Material Handling Device

Tushar kumar rakshit Vikas porwal Gurusharan kumar

Prof. Dr. Arun Tom Mathew
Project Guide
Prof. Raja Annamalai A.
Project Reviewer
HARDWARE PROJECT- FINAL REVIEW
School of Mechanical and Building Sciences,
VIT University, Vellore - 632014
Introduction
A material transfer device is a mechanical device to transfer
materials like raw material, finished product, and to transport semi
finished product from one part of the industry to other. Commonly
used material transfer devices are conveyer, cranes, truck, trolley,
etc.
In industries like steel, iron finished products are made using billet as
a primary input and transferring such big and heavy rectangular
blocks is a very difficult task. So there is a need of simple transferring
mechanism like conveyer to transfer billet safely without damage to
transferring machine. For this we are designing a conveyer
mechanism to segregate and transport billets in such industries.
For transferring billets we are using a conveyer system which
performs the task of both transferring the billets to desired destination
and to segregate them while transferring.

Hardware Project - Second Review , School of Mechanical and Building Sciences 2
Market survey
In starting our emphasis
was laid on designing and
dimensioning of structure.

We made work strategy
as depicted in the work
flow chart and
accordingly did market
survey to check
availability of desired
parts.

Designing and dimensioning of
components
Market survey to check the availability
Purchase of component and moving
forward
Yes

No
Work flow chart
Dimensioning of Geneva
Mechanism
To determine drive crank radius a
b = geneva wheel radius c = center distance = b/cos(180/n)
n = driven slot quantity a =drive crank length = (C
2
-b
2
)
p = drive pin diameter s = slot center length = (a + b) - c
t = allowed clearance w = slot width = p + t
z = stop disc radius = y-t v = clearance arc = bz/a
y = stop arc radius = a-(p1.5)

Results
We choose driven wheel calculations and results are
as follows:

b= 7 cm n = 4 p = 1cm t = 0.2 cm
c = 14/cos(180/4)= 9.89 cm
a = (9.89
2
+ 7
2
) = 7 cm
w = p+ t = 1 .2 cm y= a-p1.5 =5.5 cm
z = y-t = 5.35 cm v = bz/a = 5.35 cm

Calculation for gear selection
Since we have to segregate the billets, we have designed the
mechanism in such a way so that it transfers one billet at a time.
To accomplish that a pair of gears is used in conjunction with
Geneva wheel.
Since its a four slot Geneva it will rotate 90deg. In every complete
rotation of drive wheel.
Billet size we have assumed to be of 3cm width.
Therefore, =
Where: = angle turned by geneva/drive gear.
r = Radius of Drive gear.
L= Circumferential length of drive gear (width of bille)

2
= 3
r= 1.909cm

Calculation of shaft diameter
T= twisting moment.

T= P*60/(2*3.14*N)
POWER = f* v= mgu*d/t
=9.81*0.25*0.3*15*0.65*3.14/(60*4)= 0.08 J/s
T=0.0509 N-m.
Therefore using above relation d is found as
d = minimum diameter of shaft=9.049 x 10^-4 m.

Tau(t)= allowable shear stress= 350 Mpa
Considering twisting moment (neglecting bending moment
since it is very small.
Problems Faced in Geneva construction
Geneva has a complex design and also it was
difficult to get in metallic form according to our
dimension.
Due to small size of drive gear if we use it directly,
the instantaneous speed which is transferred to
conveyor will be high and will result in a jerk and
other billets may fall with it and also may get
damaged.
The Geneva mechanism has to be placed at a
certain height in some stand which should not
arrest its motion.


Solution
To rectify our first problem we decided to use wood
instead of metal. It is easy to make complex designs
on wood and cut them .
To rectify speed and jerk problem We decided to use
a large gear in mesh with the smaller gear so that
circumferential length rotated in one revolution is
same but speed will get reduced.
To solve the problem of height and arrested motion
we had decided for a stand with bearing so that we
can get height and free rotation of shaft also.



Construction of shafts
We did a market survey to insure the availability of required
things but we didn't get things as we needed and some of them
we found very costly so we made changes according to it.

Initially we went for search of gears to transfer power to
conveyer shaft through Geneva be we couldn't get the gears
and bearing of the same diameter so we decided to go for
stepped shaft .

It if very difficult to get a iron stepped shaft of desired diameter
so we thought to go for wooden shaft. Therefore we contacted a
carpenter for wooden shaft and gears and bearings were
assimilated.
Problem faced and solution sought while constructing
shaft.
Problem 2 :
We were thinking of using wooden shaft for
sprockets but with that it is very difficult to make
shaft that completely lock with sprocket and it is
cost ineffective also so try to avoid it where ever
we could .
Solution 2:
We used only one wooden shaft as the driving
shaft for remaining two shafts we used back
wheel hub this reduced our cost .

Problem faced and solution sought in drive mechanism
for conveyer


Problem 1:
We were thinking of using wooden wheel with a belt
drive but there was a high chance of slipping i.e.
Traction problem with belt drive.

Solution 1
To overcome the problem of wooden wheels we used
sprockets with chain as conveyer so as to avoid
traction problem and to get free rotation of wheel on
the shaft without using bearings .

.

Construction of mounting structure for Geneva.
So according to the calculations done we made
Geneva design on wooden plank.

Then we moved on to make a supporting structure
for the mechanism. We decided to take a vertical
board on which holes for the shafts can be made.
To ensure free rotation of shaft on the board we
used bearing inside the hole. Also since we had to
attach a gear to driven wheel shaft we had opted
for a stepped shaft.

Problems faced and Solution sought
Initially we made the design of Geneva mechanism on a
wooden board and tried to cut it by ourselves. Therefore
we sought help from assistants at the workshop to get the
required design.
For making wooden shafts turning operation was done but
constant depth of cut was not maintained, therefore it
resulted in one of the shaft being eccentric. We are still
working on solution.
Welding the two wheel hubs in straight was difficult and
therefore to overcome the problem we utilised the threads
over the shaft of hub and used a nut to hold the hub in
straight line and then welding was performed.


Hardware Project - Second Review , School of Mechanical and Building Sciences 14
Assembling parts
our work was focused on assembling the shafts and preparing
supporting structure for shafts .
For the back two shafts we tried to avoid use of wooden shafts
and therefore we utilised back wheel hub to form shafts. our
added advantage was that it already had bearings to make it
motion independent from shaft.
For making supporting structure we used rebar's and square
pipes. For providing rigid connections to shaft welding was
performed. First we made a plateform using square pipes after
on which rebars attached to bearings were welded. To provide
strength and rigidity to structure a rod was welded from first rebar
to last one in the middle portion at some angle.arc weld.


Hardware Project - Second Review , School of Mechanical and Building Sciences 15
THANK YOU!
Hardware Project - Second Review , School of Mechanical and Building Sciences 16