Internship Design of Belt Conveyor Project

INTERNSHIP REPORT AND PROJECT WORK
Bahir Dar University

Bahir Dar Institute of Technology
Faculty of Mechanical and Industrial Engineering
Mechanical Engineering program
Internship Report
Project Title: Design and Model of Belt conveyor
Hoisting Company: Amhara Metal Industry and Machine Technology Development Enterprise
(AMIMTDE)
BY:DesalegnMasresha (0800644(ID NO.)
EngidayeKebe(0800703)
Beletetsegaw(0800529)
FitalewGetachew(080563)
Mentor: Mr. HenokMebrate
Company Supervisor: Mr. Awel. M
Date: 15/ 1/2012 e.c
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Declaration
We the undersigned declare that this internship report is our original work, which is presented for
completion of our internship program at Amhara Metal Industry and Machine Technology Development
Enterprise (AMIMTDE) under Mentor of Mr.Henok. We declare that to the best of our knowledge, no part
of this internship report has been submitted here. All sources of material used in this report have been
acknowledged.
Name of student Signature
1. DesalegnMasresha ------------------
2.EngidayeKebe ------------------
3.Beletetsegaw---------------------
4.FitalewGetachew---------------------
This is to certify that the above statement made by the candidates is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.
Name of school advisor signature Date
Mr.HenokMebrate ______________ 15/1/2012 E.C
Acknowledgement
First of all, we would like to thank our thealmighty God for his unforgettable help in all
direction. We express our thankfulness to God for his blessing and guidance throughout our
entire training and also thank our advisor Mr. HenokMebrate to give his advice /support/
continuously throughout this project; and his staff member specially Mr. Temesgen for his help
of giving source.
We want to say thanks to all design room workers. Specially, it is extremely difficult to
communicate my heartfelt gratitude to our technical assistance Mr. Awel who has devoted
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countless of days and weekend hours to the creation of the present work and participated with
dedication in the process of its refinement.
We would like to express our profound to Amhara metal industry and machine technology
development enterprise which is willing to accept our internship program, for valuable guidance
and providing necessary facilities and source during this internship program.
Finally, we would like to tank Bahir Dar Institute of technology for providing such kind of an
opportunity for students to apply their understanding in practical knowledge and improve
theoretical knowledge.
Executive Summary
This report of an internship program at Amhara Metal Industry and Machine Technology
Development Enterprise (AMIMTDE) contains four parts. The first part contains its complete
history, products the company, main customers, its organizations and work flow. The second part
contains internship experience, working sections, work tasks, engineering methods, tools and
techniques, major challenges and problems that we faced, measurements that we have taken to
overcome this challenges and problems, improving practical skill, improving theoretical skill,
improving team playing skill, improving leadership skill, understanding about work ethics,
industrial psychology and related issues. The third part contains summary of the project,
introduction, and types of belt conveyor with their advantages, statement of problems, specific
and general objectives, components of belt conveyor, literature review and methodology or
procedure. The fourth part contains initial input data, geometric analysis of belt components,
force analysis on the components, stress analysis on each component, Final design and result of
the belt conveyor and cost analysis. Finally we have put our general conclusion and
recommendation, every reference we used to complete this internship report and appendices.
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Contents
Declaration........................................................................................................................................i
Acknowledgement............................................................................................................................i
Executive Summary.........................................................................................................................ii
PART ONE......................................................................................................................................1
1. Company Background.................................................................................................................1
1.1 History of company...............................................................................................................1
1.2. Product of company or service of the company...................................................................2
1.3. Main customers or the end users of its products or services.................................................5
1.4 Its organizational structure....................................................................................................5
1.5. Work flow.............................................................................................................................6
PART TWO.....................................................................................................................................6
2. Internship experience...................................................................................................................6
2.1. Our working section of the company....................................................................................6
2.2. Work tasks..........................................................................................................................10
2.3. Engineering methods, tools and techniques........................................................................11
2.4. Major challenges and problems we have been facing........................................................11
2.5. Measurements taken in order to overcome these challenges and problems.......................12
2.6. Improving practical skill.....................................................................................................12
2.7. Upgrading theoretical skill.................................................................................................12
2.8. Improving team playing skill..............................................................................................13
2.9. Improving leadership skill..................................................................................................13
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2.10. Understanding about work ethics, industrial psychology and related issues....................13
2.11 In terms of entrepreneurship skills....................................................................................14
In the internship period we gained the following entrepreneurship skills;..............................................14
2.12 In terms of improving your interpersonal communication skills.......................................14
2.13 Conclusions and Recommendations..................................................................................14
2.13.1 Conclusion..................................................................................................................14
2.13.2 Recommendation........................................................................................................14
PART THREE...............................................................................................................................15
3. DESIGN OF BELT CONVEYOR............................................................................................15
3.1 SUMMARY OF THE PROECT.........................................................................................15
3.3 Types of belt conveyor........................................................................................................17
3.4 Advantages of belt conveyor...............................................................................................19
3.5 STATEMENT OF PROBLEM............................................................................................20
3.6 OBJECTIVE OF THE PROJECT.......................................................................................20
3.6.1 GENERAL OBJECTIVE.............................................................................................20
3.6.2 SPECFIC OBJECTIVE................................................................................................20
3.7 COMPONENTS OF BELT CONVEYOR..........................................................................21
3.8 LITERATURE REVIEW....................................................................................................23
3.9 METHODOLOGY OR PROCEDUR.................................................................................24
4. DESIGN AND ANALYSIS OF BELT CONVEYOR..............................................................25
4.1 INTIAL INPUT DATA.......................................................................................................25
4.2 GEOMETRIC ANALYSIS OF BELT CONVEYOR.........................................................27
4.2.1 ROLLER OR PULLEY GEOMETRY.........................................................................27
4.2.2 GEOMETRY OF BELT...............................................................................................29
4.2.3 Geometry of shaft.........................................................................................................29
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4.2.4 Geometry of Frame.......................................................................................................30
4.3 FORCE ANALYSIS OF BELT CONVEYOR...................................................................31
4.3.1 Capacity of belt conveyor.............................................................................................31
4.3.2 Resistance Forces..........................................................................................................32
4.3.3 Tension force calculation..............................................................................................34
4.4 Stress analysis of belt conveyor...........................................................................................36
4.4.1 Design of Belt Conveyor Shaft.....................................................................................36
4.4.2 Stress analysis of roller.................................................................................................43
4.4.3 Stress analysis of Idler..................................................................................................45
4.4.4.Stress analysis of frame................................................................................................47
4.4.5.Stress analysis of legs...................................................................................................52
4.4.6.Stress analysis of belt....................................................................................................55
4.5 Final design and result of belt conveyor..............................................................................56
4.5.1 Design of Roller (pulley)..............................................................................................56
4.5.2 Design of belt................................................................................................................57
4.5.3 Design of shaft..............................................................................................................58
4.5.4 Design of Idler..............................................................................................................58
4.5.5 Design of motor for belt conveyor................................................................................59
4.5.6 Design of pulley for roller and Motor shaft..................................................................60
4.5.7 Design of belt for power transmission..........................................................................63
4.5.8 Design of shaft for first stage speed reduction.............................................................66
4.5.9 Design of key................................................................................................................67
4.5.10 Selection of bearing....................................................................................................69
4.5.11 Selection of bolt..........................................................................................................71
4.5.12 Selection of screw.......................................................................................................72
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4.6 Cost analysis............................................................................................................................73
4.7. Conclusion and recommendation...........................................................................................79
4.7.1 Conclusion........................................................................................................................79
4.7.2 Recommendation..............................................................................................................79
4.8 General Conclusion and recommendation...............................................................................79
4.8.1 Conclusion........................................................................................................................79
4.8.2 Recommendation..............................................................................................................80
REFERENCE................................................................................................................................81
List of table
List of figures
Figure 1.1 screed vibr1ator..............................................................................................................2

FFigure 1.2Maize Schaller...............................................................................................................3
Figure 1.3Pressure Vessels..............................................................................................................3
Figure 1.4 Beam colon.....................................................................................................................4
Figure1.5 screw dam closer.............................................................................................................4
Figure 3.1 Fabrication shop.............................................................................................................7
Figure 2.2 welding shop..................................................................................................................8
Figure 2.3.Welding shop..................................................................................................................9
Figur2.4.Machine shop..................................................................................................................10
Figure 4.1 geometry of belt conveyor............................................................................................27
Figure 4.2 geometry of roller and its disc.....................................................................................28
Figure 4.3 Belt geometry1.............................................................................................................29
Figure 4.4 geometry of shaft..........................................................................................................30
Figure 4.5 tension force on belt.....................................................................................................34
Figure 4.6 shear force and bending moment diagram of shaft......................................................37
Figure 4.7 tensional notch sensitivity factor. 4.............................................................................40
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Figure 4.8 bending notch sensitivity factor[4]...............................................................................40

Figure 4.10 Round shaft with fillet shoulder in bending. [4]........................................................42
Figure 4.11 roller, shaft, and disc..................................................................................................43
Figure 4.12 idler.............................................................................................................................46
Figure 4.13 leg...............................................................................................................................54
Figure 4.14idler..............................................................................................................................58
Figure 4.15 speed reduction system...............................................................................................60
Figure 4.16pulleys or drums..........................................................................................................62
Figure 4.17 power transmission systems.......................................................................................63
Figure 4.18 belt..............................................................................................................................64
Figure 4.19 small shaft..................................................................................................................67
Figure 4.20 key..............................................................................................................................69
Figure 4.21 ball bearing.................................................................................................................70
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AMIMTDE Page 1
PART ONE
1. Company Background
1.1 History of company
Amhara Metal Industry and Machine Development Technology Enterprise

(AMIMTDE) is located in the capital of Amhara regional state, Bahir Dar,
Ethiopia. It is 663km from Addis Ababa, the capital of Ethiopia. The company
established in 1985 by the name of Bahir Dar Rural Technology Promotion
Center with the aim of multiplying of and popularizing agricultural
implements, rural industry development and rural energy development team.
But after 1996, after the center has been re-organized with the objective of
supporting the sustainability of the agricultural development in the
regionthrough design, testing and promoting agricultural implements. Then
in 1999 the name of the center changed to Bahir Dar Agriculture
mechanization and Food Science research center and started to conduct
research on generating/selecting, developing, adopting and promoting
appropriate agricultural mechanization
technologies at the regional level. Finally in 2007 E.C its name changed to Amhara Metal
Industry andMachine Technology Development Technology Enterprise (AMIMTDE) and
directly enters in to work in 2008E.C.
Currently the Enterprise manufacture different types of technological products by the two
existedwell organizedworkshops found at Bahir Dar and kombolchacity. In addition to this, the
company is building other branch workshop called foundry plant and transformer maintenance in
Bahir Dar. The new branch is more modern than the former.
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The purpose of the company is to reduce shortages faced in production industry and agricultural
investment and to meet the regional goal in industrial translation with in overall market.
Vision of the company;
 To be one of the best top 10 Technology center in Africa since 2017E.C.
Mission of the company;
 To create metal and machine technology development market center.

 To solve problems related to agricultural and industrial technology.
 To develop competitive industries in the world that sustains continuous technology
development.
 To reduce foreign currency by reversing machines.
1.2. Product of company or service of the company
This enterprise produces many products and services that are produced according to the
customer needs orders. Currently the company basically produces the following products;
 Screed vibrator
 Maize Schaller
 Pressure vessel
 Beam colon
 Electrical instruments
 Machine tools
 Mixer machine
 Construction material
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Figure 1.1 screed vibr1ator
FFigure
1.2Maize Schaller
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Figure 1.3Pressure Vessels
Figure 1.4 Beam colon
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Figure1.5 screw dam closer
1.3. Main customers or the end users of its products or services
The end users of the company products are;
 Construction organizations
 Farmers
 Universities
 Hotels
 Fisher
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1.4 Its organizational structure
1.5. Work flow
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PART TWO
2. Internship experience
This internship program provides an opportunity to develop practical works in the company by
changing our theoretical knowledge to practical works. It also helps to develop work ethics, team
work time management with company workers and our mates.
2.1. Our working section of the company
In our company there are two sections. This is design section and shop sections. In shop sections
there are various types of shop rooms. This are;
 Machine shop
 Welding shop
 Assembly shop
 Wood shop
 Fabrication shop
Among those types of shops we have working in the machine shop. Because ourmanager
grouped in different sections based on our stream.
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Figure 2.1 Fabrication shop
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Figure 2.2 welding shop
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Figure 2.3.Welding shop
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Figur2.4.Machine shop
2.2. Work tasks
Solid work is a mechanical design automation software package used build parts and assembles
that takes advantage of the familiar Microsoft Windows graphical user interface. From this
software application we have done for one month. It helps us to analyze design and reverse
different machine parts and products, assemble and disassemble machine components, change
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design drawing to manufacturing drawing and manufacturing practical work. In addition to this
we have actively participate the following workshop sections;
 Drilling
 Facing
 Milling
 Bending
 Shearing
 Casting
 Assembling
 Welding
 Measure and cut metals for machine component
2.3. Engineering methods, tools and techniques
Methods: a way of doing practical works in the company in a systematic way. First when we go
to the company they allowed doing solid work for one month. Then they grouped in to different
shop sections based on our streams. Before started to practical work they told the function and
operation of each machine in each workshop.
Technique: Is a specific approach to efficiently accomplish a task in a manner that may not be
immediately obvious.
Tools: The following tools are used widely in the workplace;
 Caliper: is a device used to measure the dimensions of materials to be done.

 Tape ruler: is flexible ruler and used to measure the distance.
 Wrenches: it is used to turn screws, nuts, and bolts with hexagonal heads. Three types of
wrenches are; open ends, box (closed) and combination wrenches.
 Screw drivers: used to derive or turn screws. It can be flat or Philips head.
 Try square: a try square is a wood working or metal working tool used for marking,
measuring and check the accuracy of right angle of wood and metals.
 Hammer: is a tool that delivers a blow (a sudden impact) to an object.
 Mallet
2.4. Major challenges and problems we have been facing
Major challenges and problems that we faced during the internship practices are;
 Lack of computer access to do individual tasks in solid work practices.
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 Lack of information which accomplish measuring the parts to change in to solid work
modeling.
 The machinists engages all machines full of time so there is no enough time to practice
on machines.
 Have no safe working area to do within our team.
 Don’t get permission to practice on some machines individually.
2.5. Measurements taken in order to overcome these challenges and problems.
Measurements that we have taken to overcome this challenge are;
 Even if the machinists engaged full of time we follow them actively all the working
processes while they are doing different structures, like gear, pulley, bolt, tread etc.
 By doing solid work practices in groups.
 By dividing tasks and doing in groups.
 By asking operation, function and necessity of each machines from the engineer.
2.6. Improving practical skill
We know how to give attention for ever thing what we have doing.
And we had been new for solid work application until we start to learn this software application.
We improve or able to design and modeling of different machine part using solid work. This is
the base to design any machine and prepare flow chart for manufacture process.
We gain that how machine is installed and different installation requirement to prevent the
machine from any failure. And we have able to know the function and operation method of
different machines practically. Such as welding, turning, bending, drilling, painting etc. metals
during assembly work.
2.7. Upgrading theoretical skill
In internship program we upgrade our theoretical knowledge because we practice really on

machines that we know theoretically.
The internship period was a good field to read about real world problems how to solve it in
engineering department. Therefore we gained the following essential things;
 The ability to analyze and approach different problems.

 Clearly understand different machine devices working principle and mechanisms.
 We acquire more knowledge about solid wok software application.
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 We have developed our knowledge on design and modeling of different machine part
using solid work.
 Upgrading our knowledge to solve problems such as industrial, agricultural etc.
2.8. Improving team playing skill
Team work is an essential thing to solve problem when we work together. Generally our team
playing skill helps us to improve the following qualities:
 To be active participant
 To cooperate and help others
 To tolerate differences
 To overcome difficult problems
 Showing commitment to the team
2.9. Improving leadership skill
Leadership is a process of leading the careers of the company.Duringthe internship period with
respect to leadership skills we have learned the following attributes to be successful leader:
 The ability to know

 Know our self and seek self-improvement
 Be technical proficient
 Take responsibility to actions
 Make sound and timely decisions
 Leaders should be energetic and committed, maintain contact with their people, and
understand his/her strengths and weaknesses.
 General intelligence, to make sense of the complexity and difficulty of the task.
 To be technical or professional knowledge and competence.
2.10. Understanding about work ethics, industrial psychology and related issues
In internship program we worked regularly with the employees. During the working time we
understand that we need to respect rules and regulations of the company, be disciplined,
reliability, honesty and punctual. We enable to develop proper relationship with coworkers and it
enables us to create good working environment.
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2.11 In terms of entrepreneurship skills
In the internship period we gained the following entrepreneurship skills;
 Able to work different tasks.

 Innovative thinking and creativity.
 To know ones business is profitable or not.
 Able to self-motivated and plan for the feature.
 Ability to communicate to the workers and others.
 To understand different problems faced in the company.
2.12 In terms of improving your interpersonal communication skills.
We have also improved our interpersonal communication skills during the internship
program. Because during the working time we communicate to the workers how to do
different activities which used to do effectively. Good communication with the workers,
managers and group members helps us to express ideas& presenting different questions
and suggestions and operate machines effectively.
2.13 Conclusions and Recommendations
2.13.1 Conclusion
We conclude from the internship program that we have done practical works which prepares
ourselves for real practical world and also it produces skilled man power not only ideally but also
practically. Longer workingskill in the company also important to social communication and
reaction, experience of leadership and team work.
2.13.2 Recommendation
During the internship period we recommend that some machinist works carelessly and as they
want, lack of proper wearing their closes in working time. In addition to this in the company all
the cut out materials thrown outeverywhere. So it is better to wear carefully and collect all the
thrown metals in a certain place and recycle for other application. And finally we recommend to
some workers they use machines carelessly. It damage machines life.
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PART THREE
3. DESIGN OF BELT CONVEYOR
3.1 SUMMARY OF THE PROECT
Many manufacturing industries in our country are used human power to convey or transport raw
materials, manufacturing products, and components of different machines. The conveying of
materials needs conveying system; among those system belt conveyor is one of conveying
system. In this project we designed a belt conveyor to transport different machine components
and structures. This project reduces human effort and also save time.
Belt conveyors are transport equipment, which is also nowadays widely used in various
industries. Most of conveyors are designed to transport bulk materials, but they are often used for
non-bulky goods. In the case of larger mines or larger material deposits the long belt conveyors
are implemented. In some case the slope of the belt is changing along its length.
In this project the premises are to design a belt conveyor from some requirements that will be
explained later, from these requirements a reliable design as most optimized as possible has to be
find.
3.2 INTRODUCTION
A belt conveyor system is one of well-known conveyor system; which are used to convey or to
transport different materials by using a continuous motion of the belt and the pulley. A belt
conveyor system consists of two or more pulleys (drums), with an endless loop of carrying
medium –the conveyor belt –that rotates about them. One or both pulleys are powered, moving
the belt and the material on the belt forward. The powered pulley is called drive pulley while the
unpowered pulley is called idler pulley.[ 7 ]
Belt conveyors are the most commonly used powered conveyors because they are the most
versatile and the least expensive. In this conveyor product is conveyed directly on the belt so
both regular and irregular shaped objects, large or small, light or heavy, can be transported
successfully. These conveyors should use only the highest quality premium belting products,
which reduce belt stretch and results in less maintenance for tension adjustments.
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Belt conveyors can be used to transport products in straight line or through changes elevation or
direction. In certain applications they can be used for static accumulation or cartons.
A belt conveyor consists of a moving endless belt which supports material and which by its
motion caries the material from one place to another place. The belt is driven by the pulley and is
supported on both runs, going and coming by rollers or by a run away. The material may be put
on the belt by hand, shovel, chute, or some other means, and it is removed from the belt by
discharging it over the end pulley or by deflecting it at some point along the run of the conveyor.
[ 1]
Belt conveyors occupy an outstanding position in the field of bulk materials handling. They are
the most versatile and widely used of all conveyors. They are suitable for handling a wide variety
of materials. The range of sizes, which may be handled, is limited only by width of belt.
Materials may vary from extremely fine chemicals to lump ore, stone,coal,or pulpwood logs.
They can handle a wide range of capacities over longer distance than possible with other type of
conveyor systems. In addition to their dependable and economic use as means of transporting
bulk materials, they are adaptable for performing numerous other function such as weighing,
blending sampling and stock piling.[ 1 ]
Conveyor belt have been used for decades to transport bulk material and unit loads, they have
proved their worth everywhere because belt conveyor installations can be adapted to meet nearly
all local condition. They are work –safe and economical. The demand for ever increase
capacities and even longer conveying length has accelerated the development of the belt
conveyor technique, new materials are being developed, new conveying systems are planned and
tested especially those having regard to environment.
A belt conveyor consists of an endless flat and flexible belt of sufficient strength, made of fabric,
rubber, plastic, leather or metal, which is laid over two metallic flat pulleys at two ends, and
driven in one direction by driving one of the two end pulleys. Material is placed on this moving
belt for transportation. The active half of the belt is supported by idler rollers or slider bed. The
return half of the belt may or may not be supported, as it generally does not carry any additional
load other than its own weight. The endless belt is kept taught by a belt tensioning arrangement.
[ 2]
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3.3 Types of belt conveyor
Flat Belt Conveyor:
In this conveyor, the active side of belt remains flat supported by cylindrical rollers or flat slider
bed. The conveyor is generally short in length and suitable for conveying unit loads like crates,
boxes, packages, bundles etc. in manufacturing, shipping, warehousing and assembly operations.
Flat belts are conveniently used for conveying parts between workstations or in an assembly line
in mass production of goods. [2]
Troughed Belt Conveyor:
In this conveyor, comparatively wide flat belt is supported on troughed carrying rollers or
shaped supporting surface so that the two edges of the active side of the belt are elevated from
the middle part to form a trough. This provides a greater carrying capacity than a flat belt of
equal width for conveying bulk materials or those materials which would slide off flat belts.
These conveyors are used in handling bulk materials of different classes. The return side of the
belt is generally kept flat supported on cylindrical rollers.
The troughed conveyors which are used within a plant for moving bulk materials from one point
to another, are generally termed as ‘‘normal’’ or ‘‘transfer’’ conveyors. These are comparatively
of shorter lengths, and path of movements are in straight line in a horizontal or an inclined plane.
The stresses in the belt being within limit of cotton fabric belt. [2]
Closed Belt Conveyor:
In a closed belt conveyor, the specially fabricated belt, after being loaded with the material, can
be wrapped completely around the load. It essentially forms a closed tube moving along with the
material. The advantages of a closed belt conveyor are: [2]
(i) It can handle fragile materials safely and without breaking by reducing inter particle
collision,
(ii) It can handle fine bulk materials without being swept by air (however, it is not really air
tight at loading and unloading points),
(iii) Ability to handle corrosive and reactive materials without contamination and
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(iv) The tube belt can travel around bends in more than one plane and hence versatile in
layout.
Metallic Belt Conveyor:
This is a flat belt conveyor where the flexible belt is replaced by a cold rolled carbon or stainless
steel strip belt of thickness from 0.6 mm to 1.2 mm. The ends of the steel strip are lap joint
riveted with a single row of special wide flat head rivets. A steel belt runs flat on cylindrical
idlers or runs troughed on resilient idlers (made by suitable length of springs). Apart from all
rolled strip steel belts, wire-mesh, belts of different designs has been used. The entire length is
made up of short length sections. One of the designs is made up of flat wire spiral sections. The
wire-mesh belts are more flexible and the design considerations are similar to rubberized textile
belt conveyors.
Portable Conveyor:
Short length flat conveyors carried on a wheeled structure is termed portable conveyor. These are
particularly useful for loading and unloading of trucks / transport vehicles. The inclination of the
conveyor can generally be adjusted to suit application. Apart from above mentioned major types
of belt conveyors, there are a few special types worth mentioning.
Chain or Rope Driven Belt Conveyor:
In which the specially designed belt is driven by a moving chain or rope, where belt only serves
as load carrier, and motion is by a chain or rope conveyor.
Submerged Belt Conveyor:
In which a portion of the belt moves through a metallic trough (casing) which is filled with free
flowing, powdered material at the loading end. The moving belt with holes makes the material
flow to the unloading end of the trough.
3.4 Advantages of belt conveyor
The belt conveyor has the following advantages: [7]
 Low cost operation and maintenance

 Electric controlled
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 Good energetic efficiency

 Big transportation capacity
 Conveyors are not affected by climate
 Easy automation
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3.5 STATEMENT OF PROBLEM
In many industries raw materials, products and different parts of machines and structures are
conveyed or transported by human power or effort. This human conveying system is very tedious
due to it take a lot of time to transport and convey. Traditional conveying system loose time,
reduce profit, decrease work efficiency, and work safety. It is not efficient because of large
quantities of materials is not transported once by human effort or traditionally by human carrier.
Due to the above reason we design a belt conveyor to reduce the above problems. This belt
conveyor can transport machine components, different materials based on its width for various
geometries.
3.6 OBJECTIVE OF THE PROJECT
3.6.1 GENERAL OBJECTIVE
The main objective of this project is to design and model a belt conveyor machine that transport
or convey materials such as: machine components and structural parts in metal industries with a
continuous motion of a belt and with a single motor with two pulleys.
3.6.2 SPECFIC OBJECTIVE
The specific objective of this project is to:
 Reduce human power

 Reduce time loose
 Increase work efficiency
 Increase work profit
 Increase work production rate
 Reduce the fatigue of workers
 Achieve mass transport
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3.7 COMPONENTS OF BELT CONVEYOR
The belt conveyor is composed of the belt, the idlers, the pulleys, the drive equipment, the take-
up and the supporting structure. The belt is an endless moving rubber covered conveyor for
transporting materials and is made up of fibers having longitudinal strength for pulling the load,
transverse strength for supporting the load. The idlers, which carry and train the belt; the pulleys,
with their shafts and bearings, which propel the belt and change its direction of travel; the drive
equipment for transmitting power from the motor to the driving pulley or pulleys; the take-up to
maintain the slack side tension; and the structure which supports and maintains alignment of
idlers, pulleys and the drive.[ 1 ]
CONVEYOR BELTING
A belt is the main part of belt conveyor, which is a continuous loop that rotates around pulleys. It
is material carrier part and rotating part of belt conveyor. The great majority of belt conveyors
handling bulk materials use some type of rubbers protected fibers or belts. The belt must have
certain flexibility in order to wrap around the pulleys, width enough to carry the required
quantity of material, and strength enough to bear the weight of the load and transmit the pull in
the conveyor. This condition can be met by bands of metal, leather or woven fabric. The belt
cover is made of special wear-and impact- resisting rubber compound with cord breaker strips
imbedded in tough rubber. The covers to the fibers are designed to protect an expressive belt
fiber at loading points when a sharp heavy lump material is being handled under adverse loading
condition. [ 1 ]
CONVEYOR PULLEYS OR ROLLERS
At each of the two ends of a belt conveyor, one large diameter pulley is installed against which
the belt turns and changes direction. These pulleys are called terminal or bend pulley. Drive is
imparted to the belt through friction by one of the terminal pulleys called drive pulley. As the
conveyor belt passes around these bend pulleys, the plies of the belt are elongated in proportion
to the distance of the ply form center of the pulley. The differential elongation of one ply over
the other is taken up by the rubberized bonding between two plies. Larger the pulley less is
differential elongation between the plies hence less tendency to ply separation. This is the reason
the bend pulleys are made large.
AMIMTDE Page 22
DRIVE OR MOTOR FOR BELT CONVEYOR
The belt conveyors are generally driven at the head end pulley, where material is discharged. The
drive pulley is connected to the drive motor through suitable speed reduction gear box and
flexible shaft couplings. Drive of an inclined conveyor necessarily includes a braking device
which prevents downward movement of the loaded belt in case of power failure of the motor.
Practically all belt conveyors are driven by an electric motor directly connected to a speed
reducer unit through a flexible coupling. A high-speed motor, which costs less and occupies less
space, is preferred to a slow speed motor. [1]
That is why there must be speed reduction unit between the motor and the head shaft. The
preferred drive location for a belt conveyor is that which results in the least minimum belt
tension.
BELT SUPPORT FRAME AND IDLERS
Belt support frame is the carrier part of the conveyor that carry other components and the
conveyed materials that above it. The support of conveyor is normally a structural frame.
Depending on the situation the structure can be mounted on floor or on skid. The main job of the
support is to let the belt run without getting skewed. Depending on situations the support can be
made moving type. In such cases idler a wheel mounted or crawler mounted platform keeps the
necessary provision to support the idlers on which the conveyor runs. The rollers used at certain
spacing for supporting the active as well as return side of the belt are called idlers. Accurately
made, rigidly installed and well maintained idlers are vital for smooth and efficient running of a
belt conveyor.[1]
TAKE-UPS OR BELT TENSIONING DEVICE
Endless beltconveyor after being threaded through the entire length of the conveyor needs to be
tightened.So that sufficient frictional force is developed between the drive pulley and the belt, to
make the belt move. Belts working under tension invariably get elongated with time, which
needs to be taken-up to maintain the desired tension in the belt. A belt conveyor generally has a
screw-type (mechanical) or a gravity-type counterweighted take-up unit, also termed as belt
tensioning device.
AMIMTDE Page 23
3.8 LITERATURE REVIEW
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,Sandvikinvented and started the production of steel conveyor belts.
In 1905Richard 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. Hyacinth Marcel Brochette 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 of a longer life because it could expose all of its surface area
to wear and tear. Such Möbius strip belts are no longer manufactured because untwisted modern
belts can be made more durable by constructing them from several layers of different materials.
In 1970,Intralox, a Louisiana-based company, registered the first patent for all plastic, modular
belting.
Until the middle of 1970 conveyor belt development and technology was concentrated on the
search for appropriate materials for the belt and the solving of drive problem. In the first instance
transmission of traction played apart. As the demand grew up for conveyors of larger capacities
and longer length, additional requirements affecting the belt had to be considered and reached
such as greater work load, elongation, slit resistance and endless splice jointing.[8]
 Evolution of belt conveyor [7]

 In 1870 trails with plain cotton belts
 In 1914 first rubber belt developed from drive belt
 In 1926 first belt with robust balata reinforced cover
 From 1928 use of belts with Maco cotton plies
 In 1942 use PVC belts above ground.
 From 1955 development and use of steel cord belting in Europe.
 From 1970 use of reinforced material for the carcass.
AMIMTDE Page 24
 From 1980 development of new conveyor system e.g. tube conveyor,

hammock conveyor.
3.9 METHODOLOGY OR PROCEDUR
Guide lines or steps are used to design the belt conveyor. The steps help us to Designthe
component easily and to determine one parameter from the previously design one. The methods
that we follow during the design of this are the following.
 Data gathering about belt conveyor machine

 Literature study
 Background
 Observation
 Taking brief description of introduction about belt conveyor machine
 Justification of design consideration
 Proper material selection
 Design of components of belt conveyor
 Selection of motor
 Design of supporting frame, idlers
 Design of motor shaft, and pulley shaft
 Design of pulleys and belt
 Manufacturing procedure of belt conveyor
 Maintenance belt conveyor
 Result and discussion ,description about the design part
 Cost analysis
 Conclusion of the design
 Recommendation about the design
 Part drawing and assembly drawing
 Reference
AMIMTDE Page 25
4. DESIGN AND ANALYSIS OF BELT CONVEYOR
4.1 INTIAL INPUT DATA
In this project we design based on the following data.
Conveyor dimensions
 Length of conveyor distance =20m

 Height of conveyor =1m
Conveyed material
Material to be conveyed=mild steel or low alloy steel
 Density of material 7850kg/m3

 Dimension = 500mm×250 mm
 Thickness =4mm
Conveyor Belt
 Number of plies of belt=2

 Speed of belt 0.5m/s
The speed of belt is determined by human speed. The average human speed is 5Km/hr to 6km/hr.
From this we can assume that the belt speed is relative to human speed. So we select 1.8km/hr
speed of belt, which is less than human speed in order to reduce material falling and damage.
Belt speed =0.5 m/s
Table 4.1Conveyed materials dimensions
Part name Length(mm) Width(mm) Thickness(mm) Weight(g) Material
Connector plate 500 250 5 936 Mild steel
plate
Shade 234 260 200 6 1646.64 Ansi 1020
aperlinattachment
plate
Bellow pulley 164 60 5 341.57 Mild steel
holder
AMIMTDE Page 26
Filler 337 267 8 2875.28 Mild steel
Table 4.2: friction coefficient between driving pulley and rubber belting[ 1 ]
Operating Smooth bare rim Rubber lagging Polyurethane Ceramic lagging

condition steel pulley herringbone lagging with with herring
patterned groves herringbone bone patterned
patterned groves
grooves
Operation in dry 0.35 to 0.4 0.4 to 0.45 0.35 to 0.4 0.4 to 0.45
conditions
Operation in 0.1 0.35 0/35 0.35 to 0.4

clean and wet
condition
Operation in wet 0.05 to 0.1 0.25 to 0.3 0.2 0.35

condition
Table 4.3: characteristics of materials[ 1 ]
Belt Wt. Of Constants Max. Speedof Max. dimension

belt(m/s) of materials (mm)
Width moving parts
(mm) (kg/m) A b Abrasive Non- Unifor Mixed
material abrasiv m size size
e
material
300 20 0.080 30 1.5 2.0 50 75
400 24 0.085 35 1.5 2.25 70 100
500 32 0.090 45 2.0 2.25 90 150
600 38 0.095 50 2.5 2.5 110 200
700 46 50.11 60 2.8 3.0 130 250
800 55 0.11 75 3.0 3.5 150 300
AMIMTDE Page 27
900 65 0.12 90 3.0 4.0 170 350
1000 75 0.125 100 3.0 4.0 200 400
1100 82 0.13 110 3.0 4.0 230 450
1200 90 0.140 120 3.0 4.0 260 500
4.2 GEOMETRIC ANALYSIS OF BELT CONVEYOR
Figure 4.1 geometry of belt conveyor

4.2.1 ROLLER OR PULLEY GEOMETRY
Width of material conveyed has the dimension of 500m*250 mm. due to this the length of
Rollers are must be greater than width of material and also width of belt. We take the largest
sides or length of material dimension
Length (Lr)
Material length =500mm
Width of material<width of belt<length of roller

Width of belt (wb) = 500mm+100mm=600mm
AMIMTDE Page 28
Length of roller or pulley =600mm+50mm=650mm

Diameter (Dr)
Outer diameter of roller = k*i
Dr =125×2 = 250mm Where: i=number of plies

K=pulley factor i when between 2&6 k=125
But this number is large for our design because this belt conveyor is used for ashortdistance for a
small weight. So we use 150mm diameter of pulley.
Figure 4.2 geometry of roller and its disc
AMIMTDE Page 29
4.2.2 GEOMETRY OF BELT
Figure 4.3 Belt geometry[ 1 ]
The geometry of belt is calculated based on the following formula.
Based on our design the diameter 0f rollers and position or height of rollers is equal in the figure
bellow.[ 4 ]
Length of Belt
L =2c+πD
L = 2×20m+ π×0.150m = 40.47m
So length of belt is designed to 40.47m+0.04m = 40.51m
Where: c= distance between two roller center
D =roller diameter
ϴ=π
4.2.3 Geometry of shaft
Length of shaft, Lsh
The length of shaft can be calculated based on the length of roller, bearing thickness, and the
thickness of frames.
AMIMTDE Page 30
Lsh= Lr + 2tb+2tf +wp+c
If the summation of thickness of frame and allowance has 7cm therefore the shaft length is equal
to:
Lsh = 65cm+2×1.5cm+7cm+55mm= 810mm
Where: Lr = length of roller
tb= thickness of bearing (if thickness of bearing is equal to1.5cm)
wp = width of pulley for speed reductionassume
tf= thickness of frame
c = allowance
Figure 4.4 geometry of shaft

4.2.4 Geometry of Frame
The frame is the horizontal beam used for carry or support the shaft.
Length of frame
Length of frame Lf =20+Dr+c
Lf =20m+0.15m+0.1m =20.25m
Where
20 =center to center distance
Dr = diameter of roller
C =clearance
AMIMTDE Page 31
4.3 FORCE ANALYSIS OF BELT CONVEYOR
4.3.1 Capacity of belt conveyor
If the material to be conveyed is a unit load, then the capacity Q [tons/h] is calculated using
equation.[ 1 ]
Q = 3.6×qBv
Where
q = distributed load [kg/m2]
A = the cross-sectional area of the material being conveyed [m2]
v = Velocity of the belt [m/s]
B =width of belt
V= volume of the conveyed material
Ƿ =density of material
t = thickness of material
A =L×B =0.5m×0.25m =0.125m2
Mass of material, m
m = Ƿ×V =7850kg/m3×L×B×t =7850 kg /m3 ×0.5 m× 0.25 m× 0.004m =3.925kg
Distributed load, q=mass/Area=3.925kg/0.125m2= 31.4kg/m2
Q =3.6×0.6×31.4kg/m2×0.5m/s2 = 33.9ton/hr
Q 33.9
Live load or load per meter, qm = = =18.83kg/m
(3.6 × v) ( 3.6× 0.5)
4.3.2 Resistance Forces
The forces which are opposing the movement of the belt, the material and all moving parts are
due to friction on the parts and due to material transport, force required to overcome the level
difference, discharge forces and fixed resistance. [ 1 ]
AMIMTDE Page 32
1. Frictional force on the moving parts (belt, rollers, etc)
r1=fqsl
Where
r1 = frictional forces due to moving parts
f = coefficient of frictional force of the drum
qs = weight of the moving part in kg/m of the belt
l = belt length between two extreme drum centers [m] = 20m
From table 7.5 when the width of belt is 600mm the weight of moving parts is 38kg/m
We select rubber belt with steel cord and Smooth bare rim steel pulley. Because of the rubber
belt has better strength than other belts. Our environment is dry condition because the material to
be conveyed is metal. From table 7.10 the coefficient of friction between pulley and belt is 0.35-
0.4. So we select 0.37.
r1 =0.37×38kg/m×20m =281.2kg× 9.81=2758.57N
2. Frictional force due to material transport
r2 = f × qm× lm
= 0.37×18.3kg/m×20m
= 135.42kg× 9.81=1328.4N
Where:
qm = weight of material transported [kg/m of belt]
lm = the distance that the material is transported
3. Level difference Force required overcoming the level
r3=qm.H
= 18.3kg/m×1m
AMIMTDE Page 33
= 18.3kg × 9.81=176.58N
Where:
H = elevation difference = 1m
4. Discharging force
Fixed discharger:
r4=aqm
= 0.095×18.3kg/m
= 1.74kg/m
Where:
A = is discharge coefficient (a=0.095 from table 7.5 at width 600mm)
B=width of belt
r4= 1.739×B
r4=1.739kg/m×0.6
= 1.043kg =10.23N
5. Total resistant force
The total resistance force is equal to the sum of individual resistances
R =r1+r2+r3+r4
= 281.2kg+135.42kg+18.3kg+0.87kg
= 436.8kg =4273.78N
4.3.3 Tension force calculation
The operating maximum belt tension is defined as a maximum belt tension occurring when the
belt is conveying the design load from the loading point continuously to the point of design.
Maximum tension usually occurs at the discharge point on horizontal and inclined conveyor. The
AMIMTDE Page 34
belt tensions, in addition to their effect on power requirements they also influence the design and
selection of all component parts.[ 1 ]
Figure 4.5 tension force on belt

We know that R= F1-F2the relationship between F1 and F2 may also be expressed
F 1 µα
=e
F2
And F2 can be expressed in terms of the number of cords and the width of the belt.
F2=50NB where: F1= tension on drive side
F2=tension on driven or slack side
µ = coefficient of friction
α = wrap angle
N = number of cords of the belt
B = the width of the belt in meters
D =Diameter of pulley
T =Torque
R= Total resistance
Fi =initial tension
The tension on the belt are calculated the following formula.[ 4 ]
AMIMTDE Page 35
T e (fφ )+ 1
F i=
(
× ( fφ )
D ( e −1 ) )
T
F 1−F2=R=2
D
DR
T=
2
0.15× 4273.78
= =320.53N.m
2
0.52
Centrifugal force, Fc=mv2/r =3.925× = 13.08N
0.075
320.53 N . m e 0.37∗ π +1
Fi = × 0.37∗π
0.150 m e −1
= 4077.8N
F i2 e fφ
F1 =Fc +
e fφ +1
2 e0.37 × π
= 13.08N+4077.8N ×
e 0.37 × π +1
= 6224.39N
2F i
F2 =Fc+
e f φ+ 1
2× 4077.8 N
=13.08N+ 0.37∗3.14
(e +1)
=1956.7N
AMIMTDE Page 36
4.4 Stress analysis of belt conveyor
4.4.1 Design of Belt Conveyor Shaft
The shaft is the rotating part of the conveyor that rotates by motor power. It needs the selection
of proper material to carry loads. In this project we select stainless steel. Because ofstainless
steel is very hard, corrosion and wear resistance. Stainless steel 304 cold worked.
Sut=860MpaE =210Gpa
Sy=515Mpa
ρ =8000kg/m3
The shaft and the pulley are treated as a single structure. The resultant force on the bearing
(shaft) is the vector sum of belt tensions, and weight of moving parts. [ 1 ] To illustrate the
graphical representation we use values T=6224.39N; t=1956.7N and. Fig bellow illustrates a
graphical representation for a simple drive shaft arrangement subject to a combination of
bending and torque. Note that the force on the shaft R/2 is opposite to the direction of the
resultant force R. Weight of moving parts from table 3.3 is equal to 38kg/m when width of belt is
600mm.
W =38kg/m×0.6 =223.66N 340.47kg
Tt=T+t R 22.8
s = 6224.39+1956.7 =8181.09N
R = (8181.12 +223.662)1/2 =8184.2N
Therefore the force on the shaft is:
8184.2 N
Fsh= = 4092.1N
2
AMIMTDE Page 37
The force on the shaft is like simply supported beam so we can calculate the reaction force and
momentum on this shaft. [ 6]
Figure 4.6 shear force and bending moment diagram of shaft

Fsh=W=4902.1N and R1=R2= W/2=4902.1N/2=2046.05N
Maximum bending moment on simply supported beam is equal to, Mmax =fsh×110
The length of shaft (Lsh) is must be greater than the length of roller (Lr) or pulley. But length of
roller is equal to 650 mm.
 Lsh= 50+10+5+3+6 =750mm
Because the width of drum for speed reduction must be needed so we should add 55mm.
Lsh= 810mm
Mmax=2046.05× 0.11 m 225.05N.m
AMIMTDE Page 38
D
Torque is equal to, Tr=(T-t)×
2
Tr =320.53N.m
The shaft has bending, tensional, and axial stress.[ 4 ]
K f MC
σb = where: Kf and kfs stress concentration factor
I
K fs T tr C
σ sh= τ = d = diameter of shaft
J
Kf 32 Ma
σa = ,
π d3
Kf 32 Mm
σm =
π d3
32 Kf Ma 2
σ ' a= (σ a2 +3τ2a )1/2 =[( ) +3 ¿ ¿)2]1/2
πd 3
32 Kf Mm 2
σ ' m=(σ m2 +3τm2 )1/2 =[( ) +3 ¿ ¿)2]1/2
πd 3
Kf s 16 Ta
τa =
πd 3
Kf s 16 Tm
τm =
πd 3
By using failure theory of Goodman factor of safety (n) equal to
1 σ ' a σ 'm
= +
n se sut
DE-Goodman
1 16 1 1
= { [4(KfMa)2+3(KfsTa)] 1/2 + [4(Kf Mm)2 +3(KfsTm)2]1/2}
n πd 3 Se Sut
16 n 1 1
d ={ [ (4(Kf Ma)2 +3(KfsTa)2))1/2 + (4(Kf Mm)2 +3(KfsTm)2)1/2]}1/3
π Se Sut
AMIMTDE Page 39
Where: Sut =ultimate strength
Sy =yield strength
Se =endurance strength
Se=0.5 .Sut×Ka.Kb.Kc.Ke.Kf
Ka =aSutb
Table 4.4 parameters of surface modification [4]

Surface finish Factor, aSut,kpsi Sut, Mpa Exponent, b
Ground 1.34 1.58 -0.085
Machined or cold 2.70 4.51 -0.265
worked
Hot-rolled 14.4 57.7 -0.718
As-forged 39.9 272 -0.995
From this table we select hot rolled
Ka =4.51×860-0.265=0.85
Kf −1
q= or
Kt −1
Kfs−1
qshear =
Kts−1
kc = 1, bending
= 0.85, axial
= 0.59, torsion1
AMIMTDE Page 40
Figure 4.7 tensional notch sensitivity factor. [ 4 ]
Figure 4.8 bending notch sensitivity factor[4]

Let D/d =1.5 and r/d =0.1 and notch radius =2.5mm
d =2.5/0.1 =25mm
Kb=(d/7.62)-0.107 when 2.79≤ d ≤ 51 mm
= (25/7.62)-0.107 =0.96
Ke =0.814 from table 6.6
AMIMTDE Page 41
q = 0.78
qsh = 0.87
Table 4.5: stress concentration factor. [4]
We select from the table (r/d=0.1), Kt = 1.7, Kts=1.5
Kf = 1+q (Kt-1)
= 1+ 0.78(1.7-1) =1.55
Kfs = 1 +qsh(Kts-1)
= 1+0.87(1.5-1) =1.43
Se = 0.5× 860×0.85× 0.96× 0.814 ×1 ×1 = 295.1Mpa
For rotating shaft Mm =Ta =0, and Ma =225.06N.m, Tm=320.53N.m
If Factor of safety, n = 5.5
16 ×1.5 1 1
d={ [ (4(1.55×225.06)2+0)1/2 ( 0+3(1.43×320.53)2)1/2]}1/3
π 295 860
= 40.1mm
So we use the standard diameter of 40mm.
AMIMTDE Page 42
Figure:4.9 Round shaft with shoulder radius in torsion. [4]
Figure 4.10 Round shaft with fillet shoulder in bending. [4]

From figure 4.9 and 4.10 we can read at K t&Kts at D/d and at r/d so based on our data r/d
=0.1&Kt= 1.55, Kts =1.43.So D/d =1.1
D/d =1.1
D = 1.1×40mm =44mm, we use 45mm.
Therefore diameter of shaft is equal to 45 mm.
σ ' a=(σ a2 +3 τ a2 )1/ 2=¿ ¿]1/2
σ ' m=¿¿(σ m2+3 τ m3)1/2 =¿ ¿]1/2
AMIMTDE Page 43
Factor of safety , n
1 σ 'a σ' m
= +
n Se Sut
When σ’aandσ’mare maximum alternating and midrange stress.
32× 1.55× 225.06 N . m

=
σ 'a
π . 403 =55.55Mpa
16 ×1.43 ×320.53
σm′= [3( 3.14 × 403 )2]1/2=63.2=Mpa
1 189.3 63.2
= + = 0.71
n 295 860
n =5.5 ~ 5.56
This factor of safety is equal to the given factor of safety.
A von Mises maximum stress is calculated for this purpose.[ 4 ]
1
σ ' max= [ ( σ + σ )2 +3(τ +τ )2 ] 2
m a m a
Sy
n y=
σ ' a +σ ' m
515
ny = = 4.5
55.55+ 63.2
The yield factor of safety,nyis comparable to the former factor of safety. So the design is safe.
AMIMTDE Page 44
4.4.2 Stress analysis of roller
Figure 4.11 roller, shaft, and disc

In this design the material used to design roller is low carbon Ansi 1020 steel
Sy=294mpa
Sut=394mpa
E =201Gpa,
ρ=7870kg/m3
The forces in the roller are tensions, weight of belt and weight of conveyed material.
T= 6224.39N
t = 1956.8N
From table xxx weight of moving parts is 38kg/m so weight of belt is concentrated along the
length of roller and on its width.
Wb =38× 0.6× 9.81 =223.7N
Wm = 18.3kg/m× 0.6× 9.81=¿107.8N
Wt =331.4N
Total tension force Tt = 8245N
Total Force on rollers R = √2 82452 +331.42 =8252.6N

Force on roller, Fr =R/2 =4126.3N
AMIMTDE Page 45
The roller is like simply supported beam the moment on the maximum moment on the roller is
FrLr
.
4
0.65
Mmax =4126.3× =670.5 N . m
4
The torsional moment, Tm is total resistance force times radius of roller
0.15
So Tm = 4267.6N× =320.53 N . m
2
The voinmiss stress
MC M
ᵟa =
’
I
=¿ 32×
π d3
670.5 N .m
= 32× = 106.77Mpa
π × 0.0453
16 Tr
ᵟm,=[3×( π d 3
¿2]1/2
=16×320.53 /¿.0.0453) =44.2mpa
Sy
ny =
ᵟ a ’+ ᵟm
515
= =3.4
106.77+44.2
So the design of roller is safe.
4.4.3 Stress analysis of Idler
Idler is a part of belt conveyor that used to support active as well as return side of belt at certain
spacing.
There are two types of idlers used in belt conveyors:
AMIMTDE Page 46
1. Straight carrying and return idlers, which are used for supporting active side of the belt for a
flat belt conveyor and also for supporting the return belt in flat orientation in both flat and
troughed belt conveyor.
2. Toughing idler set consisting of 2, 3 or 5 rollers arranged in the form of trough to support the
belt in a troughed belt conveyor.
So for our design the preferable one is straight type of idler. Because of our design conveyor is
flat belt conveyor.
Idler dimensions: Diameter and length have been standardized by BIS in IS 8598:1987. The
carrying and return idler diameters in mm are: 63.5, 76.1, 88.9, 101.6, 108, 114.3, 127, 133,
139.7, 152.4, 159, 168.3 and 193.7. Length of the idlers varies from 100 mm up to 2200 mm.
The smaller lengths are generally made in smaller diameters while longer lengths are made in
larger diameters. The length of the straight idler set is based on the selected width of belt, and desirable edge
clearance between belt and roller edges. [1]
Length of idler = roller length + bearing width + thickness of frame +edge clearance. Edge clearance for belt
width 600mm is 4mm.
=650mm+2×15 mm +2×5.5 mm+ ¿4mm
=695mm
Based on this data we select idler, having diameter of 63.5mm for the cause of small weight of
conveyed materials and smaller length of idler. Therefore;
Outer diameter = 63.5mm
Inner diameter = 58mm
Figure 4.12 idler
AMIMTDE Page 47
It is final component of belt conveyor that contact to conveyor belting and it carry it. It has
cylindrical part and made of gray cast iron. Because to reduce vibration of motion.
Ssut =324MPA
Sy=179Mpa
ρ=7079kg/m3
Length of idler, Wb =Lr+tb+c
Where:
Lr = length of roller
tb = thickness of bearing
c = clearance
Wb = 65cm+1.5cm+1.5cm+1.5cm=69.5cm
The weight on the bed is equal to load of belt plus load of material components.
38kg/m× 9.81+ 18 kg/m× 9.81 =549.36N/m
9.81 m 9.81 m
38kg/m× 0.6 m× +18kg/m×20 m × = 3755.268N
s s
The load on idler is like uniformly distributing load
R1 = R2 =549.36 N /m× 0.695 m =10849.9N =381.6N
But it has supports with in 2m length so 8 idler is needed.
Maximum bending moment
0.695 m 0.695 m 0.695 m

M = 381.6× − × 549.36 N ×
2 2 4
= 397.6Nm
The allowable stress is bending stress
AMIMTDE Page 48
32 m 32 ×397.6 Nm
σ b= 3 = 3 = 63.8mpa
π ( D−d ) π (63.5 ¿ ¿ 3−58 )¿
Factor of safety is equal to
S y 294 mpa
n= 4.6
σ b 63.8 mpa
the factor of safety is greater than one so the design is safe .
4.4.4.Stress analysis of frame
The frame which carries the shafts, rollers, belt, brace & its supports, and the conveyed
materials. Due to this reason we use mild steel.The material is low carbon steel AISI 1045 has
excellent property.
Sut¿ 620 Mpa
Sy¿ 551 Mpa
ρ=7830Kg/m3
Wbelt = 223.7N
Wmaterial =3531.6N
Weight of roller, Wr
(Do2−Di 2) L
Volume of roller, Vr= ΠDL =π×
4
(0.1502 −0.143 2)m2 ×0.65 m

Vr = = 1.0465m3
4
3 3 7870 kg
Mass of roller =ρ ×V = 1.0465×10 m × =8.23kg
m3
9.81m
Weight of roller Wr=8.23kg × =80.8N
s
Volume of brace =19.75m× 0.69m ×0.001 m =0.0136m3
AMIMTDE Page 49
Weight of idler
( Do2−Di 2) L (63.52 −582) 695

m =8×π× ρ =π×7079 = 20.64kg
4 4
w = 202.5N
Weight of shaft, Wsh
π D2 L
Mass of shaft, Ms= ×ρ
4
Length of shaft, Lsh = Lbs+2tf+c+wi = 65cm+5.5mm ×2+ 44 mm+11 cm = 81cm

Where:
Lsb = length of roller
tf = thickness of frames
c = allowance
wi =width of drum from motor
π × 0.0452 × 0.81
ms= ×8000kg/m3
4
= 9.5kg
Wsh =9.5kg× 9.81m/s =93.6N
From the above calculation we can get the total resistant force occur on the support.
Wb= 223.7n
Wm =3531N
Wr =80.8N
Wi =202.5N
Wsh =93.6N
Wt=(223.7+3531+80.8+943.7+114.16+93.6) N =4986.96N
AMIMTDE Page 50
4986.96 N
Weight on each frame, W ¿ =2493.48 N
2
Length of frame, Lf =20+Dr+c
Lf =20m+0.15m+0.1m =20.25m
Where
20 =center to center distance
Dr = diameter of roller
C =clearance
Width of frame
Its width is must be greater than the diameter of the roller plus bending side in order to support
the conveyed material from falling. [6]
Wf =Dr+2k+2Ab+ t ' +¿2c
Where
k =bending side width
t =thickness of frame
t' = thickness of conveyed material
kba=factor to stretching
R =bending radius
c = clearance
Ab =bending allowance
α
Ab = 2π (R+Kba×t )
360
We can assume that thickness of the frame is equal to 5.5mm and bend radius is equal to 5mm.
AMIMTDE Page 51
If R<2t, Kba=0.3; and if R≥ 2t, Kba= 2t
Where: α =90 °
5<2×5.5 so Kba =0.3
90 °
Ab = 2π (5mm+0.3×5.5 mm) =10.44mm
306 °
Wf =150+60+10.44+8mm+20mm =248.44mm
= 248.5 mm
Therefore, the final dimension of frame should be
Lf =20.25m
Wf =248.5mm
MC M
tf=5.5mmStress of frame σ b= =
I Z
AMIMTDE Page 52
The force on the frame is like a uniformly distributed load on a simply supported beam.
Figure 4.13 shear force and bending moment diagram of frame
4986.96 N
So the load on its length ¿ =246.3 N /m
20.25 m
20.25
R1¿ R 2=246.3 × =2493.48 N
2
20.25 m
M ¿ 2493.48 N × −246.3 N /m× 20.25/2× 20.25/4
2
= 25246.48N.m- 12624.8N.m ¿ 12621.7N.m
I bh2
The moment of inertia modulus Z ¿ =
c 6
AMIMTDE Page 53
148.52 3
Z ¿ 5.5 × =20214.5mm
6
There are two frames in our design. So the force and the moment on each frame is divided by
two.
12621.7 N . m
Mmax¿ =6310.85 N . m
2
σ
b=6310.85×1000 N .
mm
=¿¿ 312.2Mpa
20214.5mm3
The shear stress on the frame
F 2493.48 N
τ= = =3.1 Mpa
A 148.5 mm ×5.5 mm
The maximum stress on the frame, ¿( σ ¿ ¿ 2+3 τ 2 )¿1/2
σ max= (312.22 +3 ×3.12) 1/2¿ 312.3 Mpa
Factor of safety, n
sy 551 Mpa
n¿ = =1.77
σ max 312.3 Mpa
From stress analysis factor of safety is greater than one; so the design of frame is safe.
4.4.5.Stress analysis of legs
The legs are the carrier component of all loads. Due to this reason the material it made up of is
hard and strong to resist bending and torsion loads. The design material is low carbon steel AISI
1045 it has the following mechanical properties.
Sut¿ 620 Mpa
Sy¿ 551 Mp
ρ=7830Kg/m3
The total loads on leg are the sum of all loads on it.
AMIMTDE Page 54
Mass of frames, m ¿ ρ ×V ρ × L× W ×t=216 Kg
9.81m
Wf¿ 216 Kg× =2125.9 N (for each frame)
s
Wt¿4986.48N+2×2125.9 N =9238.7 N
There is six legs therefore the load on each leg is equal to total load divided by four.
9238.7 N
Wmax¿ =1539.7N
6
The height of belt is 1m above ground. So the length of legs will be

Lleg¿ 1 m−h−t+2 × wbf +2 A b=¿1m-167.6mm-8mm+60mm+20.88mm ¿ 0.925 m
Where:
h = height of frame
t¿thickness of conveyed material
wbf= width of bending side of frame
To know the width of legs first know abending allowance Ab. [6]
α
Ab = 2π (R+Kba×t )
360
We can assume that thickness of the frame is equal to 5.5mm and bend radius is equal to 5mm.
If R<2t, Kba=0.3; and if R≥ 2t, Kba= 0.5
α =90 °
5<2×5.5, SoKba =0.3
90 °
Ab = 2π (5mm+0.3×5.5 mm) =10.44mm
306 °
Wleg¿ W bf + wb + A b=2 ×30 mm+50 mm+2 ×10.44=130.8 mm
AMIMTDE Page 55
Where: Wbf¿width of bend side frame
Ab¿bending allowance
Wb¿width between two bending side (if it equal to 50mm)
Figure 4.13 leg

Leg has buckling load. Therefore, check buckling load comparing with applied load.
Buckling load, Wbl =Cπ2EI /l2 where, E=elastic modulus
I= moment of inertia
C = end fixity coefficient
l = length of the column
Our selected material is mild steel that have E =0.21× 106 N/mm2, C = 4 for both fixed end
column, l = 41mm and I is find from the section.
1
I= (bd3-b1d31) for rectangle 50 50
12
AMIMTDE Page 56
1
Ixx1 = (50× 8543 – 39 ×8433)= 648.15×106mm4854
12
1
Ixx2 = (50×8543) = 2595.15×106mm5.5 1 2
12
Ixx= Ixx1+ Ixx2 = 648.15×106mm4 + 2595.15mm4 = 3243.3 ×106 mm4
1
Iyy1 = (854× 503 – 843 ×393) = 4.73×106mm4
12
1
Iyy2 = (854×503) = 8.89 ×106mm4
12
Iyy= Iyy1+ Iyy2 = 4.73×106mm4 + 8.89 ×106mm4= 13.62×106 mm4
So, Iyy<Ixx.Then, I = Iyy = 13.62 ×106 mm4.
Wbl = 4π2×0.21× 106 N/mm213.62 ×106 mm4/(41)2 mm2
= 6.7×107 KN
Applied load, Fapp of leg is 1539.7N.
Based on Euler formula applied load is less than buckling load the design is safe.
Therefore, Fapp<Wbl = 1539.7N <6.7 ×107 KN. i.e. design isSafe.
4.4.6.Stress analysis of belt
The belt which used for conveyor is usually chloroprene or neoprene synthetic rubber.
Commonly known today as Neoprene, it is an important specialpurposerubber. It is an especial
purpose of rubber. It has a good mechanical property than natural rubber. It has the following
mechanical properties. [5]
E = 7Mpa
Sut= 25Mpa
The standard flat belt thicknesses are 5, 6.5, 8, 10 and 12 mm. The preferred values of
thicknesses are as follows: [3]
(a) 5 mm for nominal belt widths of 35 to 63 mm,
AMIMTDE Page 57
(b) 6.5 mm for nominal belt widths of 50 to 140mm,
(c) 8 mm for nominal belt widths of 90 to 224 mm,
(d) 10 mm for nominal belt widths of 125 to 400 mm, and
(e) 12 mm for nominal belt widths of 250 to 600mm
Therefore in our design the thickness of belt is 12mm for width 600mm based on the above data.
A little consideration will show that the maximum tension in the belt (T) is equal to the total
tension in the tight side of the belt (T1). [3]
Let σ = Maximum safe stress,
b = Width of the belt, and
t = Thickness of the belt.
We know that the maximum tension in the belt,
T = Maximum stress × Cross-sectional area of belt = σ.b.t
T1 6224.39
σ= = =0.86mpa
b .t 600 mm× 12 mm
From the above calculation we can generalized the design is safe. Because ofthe maximum stress
is less than the tensile strength of belt.
4.5 Final design and result of belt conveyor
4.5.1 Design of Roller (pulley)
Design of roller is the crucial part of design. This roller is design based on the belt width and also
length of shaft. Mostly roller or pulley is manufactured by using low carbon steel and cast iron.
So we selected low carbon steel because low carbon is more preferable than cast iron due to high
tensile strength.
Outer diameter, Do=150mm
Length of roller, Lr =65mm
AMIMTDE Page 58
From stress analysis we can get the thickness or internal diameter of the roller.
2 2
πd 2 π (Do −di )
=
4 4
Where: d = diameter shaft in roller
Do = outer diameter of roller
Di =internal diameter of roller
t = thickness 0f roller
452 1502 Di2

π× =π ( − ¿
4 4 4
Di =√ 1502−452mm
Di = 143mm
To use the standard bearing the internal diameter must be standard. So the internal diameter
equal to 140mm.
t = 150mm-140mm =10mm
Factor of safety, n = 3.4
4.5.2 Design of belt
The rubber belt has plies, steel chords and fibers. They are calculated bellow. [1]
Number of steel chords, n
tmin=50.n.B
1956.39 N
n= =65/9.81 =6.6 7 chords of stel
50× 0.6 M
Where: tmin=slake side tension
B = width of belt
Number of fibers, N
AMIMTDE Page 59
T 6224.3 N
N= = =1.76 2 no of fibers
KB 6 kg /cm×60 cm ×9.81 m/s 2
Where:
N = number of fiber
K = resistance of one fiber per unit width (it varies from 5 to 7kg/cm width and per fiber)
B = width of belt = 600
Therefore in our design the thickness of belt is 12mm for width 600mm based on the above data.
4.5.3 Design of shaft
 Material = stainless steel 304 cold worked

 Maximum diameter, D =45mm
 Minimum diameter, d = 40mm
 Length of shaft, Lsh = Lbs+2tf+c =68.5cm+5.5mm ×2+5 cm =74.5mm ~ 75cm
Where:
Lbs = length of brace support
tf = thickness of frames
 Factor of safety, n =1.5
4.5.4 Design of Idler
Length of idler = belt width +edge clearance. Edge clearance for belt width 600mm is 50mm.
=600mm+50mm
=650mm
Based on this data we select idler, havingdiameter of 63.5mmfor the cause of small weight of
conveyed materials and smaller length of idler. Therefore;
Outer diameter = 63.5mm
Inner diameter = 58mm
AMIMTDE Page 60
Figure 4.14idler
4.5.5 Design of motor for belt conveyor
In order to determine the required motor power (KW), we use the total resistanceR(kg) and
calculate the power P. [1]
Rv
P=
102η
Where:η = efficiency of motor
T =belt tension on drive side
t = tension on slake side
v =roller speed
output power
η= 1-
input power
Tv
=1-
tv
1956.8 N × 0.5m/ s
= 1-
6224.39 N × 0.5 m/ s
= 0.7
4267.5
P = 9.81 )
( kg × 0.5 m/s
0.7 ×102
= 3KW
AMIMTDE Page 61
3
= Hp =4.09Hp
0.746
Therefore the selected motor is
Motor three phase Ac motor
Power = 3kw
Input = three phase
Output speed = 1500rpm
Shaft diameter = 28mm
Shaft length = 60mm
4.5.6 Design of pulley for roller and Motor shaft
AMIMTDE Page 62
Figure 4.15 speed reduction system

The diameter of roller shaft pulley must be greater than the diameter of motor shaft pulley, in
order to decrease speed of belt. To know the allowable diameter of pulley use velocity ratio is
preferable in this design.
It is the ratio between the velocities of the driver and the follower or driven. It may be
expressed, mathematically, as discussed below.
The material to design this pulley is cast iron.Because of to reduce vibration of motor.
d1 = Diameter of the driver,
d2= Diameter of the follower
N1= Speed of the driver in rpm.
N2 = Speed of the follower in rpm
Since the length of belt that passes over the driver in one minute is equal to the length of belt that
passes over the follower in one minute, therefore
Πd1N1= πd2N2
N 2 d1
=
N1 d2
If the diameter of roller shaft pulley is equal to the diameter of roller, the diameter of motor shaft
roller will be known.
N1= 1500r.p.m
v ×60 0.5 m/s ×60

N2 = = =63.7rpm
πd 2 π × 0.15 m
N2 63.7 rpm
d1 = ×d2 = × 150 mm = 6.37mm
N1 1500rpm
AMIMTDE Page 63
Figure 4.16pulleys or drums
AMIMTDE Page 64
The diameter of motor shaft pulley from the above calculation is not safe or preferable. Because
there is not standard pulley in this diameter and it is less than diameter of motor shaft. The speed
ratio is very high then this speed reduction is by using compound pulley.
Given data:
N1 = 1500rpm
N4 = 63.7rpm
If the diameter of pulley of motor shaft is 40mm, and speed of motor is decrease to 350rpm in
the first belt pulley. So N2 = N3 = 350rpm, and d3 =45mm
N1 1500 rpm
d2 = d1 = 40mm × = 171mm
N2 350 rpm
N3 350 rpm
d4 = d3× =45× = 247mm
N4 63.7 rpm
Figure 4.17 power transmission systems

4.5.7 Design of belt for power transmission
In this project power transmission between motor and roller of conveyer is by using belt drive.
So the belt type, length, width, and thickness is must be designed.In this project two belts are
needed and assume the middle shaft is at center distance between motor shaft and conveyor
roller.
AMIMTDE Page 65
Figure 4.18 belt

The length of belt between pulley one and pulley two
The total conveyor height is 1m, which means the distance between ground and conveyor roller
is 1m.
If the motor is mounted on ground and the motor shaft center is 10cm above ground; then the
center distance between motor shaft and roller shaft center is 90cm.
AMIMTDE Page 66
C 90 cm
c1 =c2= = = 45cm
2 2
d1= 40mm
d2 = 171mm
−1 d 2−d 1
θ d1 = π - 2sin
2c
−1 171−40
= π - 2sin = 163.3°
2 × 450
−1 d 2−d 1
θ d2 = π + 2sin
2c
−1 171−40
= π + 2sin = 196.7°
2 × 450
1
L = √ 4 c2 −(d 2−d 1)2+ (d1θ d1+ d2θ d2)
2
1
= √ 4 × 4502 −(171−40)2+ (40×163.7 °+ 171×196.7 °)
2
= 1240.4mm
Length of belt between pulley three and pulley four
d3 = 45mm
d4 = 247mm
−1 d 4−d 3
θ d3 = π - 2sin
2c
−1 247 mm−45 mm
= π - 2sin
2 ×450 mm
= 154°
−1 d 4−d 3
θ d4 = π +2sin
2c
AMIMTDE Page 67
= 206°
1
L = √ 4 c2 −(d 4−d 3)2+ (d3θ d3+ d4θ d4)
2
1
= √ 4 × 4502 −(247−45)2+ (45×154 °+ 247×206 °)
2
= 1381mm
The standard flat belt thicknesses are 5, 6.5, 8, 10 and 12 mm. The preferred values of
thicknesses are as follows: [3]
(a) 5 mm for nominal belt widths of 35 to 63 mm,
(b) 6.5 mm for nominal belt widths of 50 to 140mm,
(c) 8 mm for nominal belt widths of 90 to 224 mm,
(d) 10 mm for nominal belt widths of 125 to 400 mm, and
(e) 12 mm for nominal belt widths of 250 to 600mm
For both belts we can select 5mm thickness and 35mm width of belt because of this belt used to
transfer small power.
If the width of the belt is known, then width of the pulley or face of the pulley ( wp) is taken
25% greater than the width of belt (wb). [3]
wp =1.25wb
wp= 1.25×35 mm=43.75 mm 44 mm
AMIMTDE Page 68
4.5.8 Design of shaft for first stage speed reduction
The shaft in first stage speed reduction is used to speed reduction between motor shaft and roller
shaft. The material is gray cast cast iron in order to reduce of vibration of motor
P = 3kw
N= 350rpm
π dN π ×171 ×350 rpm

V= = = 3.14m/s
60 60
The torque transmitted on the shaft is,
P = T× v, T = p/v
3 kw
T= = 955.4N.m
3.14 m/s
The force on the shaft is calculated as follows,
2T 2× 955,4 Nm
F= = =11174N
d 0.171m
The diameter of motor shaft is 28mm and roller shaft is 45mm. So we can assume that the
diameter of the middle shaft is less than 45mm (d3). So we take 35mm diameter shaft.
Figure 4.19 small shaft
AMIMTDE Page 69
4.5.9 Design of key
A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to considerable
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key. [3]
There are 5 types of keys such as: sunk keys, saddle keys, tangent keys, round keys, and, splines.
But in this design a rectangular sunk key is preferable.
Rectangular sunk key: A rectangular sunk key is a rectangular shaped key. The usual
proportions of this key are:
Width of key, w = d / 4; and thickness of key, t = 2w / 3 = d / 6
Where: d = Diameter of the shaft or diameter of the hole in the hub
The diameter of the main shaft is 45mm in the roller. So thickness and width of key is9mm and
14mm respectively.
W = 45/4 =11.25mm ~12mm
t = 45/6 = 7.5mm
The material used for design shaft is Stainless steel 304 cold worked. Yield strength of 551mpa
and factor of safety of 1.5.
The key material is AISI 1018 mild steel that has yield strength of 370mpa.
If the factor of safety is assume that 2 then the maximum shear and crushing stress is as follows.
According to maximum shear stress theory the maximum shear stress for the shaft is,
s yt 551mpa
τ max = = = 137.75mpa
n 2 ×2
And maximum shear stress for the key is
AMIMTDE Page 70
s yt 350
τk = = = 87.5mpa
2 n 2× 2
And the maximum crushing stress of key is,
syt 350
σ max = = = 175mpa
n 2
We know that the maximum torque transmitted by the shaft and key is,
π 3
T= d × τ max
16
π
= × 453 mm3 ×137.75 mpa = 2.45×106N.mm
16
First of all, let us consider the failure of key due to shearing. We know that the maximum torque
transmitted (T),
d 45
T = 2.45×106 = L×w× τ k × =L×12mm×87.5mpa× =L ×23625Nmm
2 2
L =103.7mm
Now due to crushing consider the failure of key. We know that the maximum torque transmitted
by the shaft and key (T),
t d
T =2.45×106 =σ max × L× × = 175mpa×L×8/2×45/2
2 2
L = 155mm
Therefore the length of the key is the largest value, which is 155mm. but the width of disc is 25
mm so the length of the key is 25mm. so
L = 25mm
AMIMTDE Page 71
Figure 4.20 key

4.5.10 Selection of bearing
Bearing is a mechanical part that used to transfer the main load to the element in rolling contact
rather than in sliding contact. It divides in to two types. These are roller bearing and ball bearing.
For our design, we select ball bearing.
AMIMTDE Page 72
Figure 4.21 ball bearing

Designed shaft diameter is 40 mm because of this bearing bore diameter is must be the same
(40mm).By using bore diameter = 40mm we can get other dimension from standard table yyy[ ].
Outer diameter, OD = 68mm
Width = 10
Filet radius = 1mm
Shaft diameter, ds = 46mm
Hole diameter, dH = 72mm.
Table 4.6 dimensions and load ratings for single-row O2-series deep-groove and angular-contact
ball bearing
AMIMTDE Page 73
4.5.11 Selection of bolt
Bolt and nuts are an important mechanical element that used to join two or more nonpermanent
parts. In ourdesign we select M16. The material is AISI1020 low carbon steel.
Major diameter = 16
Effective or pitch diameter =14.701mm
Pitch = 2mm
Minor or core diameter = 13.546mm
Depth of belt = 1.534mm
Length of bolt ¿ 40
Table 4.7 selection of bolt and nut table
AMIMTDE Page 74
4.5.12 Selection of screw
Major diameter = 16mm
Length =160mm
4.6 Cost analysis

The cost of the belt conveyor is the sum of its components cost. This means the cost is the
combined cost of production cost and raw material cost.
AMIMTDE Page 75
This analysis is made based on current market. So
1$ = 29 birr
1 ton = 1000kg
Cost of shaft
Volume of shaft v,
Vsh = π d 2 ×l /4 = π d 2( l1+l 3)+_ π D 2 l 2
¿ π 40 2 ( 50 mm+110 mm )+ π 452 650 mm

4
= 0.001234m3
Density of shaft is 8000kg/m3.
Mass of total, mt = ρ × v = 8000kg /m3 × 0.001234 m3= 9.872kg
key mass mk =ρ ×l ×w × t = 7870 ×25×12 ×7.5=0.017 kg
Mass of shaft, msh=mt-mk = 9.855kg
Twoshafts has total mass 19.71kg
Price of stainless steel is 30birr/kg
Price = mass×msh= 597birr
Cost of roller
Mass of roller, mr =ρv=ρ ¿ - πd 32 ×l /4
(2× π ×(174 mmm)2 25 mm+ π ×〖(1500 mm)〗2 ×600 mm) 1362

mr = 7870× -π × 650 ×
4 4
= 18.48kg
The material is low carbon steel AISI1020 steel, cost is 550$/ton
C= 18kg×15.95birr =287.1birr
AMIMTDE Page 76
Cost of idler
Mass of idler ,mi
(D ¿ ¿ 2−d 2 )l × ρ
mi = π ¿
4
63.52−582
=π 695 ×7079 kg /m 3 = 2.58kg
4
But there are 8 idler so the total mass is 20.68kg
Cost of gray cast iron 17birr/kg
Ci = 20.68kg×17birrr/kg =353.83birr
Cost of disc
Vd = Vouter ring +Vinner ring + Vrectangulaaar
D 02−do2 Di2 −di 2

π l+π l+l ×w × h
4 4
1362 −1222 mm2 852 −452

π × 25+ π 25+ ¿4×18.87 × 25× 20
4 4
= 0.00021m3
Mass of disc, md = 0.00021m3×7870 kg / m3 – mk = 1.64kg
There are four disc, total mass = 6.564kg
Price of AISI 1020 carbon steel is $450-600 /ton.
Price = 500$/ton× md = 104.70birr
Cost of frames
AMIMTDE Page 77
Mass of frame, mf = 2 ×l× w ×t × ρ=20250 mm ×248.5 ×5.5 × 7830 kg/mm 3
= 433.4kg
Price of AISI 1045 mild steel is $450-500 /ton.
Price = 500$/ton×msh= 5624.56birr
Cost of speed reduction components
Cost of pulley-1
D 2−d 2
Mass of pulley, mp = π l× p
4
402−352
m=π 44 ×7870=0.101 kg
4
Ci = 0.101kg×17birrr/kg = 1.717birr
Cost of pulley 2
Vp= Vouter ring +Vinner ring + Vrectangular+Vgroove
D 02−do2 Di2 −di 2 D 02−do2

=π l+π l+l ×w × h+ π l
4 4 4
1872−1642 502−352 1712−167 2

¿π 9+π 44+4 ×58.48 ×20 × 44+ π 35
4 4 4
= 3.75×10−4
mp2 = 3.75×10−4×7870kg/m3 = 2.9kg
AMIMTDE Page 78
Cost of pulley-3
Vp= Vouter ring +Vgroove
612−35 2 452−352
¿π 9+π 44
4 4
=0.4×10−4m3
Density of pulley-3 is 7870kg/m3
Mass,m= ǷV
=7870kg/m3×0.4×10−4m3
=0.315kg
Cost of pulley-4
Vp= Vouter ring +Vinner ring + Vrectangular +Vgroove
D 02−do2 Di2 −di 2 D 02−do2

=π l+π l+l ×w × h+ π l
4 4 4
2632−2402 602 −402 2472 −2402

¿π 9+π 44+4 ×91.3 ×20 × 44+ π 35
4 4 4
=5.66×10−4m3
Density of pulley-4 is 7870kg/m3
Mass,m= ǷV
m =7870kg/m3×5.66×10−4m3
=4.45kg
AMIMTDE Page 79
Cost of belt-1
π
V= 2×t ×l× w+ ((D12-D22) + (d12-d22)) w
8
π
= 2×5 × 445 ×35+ ((18112-17122) + (5012-4022)) 35
8
= 2.17 ×10−4m3
Density of rubber = 1140kg/m3
Mass, m = ρ × v=1140 kg /m3 × 2. 17 ×10−4m3
m= 0.247kg
Cost of rubber 1.43$/kg
41.47 birr/kg×0.247kg = 10.24 birr
Cost of belt-2
π
Volume of belt-2, V = 2× l× w ×t + ((D12-D22) +(d12-d22)) w
8
π
= 2× l438.5 × 35 ×5 + ((25712-24722) + (5512-4522)) 35
8
= 0.83 ×10−4m3
Density of belt-2 is 1140kg/m3.
Mass, m =ρ × v=1140 kg /m3 × 0.83 ×10−4m3
= 0.269kg
41.47birr/kg×0.269 = 11..8 birr
AMIMTDE Page 80
Cost of small shaft
Vsh = π d 2 ×l /4 = 1.9×104 =
m = 1.345kg
c =22.86birr
Cost of Leg
Volume of leg, V= L × W ×t
= 925× 130.5× 5.5 mm3
= 6.65×10−4m3
Density of leg is 7830kg/m3.
Mass of leg, ml = ρV = 7830kg/m3×6.65×10−4m3
= 5.21kg
So for six legs, mass of leg is, ml = 6×5.21 kg =31.24 kg.
Price of AISI 1045 mild steel is $450-500 /ton.
Price = 500$/ton×msh= 5000×31.24 =407.68birr
Cost of main belt
π
V= 2× l× w ×t + ((D12-D22) + (d12-d22)) w
8
π
2× l× w ×t + ((D12-D22) + (d12-d22)) w
8
2π
= 2× 20000× 600 ×12 + ((1742-1502) 600
8
Density of belt-2 is 1140kg/m3.
Mass of belt m =0.291×1140 kg/ m 3 =331kg
AMIMTDE Page 81
Density of rubber is 1140kg/m3
29 birr/kg×331kg = 13,726.57birr
Total cost of conveyor
(597+287+353.8+104.7+ 5624.56+1.71+5.96+75.65+10.24+11.8+22.86+407.68+13, 726) birr

=21, 228.4 birr
4.7. Conclusion and recommendation
4.7.1 Conclusion
In this project we designed belt conveyor that used to conveying or transporting components of
machines and different structures from one workshop to other shop. This machine can convey
materials by speed of 5 m/s and 20m.
Generally we can conclude that we can overcome problems in transporting method by human
effort by designing the proposed model of belt conveyor to reduce different crisis or disturbance.
A belt conveyor is needed to very careful design and manufacturing due to it should be give
great careful and longer time because of if failures occur there is a great destruction of materials,
products, human life and other related damages.
Finally we recommended that when using belt conveyor for log time of life it may be stretched
above the critical length and the belt is not move. The above problem is ignored by using of
screw and increase center distance.
AMIMTDE Page 82
4.8 General Conclusion and recommendation
4.8.1 Conclusion
Internship is a crucial program to develop knowledge, improving skills, up grading theoretical

skills, tem working skill, entrepreneur ship skills, leadership skill, and understanding about work
ethics.
We have been working in Amhara metal industry and machine technology development
enterprise /AMIMTDE /during our four months internship period and we had enjoyed for
different practices. Since we have upgraded our knowledge about our field mechanical
engineering and what we have learned in theoretically. We have got enough knowledge about
our field with the necessary benefits.
In the time of internship period for about four months we have observed many problems and
strength of the company,so we made the following recommendations.
• Each and every material in the company that is not in use are material that can be used by
others as row material.
• It’s better if they give students same work tasks & leave it to them. Simply trust them
• There is material thrown and out of use like, the cutout metals, old machines that requires
simple maintenances
Finally, we recommend Bahir Dar University to keep on giving the internship chances to the
students in order to let the student get enough knowledge about the courses and the freedom of
working in more than one company in their internship time to gather different knowledge from
different company.
AMIMTDE Page 83
REFERENCE
1. Daniel kitaw,“Material handling equipment text book”.
2. Siddhartha Ray, “Introduction to material handling”. New Delhi. New age publisher, 2008.
3. R.S. Khurmi and J.K, “Gupta A text book of machine design”. 14 thed, Ram Nagar Delhi,
Eurasia publishing house, 2005.
4. Recharge G. Budyansand KeithNisbett, “Shigley’s Mechanical engineering design”. 8 thed.

New York, McGraw-Hill companies, 2008.
5. Mikell P. Groover, “Fundamental of modern manufacturing materials processes, and systems”.

4th ed. Lehigh University, Johan Wiley and son, 2010.
6. E. J. Hearn, “an introduction to Mechanics of Elastic and plastic deformation of solids and
structural material”. 3rd ed. University of Warwick United Kingdom,Scotprint, mussel burgh,
2000.
7. Palayo Lopez Garcia, “Design of belt conveyor”. Ljubljana, June 2016.
8. www.wiekipidia. Com
AMIMTDE Page 84
AMIMTDE Page 85

Internship Design of Belt Conveyor Project

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INTERNSHIP REPORT AND PROJECT WORK

Bahir Dar University

Faculty of Mechanical and Industrial Engineering

Mechanical Engineering program

Project Title: Design and Model of Belt conveyor

BY:DesalegnMasresha (0800644(ID NO.)

Mentor: Mr. HenokMebrate

Company Supervisor: Mr. Awel. M

Date: 15/ 1/2012 e.c

Name of student Signature

Name of school advisor signature Date

Mr.HenokMebrate ______________ 15/1/2012 E.C

1.1 History of company...............................................................................................................1

1.2. Product of company or service of the company...................................................................2

1.3. Main customers or the end users of its products or services.................................................5

1.4 Its organizational structure....................................................................................................5

1.5. Work flow.............................................................................................................................6

2.1. Our working section of the company....................................................................................6

2.2. Work tasks..........................................................................................................................10

2.3. Engineering methods, tools and techniques........................................................................11

2.4. Major challenges and problems we have been facing........................................................11

2.5. Measurements taken in order to overcome these challenges and problems.......................12

2.6. Improving practical skill.....................................................................................................12

2.7. Upgrading theoretical skill.................................................................................................12

2.8. Improving team playing skill..............................................................................................13

2.9. Improving leadership skill..................................................................................................13

AMIMTDE Page iii

2.11 In terms of entrepreneurship skills....................................................................................14

In the internship period we gained the following entrepreneurship skills;..............................................14

2.12 In terms of improving your interpersonal communication skills.......................................14

2.13 Conclusions and Recommendations..................................................................................14

3. DESIGN OF BELT CONVEYOR............................................................................................15

3.1 SUMMARY OF THE PROECT.........................................................................................15

3.3 Types of belt conveyor........................................................................................................17

3.4 Advantages of belt conveyor...............................................................................................19

3.5 STATEMENT OF PROBLEM............................................................................................20

3.6 OBJECTIVE OF THE PROJECT.......................................................................................20

3.6.1 GENERAL OBJECTIVE.............................................................................................20

3.6.2 SPECFIC OBJECTIVE................................................................................................20

3.7 COMPONENTS OF BELT CONVEYOR..........................................................................21

3.8 LITERATURE REVIEW....................................................................................................23

3.9 METHODOLOGY OR PROCEDUR.................................................................................24

4. DESIGN AND ANALYSIS OF BELT CONVEYOR..............................................................25

4.1 INTIAL INPUT DATA.......................................................................................................25

4.2 GEOMETRIC ANALYSIS OF BELT CONVEYOR.........................................................27

4.2.1 ROLLER OR PULLEY GEOMETRY.........................................................................27

4.2.2 GEOMETRY OF BELT...............................................................................................29

4.2.3 Geometry of shaft.........................................................................................................29

4.2.4 Geometry of Frame.......................................................................................................30

4.3 FORCE ANALYSIS OF BELT CONVEYOR...................................................................31

4.3.1 Capacity of belt conveyor.............................................................................................31

4.3.2 Resistance Forces..........................................................................................................32

4.3.3 Tension force calculation..............................................................................................34

4.4 Stress analysis of belt conveyor...........................................................................................36

4.4.1 Design of Belt Conveyor Shaft.....................................................................................36

4.4.2 Stress analysis of roller.................................................................................................43

4.4.3 Stress analysis of Idler..................................................................................................45

4.4.4.Stress analysis of frame................................................................................................47

4.4.5.Stress analysis of legs...................................................................................................52

4.4.6.Stress analysis of belt....................................................................................................55

4.5 Final design and result of belt conveyor..............................................................................56

4.5.1 Design of Roller (pulley)..............................................................................................56