Agazi.L & Migbey.T

HOST COMPANY N2ST FLOUR FACTORY
PROJECT TITLE BELT CONVEYER

PREPARED BY:
NUREDIN HASSEN
ID:: 1160/07
ADVISER
MR.SHUMEY G.
SUBMITTION DATE 19/2/2011 E.C

WLDU INTERNSHIP REPORT & PROJECT
Declaration of the student

I have been attained internship program in N2ST flour factory in Debre-tabor for four
consecutive months from March 01 to July 01 in 2010 E.c with a good participation.
Hereby declare that this internship report is certified work and my original work that is not
submitted any other person in the internship. The report has been submitted to Woldia
University faculty of technology Department of Mechanical engineering in partial fulfillment
of the requirement of engineering program.
Approval of the mentor

Mr. Nur……. _____________ ______________
Name of student signature date
Mr. Shumye G. _________________ _________________
Name of adviser signature date
PREPAIRED BY: - NUREDIN HASSEN Page I

ACKNOWLEDGMENT
First of all I would like thanks to my God and I am very appreciatively grateful to all those
who help me for the success of my internship program. Mr.Tibebu M. who was the internship
linkage. I would like to say thank you for your invaluable support. Before all I would like to
express my deepest gratitude to thank you our campus advisor, Mr.Shumey G. for his
valuable advice and my partner’s kindly help me.
I would like to thanks Mr. Kider Muhammed, Manager N2ST flour factory who gives the
opportunity to work with workers in the factory and also I would like to thank all workers of
N2ST flour factory who helped us directly or indirectly for our Internship work.
Lastly I offer my regards and thanks to all of those who helped me in any respect during the
Completion of the internship program.
PREPAIRED BY: - NUREDIN HASSEN Page II

EXCEUTIVE SUMMERY
An internship is a work related learning experience for individuals who wish to develop
hands on work experience in a certain occupational field.
It is necessary for students to develop the spirit of self -supporting and hard working.
We recently have done our internship in N2ST flour factory through internship and practical
work
The project work area on washing machine.
Life is a matter of being competitive in this global world. Therefore to be competitive good
practical knowledge and communication skill play vital role which is gained by this
internship program. Also we could learn the meaning of diligence, perseverance, frugality
and trust worth. Thus internship is very important to produce skill full generation for Ethiopia
in both practical and theoretical part.
This report contains the brief history of the N2ST flour factory and its main product as well as
its main customers and the main goal, vision and values of the company. The report also
includes the report also includes the organization structure and its work flow. And also it
includes benefits that we gained in terms of improving our practical skills, in terms upgrading
our theoretical knowledge, in terms of improving our interpersonal communication skills and
improving our leader ship skills. And finally it contains recommendation for the company for
the school and for UIL office.
PREPAIRED BY: - NUREDIN HASSEN Page III

Contents
Declaration of the student ..................................................................................................... I
Approval of the mentor .......................................................................................................... I
ACKNOWLEDGMENT ............................................................................................................. II
EXCEUTIVE SUMMERY .......................................................................................................... III
list of figure..................................................................................................................... VI
List of table ...................................................................................................................... VI
Part I Internship report ......................................................................................................... 1
CHAPTER ONE ....................................................................................................................... 1
1 Company profile ................................................................................................................. 1
1.1 Company Background ................................................................................................. 1
1.2 Mission .................................................................................................................... 1
1.3 Vision....................................................................................................................... 1
1.4 Values ...................................................................................................................... 2
1.5 Goals ....................................................................................................................... 3
1.6 Companies main product ......................................................................................... 3
1.7 Company’s main customer ...................................................................................... 3
1.8 The overall organization and work flow ................................................................... 5
CHAPTERTWO ....................................................................................................................... 7
2work section .................................................................................................................... 7
1. on the Pre Cleaning Section ....................................................................................... 7
2. Cleaning Section ........................................................................................................ 8
3. Transferring section ................................................................................................... 9
4. Milling Section ......................................................................................................... 10
CHAPTER THREE .................................................................................................................. 16
3. THE OVERALL OF BENEFIT OF INTERNSHIP................................................................... 16
3.1 Benefit of Internship .............................................................................................. 16
Part II project ...................................................................................................................... 19
CHAPTER FOUR ................................................................................................................... 19
4 DESIGN OF BELT CONVEYOR PROJECT .......................................................................... 19
PREPAIRED BY: - NUREDIN HASSEN Page IV

4.1 Introduction .......................................................................................................... 19

4.1.3 Objective of the Project ...................................................................................... 21
4.1.4 Scope of Project .................................................................................................. 21
4.1.5 Significance of the Project .................................................................................. 22
4.1.6 Limitations .......................................................................................................... 22
CHAPTER FIVE ..................................................................................................................... 23
5 LITERATURE REVIEW ........................................................................................................ 23
Chapter six .......................................................................................................................... 24
6.1 Methodology ............................................................................................................. 24
6.2 MATERIAL USED ........................................................................................................ 25
CHAPTER SEVEN .................................................................................................................. 26
7 DESIGN ANALYSIS OF BELT CONVEYER.............................................................................. 26
7.1 Belt speed ................................................................................................................. 26
7.2 Belt Capacity.............................................................................................................. 26
7.3 Belt Tension............................................................................................................... 28
7.4 .Design of Roller ........................................................................................................ 31
7.5 Design of Driving Belt ................................................................................................ 32
7.6 Determination of Power and Motor Selection ........................................................... 34
7.7 Design of Shaft .......................................................................................................... 37
7.8 Selection of Bearing ................................................................................................... 41
7.9 Selection of Key ......................................................................................................... 44
7.10 Design of Frame....................................................................................................... 44
CHAPTER EIGHT................................................................................................................... 47
COST ANALYSIS OF THE BELT CONVEYOR......................................................................... 48
CHAPTER NINE .................................................................................................................... 48
PART AND ASSEMBLING DRAWING ................................................................................. 48
CHAPTER TEN ...................................................................................................................... 54
10 CONCLUSIONS AND RECOMMONDATION ...................................................................... 54
10.1 Conclusion ................................................................................................................. 54
10.2 Recommendation ..................................................................................................... 54
REFERENCE ......................................................................................................................... 55
PREPAIRED BY: - NUREDIN HASSEN Page V

list of figure
Figure 1 over all organization flow ........................................................................................ 5
Figure 2 work flow of company ............................................................................................. 6
Figure 3 Filter and elevator ................................................................................................... 7
Figure 4Cleaning machines .................................................................................................... 9
Figure 5bucket elevator ...................................................................................................... 10
Figure 6 sifter for flour ........................................................................................................ 11
Figure 7 milling machine ..................................................................................................... 12
Figure 8packaging section ................................................................................................... 14
Figure 9 design of roller....................................................................................................... 32
Figure 10 motor selection ................................................................................................... 36
Figure 11 design ofshaft ...................................................................................................... 38
Figure 12 Radial ball bearings and housing .......................................................................... 41
Figure 12 bearing cap .......................................................................................................... 43
Figure 13 frame of conveyor ............................................................................................... 45
Figure 14 roller shaft ........................................................................................................... 49
Figure 15 roller .................................................................................................................... 49
Figure 16 horizontal conveyer frame ................................................................................... 50
Figure 17 bearing cap .......................................................................................................... 50
Figure 18 conveyer pulley ................................................................................................... 51
Figure 19 vertical stand of conveyer .................................................................................... 51
Figure 20 flat driving belt .................................................................................................... 52
Figure 21 conveying belt ..................................................................................................... 52
Figure 22 assembly drawing of belt conveyer ...................................................................... 53
List of table
Table 1mass of the moving parts ......................................................................................... 29
Table 2 application and life of bearing................................................................................. 41
Tables 3 X and Y factors for ball bearing .............................................................................. 42
Table 4 dimension and static and dynamic load capacity of ball bearing ............................. 42
Table 5 end condition and the relation between effective length and actual length ............ 45
Table 6 cost of conveyor parts............................................................................................. 48
Table 7 part name ............................................................................................................... 54
Abbreviations
N2ST = N represents Nuru
2S = represents Two member said
T = indicates Toffik
Diligence = activity
Frugality = saving
ID = identification cared
C = swept angle
Tde = electromagnetic torque
PREPAIRED BY: - NUREDIN HASSEN Page VI

Part I Internship report

CHAPTER ONE
1 Company profile
1.1 Company Background
The factory of N2ST flour industry was inaugurated in Keble 01 Debre Tabor town of south
Gonder zone Amhara regional state October 28/2016.The name N2ST are represents the first
letter of the name of the members in which N represents Nauru, 2S represents two members
of Said and the last letter T indicates Toffik. N2ST flour factory plc.Is Feasibility study to
establish in 2005 the building is completed in 2008.withInitial capital was 40million Birr
under Effort with total production area of nearly 7000 , N2STfiour factory plc. Is furnished
with new, state of-the-art production equipment and machines acquired from the most
respected companies/factories in the world wide flour industry. The flexible and superior
technological capacity we have, coupled with our highly committed work force, gives us
leverage to achieve our objectives and successfully compete in the local market.
The head Quarter of the Company is located at Gonder, and, has branch offices at Debre
tabor, to facilitate its operations.
N2ST has adequately defined its organizational structure to run its current operation and
future expansion effectively and efficiently. Currently, the Company has created employment
opportunity for about 100 permanent employees. But at D/tabor branch Company has created
employment opportunity for about 41.
In order to achieve its goals and objectives, the company has clearly defined its vision,
mission, core values, quality policy, and streamlined among its customers and stakeholders.
N2ST has core business activities and allied services in order to ensure its competitive
advantage and satisfy its customers.
1.2 Mission
To provide best flour products to the local market through maximum utilization of the
country’s hides & skins with continuous generation of wealth to the shareholders thereby
contribute its share to the regional & national economy.
1.3 Vision
Our vision is to become an exemplary organization in both the local and flour & flour
production market.
PREPAIRED BY: - NUREDIN HASSEN Page 1
Exemplary in the sense that N2ST flour factory will be noted for;
 High quality products and services
 Value in return for money invested
 On time deliver
 Integrity
 Respect and dignity for employees
 Profitability
Strategy
 Develop one stop, shop marketing
 Continuously engage in employee and product development
 Invest continuously on advanced technology where practical and

economical
 In calculate cost consciousness without compromising product excellence
 Give priority to understand customers’ needs and meet their specific

requirements
 Develop team spirit and sense of ownership
 Embrace open lines of company-wide communication
1.4 Values
Core Values
 Customer first
 Loyalty
 Learning culture
 Commitment
The values of the company are formulated based on the kind of the organizational culture the
company want develop. These values are;
 Customer oriented

 Trust and transparency
 Quality products
 Social responsibilities
 Recognize excellent performs
 Partnership and mutuality
 Excellence
 Integrity
 Honesty
 Accountability
1.5 Goals
Taking in to consideration the SWOT (Strengths, Weaknesses, Opportunities, and
Threats) analysis the following strategic goals are set.
 1) To strengthen the capital of the company consistently via increasing sales volume and
market expansion through supplying high quality products to global and local markets.
 2) Optimize return on capital investment for shareholders through continuous

improvement in operations
1.6 Companies main product

N2ST flour factory in Debre Tabor the services used for bread flour, furishika and furishikilo its
main supplier of foreign wheat world food organization and country wheat Gojam.
Three types of flour products such that first flour, second flour and third flour but first and second
flour is the same quality used to bread only .the third flour is not quality bread but used food like
enjera and others.
Furishica is the other quality so all over the biggest bread flour and furishikilo and used animal
food.
Furishikilo is less than the furishica used animal food. Differ from one another its quality.
1.7 Company’s main customer
For the above main product of this company different industries are supplied or purchased the
product. The wheat is supplied for the flour manufacturers and the machined it according to
their usage dimension. There are a lot of opportunities to approach new markets and facilitate
exports of flour based products in the new markets. The government could help further
through provision of specific grants as well in order to facilitate trade in that respect. Many of
the industries suffer from high cost of production due to energy cost and lack of patronage.

The company aimed to produce good quality flour and more productive for each customer
needs satisfied by adequate cost.
The main customer of the company
 Individual
 Group
 Private company

1.8 The overall organization and work flow
Head office
General Director
Depositor
Wheat storage Vice director
Pre cleaning
room Finance
Drying storage Secretary
Production of
wheat storage Store
Final product Marketing office
Figure 1 over all organization flow

WORK FLOW
B4 B3 B2 B1
Airlock
Flour Flour Kut

Flour Flour
Wheat Blow
scewer
1st flour Air lock
Double pin plane sieve

2nd flour
Screw conveyer
3rd flour
M3 M2 M1 S1
Furshkilo
Figure 2 work flow of company

CHAPTERTWO
2work section
Since I am a mechanical student I am working in maintenance and production activities, I
was always there wherever maintenance of production equipment’s and machineries is being
done. There are the sections I have been working below.
1. Pre cleaning
2. Cleaning
3. Transfer
4. Milling
5. Packaging section
1. on the Pre Cleaning Section
In this section we saw a lot of technique how to produce clean wheat Kernals are initially
moisture in order to soften the bran layer .put through special cleaning Machines and magnet
store move foreign objects such as dirt, straw, stones and metals. The kernels are then
brushed in order to remove the external part of the bran and any impurities that may be stuck
Figure 3 Filter and elevator

The wheat kernels are then conditioned with .First the wheat flow from the store to the
elevator and the elevator that is motor seven that pushes the wheat to the cleaning section
before coming to the cleaning there is Steel and wheat separator that separate magnetic
component from the wheat and then The wheat and other without metal components are
transfer to the separator it separate The wheat from no wheat shaped component like stone,
soil etc. that is motor six. In This section there is a capacitive sensor see in the fig below.
That is a time adjusting Sensor that open and close the no wheat carrying component when it
count the time Open and close after two minutes.
Dust and dust like components .It transfer the dust to the upper atmosphere and it Transfer
large weight from the dust to the bottom garbage this air lock receive the air from the low
pressure pump that is motor one it rotate the turbine and to produce air and then the wheat
shaped components and the wheat transfer to the next elevator that is motor five and it
transfer to the four storage below these storage there is a conveyer that rotate based on the
motor (motor27) the conveyer so that slowly and it pushes the wheat to the next elevator this
elevator transfer the wheat to the next section that is the cleaning section.
2. Cleaning Section
For the next cleaning section the wheat transfer by the elevator that is motor twenty Eight
(M28) and it transfer to the separator .The silos that hold the wheat have Dispensers which
may mix various batches of different types of wheat to produce the Required mix for the final
flour product .During this process the wheat is cleaned once Again to remove any remaining
small impurities like seed sand broken wheat. It is then brushed again to remove the outer
layer and then put through the de-stoner to remove any remaining stones. It is then disposed
in to a hydrating machine where water is Added to bring the wheat to the humidity levels
required for processing .The wheat is Then stored in the tempering silos for a specific amount
of time so that it can absorb The required humidity(wheat tempering). And the wheat transfer
to the drier cylinder. In this section there are two drier cylinders he first drier cylinder. That
separates the wheat from large size wheat like component and then transfer to the sectors that
crash the wheat without water and transfer to the Secondary drier cylinder that separate then
wash the wheat by water.

Figure 4Cleaning machines

3. Transferring section
After washing the wheat it transfer to the third section that transferring section Store and
conveyer for this section the wheat need eight hours for during .After eight Hours motor32
stand and the conveyer rotate and push the wheat to the elevator and The elevator transfer the
wheat to the next section that is grinding section before Grinding there is small store and the
sensor that sense the amount of wheat .When This sore is full motor32 stop running and
transfer the wheat then motor38 is start to Run transfer the wheat to the grinder and vice
versa.

Figure 5bucket elevator

4. Milling Section
Four different milling methods were used with the goal of obtaining a coarse, medium, fine,
and extra-fine granulation out of each wheat sample. Coarse grind It was obtained by running
the hammer mill at 4,000rpm’s, with a3.0 mm screen size.
Medium grind
It was obtained by running the hammer mill at 6,000 rpm’s with a3.0mm screen size. After
the two grinding that is course grind and medium grind there is the sifter that the broken
particles of wheat are elevated through pneumatic tubes and then dropped in to huge,
vibrating, box-like sifters where they are shaken through a series of bolting Cloths or screens
to separate the larger from the smaller particles.
Inside the sifter, there may be as many as 27 frames, each covered with it her any on or stain
less steel screen, with square openings that get smaller and smaller the farther Down they go.
Up to six different sizes of particles may come from a single sifter. Larger particles are
shaken off from to, or “scalped,” leaving the finer flour to sift to the bottom. The “scalped”
fractions of endosperm called middling's are reduced in a smooth roller system to the particle
size of flour. In hard wheat mill, the product is then subjected to a purifying process. A
controlled flow of air lifts bran particle while at the same time a bolting cloth separate sand
grades coarser fractions by size and quality seen in the fig below

Figure 6 sifter for flour

The process is repeated over and over again, sifter stop to reducing rolls moving up and down
and across the mill in a series until the maximum amount of flour is separated, about 75
percent of the wheat kernel.
Fine grind
It was obtained with a multi-step process. Kernels were run through the hammer mill at
6,000rpm’s, with a3.0mm screen size. The stock was then taken and run through Corrugated
break roll stand with the front roll set at 392rpm’sand the back roll set at 266rpm’s. This
method was created to closely resemble a commercial fine whole Wheat milling process.
It was obtained with a multi-step process. Kernels were run through the hammer mill at
6,000rpms, with a 3.0mm screen size. The stock was then taken and run through Corrugated
break roll stand with the front roll set at 392rpm’sand the back roll set at 266rpms.To create
the extra fine product, the milled stock was then taken and placed In a sifter box and sifted
for 3 min .The remaining stock with a particle size of equal to or greater than 414 microns
was Taken and put through are grind to the hammer mill. The over stock was reground

Through the hammer mill at 6,000rpm’s through a 1.0mm screen size show in fig below fig.7
milling machine
Figure 7 milling machine

Traditional semolina flow diagrams are long on roll surface to gradually reduce the durum
kernel while minimizing flour production. Most mill diagrams will include up to seven break
passages slowly open the kernel and extraction the endosperm in large pieces min the number
of break passages may be reduced when removing bran by peeling or Pearling in the pre
process conditioning system.
The first and second break passages most commonly are set to use dull-to-dull Grinding
action, while the remaining break passages and the sizing passages use sharp-to-sharp
grinding action allowing for better precision of sizing of end sperm into the correct
granulation of semolina.
The sizing system in the semolina diagram will include six or seven passages as Compared to
two or three in a flour mills. These sizing passages gradually reduce the endosperm separated
from the bran in the break system and feed the extensive Purification system.
The roll pack design found in many new roll stands allows for more stable grinding and
improved precision of granulation. Break and sizing passages can be precisely set to target
grinding releases to gently grandly and gradually reduce the endosperm Optimizing semolina
production .And also within an input pipe there is a sensor that senses the amount of wheat in
the pipe. When the sensor reading is 20-80 the grinding motor start to run. But below 20 there
is low input then the grinding motor can stop working.
5. Packaging section
This section has a hopper and a valve to close and open; performed manually by Workers.
This can be takes place by holding the sack into the hopper tip and tie the sack by belt and
rotating the valve to open and close the flow of the flour.

Figure 8packaging section
2.3 work flow in the section

Mechanical maintenance show is located in the mechanical work shop, But it works or
maintenance service electrical and mechanical equipment in -all shops. The basic objectives
of maintenance are increasing functional reliabilities of product facilitates enable product or
services quality increasing the production.
2.4 Challenges that facing the working tasks

Initially when we join in to the company there is no person that has the basic knowledge
about the machines the machines but by using experience method. So by this problem we
have not gained an introduction to the machines as well as the company until three weeks.
But after some days we have the best relation to the workers and other intern students and
helping each other by mutualism method we have to get enough knowledge and we have to
be select the problem and we have to get the solution of the problem.
The other challenges that facing the working tasks is that the company have no work flow
and organizational structure because of this in order to make that difficult work flow it
consumes more time. After some trial and error method we have finish our work.


CHAPTER THREE
3. THE OVERALL OF BENEFIT OF INTERNSHIP
3.1 Benefit of Internship
Internship is important to create skilled generation to build modern technology on the future.
This internship is used to make students able to solve any problems without any challenges.
Internship increases the performance, the work ability and social interaction. Some of the
benefits of internship are explained below.
Improving our practical Skill

Because of the teaching and learning process which have been giving hear is mainly based on
theoretical parts the benefit we gain from the internship is very large like developing practical
knowledge and some experience.
Increase Theoretical Skill
This internship is used to up grading our theoretical knowledge. It is also used to solve
problems and increase the theoretical knowledge in addition to the practical skill. Before
starting one thing it is necessary to know working procedure, how to work, what is the
purpose and for who to produce for this purpose so theoretical knowledge is important to
solve problems.
In the internship program and schedule we had upgrade our theoretical knowledge through
working hard within the department we employed, thus it was necessary by any means to change
or interpret the theoretical knowledge to practical one. The internship was very helpful in up
grading the theoretical knowledge.
Improving interpersonal communication skill
Since the most important thing for one employee is good and peace full communication and
sharing of idea with other employees, the internship has been of great help in improving our
communication skills For example, to get different kinds of information about the Industry and its
function; to acquire knowledge about the machineries, and others different over al systems, to
share once knowledge with others and square some experience. Generally we developed a very
peaceful working manner.
 Team working Skill
As we know team work is the best way to develop knowledge and exchange experience, so in
order to get these things we need to play on team and develop such mechanisms of learning and
working on the company.

 Sharing experience among the groups

 Understanding how internship is useful for every work in company
 Distribute the work load to cover within a time
 To compute among themselves just to make better work
 Develop a friend ship we respect each other’s
 Creating participation
 Leader ship skill
Since we were working with the managers and engineers and other mechanics we were
looking for the way they were leading each other, forming group leading .also we by our self
will make group that’s also parts of leadership. This helped as to organize different work
division treating customer’s discussion and solving problems. Taking responsibility in every
direction of work flow.
 Leadership skill are the tools, behaviors, and capabilities that a person needs in order to
be successful at motivating and directing others.
 We are develop a good leadership skill and ability to build consensus in the face of
uncertainty in our internship stay when we are working in group.
 During working time the workers may made technique mistake and we try to confidence
to lead the workers to correct it. Moreover, in getting things done, create trust and builds
confidence among group participants.
 Working ethics
Ethics in a sense the moral principles governing or influencing conduct or the branch of
knowledge concerned with moral principles. Work ethics related issue is the behaviors of doing
work with good conduct without separation of everything on the work place. During our
internship period, we understand what work ethics mean.
Work ethics specific to work situations
 Punctuality
 Responsibility
 Reliability
 Keeping securities confidently
 Creating coordination. Among workers
 Wastages of resources of the company or improper use of materials

 Keep the rule and regulation of the company

 Entrepreneurship skills
Entrepreneurship skills develop through experience, do not everybody born with it by nature
entrepreneurship is a skill that can developed and expanded though practicing or experience.
From this field practice we develop an entrepreneurship skills by improving the behaviors
highly confident, risk taker, thinking logically and being practical. Developing the skills and
ideologies of entrepreneurship is another important achievement that we have got from the
internship experience. We have tried to analyses the step by step development of the hosting
company by identifying the development cycle and its main elements functioning as a basic
component in the makeup of the company. As the company is founded and owned by an
entrepreneur; it has given me a chance to observe the organizational structure, background and
basic achievements which was important in understanding its entrepreneurial activities.
Understanding the basic principle of entrepreneurship including the existence of vision and
mission and commitment to organize and lead an organization and other entrepreneurial
characteristics such as need for achievement, willingness to take risk, self-confidence and
innovative skills.
It is a way of set up or creates a business or businesses, taking on financial risks in the hope of
profit. In general in the duration of the internship period we have got relevant professional skill in
the technician workers, entrepreneur skills and creative thinking etc. that are very important for
us after graduation. An entrepreneur must have the following abilities or skills:
 Risk taker
 Innovative
 Hard work
 Self confidence
 Knowledge and creativity

Part II project
CHAPTER FOUR
4 DESIGN OF BELT CONVEYOR PROJECT
4.1 Introduction
Conveying and elevating equipment serve a wide variety of purposes in practically every
industry where bulk materials are handled. Primarily, conveyers and elevators provide
transportation with a uniform flow from one operation to another, but they also provide the
means for performing many other functions, such as distributing the material to bins or
machines for weighing, mixing filling etc. [1]
Many types of variation of conveying and elevating equipment have been developed to meet
the wide spired needs of industry. They are suitable for handling wide verity of materials over
abroad range of capacity.
The common objectives is to design and /or select a conveyer that will deliver maximum
performance at minimum cost per ton of material handled. To do so, it is necessary to obtain
answer to the following key questions and to develop the facts necessary to determine the
type of conveyer that will suit the purpose for which it is to be designed and arranged.
1 what is horizontal distance over which the material is to be conveyed?
2 what is the vertical height that the material is to be lifted or lowered?
3 what kind of material is to be handled and what is its weight per cubic material?
4 what is the average required capacity in tons per hour?
5 what is the maximum required capacity in tons per hour?
Conveyors are able to safely to transport materials from one level to other, which done by
human labor would be strenuous and expensive. They can be installed almost in anywhere,
and are much safer than using other types of equipment, such as forklift or other machine and
manually to move materials. They can move loads of all shapes, sizes and weights and also
many have advanced safety features that help prevent accidents. There are so many types of
options available for running conveyor systems, including the hydraulic, mechanical and
fully automated system, and other drivers, which are equipped to fit individual needs. The
drivers are may be flexible and non-flexible drivers. The types of flexible drivers are belt,
chain and rope, the power is not directly transmitted, because of it needs transmission link

between the rotating parts. While the non-flexible drivers are gear and they are not needs a
connecting link between the rotating parts [Gupta.J.K.A2005]. But most widely used in
mechanical conveyor system in many types of industries such as automotive, agricultural,
computer electronic, food processing, aerospace pharmaceutical, chemical, bottling and
canning, print finishing and packaging. Although a wide variety of materials can be
conveyed, some of the most common including food items such as beans and nuts, bottle and
cans, automotive components, scrap metals pills and powders, wood and furniture’s and grain
and animals feed [2].
Many factors are important in the accurate selection and design development of conveyor
system. It is important to know how the conveyor system will be used beforehand. Some
individual areas that helpful to consider are the required conveyor operation, such as
transportation, accumulation, the material size, weight and shapes and where the loading,
unloading and pickup points need to be. [3].
4.1.1 Background of Belt Conveyor
Before going to transport the material, it should be identify, which types of material to be
Transported in a conveyor system. In any process and sites, the raw materials and products
Need to be conveying from one process or stage to another [4]. Belt conveyor
Is one of the common types of material handling equipment? It is designed such that
Facilitate easy, cheap fast and safely loading and unloading with less human interference and
Due to this reason the design can be ergonomically factor should be considered which is
Human capability in terms of safety of operations weight and height.
That is the materials to conveyed are non-packed and fluid type, so the arrangement is
horizontal with the slop is zero and it consists of three impact idler, seven carrying idlers and
four return idles based on the idle space length, an Endless and flexible belt of high strength
with endless and pulley (drive and driven) at affixed position supported by rollers. The
driving units of this design, electric motor, pulley, shaft and rollers and the other main parts
are, belt, frame. The installation of the design conveyor is two ways or dual which is forward
and back ward conveying system, but the design is only one. Because of the forward
direction of the conveyor is used to transport the services material and food items, from the
washing and cooking room to flooding room respectively. The back tracking movement of
the conveyor is to return the above items to the first rooms. The arrangements of the washing
room and the cooking room must be near to each other, to transport the service and food
simultaneously. In this design, the material

Characteristics to be conveying, maximum lump size, Belt conveyer efficiency, the belt speed
and capacity the belt tension, and the cost of the conveyer system is considered.
4.1.2. Statement of the Problem
In N2ST flour factory the transportation of wheat, is used manual but not use material
handling .The manual material handling system has so many feed backs, such as need high
efforts, costly, large number of labors, time consumption, reduced
Flour quality, case of conflict, and damage of materials and injury of workers. So
That the design and modeling of belt conveyor system in this mandatory, in order to solve the
above problems.
4.1.3 Objective of the Project
4.1.2.1. General Objective
The general objective of the project is:-

Design and development of Belt conveyer system in flour factory.
4.1.2.2 Specific Objective of the Project
The Specific Objective of The Project is:-

 select the proper material for production of belt conveyer
 Design and analysis using belt conveyer
 Cost analysis of belt conveyer system
4.1.4 Scope of Project
This project shows design of belt conveyor system. The detail design of the project is
calculating
Belt tension, belt capacity, design of bearing, design of key, design of shaft, cost analysis and
part and assembly drawing of belt conveyor.

4.1.5 Significance of the Project
 To minimize the transportation problem of N2ST flour factory .

 To reduce the number of labor s and labor costs.
 To reduce the cost of materials.
 To keep the bottles quality.
 Avoidance of damage of service material and injury of workers.
 Reduced time consumption.
 Improve safe operations of workers.
4.1.6 Limitations
 Shortage of materials and equipment

CHAPTER FIVE
5 LITERATURE REVIEW
In Industries, the task of mobilizing goods (i.e. raw material or finished product) are carried
out by „belt conveyor system‟ which is essentially a closed loop pre-tension belt (or chain in
case of chain drive) sliding upon rollers (& idler) and driven by an actuator(s). Belt conveyor
are most common in industries which are based on automatic machines because they are able
to deliver work pieces to the operating machine continuously or over fixed intervals. Because
of their constant operating speed, high efficiency and low operating cost; they are more
acceptable than forklifts and other machines. Apart from manufacturing line, these system are
appropriate for carrying goods over long distances such as in mineral extraction sighs where
coal and mineral ores are extracted on a large scale and conveyed from fixed origin to fixed
destination. It omits the effort and time to be consume in loading/unloading and hence boost
productivity. Because of simplicity in design and employability, belt conveyors are needed to
be optimized for a given environment and hence research and development accounting
energy saving &efficiency, friction, fire and safety, maintenance, inspection and cost is a
subject of consideration.
[5]: The paper reports theoretical and experimental study on the pressure distribution caused
by the bulk material loading on a belt. A theoretical model based on active and passive stress
states of the bulk material has been presented to predict the pressure distribution pattern but
the results are not yet verified.
In this paper, the author worked on closed-loop model predictive control (MPC) approach. A
belt conveyor system containing 6 belt conveyors in a coal-fired power plant is taken as an
object of study. Operation level is practical for field application. This paper employs
optimization methodology to achieve cost-optimal operations of a belt conveyor. The energy
efficiency can be improved at any one of the four levels: operation, equipment, performance
and technology. To adjust forecasting disturbance and execution disturbance, a proposal of
closed-loop MPC approach is made.
[6] Presents a paper on Belt Conveyor Pulley Design – Why the Failures. A system for the
design and dimensioning of conveyor belt pulleys, in a manner which permits use at drawing
office or computational level, is laid out. The theoretical model is used to explain the reason

for some common failures and to place in context some of the pulley construction features
seen in recent years. Lastly, an account is given of the factors which limit the life of a pulley
and a design is proposed for the next generation of long-life, low cost pulleys for the South
African market.
[7] Studied about the Failure Analysis of Conveyor Pulley Shaft. The shaft of pulley of belt
conveyor is failed during working. An investigation was performed to find out the cause of
failure and factors which are contributing in failure of shaft. In his Investigation methods they
examine about visual examination, optical and scanning electron microscope analysis,
chemical analysis of the material and mechanical tests.
[8] studied and prepared his thesis on manufacturing industry, raw materials and products that
are need to be conveyed from one manufacturing stage to another. Author observes material
handling equipment must be design to facilities easy, cheap, fast and safe loading and
unloading with least human effort. The paper discus the designed calculation of belt used to
transport line stones over distances.
[9] Studied belt conveyors in coal and mineral mine. A linear static structural analysis of
stress is done on a roller shaft with the help of Hyper Mesh. By using design failure modes
and effects of analysis (DFMEA) for systemic, proactive method for identifying where and
how it might fail.
[10] Studied existing Belt conveyor system and optimizes the parts like Roller, L-channels
and support, to minimize the overall weight of system. Results of Linear static, Modal and
Transient analysis of existing design and optimized design are compared to prove design is
safe.
Chapter six
6.1 Methodology
A series of methods were followed during the design of the project. The major ones are described
as follows
 Identifying part components which are needed for the machine
 Checking availability and manufacturability of those components
 Selecting materials for each component
 Analyzing each component strength wise
 Choosing method of joining for components
 Assembling orderly solid work
For doing our design we use different methods getting information and data. The main

Methodologies are:
a) Data collection:-We take different measurement data collection from service information
System. I use different types of data collection mechanisms and document analysis. Open and
closed ended questionnaires was distributed for some selected employees. The primary data
was collected by direct participation of respondents, because of survey method is utilized.
Secondary data was collected from different books, documents manuals.
b) Internet sources:-Our main source of information in our project was the internet.
Besides using as a source of literature we used internet to get detail information about
Some component that we used in our design.
6.2 MATERIAL USED

Systematic selection for applications requiring multiple criteria is more complex. For
example connecting rod which should be stiff and light requires a material with high young
modulus and low density. If the rod will be pulled in tension, the specific modulus, or
modulus divided by density=E/p will be determined the best material. But plates bending
stiffness scales as its thickness cubed, the material for stiff.
Thickness=cubic rot of stiffness per density
In this design the material select to manufacture handle is cast iron the material selected
unallied to be the following maintain
High wear resistance
High strength
It has high wear resistance
In this design the material selected to manufacture pad is carbon steel the material selected
It is highly corrosion resistance
It is standard in dimension
It is easily available from market

CHAPTER SEVEN
7 DESIGN ANALYSIS OF BELT CONVEYER
7.1 Belt speed
The maximum speed of a belt conveyor in this field has reached limits not thought possible
some years ago.
Very high speeds have meant a large increase in the volumes conveyed.
Compared with the load in total there is a reduction in the weight of conveyed material per
linear meter of conveyor and therefore there is a reduction in the costs of the structure in the
toughing set frames and in the belt itself.
The belt speed can be calculate as, =
Where, V=belt speed in m/s
d=roller diameter in mm
N=revolution in rpm
7.2 Belt Capacity

For a maximum efficiency conveyors should be operated fully loaded at a maximum
Recommended speed. The belt capacity dependent up on these inter-related factors.
 Belt width
 Belt speed
 The density of conveying materials
 Surcharge angle and repose angle
 The cross-sectional area of the belt
The belt capacity is expressed in ton per hour (T/hr.) or in kg/second. Generally the belt
conveyor Capacity can be calculating as follows.
= 3.6. .
Where, Q=Belt capacity in (kg/s)
A=the load cross-sectional area in (m2)
V= the belt speed in (m/s)
⍴ = the density of conveying materials in (kg/m3)
In order to arrive to determine the conveyor capacity using the other alternative relationship,
This is given by: =
Where,
V= the specific volume required to conveyed in (m3/hr.)

Q= the peak tonnage quantity in tone/hr. or kg/s

⍴ = density of the material in (kg/m3)
The specific volume and the required cross-sectional load area are related by
V=3600.A.v.k Where, v= belt speed (m/s)
A=the load area in (m2)
The factor k is reducing factor used for inclined and declined conveyor, but a horizontal
conveyor the reducing factor (K) is negligible. The cross-sectional area of a flat belt is
depending on the surcharge angle, which is the angle of repose of a material in dynamic
motion. This angle is based on the follow ability of the materials. The angle of repose (∅) at
rest is different from the angle of repose in motion (∅m) and the relation is given by:
= 0.7∅
For the characteristics of material follow ability is uniform size with the repose angle at
motion is equal to 19°.From this to determine the cross –sectional area of the belt. The cross
section area of the belt (A).
Pulley face width=B+2.edge clearance
Where, The edge clearance for a belt width 800mm to 1000mm is75mm
B=the belt width in mm
H= the height in mm
When ∂ = ∅m
∅m = angle of repose at motion in (°)
A1= the cross-sectional area of the belt section one (m2)
A2= the cross- sectional area of the belt section two (m2)
A = the total area of the belt which is = +A2 in (m2)
The cross sectional area of section one and two is can be calculated by using right angle area
Formula as follows.
ℎ
1= 1∗
2
ℎ
2= 2∗
2
But h is can be determine by the function of repose angle (∅m)
h=h1=h2= B1.tan∅m where ∅m =19°
1 = 2 = And B=the belt width its volume is 800mm=0.8m from the specification.
1 = 2 = 0.4

= 0.4 . tan 19 = 0.138

1 = 2 = 1ℎ
2 = 0.4 ∗ 0.138 2 = 0.0276 2
= 1 + 2 = 2 1 = 2 2 = 2 ∗ 0.0276 2 = 0055 2
The capacity of the belt conveyor is given by
= 3.6. . . ( )
Where, Q= capacity of belt (kg/s)

A=area of the belt (m2)
V=belt speed (m/s)
⍴=Density of material (kg/m3)
Belt capacity (Q) = maximum load * safety fact
=4 ∗ 1.8 = 6.4
From the specification the capacity (Q) =6.4kg/s and the belt speed can be determine by
Using
= . ∗ ∗ M/s
.
= v=2m/s
. ∗ ∗ .
From equation (4) the specific volume and they require cross-sectional load area can be
determine by = 3600 . ( )
Where, V=is the specific volume required to conveying (m3/hr)

v=belt speed (m/s v=3600*0.055m2*0.05m/s=11m3/hr.
The mass of the material (Mm) or live load per meter (unit length) in kg/m can be calculate
by using
Mm= . ∗
=0.278
Mm =36 kg/m.
7.3 Belt Tension

It is necessary to consider the different tensions that must be verified in a conveyor with a
powered belt system. In order to calculate the maximum belt tension and the strength of the
belt is required. It is first necessary to calculate the effective tension.

The effective tension (TE) is a function of many factors. The most common factors are the
length of the conveyor, the weight of the moving parts, the belt idles, the weight of rotating
idle parts and the frictional force involved against the movement of belt and the load it is
carrying. To determine the different forces involved the following relation is must be applied
for horizontal belt conveyor.
TE=TX + TY
Where, TX=the tension component for the empty belt.
TY= the tension or the force required to move the load on the conveyor length.
TX is the force necessary to move the only the empty belt along the conveyor length (L). The
weight of the rotating parts, such as belt, idlers, pulley and the coefficient of rolling friction
between the belt and idlers. Ty will be depends on the conveyor length, the rate of loading
and the coefficient of friction between the belt, and idlers and the mass of moved parts. TX
and Ty are given in Newton (N) is given by:
= 9.81. . .
= 9.81. . .
Where, L is the conveyor length and equal to the center to center distance of pulley’s is in
plus 45mm(0.045m) for normal driving condition .FB and FL the friction coefficient for the
empty and loading belt respectively and their values being generally take to be around
0.03. Where, P is the weight of the moving parts in kg/m
M is the weight of the material load in kg/m and given by M=0.278*
The mass of the moving parts can be determine from the standard table and apply an
interpolation method to determine the unknown mass.
Table 1mass of the moving parts
Belt width(mm) Mass (kg/m)
Medium duty 127 mm idles, Moderate

.
belt
400 22
450 25
600 36
750 46
900 55

For this design the belt width is 800mm, so that to determine the mass of the moving parts
By applying the interpolation methods. For the medium duty, 127mm idlers and moderate
Belt and belt width 400mm the mass of the moving parts can be determine by:
750=46
800=m
900=55
= Then, M=49kg
Where, m is the mass of the moving parts and the value is equal to P value. The mass of
Material (Mm) is equal to M which is the live load per meter it is already determine from
Equation (8) its value is 36 kg/m. then calculate the tension on the empty belt and the tension
On the load belt and the total or effective tension.
The empty load of the belt (TX) is given by.
= 9.81 ∗ ∗ ∗
Where L=12.045m
P=49kg/m
FB=0.03
TX=1707N
The tension for a loaded belt is TY which is given by:
= 9.81 ∗ ∗ ∗
Where, L = 6.045m
FL = 0.03
M = 36kg/m
P = 49kg/m
TY =1256N
The maximum effective tension of the horizontal belt conveyor (TE) is given by adding the
Empty belt tension (TX) and the loaded tension (TY) of the belt
TE=TY+TX
TE=2963 N
Total empty friction= ( + )∗ ∗ 9.81 − 3(12)
Load friction = ( + ) ∗ 9.81 − 3(13)
Return side friction= Fe*W*L*0.4*9.81e-3
Where, Tf = Terminal friction constant (60m)
W = weight of the material and belt
Fe = equipment friction factor (0.03)

L = Length of conveyor
V = belt speed
Q = belt conveyor capacity
From equations (12)
 Total empety friction=28.8N
Load friction = 4.22N
Return side friction = 2.052
Total friction force = total empty friction +load friction +return side friction =35.072N
The total power losses due to friction are:
1= ∗
Where,
Pl = power losses due to friction
Tf = tension n due to friction
. ∗ .
P1= =0.0176W
7.4 .Design of Roller

The roller is support belt and facilities easy to as well as free rotation of the belt conveyor in
all
Direction.
The correct choice of roller diameter must take in to account the belt width. From the
Relation of the maximum belt speed, the roller diameter able to determine the relative
Revolution per minute (rpm) by using the formula
∗ ∗
N= ∗
rpm
Where, d= the core diameter of the roller (mm)

V= the belt speed (m/s)
N= revolution in rpm
The belt width is designed 800mm, the belt speed calculated from equation (2) and its value
Is 0.05m/s and the roller diameter 127mm. The basic belt length (L) is =2* length along the
Conveyor route
L=2*12m=24m
The diameter of rolled belt (D) is calculate as follows

4∗ ∗ 2
=
(15)
Where,
d= bore diameter
L=basic belt length
T=thickness of belt
D= roller diameter
∗ ∗ ∗
= =320m
Figure 9 design of roller

7.5 Design of Driving Belt
There are many types of driving mechanisms, but generally it can be grouped in to two.
These are flexible and non-flexible (rigid) types of driver. The flexible driver mechanisms
Are belt, chain and ropes and the rigid driver mechanisms is gear.
The importance of flat Belt drives overall others are:-
 It is relatively cheap and easy to maintain
 When it worn out they are easy to replace
 They do not required precise alignment of shaft
 The design is simple and inexpensive.
 They can be used for long center distance up to 15m. [Robert Mott 2003]
 High efficiency
 High machine performance
 Low energy consumption
 Low cost
 Energy and cost saving- Energy consumption reduced by4%-6%
 Reduced operating cost
 No vibration
 High machine speed
TE is a result of the difference between the two
Standards of the belt located on either sides of the pulley. These sides are the
Higher tension subjected is as refers to as tight side and the other side is slake
Side. The above two tensions are denoted by T1and T2 respectively. They are

Related to each other by the formula:

1
=
2
Where, The coefficient of friction between the drive pulley and the belt
For a leather belt the value of is determine as
42.6
= 0.54 − ( + )
152.6
Where, v=belt speed
= 0.26
The wrap angle ( ) in radians the arc of contact on the drive pulley and the value is 186.1°.
E is the base of naperies logarithms=2.718
The driving factor (k) is determine by
1 2
=1 −1
K=1.8
The drive (wrap) factor is mathematical value used in the determination of effective belt
Tension (TE) that can be dependably by the drive pulley. The TE that can be developed is
Governed by coefficient of friction between pulley and the belt and the values of the slake
Side and the tight side tension.
TE=T1-T2
T1=TE+T2 (19)
` T1=TE .k (20)
The tension in the tight side (T1) is determined from the above relation.
T1=TE*k
Where, K=1.8
TE=2963N
T1=2963N*1.8=5334N
The tension on the slake side (T2)
T2=T1-TE
T2=5334N-2963N=2371N
The recommended maximum tension rate or working strength of the selected belt is
80N/mm with the belt width 800mm and number of ply four.
Tmax =80N/mm*800mm/4=16000N is the maximum working tension.
80
= = =2
80 ∗ 0.5
The percentage ratio of the tight side tension and the working tension used to determine the
Minimum pulley diameter.
∗ 100%
5334
∗ 100% = 34%
16000
Pulley diameters:
The minimum pulley diameter recommended for particular belt depends up on three
Factors.

1. Carcass thickness
The wire rope diameter in the case of steel cord belts.
 The overall thickness of all plies plus the rubber skins between plies in the case of
 Ply Type belts.
 The overall thickness of the thick woven fabric separating the top and bottom covers
In The case of solid woven belts.
2. Operating tension- the relationship of operating tension of the belt at the particular
Pulley to the belt allowable working tension.
3. Carcass modulus- the relationship between the elongation the carcass and the resulting
Stress. [Technical manual Dunlop conveyor 2012]
Based on this and the % ration of the tension, which is 30% up to 60% the specified
Recommended minimum pulley diameter, are as follows as:
Driven pulley=500mm, Drive pulley=400mm [Fener Dunlop 2009]
7.6 Determination of Power and Motor Selection

The longer length of the belt the more the power required for the conveyor.
To find the required power of the motor that used to drive the system is given by
∗
=
1000
Where,
P= power required to drive the system (KW)
V=belt speed (m/s)
TE=effective tension (N)
P=2963N*2.8m/s/1000=8Kw
Based on this power to select the appropriate types of motor that can be drive the system,
The types of motor which is selected permanent magnet servo motor with the following
Parameters.215mm frame at, 8.6 Kw, 1500rpm, 55mm unit price us$200.0 which is equal to
4115.3 birr, model number 215YSA15F number of poles is 8, speed constant, and function
Drive and control.
The efficiency of motor power is given by
( )( )
Efficiency = ( )( )
∗ 100%
= .
∗ 100% = 93%
To determine the maximum belt tension at start up and the appropriate belt strength
Depending on the following points.
 Installed motor power
 The belt speed
 The belt width
The maximum belt tension at start up can be calculated with. [Technical manual Dunlop
conveyor2012]
3.2 ∗
=
∗
Where,
F= the belt tension at start up (N/mm)
P=motor power (KW)
V=belt speed (m/s)

B=belt width (m)
3.2 ∗ 86
= = 12.3
∗ 0.8
The appropriate belt strength easily calculated by the following formula

∗ 54
=

Where, η=splice efficiency and its value is determine based on the number of plies and ply
Steps. For number of plies is 4and 3ply step the value is 0.75.
Ts=the tensile strength (N/m).
∗ 54
= = 88.56
0.75
The output revolution is can be determine based on the pulley diameter and belt speed and it
Can be calculated as follows.
∗ ∗
=
60
Where, V=belt speed in m/s
D=pulley diameter in mm
N =revolution in rpm
From the above equation to be evaluate the revolution
∗ 60
=
∗
.
∗
= . ∗
=105.66rpm
The extra diameter of pulley to provide the purpose of lagging is 6mm
For designing a flat belt drive involves including the following information.
 Power
 Speed of the drive unit
 The speed of the driven unit
 The desired center distance, and
 The service condition.
So based on the input data the following parameters are calculated as follow.
Input data
 Power=8.5KW
 The allowable tensile strength of the material=1.7Mpa
 Driven pulley diameter=500mm
 Drive pulley diameter=400mm
 Revolution of motor shaft=1500rpm
From= =

1 ∗ 1 1500 ∗ 400
2= = = 1200
2 500
∗ ∗ ∗ ∗
The velocity ratio = = = 10
∗ ∗
The centrifugal stress =
( ∗ ( ∗ )
Where w = specific weight of belt material = = 0.102
The power transmission /mm2 areas, p/mm2 σ1
= ∗ ∗ , where = = 0.598
1.7 − 0.102
= ∗ 0.598 ∗ 10 = 0.096
100
The areas of cross section of the belts
Figure 10 motor selection

∗
Area, A = = = 83.33
.
Then the belt width will be, a= b*t

Where, t =10 mm from the standard.
1267.38
= == 12.738
10
The distance between two pulley (c) is depends on the service condition. So for this
Application c =1000 mm, then the length of the belt, L can be determine by the relation,
1
= (4 )−( − ) + ( ∗ 1+ ∗ )
2
− 500 − 400
1 = 180 + 2 sin ( )∗ = 180 + 2 sin ( )∗ = 3.1916
2 180 2 ∗ 1000 180
− 500 − 400
= 180 − 2 sin ∗ = 180 − 2 sin ( )∗ = 3.041
2 180 2 ∗ 1000 180

1
= (4 )−( − ) + ( ∗ 1+ ∗ )
2
1
= (4 ∗ 1000 ) − (500 − 400) + (500 ∗ 3.196 + 400 ∗ 3.041) = 3403.59
2
=3.40359m
The power transmitted capacity of driving belt is:
P = (T1-T2) V
P= (7704-3424)10
=42800W
=42.8KW
The factor of safety for the driving belts is the ratio of the allowable tensile strength of the
Belt to the maximum shear stress. According to the maximum shear stress theory
τmax =0.5*Sut
τmax=0.5*1.7N/mm2=0.85N/mm2
1.7
. = = =2
t 0.85
7.7 Design of Shaft

Considering all the resistances including the wrap and bearing resistances to get the torque
From the formula
2∗ ∗ ∗
=
60
Where,
P=power in kW
T= torque in Nm
N= revolution (N=76.4 rpm output)
∗ 60
=
2∗
∗ .
= ∗ . ∗
= 1070 =1.070KNm
The determination of force on the shaft of pulley is shown below. For a pulley weight
of198.9N

Figure 11 design ofshaft

W (pulley weight)
Resolving horizontal and vertical force components
FH=horizontal force component
FV= vertical component
FH=T1*cos6.1° +T2*cos6.1° (30)
FV=T1*sin6.1° +W- T2*sin6.1°
From equation (26) the vertical component force is determine.
The value of T1 =5334N and T2=2371N
FH=5334N* cos6.1°+2371N *cos6.1° =7.661KN
FV=5334N* sin6.1°+198.9N-2371N* sin6.1°=514N
Determination of horizontal load on the pulley shaft the length of the shaft is 1500mm,
Which.is 1.5m.
The horizontal load acting on the point, B, RHB equal to the horizontal load acting on the
Point, C RCH and the value is equal to half of the horizontal force FH .That is
RBH = RVH=
.
RBH=RVH= = =3.83KN
The other reaction force can be calculated using the relationship between forces and bending
moments.
Taking the moment at point, A which is MHA=0
MHA=RBH*0.275m+RCH*(0.275+0.95)-RDH*1.5m.
0=3.83KN*0.275m+ 3.83*(0.275+0.95)-RDH*1.5m.
1.5RDHm=5.745KN
.
= . =3.83m
Therefore the value of the reaction force RAH is equal to the value of the reaction force RDH
which is 3.83KN.
Determine the horizontal moment, using the above horizontal forces can be determined the
horizontal moment as follows.

The moment at B, MBH=RHB*0.275m

MBH=3.83KN*0.275m=1.052KNm
Moment at C, MCH=RCH*0.275m=3.83KN*0.275m=1.052KNm.
Determination of Vertical Load
Point load at B, and at point C, are represent by RBV and RCV respectively. And its value
can be determined from the vertical load FV.
RBV=RCV= which distribute load of FV.
RBV=RCV= = =0.257KN
MAV=0
=RBV*0.275m+RCV*(0.275+0.95= RDV *1.5m.
=0.257KN*0.275m+0.257KN*(0.275+0.95)-RDV *1.5m. =0
=0.406KN=1.5RDV.
.
RDV= . =0.2708KN
The value of RAV is similar to the value of RDV since it is distribute load which is
0.3269KN.
Calculate Vertical moment

Moment at point B, MBV=RBV*0.275m

=0.257KN*0.275m=0.07068KNm.
Moment at C, MCV=RCV*0.275m
=0.257KN*0.275m=0.07068KNm.
Resultant moment at point B is denoted MBR= ( + )
MBR= ( . ) +( . ) =1.055KNm
Resultant moment at C, MCR=√ +
MCR= (0.07068 ) + (1.052 ) =1.055KNm
Therefore the value of MBR=MCR=1.055KN-m.
Then calculate the equivalent torque (Teq)
Teq = (( ∗ ) + ( ∗ ) )
Where T=torque=1070Nm=1.070KNm
Kb=bending service factor=1.5
Kt=torque service factor=1.25 then equivalent torque Teq is
Teq = ((1.052 ∗ 1.5) + (1.070 ∗ 1.25) )=2.65KNm
∗
The allowable (maximum) shear stress = ∗
For the maximum shear stress is calculated from the minimum of 30% of the yield strength
And 18% of the ultimate tensile strength of the shaft material times 75%.
Take the minimum of
=0.3Syt, Sty=1150Mpa
=0.3*1150Mpa=345N/mm2
=0.18Sut, Sut =1400Mpa
=0.18*1400Mpa=252N/mm2 which is the minimum values.
Then, τmax =0.75*252N/mm2=189N/mm2.
Determine the shaft diameter (d)
∗
d= ∗
d=41.48mm but for the standard manufacturing the shaft diameter is
50mm
Factor of safety (F.S)= ∗ , since the shaft material is ductile

FS= ∗ =3
7.8 Selection of Bearing

Bearing is a mechanical element that permits a relative motion between two parts. Such as
Shaft and housing, with minimum friction. The main function of bearings is:
 The bearing ensures free rotation of the shaft or axle with minimum friction.
 The bearing supports the shaft or axles and holds it in correct position.
 The bearing takes up the forces that act on the shaft or axle and transmits to
The frame (foundation).
There are so many types of bearings but for this design select the rolling contact type ball
bearing. Since the rolling contact bearing have the following advantages over the sliding
Bearing.
 Low starting and running friction except very high speeds
 Ability to with stand momentary shock loads
 Accuracy of shaft alignment
 Low cost of maintenance, as no lubrication is required while in service
 Small over all dimensions
 Reliability of service
 Easy to mount and elect
 Cleanliness
A ball bearing consists of an inner race which is mounted on the shaft or journals and an
outer race which is carried by the housing or casing, in between the inner and outer race anal
is placed.
Figure 12 Radial ball bearings and housing

When a ball bearing supports only a radial load (WR), the plane of rotation the ball is normal
to the centerline of the bearing.
Table 2 application and life of bearing

Application of bearing Life of bearing hour
Machine working intermittently, while break

down would
Have serious consequences, and auxiliary 8000_12000
machinery
Power station, conveyor plant for flow

production lift
Cranes for piece good and machine tools used
frequently
Tables 3 X and Y factors for ball bearing
Fa/cCO Fa/Fr<e Fa/Fr>e E
X Y X Y
0.025 1 0 0.56 2.0 0.22
0.040 1 0.56 1.8 0.24
0.070 1 0 0.56 1.6 0.27
0.130 1 0 0.56 1.4 0.31
0.250 1 0 0.56 1.2 0.37
0.500 1 0 0.56 1.0 0.44
Table 4 dimension and static and dynamic load capacity of ball bearing
Dimension(mm) Basic load rating Designation
D D B C Co 61809
45 58 7 6050 3300 16009
_ 75 10 15600 9300 6009
_ 75 16 21200 12200 6209
_ 85 19 33200 18600 6309
_ 100 25 52700 30000 6409
_ 120 29 76100 45500 6509
_ 65 7 6240 4250 61810
50 100 21 43600 2500 6211
1. Determine the radial and thrust force the value from the calculation:
Fr=7.661KN
Fa=514N
Shaft diameter=48mm
2. Determine the value of X and Y which is the radial and thrust factor respectively.
3. Calculate the equivalent dynamics load (Pe)
Pe=X*Fr+y*fa
Where from the table, X=0.56 & Y=1
Pe=0.56*7661N+1*514N=4805N
4. Make a decision the excepted bearing life is 8000hr.
∗ ∗
L10= =24792 million revolution
5. Calculate the dynamic load
C=P (L10)1/3

C=4805(247.92)1/3=30185.4N
6. Select the types of bearing for this application bearing number 6309(C=30185N) is
suitable.
Bore diameter 45mm and outside diameter=85mm.
Design of bearing cap and bolts
Depending on the ratio of the length of bearing to the diameter, the following parameters
determine from the table.
= =0.23,Where, B = bearing length
D = outer diameter of bearing absolute viscosity (Z) = 0.06 kg/ms
The bearing pressure (p) =12.6 Mpa
The working temperature at z =0.06kg/ms is (to) 30co
.
Coefficient of friction ( )k= = =0.233
= ( )( ) +k
= (0.7) (0.001) +0.23=0.233
When split bearing is used, the bearing cap is tightened on the top. The load is usually cared
by the bearing not the cap. For the cap and the holding down bolts must be designed for full
load. The cap is generally regard as a simple supported beam, supported by holding down
Bolts and loaded at the center.
Figure 12 bearing cap

W=load supported at the center
a= the distance between the holding down bolts
l= the length of the bearing and
t=the thickness of the cap
The maximum bending moment at the center is
∗ ( ∗ . )
M=( ), a= ( ) = .
=1.02m
The section modulus of the cap
∗ ∗( . )
Z= = =19.6557
=0.00196
.
= = .
=537.24KN/

∗ . ∗ .
t= (3 ∗ )/2 = ∗ . ∗
The deflection of the cap should be limited to about 0.025mm

In order to design the holding down bolt, load on each bolt is taken 33% higher than the
Normal load on each bolt. In other words, load on each bolt is taken , where n is the number
of bolts used for holding down the cap. Let dc = core diameter of the bolt, and σt =tensile
stress for the material of the bolt= ( ) 2 ∗ = from this equation the core
Diameter is determine. Dc = 17.2mm.
7.9 Selection of Key

Key is can be defined as a machine elements that is used to connect the transmission shaft to
The rotating machine elements, like pulley, gear, sprocket or flywheel. There are different
Types of keys. These are:
 Saddle and sunk key
 Square and flat key
 Taper and parallel key
 Key with and without gibe head
The selection of key for a given application depends on the following factors
1. Power to be transmitted
2. Tightness of fit
3. Stability of connection
4. Cost
For this design to select the sun key, because of sunk key is suitable for heavy application
duty since there is no possibility of the slip around the shaft. It is the positive drive over the
saddle. Sunk key has a square or rectangular cross- section is widely used in practices. The
rectangular cross-section is a flat key. While the selection of the rectangular cross section
sunk key without stress analysis according to thumb rule dimensions as follows.
= ,ℎ= , = 1.5
Where,
d=shaft diameter=50mm
b=width of key (mm)
h=thickness or height of key (mm)
L= length of key (mm)
b=13mm, h= 8mm, L=75mm
Key size=b*h =104mm, key depth=6.0
7.10 Design of Frame

Frame is one of the belt conveyor components and its function is to support all parts and load
s that exert by the system.
Equivalent length of frame
According to Euler’s formula the crippling load for equivalent length of column calculated
As
Pc =
Where, L is the equivalent length or effective length of the column. The relation between the
equivalent length (L) and actual length (l) for the given end condition is shown in the
following table.

s.no End condition Relation b/n effective length(l) and actual

length(l)
1 Both ends hinged 1
2 Both ends fixed ½
3 One end fixed and other end hinged 1/√2
4 One end fixed and other free 2I
Table 5 end condition and the relation between effective length and actual length
Total load =life load + dead load

528Kg +57.82KG =585.82Kg
W = mg
585.82*9.81 =5746.87N
Since there are four pairs of column frame the above load should be distributed equally. So
The load on each column frame obtained by:
.
Load on each column frame=
= =718.385N
Figure 13 frame of conveyor

Functional length =720mm of support column frame is required for easy operation and
ergonomically for workers. Consider column AB of length L is fixed at both ends effective
length le =
=360mm
Least moment of inertia
ℎ
= −
12 12
∗ ∗
I= − =9.145578*10 mm
Modulus of elasticity of grey cast iron is 200KN/mm2
=
Where pc= crippling load
Le=effective length
∗ ∗
= =139297.8395
( )
Safe load (Ps) =
.
Ps=

Ps = 46432.61N Ps > load on column frame.46432.61N>718.35N, hence the design is safe

CHAPTER EIGHT
COST ANALYSIS OF THE BELT CONVEYOR

From the back ground that stated the
Number of belt conveyor operator four workers and one conveyor engineer will be
Needed. The paid monthly wage of the four operators is 600 birr for each and the total
Monthly and yearly paid wage 2400 birr and 28800 birr respectively. The monthly paid
Wage of the engineer is 3000 birr and yearly wage is 36000 birr .The total yearly cost of the
Operator and the engineer is 64800 birr. In the table below illustrate the list of the parts and
The cost of each.
Table 6 cost of conveyor parts

S.NO Component Quantity Unit cost in Total cost in
birr birr
1. Belt 1 1300 1300
2. Bearing 4 140 560
3. Shaft 2 350 700
4. Pulley 2 180 360
5. Idler(roller) 9 130 1170
6. Frame 4 150 600
7. Driving belt 1 160 160
8. Motor 1 4100 4100
9. Bolt and nut 10 8 80
10. Vertical stand 8 10 80
Total 42 9110
From the above table the total cost of the material is 9110 birr and for a dual system of a
Belt conveyor 18891 birr. The total labor cost is 64800 birr and the manufacturing cost is
5000 birr. Then the total production cost of the belt conveyor is the sum of the labor cost,
The material cost and the manufacturing cost, which is equal to 88355birr
CHAPTER NINE
PART AND ASSEMBLING DRAWING

Figure 14 roller shaft
Figure 15 roller

Figure 16 horizontal conveyer frame
Figure 17 bearing cap

Figure 18 conveyer pulley
Figure 19 vertical stand of conveyer

Figure 20 flat driving belts
Figure 21 conveying belt

Figure 22 assembly drawing of belt conveyer

Table 7part name
CHAPTER TEN
10 CONCLUSIONS AND RECOMMONDATION
10.1 Conclusion
Industrial attachment sends me to the expected destiny of practical life. By completing this
report
I have got overall idea of industrial processes and these may be helpful to know about the
technical and management knowledge of industries and related organizations. This Internship
program will help me in the further challenges of life. I try my best to make this project
enriched with lots of different documents. And also when I stayed in the internship program,
I followed and I have to identify the problems with putting my suggestion for the solution of
those problems
10.2 Recommendation
All the following recommendations should be addressed for the responsible persons and
company departments if they want to achieve success. However, the recommendations should
be treated as flexible guidelines. So based on the study, I want to recommend that, the
company should use the proposed system to solve all the problems exist in each packing lines
of production department.
To the company:-
I am very much delighted and thankful to the organization for allowing me to do internship in
their organization. I got the platform to have exposed on the industrial processes and enhance
my knowledge and ideas. I am grateful for providing me such opportunity. I would also like
to provide some suggestions and recommendation which I believe that it would enhance the
quality of its applications.

Improve its salary: - There is no skillful worker like engineers, economists, and the like in
the company, b/c the company pays a little salary for them and also there is no additional
benefit for the employers, and it causes less responsibility for the workers.
Thus the company should improve its salary and hire a skilled manpower. The seal and level
work space changed by machine, because to facilitate the activity the human power must be
substitute by machine. The company will reduce excess cost of employees especially for the
temporary workers hires due to lack of knowing the standard time as each packing line. The
amount of products packs per shift will be increased.
Proper manipulation of documents: In my view, proper handling of documents based
on some scientific method are needed to accommodate all the files and documents that would
result on better work processes and those files could be easily accessed whenever required.
Unnecessary delay, idle times and bottleneck activities will be reduced.
Lack of spare parts:-there are no enough spare parts for each machines, because of this
the machines will cease during the work time. Therefore the company should ensure the
availability of the spare parts. Most of the time the company not used good performance
operators, therefore this must be corrected.
Modern managerial system: - on the company there is no a strong link b/n top
managers and their followers, which creates unwillingness on the workers. So to
*overcome such problems the company should organize the managerial system.
Improper use of machines:-during starting and breaking of the machine there is no
care; this leads reduction of the life time of the machines and also creates manual operation of
machines rather than automatic operation. Thus the company should command strict
regulations to machine operators and workers for proper use of machines
To the University/Department:-
I am very much delighted and thankful to the university/department for allowing me to do
internship or practical education in the industry. Next I would also like to provide some
suggestions and recommendation which I believe that it would enhance the quality of
education for students.
The initiative by the college management for field visit to the respective organization
where the students were undertaking their internship program during internship hour was
highly appreciable. However, due to the problem of our country we didn’t access it thus
establishing corporate relationship with tertiary institutions within the sub-region is very
important.
The UIL (university industry linkage) should give an attention in placement of students,
rather than throwing them to some place. The UIL should place the students in a place where
they get enough work experience.
REFERENCE
 I) Amir Jauidiinejad, structured Teaching of machine Design for future Design
Engineers, International Journal of Mechanical Engineering and Technology,
3(2), 2012, pp 120-127
 II) [zazzal and Elnashar ahmed 2007]
 III) [ESPEE LAGE.W 2003].

 IV) [Ananthetal 2014].

 V) [Xiangwei Liu, et al. (Elsevier, Measurement, 2016]
 VI)[Terry King Pr. Eng. Design Engineer to the Bosworth Group of Companies ]
 VII) [Gys van Zyl, Abdul Mohsin and Al Sahli (Sabib T&I, 2013)]
 VIII) Daniyan (JAET, Jan 2016)
 IX) Harshavardhan A. Kadam, et al. (IJETT, 2016)
 X) Mr. Memane Vijay S, et al, (JETIR, May 2015)


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HOST COMPANY N2ST FLOUR FACTORY

PROJECT TITLE BELT CONVEYER

SUBMITTION DATE 19/2/2011 E.C

Declaration of the student

Approval of the mentor

Name of adviser signature date

PREPAIRED BY: - NUREDIN HASSEN Page I

PREPAIRED BY: - NUREDIN HASSEN Page II

PREPAIRED BY: - NUREDIN HASSEN Page III

PREPAIRED BY: - NUREDIN HASSEN Page IV

4.1 Introduction .......................................................................................................... 19

PREPAIRED BY: - NUREDIN HASSEN Page V

PREPAIRED BY: - NUREDIN HASSEN Page VI

Part I Internship report

 High quality products and services

 Value in return for money invested

 Respect and dignity for employees

 Continuously engage in employee and product development

 Invest continuously on advanced technology where practical and

 In calculate cost consciousness without compromising product excellence

 Give priority to understand customers’ needs and meet their specific

 Develop team spirit and sense of ownership

 Embrace open lines of company-wide communication

PREPAIRED BY: - NUREDIN HASSEN Page 2

 Trust and transparency

 2) Optimize return on capital investment for shareholders through continuous

1.6 Companies main product

PREPAIRED BY: - NUREDIN HASSEN Page 3

PREPAIRED BY: - NUREDIN HASSEN Page 4

1.8 The overall organization and work flow

Wheat storage Vice director

Drying storage Secretary

Final product Marketing office

Figure 1 over all organization flow

PREPAIRED BY: - NUREDIN HASSEN Page 5

Flour Flour Kut

Double pin plane sieve

Figure 2 work flow of company

Figure 3 Filter and elevator

PREPAIRED BY: - NUREDIN HASSEN Page 7

PREPAIRED BY: - NUREDIN HASSEN Page 8

Figure 4Cleaning machines

PREPAIRED BY: - NUREDIN HASSEN Page 9

Figure 5bucket elevator

PREPAIRED BY: - NUREDIN HASSEN Page 10

Figure 6 sifter for flour

PREPAIRED BY: - NUREDIN HASSEN Page 11

Figure 7 milling machine

PREPAIRED BY: - NUREDIN HASSEN Page 12

PREPAIRED BY: - NUREDIN HASSEN Page 13

Figure 8packaging section

2.3 work flow in the section

2.4 Challenges that facing the working tasks

PREPAIRED BY: - NUREDIN HASSEN Page 14

PREPAIRED BY: - NUREDIN HASSEN Page 15

Improving our practical Skill

PREPAIRED BY: - NUREDIN HASSEN Page 16

 Sharing experience among the groups

 Leader ship skill

PREPAIRED BY: - NUREDIN HASSEN Page 17

 Keep the rule and regulation of the company

 Knowledge and creativity

PREPAIRED BY: - NUREDIN HASSEN Page 18

PREPAIRED BY: - NUREDIN HASSEN Page 19

Agazi.L & Migbey.T

Agazi.L & Migbey.T