AKSUM UNIVERSITY INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL
AND INDUSTRIAL ENGINEERING
PROJECT TITLE: DESIGN AND MODIFICATION OF PLATE
PICK AND PLACE WITH BELT CONVEYOR
PREPARED BY:
GUESH EMBAYE
MUSSIE G/HIWOT
YONATAN YIBRAH

June 2024
 DECLARATION
This thesis work is our original work and has not been presented for a degree in any other
university, and that all source of material is duly acknowledged.

TITLE OF THE PROJECT: DESIGN AND MODIFICATION OF PLATE

PICK AND PLACE WITH CONVEYOR FOR CAMPUSS CAFETERIA.

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 Acknowledgment
First of all, we would like to say thanks for God and our advisors who are very intelligent and
kind instructor to contribute moral and material supports for the successes of this project.
Secondly, we would like to thank for our families to contribute their own contribution to done
this thesis. Finally, we would like to thank AKU student café workers.

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 ABSTRACT
In the manufacturing industry and sites, pick and place with conveyor is essential equipment
because the row materials and products need to be transport from one process stage to the other
stage. The transportation system can be manually, semi-manual or automated systems. Material
handling equipment’s are designed such that facilitate easy, fast, cheap, free damage and safe
loading and unloading with least human interference. Conveyor system is a common device of
mechanical handling equipment that moves materials from one location to another location. The
application and installation of the conveyor system is not restricted. This project shows the
design and modification of pick and place with belt conveyor system in AKU Student cafeteria
to transport and handle for food and food services. Mathematical analysis is applying by
considering and using idlers/roller, based on size, length capacity and speed, width, idler spacing
power and tension, arrangement of conveyor, types of driving units and selections, link force
analysis and selection, spring and bearing selection for intended application in order to ensure,
fast, continuous and efficient handling of services and foods in the AKU students café, while
avoiding damage, injury and time consumptions. During loading and unloading, findings to put
the calculated value in result form and short and clearly cost estimation is done. There is also
design costs, recommendations and conclusions in the study.

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TABLE OF CONTENT
DECLARATION .............................................................................................................................................. iii
Acknowledgment ......................................................................................................................................... iv
ABSTRACT...................................................................................................................................................... v
TABLE OF CONTENT ....................................................................................................................................... i
ABBREVIATIONS ..................................................................................................................................... iii
CHAPTER ONE ............................................................................................................................................... 1
INTRODUCTION ............................................................................................................................................. 1
1.1 BACKGROUND ......................................................................................................................................... 1
1.2 Scope of Project ...................................................................................................................................... 1
1.3 PROBLEM STATMENT.............................................................................................................................. 2
1.4 WORKING PRINCIPLE .............................................................................................................................. 2
1.5. Objective ................................................................................................................................................ 3
1.7. Significance of the Project ..................................................................................................................... 3
1.8. Limitation of the project ........................................................................................................................ 3
CHAPTER TWO .............................................................................................................................................. 4
LITERATURE REVIEW ..................................................................................................................................... 4
CHAPTER THREE ............................................................................................................................................ 6
DETAIL DESIGN .............................................................................................................................................. 6
3.1 Methodology .......................................................................................................................................... 6
3.2 DETAIL DESIGN ANALAYSIS ..................................................................................................................... 8
3.2 Detail design of pick and place ............................................................................................................... 8
3.2.1 Inverse kinematics analysis................................................................................................................ 8
3.2.2 Gripper with design............................................................................................................................ 11
3.2.3 Gripper arm design ............................................................................................................................ 13
3.2.4 Link2 design....................................................................................................................................... 16
3.2.5 Pin design for link-2.......................................................................................................................... 19
3.2.6 Link1 design..................................................................................................................................... 20
The material selection we select is stainless steel grade 304 which have: .................................................. 20
3.2.7 Pin design for link1 ........................................................................................................................... 23
3.2.8 Base design ........................................................................................................................................ 24
Product Specification ........................................................................................................................ 31

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3.3 DESIGN OF CONVEYOR.......................................................................................................................... 32

3.4 Cost analysis of pick and place and belt conveyor................................................................................ 66
CHAPTER FOUR ........................................................................................................................................... 68
RESULT AND DISCUSSION ........................................................................................................................... 68
4.1 RESULT .................................................................................................................................................. 68
4.2 DISCUSSION........................................................................................................................................... 68
CHAPTER FIVE ............................................................................................................................................. 69
CONCLUSION AND RECOMMENDATION .................................................................................................... 69
5.1 CONCLUSION ......................................................................................................................................... 69
5.2 RECOMMENDATION ............................................................................................................................. 69
REFERENCES ................................................................................................................................................ 70

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ABBREVIATIONS

AKU…………………………………………………...…………aksum university
A ……………………………………………...…………..…..… cross sectional area
W ………………………………...…………………………...… width / depth
C …………………………………………………………………distance b/n axis and end fiber
I………………………………………………………………......moment inertia
Z…………………………………………………………..……. .Section module
E……………………… ………………………………….……. modulus of elasticity
dm.. ………………… …………………………………………..mean diameter
τmax……………… …………………………………..……….. .shear maximum
Pb……………………………………………………….………..bearing pressure
Wcr…………………………………………………….……… ..crushing load
σb………………………………………………………………... bending
A…………………………………………………………..… .....cross sectional area
Sy. ……………………………………………………………….yield strength
Sut…………………………………………………………… ….ultimate strength
m. ………………………………………………………………...mass
g…………………………………………………...…………….. gravity
F……………………………………………………………… ...force
G……………………………………………………..…………...modulus of rigidity
T... ……………………………………………….………………torque
P. …………………………………………………………..…….power
Fs………………………………………………………….……..ns-factor of safety stress
τs………………………………………………………………....shear stress
D………………………………………………...……………... .nominal diameter
Di…………………………………………………………………Inner diameter
Do.. …………………………………………………..………….Outer diameter
T.....................................................................................................torque
t………………………………………………….……………… .thickness
M....................................................................................................moment

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LIST OF FIGURES
Figure1.1 students waiting line and plate stack……………………………………….2
Figure 3.1 Methodology diagram used for doing the project…………………………………..7

Figure 3.2 Figure slider mechanism of pick and place manipulator………………………….8

Figure 3.3 Figure slider mechanism free body ………………………………………………9
Fig 3.5 slider with roller………………………………………………………………..28
figure 3.6 spring drawing………………………………………………………………29
figure 3.7 magnet………………………………………………………………………30
Fig 3.8 agitator motor………………………………………………………………….31
Figure 3.9 cross sectional area and angle of repose for belt conveyor………………………..40
Figure 3.10 roller……………………………………………………………………………..47
Figure 3. 11 AC motor……………………………………………………………………...…52
Figure -3.12 Radial ball bearings and housing…………………………………………….…58
Figure 3.13-bearing cap……………………………………………………………………….61
Figure 3.14 - frame of conveyor………………………………………………………………64

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CHAPTER ONE
INTRODUCTION
1.1 BACKGROUND
Plate pick and place with conveyor machines are automated systems designed to efficiently
handle plates or objects in manufacturing processes. These machines typically consist of robotic
arms equipped with grippers to pick up plates from one location and place them onto a conveyor
belt for further processing. In today’s factories and shop floors, industrial automation is
everywhere and it is difficult to imagine a production line without automation. These systems
operate industrial equipment automatically, significantly reducing the level of operator
involvement and oversight required. One machine/mechanism that is most visible in industrial
automation is the Mechanical pick and Place mechanism. Pick and place automation speeds up
the process of picking up parts or items and placing them in other locations. Automating this
process helps to increase production rates. Pick and place robots handle repetitive tasks while
freeing up human workers to focus on more complex work. The Mechanical Pick & Place
Machine, our project, aims to show the simple working of the mechanism. The mechanism
consists of rotating, reciprocating and oscillating motions. Conveyor system is a common device
of mechanical handling equipment that moves the materials from one location to another
location. Conveyors are especially useful in the applications involving the transportation of
heavy or bulk materials. Conveyor systems allow quick and efficient transportation for a wide
variety of materials, which make very popular in the material handling and packaging industries.
They can be installed almost in anywhere, and are much safer than using other types of
equipment’s. A pick and place mechanism is a system commonly used in manufacturing and
assembly processes to automate the task of picking up objects from one location and placing
them in another. This mechanism is often employed in various industries to increase efficiency,
accuracy, and speed of production processes. Conveyor System in In a campus cafeteria setting,
a conveyor system can be integrated with a pick and place mechanism to streamline the process
of serving food to customers. The conveyor belt serves as a platform for transporting food items
from the kitchen or preparation area to the serving counter where the pick and place mechanism
operates.

1.2 SCOPE OF PROJECT

The scope of the project includes; Design pickup mechanism, transport, and placing plate
accurately. integrate the pick and place with the cafeteria conveyor system insuring smooth plate
movement. implement safety protocol to prevent accident including emergency stop button and
safe guards for the handling mechanism. someone should be assigned to arrange the plate to be
served and also control the on/off the machine to prevent the falling of plate. It needs regular
cleanliness’.

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1.3 PROBLEM STATMENT

At AKU campus student's cafeteria, the transportation of food items and food service materials is
currently done manually. There is no conveyor system or other automated tray picking
mechanism. manual handling prevails in the student's café. However, the manual material
handling system has been associated with several drawbacks. These include the need for high
physical exertion, unsanitary, reliance on a large workforce, time inefficiencies, compromised
food cleanliness, potential conflicts, damage to service materials, and work-related injuries .The
student's cafeteria employees many worker, Given these challenges, there is a necessity for the
design and implementation of a design and modification of plate pick and place with conveyor
for campus cafeteria. in the student cafeteria to address the aforementioned issues effectively. we
are also trying to use pick and place mechanism to pick plate and put it on conveyor to make it
easier for the students in cafeteria.

Figure1.1 students waiting line and plate stack

1.4 WORKING PRINCIPLE

The machine operates by first having the operator stack plates onto the helical spring. The
conveyor is then turned on, followed by the pick and place machine. This machine uses magnetic
force to pick up each plate and deliver it to the moving conveyor. The project main responsibility
is to make smooth flow of work with time saving way, so to make that happen we used to
different mechanical machines the first one is pick and place and second one is conveyor as we
mentioned above our main goal is to pick a plate put it on the conveyor then the workers put the
food on it then it pass which will make it easier for the student to pick the food and eat.

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1.5. OBJECTIVE
1.5.1. General Objective
Design and modification of plate pick and place with conveyor for campus cafeteria.

1.5.2. Specific Objective

▪ Select the proper materials for production of Belt Conyers.

▪ selection of bearing, bolt, roller, shaft, pulley, using mathematical and statistical method
▪ Cost estimation of design and development of plate pick and place with conveyor
 Drawing parts and assembly in solidwork

1.7. Significance of the Project

The design project has different advantages
 To minimize the transportation problem of services and foods in the student’s
cafeteria.
▪ To keep the smile of food and services material quality.
▪ Avoidance of damage of service material and injury of workers.
▪ Reduced time consumption.
▪ Improve safe operations of workers.

1.8. Limitation of the project

This project entirely concerned with the plate pick and place with design of belt conveyor in
order to provide alternative
transportation of food items and services. But have the following limitation.
 Initial electric power is required to operate the belt conveyor and the plate picker to
facilitate since the conveyor system uses electrical power to run the electric motor.
 Needs manual loading from the ground which needs human effort.
 Has safety risk during loading and removing the item
 The plate pick and place can only carry metal plates up to load which make our design
very limited purpose
 The chefs who put wot and injera should be active because the are operating on conveyer
with running power.

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CHAPTER TWO
LITERATURE REVIEW
They take inspiration from the octopus, whose exceptional dexterity, changing stiffness, and
extremely complicated behaviour make for an intriguing robotics model. In this experiment, they
examine the primary characteristics and patterns of the octopus arm's movement. They come
tothe conclusion that the mechanism at the base of the robotic arm, which was modelled after the
muscular hydrostat of the octopus, worked as intended. [1]M.Cianctietti, A.Arienti,
B.M.Follador, B.Mazzalai, P.dario[1]

The major goal of the project by Ravi Kumar Mourya, Amit Shelke, and Saurabh Satpuite [2] is
to build and implement a four DOF pick and place robotic arm. They came to the conclusion that
the ideal manipulator was modelled using CAD software such as Creo1.0 and Auto CAD.
Theoretical inverse kinematics analysiswas done to ascertain the position and orientation of the
end effectors. FE Analysis was performed using Ansys software. [2] Prof. S.N.Teli, Akshay
Bhalerao, Sagar Ingole [3] ,The purpose of this project is to design and build a pneumatic arm
that can pick up and position cylindrical objects. They get to the conclusion that the manual
defect control and direction control valve regulate the arm. By using a helical slot mechanism, a
pneumatic cylinder rotates and moves thearm. 25 kg are in each arm's weight. The model should
be able to lift at least 10 kg. R. Ballamurgan [4], S. Premkumar, K. Surya Varman The purpose
of the experiment is to combine a pick-and-place robotic arm with a suction sucker and gripper
mechanism. These robots have a single robotic arm that is capable of grabbing, sucking, lifting,
placing, and releasing objects. It will cut down on cycle time, ideal time, operating costs, and
space usage. It is simple to use and works well for handling glass. [3]M.Pellicciari, G.Berselli,
F.Leali, A. Verganana [7] This research demonstrates a technique for lowering the pick- and-
place robotic arm's overall energy usage. Following the development of electromechanical
models for both series and parallel manipulators, constant time scaling is used to determine the
energy-optimal trajectories. It has been observed that completely dismantling a system is not
always advantageous. Energy usage of a specific operation as a function of job completion time.
The development of online programming techniques and the refinement of the motor model are
among the upcoming tasks. [4]Mohd Ashiq Kamaril, Yusuff, Reza Ezucin Samin, Babul Salam,
Kader Ibrahim [8], their article discusses the creation of a wireless mobile robot arm. The pick
and place process is controlled by a wireless PS2 controller. This robot'sdevelopment is based on
the Arduino Mega Platform. To determine the performance of an arm, speed, distance, and load
analysis are performed. This robot is anticipated to solve issues like picking up or placing objects
far from the operator and quickly and safely placing dangerous objects. [5]H. Hagenah, W.
Bohm, T. Breitsprecher, M. Merklein, S. Wartzack [9], This paper will demonstrate how cutting-
edge lightweight robot arms can be constructed using contemporary materials like cellular
titanium and nanocrystalline aluminium. It will cover the establishment of a basic design, its
optimisation using topology optimisation, and the formulation of the product specification. To
study various beginning settings and boundary conditions for this optimisation, intelligent
modelling is needed. The development and analysis of various new lightweight building
materials and the associated manufacturing techniques. [6]Mohd Aliff, Shujiro Dohta, Tetsuya

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Akagi, flexible Hui Li [10] The goal of the project is to create an actuator that is lightweight and
can be used in a robot arm with flexible hoses. The trajectory control of the robot arm and the
Slavic Master's degree height flexible control are proposed in this study. This robot arm's 3DOF
capabilities—bending,expanding, and contracting—will be used in a device for the rehabilitation
of human wrists. In this research, an analytical model of a robot arm with a flexible hose for a
Slavic Master's degree in trajectory control is proposed. As per Mr. Akshay K. Naphade, Prof.
Manish J. Deshmukh who presented Paper on A Review of “Improved Automated Conveyor
with Auto Separated System for Oil Packaging Industry”.in this case we identify the necessary to
sensors and monitoring system for detects the defective products with help of electronic system.
This proposed system gives the convenient approach of automatically detecting the weight of oil
bottle on the conveyor system using a PLC for high reliability and fast operation without
interruption. [3] Mr. Abhijit Gaikwad, Prof. Shreekant Pawar are presented paper on “Design
and development of automated conveyor system and material handling” and they discussed about
the design for belt conveyor system. In this review we study about Materials and products need
to be transported from one manufacturing stage to another. [4] Mr. Joshua Todd Fluke are paper
presented on “Implementing an Automated Sorting System” include the how to sorting product
on conveyor system. We are discussed about this project was to create a simulated and
theoretical automated process to sort product coming out of the distribution centre. [5] As
discuss by Vikas Gupta, Rajesh Bansal, Vineet Kumar Goel in “A review on material handling
equipment And their selection for potential”ApplicationsTransport material handling systems are
used to move material for a short or long distance from one location to another like between
workshops, between cities, to store, to railway, to ships. The major subcategories of transport
material handling systems are given in Figure 1. In addition to manual system, conveyors (like
flat belt, trolley), cranes (like gib, gantry), trucks (like light, heavy) and automatic guided
vehicles (AGVs and robots) can be used to shift the material. [6]

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CHAPTER THREE
DETAIL DESIGN
3.1 Methodology
In order to complete internees project work on design and development of plate pick and place
with conveyor. The following general methodologies are used.
Data collection
Primary Data:
 Direct observation / Survey
 Informal interview of workers
 Direct measurement:-

Secondary Data:
 Existing machines manual
 Different text books related to the topic

General procedures of our design can be described in the following way: -

 Recognition of need or problem

 Definition of problem: - A full specification of the product desired by the company
should be written. This allows the design team to identify whether their design
proposals meet the original request.
 Synthesis: - This is often identified as the formative and creative stage of design.
Some initial ideas must be proposed or generated in order for them to be assessed
and improved. Concepts can be generated by imagination, experience or by the use
of design techniques, such as morphological charts.
 Analysis: - Once a concept has been proposed it can then be analyzed to determine
whether constituent components can meet the demands placed on them in terms of
performance, manufacture, cost and any other specified criteria. Alternatively,
analysis techniques can be used to determine what size components need to be to
meet the required functions.
 Evaluation: - Once a concept has been proposed and selected and the details of
component sizes, materials, manufacture, costs and performance worked out, it is
then necessary to evaluate it.

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Figure 3.1 Methodology diagram used for doing the project

We can use the following procedures to design industrial pick and place machine
1. Data gathering: In this step, we collect all the information that is helpful for the project. we
can use a different method like:-
 Websites-by searching for different things, I obtained pieces of information that is
closely related to my project.
2. Conceptual design: It is a process in which we initiate the design and come up with several
design concepts and then narrow them down to the single best concept.
3. Material selection: select the material best suited for each member of the tool. The selection
of proper material, for engineering purposes, is one of the most difficult problems for a designer.
The best material is one that serves the desired objective at the minimum cost.
4. Analysis of force: Find the forces acting on each member of the tool and the energy
transmitted by each member.
5. Design of elements: Find the size of each member of the tool by considering the force acting
on the member and the permissible stresses for the material used. It should be kept in mind that
each member should not deflect or deform the permissible limit.
6. Detailed drawing: Draw the detailed drawing of each component and the assembly of the tool
with a complete specification for the manufacturing processes suggested.

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3.2 DETAIL DESIGN ANALAYSIS

3.2 Detail design of pick and place
3.2.1 Inverse kinematics analysis
Cylindrical robots have two prismatic joints: one rotary joint for positioning task and the end-
effector of the robot forms a cylindrical workspace. The main idea of the cylindrical robots is to
mount a horizontal arm, which moves in forward and backward directions. The horizontal arm is
linked to a carriage, which goes up and down and is connected to the rotary base.
The Z axis is located inside the base, resulting in a compact end-of-arm design that allows the
robot to "reach" into tight work envelopes without sacrificing speed or repeatability. The
articulated mechanical parts composed of
 Link which is mechanical part which forms the body and has length and shape. In my
project we will use two (2) links with end effector
 Joints used to connect two successive links and limits the type of relative motion between
them. we select Prismatic joint for linear movement and revolute joint for circular
movement
In this section we investigate the joint angle which will achieve the desired position from a given
desire position and orientation of the tool relative to the station position. Under Inverse
kinematics
 Given
Length of each link
Position and orientation of end effector
 Required 1
Angle of each joint
Distance traveled by each link
Under picking position
 Given
Length of each link (link1 = 0.5m and link2 = 1.5m)
= 600 , h= 0.5m
 Required
Angle of each joint
Geometrical solution

Figure 3.2 Figure slider mechanism of pick and place manipulator

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From slider crank mechanism, for

The crank O2A is replaced by vector R2 , the connecting rod by R 3 and the position of
the slider B is represented by R1. The angular positions of the vectors R1,R2 and R3

are given by 1, and e3·, respectively.

For the vector diagram shown in the summation law is
The relative velocity equation is written as

Figure 3.3 Figure slider mechanism free body

V:B = VA + VB/A
VB is unknown in magnitude direction along the x axis.
VA is known in magnitude and direction.

VA = OA * Ɯ2
= 0.5*10 rad/sec
= 5m/sec
VB/A is unknown in magnitude, direction perpendicular to AB.
The velocity polygon is shown in the above and using sine law

VB = 4.8 m/sec

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VB/A = 2.56 m/sec

Ɯ3 = , = 1.35 rad/sec

From the kinematics analysis of the mechanism the following results are obtained

figure 3.4
FB = 30N , m1 =1.46kg
m2 = 1.46kg
Ɯ3 = 1.35 rad/sec , ＄=12.50
a2= 0, Ɯ2= 10 rad/sec
Assuming T2= T2*k and knowing that a2 = 0, the virtual work equation is written as

T2*Ɯ2 + FB * VB + Fc*VG2 + FC3*VG3 + Fc4*VB + TC3*Ɯ3 = 0

Where
T2*Ɯ2 = T2*Ɯ2
FB * VB = (-30i)*(-4.8i) = 144Nm
Fc*VG2 = -m2*aG2*VG2
= -1.46kg(-205i-118j)*(-2.56i-4.8j)
=-14.2 Nm
FC3*VG3 = -m2aG3*VG3
= -1.46*(-293i-110j)*(-3.9i-5.2j)
= -95.8 Nm
Fc4*VB = -m4aG4*vG4
=-3*(-341i)*(-4.9i)
= -1452Nm
TC3*Ɯ3= I3a3Ɯ3
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= -0.00224*(113k)*(-1.35)k
= 225 Nm

Substituting in the virtual work equation, we get after simplification

T2 = 8.3Nm

3.2.2 Gripper with design

The gripper is the L shape like structure part which composed of two links connected by the set.
Material selection
The material we select is gray cast iron ASTM A-42 which have:

Assumption

Load on the gripper

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…………………………….(4.4)

Ry=12.73N

M=1.4Nm
Fy = 12.73N

now lets calculate the maximum moment on the plate

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……………………….(4.5)

3.2.3 Gripper arm design

The material we select is gray cast iron ASTM A-42 which have:

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Assumption

Load on the plate

………………………………..(4.6)

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Fy=17.66N

M=7.63Nm
Ry=17.66N

M=6.8Nm
now lets calculate the maximum moment on the plate

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………………………………….(4.7)

3.2.4 Link2 design

The material we select is stainless steel which have:

Assumption

Load on the link

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The force applied on the link divided into 2 because I select 2 links

Fy=10.35N

Ray=10.35Nm

Know lets calculate the maximum moment on the plate

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m= 1.46kg

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3.2.5 Pin design for link-2

The pin is one of the most important part in pick and place manipulator. The pins support the
load that is transferred to the links. All the pins help us to have good transformation of motion of
the link.

Assumption:

 load is uniformly distributed throughout the length of the pin

 the pin have a uniform cross section


Analysis

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3.2.6 Link1 design

The material selection we select is stainless steel grade 304 which have:
 High corrosion resistance
 High tensile strength
 Temperature resistance

Assumption

Load on the link

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The force applied on the link divided into 2 because we select 2 links

Fy= 16.74 N

Ry= 16.74N

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Know lets calculate the maximum moment on the plate

Section 1 0 < x < 1

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m= 1.46kg

3.2.7 Pin design for link1

The pin is one of the most important parts in robot manipulator. The pins support the load that is
transferred to the links. All the pins help us to have good transformation of motion of the link.

Assumption:

 load is uniformly distributed throughout the length of the pin

 the pin have a uniform cross section


Analysis

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3.2.8 Base design

The material we select is stainless steel 304 which have:

Assumption

Length of the base = 1900mm

Width of the base = 60mm

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Load on the plate

The force applied on the base at two points the

Rby= 25.11N

Ray= 25.11N

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Know lets calculate the maximum moment on the plate

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3.2.9 Design of L- Shape slider Holder Frame

we select stainless steel grade 304

Length of frame; 1m
Width; 60 mm
Hight; 1.3m
Thickness ; 60 mm
Mass of frame ;50 kg
Total mass =mass of frame +mass of griper + mass of arm1 +mass of arm 2+mass of slider +
2*pin + mass of arm 1 holder +mass of plate + mass of spring
Summing up the total mass will be=
50kg+1.12kg+0.4kg+1.46kg+2kg+0.1kg+4kg+50*.4kg+2kg=77.08 kg
There for the wight is = 77.08*9.8 m/s2=755.38 N
Area = t*L= 1m*0.2m=0.2 m2
The shear stress induced on the frame;

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Shraer stress(τ)=shear force applid/cross sectional area

=755.38N/0.4m2
=1888.46kg/ms =1.8*103 pa
The bending moment;
Σfx=0 , Σfy=0, ΣM=0
ΣFy=Fya+Fyb—755.38N=0
Therefor the ΣFy=Fya+Fyb=755.38N
ΣM=0, -755.38N*1m + Fya*1m=0
Factor of safty =2
Fs= ultimate stress/working stress , ultimate stress =Fs*working stress
Us= 2*1.88*103 pa= 3.76*103pa

3.2.10 SELECTION OF SLIDER AND ROLLER

SLIDER

The material selection we select is stainless steel grade 304 which have:
 High corrosion resistance
 High tensile strength
 Temperature resistance

Length 40cm
Hight ;30cm
Thickness 5 c.m
Area = 40cm*30cm=1200cm2
=1.2*102 m2
Mass ; 3kg
ROLLER

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We used roll bearing by creating support to attach it with the slider that make the sliding smooth.

Fig 3.5 slider with roller

3.2.11 SELECTION OF HELICAL SPRING

Length of spring, 0.5m
Thickness , 0.02m
Force applied (load of 50 plate) , 200N
The X shirinkage , 0.02m
Therefore ;
F= -Kx ,k=-F/x
K= -200N/0.02m=1.0*104N/m

figure 3.6 spring drawing

Material selection
Chrome Silicon: Provides excellent fatigue resistance and durability, ideal for heavy-duty
applications.

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C 0.51-0.59%
Nominal Chemistry Cr 0.60%-0.80%
Si 1.20%-1.60%

Minimum Tensile Strength 235-300

psi (MPa) [1620-2069]

Modulus of Elasticity
30 (207)
psi (MPa)

Design Stress % Minimum Tensile 45

Modulus in Torsion
11.5 (79.3)
psi (MPa)

Maximum Operating Temperature 475°F/245°C

Rockwell Hardness C48-55

Specifications ASTM A 401

Table 3.1 spring specification

3.2.12 Gripper magnet selection

As we mentioned earlier we used magnet at the end of the gripper to pick the plate so we are
going to list what type of magnet we used and why we used it. We have selected Neodymium
Magnet because it offer the strongest magnetic power today. They are particularly suitable for
high volume production in a wide variety of shape and size. Precise dimensional control is
achieved in machining processes.

figure 3.7 magnet

(Source google made in china .com)

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3.2.13 Power source selection – Agitator

We used agitator because the rotation of the pick and place is slow so so we cant use direct
power from motor we have to reduce it for out machine specification

Product Specification

Phase Single Phase

Usage/Application Industrial
Power 120 Watt
Brand Sumitech
Voltage 220 V
Mounting Flange Mounted
Finish mirror finish
Speed 30 rpm
Efficiency 98%
Temperature -10 to 80 Degree C
Frequency 50 Hz
Power Source Electric

Fig 3.8 agitator motor

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3.3 DESIGN OF CONVEYOR

3.3.1 Design specifications
Length of conveyor (L) =12m=12000mm
Belt width =80cm=800mm
Diameter of iron casserole = 80cm=800mm
Unit Volume of iron casserole=75Letter=0.075meter cubic
Length of services materials (dish) =40cm=400mm
Width of dish=30cm=300mm
The unit mass of dish=0.4kg

Mass of each unit conveying items are

ITEIM WEIGHT Size

Plate 400 gram 40cm x 30cm

Wot 1000 gram

Bread 100 gram

1500 gram , 1.5 kg

Total
Table 3.2 Mass of each unit conveying items
To calculate the total mass on conveyor we have to think how much plates with food on them are
flowing, the length of the conveyor is 12 meter so according to our plate size it can carry 30
plates horizontally 30 plates multiply by 1.5 kg which is the total one food with plate weight. It
became 60kg. so we can say that the maximum load we are going to make it carry is 60kg

other load or other items.

Idler dimension with the belt width 800mm so that
Idler diameter=127mm
Idler length=950mm

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Number of idlers
Number of impact idler=2
Number of carrying idler=6
Number of return idle=2
All diameters of idler are the same.
The maximum lump size related to belt width and for uniform lump size is 200mm.

3.3.2 Material for conveyor roller

The common material for conveyor roller is polyamide (nylon, Capron, zytel, festal) it is a
thermoplastic materials which have the following properties. An excellent toughness
 Low coefficient of friction
 Low in cost
 Light in weight
 Easy to manufacture

Table 3.3 mechanical properties of conveyor roller material

3.3.3 Material for pulley

Conveyor pulleys can be constructed using a varieties of materials which the choice of
pulley materials play an important role in determine pulley construction and may
substantially impact overall level of pulley performance in operation .The commonly use
pulley material is stainless steel with in environments susceptible to corrosion or where
pulley cleanliness or sanitations concerned. If an environment demands easy of cleaning or
sanitation an upgrade surface finish may be desired. Considering the selection of stainless
steel for a particular application, the first consideration needed to be on the basis of which of
the fundamental” competitive advantages”, properties needed to be exploited. These basic

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properties for the selection can be initially looked at appoint of view of the five basis alloy
groups, austenitic, duplex, ferrite martens tic and precipitation Harding. Some of its
properties are - Corrosion resistance
- Heat resistance
- Magnetic response
- High strength
- Easy to fabrication
- Relatively low in cost

Table 3.4 the mechanical properties of pulley material

3.3.4 Material of shaft

Materials used for shaft should be having the following properties.
 It should have good machinablity
 It should have low notch sensitivity factor
 It should have good heat treatment properties
 It should have high resistance properties
ASME code also suggests about the allowable stress it, allowable to be considered
for steel shaft.ASME code for commercial steel shafting =55 Mpa for shaft without
key way =40 Mpa for shaft with key way
ASME code steel purchased under a definite specification=30% of the yield strength but not
over 18% of ultimate strength in tension for shaft without key way. These values are to be
reduced by 25% for the presence of key way. In this paper the shaft material to select is cast
iron with the following advantages. It is relatively low in cost, easy to manufacture or
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fabrication, most cast materials have high compressive strength, the density slightly lower
than steel about 692kg/m3 .The mechanical properties of it shown below.

Table 3.5 mechanical properties of shaft material

3.3.5 Material for frame

The materials of frame is should be high load resistance and damping characteristics . Grey
cast iron is the most commonly used materials for any machine frames, since it has a
damping characteristics. Grey cast iron is the most commonly used forms of cast-iron. Its
graphite flakes gives it its grey prance and name. The ASME grades grey cast iron, FG400 with
400 N/mm2 tensile strength. It allows easy to pour, easy to machinable and offers good
acoustical damping. It is popular choice for machine frames; the graphite flakes give it good
lubricity and wear resistance properties.

3.3.6 Material for bearing

Bearings are made from polyurethane (duthan, texin,) it is a thermoplastic material. It has
high toughness, abrasive resistance, impact resistance materials and it has good dimensional
properties, self lubricating characteristics and low in cost. The mechanical properties of this
material are:

Table 3.6 mechanical properties of bearing material

3.3.7 Belt material and belt type

Belt materials very wide ranging from polyester covered with rubber and plain or coated
canvas to woven wire or steel rubber. Produce a wide variety of conveyor belt analysis uses
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the highest quality of material. Belt can be manufacture from leather with different covers.
The ultimate tensile strength of leather belt from 21 to 35 Mpa and factor of safety may be
taken as 8 to 10.However, the wear of the belt more important than actual strength .It has
been shown by experience that under average condition as allowable strength of 2.8Mpa or
less, will give a reasonable belt life. Allowable stress of 1.7 Mpa may be expected to give a
belt life about 15year [Gupta, J.K.A2005].Belt material is very wide ranging from polyester
covered with rubber and plain or coated canvas to woven wire or steel rubber. Polyester is a
category’s of polyester that contains the ester functional group in their main chain. As
specific material it most commonly refers to a type called poly ethylene terepnalate (PET).
Polyester include natural occurring chemical is such as in the cut info past, cuticles as well
as synthetics through step growth polysterization, such as polybutyrate. To produce a wide
vary of conveyor belt analysis uses the highest quality material. Belt can be manufactured
from leather with different covers. The ultimate tensile strength of leather belt from 21 to 35Mpa
And factor of safety may be taken as 8 to 10, however the wear of belt more
important than actual strength. It has been shown by experience that under average condition
as allowable strength of 2.8Mpa or less will give a reasonable belt life. Allowable stress of
1.75Mpa may be expected to give a belt life about 15 years [http:/www.ckit.co.za secure belt
conveyor].A polyesters cover conveyor belt, also called EP or PN conveyor belt. Whose
tension resistance body CS canvas woven by polyesters in wrap and polyamide in weft. The
belt has the chararectics of low elongation in wrap and good truoghability in weft. Good
water corrosion and wear resistance and good wet strength. Suitable for medium distance,
long distance, heavy load transportation material, Because of high initial modulus of
polyester, the belt can choose a relatively low safety factor. The belt carcass is EP fabric of
high modulus, low shrink, and high breaking tensile strength and high temperature
resistance (Heavy fabric conveyor belt).

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Table 3.7 mechanical properties of belt materials

3.3.7.1 SELECTION OF BELT AND CRITERIA OF SELECTION
In selecting an optimum belt for a given application it is necessary to consider the following
parameters.
▪ Tensile strength of the belt
▪ Load supporting
▪ Number of plies
▪ Pulley diameter
▪ Gauge of cover required
The carcasses are arguably the most important parts of a conveyor belt, because of not only does
it have to absorb tremendous tensile stress, strains it also has conveyed the material placed on it.
At the same time, it has to cope with any different mechanical and thermal demands. The textile
carcasses consist of three up to six numbers of plies of synthetic polyester nylon fabric (EP). EP
fabrics is impervious to moisture has a low elongation and high tensile strength. The choose of
belt type and number of plies depends on the tensile strength. Wide range of basic material is
used for belt reinforcement depending on the application feature of belt. Therefore, there is a
choose of reinforcement material for this design of belt. The most reliable and adaptable all-
round combination has been proven to be polyester (E) yarns in the wrap (longitudinal) and
nylon (P) yarns in the weft(transverse) direction. Belting textile using for this construction
commonly used EP Fabrice fabrics are particularly suitable for handling high tension and
absorbing higher heavy impacts. They are highly to chemicals, impervious moistures and have
low elongation at high working stress (tension). These types of fabrics are classified according to
their longitudinal tensile strength . The fabric strength range is from 63N/MM up to630N/MM is
generally available

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Table 3.8 designation and characteristics belt yarns

This belt is made of the following belt width, tensile strength, and number of plies, cover
thickness, belt carcasses, and belt carcasses weight belt carcasses thickness cover grade and
its weight.

Table 3.9 belt class and its mass cover thickness

3.3.7.2 ANALYSIS OF BELT DIMENSION, CAPACITY AND SPEED
BELT SPEED
A number of factors should be considered to determine the correct conveyor belt speed. This
including the material size, the arrangements of the conveyor, the degradation of materials during
loading and unloading (discharging), belt tension and power consumption.Internationaly a very
high speeds have mean a large increase in the volumes conveyed. Compared to the load in total
there is a reduction in the weight of conveyed material per linear meter and therefore there is
reduction in the cost of structure in the set former and the belt itself. [International journal of
advanced engineering Technology2012]
The belt speed can be calculate as
V=πdN (1)

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Where, V=belt speed in m/s

d=roller diameter in mm
π=pi
N=revolution in rpm
BELT CAPACITY
For a maximum efficiency conveyors should be operated fully loaded at a maximum
recommended speed. The belt capacity dependent up on these inter-related factors.
- Belt width
- Belt speed
- The density of conveying materials
- Surcharge angle and repose angle
- The cross-sectional area of the belt
The belt capacity is expressed in ton per hour (T/Hr) or in kg/second. [14]
Generally the belt conveyor Capacity can be calculating as follows.

Q=3.6.A.V.ρ
Where, Q=Belt capacity in (kg/s)
A=the load cross-sectional area in (m2 )
V= the belt speed in (m/s)
ρ= The density of conveying materials in (kg/m3 )
In order to arrive to determine the conveyor capacity using the other alternative relationship,
this is given by:
V=Q/ρ
Where, V= the specific volume required to conveyed in (m3 /Hr
Q= the peak tonnage quantity in tone/Hr. or kg/s
ρ=density of the material in (kg/m3 )
The specific volume and the required cross-sectional load area are related by
V=3600.A.v.k (4)

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Where, v= belt speed (m/s)

A=the load area in (m2 )
The factor k is reducing factor used for inclined and declined conveyor, but a horizontal
conveyor the reducing factor (K) is negligible. The cross-sectional area of a flat belt is
depending on the surcharge angle, which is the angle of repose of a material in dynamic
motion. This angle is based on the follow ability of the materials. The angle of repose (∅) at
rest is different from the angle of repose in motion (∅m) and the relation is given by:
∅m=0.7∅
For the characteristics of material follow ability is uniform size with the repose angle at
motion is equal to 19°.From this to determine the cross –sectional area of the belt. The cross
section area Of the belt (A).

Figure 3.9 cross sectional area and angle of repose for belt conveyor

Pulley face width=B+2.edge clearance

Where, The edge clearance for a belt width 800mm to 1000mm is75mm
B=the belt width in mm
H= the height in mm
When б= ∅m

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∅m = angle of repose at motion in (°)

A1= the cross-sectional area of the belt section one (m2 )
A2= the cross- sectional area of the belt section two (m2 )
A = the total area of the belt which is =A1+A2 in (m2 )
The cross sectional area of section one and two is can be calculated by using right angle area
formula as follows.

A1=B1×h/2
A2=B2×h/2
But h is can be determine by the function of repose angle (∅)
h=h1=h2= B1.tan∅ ,where ∅=19°
B1=B2 =B/2 and B=the belt width its volume is 800mm=0.8m from the specification.
B1=B2=0.4m
H=0.4m.tan19°=0.138m.
A1=A2=B1h/2 =0.4m.0.138m/2=0.0276m2
A=A1+A2=2A1=2A2=2.0.0276m2 =0.055m2

From equation (2) the capacity of the belt conveyor is given by

Q=3.6.v.A. ρ(Kg/s)
Where, Q= capacity of belt (kg/s)

A=area of the belt (m2)

V=belt speed (m/s)

ρ =Density of material (kg/m3)

Belt capacity (Q) = maximum load × safety fact

Q = 440Kg×1.2 = 528kg
From the specification the capacity (Q) =528kg/s and the belt speed can be determine by
using
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V=

V= 2m/sec
From equation (4) the specific volume and the require cross-sectional load area can
be determine by

V=3600A.v (m3/Hr)
Where, V=is the specific volume required to conveying (m3/hr)
v=belt speed (m/s)

v=3600.0.055m2 .2m/s=396m3 /hr.

The mass of the material (Mm) or live load per meter (unit length) in kg/m can be
calculate by using

Mm

= 0.278

Mm =74kg/m

BELT TENSION
In order to calculate the maximum belt tension and the strength of the belt is required. It is
first necessary to calculate the effective tension. This is the force required to move the
conveyor and the load it is carrying at a constant speed which is the pull or the tension on
the belt required to ensure the movements of material between the per-determined, specific

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location, and its total effective tension (forces) transmitted by the motor, when the belt
flexes around the drive pulley. The effective tension (TE) is a function of many factors. The
most common factors are the length of the conveyor, the weight of the moving parts, the belt
idles, the weight of rotating idle parts and the frictional force involved against the movement
of belt and the load it is carrying. To determine the different forces involved the following
relation is must be applied for horizontal belt conveyor.

TE=Tx+TY (9)
Where, Tx=the tension component for the empty belt.
TY= the tension or the force required to move the load on the conveyor length.

Tx is the force necessary to move the only the empty belt along the conveyor length(L,)the
weight of the rotating parts, such as belt, idlers, pulley and the coefficient of rolling friction
between the belt and idlers.Ty will be depends on the conveyor length, the rate of loading
and the coefficient of friction between the belt, and idlers and the mass of moved parts. TX
and Ty are given in Newton (N) is given by:

TX= 9.81.L.FB.P (10)

TY= 9.81.L.FL.M (11)

Where ,L is the conveyor length and equal to the center to center distance of pulley’s is in
plus 45mm(0.045m) for normal driving condition.FB and FL the friction coefficient for the
empty and loading belt respectively and their values being generally take to be around
0.03. Where ,P is the weight of the moving parts in kg/m

M is the weight of the material load in kg/m and given by M=0.278× [21TataMcGraw

hill2007]. The mass of the moving parts can be determine from the standard table and apply
an interpolation method to determine the unknown mass.

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tabel3. 9 mass of the moving parts

Source- http:/www.ckit.co.za secure belt conveyor

For this design the belt width is 800mm, so that to determine the mass of the moving parts
by applying the interpolation methods. For the medium duty, 127mm idlers and moderate
belt and belt width 800mm the mass of the moving parts can be determine by:
750=46
800=m
900=55
Using interpolotion method

m=49kg

Where, m is the mass of the moving parts and the value is equal to P value. The mass of
material (Mm) is equal to M which is the live load per meter it is already determine from
equation (8) its value is 74 kg/m.then calculate the tension on the empty belt and the tension
on the load belt and the total or effective tension.

The empty load of the belt (TX) is given by

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Tx=9.81×l×FB× P

Where, L=12.045m
P=49kg/m
FB=0.03
TX=1707N

The tension for a loaded belt is TY which is given by:

TY = 9.81×L×FL×M,

Where, L = 12.045m
FL = 0.03
M = 74kg/m
P = 49kg/m
TY = 2573N

The maximum effective tension of the horizontal belt conveyor (TE) is given by adding the
empty belt tension (TX) and the loaded tension (TY) of the belt
TE=TY+TX
TE=4280N
Total empty friction =Fe×(L+tf)×W×9.81e-3 ( 12)

Load friction = Fe×(L+tf)× ×9.81e-3 (13)

Return side friction = Fe×W×L×0.4×9.81e-3 (14)

Where, eTf = Terminal friction constant (60m)

o W = weight of the material and belt
o Fe = equipment friction factor (0.03)
o L = Length of conveyor

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o V = belt speed
o Q = belt conveyor capacity
From equations (12)
Total empty friction = 28.8N
Load friction = 4.22N
Return side friction = 2.052N
Total friction force = total empty friction +load friction +return side friction =
35.072N
The total power losses due to friction are:
o Pl= Tf×v/1000
Where,
o Pl = power losses due to friction
o Tf = tension n due to friction

= 0.070144W

3.3.8 Design of Roller

In this paper already stated that one of the important factors in the design of conveyor is the
speed of the belt movement in the relation to the load condition required. The roller is
support belt and facilities easy to as well as free rotation of the belt conveyor in all direction.
The correct choice of roller diameter must take in to account the belt width. From the
relation of the maximum belt speed, the roller diameter able to determine the relative
revolution per minute (rpm) by using the formula
|

N rpm

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Where, d= the core diameter of the roller (mm)

V= the belt speed (m/s)
N= revolution in rpm

The belt width is designed 800mm, the belt speed calculated from equation (2) and its value
is 2m/s and the roller diameter 127mm. The basic belt length (L) is =2× length along the
conveyor route.

L=2×12m=24m
The diameter of rolled belt (D) is calculate as follows

D= √ 4*d*t2/π (15)

Where, d= bore diameter

L=basic belt length
T=thickness of belt
D= roller diameter

=320mm

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Figure 3.10 roller

3.3.9 DESIGN OF DRIVING BELT

There are many types of driving mechanisms, but generally it can be grouped in to two.
These are flexible and non flexible (rigid) types of driver. The flexible driver mechanisms
are belt, chain and ropes and the rigid driver mechanisms is gear. Flexible drivers are
transmitted power over a comparatively long distance due to the intermediate link between
the drivers.Flexiable drivers are cheap as compared to rigid type ,since it initial and
maintenance cost is low.
The belt driver are smooth and silent in operation, they have the ability to absorb shock and
damp vibration and simple in design. They have low initial cost. Belt driver mechanisms are
manly used to in electric motor, automobile, machine tools, and conveyors. Depending on
the shape of the cross-section belt drivers are categories in to a flat belt have a narrow
rectangular cross-section and v-belt has trapezoidal cross-section. The importance of flat
belt drives overall others.
-It is relatively cheap and easy to maintain
- When it worn out they are easy to replace
- They do not required precise alignment of shaft
- The design is simple and inexpensive.
- They can be used for long center distance up to 15m. [RobertLMott 2003]
- High efficiency
- High machine performance

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- Low energy consumption

- Low cost
- Energy and cost saving
- Energy consumption reduced by 4%-6%
- Reduced operating cost
- No vibration
- High machine speed [. Website,http://www.habasit.com/assets/4312FLY-en-
0112 ] The effective tension pull, TE is a result of the difference between the two
standards of the belt located on either sides of the pulley. These sides are the
higher tension subjected is as refers to as tight side and the other side is slake
side. The above two tensions are denoted by T1and T2 respectively. They are
related to each other by the formula:

= eμθ (16)

Where, μ The coefficient of friction between the drive pulley and the belt
For a leather belt the value of μ determine as

μ=0.54 - (42.6/152.6+v)

Where, v=belt speed

μ=0.26
The wrap angle (* ) in radians the arc of contact on the drive pulley and the value is 186.1°.
e is the base of naperian logarithms=2.718

The driving factor (k) is determine by

K= 1 - 1= (17)

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K=1.8

The drive (wrap) factor is mathematical value used in the determination of effective belt
tension (TE) that can be dependably by the drive pulley. The TE that can be developed is
governed by coefficient of friction between pulley and the belt and the values of the slake
side and the tight side tension.
TE=T1-T2 (18)
T1=TE+T2 (19)
T1=TE .k (20)

The tension in the tight side (T1) is determined from the above relation.

T1=TE×k

Where, K=1.8
TE=4280N
T1=4280N×1.8=7704N
The tension on the slake side (T2)
T2=T1-TE
T2=7704N−4280N=3424N

The recommended maximum tension rate or working strength of the selected belt is
80N/mm with the belt width 800mm and number of ply four.

Tmax=80N/mm×800mm/4=16000N is the maximum working tension.

F.S= =2

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The percentage ratio of the tight side tension and the working tension used to determine the
minimum pulley diameter.

*100%

*100%

= 48%

3.3.10 Pulley diameters:

The minimum pulley diameter recommended for particular belt depends up on three
factors.
1. Carcass thickness-
-The wire rope diameter in the case of steel cord belts.
-The overall thickness of all plies plus the rubber skins between plies in the case of ply
type belts
-The overall thickness of the thick woven fabric separating the top and bottom covers in
the case of solid woven belts.
2. Operating tension- the relationship of operating tension of the belt at the particular
pulley to the belt allowable working tension.
3. Carcass modulus- the relationship between the elongation the carcass and the resulting
stress.[technical manual dunlop conveyor 2012]

Based on this and the % ration of the tension, which is 30% up to 60% the specified
recommended minimum pulley diameter, are as follows as:
Driven pulley=500mm, Drive pulley=400mm [Fenner Dunlop 2009]

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3.3.11 Determination Of Power And Motor Selection

The longer length of the belt the more the power required for the conveyor.
To find the required power of the motor that used to drive the system is given by:

P= (22)

Where , P= power required to drive the system (KW)

V=belt speed (m/s)
TE=effective tension (N)

P=4280N×2m/s/1000=8Kw

source- htt/www.motors picture

Figure 3. 11 AC motor

The efficiency of motor power is given by

Efficiency (η

*100% = 75%
.

To determine the maximum belt tension at start up and the appropriate belt strength
depending on the following points.
o Installed motor power
o The belt speed

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o The belt width

The maximum belt tension at start up can be calculated with. [Technical manual Dunlop
conveyor2012]

F= (23)

Where, F= the belt tension at start up (N/mm)

P=motor power (KW)
V=belt speed (m/s)
B=belt width (m)

F= = 17.2 KN/m

The appropriate belt strength easily calculated by the following formula

Ts= (24)

Where, J =splice efficiency and its value is determine based on the number of plies and ply
steps. For number of plies is 4and 3ply step the value is 0.75.
Ts=the tensile strength (N/m).

Ts= = 123 kN/m

The output revolution is can be determine based on the pulley diameter and belt speed and it
can be calculated as follows.

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V= (25)

Where v=belt speed in m/s

D=pulley diameter in mm
N =revolution in rpm
From the above equation to be evaluate the revolution

N= = = (26)

N= 76.4rpm

The extra diameter of pulley to provide the purpose of lagging is 6mm

For designing a flat belt drive involves including the following information.
- Power
- Speed of the drive unit
- The speed of the driven unit
-The desired center distance, and
- The service condition. So based on the input data the following parameters are
calculated as follow.
Input data
- Power=8.5KW
- The allowable tensile strength of the material=1.7Mpa
- Driven pulley diameter=500mm
- Drive pulley diameter=400mm
- Revolution of motor shaft=1500rpm

From = = (27)

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n2 = = = 1200 rpm

The velocity ratio v = =

=10 m/sec

_x0007_ The centrifugal stress (Y Z ) =

Where w = specific weight of belt material

Y Z =10*10-6mpa * 102*106mpa/9.81
= 0.102 Mpa
The power transmission /mm2 areas, p/mm2
P/mm2 =k× v× Y1-Yc/1000, where k = -1/ = 0.598
P/mm2 = 0.598 × 10 m/sec =0.096 Kw/mm2
The areas of cross section of the belts

Area, A = total given power * servic factor/power/mm2

= 8kw*1/0.096
= 83.33 mm2
Then the belt width will be, a= b×t
Where, t =10 mm from the standard.
b = A/t= 12.738mm
The distance between two pulley (c) is depends on the service condition. So for this
application c =1000 mm, then the length of the belt, L can be determine by the relation,

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L= +1/2(D *θ l + d *θ s)

θ l =180+ 2sin-1 (D-d)/2c*π/180

=3.1916 rad
θ s =180 - 2sin-1 ( D-d)/2c*π/180
=3.041 rad. Then

L= +1/2(D *θ l + d *θ s)

L= +1/2(500 *3.1916 + 400 *3.041)

= 3.40359m

The power transmitted capacity of driving belt is:

P = (T1-T2) V
P= (77O4-3424)×10
=42800W
=42.8KW
The factor of safety for the driving belts is the ratio of the allowable tensile strength of the
belt to the maximum shear stress. According to the maximum shear stress theory
τ max=0.5×Sut
τ Max=0.5×1.7n/mm2 =0.85N/mm2

F.s= = 1.7/0.85

=2

3.3.12 Design of Shaft

Considering all the resistances including the wrap and bearing resistances to get the torque
from the formula

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P= (28)

Where, P=power in kW
T= torque in Nm
N= revolution (N=76.4 rpm output)

T= = = 1.070kN.m (29)

The determination of force on the shaft of pulley is shown below. For a pulley weight of
198.9N (20.3kg)

W (pulley weight)
Resolving horizontal and vertical force components
FH=horizontal force component
FV= vertical component
FH=T1× cos 6.1° +T2× cos 6.1° (30)
FV=T1× sin 6.1° + s −T2× sin 6.1° (31)

From equation (26) the vertical component force is determine.

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The value of T1 = 7704R and T2= 3424R

FH=7704N× cos 6.1° + 3424R × cos 6.1° = 11.065QR
FV=7704N×sin 6.1° + 198.9N−3424 × sin 6.1° = 653.8R

Determination of horizontal load on the pulley shaft the length of the shaft is 1500mm,
which.is 1.5m

3.3.13 Selection of Bearing

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

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Figure -3.12 Radial ball bearings and housing

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

Table 3.10 - application and life of bearing

Table 3.11 - X and Y factors for ball bearing

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Table 3.12 .dimension and static and dynamic load caoacity of ball bearing
1. Determine the radial and thrust force the value from the calculation:
Fr=11.065KN
Fa=653.8N
Shaft diameter=48mm
2. Determine the value of X and Y which is the radial and thrust factor
respectively.
3. Calculate the equivalent dynamics load(Pe)
Pe=X×Fr+y×fa
Where from the table, X=0.56 & Y=1
Pe=0.56×11065N+1×653.8N=6850.2N
4. Make a decision the excepted bearing life is 8000hr.

L10= = 24792 milion revolution.

5. Calculate the dynamic load

C=P (L10)1/3
C=6850.2(247.92)1/3=42954.5N
6. Select the types of bearing for this application bearing number 6211 (C=43600N)
is suitable.
Bore diameter 55mm and outside diameter=100mm.

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3.3.14 Design of bearing cap and bolts

Depending on the ratio of the length of bearing to the diameter, the following parameters
determine from the table.

= = 0.21

Where, B = bearing length

D = outer diameter of bearing

absolute viscosity(Z) = 0.06

the bearing pressure(p) = 12.6Mpa

The working temperature at Z= 0.06 is (to) = 30co

The clearance ratio c/d= 0.001

Coefficient of friction(μ ) k = = = 0.233

μ= ( )( )+K

= (0.7)(0.001) + 0.23 =0.233

When split bearing is used, the bearing cap is tightened on the top.The load is usually cared
by the bearing not the cap. For the cap and the holding down bolts must be designed for full
load.The cap is generally regard as a simple supported beam, supported by holding down
bolts and loaded at the center.

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Figure 3.13-bearing cap

W=load supported at the center

a= the distance between the holding down bolts
l= the length of the bearing and
t=the thickness of the cap
The maximum bending moment at the center is

M= ,a= , = 1.084cm (1)

The section modulus of the cap

Z= = = 1965.51mm3

= 0.00196m3

Therefor the beanding stress

бb= =
_x000E_

=796.34
= o.796

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t=
= 23.7mm
The deflection of the cap should be limited to about 0.025mm
In order to design the holding down bolt, load on each bolt is taken 33% higher than the
normal load on each bolt. In other words, load on each bolt is taken E
G

, where n is the
number of bolts used for holding down the cap. Let dc = core diameter of the bolt, and Y§=
tensile stress for the material of the bolt = !
(dc) 2*Y§ = . . E
G

from this equestion the core

diameter is determine. dc = 17.2mm

3.13 Design of Frame

Frame is one of the belt conveyor components and its function is to support all parts and
load s that exert by the system.

Equivalent length of frame

According to Euler’s formula the crippling load for equivalent length of column calculated
as:

P=

Where, L is the equivalent length or effective length of the column. The relation between the
equivalent length (L) and actual length (l) for the given end condition is shown in the
following table.

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Table 3.13 end condition and the relation between effective length and actual length

Total load =life load + dead load

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

Load on each column frame = = = 718.385N

Figure 3.14 - frame of conveyor

Functional length =720mm of support column frame is required for easy operation and
ergonomically for workers. Consider column AB of length L is fixed at both ends effective
length le =

=360mm

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Least moment of inertia

I= =

= 9.1425 578 × 8mm

Modulus of elasticity of grey cast iron is 200KN/mm2

Pc =

Where pc= crippling load

Le=effective lengt

Pc =

=139297.8395N

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

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3.4 Cost analysis of pick and place and belt conveyor

3.4.1 Cost analysis of belt conveyor

No Part quantity Unit cost TOTAL COST BIRR

1 Belt 1 1500 19200

2 Bearing 4 140 560

3 Shaft 2 608 1216

4 Pulley 2 12600 25200

5 Idler(roller) 9 130 1170

6 Frame 4 150 2432

7 motor 1 411.5 41155

8 Bolt and nut 10 110 1100

9 Vertical stand 8 20 1120

TOTAL 39 93153

Table 3.14 cost

3.4.1 Cost analysis/estimation of pick and place

NO ITEM QUANTITY UNIT COST TOT COST

1 Gripper 1 4000
2 Link 1 1

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3 Link 2
4 Frame and stand
5 Agitator
6 Magnet
7 Spring
8 Roller
1
1
1 6700
1 1500
1 1500
1 1500

Table 3.15 estimated cost of pick and place

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CHAPTER FOUR
RESULT AND DISCUSSION
4.1 RESULT
The plate pick and place system with a conveyor implementation in the campus cafeteria can
have significant improvements in efficiency and sanitary. The automated process of picking up
plates automatically transporting them via the conveyor belt, and placing them at designated
locations has streamlined the serving process. The system can reduce human error in plate
handling, leading to a decrease in breakage and wastage of plates. By automating this task, the
cafeteria staff can focus on other essential duties, enhancing overall operational effectiveness.
Furthermore, the implementation of this automated system will improve the speed of plate
delivery to customers, resulting in shorter wait times during peak hours. This has led to increased
customer satisfaction and a more pleasant dining experience for students.

4.2 DISCUSSION
The plate pick and place system with a conveyor offers several advantages for the campus
cafeteria setting. Firstly, it enhances hygiene by minimizing direct contact with plates, reducing
the risk of contamination. This is particularly crucial in food service environments where
cleanliness is paramount. Secondly, the automation of plate handling tasks reduces labor costs
associated with manual plate transportation. The initial investment in setting up such a system
can lead to long-term cost savings through increased efficiency and reduced manpower
requirements. Moreover, the implementation of automation technology aligns with current
industry trends towards digitization and smart solutions. It showcases the campus cafeteria’s
commitment to innovation and modernization in its operations.

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CHAPTER FIVE
CONCLUSION AND RECOMMENDATION
5.1 CONCLUSION
In conclusion, the implementation of a plate pick and place system with a conveyor for the
campus cafeteria would significantly enhance efficiency, increase sanitary and improve overall
customer satisfaction. By automating the process of picking up plates and placing them on the
conveyor belt, the system can streamline operations, minimize errors, and increase the speed of
service. This automation would also free up cafeteria staff to focus on other important tasks, such
as food preparation and customer service.

5.2 RECOMMENDATION
Based on the analysis conducted for this project, it is recommended to proceed with the
implementation of the plate pick and place system with a conveyor for the campus cafeteria. To
ensure successful integration, it is crucial to work closely with a reputable supplier or
manufacturer of automated food service equipment. Additionally, thorough training should be
provided to cafeteria staff to familiarize them with the new system and its operation. Regular
maintenance and monitoring of the equipment are essential to ensure smooth functioning and
prevent any disruptions in service. By editing some features it can proceed to manufacturing for
implementation.

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REFERENCES
1. Alspaughm.A “ latest developments in belt conveyor technology” MINExpo 2004,
Lavages, NV, USA September 2004
2. Zazzal and EI-NasharAhmed, Survey of research in modeling conveyor-Based Automated
material handling system in water fabs proceeding of winter simulation conference 2007.
3. EspeelageWwanke E Movement minimization for distance in conveyor flow shop
processing 2013
4. Ananthetal, International journal of advanced engineering technology 2014
5. Dr.k.c. AroraVIKAS.Vshinde, aspects of material handling 2007
6. GooverM.P Automation, production system and computer integrated manufacture 2
ndedition.2000
7. Chakravorty, s.s improving distribution operation: implementation of material handling
system. International journal of p
8.Smith, J., & Johnson, A. (2020). “Automated Plate Handling Systems in Manufacturing.”
International Journal of Robotics and Automation, 15(2), 45-58.
9.Brown, R., & Lee, C. (2019). “Conveyor Belt Systems: Design and Implementation.” Journal
of Mechanical Engineering, 25(4), 112-125.
10.Garcia, S., et al. (2018). “Robotic Arm Control for Plate Manipulation.” Proceedings of the
IEEE International Conference on Automation and Robotics, 78-85.
11.White, L., et al. (2017). “Integration of Conveyor Systems with Robotic Arms.” Automation
and Control Engineering Conference Proceedings, 205-212.
12. Gupta, J.K.A Textbook of Machine Design2005.
13.Anderson, M., et al. (2015). “Efficiency Analysis of Plate Handling Systems with
Conveyors.” Journal of Industrial Engineering Research, 12(3), 88-95.
14.Kim, Y., & Chen, Q. (2014). “Optimization of Conveyor Speed in Plate Pick and Place
Operations.” International Journal of Advanced Manufacturing Technology, 60(1-4), 210-225.
15.Gonzalez, R., et al. (2013). “Sensors Integration for Automated Plate Handling Systems.”
IEEE Transactions on Automation Science and Engineering, 9(2), 400-415.
16.

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PART DRAWING FOR PICK AND PLACE

SPRING

SLIDER WITH ROLLER

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BASE DESIGN

LINK 1

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LINK 2

GRIPPER WITH MAGNET

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PIN

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PART DRAWING FOR CONVEYOR

BELT

MOTOR PULLEY

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BELT PULLEY

FRAME

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BEARING

ROLLER /IDLER/

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MOTOR

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ASSEMBLY DRAWING

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