Design And Fabrication Of Industrial Conveyor Using Crank Mechanism
The title “Design and Fabrication of Industrial Conveyor Using Crank Mechanism” encapsulates a comprehensive engineering project that involves the development and construction of an industrial conveyor system driven by a crank mechanism. This endeavor encompasses the integration of mechanical engineering principles to create a dynamic and efficient conveyor tailored for industrial applications. The utilization of a crank mechanism adds a unique dimension to the design, enabling precise control and smooth motion in transporting materials within the industrial setting. The engineering challenge lies in optimizing the conveyor’s structural integrity, ensuring seamless operation, and incorporating safety features. This project not only demands expertise in mechanical design and fabrication but also underscores the importance of innovation in addressing the specific requirements of industrial conveyor systems, showcasing a meticulous blend of theoretical knowledge and practical implementation.
This machine is basically works on the principle of Single Slider Crank Mechanism. Which is the heart of this machine and it converts rotary motion into a reciprocating motion. Here Fabricated the conveyor using crank mechanism machine, this project can be utilized in industry. Industries in worldwide use conveyors as a mechanism to transport boxes from place. This mechanism do not includes strong belts, pulleys and heavy motors to rotate the pulley to move the conveyor. As an alternative to this conveyor type, more simple and comfortable machine using four bar mechanism can be used. This box shifting machine helps in transfer of boxes smoothly by use of four bars with a simple arrangement. The four bar mechanism includes four links. One link is fixed and the other links act as crank, follower and connecting rod. The rotary motion of the crank is transferred to the follower by using connecting rod and is converted to the same rotary motion. This machine requires an electric motor to provide input to the system.
CHAPTER ONE
INTRODUCTION
There has been a serious demand for intermittent movement of packages in the industries right from the start. Though the continuous movement is more or less important in the same field the sporadic motion has become essential .The objective of our project is to produce a mechanism that delivers this stop and move motion using mechanical linkages. The advantage of conveyor system is that the system has a time delay between moving packages and this delay can be used to introduce any alterations in the package or move the package for any other purpose and likewise. While in conveyor system such actions cannot be performed unless programmed module is used to produce intermittent stopping of the belt which basically is costly. The prototype design requires electric motor, shafts and the frame of which the frame and platform on which the packages are moved is fabricated. All the links are being made of Aluminium which reduces the weight of the whole system including the head which has a direct contact with the boxes being moved. The system is expected to move as heavy packages as 2 to 3kgs approximately.
1.1 DEFINITION OF THE PROJECT
This machine is basically works on the principle of Single Slider Crank Mechanism which is the heart of this machine and it converts rotary motion into a reciprocating machine to crush the Cans/Plastic bottles. In this, link 1 is fixed and link 2 which is a crank is rotating about fixed link 1 and converts this rotary motion into the reciprocating motion of slider (corresponds to the link 4) by means of connecting rod which corresponds to the link 3. This is the inversion of single slider crank which is obtained by fixing link.
Fig-2:Single slider crank mechanism
About material Handling Starting from the time, raw material enters the factory gate and goes out of the factory gate in the form of finished products, it is handled at all stages between, no matter it is in stores or on shop floor. It has been estimated that average material handling cost is roughly 20 to 60 % of the total cost. It thus, becomes clear that the cost of production of an item can be lowered considerably by making a saving in the material handling cost.
1.2 AIM OF THE PROJECT
The aim of this project is to fabricate the box moving mechanism, which can make easier to move boxes from one section to the other while processing in the factories. In a workstation, an assembly line in order to obtain the required production rate and to achieve a minimum amount of idle time.
1.3 OBJECTIVE OF THE PROJECT
The objective of this work is to:
1. Fabricate a Box transport mechanism which can move things from one place to another
2. Understand project planning and execution.
3. Understand the fabrication techniques in a mechanical workshop.
4. Understand the usage of various mechanical machine tools and also measuring tools.
1.4 PURPOSE OF THE PROJECT
The purpose of this work is to have an easy moving in-and-out of products from one section to the other while processing in the factories.
1.5 APPLICATION OF THE PROJECT
i. We can use this mechanism in medical production fields.
ii. We can use this mechanism in bottle filling process.
iii. We can use this mechanism in cool drinks production companies.
1.6 ADVANTAGES OF THE PROJECT
- Lubricants not
- Simple to construct.
- Low speed motor is sufficient
- Easy
- Less skilled operator is
- Noise of operation is reduced
1.7 SCOPE OF THE PROJECT
In this machine can comfortable for moving the product from one place to another place with safely. The machine is placed and working process is very easy for using persons. In this machine, the control unit is control the motor drive for rotation of the crank shaft .The motor is placed and the crank shaft is attached with the motor with the help of bearing. The products are safely placed in the stored place and then motor is ON. The crank is rotated and the first box is move from first place to second place in the first rotation, after that the second box is placed in the first position, the second rotation is started the first box is move from second place to third place , in the mean time the second box is move from first place to second place . In this based the boxes are move from one place to another place simultaneously .The products are safely transfer from one place to another in conveyor using crank mechanism.
1.8 PROBLEM OF THE PROJECT
The problem of the system is the high wear on conveyor drive components due to the repeated acceleration and deceleration required to move goods along the conveyor. Accordingly, prior art linear motion conveyors are frequently designed and constructed in an oversized or “beefed-up” manner to obtain reasonable reliability and acceptable maintenance levels. This oversizing practice inherently increases the cost and weight of the entire conveyor system.
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Design And Fabrication Of Industrial Conveyor Using Crank Mechanism:
Designing and fabricating an industrial conveyor system using a crank mechanism involves several steps, including conceptualization, design, fabrication, and testing. In this guide, I’ll walk you through each of these steps to help you create a functional and efficient conveyor system.
1. Conceptualization:
Before diving into the design process, it’s essential to understand the requirements and constraints of the conveyor system. Consider factors such as:
- Material to be conveyed: Determine the type, size, and weight of the materials that will be transported on the conveyor.
- Distance and speed: Calculate the required conveyor length, speed, and capacity to meet production needs.
- Environment: Consider the operating environment, including temperature, humidity, and any potential hazards.
- Space constraints: Assess the available space for installing the conveyor system within the industrial facility.
2. Design:
Once you have a clear understanding of the requirements, you can begin the design process. Here’s a step-by-step approach:
2.1. Selection of Conveyor Type:
There are various types of conveyors available, including belt conveyors, chain conveyors, roller conveyors, and screw conveyors. Choose the type that best suits your application.
2.2. Crank Mechanism:
The crank mechanism is a fundamental component of the conveyor system that converts rotary motion into linear motion. Design the crank mechanism based on the conveyor’s load capacity and speed requirements. Consider factors such as crank length, crankshaft diameter, and bearing selection.
2.3. Frame Design:
Design a sturdy frame to support the conveyor system and withstand the weight of the materials being transported. Consider using materials such as steel or aluminum for the frame construction.
2.4. Conveyor Belt:
If you’re opting for a belt conveyor, select an appropriate belt material based on the type of materials being conveyed and the operating environment. Design the belt to withstand the load and provide sufficient grip for smooth material transport.
2.5. Drive System:
Choose a suitable drive system to power the conveyor, such as an electric motor or hydraulic system. Calculate the motor horsepower required to achieve the desired conveyor speed and torque.
2.6. Safety Features:
Incorporate safety features into the design, such as emergency stop buttons, guards, and sensors to detect obstructions or malfunctions.
3. Fabrication:
Once the design is finalized, you can proceed with fabricating the conveyor system. Here are the basic steps involved:
3.1. Material Procurement:
Gather all the necessary materials and components based on the design specifications. This may include steel beams, conveyor belts, bearings, motors, and electrical components.
3.2. Machining and Fabrication:
Use machining tools such as lathes, mills, and welding equipment to fabricate the components according to the design drawings. Ensure precision and accuracy during fabrication to maintain the integrity of the conveyor system.
3.3. Assembly:
Assemble the fabricated components, including the frame, crank mechanism, conveyor belt, drive system, and safety features. Follow the assembly instructions carefully to ensure proper alignment and functionality.
3.4. Testing:
After assembly, conduct thorough testing of the conveyor system to verify its performance and safety. Test for factors such as conveyor speed, load capacity, belt tension, and smooth operation. Make any necessary adjustments or modifications based on the test results.
4. Installation and Commissioning:
Once the conveyor system passes the testing phase, it can be installed in the industrial facility. Ensure proper alignment and secure installation to prevent any accidents or malfunctions. Commission the conveyor system by gradually ramping up production and monitoring its performance.
5. Maintenance and Monitoring:
Regular maintenance is essential to ensure the optimal performance and longevity of the conveyor system. Implement a maintenance schedule for lubrication, inspection, and repair of components. Monitor the conveyor’s operation regularly to identify any issues early and address them promptly.
By following these steps, you can design and fabricate an industrial conveyor system using a crank mechanism that meets the specific requirements of your application. Continuous improvement and adherence to safety standards are key to maintaining the efficiency and reliability of the conveyor system over time