conveyor
system while being considered as a mechanical method for mass materials passing on.

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Some of the advantages of the belt conveyor system is as follows

1. Belts can have sidewalls added to stop item spillage.

2. Grade belts can have spikes added to the belt to stop item move back.
3. Belt conveyors can turn toward one side enabling the release to be moved over a
circular segment (outspread stacking).
4. Measure belt areas can be included for constant item weighing.
5. Belt conveyors can have metal separators composed in.
6. Belts can be stacked for all intents and purposes wherever along the belt.
7. The belt can have trippers to empty the belt wherever.
8. The material can be unmistakable on the belt while being passed on.
9. The conveyor can have changes in height.
10. There is for all intents and purposes no debasement of your item caused by
passing on.
11. It is one of the least expensive approaches to move material long separations.

Some of the disadvantages of belt conveyor systems are as follows:

1. On the off chance that the material is sticky, belt cleaning can be troublesome and
for the most part not extremely fruitful.
2. The ordinary outline of a belt conveyor is opened. On the off chance that your
item should be contained, covers or potentially dribble skillet can end up plainly
costly and lumbering.
3. Odder control is for all intents and purposes incomprehensible.
4. On the off chance that the material being passed on is sticky it will at last get
exchanged to the arrival side of the belt and after that to the moves, idlers and
pulleys, at that point belt following can be a progressing issue.
5. There is quite often material persist from the belt release and this turns into a
house keeping issue.

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DESIGNING PROCEDURE

Designing of Frame

The outline started by following the parameters provided by Nunes Farms. The most
imperative part ofthe assembly was that the unit should be light due to the restricted space in
the distribution center. The conveyor could be placed on caster wheels so that it could be
effortlessly transported all through the workplace. Scattered and non-stationary hardware in
the workplace additionally implied the transport would no doubt should be moved now and
then and have the capacity to fit in tight spaces. Locking breaks could be provided to the
caster wheels, in order to keep the framework stationary when bolted.

Figure : 6 (Frame steel takeoff)

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Designing the Oven Box

The oven was designed as per the requirement and considerations. The best material choice in
view of these requirements was to utilize sheet metal made of stainless steel. The most
extreme size of the sheet metal that was accessible was outlined on the broiler box. It decided
how extensive the broiler box could be framed into a crate shape utilizing a solitary sheet of
stainless steel sheet metal (Khurmi and Gupta, 2006). There were various twists that should
have been made on the warmth confine request to get the case shape. The infrared warming
components acquired to warm the crate determines the contemplations for the oven.

Figure : 7 (Front view of Heating subsystem)

The material has to be heated as well as moved using a belt conveyer to make a system that
works together and the framework should support both to maintain equilibrium. Ventilation
inside the case was likewise of worry because of the dissipation of the holding specialist from
the materials as they go through the broiler box. A vent gap on the top, center segment of the
crate was basic with a specific end goal to give a zone to a power venter connection for
ventilation of the broiler box.

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Designing the Hopper

Keeping in mind the end weight of material to be processed, the container width should be
determined. This size was controlled by the space between the front legs on the frame with
the goal that it could without much of a stretch be dashed within the front legs of the square
container of the frame. With a specific end goal to have the capacity to modify the containers
frame, a turnbuckle connection was mounted to the underside of the container. This
connection point was intended to hold one end of the turnbuckle to the container. The flip
side of the turnbuckle was held in position with a bit square tube jutting from the cross
support on the casing. The purpose behind this plan was to have the capacity to alter the
container for the ideal frame of rest, with the goal that the materials can be bolstered
consistently onto the belt chain and the container limit was planned accordingly. The side
dividers were intended to be a few inches tall to give a lot of surface zone for the material
holding limit.

Figure : 8 (Hopper)

Belt Conveyor Designing

The parameters to be considered and calculated for designing the belt conveyor system are its
capacity, roller diameter, speed of rotation, moto specifications, belt power, loading capacity
of the system,location of the arrangement, pulley diameter, belt tension (Guthrie, 1968). The

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dimension and type of the belt conveyor determines the diameter of the driver pulley and the
driver and it should be so designed that it does not stress the belt so much. The length from
the belt line to the center of the pulley represents the length of the belt therefore it is
dependent on the center distances and the pulley diameter. The belt speed is given by V=2 *
π * d; where, V is the speed and d is the diameter of the roller (Yuan, 2014). Belt Capacity is
calculated using the formula 3.6 A * * V; where, A is the area of the belt section, V is the
speed of the belt and is the density of the material.

Figure : 9 (Conveyor prototype with heating subsystem)

Length of the belt is given by twice the length of the conveying route. Diameter of the roller
is represented as n = ; where d is the diameter of the roller, V is the belt speed in m/s

and n is the number of revolution per minute (El-Gindy, 2009). Conveyor capacity is
calculated by C = 3.6*50*V*M; where, C is the conveyor capacity, M is the live load per
meter on the conveyor belt and V is the speed of the belt in m/s.Belt power is calculated as
; L is the length of the conveyor belt and C is the conveyor capacity. As per the belt

power equation belt power increases with increase in conveyor capacity and belt length.

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The weight of the idlers and materials along with the rotation of the electric drive cause
tension in the conveyor belt. The slippage between the belt and the pulley could be prevented
if the belt tension is large enough and it is represented as

Ts = 1.37*µ*L*g*(2*Mi + (2*Mb + M)*cos(ø)) + (H*g*M);

where, µ is the frictional coefficient, L is the length of the conveyor, M is the mass of the
materials, Mi is the idler mass, Mb is the belt mass, ø is the conveyor inclination angle, H is
the conveyor’s vertical height and g is the acceleration due to gravity. Ts is the steady state
belt tension, whereas the belt tension at start is given by Tstart = Ts*Ks and this tension will be
higher than the steady state tension in the belt where, Ks is the start-up constant.

Moment due to Torsion is given by Mt = ; where W is the combined weight of belt

and material, d is the diameter of the pulley, and F is the Effective load given by the equation
F = µT*g*(M + ) + µR*g*( + Mi); whereµT is the frictional coefficient of the support

rollers and µR is the frictional coefficient of the skid plate. The size of the motor is
determined by the minimum power of the motor and it is given by dividing the power
generated by the drive pulley divided by the efficiency of the reduction gear. The conveyor
cycle time is given by Ct = , where V is the Belt speed and L is the belt length.

Design of the Shaft

Shaft configuration comprises of estimation of the right shaft measurement that guaranteesthe
required strength and rigidity during transmission of motion by the shaft under different
loading and operating conditions. The estimations of pulley diameter and belt width helps in
choosing the span of shaft measurement.

Figure : 10 (Shaft)

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Designing the Controller

The system could be controlled using Variable Frequency Drives (VFD). These controllers
would be able to utilize time control and supervisory capacities like, deceleration and
acceleration, speed and belt slip control, speed control of individual drives, speed control of
the conveyor, over-burden security, start and stop control, and driving drum (Jain, 2013).
Furthermore, VFDs accelerates the engine progressively so as to reduce the engine startup
inrush current. Hence, VDFs are appropriate for conveyors that take advantage of controlled
and reduced speed of operation.

Designing the Gear Box

Bonfiglioli Handbook was used to select the suitable gear motor by evaluating the required
constraints. Which is Compact, but then greatly intense, are the units of the 300 Planetary
gear engine arrangement. Their planetary drive is the perfect solution for all the extreme
applications where shock impacts and loadings are higher. The system setup is very flexible,
because of a few choices to extent the mounting, the motor interface, the output shaft and the
gear format (Kolte, 2015). Finding the ideal match to any drive issue is consequently more
than a desire, it is something clients can securely depend on - dependably.

Figure : 11 (Geared motor)

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Heating Subsystem

Heating Sub-systems with conveyor belt systems are quickly spreading because of its
productivity and speed (Metaxas and Meredith, 1986). Conveyor belt helps stack through the
info and yield ports of the modern applications. To enhance warm medicines, it is important
to comprehend the diverse marvels that happen inside the implement.

Figure : 12 (Heating subsystem)

A conveyor belt heater is a heater utilizes a conveyor or belt to bring process parts or material
through the essential warming chamber for quick warm preparing. It is intended for quick
drying and curing of items and is these days broadly utilized as a part of the terminating
procedure of thick film and metallization procedure of sunlight based cell fabricating.
Different names for conveyor belt heater incorporate metallization heater, belt heater, air
heater, infrared heater and quick fire heater, to simply list a couple.

Ordinarily a conveyor heater embraces a passage structure and is made out of different
controlled zones which incorporate zones for preheating, cover wear out, warming,
terminating, and cooling. A conveyor heater additionally includes quick warm reactions,
uniform and stable temperature appropriation; it can warm treated parts to 1050 ºC. Belt
speed of a conveyor heater can be up to 6000mm/min. Items are warmed proficiently by

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infrared radiation and are dried and let go subsequent to going through the controlled zones,
trailed by quick cooling. The various components of the heating system are as follows.

Heating Components: Fired silicon carbide sort warming components mounted above and
unsportsmanlike give proficient, uniform warming. They can be effortlessly changed while
the heater is at temperature. Heaters may likewise be provided with resistance warming lace
components (Jyotsna, 2015).

Tap Changing Transformer: A tap changing transformer licenses fluctuating the voltage to
the components to make up for any adjustments in resistance because of slow component
maturing; not required when utilizing strip components.

Cooling Chamber: The gas-tight, water cooled chamber is of twofold divider development
with water circling on each of the four sides. Thermostatic controls consequently alter water
stream for ideal cooling and least water utilization. Numerous zones of water temperature
control are given to alter cooling rates to various burdens. Removable spreads rearrange
occasional cleaning.

Belt Drive and Mesh Drive: A 10:1 apportion variable speed drive unit with generally
movable belt speeds permits the treatment of various thicknesses of materials with fluctuating
temperature necessities (Vanamane et al, 2011). The warmth safe nickel-chrome combination
belt is driven from the charge end of the heater by a squeeze move, which presses the work
belt firmly against an elastic secured drive drum. An idler drum at the release end of the
heater places pressure on the belt to offer help all through the arrival. Belt extending is
decreased since just a base pressure is expected to pull the belt through the heater. Belt take-
up is made without manual change.

Piers and Hearth Supports: Hearth bolsters are made of a progression of silicon carbide tiles
for uniform, low erosion backings of the belt as it slides through the warming chamber. This
outline limits any anxiety and warpage because of temperature changes. Tiles are effortlessly
supplanted. Block bolster docks are used to help the silicon carbide hearth all through the
warming chamber.

Heating Chamber Assembly: The heater packaging, when utilizing welded gas tight
development, is fixed with high temperature safe block protection in the side dividers and
floor. The removable rooftop fixed with a lightweight protection, considers simple openness
to the warming chamber for upkeep.

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Entryways: Passage and leave entryways are manual, flexible to limit air utilization and
tainting. Throat-sort stubborn inward entryways are standard on all models with entryway
openings 18" or more extensive.

Fire Curtains: An air-gas fire blind at each finish of the heater lights getting away climate
gasses and limits air filtration.

Air Curtains: Removable, various warmth safe window ornaments inside the charge and
release opening lessen environment misfortunes and limit penetration of outside air. Fumes
hoods at each finish of the heater divert squander environment and results of ignition.

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REFERENCES

Bhandari, V.B. (2003). Design of Machine Element. 8thed New Delhi: Tata McGraw Hill
publishing company.

Daniyan, I.A., Adeodu, A.O. and Dada, O.M. (2005). Design of a Material Handling
Equipment: Belt Conveyor System for Crushed Limestone Using 3 roll Idlers.Journal
of Advancement in Engineering and Technology.

El-Gindy, A.M., Baiomy, M.A., Abdelhamed, M.M. and Mosa, S. A. (2009). Design and
fabrication of a simplified mechanical handling system of rice straw baling operation
to reduce environment pollution.

Guthrie, A.M. and Pilcher, J.R. (1968). The Design of belt conveyor for bulk sugar handling.

Jain, R.K. (2013). Machine Design. New Delhi: Khanna publication

Jagtap A.A. (2015). Design of Material Handling Equipment:Belt Conveyor System For
CrushedBiomass Wood Using V Merge Conveying System.Int. J. Mech. Engg. & Rob.

Jyotsna, P., Date, D.D. and Galke, A.B. (2015). Design, Analysis and Weight Optimization of
Belt Conveyor for Sugarcane Industries. International Journal of Scientific Engineering
and Applied Science. 1(5), pp. 149-155.

Khurmi, R.S. & Gupta, J.K. (2006). Design of machine elements. 5thed New Delhi: Eurasia
publishing house (pvt.) Ltd.

Kolte, S., Khandre, R. and Patil, U.V. (2015). Design and Manufacturing Methodology for
Conveyor.International Journal of Science, Technology & Management. 4(5), pp:
2394-1537.

Metaxas, A.C and Meredith, R.J (1986). Industrial Microwave Heating. London: The
Institution of Engineering and Technology.

Padwal, Y.T., Rajmane, S.M. and Kulkarni, S.S. (2013). Design and Analysis of a Roller
Conveyor for weight optimization & material saving. International Journal of Advanced
Engineering Research and Studies. pp. 138-140.

Yuan, X.Q. et al. (2014). Analysis and Design of the Roller for Belt Conveyor Based on
ANSYS.Advanced Materials Research. 1027, pp. 315-319.

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Vanamane, S.S., Mane, P.A. and Inamdar, K.H. (2011). Design and its Verification of Belt
Conveyor System used for Cooling of Mould using Belt Comp Software.

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