ABSTRACT
Belt Conveyor Systems, referred to as BCS, have been used worldwide
for conveying passengers, general cargo and bulk cargo for about 250
years. BCS plays an important role in continuous bulk material transport
in the mining industry, on bulk terminals, in cement plants, power plants,
chemical production, and so on. Compared to other transportation modes
often used for the transportation of bulk solid materials, such as trains or
trucks, BCS are the most encouraged means to transport large volumes
rapidly and efficiently through production processes in areas where
roads and railway infrastructures do not exist or are under-developed.
BCS transports work materials from one point to another with less
consumption of energy and man power. For that, BCS has to work
continuously without any stop even when there is no load on the
conveyor belt. This traditional Conveyor would consume more useful
energy and result in equipment fatigue in less time unnecessary. To
avoid this demerit of BCS we would like to introduce “Energy saving
Conveyor System” that not only saves energy but also increases the
lifespan of the conveyor automatically. The productivity level in an
advanced manufacturing environment can be improved by proper design
of mechanism at the initial stage in the manufacturing system. By using
IR load sensors and smart techniques we can control functioning of
Conveyor system efficiently. Not only that but the approach of modelbased design and simulation was used to achieve optimal efficiency of
conveyor belt during its operation.
Working parameters that can determine the measurable performance of
conveyors were studied and presented in a classical model.
Keywords : Belt Conveyor System ; Conveyor ; Efficiency ; IR-sensors ;
transport ; Modeling ; Simulation ;
CONTENTS
TITLE
0 - INTRODUCTION
PAGE NO
1
0.1- BRIEF CLASSIFICATION OF CONVEYORS
4
0.2- LITERATURE REVIEW
4
0.3- OBJECTIVES OF OUR PROJECTS
4
1 – CONSTRUCTION
5
2 – THE USE OF IR SENSORS
7
2.1 – TYPES OF IR SENSOR
7
2.2 - IR SENSOR REQUIRED FOR ENERGY
SAVING CONVEYOR
2.3-WORKING PRINCIPLE OF IR SENSOR
8
10
3 – DESIGN AND SIMULATION
14
4 – WORKING PRINCIPLE
17
5 – DESIGN CONSIDERATION AND CALCULATION
6 – MATERIALS AND COMPONENETS
REQUIRED
7– ADVANTAGES AND DISADVANTAGES
23
24
7.1 – ADVANTAGES
24
7.2 – DISADVANTAGES
24
8 - CONCLUSION
26
9 - FUTURE SCOPE
27
10-REFERENCE
28
LIST OF FIGURES
TITLE
PAGE NO
Figure 1 -Conventional troughed belt conveyor
1
Figure-2 – Construction of Conveyor belt
5
Figure 3 -Belt conveyor Assembly
6
Figure 4a -IR sensor Circuit
7
Figure 4b- IR Sensor Circuit
10
Figure 5- Schematic representation of sensor
12
Figure 6- Full Assembly without sensor
14
Figure 7-Rope belt
14
Figure 8- Clamp for the Roller
16
Figure 9- base frame
16
Figure 10 - Roller
17
Figure 11-Conveyer Trainer Board
19
1
0. INTRODUCTION
Primitive conveyor belts were used since the 19th century. In 1892,
Thomas Robins began a series of inventions which led to the
development of a conveyor belt used for carrying coal, ores and other
products. In 1901, Sandvik invented and started the production of steel
conveyor belts. In 1905 Richard Sutcliffe invented the first conveyor
belts for use in coal mines which revolutionized the mining industry. In
1913, Henry Ford introduced conveyor-belt assembly lines at Ford
Motor Company's Highland Park, Michigan factory. In 1972, the French
society REI created in New Caledonia the longest straight-belt conveyor
in the world, at a length of 13.8 km. Hyacynthe Marcel Bocchetti was
the concept designer.
In 1957, the B. F. Goodrich Company patented a Möbius strip conveyor
belt, that it went on to produce as the "Turnover Conveyor Belt System".
Incorporating a half-twist, it had the advantage over conventional belts
Figure 1-Conventional troughed belt conveyor
2
of a longer life because it could expose all of its surface area to wear and
tear. Fig. 1.1 shows a conventional troughed belt conveyor.
Conveyors are durable and reliable components used in automated
distribution and warehousing, as well as manufacturing and production
facilities. In combination with computer-controlled pallet handling
equipment this allows for more efficient retail, wholesale, and
manufacturing distribution. It is considered a labor-saving system that
allows large volumes to move rapidly through a process, allowing
companies to ship or receive higher volumes with smaller storage space
and with less labor expense.
Belt conveyors are the most commonly used powered conveyors because
they are the most versatile and the least expensive. Products are
conveyed directly on the belt so both regular and irregular shaped
objects, large or small, light and heavy, can be transported successfully.
Belt conveyors are also manufactured with curved sections which use
tapered rollers and curved belting to convey products around a corner.
These conveyor systems are commonly used in postal sorting offices and
airport baggage handling systems.
Belt conveyors are generally fairly similar in construction consisting of
a metal frame with rollers at either end of a flat metal bed. Rubber
conveyor belts are commonly used to convey items with irregular bottom
surfaces, small items that would fall in between rollers (e.g. a sushi
conveyor bar), or bags of product that would sag between rollers. The
belt is looped around each of the rollers and when one of the rollers is
3
powered (by an electrical motor) the belting slides across the solid metal
frame bed, moving the product. In heavy use applications the beds which
the belting is pulled over are replaced with rollers. The rollers allow
weight to be conveyed as they reduce the amount of friction generated
from the heavier loading on the belting. The exception to the standard
belt conveyor construction is the Sandwich Belt conveyor.
The
Sandwich Belt conveyor uses two conveyor belts, instead of one. These
two conventional conveyor belts are positioned face to face, to firmly
contain the items being carried in a "sandwich-like" hold.
4
0.1. BRIEF CLASSIFICATION OF CONVEYORS
A wide variety of related conveying machines are available, different as
regards principle of operation, means and direction of conveyance,
including vibrating
1. Screw conveyors
2. Pneumatic conveyors
3. The moving floor system, which uses reciprocating slats to move
cargo, and
4. Roller conveyor system, which uses a series of powered rollers to
convey boxes or pallets.
0.2. LITERATURE REVIEW
After verifying all the research works and journals similar to our project,
we were able to guide our project to achieve all the problems they could
not solve through introducing sensors and variable speed mechanism
into conveyors as a result of which we will be able to save more 20%
energy.
0.3.OBJECTIVES OF OUR PROJECT
A. Determining of all the equipments to be bought for making the
prototype
B. CAD designing and analysis of the project through CATIA and
ANSYS
C. Making of prototype model
D. Examining the prototype.
5
1. CONSTRUCTION
One typical layout of BCS is the conventional troughed belt conveyor
(Figure 1.1 and Figure 1.2). The length of a belt in such a system may
vary from 10 m to 20,000 m. The velocity can reach up to 9 m/s and the
width can vary from about 0.3 m to 3.2 m. Today’s the highest capable
belt conveyors carry up to 40,000 tons/hour of lignite at the RWE lignite
mines in Germany (Küsel, 2004). A troughed belt conveyor normally
consists of an endless rubber belt reinforced in the warp or longitudinal
direction by a polyester or nylon fabric or steel cords. The belt is
supported along its length by rotating idler rolls and suspended between
pulleys at either end. A drive pulley is powered to rotate the belt and
Figure-2 – Construction of Conveyor belt
move the materials on the belt forward. A tensioning device, also called
a take-up, applies pre-tension on the belt to limit belt sag and to allow
6
drive power transmission (Figure 1.3). The belt can be stopped by means
of an operational stop utilizing the motors or an emergency stop utilizing
brakes if the BCS has brakes.
Figure 1.3 shows the principle assembly of the system of a belt conveyor.
The configuration and applied components of the system can vary based
Figure 3-Belt conveyor Assembly
on design requirements. Taking the assembled elements into account, a
belt conveyor can be considered as a system that consists of a number of
components. Such a system is as reliable as the combined reliability of
its components. The malfunction of one of the components may lead to
expensive downtime if it causes a total shutdown of the system. The
downtime of one of the conveyors in a sequential conveying system may
result in a stop of the production process. Increasing the reliability of the
components of a BCS, and therefore of the BCS itself, is a direct way to
minimize system downtime and to reduce the cost of downtime for the
companies using belt conveyors. Since a BCS cannot be designed to be
100% reliable and the reliability of BCS components decreases with
7
aging and when wear occurs, proper maintenance techniques are
required to maintain the reliability of the various components and the
system.
2. THE USE OF IR-SENSORS
An infrared sensor is an electronic device, that emits in order to sense
some aspects of the surroundings. An IR sensor can measure the heat of
an object as well as detects the motion. These types of sensors measure
only infrared radiation, rather than emitting it that is called a passive IR
sensor. Usually, in the infrared spectrum, all the objects radiate some
form of thermal radiation. These types of radiations are invisible to our
eyes, that can be detected by an infrared sensor. The emitter is simply an
IR LED (Light Emitting Diode) and the detector is simply an IR
photodiode that is sensitive to IR light of the same wavelength as that
emitted by the IR LED. When IR light falls on the photodiode, the
resistances and the output voltages will change in proportion to the
magnitude of the IR light received.
2.1. TYPES OF IR SENSORS:
 Active IR Sensors:
Active IR Sensors are the type of IR Sensors that employs an IR source &
IR detector (emitter & receiver). They operate by transmitting energy
from either a light emitting diode (LED) or a laser diode. A phototransistor
is used as an active IR detector. In these types of IR sensors, the LED or
laser diode illuminates the target, and the reflected energy is focused onto
8
a detector. Photoelectric cells, Photodiode or phototransistors are
generally used as detectors. The measured data is then processed using
various signal-processing algorithms to extract the desired information.
Active IR detectors provide count, presence, speed, and occupancy data.
 Passive IR Sensors:
These are basically IR detectors; they don’t use any IR source. These
form the major class of IR sensors/detectors.
A passive infrared system detects energy emitted by objects in the field of
view and may use signal-processing algorithms to extract the desired
information. It does not emit any energy of its own for the purposes of
detection. Passive infrared systems can detect presence, occupancy, and
count.
2.2-IR SENSOR REQUIRED FOR ENERGY SAVING CONVEYOR
Obstacle Sensing Circuit or IR Sensor Circuit
A typical IR sensing circuit is shown below. It consists of an IR LED, a
photodiode, a potentiometer, an IC Operational amplifier and an LED.
IR LED emits infrared light. The Photodiode detects the infrared light.
An IC Op – Amp is used as a voltage comparator. The potentiometer is
used to calibrate the output of the sensor according to the requirement.
When the light emitted by the IR LED is incident on the photodiode after
hitting an object, the resistance of the photodiode falls down from a huge
9
value. One of the inputs of the op – amp is at threshold value set by the
potentiometer. The other input to the op-amp is from the photodiode’s
series resistor. When the incident radiation is more on the photodiode,
the voltage drop across the series resistor will be high. In the IC, both
the threshold voltage and the voltage across the series resistor are
compared. If the voltage across the resistor series to photodiode is
greater than that of the threshold voltage, the output of the IC Op – Amp
is high. As the output of the IC is connected to an LED, it lightens up.
Therefore, if we adjust the threshold voltage according to the load then
at a specific minimum load, conveyor starts moving until the load is
unloaded and once unloaded it stops automatically. Basically, we see a
part of this in conveyors of escalator but those sensors are single starter
that is if it starts, even after unloading it does not stop at the moment and
takes time to stop and load detection is for a certain range around 5- 15
m maximum. But if we are looking to incorporate it within a standard
industrial conveyor which spreads over kilometres then those sensors
must be fitted at regular intervals and must be powerful enough and
along with it there should other sensors to monitor there functioning.
And to advantage if we properly design it through simulation to make it
variable speed mechanism that is different speeds for varied loads then
a massive amount of power consumption can be compromised.
10
The threshold voltage can be adjusted by adjusting the potentiometer
depending on the environmental conditions.
The positioning of the IR LED and the IR Receiver is an important
factor. When the IR LED is held directly in front of the IR receiver, this
Figure 4a -IR sensor Circuit
setup is called Direct Incidence. In this case, almost the entire radiation
from the IR LED will fall on the IR receiver. Hence there is a line of
sight communication between the infrared transmitter and the receiver.
If an object falls in this line, it obstructs the radiation from reaching the
receiver either by reflecting the radiation or absorbing the radiation.
2.3-WORKING PRINCIPLE OF IR SENSOR
An infrared sensor circuit is one of the basic and popular sensor module
in an electronic device. This sensor is analogous to human’s visionary
senses, which can be used to detect obstacles and it is one of the common
11
applications in real-time. This circuit comprises of the following
components
 LM358 IC 2 IR transmitter and receiver pair

Resistors of the range of kilo-ohms.

Variable resistors.

LED (Light Emitting Diode).
Figure 4(b)- IR Sensor Circuit
In this project, the transmitter section includes an IR sensor, which
transmits continuous IR rays to be received by an IR receiver module.
An IR output terminal of the receiver varies depending upon its receiving
of IR rays. Since this variation cannot be analyzed as such, therefore this
output can be fed to a comparator circuit. Here an operational
amplifier (op-amp) of LM 339 is used as comparator circuit.
When the IR receiver does not receive a signal, the potential at the
inverting input goes higher than that non-inverting input of the
comparator IC (LM339). Thus, the output of the comparator goes low,
but the LED does not glow. When the IR receiver module receives signal
to the potential at the inverting input goes low. Thus, the output of the
comparator (LM 339) goes high and the LED starts glowing. Resistor
12
R1 (100), R2 (10k) and R3 (330) are used to ensure that minimum 10
mA current passes through the IR LED Devices like Photodiode and
normal LEDs respectively. Resistor VR2 (preset=5k) is used to adjust
the output terminals. Resistor VR1 (preset=10k) is used to set the
sensitivity of the circuit Diagram. Read more about IR sensors.
13
Figure 5- Schematic representation of sensor
DC motor that operated at 12(v)/24(v) DC supply. The voltage depends
upon speed require for the process. This conventional method of
conveyor control is further mobilized by use of dimmers. They were
better option in the case of on off control they can be operated in full
load condition also. But the main problem with them is stoppage of
conveyors. the pneumatic stoppers were used which did not stop the belts
completely but use to stop materials on it. This leads to wear and tear of
the belts as well as the product also the rejection ratio is increased.
Computerized conveyor belt system issued. In this the control of these
belts is achieved by the use of the pc interface and embedded system
based. These lead to better option of conveyor control in today’s
industrial environment. It is very difficult for those to maintain them at
14
constant or through variable speeds. Recently single shop conveyor belt
systems are modified to become multiple type i.e. instead of single
conveyor multiple conveyors are used in series, parallel and speed is
controlled using remote monitoring. Also, the recent trend is3
emerging towards controlling the speed of these conveyors by the use of
computer technology. Conveyors are used in a broad range of industries
and applications to move packaged goods, assemblies, process
byproducts, or any material from one place to another. A process
designer will typically look for opportunities to use the force of gravity
to accomplish product movement. Electric motors are commonly used
when gravity cannot be employed or when the speed of a gravitational
fall needs to be controlled. Airports, mines, cement plants, distribution
facilities, assembly, and food processing plants all utilize conveyors.
Conveyors are typically constant torque loads, meaning the required
torque to drive a conveyor is independent of speed. A fixed amount of
torque is also required to overcome the frictional, or machine drag,
portion of the total load. Conveyors can have nominal amounts of
friction and machine inertia for which to compensate. Material flowing
over the belt may be weighed in transit using a belt weigher.
15
3. DESIGN AND SIMULATION
Figure 6-Full Assembly without sensor
Figure 7-Rope belt
16
Figure 8-Clamp for the Roller
Figure 9-base frame
17
Figure 10 - Roller
4. WORKING PRINCIPLE
The use of IR-sensor enables the conveyor mechanism to detect the load
on the conveyor belt. When a load rests on the conveyor belt IR sensor
senses and sends the signal to processing unit. Processing units activates
the driving wheel of the conveyor, the conveyor transports the materials,
and stops when there is no load on the belt.
Variable Speed Mechanism –
Different load conditions will have different reflectivity for IR rays.
Depending on the conditions of load carrying capacity, threshold voltage
at the potentiometer are adjusted though computer aided control. In other
words, we can say, heavy loads have higher triggering voltages hence
the speed of conveyors will be faster for those and small loads will have
18
lesser speed of conveyor. Hence continuous moving conveyor is now a
variable speed-controlled conveyor achieved through IR sensors.
Problem of High Starting Torque for the electric drive motor that drives
the conveyor is also solved in this process by incorporating AC drives
coupled with IR sensors. Conveyors with a very high starting torque
have the potential to damage both the mechanical equipment and the
power supply. On long conveyors in particular, the loads can be very
high as there is more material on the belt, with higher starting torque and
more current required. Soft starters can be used to reduce the starting
current, but they also reduce the torque. If the conveyor is fully loaded
at start-up, it may not start at all if the torque is insufficient.
The AC drive offers high starting torque combined with low starting
current, eliminating current peaks and voltage fluctuations on the
network. In addition, power factor is close to unity at all times. With a
more stable network, all electrical equipment on site will run more
reliably, increasing productivity and reducing the need for
maintenance. Smooth starting with accurate torque also minimizes belt
stretching and slippage. On belts that are already stretched, the AC
drive minimizes the risk of slippage.
19
Figure 11-Conveyer Trainer Board
20
5. DESIGN CONSIDERATIONS AND CALCULATION
Li = (mass of idlers – mi)/ (spacing between idlers-l)
Lc = cc/v
Notations and specific values
Tb= belt tension
Tp= tension in pulley
Fx= friction coefficient = 0.02
Fy= run factor of conveyor=0.014
L= length of conveyor(mm)
Li= idler load(kg/m)
Lb=load effect of belt (kg/m) =17kg
Lc=load of conveyor material (kg/m)
H= conveyor height(m)=20mm
Pp= power required by drive pulley(kw)
Pm= power required to drive the electric motor
v=speed of conveyor belt(m/s) =2.4m/s
A=conveyor belt acceleration(m/secs)2
Bf= belt fracture strength
I= spacing between idler=240mm
D=diameter of driving pulley=0.62
T=ambient temperature
N=number of revolutions per minute=75 rev/min
g= acceleration due to gravity=9.8 m/s2
21
δ=angle of inclination of conveyor (in degrees) =6
Tt=operating time=12s
Sk=start up coefficient
Cc= capacity of conveyor=400kg/sec
Cr=factor responsible for friction to occur
Mi= mass of idler
1. Li= mi /I =20/1.4=14285.71 kg/m
2. Lc=Cc/v =400/2.4=166.66 kg/m
3. Tb= 1.37=Flg(2Li+2Lb+Lc) cosδ+HgLc=
1.37*0.02*240*10-3*9.81[(2*14285.71) +(2*17) +166.66] +
(20*10-3*9.81*166.66) =1878.633N
4. Pp= Tb*v /1000 kw = 1878.633*2.4/1000=4.508 kw
5. Pm= Pp/ Df = 4.508 /0.9 = 5.0088 kw
6. Tt = 60 A = 60* 0.136=8.161
7. V= Ꙥ*D*N /60 m/s =Ꙥ*0.62*75 /60 = 2.435 m/s
22
8. Hp = (Pp+Pm) *1.05 kw
= (4.508 + 5.0088) *1.05 kw
= 9.9926 Kw
9. Tp = Tb + Sk= 1878.633*1.5 = 2817. 9495
10.
A (Tp – Tb)/ L (2Li + 2Lb+ Lc = 939.316/ 6985.2992= 0.136
m/s2
23
6. COMPONENT USED AND FINAL COST
NAME
PRICE
NO.
COST
CONVEYOR CONTROLLER
3500
1
3500
RELAY MODULE
600
1
600
MOTOR
400
1
400
BATTERY
800
1
800
ROLLER SETUP AND BELT
3000
1
3000
OBJECT SENSOR IR
500
2
1000
LED LIGHT
20
1
20
L CHANNEL MATERIAL
1500
1
1500
PAINT
500
350
OTHER
3000
2500
MODULE
TOTAL
Estimated cost = Rs 14320
Final cost
= Rs 13670
Hence the project is feasible as per price is concerned
13670
24
7. ADVANTAGES AND DISADVANTAGES
7.1 Advantage:
1. Minimises Expenditure
Automated conveyor systems would speed up productivity. The work
can get done faster and with less energy and people than with manual
equipment. It is an economical investment.
2. Improved efficiency
Workers are better able to do their tasks using automated equipment,
meaning they can work much more efficiently. The automated conveyor
system will consume less energy for the same amount of material
transport compared to traditional conveyor system as it has the ability to
sense when it has to work and when to stop.
3. Reduce accidents
Employee safety is a top concern for businesses in the industrial sector.
As this conveyor system stays idle when there is no material on it to
transfer there is a reduced chance of accidents to occur.
4. Avoiding Fatigue
As there involves idle time when there is no material on the conveyor,
the continuous working of the belt and associated equipment are
avoided. Eventually the lifespan of conveyor increases to a great extent.
7.2 Disadvantage:
1. Initial cost of equipment
The initial cost for IR equipped smart conveyor system would be high.
However, the less energy consuming and automatic smart conveyor will
eventually pay for itself.
25
2. Reduced flexibility for change
Once systems are in place, it is likely not as easy to make changes in
your workspace. But once you go automated and see how smoothly
everything runs, it’s not likely you’ll want to return to manual equipment
afterward.
3. Possible downtime due to malfunction
With automatic machines there is always the chance of a problem or
breakdown, which can lead to considerable downtime while it is
repaired. If the problem cannot be fixed by anyone on site, an outside
specialist may need to be called, which could mean more time spent
waiting. Equipment malfunction can be avoided in most cases with
routine maintenance of all machinery. If proper care is taken to keep
automated systems in good shape, breakdowns should only occur rarely.
4. Maintenance costs
Equipment needs maintenance. Routine maintenance may be performed
regularly by onsite workers, but periodic professional maintenance
should be handled by specialists who are trained to inspect and tune-up
machinery so that it runs smoothly and efficiently, easing the overall
lifespan of your systems.
26
8. CONCLUSIONS
By employing the automatic conveyor at the level crossing, the
arrival component, we can reduce the consumption, neglect the
unwanted motion of the conveyor and to avoid wastage on life duration
of conveyor and its equipments
27
9. FUTURE SCOPE
Further much more accessories and modifications such as
1. use of variable speed gear motor and
2. pocket belts
will increase its applications, effectiveness in various fields.
If the enlarge scaling of machine is done then it may be used to
accurately count the large object such as in food processing industries.
28
10. REFERENCES
1. Konakalla Naga Sri Ananth1, Vaitla Rakesh2, Pothamsetty Kasi Visweswarao –
“Design and Selecting the Proper Conveyor-belt” - International Journal of
Advanced Engineering Technology Vol. 4 issue 2- April 13, 2012
2. Shalom Akhai, Harpreet Singh. - “Design Optimization for Modification of
Trough Belt Conveyor to Reduce Material Spillage Used in Clinker Transport in
Cement Plant” - International Journal of Research in Advent Technology - Volume
1, Issue 4, November 2013
3. Tasmin F. A riff, Muhd. Fahmi B. Jusoh, Malek Parnin and Mohd. Hanif Azenan.
- “Design Improvements and Fabrication of Conveyor Belt Cleaner and Washing
System at Westports Malaysia” - International Journal of Education and Research
-Vol. 1 No. 10 October 2013
4. Suhas M. Shinde and R.B. Patil – “Design and Analysis of a Roller Conveyor
System for Weight Optimization and Material Saving” - International Journal on
Emerging Technologies- 25 April, 2012
5. Ilesanmi Afolabi Daniyan, Adefemi Adeodu And O M Dada – “Design of A
Material Handling Equipment: Belt Conveyor System for Crushed Limestone
Using 3 Roll Idlers” – Journal of advancement in engineering and technology January 16, 2014.