Design, Analysis and Weight Optimization of Roller Conveyor System by using Glass Fiber Composite Material

Abstract

In this paper I studied problem in existing conveyor system and optimized critical part of roller conveyor system like Roller. Industrial roller conveyor having MS rollers due to this sagging is induced in roller support. Hence Company required optimizing weight of roller to avoid sagging. Paper contains geometrical modelling and finite element analysis of existing design and optimizes design. Geometrical modelling is done Using CATIA V5R20 and FEA was done with the help of ANSYS 14.5. also manufacturing of new roller using glass fiber material and testing of both roller by using UTM to validation of ANSYS results.

Introduction

I. INTRODUCTION

Today’s world is of automation and modernization in the manufacturing techniques. Material Handling is the part of this modern technique which are of importance in any of the industry. Almost every item of physical commerce is transported on a conveyor or lift truck or other type of material handling equipment in manufacturing plants, warehouses, and retail stores. Conveyor system is used for transportation of material from one place to other.

It is a material handling equipment that moves heavy and bulky material [1]. conveyors transport material with fast and efficiently, which make them very popular in packaging industries for material handling. Many types of conveyor systems are available like powered operated, nonpower operated, gravity conveyor, chain conveyor, roller conveyor, vibrating conveyor, pneumatic conveyor etc. and they are used according to the needs of different applications. Many factors are important to selection of accurate conveyor. Roller conveyor consists c-channel, bearings, rollers etc. for reducing cost and weight roller is a measure parameter [3]. Size and shape optimization technique used for reducing weight of roller. In conveyor now, a day’s various advanced safety features added which help to prevent accidents [4]. Existing conveyor are used for moving water bottles which is 25 kg. so, load is divided on two rollers which is 12.5 kg.

Conveyor can be safer than using forklift or other machine to move materials [5]. They can be used in various industries like agriculture, automotive, computer, electronic, aerospace, food processing, bottling and canning, chemical, print finishing and packaging etc. [6].

There are many options available for running the conveyor such as hydraulic, pneumatic, mechanical, electric and fully automated system. Non-powered, gravity roller conveyors are used for moving unit load applications [8]. Testing and manufacturing is not possible for each roller so for optimizing weight of roller it’s an iterative process for manufacturing physical design. It could be done by suitable software for analysis. For optimization glass fibre composite material used and appropriate new design of composite material get by iterative method and using optimization tool.

II. PROBLEM STATEMENT

The aim of this project is to redesign existing gravity roller conveyor system by designing the critical parts (Roller, Shaft, Bearing and Frame) to minimize the overall weight of the assembly and to save considerable amount of material. Industrial roller conveyor having MS rollers due to this sagging is induced in roller support.

Sagging problem occurs due to its own weight. Weight of existing conveyor is maximum. If we want to optimize weight of roller conveyor then 70% weight is only about roller.

Conclusion

After studied the existing conveyor get the information about geometrical as well as structural analysis of roller conveyor and we will get the result of equivalent stress and deformation at required force. When MS material is used, stress is more as compared to GF composite material. Value of deformation and stress is more in case of GF but it is allowable. GF composite material used for weight reduction at the same capacity of roller conveyor system. 42.42% of weight reduction done. Another benefit is that by using glass fibre roller noise get reduced than MS.

References

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Copyright

Copyright © 2022 Vikram Ashok Nangare, Dr. P. R. Sonawane. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.