Geneva Use

BELT CONVEYOR SYSTEM
A Major Project Report

Submitted to
Siksha 'O' Anusandhan University, Bhubaneswar
Department of Mechanical Engineering

Institute of Technical Education & Research, Bhubaneswar
In partial fulfillment of the requirement for the
AWARD OF DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By
Ashutosh Panda -1241018237
Saurav Panda -1241018226
Dibyajyoti Swain -1241018365
Rakesh Roshan Pal-1241018371
Chandan Kumar Behera-1241018362
Bibhuti Bhusan Pradhan - 1141018383
Section-D (8th Semester)
DEPARTMENT OF MECHANICAL ENGINEERING

ITER , SIKSHA 'O' ANUSANDHAN UNIVERSITY
(Declared u/s. 3 of the UGC Act. 1956)
Bhubaneswar-751030
May-2016
CERTIFICATE
This is to certify that the project report entitled BELT CONVEYOR SYSTEM
being submitted by (Ashutosh Panda -1241018237 , Saurav Panda -1241018226 ,
Chandan Kumar Behera-1241018362, Dibyajyoti Swain -1241018365, Rakesh
Roshan Pal-1241018371, Bibhuti Bhusan Pradhan - 1141018383 of Section-D) to
the Institute of Technical Education and Research, Siksha O Anusandhan
University, Bhubaneswar for the partial fulllment for the degree of Bachelor of
Technology in Mechanical Engineering is a record of original bonade work
carried out by them under our supervision and guidance. The project work, in our
opinion, has reached the requisite standard fullling the requirements for the
degree of Bachelor of Technology.
The results contained in this report have not been submitted in part or full to any
other University or Institute for the award of any degree or diploma.
Prof.H.C.Das
Prof.J.K.Nath
(Internal Design Panel-ME)
Dr.S.K.Acharya
Dr.D.N.Thatoi
DECLARATION
We declare that this written submission represents our ideas in our own words and where others
ideas or words have been included, We have adequately cited and referenced the original sources.
We also declare that we have adhered to all principles of academic honesty and integrity and have
not misrepresented or fabricated or falsified any idea/fact/source in our submission.
WE understand that any violation of the above will be cause for disciplinary action by the
University and can also evoke penal action from the sources which have thus not been properly
cited or from whom proper permission has not been taken when needed.
Ashutosh Panda-1241018237
Saurav Panda-1241018226
Dibyajyoti Swain-1241018365
Place: Bhubaneswar
Date: 14th MAY, 2016
Rakesh Roshan Pal-1241018371

Bibhuti Bhusan Pradhan-1141018383
ITER, S'O'A University, Bhubaneswar
2
ACKNOWLEDGEMENT
We would like to express our deepest appreciation to all those who provided us the information
to complete this report. We express our gratitude and heartiest thanks to Prof. Dr. Rabindra
Narayan Mahapatra, Prof. Dr. Niranjan Kavi, Prof. Dr. Amiya Kumar Dash , Prof. Manoj Kumar
Sarangi, Prof. Soumya Aditya Ohid,
Department Of Mechanical Engineering, Institute Of
Technical Education & Research, Siksha O Anusandhan University, Bhubaneswar for their
contribution in stimulating inspiration, suggestions, encouragement & guidance that helped us to
write this report.
Furthermore we convey our sincere thanks to our project Co-Ordinator Prof. Dr. Saroj Kumar
Acharya who has spent his valuable time in guiding our group. I am also thankful to all the
faculty members, technical and nontechnical staffs of our department who helped us achieving
our desired goal whenever we needed it.
Last but certainly not the least, we would also pay my heartiest thanks to our parents, respected
teachers and our friends for their encouragement and support at different level of work.
Thank you
Ashutosh Panda-1241018237
Saurav Panda-1241018226
Dibyajyoti Swain-1241018365
Rakesha Roshan Pal-1241018371
Bibhuti Bhusan Pradhan-1141018383
Mechanical-D (8th Semester)
ITER, S'O'A University, Bhubaneswar
REPORT APPROVAL
This project report entitled" BELT CONVEYOR SYSTEM " by (Ashutosh Panda -1241018237
, Saurav Panda -1241018226 ,
Chandan Kumar Behera-1241018362, Dibyajyoti Swain
-1241018365, Rakesh Roshan Pal-1241018371, Bibhuti Bhusan Pradhan - 1141018383 of

Section-D, Group-1) is approved for the degree of Bachelor of Technology in Mechanical
Engineering.
Examiners
Supervisor
Chairman
Place:
Date:
PLAGIARISM CHECK CERTIFICATE
Plagiarism was checked and the similarity index is 13 % .
Signature of Chief
Librarian
ABSTRACT
A conveyor system is a common piece of mechanical handling equipment that moves materials
from one location to another. Conveyor systems allow quick and efficient transportation for a
wide
variety
of
materials,
which
make
them
very
popular
in
the material
handling and packaging industries. Many kinds of conveying systems are available, and are used
according to the various needs .This report discusses about the design and fabrication of belt
conveyor system by using external Geneva mechanism with four slots (Maltase Cross
Mechanism) in terms of size, length, capacity and speed, roller diameter, power and tension, type
of drive unit, location and arrangement of roller , continuous and efficient movement of materials
while avoiding fatalities during loading and unloading. The Geneva mechanism is a timing
device. The Geneva drive is a mechanism that translates a continuous rotation into an
intermittent rotary motion The goal of this mechanism is to eliminate the acceleration jump at the
beginning and end of the Geneva wheel motion. The Geneva Mechanism includes a star wheel
and a rotating driver. The star wheel includes slots and is operationally associated with the load.
The rotating driver includes a drive pin which cooperates with the slots to cause an intermittent
rotation of the star wheel. Either the slots or the drive pin is shaped in a controlled manner to
permit optimum acceleration and deceleration of the star wheel. Due to this intermittent motion
in conveyor system, more material can be loaded during the time gap and no space is maintained
in the conveyor belt by which in same input power more material can be transported easily and
safely. Belt conveyor has high load carrying capacity (up to 30000 t/h), it can be achieved at
different distances, different materials transportation , simple design, easy maintenance and high
reliability of operation. Belt conveyor system can be employed for easy handling of materials
beyond human capacity in terms of weight and height. The modeling of the belt conveyor system
is created using Solid Works Software. Finite element analysis (FEA) is performed to obtain the
variation of stress at critical locations of the system using the Solid Works software and applying
the boundary conditions to evaluate the total deformation, equivalent (von-misses) stress and
shear stress. The successful completion of this project work has generated design data for the
development of an belt conveyor system which is simple, safe, efficient and low cost.
Keywords:
Conveyor , Geneva Mechanism, Intermittent, Solid Works, FEA, Deformation, Stress
6
TABLE OF CONTENTS
List of Tables
List of Figures
xii
List of Symbols
xv
Chapter-1 : Introduction
1.1
General Description & Practical Relevance
1.2
Principle of Operation
1.2.1
Geneva Mechanism
1.2.2
Background of Geneva Mechanism
1.3
Students outcomes & Blooms Taxonomy of Learning level
1.4
Course Outcomes
1.4.1
Course Description
1.4.2
Course Objective
1.5
Design Checkpoint
1.6
Design Team Formation & Team charter
10
Chapter-2 : Customer Needs Recognition
12
2.1
Task Distribution & Monitoring
12
2.2
Customer Need Data
12
2.3
Gathering Customer Needs
13
2.3.1
Questionnaire Method
14
2.3.2
Interview Method
14
2.4
Organizing & Prioritizing Customer need
15
2.5
Selected Needs for Redesign
16
2.6
Problem Statement
16
Chapter-3 : Function Decomposition
17
3.1
17
3.2
Function Modeling Basics
18
3.3
Function Tree
18
7
3.3.1
Function tree by FAST Method
18
3.3.2
Function tree by Subtract & Operate Procedure
20
3.4
Black box modeling
20
3.5
Function Structure by Energy Diagram
22
Chapter-4 : Product Tear Down & Engineering Specification
23
4.1
23
4.2
Product Teardown
24
4.2.1
Subtract & Operate Procedure
24
4.3
Post Teardown Reporting
26
4.3.1
Disassembly plan & Bill of Material
26
4.4
Benchmarking approach
27
4.5
Proposal on Opportunities to Redesign
29
4.6
Benchmarking the Competition
29
4.7
Setting Product Specification
29
4.7.1
Specification Process
29
4.7.2
Functional Requirements Vs. Product Constraints
30
4.7.3
Basic method: Specification Sheets
30
4.7.4
Basic Method: The House of Quality
31
Chapter-5 : Product Architecture
34
5.1
34
5.2
Modular Design by Basic Clustering
35
Chapter-6 : Concept Generation
36
6.1
36
6.2
Brainstorming Method
37
6.3
C-sketch/6-3-5 Method
39
6.4
Morphological Analysis
39
6.5
Concept Variant
40
Chapter-7 : Concept Selection
41
7.1
41
7.2
Using Pugh chart as decision making tool
42
7.2.1
Redesign Concept
43
8
Chapter-8 : Product Embodiment
44
8.1
44
8.2
Refining Geometry & Layout
44
8.3
System Modeling
45
8.3.1
Failure Modes & Effect analysis
46
Chapter-9 : Product Metric Model
48
9.1
48
9.2
Model Selection
49
9.3
Constructing Product Model
50
9.3.1
Solid Modeling Software
51
9.3.2
Solid Modeling Parts of Belt Conveyor System by Solidworks
51
10
Chapter-10 : Design for Manufacture, Assembly & Environment
53
10.1
53
10.2
Applying Design Guidelines
54
10.3
Manufacturing Cost Analysis
55
10.4
Design for Environment
59
10.4.1
List of Environmental Issues & Guidelines
59
11
Chapter11 : Analytical & Numerical Model Solutions
63
11.1
63
11.2
Theoretical Analysis
63
11.3
Finite Element Analysis
81
11.4
Comparison between Theoretical Analysis & FEA
93
12
Chapter-12 : Physical Prototype
94
12.1
94
12.2
Mock up Material & Processes
95
12.3
Prototype Planning & Design
96
12.4
Fabricate the Components
96
12.5
Assembly of Components
99
13
Chapter-13 : Prototype Testing & Improvement
101
13.1
101
13.2
Design of Experiments
101
9
13.3
Improvement
103
13.4
Product Cost & Bill of Material
103
14
Chapter-14 : Conclusion
105
15
Chapter-15 : References
107
Appendix
111
10
LIST OF TABLES
Table No.
Description
Page No.
1.1
Students Outcomes
1.2
Bloom's Taxonomy
1.3
Topics to be Covered during the duration of Course
1.4
Description of Course outcomes defined by the Course
1.5
Outcome elements that are satisfied by Course outcomes
1.6
Course outcomes mapped to Program outcomes
1.7
Design checkpoints & Student outcomes
10
1.8
Timeline for Design checkpoints
10
1.9
Team allocation & Problem selection
11
1.10
Team Charter
11
2.1
Work done by each member
12
2.2
Questionnaire for the product
14
2.3
Interview form for the product
15
2.4
Prioritized Customer need
16
3.1
17
4.1
23
4.2
Conveyor system SOP Effect table
25
4.3
List of Possible Measurements for the Remove Solid Sub
26
4.4
functions
Specification sheet of Belt Conveyor System by using Geneva
30
5.1
mechanism
34
6.1
37
6.2
39
6.3
Weighted Sub function value
39
6.4
Initial Morphological Chart
40
7.1
Morphological matrix with solution
41
7.2
42
11
7.3
Conveyor system Redesign concept for Power transmission
43
8.1
Redesign criteria
44
8.2
46
8.3
Partial failure modes & Effect analysis of Belt Conveyor System
47
9.1
Properties of Relevant material choices
48
9.2
49
10.1
Possible matrix for a Belt Conveyor System
53
10.2
59
10.3
Parts Cost Analysis
60
10.4
Product Structure Guidelines
61
10.5
Material Selection Guidelines
61
10.6
Labeling & Finish Guidelines
62
11.1
Fastening Guidelines
63
11.2
72
11.3
Calculation of Output Torque at same Input Torque
75
11.4
Calculation of Wheel angle from Crank angle
76
11.5
Calculation of Angular velocity of wheel from Crank angle
78
11.6
Calculation of Angular acceleration of wheel from Crank angle
83
11.7
Material properties of Belt & Roller

Material properties of Geneva wheel, Driver wheel & Driven
11.8
Roller
Material properties of Geneva wheel, Driver Wheel & Driven
11.9
86
88
Roller
Material properties of Geneva wheel, Driver Wheel & Driven
91
11.10
Roller
93
12.1
Comparison between FEA & Theoretical Analysis
94
12.2
95
12.3
Prototype Properties of Wood
95
12.4
Prototype Properties of Metal
96
13.1
List of Standard components with Specification used in system
101
13.2
103
12
Product cost & Bill of Material
LIST OF FIGURES
Figure No.
Description
13
Page No.
1.1
Different Parts in
1.2
Belt Conveyor
1.3
System
1.4
Four slot Geneva
3.1
mechanism
19
3.2
Different Positions
of Geneva wheel in a
20
3.3
Single rotation
21
3.4
Learning levels of
Students outcomes
22
4.1
FAST diagram for
23
4.2
Belt Conveyor
24
4.3
System
25
4.4
Belt Conveyor
26
4.5
system Function tree
27
4.6
generated using
33
5.1
Subtract & Operate
35
5.2
Procedure
35
6.1
Black box model of
38
6.2
Belt Conveyor
40
7.1
System
43
8.1
Belt Conveyor
45
9.1
system Function
49
9.2
structure generated
50
9.3
by Energy diagram
51
9.4
Exploded view of
51
9.5
Belt Conveyor
51
9.6
System
51
9.7
SOP Hierarchy
52
9.8
Product hierarchy for
52
9.9
Product with
52
9.10
electricity as Primary
52
9.11
input
52
9.12
Data template
52
9.13
Disassembly &
52
9.14
Experimentation
14
52
10.1
Bill of Materials
55
10.2
House of Quality
57
LIST OF SYMBOLS
d1
Diameter of Driver roller
d2
Diameter of Driven roller
Angle of contact between Belt & Roller
Center distance between two Roller
Length of Conveyor Belt
Tss
Steady state belt tension
Co-efficient of friction
Acceleration due to gravity
mi
Load due to idler
mb
Load due to belt
mm
Load due to conveyed material
Angle of inclination
Vertical height from base
Ts
Belt tension while starting
Ks
Load correction factor
T1
Tension in tight side
T2
Tension in slack side
Radius of roller
Ultimate strength of belt (MPa)
Thickness of belt
Width of belt
Ta
Allowable tension (N/mm)
Cross-sectional area
Dynamic load capacity
C0
Static load rating
dm
Mean diameter of bearing
db
Diameter of ball
Radial thickness of bearing

15
Number of balls
dc
Diameter of driving crank
dp
Diameter of drive pin
Length of slot
dw
Shaft diameter of Geneva wheel
Center distance between Geneva wheel & driving crank
Radius of Geneva wheel
Width of slot
Number of slots
Semi indexing angle of Geneva wheel
Angular acceleration of Geneva wheel
Semi indexing angle of crank in driver wheel
Wheel angle in any position except entry in slot
Ratio of crank radius to centre distance
Angular velocity of crank [rad/sec]
Angular velocity of wheel [rad/sec]
Stop arc radius
S1
S2
S
P
Shear stress
Slip between driver Roller & Belt
Slip between driven Roller & Belt
Total percentage of Slip
Power
Efficiency
16
Chapter 1
Introduction
1.1.
General Description and Practical Relevance
A conveyor system is a common piece of mechanical handling equipment that moves bulk or
grain size solid materials from one location to another. Conveyor systems allow quick and
efficient transportation for a wide variety of materials, which make them very popular in
the material handling and packaging industries.
A belt conveyor system consists of two or more pulleys ,with an endless loop of carrying
medium - the conveyor belt- that rotates about them. One or both of the pulleys are powered,
moving the belt and the material on the belt forward. The powered pulley is called the drive
pulley while the
unpowered
pulley
is
called
the
idler
pulley. Pulleys are used for
providing the drive to the belt through a Geneva wheel powered by an electric DC motor.
The drive imparts power to one or more pulleys to move the belt and its loads. Materials are
transported over the required distance as a result of friction generated between the roller surface
and the moving belt set in motion by a rotating pulley (drive pulley). The other pulley (driven or
idler pulley) acts as a wheel around which the material rotates and returns in a continuous
process. Continuous processes are characterized by non-stop motion of bulk or unit loads along
a path without halt for loading and unloading .
Fig. 1.1 : Different Parts In The Belt Conveyor System

1
The belt consists of one or more layers of material. Many belts in general material handling
have two layers. An under layer of material to provide linear strength and shape called a
carcass and an over layer called the cover. The carcass is often a woven fabric having a warp
& weft. The most common carcass materials are polyester, nylon and cotton. The cover is
often various rubber or plastic compounds specified by use of the belt. Covers can be made
from more exotic materials for unusual applications such as silicone for heat or gum rubber
when traction is essential. The belt is specified by the width of belt ,quality of the cover, number
of piles, quality of the fabric, thickness of top cover& the thickness of bottom cover.
The peculiarities of a belt conveyor is that it is easy and cheap to maintain, it has high
loading and unloading capacity and can transport dense materials economically at very high
efficiency and low cost over long distance allowing relative movement of material . Belt
conveyor can also be used for diverse materials: abrasive, wet, dry, sticky or dirty material.
Only a single roller needs to be powered by driver pulley and the roller will constantly spin
causing the materials to be propelled by the driving roller. Material handling equipment such as
belt conveyors are designed to load and unload materials from one stage of processing to
another in the fastest, smoothest, most judicious, safest, and most economical way with
minimum spillage. Belt conveyors are employed for conveying various bulk and unit loads
along horizontal or slightly inclined paths and for transporting articles.
1.2.
Principle of Operation
This belt conveyor system is based on Geneva mechanism .The driver wheel attached with the dc
motor and the Geneva wheel attached with the drive pulley of conveyor system. When power
will be given by the dc motor, it transmits power to driver wheel and then it transmits to Geneva
wheel. Due to 4 slots in Geneva wheel, the continuous rotation of driver wheel is converted to
intermittent rotary motion. Then power will be transmitted from Geneva wheel to drive pulley.
Due to friction between belt and pulley, the belt with loads move forward and transports
materials from one position to another position .
1.2.1.
Geneva Mechanism
Geneva mechanism is a simple and widely used timing mechanism that provides intermittent
motion from a continuously rotating input. It consists of a rotating drive wheel (Driver) with a
pin that reaches into a slot of the driven
wheel (Geneva wheel) advancing it by one
step. The goal of this mechanism is to
eliminate the acceleration jump at the
beginning and end of the Geneva wheel
motion.
An epitrochoidal path replaces the circular
path for the driving pin in a classical
Geneva wheel drive. The epitrochoidal
path is generated using a gear train and
results in zero velocity, acceleration, and
jerk at the beginning and end of the
Geneva wheel motion. Subsequently, the
motion of the Geneva wheel is modified
Fig. 1.2 : 4-Slot Geneva Mechanism
by introducing a non-circular gear pair to adjust the timing of the epitrochoidal path. The motion
of the non-circular gear pair is determined by reducing the extreme jerk of the Geneva wheel.
The basic structure of a four slot Geneva wheel as shown in Fig. 1.2 . The system consists of a
constantly rotating disk coupled with a slotted disk, which gives rise to the desired discrete
motion.
They are cheaper than cams, have good motion curve characteristics compared to ratchets and
maintain good control of its load at all times. In addition, if properly sized to the load, the
mechanism generally exhibits very long life. Geneva mechanisms have long been popular as a
means of producing positive incremental motion. This popularity stems in part from the
simplicity of the mechanism, both in design and construction, which makes it a relatively lowcost indexing device.
1.2.2.
Background of Geneva Mechanism
The name derives from the device's earliest application in mechanical watches, Geneva,
Switzerland being an important centre of watch making. The Geneva drive is also commonly
called a Maltese cross mechanism due to the visual resemblance when the driven wheel has four
spokes. Since they can be made small and are able to withstand substantial mechanical stress,
these mechanisms are frequently used in watches.
Fig. 1.3 : Different Positions of Geneva Wheel in a Single Rotation

In the most common arrangement, the driven wheel has four slots and thus advances by one step
of 90 degrees for each rotation of the drive wheel. If the driven wheel has n slots, it advances by
360/n per full rotation of the drive wheel .
1.3.
Student Outcomes and Blooms Taxonomy of Learning Levels
There are six levels of learning as defined in the Blooms Taxonomy. Blooms Taxonomy is a
multi-tiered model of classifying thinking according to the six cognitive levels of complexity.
The levels have often been depicted as a stairway, which encourages the students to climb to a
higher (level of) thought. The lowest three levels are: knowledge, comprehension, and
application. The highest three levels are: analysis, creation and evaluation. The taxonomy is
hierarchical, which means, each level is subsumed by the higher levels. In other words, a student
functioning at the application level has also mastered the material at the knowledge and
comprehension levels.
Kno
wle
Compre
dge
hension
Application
Analysis
Synthesis
Evaluation
Fig. 1.4 : Learning Levels of Student Outcome

Table 1.1 : Student Outcomes
Outcome
Description
An ability to apply knowledge of mathematics, science, and engineering.
An ability to design and conduct experiments, as well as to analyze and interpret

data.
An ability to design a system, component, or process to meet desired needs within

realistic constraints such as economic, environmental, social, political, ethical,
health and safety, manufacturability, and sustainability.
An ability to function on multidisciplinary teams.
An ability to identify, formulate, and solve engineering problems.
An understanding of professional and ethical responsibility.
An ability to communicate effectively.
The broad education necessary to understand the impact of engineering solutions in

a global, economic, environmental, and societal context.
A recognition of the need for, and an ability to engage in life-long learning.
A knowledge of contemporary issues.
An ability to use the techniques, skills, and modern engineering tools necessary for
engineering practice.
Table 1.2 : Blooms Taxonomy

Level
Name
L-1 Knowledge
Description
Retrieving, recognizing, and recalling relevant knowledge from
long-term memory.
L-2
Comprehension Constructing meaning from oral, written, and graphic messages

through
interpreting,
exemplifying,
classifying,
summarizing,
inferring, comparing, and explaining.

L-3
Application
Carrying out or using a procedure through executing, or

implementing.
L-4
Analysis
Breaking material into constituent parts, determining how the parts

relate to one another and to an overall structure or purpose through
differentiating , organizing, and attributing.
L-5
Creation
Putting elements together to form a coherent or functional whole;

reorganizing elements into a new pattern or structure through
generating, planning, or producing.
L-6
Evaluation
Making judgments based on criteria and standards through

checking and critiquing.
1.4.
Course Outcomes
1.4.1. Course Description
This course will focus on the design and manufacturing process in all areas of mechanical
engineering along with other multi disciplinary areas. Typical topics included are the
6
development of a product mission statement, identification of the customer needs, function

decomposition, benchmarking and development of target specifications, concept generation and
selection, final design and analysis, physical prototype manufacturing and testing, engineering
professionalism and its responsibility to society.
1.4.2. Course Objective
The objective of this course is to provide students the working knowledge of practical design
issues to solve product design problem, work effectively on an engineering team, customer
survey and evaluation of their requirements, engineering problem definition, generating an
engineering specification document, applying creative techniques to generate conceptual design
solutions, selecting appropriate engineering concepts in a team environment, design and analysis
of the system, manufacturing and testing of prototype, communicate and present the results
orally, graphically and in writing, understanding the codes of ethics, global issues, socio
economic issues and their implications in engineering practice, alternative learning plans for
future work.
Table 1.3 : Topics to be Covered during the Duration of Course
Sl. No.
1
Introduction to product design
Topics
Product development Team
Understanding the customer needs
Establishing product function
Benchmarking and engineering specification
Concept generation and selection
Modeling and analysis of product by analytical or numerical methods
Design for manufacturing and assembly
Development of physical prototype and experimentation
10
Professional ethics and responsibility in engineering
Table 1.4 : Descriptions of Course outcomes defined by the Course

Outcome
Description (Ability to)
CO - 1
Learn theories of product design process.
CO - 2
Work effectively in team to achieve a common goal.
CO - 3
Gather and interpreting customer needs for redesign of product.
CO - 4
Decompose a product design problem into simpler sub problems for analysis.
7
CO - 5
CO - 6
CO - 7
CO - 8
CO - 9
CO - 10
CO - 11
CO - 12
CO - 13
CO - 14
Evaluate the quality, value and performance of the product through benchmarking.
Develop possible alternatives and selecting the best one for solving the product
function.
Develop model and analyze it by various methods.
Design for manufacturing and assembly a product by effective methodology to
reduce product cost.
Develop the physical prototype and experiment it using experimental techniques.
Use design resources such as professional journals, trade journals, catalogs, and
the internet in project design for lifelong learning.
Understand the global issues and social responsibility in product design.
Discuss various socio-economic issues related to the developed product.
Understand professional code of ethics.
Communicate effectively.
Table 1.5 : Outcome elements that are satisfied by the Course outcomes
Course
Outcome
CO-1
ABET
Outcome
Outcome Elements Satisfied
Satisfied
A
Apply knowledge of Science and engineering
fundamental.
CO-2
CO-3
CO-4
CO-5
CO-6
CO-7
C, K
CO-8
CO-9
CO-10
CO-11
CO-12
CO-13
CO-14
Higher
Taxonomy
Level
Knowledge
Understanding of and willingness to be fully

involved in team efforts.
Identify stated and unstated wants and needs that
motivate the design efforts, converts them into a
need statement.
Development of a design strategy, decomposition
of design problem into subtasks.
Gather information about the design problem,
including the need for a solution, user needs and
expectations and feedback from users.
Generates many potential solution to a given
problems.
Use modern engineering techniques, skills, and
tools such as computer software and simulation
packages.
Evaluate feasibility of alternatives or proposed
solution by considering stated constraints such as
manufacturability, cost, compatibility.
Designing, conduct experiments and analyze data.
Application
Identifying,
retrieving,
and
organizing
information.
Understand the impact of engineering solutions in
a global and societal context.
Ability to address the major socio-economic issues
facing US and World.
Demonstrates knowledge of a professional code of
ethics.
Communicates information, concepts and ideas
effectively in writing ,graphically and orally
through presentation.
Application
Table 1.6 : Course outcomes mapped to Program outcomes
Analysis
Analysis
Evaluation
Knowledge
Analysis
Application
Application
Knowledge
Comprehension
Comprehension
Application
AOa
CO - 1
AOb
AOc
AOd
AOf
AOg
AOh
AOj
AOk
CO - 3
CO - 4
CO - 5
CO - 6
CO - 7
CO - 8
CO-10
CO-11
CO-12
CO-13
CO-14
1.5.
AOi
CO - 2
CO - 9
AOe
Design Checkpoints
The product design goes through a number of phases. Each phase is divided into a number of
steps. These steps must be properly executed and evaluated. Checkpoints are used as the point
of evaluation of those design steps. The checkpoints ensure a systematic and timely completion
of the design product. These stages are called here as checkpoints. The final product has been
demonstrated by each team at the time of final presentation. These checkpoints are shown in
Table 1.4 and the design team has passing through each checkpoint. The internal design panel
will allot the number of weeks required for each checkpoint.
Table 1.7 : Design checkpoints and Student outcomes
Sl.No.
1
2
3
4
5
6
7
Checkpoints
Customer needs recognition
Function decomposition
Engineering specification
Product architecture
Concept generation
Concept selection
Product embodiment
A B C
10
D E F G H I J K
8
9
10
11
12
13
Product metric model

DFM, DFA, DFE
Analytical and numerical solution
Physical prototype
Testing and improvement
Final product and Final Report
Table 1.8: Time line for Design checkpoints

Sl. No.
Checkpoints
Customer needs recognition
Function decomposition
Engineering specification
Product architecture
Concept generation
Concept selection
Product embodiment
Product metric model
DFM, DFA, DFE
Analytical and numerical solution
Physical prototype
Testing and improvement
Final Report
1
2
3
4
5
6
7
8
9
10
11
12
13
Set time line

20/02/2016 - 25/02/2016
25/02/2016 - 27/02/2016
04/03/2016 - 05/03/2016
05/03/2016 - 06/03/2016
09/03/2016 - 12/03/2016
09/03/2016 - 12/03/2016
14/03/2016 - 16/03/2016
16/03/2016 - 23/03/2016
23/03/2016 - 24/03/2016
24/03/2016 - 03/04/2016
04/04/2016 - 16/04/2016
17/04/2016 - 18/04/2016
19/04/2016 - 22/04/2016
1.6.
Design Team Formation and Team Charter
At the outset of the internal design panel (IDP) had divided students into small teams, specify or
approve the design problem and allotted a guide for each team.
Table 1.9 : Team allocation and Problem selection
Member 1
Member 2
Team Members
Asutosh Panda
Saurav Panda
1241018237
1241018226
Design Problem
Member 3
Member 4
Member 5
Chandan Kumar Behera

Dibyajyoti Swain
Rakesh Roshan Pal
1241018362
1241018365
1241018371
Design & Modification of
Member 6
Bibhuti Bhusan Pradhan
1141018383
using Geneva Mechanism.
Project Guide:
Prof. Dr. Rabindra Narayan Mahapatra
Belt Conveyor System by
Signature of IDP with Date
Table 1.10 : Team Charter

Team Id-1
Section-D
11
Semester-8th
Our Objective: To make a belt conveyor system by using Geneva Mechanism.

We are Involved
Name
Registration No.
Member 1:
Ashutosh Panda
1241018237
Member 2:
Saurav Panda
1241018226
Member 3:
Chandan Kumar Behera
1241018362
Member 4:
Dibyajyoti Swain
1241018365
Member 5:
Rakesh Roshan Pal
1241018371
Member 6:
1141018383
Project Guide:
Name of Guide: Prof. Dr. Rabindra Narayan Mahapatra
Designation : Associate Professor
Our Goals:
To Design a low cost, less jerk, simplest and good service life belt conveyor system with
low maintenance cost.
Declaration:
We, the members of design Team 1, Section D, Department of Mechanical Engineering,
ITER, Siksha O Anusandhan university, hereby declare that we have created our own
team charter, Understood it and agree to abide it.
Signature Of Team Members:
Member 1: Ashutosh Panda
Member 2: Saurav Panda
Member 3: Chandan Kumar Behera
Member 4: Dibyajyoti Swain

Member 5: Rakesh Roshan Pal
Member 6: Bibhuti Bhusan Pradhan
12
Chapter 2
Customer Needs Recognition

A customer need is required to develop or improve a new product for future .By taking customer
needs we can to increase or change the facility in the product because a customer has facing
which problem when it uses their product.
2.1.
Task Distribution and Monitoring
The task for this work has been divided among the group members. The Team leader has
assigning different tasks to different members and set the timeline for completion of this task as
shown in Table 2.1 :
Table 2.1 : Work Distribution
Work done by each member of Team ID 1 of Section D
Team leader: Ashutosh Panda
Team members
Task(s) to be performed
Task assigned date
1: Ashutosh Panda
Question Preparation
20.2.2016
Weight age Calculation
PPT Preparation
2: Saurav Panda
20.2.2016
3: Chandan Kumar
20.2.2016
Behera
Customer Survey
4: Dibyajyoti Swain
20.2.2016
Customer Survey
5: Rakesh Roshan Pal Question Preparation
20.2.2016
Weightage Calculation
6: Bibhuti Bhusan
20.2.2016
Pradhan
Task completed with alternative arrangement:
Task name
Originally assigned to
Reason for noncompletion
Signature of Team Members:
Task completed on
25.2.2016
22.2.2016
23.2.2016
23.2.2016
24.2.2016
21.2.2016
Member, who
completed it

2.2.
Customer Need Data
Customer needs can be profitably considered in general category based on how easy the
customer can express them and how rapidly they change. These are conceptual categories, not
13
distinct objective groupings. It is important through to understand the differences among them.
Different types of customer needs are
a. Direct Need: These are the needs that ,when asked about the product ,customers have no
trouble declaring as something they are concerned about.
b. Latent Need: These are the needs that typically are not directly expressed by the customer
without probing.
c. Constant Need: These needs are intrinsic to the task of the product and always will be.
When a product is used , this need will always be there. Such needs are always effective to
examine with customer need analysis.
d. Variable Need: These needs are not necessarily constant, if a force able technological
change can happen, these needs go away.
e. General Need: These needs apply to every person in the customer population.
f. Niche needs: These needs apply only to a smaller market segment within the entire buying
population. The rate of change of these boundaries in the customer need space is completely
dependent on the state of technology and its rate of change. The first category considers
observability , and the second considers technology change.
2.3.
Gathering Customer Needs
We have collecting customer requirements using various techniques, like, Questionnaire,
Conducting Interview, Focus Group Discussion, and Be a Customer. They will place similar
requirements into groups to get numbers of unique requirements. They will also identify needs
and constraints.
There are several methods available for a design team to understand the customer needs.
Different techniques are applying for customer needs are
a. Questionnaires: The team develops a list of criteria where it thinks is relevant to the
customer's concerns. It then ranks the product on these criteria.
b. Interviews: The design team members discusses the needs with a single customer , one at a
time. such interviews are usually held in the customer environment, where the customer uses
the product. the design team member records the customer responses. this process works well
for products that have a process associated with their customer use.
c. Focus Group: A moderator facilitates a session with a group of customers. This session is
usually held in the product developer's environment.
Questionnaire Method
2.3.1.
We are Preparing questions relating to product criteria. Sit together, discuss all these questions,
choose, modify, and prepare the final questionnaire.
Table 2.2 : Questionnaire for the Product
14
2.3.2.
Belt Conveyor System By Using Geneva Mechanism
In
Customer name: Bikash Mishra

Occupation
te
: Employee at TATA Sponge Iron
rv
Address
: Joda, Keunjhar
ie
Q. 1
Are you using conveyor system in your daily life?
Q. 2
Where you use it?
w
Q. 3
How this system is helpful to you?
Q. 4
What are the advantages of this system?
Q. 5
What problems you face?
Q. 6
What is the cost of maintenances ?
Q. 7
What modification you want?
Q. 8
How much electric power it consumed?
Q. 9
Give some suggestion about it.
Method
There is a basic header information related to the project and the interview subjects . The form
itself has three columns. The first column is used to record any particular questions that sparks a
customer response ,the middle column is the actual customer statement and the last column is the
conversion of this actual customer statement into a succinct noun, verb, adverb form, using the
same words as the subject stated as recorded in the second column. The Like/Dislike method has
general row category to record customer statements. If the customer likes the way a need is
implemented , it is recorded in Likes
rows. If the customer doesn't like how a need is
implemented, it is recorded in the Dislike rows . The structure permits immediate understanding
of what needs to be focused on when redesigning a product. The fourth column records linguistic
expressions of importance that the customers may have used. For Example follow Table 2.3
Table 2.3: Interview Form for Product

Customer Name:- Bikash Mishra
Occupation:-Employee at TATA Sponge Iron
Address:-Joda,Keunjhar
Questions
Customer response to
question
What are the
uses of the
current product
or similar
Industrial purpose
Transportation of raw
material
Packaging
15
Interviewer:-Chandan Kumar Behera

Date:-21/02/16
Interpreted need
statement by
interviewer
Industrial purposes
Luggage
transportation in
airport
Importance
rating assigned
by customer
product?
Questions that
expose the
LIKES of the
product
Questions that
expose the
DISLIKES of
the product
Suggestions for
improving the
current product
Escalator
Escalator
Airport
Satisfy daily need
Less time taken
Less human effort
Easy to handle
More productivity
Less production cost
Rapid movement
Unsafe
High power
consume
Not easy to
disassembly
Time delay cant
achieved
Less cost
Less maintenance
Less power consume
Easy to assembly
Easy to disassembly
Less equipment
More productivity
Consume less time
Less production cost
Less human effort
Less power consume

Unsafe
Easy to assembly and
disassembly
Must
Must
Good
Must
Must
Should
2.4.
Organizing and Prioritizing of Customer Need
After collecting all the needs from 10 customers, we have calculating the weightage for
redesigning the product. These are shown in Table 2.4. In this table 4 ratings are given. Rating ( 4
-1)shows best to worst level. Following these weightage , we have to modify our design.
Table 2.4 : Prioritized Customer Needs (Weightage Calculation)

Sl.No.
1
2
3
4
5
Questions
Rate of production is increasing day by day.
Conveyor system is used in your daily life.
Easy transportation.
Transportation is cost effective.
It decreases the cost of production.
16
W(4-1)
4
3
4
3
3
4
6
4
7
3
2
3
4
4
3
4
6
2
2
3
2
6
7
8
9
10
11
12
13
Less maintenance cost.

Consuming more electric power.
Conveyor system is costlier.
Easy to disassemble your system.
Your system performance is good.
Safety for your daily life.
Use of Geneva can decrease the cost of production.
Conveyor system by use of Geneva is useful for only small
3
3
3
2
3
3
3
3
1
4
2
3
2
2
3
4
3
7
1
6
6
5
4
5
2
2
4
1
3
1
1
1
4
1
2
industry.
Example: Weightage calculation of Sl. No. 13 is
WT=(3x4+4x3+1x2+2x1)/10=2.8=3
2.5.
2.6.
Selected Needs for Redesign
Should be simple
Easy to disassemble
Low maintenance cost
Long service life
Time delay should be achieved

Problem Statement
To design & development of belt conveyor system which is simple, low maintenance cost ,good
service life, easy transportation ,safe system and more material handling in same input power by
using Geneva mechanism.
17
Chapter 3
Function Decomposition
After we know what the customer wants from a product, we will develop a model of how a
product should function. It is needed to clarify and design the product architecture. Functionally
all products do something. Products accept inputs and operate to produce outputs. The output is
the desired performance. We can model any product, assembly, sub-assembly, or component as a
system, with inputs and outputs that traverse a system boundary. The essence of such a model is
the need-function-form definition of engineering design, where our focus is on translating the
customer needs for a product to the product functions.
3.1.
shown in Table 3.1:
Work Done by each Member of Team Number 1 of Section D
Team Leader : Ashutosh Panda
Team Members
Assigned Date
1: Ashutosh Panda
PPT Preparation
2: Chandan Kumar
Fast method
Behera
4: Dibyajyoti Swain
SOP Method
3: Rakesh Roshan Pal Fast Method
Task completed with alternative arrangement
Task number
Originally Assigned to

Member 1:Ashutosh Panda
Member 2:Saurav Panda
Member 3:Chandan Kumar Behera
Completion Date
26.2.2016
27.2.2016
25.2.2016
26.2.2016
25.2.2016
25.2.2016
26.2.2016
26.2.2016
Reason for Noncompletion
Who Completed
it
Member 4:Dibyajyoti Swain

Member 5:Rakesh Roshan Pal
Member 6:Bibhuti Bhusan Pradhan
18
3.2.
Function Modelling Basics

a. Function
A function of a product is a statement of a clear, reproducible relationship between the available

input and the desired output of the product, independent of any particular form.
b. Sub function
A sub function is a component of a product function. An overall function can and often must be
divided into identifiable sub functions corresponding to subtasks. The relationship between some
sub functions and the overall function is often governed by a constraint or input output
relationship.
c. Abstraction
Abstraction is the process of ignoring what is particular or incidental and emphasizing what is
general and essential. Such generalization leads to the crux of the problem. If a product is viewed
in the abstract, one is better able to define overall functional requirements.
d. Constraints
A Constraint is a statement of a clear criterion that must be satisfied by a product and requires
consideration of the entire product to determine the criterion value.
3.3.
Function Tress
Function trees are fast and simple to construct but this ease of construction is gained at the
expense of understanding interactions between the expanded sub functions. Interconnecting links
among the sub function black boxes are not considered. Developing function trees can be
approached in a number of ways, two of which are presented in the subsections below.
The first is a top down approach, using the systematic FAST method.
The second is a bottom up approach using the Subtract and Operate Procedure.
3.3.1. Function Tree by FAST Method

The Function Analysis System Technique(FAST) is used to define, analyse, and understand
product functions, how the functions relate to one another, and which functions require attention
to increase the product value. It is used to display functions in a logical sequence, prioritize them
and test their dependency.
During this process, these functions have different levels of importance. Out of all functions, one
function that is overall product function has to be selected. The product function again represents
the main reason that the product exists in the eyes of the customer. Once the basic function is
19
identified, all other functions either as a whole or within any of its subsystems are subordinate to
the basic functions. These secondary functions are essential to the performance of the basic
function and further they are a direct cause of the basic function. Secondary function can be
categorized into three types :- Required, Aesthetic and Unwanted. The secondary functions
between the product function and external
secondary function forms the critical path of
secondary functions. For each secondary function, typically achieving the sub function
introduces ill side-effects. New functions therefore arise to mitigate these effects.
The FAST approach is a top down approach which starts with the overall function and then
decomposes it.
Initial Input
Electric
Power
Conversio
n of
Electrical
energy to
Mechanica
l energy
Motor
Starts
Transmission
to Motor shaft
Rotation of
Motor shaft
with Driver
wheel
(CRANK)
Efficiency
& Loss
Mechanism
Rotation
of Driver
wheel
Engagement
of driver pin
with
connecting
pin
Motion
transmitted
to crusher
(Slider)
Crusher
reciprocates
Link of
feeding
mechani
--sm
Conversion of
Continuous
Circular
motion to
Linear motion
FAST diagram for Dual Acting CAN Crusher
3.3.2. Function Tree by Subtract and Operate Procedure
20
Outpu
Crushing
of cans
The subtract and operate procedure is one such bottom up approach to developing a function tree
.The underlying assumption to use this method is that either a form concept or actual product
exists this product or concept will then be reverse engineered using the subtract and operate
procedure.
Belt Conveyor System
Input
Accept
Power
Transmit
Power
Rotation of Shaft
Switch
Power
Support
Motor
Rotation
of Driver
wheel
Geneva
Wheel
Rotates
Output
Roller
Rotates
Conveyor
Moves
Fig. 3.2 : Belt Conveyor System Function Tree Generated using the Subtract and Operate Procedure
3.4.
Black Box Modeling
A system black box model allows to focus on the greatest, overall need for the product. It also
initiates technical understanding of a product based on its inputs and outputs, known as material,
energy and signal flows. These flow types are sufficient to describe a technical system or
product.
Black boxes models help maintain the focus on the driving product function. It also provide a
first mapping of customer needs to a technical understanding of a design problem. The inputs
and outputs of the black box provide this mapping.
Certain definitions to describe black box and other functions are:a. Systems/Subsystems
It is defined as an entity that is connected to its environment by means of inputs and outputs
identified at its boundary. System can be defined in terms of mechanical construction(form) or
by function. Any system can be decomposed into subsystems, connected to each other by means
of inputs and outputs defined at subsystem boundaries.
b. Boundary Interactions(flows)
21
For systems that manipulate matter inputs and outputs are found to be profitably categorized into
three types :- Energy, Material and Information . In each flow instance, both the quantity and
quality of the inputs and outputs has been defined in different types of arrows .
Energy
Material
Information
c. Information
Information is what we term the provided internal decision making capability of a device or
sensory data provided to or by a device or process.
d. Matter/ Material
Matter is usually referred to as material with properties of form, mass, colour, condition and so
forth. Materials can be mixed, separated, chemically changed, dried, cooked, dyed, etc.
e. Energy
Energy is the ability to make something happen. It must flow in or out of the system for
something to happen. It must be conserved.
f. Function Structure
The overall objective of a design cannot be considered properly defined until it has been clearly
stated in terms of its function. Functional relationships must be carefully worked out, that is,
designed to accomplish the objective specified. In a process there must be clearly defined
relationship between the beginning and at the end.
22
Electrical Energy
effort
Rotational Ene
Transportation of Materials from one end of Conveyor to other

UnpackedSolid Materials
Packe
Solid Mat
Weight of Materials
Material Stops at D
Length of Conveyor
No. of Stations
Fig. 3.3 : Black box model of Belt Conveyor System by using Geneva m
3.5.
3.6.
3.7.
3.8.
Function Structure by Energy Diagram
Electrical
Energy
Conversion
of Electrical
energy to
Mechanical
Energy by
motor
Apply
Force on
Driver
pin
23
Apply
Torque
on
connect
ing rod
Rocking
Motion
++
Chapter 4
Empty
Cans
Product Teardown and Engineering Specifications

Slider (crusher)
reciprocating
Translational
Energy in
Crusher
Crushing
of
Crushed
Cans
To benchmark a product against the competition, product tear down is required. The
current
materials
version must be analyzed and this analysis must be transformed into information that can be used
as a part of the new redesign. After teardown is completed, engineering specification is created
Can crushed
and dropped
down
Reciprocating
Motion
for the product.
Front roller
Bearing
Motor
Conveyor Belt
Belt
Scre
w
Front casing
parts
Rear roller
Casing
Fig. 4.1 : Exploded view of Belt Conveyor system

4.1.
Table 4.1 : Work done by each member
Work done by each member of Team 1 of Section D
Team member
Task(s) to be performed Task assigned date
1:Ashutosh Panda
Bench Marking
04.03.2016
2: Saurav Panda
Disassembly plan
04.03.2016
24
Task completed on
05.03.2016
05.03.2016
3:Chandan Kumar
Behara
4:Dibyajyoti Swain
Specification Sheet
04.03.2016
05.03.2016
Product Tear Down,

Teardown Reporting
House of Quality
Bill of Material
04.03.2016
04.03.2016
05.03.2016
04.03.2016
05.03.2016
05.03.2016
Member, who
completed it
5: Rakesh Roshan Pal

6:Bibhuti Bhusan
Pradhan
Task name

4.2.

Product Teardown
Product tear down is the process of taking part a product to understand it, and to understand how
the company making the product succeeds. A product teardown serves three primary purposes:
1. Dissection and analysis during reverse engineering
2. Experience and knowledge for an individual's personal database
3. Competitive benchmarking
4.2.1.
Subtract & Operate Procedure (SOP)
It is another method of product teardown. SOP is a logical tool in product teardown. It
determines component functionality and/or redundancies (or potential redundancies) in an
assembly.
Conveyor
System
Gear
box
Motor
Conveyor
Assembly
Gears
Belt
Grill
Stand
Idler
Bearing
Fig. 4.2 : SOP Hierarchy

SOP determines redundancies by exposing the functionality that is subtracted from the system
resulting from removal of a component. If this functionality is redundant, the design is over
25
constrained and the component can be removed if the degrees of freedom remain unchanged
when subtracting a piece, but other functionality is affected, there may exist.
Assembly
Conveyor belt
Bearing
Base
Motor
Coupling
Side grill
Gear box
Degree off
Effect of removal
Deduced sub function &
freedom
Affected Customer Needs
Table 4.2 : Conveyor System SOP Effects Table
2
Transmission problem
Transportation
1
No support for idler &
Support to the idler
increase in friction
1
No support for whole system
Support to the idler
1
No input power
Support to the whole
arrangement
1
No power transmission
Input
1
No protection
Connection of input roller
and motor
1
Motion cannot be transmitted Safety
Electricity
Energy
transfer
Rotational
energy
Heat (lost
by motor)
Cans
Energy
transfermation
Crusher
Vibration
Wheel
(Crank)Angular
velocity
Material
Solid
Linear velocity
(Crusher)
Fig. 4.3 : Product Hierarchy for Products with Electricity as Primary input flow
Table 4.3 : List of Possible Measurements for the Remove Solid Sub Functions
26
Remove Solid Sub Functions

Conveyor belt
Roller
Bearing
Stand
Motor
Side grill
Coupling
Nut & bolt
Gears
4.3.
Units
mm
mm, gm
gm , mm
Kg
Watt
Kg, mm
gm, mm
gm
mm, gm
Post-Teardown Reporting
These documents include a disassembly plan, an intended Bill of Material ,Exploded views and
an actual function structure of the product.
4.3.1.
Disassembly Plan & Bill of Material
The disassembly plan & Bill of Material should be created during the teardown of a product. A
disassembly plan documents when a product was disassembled, how disassembled it and a step
by step plan for disassembling the product. A template for a disassembly plan as shown in figure
4.3. This template is incrementally developed as a product is disassembled.
Product Disassembly
Project Name: Belt Conveyor System
Disassembly
Tasks
Tools
part
Step-1
Power disassemble the motor Wrench, Hammers, Slotting files, Wedge
drivers,
Step-2
Step-3
Step-4
Step-5
Wedge
removers,
Wire
slot
cleaning brushes
Hammer, Wrench, Screw driver
Screw driver
Hammer, Spanners
Hammer ,Hollow Mandrel
Removal of grill
Removal of conveyor belt
Removal of Roller
Removal of bearing
Fig. 4.4 : Data Template Disassembly and Experimentation

In addition to disassembly plan, a bill of material (BOM) is developed for a product . A BOM , as
shown in figure 4.4, provides a means to record vital structural, physical and functional
information about a product.
27
Bill Of Material
Project Name: Belt Conveyor System
Functional Analysis
Part No.
Name
1
2
Conveyor
belt
Idler
Function
Manufacturing
process
Rolling,
Extrusion
Facing, Turning,
Grooving
DFM Cost Analysis
Quantit
y
1
Transportation
Support
Bearing
12
1 Kg
Motor
Support the
roller
Power supply
5 Kg
Stainless
steel
-
Base
50 Kg
Cast iron
Grill
Support the
system
Safety
Welding
5 Kg
Mild steel
Gear box
Milling
10 Kg
Alloy steel
Power
transmission
Mass
Material
15 Kg
Rubber,
Plywood
Mild steel
10 Kg
Fig. 4.5 : Bill of Materials
4.4.
Benchmarking Approach
Benchmarking can be defined as the continuous process of measuring products, services and
practices against the toughest competitors or those recognized as market leaders.
This best in class comparative information is required at all stages of the product developments :
1. For the front end of the design process for identifying customer needs.
2. For improving concept generation.
3. For embodying a product.
4. For establishing product specifications.
5. For executing detailed designs.
There is a 6-step approach for product benchmarking :
Step 1 : Forms a List of Design Issues

A list of design issues should be developed for comparative benchmarking. This list should be
continually revised and updated. With a focus for benchmarking efforts, an efficient exploration
path may be pursued. The result is a reduction in wasted time and resources.
28
Step 2 : Form a List of Competitive or Related Products

For a product, One has to list all competitors and their different product models. This step is an
identification of the competitors basically as company names and product names. Highlighting
the particular competitors that appear most crucial for the design team will be helpful.
Step 3 : Conduct an Information Search
The design team must gather as much information about the product as possible. Corporate
library is the best place to start this search .A design team should gather information on
1. The products and related products.
2. The functions they perform.
3. The targeted market segments.
Step 4 : Teardown Multiple Products in Class
It completes the teardown of the products listed . The result is an indented bill of materials, for
each product, a functional model for each product, an exploded view of each product and the
function to form mappings of the functions to the assemblies.
Step 5 : Benchmark by Function
For a new product development effort, one should establish the new products functional model.
Then for each function , find the same function in the other products function models. List the
various physical forms found among the competition to solve this function and under each list
the performance measurements for comparison purposes.
Step 6 : Establish Best-In-Class Competitors by Function
For each function the highest performing solution can be called out as best-in-class. The least
expensive solution can be called out as well.
Step 7 : Plot Industry Trends
Arrange and transform the information according to a clear explanation of implications for the
redesign task.
The process should include :
Categorization of the market

o Market categorization is categorizing product solutions by socio-economic status
of the typical customer of the individual product and by percentage of the market.
Benchmarking of technical solution
29
o It is an approach to comparing how products perform. The most effective

approach is the development of a thorough technology time line using s-curves.
Benchmarking of competitors
o It is similar in spirit to the bench marking of technical solutions and considers the
performance on business criteria.
Proposal on Opportunities to Redesign
4.5.
One can compare the current product to others with respect to customer needs and determine
whether each of the needs are worth addressing. We have to determine whether there is a strong
demand to address the need. We have to determine where and what design work to perform.
There are two methods to do this:
1. House of Quality
2. Value Analysis
4.6.
Benchmarking The Competition
Competitive benchmarking can help forecast the trends in the industry and it can identify key
innovations and key technologies. The benchmarking of technical solutions is comparing how
products perform. All technological innovations manifest themselves over time into the market
along an s-curve timeline behavior . The benchmarking of competitor considers the
performance over time of the entire portfolio of a company . Corporate strategies may be
deciphered.
4.7. Setting Product Specifications
Having benchmarked competitive products on customer and technical criteria , this information
is to use to set targets for a new product development effort.
4.7.1. Specification Process
Specifications for a new product are quantitative measurable criteria that the product should be
designed to satisfy. They are the measurable goals for the design team. There are two aspects to a
specification:
It is on a dimension that can support units.
It needs a target value.
We develop specifications using two approaches, first form a checklist viewpoint, and the second
from a viewpoint of the translation of qualitative customer needs. For translation of customer
needs we have two methods, House of Quality &Value Analysis
30
4.7.2. Functional Requirements Vs. Product Constraints

Engineering requirements fall into two categories, functional requirements and constraints .
Functional Requirements are the statements of the specific performance of a design, what
the device should do. They focus on performance. Relationship between the inputs and
outputs establish the function of the system. So a Function is an abstract formulation of
the task to be accomplished, and is independent of any particular solution that is
employed to achieve the result.

Constraints are external factors that, in some way, limit the selection of system or
subsystem characteristics. They are not directly related to the function of the system, but
apply across the set of functions for the systems. Cost, schedule, size, weight, safety
issues etc are examples. Constraints can drive the solution of many products, especially
large scale systems. Constraints should be established only after critical evaluation.
4.7.3. Basic Method: Specification Sheets
It is important to supplement and complement consumer needs and engineering requirements.
We may use a method called Specification List Generation which uses decomposition to guide a
search for relevant specifications. This focuses on latent specification, with designating each
specification as a required demand or desirable wish will communicate its level of importance.
Table 4.4 : Specification Sheet of a Belt Conveyor System by using Geneva Mechanism
Specification
Parts Used
Stand
Geneva Wheel
Oak wood, Ply wood

Aluminum alloy,4slot,Outer Diameter-80mm,Thickness-7mm
Driver Wheel
Aluminum alloy, Single Pin, Total Thickness-12mm,Outer Diameter-90mm
Dc Motor
Ball Bearing
Electric Wire
Adapter
Coupling Pin
Conveyor Belt
Roller
12volt,(1-5 Amp)DC
Deep groove, Series 6004,Stainless Steel
1-5 Amp
12Volt, 5 Amp
Stainless Steel , 3mm diameter
Grade M-24, length-1m , Thickness-1.8 mm
Alloy Steel, Outer diameter- 40 mm, Bead length - 60 mm
4.7.4. Basic Method: The House Of Quality
31
The design team should understand the customer needs, understand the current product and how
it satisfies these needs. We now need to determine the priorities for design to achieve the design
goals and make the product better. We must:
Find the weakly satisfied customer needs.
Their dependencies or inter-relationships.
Determine what product changes we can affect to improve these weak points.
This process will define the level of modeling required, both in function and in product
components.
Quality Function Deployment (QFD) is a methodology for defining the customers desires in the
customers own voice, prioritizing these desires, translating them into engineering requirements
and establishing targets for meeting the specifications. It also embodies tool for defining the "
right" problem to solve where a series of matrices are used to structure information acquisition
and documentation . Each matrix called a house of quality. It focuses on learning from customer
experience and reconciling what customers want with what engineers can reasonably build.
The main highlights of House of Qualities are
Establish engineering requirements that can be used as measurable surrogates for the
more qualitative customer needs.
Make the relationship clear between customer needs and engineering requirements by
establishing target values, checking for conflicts etc.
It forms a clear summary of the product specifications and supporting data.

Process
Identify the customer needs(both internal and external).
Determine the customer needs or customer requirements i.e. the whats to be done?
These can be listed as primary, secondary or tertiary sequence according to customers
opinion.
Assign a relative importance or priority to the customer needs (scale of 1-5).
Translate the needs into measurable engineering requirements (or HOWs), and determine
how the product can be changed in performance to better meet customer needs. The
customer domain tells us how to do it, at least in terms of measurements . For any
customer need, there may be multiple engineering requirements that can be expressed in
quantifiable terms. One should document :
32
I.
Each how in terms of a label and specification value.
II.
The direction for improvement for each how using a + or arrows
Determine the relationship of engineering design requirements to customer needs, and the
strength b/w the same.
- Indicates a strong relationship or much importance

- Indicates some relationship or some importance
- Indicates a small relationship or importance
Blank
- Indicates no relationship(0)
Perform competitive benchmarking to determine how the customer perceives the
competition's ability to meet each of their needs on a scale of 1-5, with 1 representing not
satisfied and 5 represents fully satisfied. This step represents a qualitative benchmarking
exercise, capturing the "feeling" of the customer.

Rank the technical difficulty of each engineering requirement. The technical difficulty of
achieving each customer need in terms of the changes defined by the engineering
requirement should also be defined on a scale of 1-5 .

Correlate technical relationships to determine inter-relationships of design requirements.
This step entails completing the "roof" of the House Of Quality. Technical characteristics
may be competing rather than complementary. These relationships must be defined and
resolved.
Indicates high positive correlations
+ Indicates positive correlations
- Indicates negative correlations
Indicates high negative correlations
Set engineering requirement targets or specifications for the design team. Compare the
requirement measurement of each of the benchmarking products and positioning the new
product among these specifications. While setting a target consider 1. Cost 2. Benefit of
it. Relatively narrow ranges of values are used.

Select areas for improvement. QFD matrix is to define final design targets, identify areas
that need further concentrated effort. To make these decisions, the importance rating of
customer needs must be considered in the considered in conjunction in the qualitative
bench marking.
33
Fig. 4.6 : Belt Conveyor System House of Quality
34
Chapter 5
Product Architecture
It is the stage where we begin to take key decisions on how the product will physically operate. It
starts the creation of effective layouts of components and subsystems.
Architecture Types
There are two types of architectures : Product and Portfolio. Portfolio architectures relate to a
group or family of products where as product architectures relate to specific product. Strategies
for product design revolve around the product's market & performance.
Integral
Integral product architectures are physical structures where all of the sub functions map to a
single or very small number of physical elements.
Modular
Product modules are defined as integral physical products substructures that have a one to one
correspondence with a subset of a product's function model.
5.1.
Team member
Task assigned date
1:Dibyajyoti Swain
Geometric Layout
05.03.2016
2:Saurav Panda
Function Structure
05.03.2016
3:Rakesh Roshan Pal Hierarchy Model
05.03.2016
Task name
5.2. Modular Design by Basic Clustering
Task completed on
06.03.2016
06.03.2016
06.03.2016
Member, who
completed it
Member 2:Saurav Panda

35
This section represents a basic technique for establishing a modular product architecture. The
overall goal is to translate customer needs into rough layouts of a product. To accomplish this
goal ,small modules must be identified in the product. A product function structure begins the
process followed by clustering , generating rough geometry and defining interactions.
Product: Conveyor system
Handling System
Electrical
Conveyor
Chassis
Switch
Geneva Wheel
Base
Stand
Power Supply
Motor
Motor
Mechanical
Belt & Roller
Geneva Wheel
Driver Wheel
Conveyor
Bearing
Fig. 5.1 : Component Hierarchy

Geneva & Driver Wheel
Handling System
Belt
Motor
Base Stand
Fig. 5.2 : Rough Geometric Layout
36
Output
Input
Chapter 6
Concept Generation
This stage provides a forum for designers to apply creative ideas and contribute their personal
skill . The main goal of concept generation is to develop as many ideas as possible . It also
represents the time when technology is chosen or developed to fulfill the customer needs. This
approach will lead to a broad number of solution ideas for each of the product functions. These
solutions principles may be applied to alternative layouts that are created or alternative concept
classes defined by the portfolios. The process is to combine the solution ideas per product
function into concept variants, that is alternative design . This step in the process is challenging
and nonlinear. Concept generation methods broadly are of two types :
1. Intuitive methods
It focuses on idea generation from within an individual or group of individuals .The methods
works to remove barriers to divergent thinking leading to better visualization of the features in a
product, the environment of idea generation may be filled with conditions that promote
creativity. Examples of this methods include brainstorming and morphological charting.
2. Directed(logical)
Directed methods are systematic, step by step approach to search for a solution. This method rely
on technical information ,expertise and guidelines to seek solutions to technical problems.
6.1.

37

Team member
1:Ashutosh Panda
Memory map, C-Sketch
09.03.2016
2:Chandan kumar
Idea Generation
09.03.2016
Behera
3:Saurav Panda
Morphological Chart
09.03.2016
4:Dibyajyoti Swain
Assembly Sketching
09.03.2016
5:Rakesh Roshan Pal Concept Variants
09.03.2016
6:Bibhuti Bhusan
Concept Variants
09.03.2016
Pradhan
Task name
Member 3: Chandan kumar Behera
6.2.
Task completed on
10.03.2016
11.03.2016
11.03.2016
11.03.2016
11.03.2016
11.03.2016
Member, who
completed it

Brainstorming Method
It is a powerful technique for generating concepts by intuitive method .The main focus is on
product function and architecture where team members communicate ideas verbally during a set
of time period .The aim of brainstorming is to produce several concepts that might work as
solution principles to a piece of the design problem. The main advantage of brainstorming is the
ability of a set of individuals to collectively build on each other to generate ideas that would not
arise individually .Team members will have to piggyback and leapfrog each other . Piggyback
creates building block ideas to words, body language, statements and concepts stated by a team
member. leapfrog will help in bringing different expertise ,skills, and personality to a group
effort.
Disadvantage of this method is that "right idea" will not come at "right time". Group conventions
may get side tracked or original ideas get inhibited.
38
Horizontal or
Vertical or Inclined
or Vibrating type
Conveyor
Time Delay Can Be

Achieved
Used for small & medium

scale production, Not for
large scale production
Belt or Bucket
type or Roller
Conveyor
Used In Fly
Ash Brick
Plant, Railway
Station,
Airport,
Beverages
Industry
Give Continuous
Motion To
Intermittent
Motion
More Time &

More Material
Loading
Gear also Can
be used for
transmitting
power
Geneva mechanism is very

simple ,easy to disassemble and
low maintenance cost than
stepper motor. Also convert
continuous motion to
intermittent motion.
Takes Less Time Than
4 Slot
Four Slot
Six Slot
Both Roller And Idler

Will Be Used
Geneva Mechanism Or
Stepper Motor
Smaller conveyor belt will
be taken
Conveyor System
Motor
Distributed Load Will Be

Taken On Conveyor Belt
During Analysis
Only Roller Will Be

Attached
AC
DC
Can't
sustain
more load
6V
12V
1-5 Amp current will be

given & can sustain to
transmit the material
Driver Wheel And

Geneva Wheel Will Be
Manufactured
By
lighter Material And
Avoid of Rusting
Gear can
be attached
for
transferring
power
Key or Coupling
RPM will be reduced

from output of motor to
input of roller
But without coupling you can't attach the

two wheel in the two shaft . In other
method more problem will be created. So,
coupling is must. Then more raw material&
more space will be required.
But no transformation of continuous

motion to intermittent motion
Fig. 6.1 : Memory Map for the Function of Belt Conveyor System
6.3.
C-Sketch / 6-3-5 Method

39
Table 6.2 : Weighted Sub Function Values for the Belt Conveyor System Application
Sub function
Associated customer need
Weighted customer
rating
4,3
4
4,3,2
2,1
3,2
2,1
4,3,2
4,3,1
3,1
4,3
4,3
4
4
need rating
7
4
9
3
5
3
9
8
4
7
7
4
4
Convert electricity to torque

Usefulness
Regulate rotation
Regulate translation
Allow rotational DOF
Costlier system
Easy Disassemble
System performance
Safety
Change RPM
Transmit power
6.4.
Morphological Analysis
A systematic method for this assembly and continued idea creation is known as morphological
analysis or charting. It is a tool that provides a structured search and combination of concepts in
product design.
Table 6.3 : Initial Morphological Chart for Belt Conveyor System
Starting
Assemblies name & sub functions
Current
Switching on motor
Power transmission from motor to shaft
Shaft coupling +Gear Box
Power transmission from shaft to input roller
Shaft rotation
Motion transmission Tangential velocity of belt
Angular velocity of input roller
Table 6.4 : Morphological Matrix with Additional Solutions

Assemblies name & Sub
Current
Stepper motor
Geneva mechanism
functions
Starting
Switching on motor
Switching on
Switching on motor
motor
Power transmission from
Shaft coupling +Gear
motor to shaft
box
Shaft coupling
Driver wheel +
Geneva wheel
40
Power transmission from
Shaft rotation
Shaft rotation
Shaft rotation
Motion transmission
Angular velocity of
Angular
Angular velocity of
Tangential velocity of
input roller
velocity of
input roller
shaft to input roller
belt
input roller
6.5.
Assembly Sketching of Concept Variants
After brainstorming different ideas were generated and analyzed. These ideas are shown below
by different sketching format.
Fig. 6.2 : Assembly Sketching of Concept Variants
41
Chapter 7
Concept Selection
Each concept variant developed earlier must be evaluated, compared and one feasible concept
must be chosen. The order of magnitude estimation should be employed to determine the
technical feasibility of a product concept. Then, to select a concept among the concepts that pass
the order of magnitude analysis, a more refined decision making analysis must be applied. A
basic method intended for this is called Pugh chart. In top level, Product development can be
thought of as having three basic tasks such as gathering information, making decisions, or
disseminating information. The concept selection process presented here is a means to deal with
this uncertainty. The selection process is a five step process plus iterations:
1.
2.
3.
4.
5.
Forming consensus on the criteria.

Forming consensus on the alternatives.
Ranking the alternatives.
Evaluating the alternatives.
Attacking the negatives.
7.1.

Team member
1:Ashutosh Panda
About Concept
11.03.2016
Selection, PPT& Report
2:Sourav Panda
Pugh Chart
11.03.2016
3:Chandan Kumar
Involved in making
11.03.2016
Behera
Pugh Chart
4:Dibyajyoti Swain
Involved in making
11.03.2016
Pugh Chart
5:Rakesh Roshan Pal Involved in making
11.03.2016
Pugh Chart
6: Bibhuti Bhusan
Pradhan
Involved in making
Pugh Chart
11.03.2016
42
Task completed on
12.03.2016
12.03.2016
12.03.2016
12.03.2016
12.03.2016
12.03.2016

Task name

7.2.
Member, who
completed it
Member 2: Sourav Panda

Using Pugh Chart as Decision Making Tool
Concept selection with decision making tools was developed by Pugh in 1990. This chart uses a
minimal evaluation scale and three overall ranking metrics. It is the most effective known tool
for preliminary concept selection where there is minimal information quality available. They are
also effective as the information quality increases and the selection scale is refined. The Pugh
charts evaluation scheme presented earlier involves set of alternatives, set of criteria and a
better /same/worse evaluation against a datum .
With the set of alternatives and criteria, there are three basic mathematical tasks that are
completed:
1. Identify a datum alternatives.
2. Rank every other alternatives as better/same/worse for each criterion.
3. Sum the ranks for an overall evaluation of each configuration.
Table 7.2 : Conveyor System Redesign Concepts for Power Transmission
Functions
Normal
conveyor
Stepper
motor
Gear
Arrangement
Geneva
wheel
+
-
Single
tooth
Gear
+
+
-
Cost
Complexity
Development difficulty
Time for movement of
conveyor belt
Put in weight
Handling
S
S
S
S
S
S
0
0
0
S
+
1
-4
-3
+
2
-3
-1
2
-4
-2
3
-3
0
+
+
+
-
7.2.1. Redesign Concepts

From Pugh chart ,we have achieved time delay by using Geneva wheel and more material will be
transported due to intermittent motion of wheel. It is also easy to handle and easy to disassemble.
43
In order to obtain high velocity ratio we have to change the diameter of the wheel. For higher
power ,we will attach high capacity motors in the driver pulley.
Fig.
7.1 :7.3
Selected
Assembly System
Sketching
for Redesigning
Table
: Belt Conveyor
Redesign
Criteria
Cost
Unit Manufacturing Cost + Operational Cost + No Delivery Cost
Complexity
The no parts used in designing
Time For Movement of
From the time the weight is put on at the starting cost point till it
Conveyor Belt
Handling
reaches the end point

Delivering of the weight smoothly & precisely from one point to
other
Chapter 8
Product Embodiment
This stage aims to transform product concepts and architectures into realized systems. These
systems must satisfy customer needs, be robust with respect to all environmental and user
44
conditions, and be designed to reduce the likelihood of failure.

8.1.
Team member
Task assigned date
1:Ashutosh Panda
2:Sourav Panda
3:Chandan Kumar
Behara
4:Dibyajyoti Swain
Material Properties
Choosing
FEMA Model
Geometry & L:ayout
Material Properties
Choosing
5:Rakesh Roshan Pal
FEMA Model
Task name

Member 3: Chandan Kumar Behara
8.2.
Task completed on
14.03.2016
14.03.2016
14.03.2016
14.3.2016
16.03.2016
15.03.2016
14.03.2016
14.03.2016
14.03.2016
16.03.2016
Member, who
completed it

Refining Geometry and Layout
In the context of creating a robust product or family of products, two issues drive concept
embodiment
1. Refining a product's geometry and architecture
2. Systems modeling towards detail design.
These two issue pertain to four design scenarios: original design, adaptive design where a
significant new technology is introduced, adaptive design where a simple subsystem is modified,
or parametric design.
Embodied design moves the process iteratively toward a definitive form:
Geometric layout.
Material composition.
Quality & manufacturability issues.
Economics
45
Fig. 8.1 : Embodided Design of a Belt Conveyor System
8.3.
Systems Modeling
This technique can be applied when embodying a concept. Systems models are representation of
a product that predict the product's performance under varying input(environmental &boundary )
conditions. These models need to be extended to facilitate design parameter and manufacturing
decision during concept embodiment.
8.3.1.
Failure Modes and Effect Analysis (FMEA) Method
The foundation of robust product design is built on the combined concepts of customer quality
and engineering quality. Customer quality is to minimize the performance variation of a product
for all environmental and user conditions . Engineering quality is to ensure that a product
functions as it is intended, without falling short of customer's implicit expectation. The second
type of quality is intended to ensure that a product has adequate strength, reliability,
environmental impact prevention and accident prevention measures. A more advanced and
complementary technique is known as failure modes and effect analysis(FMEA). FMEA is an
analytical technique used by a product design team as a means to identify ,define and eliminate
46
to the extent possible known as potential failure modes of a product system. This technique
should be used cooperatively with systems modeling to investigate and determine good choices
for variables defining a product.
Table 8.2 : Partial Failure Modes and Effect Analysis of Conveyor System
Part &
Functio
n
Geneva
:conver
sion of
contino
us
motion
to
intermi
ttent
motion
Potential
failure
mode
Potential
effects of
failure
S
E
V
E
R
(S)
Potential
Causes
O
C
C
U
R
(O)
Current Design
Control/Tests
Wearing
&
shearing
Conveyo
r stops
Insuffiien
t
clearance
Solidworks
simulation
Strength
of metal
Material testing
machine
D
E
T
E
C
T
(D)
1
Recomme
nded
Actions
R
P
N
Thickness
reduced
40
Proper
metal was
chosen
16
Where ,
RPN=Risk Priorrity Number
RPN=(S)*(O)*(D)
=8*5*1
=40
Table 8.3 : Properties of Relevant Material Choices
Materials
Stainless steel
Alloy steel(EN 24)
Mild steel
Aluminum alloy(2024)
Wood(Oak)
yield
(Mpa)
172.34
620.42
220.59
75.83
-
ultimate
(Mpa)
513.61
723.83
399.83
186.83
-
47
Young's Modulus (E) (Mpa)

200000
210000
210000
73000
-
Natural Rubber
20
48
0.01
Chapter 9
Product Metric Model

A model of a product metric is simply a representation, simplification, or estimation of a
product's realization to aid in making product decisions. Before a product model is considered , a
product development team must take stock of its current design status. A wealth of data usually
exists when analytical models are being developed for product concepts.
9.1.
Team member
1:Ashutosh Panda
Weight age of product
function based on
16.03.2016
performance level
2:Sourav Panda
Model Preparation &
Selection Based On
16.03.2016
Metric System,
3:Chandan Kumar
Parts Drawing by
16.03.2016
Behara
Solid works
5:Rakesh Roshan Pal
Parts Drawing by
Solid works
16.03.2016
Task name
9.2.
Task completed on
17.03.2016
18.03.2016
23.03.2016
23.03.2016
Member, who
completed it

Model Selection by Performance Specifications

49
When creating a product model , the overriding goal is to formulate a representation that may be
tested to measure a customer need over a range of possible choices . Thus we are modeling
customer needs as metrics, creating simplified versions of the product for testing, and measuring
the product against clear target values.
Customer needs
Convert electricity to torque
Usefulness
Regulate rotation
Costlier system
Easy Disassemble
System performance
Safety
Weightage
4
4
3
3
3
3
2
3
3
Scaled Weight
7
Importance
4
9
3
9
8
4
7
7
Fig. 9.1 : Weighting of Product Function using Quantified Customer Needs

Table 9.2 : Possible Metrics for a Conveyor System
9.3.
Transmit Motion & Torque

Torque
Initial Angular Velocity
Final Angular Velocity
Initial Rpm
Final Rpm
Weight
Power
Voltage
Current
Belt Tension
Constructing Product Models
Units
N.m
rad/sec
rad/sec
min-1
min-1
N
Watt
Volt
Amp
N
Early stages of product development provides us with the necessary informal description of
what we need to model in a design problem. Model preparation and selection establishes the first
link of this informal description to a quantified metric. Having a complete functional model &
architectural layout provides us with additional structure to construct a formal model.
A functional decomposition is the first step in constructing a full engineering model . A function
structure contains a simple identification of informal information. The entries are not necessarily
model variables, but simply flows of energy ,materials and signals through component concepts
50
that solve the function. More structure is needed to maximize product performance .This
structure is simply obtained by relating performance values to the design configuration options
through design variables.
Identify The Customer Need & Engineering Requirement

Identify The flow (Desired Inputs & Outputs)
Identify Physical Mechanisms
Target The Dimension & Precision
Construct The Model
Apply Dimensional Analysis, Similitude & Group Variables
Implement Computationally
(Theoretical Analysis by spread sheet& Computational analysis by FEM etc.)
Interrogate The Model (Compare This Analysis)
Display , Use the model
Fig. 9.2 : Advanced Modeling Approach For Product Metrics
51
9.3.1. Solid Modeling Software

Solid modeling is a set of principles for mathematical and computer modeling of threedimensional solids. Solid modeling is distinguished from related areas of geometric modeling
and computer graphics by its emphasis on physical fidelity. Together, the principles of geometric
and solid modeling form the foundation of computer-aided design (CAD) and in general support
the creation, exchange, visualization, animation, interrogation, and annotation of digital models
of physical objects.
Here we are using Solidworks2014 x 64 Edition for our part modeling.
Fig. 9.3 : Graphics Area of the Solid Works Software

9.3.2.
Solid Modeling Parts Of Belt Conveyor System by SOLIDWORKS
Fig. 9.4 : Ball Bearing

Fig. 9.7 : Driver Wheel
Fig. 9.5 : DC Gear Cum Motor Fig. 9.6 : Geneva Wheel

Fig. 9.8 : Driver Roller
Fig. 9.9 : Driven Roller
52
Fig. 9.11 : Coupling Pin
Fig. 9.10 : Conveyor Belt
Fig. 9.13 : Conveyor Stand
Fig. 9.12: Nut
Fig. 9.14 : Assembly view
Chapter 10
53
Design for Manufacture, Assembly and Environment

A common failure in product development is making products that work but that are also very
difcult to build. Difculty in manufacture makes a product expensive. Design for manufacture
and assembly is the analysis and redesign of a product to make it easier to produce. Society
generates and consumes such a large fraction of the earths resources that we must consider our
impact on the environment in our technical decision making. Design for environment is a
product design approach for reducing the impact of products on the environment.
10.1.
Team member
Task assigned date
1:Ashutosh Panda
Production Cost Analysis
23.03.2016
Breakdown
2:Sourav Panda
Production Cost Analysis
23.03.2016
Breakdown
4:Dibyajyoti Swain
Parts Cost Analysis
23.03.2016
6: Bibhuti Bhusan
Parts Cost Analysis
23.03.2016
Pradhan
Task name
10.2.
Task completed on
24.03.2016
24.03.2016
24.03.2016
24.03.2016
Member, who
completed it

Applying Design Guidelines
54
The most basic approach to design for manufacture and assembly is to apply design guidelines.
After developing a design concepts , one should examine it on each of the design guidelines and
change the design to satisfy the guidelines.
DFA Guidelines
1. Minimize part count by incorporating multiple functions into single parts.
2. Modularize multiple parts into single subassemblies.
3. Assemble in open space, not in confined space.
4. Makes parts to identify how to orient them for insertion.
5. Standardize to reduce part variety.
6. Maximize part symmetry.
7. Design in geometric or weight polar properties if non symmetric.
8. Eliminate tangy parts.
9. Color code parts that are different but shaped similarly.
10. Prevent nesting of parts.
11. Provide orienting features of non symmetric.
12. Design the mating features for easy insertion.
13. Provide alignment features.
14. Insert new parts into an assembly from above.
15. Insert from the same direction or very few. Never require the assembly to be turned over.
16. Eliminate fasteners.
17. Place fasteners away from obstructions.
18. Deep channels should be sufficiently wide to provide access for fastening tools. No
channel is best.
19. Providing flats for uniform fastening & fastening ease.
20. Proper spacing ensures allowance for a fastening tool.
10.3.
Manufacturing Cost Analysis
The design for manufacturing and assembly philosophy underneath cost analysis is to determine
how the product delivery major costs compare with the competition. Major cost drains can arise
from material procurement , part production, assembly or finalized product delivery.
Manufacturing cost is the sum of all expenditures to purchase inputs and dispose of outputs to
the manufacturing system. This includes raw materials, purchased components, employee's
55
efforts ,energy, equipment, maintenance materials and plant disposal costs. A metric of cost
commonly used is a unit manufacturing cost, which is the total manufacturing expenses over a
period divided by the number of units produced during that period.
Selling Price
Manufacturing Cost
Piece Parts
Original
Equipment
Manufacturing
Parts
Material
Distribution Cost
Overhead
Assembly
Custom
Parts
Retail Cost
Labor
Tooling
Tooling
Set Up
Processing
Fig. 10.1 : Production Cost Analysis Breakdown

For product development purposes, a more effective breakdown is to consider costs according to
physical manufacturing processes. Each of these can then be costed and different processes
considered. As shown in figure 10.1 , we will form a contributing manufacturing cost breakdown
consisting of :
Piece Part Costs: This covers the costs of both parts made and bought from suppliers.
Assembly Costs: This covers the costs of assembling the part into the product.
Overhead Rate: This covers the costs of supporting direct production of parts and
assembly.
56
Simple Parts
Medium Complexity Parts
Rear Roller
Complexity Parts
Front Roller
Driver Wheel
Geneva wheel
Fig. 10.2 : Typical Manufacturing Parts
Assembly Tree
The first step in establishing an assembly cost model is to establish the assembly sequence
hierarchy. In the tree diagram, the final product as the trunk and each attached part as a leaf node.
Exploded view (Figure 10.3) diagrams are very helpful in constructing the assembly tree.
57
Conveyor Belt
Ball Bearing
Coupling Pin
Driven Roller
Geneva Wheel
Motor
Driven Roller
Rectangular Frame
Driver Wheel
Conveyor Stand
Motor Stand
Base
Fig. 10.3 : Exploded View of Belt Conveyor System
Power Adapter
Op 04
Wooden Stand
Op 19
Bearing
Op 18
Coupling Pin
Op 14
Conveyor Belt
Op 16
Cord
Op 03
Driven Roller
Op 17
Switch
Op 02
Base Frame
58
Op 01
Driver Roller
Op 15
Geneva Wheel
Op 13
Driver Pin
Op 12
Motor
Op 09
Input Shaft
Op 08
Driver Wheel
Op 11
Gear Box
Op 07
Coupling Pin
Op 10
Wiring Assembly
Op 06
Electrical Circuit
Op 05
Fig. 10.4 : Belt Conveyor System Assembly Tree
59
Table 10.2 : Belt Conveyor System Parts Cost Analysis

Part
DC Gear cum motor
Adaptor
Conveyor belt
Deep Groove Ball Bearing
Nut, Bolt, Screw
L-Shape Clamp
Stand
Driver Wheel
Geneva Wheel
Front Roller
Rear Roller
10.4.
Material Cost
Rs 300/Rs 300/Rs 238/Rs 235/-
Tooling cost
-
Processing cost
Total
Total Cost
Rs 1050/Rs 300/Rs 215/Rs 440/Rs 30/Rs 60/Rs 300/Rs 300/Rs 238/Rs 235/Rs 3168/-
Design for Environment (DFE)
Design for the environment is an important activity for a design team because environmental
damage is, as are the most things greatly influenced in the early design phases.
We can no longer think of our technical and industrial society of much larger system that we can
extract materials from and dump waste into. Society generates and consumes such a large
fraction of the earth recourses that we must consider our impact on the environment in our
technical decision making. A growth area for society ,engineering and design is to simply
maintain the standard of technological living we now enjoy into next centuries, but at a
sustainable level of low environmental impact. Design for the environment is a product design
approach for reducing the impact of products on the environment.
10.4.1. List of Environmental Issue & Guidelines
There are basically two issues according to the environmental impact : Global Issues
There are pollution problems whose manifestations exists on a global scale. These include
concerns over climate change, ozone depletion, biodiversity loss. Our systems has no global
issues.
Regional & Local Issues
60
These are the environmental problems exists on a more regional, society level. These include
problems on acid rain, where pollution byproducts in one region can cause acid rain in another
region. Air pollution & smog also are regional problems. Water pollution ,either in the ground
water, river, bay, or ocean, is also a regional problem, often caused by herbicides and pesticides,
in addition to suburban & urban street water runoff. Our system has no local issues for
environment.
DFE Guidelines
Table 10.3 : Product Structure Guidelines
Guideline
Design a product to be multifunctional.
Reason
More ecoefficient than many unique function
products.
of parts. create Reduces disassembly time & resources.
Minimize the number

multifunctional parts.
Avoid separate springs, pulleys or harnesses.
Instead, embed these functions into parts.
Make designs as modular as possible, with
separation of functions.
Design a reusable platform & reusable
modules.
Locate unrecyclable parts in one subsystem
that can be quickly removed .
Locate parts with the highest value in easily
accessible places, with an optimized removal
direction
Design parts for stability during disassembly
Reduces disassembly time & resources.

Allow options of service, upgrade &
recycling.
Allows options of service, upgrade &
recycling.
Speeds disassembly.
Enables partial disassembly for optimum
return.
Manual disassembly is faster with a firm

working base.
In plastic parts, avoid embedded metal inserts Creates the need for shredding & separation.
or reinforcements.
Access and break points should be made Logical structure speeds disassembly &
obvious.
training.
Specify remanufactured parts.
Stimulate demand for remanufacturing,
reducing raw material consumption.
Specify reusable containers for shipping or Reduces raw material consumption.
consumables within the product
Design power down features for different Eliminate unnecessary power consumption
subsystems in a product when there are not in for idle components.
use.
Lump individual parts with the same material. Eliminates the need for disassembly during
61
recycling. Neighbor parts may be ground or

melted as a group.
Table 10.4 : Material Selection Guidelines
Guideline
Avoid regulated and restricted materials.
Minimize the number of different types of
material.
For attached parts ,standardize on the same or
a compatible material. Eliminate incompatible
materials.
Mark the material on all parts.
Use recycled materials.
Use materials that can be recycled, typically
ones as pure as possible (no additives).
Avoid composite materials.
Use high strength-to-weight materials on
moving parts.
Use low alloy metals that are more recyclable
than high alloy ones.
If the same base metal can be used , different
metals can be fastened.
Hazardous parts should be clearly marked and
easily removed.
Reason
They are high impact.
Simplifies the recycling process.
Reduces the need for disassembly and sorting.
Many materials value is increased by accurate

identification and sorting.
Stimulate the market for material that has
been recycled.
Minimize waste; increase the end-of-life
value of the product.
Composites are inherently not pure materials,
and so not amenable to recycling.
Reduce moving mass and therefore energy
consumption.
More pure metals can be recycled into more
varied applications.
Aluminum, steel and magnesium alloys are
readily separated from shredder output and
recycled.
Rapidly eliminate parts of negative value.
Table 10.5 : Labeling and Finish Guidelines

Guideline
Ensure compatibility of ink where printing is
required on parts.
Eliminate incompatible paints on parts -use
label imprints or even inserts.
Reason
Maintain maximum value of recovered
materials.
Many label-removal operations for paints
cause part deterioration.
Use unplated metals that are more recyclable Some plating can eliminate recyclability.
than plated.
Use electronic part documentation.
These parts can be reused.
62
Table 10.6 : Fastening Guidelines

Guideline
Minimize the number of fasteners.
Reason
Most disassembly time is fastener removal.
Minimize the number of fastener removal Tool changing costs time.

tools needed.
Fasteners should be easy to remove.
Save time in disassembly.
Fastening points should be easy to access
Awkward movements slow down manual
disassembly.
Snap fits should be obviously located and able Special tools may not be identified or
to be torn apart using standard tools.
available.
If two parts cannot be compatible ,make them They must be separated to recycle.
easy to separate.
Eliminate adhesives unless compatible with Many adhesives cause complete
both parts joined.
contamination of parts for material recycling
Minimize the number and length of Flexible elements slow to remove ; copper
interconnecting wires or cables used.
contaminates steel, etc.
Connections can be designed to break as an Fracture is a fast disassembly operations.
alternative to removing fasteners.
63
Chapter 11
Analytical and Numerical Model Solutions

The concept is modeled, analytically or numerically, so that multiple configurations may be
searched to realize preferred solutions. A number of computational solution methods exist to
solve product models. These methods include finite element method, finite difference method,
modal analysis, dynamic simulations, optimization, etc.
11.1. Task Distribution and Monitoring
Team member
1:Ashutosh Panda
31.03.2016
2:Sourav Panda
24.03.2016
3:Chandan Kumar
31.03.2016
Behara
4:Dibyajyoti Swain
24.03.2016
5:Rakesh Roshan Pal Theoretical Analysis
24.03.2016
Task name
11.2.
Task completed on
03.04.2016
30.03.2016
03.04.2016
30.03.2016
30.03.2016
Member, who
completed it

According to the design of an effective and efficient material handling system which will
increase productivity and minimize cost. The design of belt conveyor system involves
determination of the correct dimension of the belt conveyor components and other critical
parameter values so as to ensure optimum efficiency during loading and unloading conditions.
64
d1
d2
C
Fig. 11.1 : Conveyor belt with driver & driven roller

Assumption :
The diameter of driver roller , driven roller, diameter of roller shaft, length of shaft, Capacity of
the conveyor & length of conveyor are given below :
Centre distance between two roller :
The diameter of Driver Roller (d1) = 40mm = 0.04 m
The diameter of Driven Roller (d2) = 40mm = 0.04 m
Angle Of Contact () =1800-(
d1 d 2
)600
C
[2]
where,
C = Center distance between two roller, mm
= 1800
Perimeter of half roller =
= 3.14*20
= 62.83 mm
( L)
Length of the belt
d d2
( d1 d 2 ) 2C ( 1
)
2
4C
1000 =
(40+40)+2
65
[2]
= 437.16 ~ 437.2 mm
Driver
Slack Side
Driven
t
Tight Side
Fig. 11.2 : Open Belt Drive

For driver roller :
For driven roller:
Diameter of the Roller shaft = 20mm
Diameter of the shaft=20mm
Length = 155mm
Length=120mm
Mass = 755gm = 0.755kg
Mass=720gm
Tension in Belt :
The belt of the conveyor always experience tensile load due to the rotation of the electric drive ,
weight of the conveyed material and due to idler . The belt tension must be great enough to
prevent slippage between the drive pulley and the belt. Belt tension at steady state is given as:
1.37 l g [2 mi (2 mb mm ) Cos ] ( H g mm )
Tss =
66
[6]
where,
= Co-Efficient of friction = 0.3
l = length of conveyor =
[2]
belt length = 0.5 m
g = Acceleration due to gravity = 9.81(m/sec2)

mi = Load due to idler(kg/m)
where,
i = idler spacing = 0
mi=(mass/idler spacing) = 0
mb = Load due to belt(kg/m) = 0.2(Kg/m)
mm= Load due to conveyed material = 0.400/0.040=10 kg/m
= Inclination angle of conveyor = 00
H = Vertical height from base=400mm

Tss = 1.37*0.3*0.5*9.81[(2*0)+(2*0.2+10) Cos (0)]+(0.400*9.81*10)
= 67.18 N
Initial tension of the Belt :
During the start of the conveyor system, the tension in the belt will be much higher than the
steady state. The belt tension while starting is
Ts=Tss * Ks
(Take , Ks=1.2)
where,
Ts = Belt tension while starting (N)
Tss = Belt tension at steady state = 67.18 N
Ks = Load correction factor or Service factor
= 1.2 (For Steady Load) [2]
67
Ts = 1.2 * 67.18 = 80.61 N

Maximum Tension in the Belt :
The operating maximum belt tension is defined as the maximum belt tension occurring when the
belt is conveying the design load from the loading point continuously to the point of discharge.
Operating maximum tension usually occurs at the discharge point on horizontal or inclined
conveyors and at the loading point on regenerative declined conveyors.
Maximum tension (Tmax) is the belt tension at the point where the conveyor experiences the
greatest stress . Tmax can be found at different sections in the belt.
Torque (T) = (T1-T2)*r
where,
T1 =Tension in Tight Side
T2 =Tension in Slack Side
r = Radius of roller
T1-T2= 80.61N
Ratio of tensions of the belt
T1
T2
[2]
e
=
(Neglecting centrifugal force i.e for low velocity)
180
As, = 0.3 & = 1800 = radian
[10 =
T1
T2 e *0.3
=
T1
2.566
T2
68
radian]
T1=2.566 * T2
1.56 * T2 = 80.61
T2 =51.67N
T1 2.56 * 51.67
= 132.27 N
So, Toque required (T)=(T1-T2) * r

=(132.27-51.67)*20
=1700 N.mm
=1.7 N.m
Tmax = T1 = 132.27 N
Stress on Conveyor Belt :
Tmax= Stress * Cross sectional area of belt
* (b * t )
where,
b=Width of belt
t = Thickness of belt
= Ultimate strength of rubber =35Mpa [2]
T1
Ta
[2]
Minimum width of belt (b) =

Where, Ta = Allowable tension in Newton/mm width of belt
= 7.85 (for rubber material and 3 number of piles)
Then, b=
132.27
7.85
=17.02 mm
69
[2]
Let, Factor of safety for flat rubber belt = 8

max
So,
35
4.4 Mpa
8
F
A
max
Where ,
F=Maximum Tension (T1)
A=Belt Cross-sectional area
max
A=
132.27
4.4
30.76 mm2
Thickness of belt (t) =
30.76
17.02
=1.82 mm
Design of Ball bearing :

For Deep Groove Ball Bearing ,(Series - 6004)
Inner Diameter (d) = 20 mm
Outer Diameter (D) = 42 mm
Width Of Bearing (B) = 12mm
Fillet radius (r) = 1mm
Mean diameter (dm) =
Dd
2
42 20
2
= 31 mm
Diameter of ball (db) = 0.3(D-d) = 0.3(42-20) = 6.6 mm
70
Fig. 11.3 : Dimensions of deep groove ball

bearing
Radial thickness of races (s) = 0.15(D-d) =
Number of balls (n) = 2.9(

Basic capacity
Dd
Dd
) =2.9(
db
2
6.6
2
42 20
42 20
= 3.3
) = 8.17 ~ 9
For Static(C0) = 4415 N

For Dynamic(C) = 7350 N
Maximum permissible speed = 16000 rpm
Fig. 11.4 : Deep Groove Ball Bearing
Radial loads on the bearing are calculated from moment equations as follows :
MC 0
-7.4 * 60 - Rb * 120 = 0
Rb =
7.4 * 60
120
60 mm
= -3.7 N = 3.7 N (
Rb Rc 3.7 N
Fig.
Design Of Geneva Mechanism :
71
60 mm
7.40 N
11.5 : Load on Ball Bearing
(a)
Fig. 11.6 : Nomenclature of Geneva Mechanism
Fig. 11.7 : Angular positions of the Geneva Mechanism
r
[2]
sin( )
Centre distance between crank &wheel centers (e) =
Where, Sin() = Sin
180
Z
Z = Number Of slots = 4
72
(b)
Sin() = Sin
180
4
Sin 1 ( Sin
180
)
4
= 450
i.e. the active rotation angle of the crank expressed depending on the number of slots .
Centre distance between drive wheel & drive pin (r) =40 mm
40
r
sin( ) Sin ( 450 )
e=
= 56.56 mm
Radius of Geneva wheel (R) = e * Cos(
= 56.56 * Cos(450)
= 40 mm
Length of slot (h) = r + R - e
[2]
= 40+40-56.56
= 23.44 mm
Diameter of crank's shaft = dc< 2(e-R)
[2]
(To avoid interference between the crank

shaft and Geneva wheel)
= dc < 2(56.56-40)
= dc < 33.12 mm
Diameter of Geneva wheel shaft = dw < 2(e-r)
[2]
= dw< 2(56.56-40)
= dw< 33.12 mm
Also, dw=
Rh
1.5
[2]
73
dw =
40 23.44
1.5
= 11.04
Variation of Output Torque in Geneva Mechanism :
Fig. 11.8 : Maximum Torque Position In Geneva Mechanism

When the same input torque given by the drive wheel, the different output torque has been
formed in the Geneva wheel at different input angular position or Crank angle position. All the
values in details for different angular positions are shown in Table 11.2 :
Table 11.2 : Calculation of Output Torque at Same Input Torque
Sl. No.
Input
Torque
( N. m)
1
2
3
4
5
6
7
1.7
1.7
1.7
1.7
1.7
1.7
1.7
Input
Angular
Position
(Degree)
0
15
30
45
60
75
90
Perpendicular
Distance From
Driver Wheel
(mm)
0
2
28.29
40
28.31
12.14
0
Perpendicular
Distance From
Geneva Wheel
(mm)
40
29.7
20.83
16.56
20.69
29.65
40
Force
(N)
Output
Torque
(N. m)
0
14.02
60.07
42.5
60.04
140.03
0
0
4.163
1.251
0.703
1.243
4.151
0
Now, the different output torques Vs. different input angular position for same input torque are
plotted in a graph as shown in Figure 11.9 :
74
5
4
Output Torque ( N.m.):-
3
2
1
0
0
-1
10
20
30
40
Y-Values
50
60
70
80
90
100
-2
-3
-4
-5
Fig. 11.9 : Input Angular Position Vs. Output Torque

From the output torque analysis graph, the design of driver pin can be calculated as below:
Fmax =140 N (From Figure 11.9 Graph)
yield =75Mpa (For Aluminum Alloy)
Let, Factor of safety = 9
yield
max
Factor of safety =
max
=
max
=
75
9
= 8.33 Mpa
F
A
A= shearing area
75
F
*d2
4
max
140
*d2
4
8.33
* d 2 16.82mm2
4
d = 4.8 mm (i.e. the diameter of driver pin)

[2]
Stop arc radius(y) = r - (p*1.5)
= 40 - (4.8*1.5)
= 32.8 mm
Where,
p = Drive pin diameter = 4.8 mm
[2]
Stop disk radius(z) = y +t
=32.8 + 0.4
=33.2
Slot width(w) = p + t
[2]
= 4.8 + 0.4
= 5.2 mm
Where, t = Clearance
Wheel angle (
Where,
)=
tan 1
* Sin ( )
1 * Cos( )
[
[2]
r
Sin ( ) Sin (45) 0.707
e
= Crank Angle
76
The different wheel angle are formed in the Geneva wheel at different Crank angle position at
indexing period . All the values in details for different angular positions are shown in Table 11.3:
Table 11.3 : Calculation of Wheel Angle from Crank Angle

Sl. No.
1
2
3
4
5
6
7
8
9
Crank Angle
( )
(Degree)
0
5
10
15
20
25
30
35
40
Wheel angle (
(Degreee)
0
11.77
22
29.98
35.77
39.75
42.35
42.93
44.75
Sl. No.
Crank Angle ( )
(Degree)
10
11
12
13
14
15
16
17
50
55
60
65
70
75
80
85
Wheel angle (
(Degreee)
44.8
44.25
43.44
42.42
41.22
39.89
38.44
36.89
Now, the Crank angle position Vs. Wheel angle are plotted in a graph as shown in Figure 11.10 :
50
Wheel angle(Degrees):-
45
40
35
30
25
Y-Values
20
15
10
5
0
0
10
20
30
40
50
60
Fig. 11.10 : Crank angle Vs. Wheel angle

77
70
80
90
d
(Cos )
[
]c
dt
(1 2Cos 2 )
w
Angular velocity of Geneva wheel =
Where,
[2]
r
Sin ( ) Sin (45) 0.707
e
= Crank Angle
c = Angular velocity of driver wheel (crank) , rad/sec
Angular velocity of driver wheel :
180
10 =
radian
900 =1.57 radian

900 rotation of Geneva wheel = 3600 rotation of driver wheel i.e. Geneva requires 4 seconds to
complete 1 rotation
In the driver wheel, 3600 =6.28 radian
So, We have to rotate the driver wheel in 6.28 rad/sec.
Angular velocity of driver wheel(c)=6.28 rad/sec
The angular velocity of Geneva wheel changes when the Crank angle position changes. All the
values in details for different angular positions are shown in Table 11.4:
Table 11.4 : Calculation of Angular velocity of wheel from Crank Angle
Sl. No.
Crank Angle
( )
(Degree)
Angular velocity
of wheel(w)
(rad/sec)
Sl. No.
Crank Angle
( )
(Degree)
Angular velocity
of wheel(w)
(rad/sec)
1
2
3
4
5
0
10
20
30
40
15.15
11.5
6.03
2.56
0.629
6
7
8
9
10
50
60
70
80
90
-0.48
-1.16
-1.6
-1.88
-2.1
78
Now, the Crank angle position Versus Angular velocity of wheel are plotted in a graph as shown
in Figure 11.11 :
15
10
Angular velocity of wheel(rad/sec):-
20
0
0
Y-Values
10
20
30
40
50
60
70
80
90
100
-5
Fig. 11.11 : Crank angle Vs. Angular velocity of wheel
d 2
(1 2 ) Sin
2
[
]c
2
2 2
dt
(1 2Cos )
w
Angular acceleration of wheel =
[2]
Where,
c = Angular velocity of driving crank
= Angular displacement
t = Time
The angular acceleration of Geneva wheel also depends on the Crank angle position .The angular
acceleration of Geneva wheel can be calculated by differentiation method. All the values in
details for different angular positions are shown in Table 11.5 :
79
Table 11.5 : Calculation of Angular Acceleration of Wheel from Crank Angle

Sl. No.
Crank Angle
( )
(Degree)
Angular
acceleration of
wheel(w)
(rad/sec2)
Sl. No.
Crank Angle
( )
(Degree)
Angular
acceleration
of wheel(w)
(rad/sec2)
1
2
3
4
5
0
10
20
30
40
15.15
11.5
6.03
2.56
0.629
6
7
8
9
10
50
60
70
80
90
-0.48
-1.16
-1.6
-1.88
-2.1
Now, the Crank Angle Position Vs. Angular Acceleration of Wheel are plotted in a graph as
shown in Figure 11.12 :
Angular acceleration of wheel(rad/sec2):-
250
200
150
Y-Values
100
50
0
0
10
20
30
40
50
60
70
80
90
100
Fig. 11.12 : Crank Angle Vs. Angular Acceleration of Wheel

Required Rpm For Given Output :
Considering the Intermittent motion , the rpm of Geneva wheel can be calculated as follows:
If you are taking each stoppage in conveyor as a station then required rpm for a given output is
Station-1
Station -2
Station -3.
80
During the rotation of Geneva , Engagement angle is 900 & Dual angle is 2700.
So, Distance between station 1&2 is :
let 14 stations are there distance between 2 stations is 31.21mm .
So we assumed, Belt velocity (v) = 31.21 mm/sec .
v = 0.031 m/sec
We know that, v =
N=
0.031 * 60
* 0.040
*d *N
60
=14.93~15 RPM=Nw
Hence,
For 900 rotation ,Geneva requires 1 sec.
So, 900 = 0.25second=Engagement time in Driver pin with Geneva wheel
(i.e. movement of conveyor from one station to another station)
2700=0.75second=Delay time (i.e. stoppage of conveyor in one station)
c
2 * * N1
60
Nc=60 rpm
Velocity Ratio of Conveyor belt :
N 2 d1
N1 d 2
As d1=d2=40 mm & thickness of belt is same

So, velocity ratio =1
Slip of the belt :
Let,
81
S1 %=Slip between driver roller & belt

S2 %= Slip between driven roller & belt
Belt velocity (v) = 0.03 m/sec .
Velocity of belt passing over the driver per second
v=
v=
* d1 * N w * d 2 * N w S1
60
60
100
* d1 * N w
S
(1 1 )
60
100
[2]
As d1=d2=40 mm
* 0.04 *15
S
(1 1 )
60
100
0.03 m/sec =
S1 =4.7 %
and the velocity of belt passing over the driven roller per second
* d2 * Nw
S
v(1 2 )
60
100
* 0.04 *15
S
0.03(1 2 )
60
100
S2= - 4.7%
So, Total percentage of slip (S) = S1+S2
= 4.7-4.7
=0
Motor Power :
Torque Required to drive the crank = 1.7 N.m
82
Angular velocity of driving crank (c) = 6.28 rad/sec
( pout )
Output Power
=T * c
= 6.28 *1.7
= 10.67 Watt
motor
Taking Motor Efficiency(
) = 70 % (According To Testing)
pout
pin
pin
pout 10.67
15.25
0.7
=
11.3.
Watt
Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who utilized the Ritz
method of numerical analysis and minimization of variational calculus. By this analysis an
effective design occurs. An effective design helps in performing the required task efficiently. It is
inexpensive in materials used and also safe in operating condition.
SOLIDWORKS Simulation uses FEA methods to calculate the displacements and stresses in
your product due to operational loads such as:
Solid
Forces
Pressures
Accelerations
Temperatures
Contact between components
works simulation uses the displacement formulation of the finite element method to
calculate component displacements, strains, and stresses under internal and external loads. The
geometry under analysis is discredited using tetrahedral (3d), triangular (2d), and beam elements,
and solved by either a direct sparse or iterative solver.
For shell meshing, solid works simulation offers a productive tool, called the shell
manager, to manage multiple shell definitions of your part or assembly document. It improves
83
the workflow for organizing shells according to type, thickness, or material, and allows for a
better visualization and verification of shell properties.
Since the majority of industrial components are made of metal, most FEA calculations
involve in metallic components. The analysis of metal components can be carried out by either
linear or nonlinear stress analysis.
Solid works simulation offers the capability to mesh the cad geometry in tetrahedral (1st and 2nd
order), triangular (1st and 2nd order), beam, and truss elements. The mesh can consist of one
type of elements or multiple for mixed mesh. Solid elements are naturally suitable for bulky
models. Shell elements are naturally suitable for modeling thin parts (such as sheet metals), and
beams and trusses are suitable for modeling structural members.
As solid works simulation is tightly integrated inside solid works 3d cad, the topology of
the geometry is used for mesh type:
I.
II.
Shell mesh is automatically generated for sheet metal model and surface bodies.
Beam elements are automatically defined for structural members.
So their properties are seamlessly leveraged for FEA . To improve the accuracy of results in
a given region, the user can define local mesh control for vertices, points, edges, faces, and
components.
Principles
The finite element analysis is a computational technique used to obtain approximate
solutions of boundary value problems in engineering. Boundary value problems are also called
field problems. The field is the domain interest & most often represents a physical structure. The
field variables are the dependent variables of interest governed by the differential equation. The
boundary conditions are the specified values of the field variables (or related variables such as
derivatives) on the boundaries of the field.
Purpose
It is useful for problems with complicated geometries, loadings and material properties
where analytical solutions cant be obtained. Stress analysis for trusses, beams and other simple
structures are carried out based on dramatic simplification and idealization .Mass concentrated at
the centre of gravity. Beam simplified as a line segment (same cross section). Evaluate the stress
84
or temperature distribution in a mechanical component. Perform deflection analysis. Analyze the

kinematics or dynamic response. Perform vibration analysis.
11.3.1. Load on the belt

Model Information :
Fig. 11.13 : Model Information of Belt due to Load
Material Properties :
Table 11.6 : Material Properties of Belt & Roller
Model Reference
Properties
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
85
Components
SolidBody 1(Sweep1)
Rubber
Linear Elastic Isotropic (Belt-1)
Unknown
9.23737e+006 N/m^2
1.37871e+007 N/m^2
6.1e+006 N/m^2
0.49
1000 kg/m^3
2.9e+006 N/m^2
Thermal expansion
coefficient:
0.00067 /Kelvin
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
Alloy Steel
SolidBody 1(CutLinear Elastic Isotropic Extrude3)(Roller1-1),
Unknown
SolidBody 1(BossExtrude5)(Roller2-1)
6.20422e+008 N/m^2
7.23826e+008 N/m^2
2.1e+011 N/m^2
0.28
7700 kg/m^3
7.9e+010 N/m^2
1.3e-005 /Kelvin
86
Fig. 11.14 : Mesh analysis of Belt due to load
Mesh Information :
Mesh type
Mesher Used
Mesh Quality
Jacobian points
Total Nodes
Total Elements
Element Size
Tolerance
Solid Mesh
Standard mesh
High
4 Points
19658
10441
8.97749 mm
0.448874 mm
Maximum aspect ratio
Study Results :
Fig. 11.15 : Stress Profile of Conveyor belt due to Loads
Fig. 11.16 : Strain Profile of Conveyor belt due to Loads
87
Fig. 11.17 : Displacement Profile of Conveyor belt due to Loads
11.3.2. Torque on Geneva Wheel

Model Information :
Fig. 11.18 : Model Information of Geneva wheel during Torque
88
Material Properties:
Table 11.7 : Material Properties of Geneva wheel, Driver wheel & Driven roller
Model Reference
Properties
Components
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
2024 Alloy (SN)

SolidBody 1(BossLinear Elastic Isotropic Extrude1)(Assem of
Unknown
wheel-1/drive wheel 1-2),
SolidBody 1(Boss7.58291e+007 N/m^2
Extrude2)(Assem of
1.86126e+008 N/m^2
wheel-1/drive wheel 2-2),
7.3e+010 N/m^2
SolidBody 1(Boss0.33
Extrude1)(Assem of
2800 kg/m^3
2.8e+010 N/m^2
wheel-1/pin-2)
2.3e-005 /Kelvin
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
Alloy Steel
Unknown
SolidBody 1(Revolve1)
(roller coupling pin-1)
6.20422e+008 N/m^2
7.23826e+008 N/m^2
2.1e+011 N/m^2
0.28
7700 kg/m^3
7.9e+010 N/m^2
1.3e-005 /Kelvin
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
2024 Alloy (SN)

SolidBody 1(CutLinear Elastic Isotropic Extrude2)(geneva wheel-1)
Unknown
Mesh Information :
89
7.58291e+007 N/m^2
1.86126e+008 N/m^2
7.3e+010 N/m^2
0.33
2800 kg/m^3
2.8e+010 N/m^2
2.3e-005 /Kelvin
Mesh type
Mesher Used
Mesh Quality
Jacobian points
Total Nodes
Total Elements
Element Size
Tolerance
Solid Mesh
Standard mesh
High
4 Points
15633
9424
5.56627 mm
0.278313 mm
Maximum
aspect
Fig. 11.19
: Meshratio
analysis of Geneva wheel due to Torque
90
Study Results :
Fig. 11.20 : Stress Profile of Geneva wheel due to Torque
Fig. 11.21 : Displacement Profile of Geneva wheel due to Torque
Fig. 11.22 : Strain Profile of Geneva wheel due to Torque

91
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
11.3.3.
Torque on Drive Pin
Model Information :
Fig. 11.23 : Model Information of Driver pin due to Torque
Material Properties :
Model Reference
Properties
92
Components
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
Alloy Steel
SolidBody 1(Boss-Extrude1)
Linear Elastic Isotropic (Assem of wheel-1/drive
Unknown
wheel 1-2),
6.20422e+008 N/m^2
(Assem of wheel-1/drive
7.23826e+008 N/m^2
wheel 2-2),
2.1e+011 N/m^2
0.28
(Assem of wheel-1/pin-2)
7700 kg/m^3
7.9e+010 N/m^2
1.3e-005 /Kelvin
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
2024 Alloy (SN)

SolidBody 1(Cut-Extrude2)
Linear Elastic Isotropic (Roller1-2),
Unknown
7.58291e+007 N/m^2
1.86126e+008 N/m^2
7.3e+010 N/m^2
0.33
2800 kg/m^3
2.8e+010 N/m^2
2.3e-005 /Kelvin
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
2024 Alloy (SN)

SolidBody 1(Cut-Extrude2)
Linear Elastic Isotropic (geneva wheel-1)
Unknown
7.58291e+007 N/m^2
1.86126e+008 N/m^2
7.3e+010 N/m^2
0.33
2800 kg/m^3
2.8e+010 N/m^2
2.3e-005 /Kelvin
Mesh Information :
93
Mesh type
Mesher Used
Mesh Quality
Jacobian points
Total Nodes
Total Elements
Element Size
Tolerance
Solid Mesh
Standard mesh
High
4 Points
15633
9424
5.56627 mm
0.278313 mm

Figure 11.24 : Mesh analysis of Driver pin due to Torque
Study Result :
Fig. 11.25 : Stress Profile of Driver pin due to Torque
94
Fig. 11.26 : Displacement Profile of Driver pin due to Torque
Fig. 11.27 : Strain Profile of Driver pin due to Torque
Fig. 11.28 : Deformed Shape of Displacement Profile of Driver pin due to Torque
95
11.3.4. Torque on Coupling Pin

Model Information:
Fig. 11.29 : Model Information of Coupling pin due to Torque
Material Properties:
Model Reference
Properties
Components
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
2018 Alloy
SolidBody 1(BossLinear Elastic Isotropic Extrude1)(Assem of
Unknown
wheel-1/drive wheel 12),
3.17104e+008 N/m^2
SolidBody 1(Boss4.20507e+008 N/m^2
Extrude2)(Assem of
7.4e+010 N/m^2
wheel-1/drive wheel 20.33
2),
2800 kg/m^3
2.7e+010 N/m^2
SolidBody 1(Boss2.2e-005 /Kelvin
Extrude1)(Assem of
wheel-1/pin-2)
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
Alloy Steel
Unknown
6.20422e+008 N/m^2
7.23826e+008 N/m^2
2.1e+011 N/m^2
0.28
7700 kg/m^3
7.9e+010 N/m^2
1.3e-005 /Kelvin
96
Name:
Model type:
Default failure
criterion:
Yield strength:
Tensile strength:
Elastic modulus:
Poisson's ratio:
Mass density:
Shear modulus:
Thermal expansion
coefficient:
2024 Alloy (SN)

SolidBody 1(CutLinear Elastic Isotropic Extrude2)(geneva
Unknown
wheel-1)
7.58291e+007 N/m^2
1.86126e+008 N/m^2
7.3e+010 N/m^2
0.33
2800 kg/m^3
2.8e+010 N/m^2
2.3e-005 /Kelvin
Fig. 11.30 : Mesh analysis of Coupling pin due to Torque
Mesh Information:
Mesh type
Mesher Used
Mesh Quality
Jacobian points
Total Nodes
Total Elements
Element Size
Tolerance
Solid Mesh
Standard mesh
High
4 Points
15633
9424
5.56627 mm
0.278313 mm
Study Results :
Fig. 11.31: Stress Profile of Coupling pin due to Torque
97
Fig. 11.32 : Displacement Profile of Coupling pin due to Torque
Fig. 11.33 : Strain Profile of Coupling pin due to Torque

11.4.
Comparison Between Theoretical Analysis & FEA

Table 11.10 : Comparison Between Theoretical Analysis & FEA
Sl. No.
Part name
Stress from
Stress from
theoretical
finite element
analysis
analysis
Safe Stress
Value
% of
deviation
Belt
4.4MPa
0.105MPa
35MPa
97.6%
Driver pin
8.33MPa
6.875MPa
75MPa
17.46%
Coupling Pin
10.68MPa
9.3MPa
220MPa
12.9%
Chapter 12
98
Physical Prototype
A physical prototype is an object or set of objects that is fabricated from a variety of materials to
approximate an aspect of how a product concept will perform. It is a simplification of a product
concept. It is tested under a certain range of conditions to approximate the performance,
constructed to control possible variability in the tests and is ultimately used to communicate
empirical data about the product so that development decisions may be made with high
confidence and reduced risk .
12.1. Task Distribution and Monitoring
Team member
Task assigned date
Task completed on
1:Ashutosh Panda
Marketing &
4.04.2016
16.04.2016
manufacturing
2:Sourav Panda
Manufacturing
4.04.2016
16.04.2016
3:Chandan Kumar
Manufacturing
4.04.2016
16.04.2016
Behara
4:Dibyajyoti Swain Marketing &
4.04.2016
16.04.2016
Manufacturing
5:Rakesh Roshan
Manufacturing
4.04.2016
16.04.2016
Pal
6:Bibhuti Bhusan
Marketing &
4.04.2016
Pradhan
Manufacturing
Task name
Reason for nonMember, who
completion
completed it
Marketing &
Dibyajyoti Swain
Manufacturing
12.2. Mock-Up Materials and Processes
99
For the material choosing , a number of criteria should be applied when making a decision :
1. Cost
2. Availability
3. Ability to accept changes
4. Ease of use and forming capability
5. Scalable geometry
6. Scalable properties
Based on these criteria , we have choosing materials that are available for prototyping.
Wood and Wood Products
overall, wood materials are very useful when constructing early prototypes .wood materials are
readily available , easy to work, using inexpensive hand and power tools, and available in large
variety of sizes.
Table 12.2 : Prototyping Properties of Wood
Hard woods
(Oak, Cherry, Birch, Mahogany etc.)
Plywood
Generally higher quality than pine in terms

of appearance, absence of knots, etc.
More expensive than pine
Makes more precise joints
Holds fastener better
Higher load capability
High strength
Available in large sheet
Both hardwood & softwood varieties
Choice of grades
Metals
The use of metals is appropriate for prototype construction. For smaller scale customer
products ,off the shelf components are frequently used when metal subsystems are needed in
prototypes.
Table 12.3 : Prototyping Properties of Metals
Aluminum
Machines well
High strength to weight ratio
Corrosion resistant
Difficult to weld
Available in variety of alloys ,heat treatments and shapes
Steel
High strength
Welds easily
Available in extrusion(angles, etc.)and bar stock.
Prototyping processes
100
Numerical models enable the "experimentation" of products without trial-and-error fabrication.

Likewise ,computer solid modeling and rendering have enabled the visualization and error
checking of product geometry with the ability to make changes. Nevertheless , the production of
a "hands-on-product" is essential .prototyping fabrication process makes this step possible. A
number of fabrication processes exist for producing prototypes. They range from hardworking
techniques(hand tools, knives, sanding blocks and small power tools) to advanced precision
equipments.CNC machining and operation in lathe are two processes for our system.
12.3.
Prototype Planning and Design

Table 12.4 : list of Standard Components with Specification used in the System
Sl.No
.
1
2
3
4
5
6
7
8
9
10
11
12.4.
Components buy from

market
DC Gear cum motor
Adaptor
Conveyor belt
Deep Groove Ball Bearing
Nut, Bolt, Screw
L-Shape Clamp
Wood
Aluminum alloy
Aluminum alloy
Alloy steel
Alloy steel
Specification
12 V,5A,60rpm
12V,5A
Grade M-24
6004
M3 x 1 x 30, Steel
4-Inch
Oak
2024
2024
EN 24
EN 24
Components have to
manufactured in the workshop
Stand
Driver wheel
Geneva wheel
Front roller
Rear roller
Fabricate The Components
For Roller
-
Raw Material is Alloy steel.

Shaft has been cut by chop saw.
Facing operation of roller has done by lathe.
Turning operation of roller has done by lathe.
Step turning process has been done by lathe.
Grooving operation of roller has been done by lathe.
Drilling operation has done by drilling machine.
For Geneva Wheel

-
Raw Material is Aluminum alloy.

Shaft has been cut by hacksaw.
Facing, Turning, Step turning operation has been done by lathe.
Drilling, Milling operation by CNC .
For Driver Wheel

101

Moon Plate has made by CNC .
For Driver Pin

-

For Stand
-
Raw material is oak wood.

The tools has been used for making the stand: Chisel, Jackplane, Hammer, Steel rule,
Tape, File, Bench vice, Vernier calliper
102
103
Fig. 12.1 : Fabrication of the Components of the Product
12.5. Assembly of all components :

- Stand was made.
- Bearing was fitted on the stand.
- Roller was made to fit inside the bearing.
- Conveyor belt was attached.
- Geneva wheel was attached to the driver roller.
- Geneva wheel & driving roller was attached by coupling pin.
- Motor stand was made in which motor was rested.
- Driver wheel was fixed to the motor by using coupling pin.
- Driver wheel and Geneva was correctly attached.
104
Electric power was provided to the motor by the adaptor.

Then, Due to electric power Geneva rotates and the load transported through conveyor belt.
Fig. 12.2 : Final Assembly of Belt Conveyor System
105
Chapter 13
Prototype Testing and Improvement

The key issues in prototype fabrication and testing are how many to build, what variables to vary,
how to control noise and experimental uncertainties, and how to formalize the results of testing.
These issues give rise to the subject of design of experiments. It provides a statistical basis for
monitoring and analyzing the inherent noise in an experiment. Perform experiments iteratively
and bring out improvements in the product.
13.1.
Team member
Task assigned date
1:Ashutosh Panda
Testing
17/04/2016
2:Sourav Panda
Testing, Product cost and
17/04/2016
Bill of materials
3:Chandan Kumar
Testing
17/04/2016
Behara
4:Dibyajyoti Swain
Testing
17/04/2016
5:Rakesh Roshan Pal Testing
17/04/2016
Task name
13.2.
Task completed on
18/04/2016
18/04/2016
18/04/2016
18/04/2016
18/04/2016
Member, who
completed it

Design of experiments
Design of experiments(DOE) is an experimental theory and methodology. It is used to determine

the minimum number of experiments that will be required for adequately predicting a physical
106
phenomenon. A design space ( ) and a performance metrics(p) are identified for modeling a
product.
f (d )
Fig. 13.1 : Design equation for empirical model building

d:-design space
p:-performance metrics
We have no expression f in the equation p = f( )

Figure 13.1 illustrates the abstract relationship between the product performance metric and the
design variable choices .
f (d , n, t )
Fig. 13.2 : Black box Input-Output Concept of Empirical Model Building

Where,
p:
Performance response
: Design Variables
n:
Noise variables
t:
Turning variables
Performance variables : Speed of the belt drive

107
Noise factor(Noise variables) : Friction surface , Power source proximity (Intensity)

Control factors(Design variables) : Wheel radii, motor parameter, bearing friction, A variable
source will emulate varying motor parameters.
In our experiment 2control parameters:
To reduce noise
Weights to be placed on the belt drive are chosen
Design Variables:d1 = Power Source (12V, 5A, 60 rpm )

d2 = Weight(200gm , 400gm)
Method for Eliminating Noise :
Oil has given in the bearing for lubrication in bearing.

Oil is also used in Geneva wheel and driven wheel.
Testing has been done and the results are analyzed.
Evaluation of Results :Different weights of 400gm were placed on the conveyor belt and successfully moved
intermittently from one end of conveyor to other. Due to intermittent motion of conveyor belt ,
time delay has been achieved and more material can be loaded. Weight and power interact
implying that high motor torque needs to be used. Due to absence of idler, more than 500gm
weight can't transferred properly and the conveyor belt moves efficiently. So, for transporting
more material idler must be required .
13.3.
Improvement
The product has been tested successfully and the improvement in our product are
Geneva wheel has used to provide intermittent motion.
Dimension has changed depending upon load capacity.
Noise is reduced by proper lubrication and oiling of the bearing.
13.4.
Product Cost and Bill of Materials
Table 13.2 : Product Cost & Bill of Materials
Sl.
No.
1
Components buy
from Market
Specification
Components have
to Manufactured in
the workshop
Material
Cost
Total Cost
12V,5A,60rm
Rs 1050/-
DC Gear cum
Motor
Adaptor
12V,5A
Rs 300/-
Conveyor belt
Grade M-24
Rs 215/-
108
6004
Rs 440/-
Deep Groove Ball

Bearing
Nut, Bolt, Screw
M3 x 1 x 30, Steel
Rs 30/-
L-Shape Clamp
4-Inch
Rs 60/-
Wood
Oak
Stand
Aluminum alloy
2024
Driver wheel
Rs 300/-
Rs 300/-
Aluminum alloy
2024
Geneva wheel
Rs 300/-
Rs 300/-
10
Alloy steel
EN 24
Front roller
Rs 238/-
Rs 238/-
11
Alloy steel
EN 24
Rear roller
Rs 235/-
Rs 235/-
Product Cost : Rs 3168/-
109
Chapter 14
Conclusions
Our project Belt Conveyor system was a success and provided positive results when tested.
Now a day's Belt Conveyor System is used widely in every sector. Our aim was to replace the
use of stepper motor in the conveyor system . Geneva wheel mechanism is an excellent
mechanism for obtaining intermittent motion from a continuously moving source . The Geneva
mechanism which has employed in our conveyor system is able to provide intermittent motion
carrying around 400 gm/m. Though its a smaller prototype its bigger version can be used in
various factories , railways and in airports so as to handle the materials easily beyond human
capacity in terms of weight and height. The 4 slots which is used in our project can be replaced
by various number of slots which when used produce different speeds. Hence, the successful
completion of this project work has generated design data for the development of a belt conveyor
system which is simple, safe, efficient and low cost. The best part of our product is it can more
material handling , easily designed , manufactured & disassembled.
Group Learning
- Work with other members in team.
- Willing to face any challenges.
- Group takes better decision than individuals.
- Plan & manage time.
- Refine understanding through discussion & explanation.
- Develop stronger communication skills.
- Pool of ideas.
- Ask questions to clarify other ideas & emotions.
Individual Learning
- Leadership skill.
- Managing skill.
- Presentation skill.
- Designing skill.
- Patience & hard work.
- How to do a Project.
- How to do a Report & PPT.
- Know about manufacturing & assembly work.
- Create more knowledge from project work
110
111
Chapter 15
References
[1].Kevin N. Otto And Kristin L. Wood "Product Design"2006, ISBN 978-81-7758-821-7,
Pearson India Education Pvt. Ltd. , Noida (U.P.), India, 2015.
[2].S. Md. Jalaludeen " Design data handbook", Second Edition;2014,(Chapter-2,20,23,34)
;ISBN: 978-81-8472-269-7,M.Sethuraaman, Anuradha Publications, Chennai, India.
[3].Shigley J.E. and Uicker J.J, JR., (1995) Theory of Machines and Mechanisms, Second
Edition, Singapore: McGraw-Hill, Inc. 372-376.
[4].R.S. Khurmi, J.K. Gupta (2005) "Machine Design" Fourteenth Edition , S. Chand and
Company Ltd, Eurasia Publishing House(Pvt.) Ltd.; New Delhi, India.
[5].S. S. Ratan " Theory Of Machines " 3rd edition;2013,McGraw Hill Education (India)
Private Limited; New Delhi.
[6].I.A.Daniyan,(Design of a material handling equipment :belt conveyor system for crushed
lime stone using 3 -roller idlers), "Journal of advancement in engineering & technology"
Volume-3/Issue-1, ISSN:2348-2931,(2014).
[7].Han Jiguang Yu Kang, Analysis and Synthesis of Geneva Mechanism with Elliptic Crank,
" International Journal of Hybrid Information Technology" Vol.8, No.8 (2015), pp.253260.
[8].Rohini N. Sangolkar, Vidhyadhar P. Kshirsagar"Modeling And Analysis Of Industrial Belt
Conveyor System Using Creo Parametric And Ansys Software " International Journal of
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Appendix
[1]. Part Program for Geneva Wheel in CNC :
O0026 (GENEVA) ;
115
G21 G94 ;
G40 G80 ;
G91 G28 Z0 X0 Y0 ;
M03 S2000 ;
G00 G90 G42 X7.49 Y-39.29 Z5.0
D01 ;
#1=7.0 ;
N10 G01 Z-#1 F50 ;
#1=#1+0.2 ;
G02 X39.29 Y-7.49 R32.50 F1000 ;
G03 X39.92 Y-2.60 R40.0 F1000 ;
G01 X13.92 Y-2060 R40.0 F1000 ;
G02 X13.92 Y2.60 R3.65 ;
Figure A.1: Geneva Wheel
G01 X39.92 Y2.60 ;

G03 X39.29 Y7.49 R40.0 ;
G02 X7.49 Y39.29 R32.50 ;
G03 X2.60 Y39.92 R40.0 ;
G01 X2.60 Y13.92 ;
G02 X-2.60 Y13.92 R3.65 ;
G01 X-2.60 Y39.92 ;
G03 X-7.49 Y39.29 R40.0 ;
G02 X-39.29 Y7.49 R32.50 ;
G03 X-39.92 Y2.60 R40.0 ;
G01 X-13.92 Y2.60 ;
G02 X-13.92 Y-2.60 R3.65 ;
G01 X-39.92 Y-7.49 ;
G03 X-39.29 Y-7.49 R40.0 ;
G02 X-7.49 Y-39.29 R32.5 ;
G03 X-2.60 Y-39.92 R40.0 ;
G01 X-2.60 Y-13.92 ;
G02 X2.60 Y-13.92 R3.65 ;
116
G01 X2.60 Y-39.92 ;

G03 X7.49 Y-39.29 R40.0 ;
IF [#1 LE 7.41] THEN GOTO 10 ;
G00 Z100 ;
G28 Y0.0 ;
M05 ;
M30 ;
%
[2].Part Program for Driver wheel in CNC :
O0045 (GENEVAMOON) ;
G21 G94 ;
G40 G80 ;
G91 G28 Z0 X0 Y0 ;
M03 S200 ;
G00 G90 G54G41 X0.02 Y-39.98
Z5.0
D01 ;
#1=0.0 ;
Figure A.2 : Driver Wheel
N10 G01 Z*#1 F50 ;

#1=#1+0.2 ;
G03 X-39.98 Y0.02 R40.0 F1000 ;
G01 X-50.0 Y-50.0 F1000 ;
G01 X0.02 Y-39.98 ;
IF [#1 LE 6.21] THEN GOTO 10 ;
G00 Z100 ;
G28 Y0.0 ;
M05 ;
M30 ;
%
117
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BELT CONVEYOR SYSTEM

A Major Project Report

Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

(Internal Design Panel-ME)

(Internal Design Panel-ME)

(Internal Design Panel-ME)

(Internal Design Panel-ME)

Rakesh Roshan Pal-1241018371

Department Of Mechanical Engineering, Institute Of

Chandan Kumar Behera-1241018362, Dibyajyoti Swain

-1241018365, Rakesh Roshan Pal-1241018371, Bibhuti Bhusan Pradhan - 1141018383 of

PLAGIARISM CHECK CERTIFICATE

Plagiarism was checked and the similarity index is 13 % .

General Description & Practical Relevance

Background of Geneva Mechanism

Students outcomes & Blooms Taxonomy of Learning level

Design Team Formation & Team charter

Chapter-2 : Customer Needs Recognition

Task Distribution & Monitoring

Customer Need Data

Gathering Customer Needs

Organizing & Prioritizing Customer need

Selected Needs for Redesign

Chapter-3 : Function Decomposition

Task Distribution & Monitoring

Function Modeling Basics

Function tree by FAST Method

Function tree by Subtract & Operate Procedure

Black box modeling

Function Structure by Energy Diagram

Chapter-4 : Product Tear Down & Engineering Specification

Task Distribution & Monitoring

Subtract & Operate Procedure

Post Teardown Reporting

Disassembly plan & Bill of Material

Proposal on Opportunities to Redesign

Benchmarking the Competition

Setting Product Specification

Functional Requirements Vs. Product Constraints

Basic method: Specification Sheets

Basic Method: The House of Quality

Chapter-5 : Product Architecture

Task Distribution & Monitoring

Modular Design by Basic Clustering

Chapter-6 : Concept Generation

Task Distribution & Monitoring

Chapter-7 : Concept Selection

Task Distribution & Monitoring

Using Pugh chart as decision making tool

Chapter-8 : Product Embodiment

Task Distribution & Monitoring

Refining Geometry & Layout

Failure Modes & Effect analysis

Chapter-9 : Product Metric Model

Task Distribution & Monitoring

Constructing Product Model

Solid Modeling Software