FYP2016 Without Appendixes

2015/2016
FINAL YEAR PROJECT

Submitted in fulfillment of the requirements for the
ENGINEERING DEGREE FROM THE LEBANESE UNIVERSITY
FACULTY OF ENGINEERING BRANCH II
Major: Mechanical Engineering
Prepared By:
CHAKHTOURA Anthony
HELOU Mario
____________________________________________________________
Small clat With Auto Feeder

Supervised by:
Dr. RIZK Rany
Dr. YAMMINE Ziad
Defended on 15 September 2016 in front of the jury:
Dr. HANNA Fady

Dr. KARAM Wissam
Dr. KASSIS Carine
President
Member
Member
FYP 2016
Small ECLATE With Auto Feeder
Acknowledgments
This project consumed huge amount of work, research and dedication. Still, execution
would not have been possible if we did not have a support of many individuals and
organizations. Therefore we would like to extend our sincere gratitude to all of them.
First of all, we are thankful to Dr. Ziad Yammine, head of La Socit Libanaise
Du Marbre et Prophyre, for their financial and logistical support and for providing
necessary guidance concerning projects implementation.
Second, we are also grateful to Dr. Rany Rizk for provision of expertise, and
technical support in the execution. Without their superior knowledge and experience,
Small clat with Auto feeder would be diminished in quality of outcomes, and
thus their support has been essential.
Third, we would like to express our sincere thanks towards Mr. Georges Bassila
who devoted their time and knowledge in the realization of this project, stimulating
suggestions and encouragement.
Nevertheless, we would like to express our deepest appreciation to all those who
provided us the possibility to complete this report. A special gratitude we give to Dr.
Carine Kassis, whose contribution helped us to coordinate our project especially in
writing this report.
Likewise, equitable recognition goes to Eng. Hekmat Francis for all the insights
into electrical design aspect.
Finally, we express our gratitude toward our families and colleagues for their kind cooperation and encouragement which help us in completion of this project.
CHAKHTOURA Anthony | HELOU Mario
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Abstract
This document records details and specifications of the execution of a small clat with
Auto feeder machine along with the testing process.
The project consists of executing an automated machine that takes small stone blocks
parallelepiped
shaped
to
produce
clat
stones
ready
to
use.
This manufactured machine is characterized by the implementation of new ideas
specifically in the feeding technique realm. It will be efficient in the near future.
A literature survey initiates the report taking into account the various parameters of
the project and the extent of the project. Following the literature review, an overview of
the design process unrolls taking into consideration all necessary requirements for
execution, discussing feeding, conveying and splitting techniques.
Finally, an electrical system design that itemizes several types of electrical components
and controllers is presented. The machine was tested after the installation of the electrical
equipment and wiring systems.
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Table of Contents
Acknowledgments ............................................................................................................ i
Abstract ............................................................................................................................ ii
List of Figures .................................................................................................................. v
List of Tables ................................................................................................................ viii
List of Symbols ............................................................................................................... ix
Introduction ..................................................................................................................... 1
1
Literature Survey .................................................................................................... 3
1.1- Introduction ................................................................................................................ 3
1.2- Splitting techniques Blade system........................................................................... 3
1.3- Stone block feeding Conveying .............................................................................. 6
1.4- Stone block centering ................................................................................................. 6
1.5- Chassis ........................................................................................................................ 6
1.6- Conclusion .................................................................................................................. 7
2
Design Process ........................................................................................................ 8
2.1- Introduction ................................................................................................................ 8

2.2- Pre-Processing ............................................................................................................ 8
2.3- Hydraulic Cylinder ................................................................................................... 10
2.4- Chassis ...................................................................................................................... 13
2.5- Blade System ............................................................................................................ 17
2.6- Blade system accessories ......................................................................................... 19
2.7- Stone delivery system............................................................................................... 25
2.8- Stone block feeder .................................................................................................. 28
2.9- Conveyor .................................................................................................................. 34
2.10- Conclusion .............................................................................................................. 53
3
Hydraulic Unit ...................................................................................................... 54
3.1- Introduction .............................................................................................................. 54

3.2- Hydraulic components.............................................................................................. 54
3.3- Hydraulic unit sizing ................................................................................................ 55
3.4- Conclusion ................................................................................................................ 57
4
Electrical Design ................................................................................................... 58
4.1- Introduction .............................................................................................................. 58

4.2- Electrical Components ............................................................................................. 58
4.3- Electrical Circuits ..................................................................................................... 64
4.4- Electrical Board ........................................................................................................ 64
4.5- Conclusion ................................................................................................................ 66
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Final Sketch Execution Testing ...................................................................... 67
5.1- Final Sketch .............................................................................................................. 67

5.2- Execution .................................................................................................................. 69
5.3- Testing ...................................................................................................................... 71
Conclusion ..................................................................................................................... 73
References ..................................................................................................................... 74
Appendix A - Drawings
Appendix B - Electrical Design
Appendix C - Datasheets
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List of Figures
Figure 1.1 Plug and Feather ............................................................................................. 3
Figure 1.2 Chisels ............................................................................................................ 3
Figure 1.1.3 Semi-Automatic Simple Blade .................................................................... 4
Figure 1.4 Manual Simple Blade ..................................................................................... 4
Figure 1.5 Hydraulic Multi Blade System ....................................................................... 5
Figure 1.6 Mechanical Multi-Blade System .................................................................... 5
Figure 1.7 Semi-Automatic "clat" Machine ................................................................. 5
Figure 1.8 Small Stone Block Feeder .............................................................................. 6
Figure 1.9 C-Frame Chassis ............................................................................................ 7
Figure 1.10 H-Frame Chassis .......................................................................................... 7
Figure 2.1 Pneumatic and Hydraulic Actuators............................................................. 10
Figure 2.2 Electrical Actuator ....................................................................................... 11
Figure 2.3 Hydraulic Cylinder ....................................................................................... 11
Figure 2.4 C-Frame Dimensions ................................................................................... 14
Figure 2.5 Chassis Assembly......................................................................................... 15
Figure 2.6 Stress Analysis of the Chassis ..................................................................... 16
Figure 2.7 Hydraulic Cylinder Coupling ....................................................................... 16
Figure 2.8 Simple Blade System ................................................................................... 17
Figure 2.9 Multi-Blade System ..................................................................................... 17
Figure 2.10 V-Shape Blade End .................................................................................... 18
Figure 2.11 Upper Blade Basic Design ......................................................................... 19
Figure 2.12 Shear Stress on Pin ..................................................................................... 20
Figure 2.13 Pin .............................................................................................................. 20
Figure 2.14 Tang............................................................................................................ 21
Figure 2.15 Clevis, Tang and Pin Connection ............................................................... 21
Figure 2.16 Piston-Upper Blade Housing Connection .................................................. 22
Figure 2.17 Unwanted Rotations of the Upper Blade ................................................... 22
Figure 2.18 Tilting Angle Needed for Best Contact with the Stone block .................... 22
Figure 2.19 Different Types of Linear Guidance Systems ............................................ 23
Figure 2.20 Modified Tang ............................................................................................ 23
Figure 2.21 Upper Blade System with the Linear Motion Guidance ............................ 24
Figure 2.22 Lower Blade Sub-Assembly ...................................................................... 24
Figure 2.23 C-Frame Chassis, Piston and Blade System Assembly ............................. 25
Figure 2.24 Chain Conveyor ......................................................................................... 26
Figure 2.25 Belt Conveyor ............................................................................................ 26
Figure 2.26 Roller Conveyor ......................................................................................... 26
Figure 2.27 Two Belt Concept ...................................................................................... 27
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Figure 2.28 V-Belt Configuration ................................................................................. 27

Figure 2.29 Lower-Blade and Belt ................................................................................ 27
Figure 2.30 Tapered Bore Vs. Solid Hub Pulleys ......................................................... 28
Figure 2.31 Feeder Proposal A ...................................................................................... 29
Figure 2.32 Feeder Proposal B ...................................................................................... 29
Figure 2.33 Feeder's Preliminary Sketch ....................................................................... 30
Figure 2.34 Slider .......................................................................................................... 32
Figure 2.35 Feeder's Chassis ......................................................................................... 32
Figure 2.36 Feeder Slider .............................................................................................. 33
Figure 2.37 Experiment Preparation .............................................................................. 33
Figure 2.38 Feeder's Final Sketch ................................................................................. 34
Figure 2.39 Pulley Design Sketch #1 ............................................................................ 35
Figure 2.42 Pin Position ................................................................................................ 38
Figure 2.43 Feeders Pulleys Assembly ........................................................................ 39
Figure 2.44 Pin or Stone Pusher .................................................................................... 39
Figure 2.45 Stone block Free body Diagram ................................................................. 40
Figure 2.46 Forces acting on Stone block in the feeder ................................................ 41
Figure 2.47 Proposal A of the Conveyors Chassis ....................................................... 43
Figure 2.48 Proposal B of the Conveyor's Chassis ........................................................ 43
Figure 2.49 Radial Load On shaft ................................................................................. 45
Figure 2.50 T bearing or UCT ....................................................................................... 45
Figure 2.51 T bearing and rails ...................................................................................... 46
Figure 2.52 T bearing Catalogue, Appendix C .............................................................. 46
Figure 2.53 Front U beam Design ................................................................................. 47
Figure 2.54 Back U beam Design .................................................................................. 47
Figure 2.55 Gearbox Beam Design ............................................................................... 47
Figure 2.56 C-Frame Chassis with Conveyor ............................................................... 48
Figure 2.57 Cantilevered Back U beam......................................................................... 48
Figure 2.58 U beam Parameters .................................................................................... 49
Figure 2.59 Cantilevered Geared Motor Beam ............................................................. 50
Figure 2.60 Rectangular Beam Parameters ................................................................... 50
Figure 2.61 Front Beam Fixture .................................................................................... 51
Figure 2.62 Normal Force on Front U Beam................................................................. 51
Figure 2.63 Feeder Load on Front U Beam ................................................................... 51
Figure 2.64 Normal Load on Front U beam .................................................................. 52
Figure 2.65 Feeder Connection to Conveyor................................................................. 52
Figure 2.66 Gearbox/Driving Shaft ............................................................................... 53
Figure 2.67 Idler Shaft ................................................................................................... 53
Figure 3.1 Gear Pump .................................................................................................... 54
Figure 3.2 Directional Valve ......................................................................................... 55
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Figure 3.3 Hydraulic Unit on Chassis ........................................................................... 57

Figure 4.1 Operations Diagram .................................................................................... 59
Figure 4.2 PLC DVP SA2 ............................................................................................. 60
Figure 4.3 Variable Frequency Drive ............................................................................ 61
Figure 4.4 Encoder Outputs ........................................................................................... 62
Figure 4.5 Pressure Switch ............................................................................................ 62
Figure 4.6 Photoelectric Sensor BPS Series .................................................................. 63
Figure 4.7 Power Supply ............................................................................................... 63
Figure 4.8 Eletrical Board Sketch.................................................................................. 65
Figure 4.9 Enclosures Operator Interface .................................................................... 66
Figure 5.1 Final Sketch, drawing 1................................................................................ 67
Figure 5.2 Final Sketch, drawing 2................................................................................ 68
Figure 5.3 Photos from the execution process ............................................................... 69
Figure 5.4 Photos of the "clat" machine .................................................................... 70
Figure 5.5 Concept Feeder Test ..................................................................................... 71
Figure 5.6 Feeder Test ................................................................................................... 71
Figure 5.7 PLC program Test ........................................................................................ 72
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List of Tables
Table 2.1 Calculated Splitting Force (Kg)....................................................................... 9
Table 2.2 Experimental Splitting Force (Tons) ............................................................... 9
Table 2.3 C-Frame Opening .......................................................................................... 14
Table 2.4 Study of Existing Conveyors ......................................................................... 26
Table 2.5 Cycle Study ................................................................................................... 37
Table 2.6 Comparison of Conveyor's chassis Proposals ............................................... 44
Table 2.7 Stress Analysis of Front U Beam .................................................................. 52
Table 3.1 Hydraulic Calculations .................................................................................. 56
Table 4.1 Electrical Components................................................................................... 64
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List of Symbols
F
P
L
H
S
d
r
x
t
W
m
v
T
M
I
N
Sy
Hp
Force
Pressure
Length
Height
Area
Pi
Safety factor
Stress
Shear stress
Diameter
Radius
Angle
Angle
Angular velocity
Displacement
Time
Weight
Mass
Volume
Density
Gravitational acceleration
Friction coefficient
Torque
Bending moment
Geometrical moment of inertia
Axial force
Yield strength
Horsepower
N
Pa
m
m
m2
Pa
Pa
m
m
degree
degree
rad.s-1
m
s
N
kg
m3
kg.m-3
m.s-2
N.m
N.m
m4
N
Pa
hp
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Introduction
Introduction
In geology, rock or stone is a naturally occurring solid aggregate of one or more minerals.
From the Stone Age, rocks have been used for tools, today, stones are used in several
applications and especially in the building sector for commercial/residential exterior,
residential interior and landscaping. clat stone is one of the decorative stones that is
usually used to decorate the walls. The clat stone can be obtained by splitting stone
blocks instead of cutting them with a saw. Splitting occurs when a stone block is
squeezed between two blades and the two split halves will present a mushroom face
instead of the smooth faces that can be obtained if the stone block was cut.
The high demand on the clat stone and the fact that it can be made from waste
stones, encourage all the stone dealers to invest in machines that are able to produce
clat halves and turn trash stones into cash. La Socit Libanaise du Marbre et du
Porphyre has a conventional hydraulic splitting machine, it is semi-automatic, the
worker has to feed and adjust the blade system along the height of the stone block to be
split. After splitting, the worker needs to cut the clat stone in two halves. This
process takes time, and needs more effort from the worker to achieve the work, because he
will have to collect the two side split block and arrange it in a chain where the block
will be cut. So it has been decided to redesign a new machine that will take clat splitting
to a new level where feeding, conveying, splitting and collecting will be automated. To
simplify the splitting operation, a previous final year project in 2012, resulted in a swing
cutter that prepares large stone blocks into small rectangular stone block. The rectangular
stone blocks will be fed into the new clat machine and once they are split, the
clat halves will be ready to be delivered. So the objective of this project is to design
an automatic feeder and conveyor and to redesign the hydraulic splitters.
In order to properly launch the project, a survey of the different techniques and
machines used for the clat operation must be involved. The design process of the
machine will begin by studying the different blades system to choose the best system that
accommodates with the automatic feeding. Once the blade system is clear, the chassis
of the machine must be designed and the feeder that will contain the stone blocks as well.
The design of the feeder will affect the design of the conveyor that should deliver the
stone blocks from the feeder into the blade system and then into a container box. The
mechanical design of the machine will be followed by the electrical design and PLC
programming to fully automate the machine.
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Introduction
The new machine will increase the productivity of stone work and will save the effort
of the worker in the clat operation. The worker will have to put the stone blocks in
the feeder and push the start button and the clat halves will be collected in seconds.
None of the machines present on the market offers an automatic feeding technique for
different sizes of stone blocks. After the execution and the assembly of the machine, a
test will be conducted to make sure that the electrical components and the PLCs program
are working as intended.
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Chapter 1
Literature Survey
Literature Survey
1.1- Introduction
Throughout history, natural stone has been the premier building material all over the
world. Even today, stone in some form enters our lives probably a hundred times even
before we leave the house each day [1]. It is ideal for several applications and especially
in the building sector for commercial/residential exterior, residential interior and
landscaping. Since it is a hard and durable material that can be cut and carved, splitting
tools and machines were developed to split stones into the required shape and size
depending on its use. Next, paragraph two will expand the evolution of stone splitting
tools and machines to sum up with a conclusion.
1.2- Splitting techniques Blade system

The early stone tools began with the Plug and feather method that has been used since
ancient Egyptian times. It refers to a technique and a three-piece tool set used to split
stone and each set consists of a metal wedge (the plug), and two shims (the feathers), as
shown in Figure 1.1. [2]
Figure 1.1 Plug and Feather
Another hand set tool is the chisel. It is used to carve or cut stone, bricks or concrete
slabs. The tool is held against the stone, the lower edge touches the stone but not the
upper part until it is struck with the hammer (Figure 1.2). This way of splitting has been
used by the Romans and also in pre-industrial quarries in New England until the 18th
century. [3]
Figure 1.2 Chisels
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Chapter 1
Literature Survey
The Industrial Revolution with the major change in the metal industries was the transition
to new manufacturing processes. The introduction of splitting machines took place and
the plug and feather method was replaced by modern splitters that use various types of
blades depending on the stone block to be split. [4]
One of the first basic splitting machines used to be manually operated consists of two
hardened steel blades: the lower blade is fixed and the upper blade can move toward the
lower blade when the flywheel is rotated. Splitting is performed by squeezing the stone
between the blades, causing it to shear in two pieces along a surface between the blades.
In order to make the work easier and faster, semi-automatic simple blade splitters were
introduced: the operator has only to center the block and the split is performed by a piston
that moves the upper blade toward the lower one. This type of machine is still used today
for small blocks (Figures 1.3 and 1.4). The upper blade can be hinged to allow it to find
best contact with the rough surface of the stone block. This type of blade system is the
most commonly used in the clat splitting operation.
Figure 1.3 Semi-Automatic Simple Blade
Figure 1.4 Manual Simple Blade
For large stone blocks, multi-blade systems were developed to satisfy uniform force
during the split. Two types of multi-blade system can be distinguished, the Hydraulic
multi-blade system and the Mechanical multi-blade system (Figures 1.5 and 1.6).
The Mechanical Multi-Blades System consists of multiple-blades (chisels), steel
wedges and springs. The chisels rest first on the rigorous surface, the wedges then fill
the space between the blades and the main piston. When the main piston moves
downward, it will act uniformly on all the blades and the block will be split accordingly.
While the Hydraulic Multi-Blades System uses a manifold that contains oil and
grease, a set of chisels connected to small pistons and all small pistons can communicate
between each other. When the main piston moves downward, the manifold and the small
pistons will move accordingly until some of the chisels are in contact with the stones
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Chapter 1
Literature Survey
surface. When the pressure increases in a piston, the fluid will transfer this pressure to
another piston, therefore a piston will move downward much then the other. The
manifold provides this link between the pistons and ensures a constant pressure on all
the chisels even during the split. The Multi Blade system will allow also every blade to
find best contact with the surface of the stone block and the split will be more accurate.
[5, pp. 13,14]
Figure 1.5 Hydraulic Multi Blade System
Figure 1.6 Mechanical Multi-Blade System
In 1999, a group of students from the mechanical engineering department- Lebanese

University- Roumieh, designed and executed a semi-automatic clat machine (Figure
1.7). The machine is fed by rectangular stone blocks so that the hydraulic piston moves
the upper blade downward to split the stone block in two halves, the lower blade being
fixed.
Figure 1.7 Semi-Automatic "clat" Machine

- FYP 1999-
Conclusion
Different types of blade systems are used on the conventional splitting machines. The
design of the new hydraulic splitters should reveal the most reliable, simple and
productive design that accommodates also with the required automatic feeding of stone
blocks.
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Chapter 1
Literature Survey
1.3- Stone block feeding Conveying

Stone blocks are fed to the conventional splitting machines by the worker. In order to
reduce the effort made by the worker to put the stone block between the blade systems,
several types of stone conveying and feeding were developed. Stone blocks can be fed
to the machine on chain conveyors, belt or roller conveyors. One simple feeding
technique was developed for small stone blocks. It consists of a piston that moves
backward and forward in order to push the stone blocks under the blades, out of a stone
block feeder having an angle to the horizontal (Figure 1.8). This Stone block feeding
technique discussed previously does not accommodate the change in the shape and
dimensions of the stone block. Therefore, a new feeding technique must be designed.
Figure 1.8 Small Stone Block Feeder
1.4- Stone block centering

Stone block centering remains a need especially for small blocks when you have to split
the block into two identical halves. Some of the machines on the market offer this option
using 2 pistons to center the block but the stone blocks fed to the machine must have the
same shape and dimensions which is not practical and very expensive to obtain. So the
design of a centering mechanism is required to obtain an accurate cut.
1.5- Chassis
Stone splitting is performed by applying a force generated by a hydraulic unit on a system
of blades. This force can vary from five to hundreds of tones depending on the type and
the shape of a stone. Two most commonly used chassis can be found in the machines on
the market. The first is the C-Frame chassis (Figure 1.9) that holds the hydraulic cylinder
in its upper part. The second is the H-Frame chassis (Figure 1.10) that holds the hydraulic
unit between the upper parts of the H. The C-Frame chassis is used for small to medium
stone blocks, while the H-Frame chassis is used for large stone blocks with a multi-blade
system (mechanical or hydraulic). The design of the new chassis will be affected by the
system of blades used and by the automatic feeding technique.
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Figure 1.9 C-Frame Chassis
Chapter 1
Literature Survey
Figure 1.10 H-Frame Chassis
1.6- Conclusion
After reviewing the type of blade system used on the conventional hydraulic splitters and
after exposing the stone block feeding and conveying techniques already used on some
of the machines, the design of the new clat machine can now be launched. The next
chapter will reveal and expand the design process of the new clat machine, mainly
the blade system, the conveying and feeding technique.
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Chapter 2
Design Process
Design Process
2.1- Introduction
Designing a machine requires setting up different mechanisms that work together in
order to satisfy the needs of the customer. The clat machine has to be fully
automated to cover the following tasks: feeding, conveying and splitting. The design
process will begin with the design of individual components or machine elements
involving detailed stress and deflection analysis, in order to determine the geometric
dimensions of the components using a suitable factor of safety to come up with the final
sketch. The design of the blade system, the feeder, the conveyor and other hydraulic and
mechanical components in the machine will be detailed up next before the reveal of the
machines final sketch.
2.2- Pre-Processing
2.2.1- Introduction
The objective of this project is to develop an automatic feeding, loading and
unloading device and to redesign the hydraulic splitters to accommodate automatic
feeding. Stone splitting relies on exerting the exact needed force to split a stone block
at the right angle to the plane of splitting. This force can be calculated or derived
from experimental data as follows.
2.2.2- Splitting force calculation
A previous final project of a group of students from the Lebanese university mechanical engineering department 1999, resulted in a semi-automatic clat
machine that splits rectangular stone blocks in two halves. The machine can be fed
by large rectangular stone blocks 80 cm 50 cm. [5, p. 9]
In their design process, several experiments and researches led them to the
following formula:
F = 2.33 L0.686 H2.056
(2.1)
Equation (2.1) gives the force F (kg) needed to split a stone (except granite or
material of same hardness) as a function of length L (cm) and height H (cm).
Applying this formula on the small slabs of different dimensions, the theoretical force
needed to split a slab is shown in table 2.1.
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Chapter 2
Design Process
Length
L, cm
Height H, cm
2
10
47.02
108.22
195.52
309.34
450.02
617.84
15
62.1
142.93
258.22
408.54
594.34
815.97
20
75.64
174.11
314.56
497.67
724
993.99
Table 2.1 Calculated Splitting Force (Kg)
It has been decided to redo a more detailed experiment on marble and granite
slabs to determine the required splitting force.
2.2.3- Splitting force - Experimental data
The force needed to split a stone block can be obtained also from the pressure acting
on the surface of the stone block that builds up during the split, equation 2.2. By
installing a pressure sensor on the existing small clat, pressure data was collected
for different kinds of stone having different dimensions.
Knowing
F=PS
(2.2)
Where P is the working pressure; S is the inner area of the hydraulic cylinder. [6]
The splitting force can be calculated in table 2.2 as follows:
Stone Type
Marble
Hard Marble
Granite
Length
15
7
13
15
20
15
12
14.5
18.5
Height
mm
3
4
5
7
7
3
4.5
5.5
2
Pressure
PSI
Bars
350
24.13
400
27.58
400
27.58
1200
82.74
1700
117.21
400
27.58
500
34.47
600
41.37
2200
151.69
Force
Tons
1.53
1.75
1.75
5.26
7.45
1.75
2.19
2.63
9.64
Table 2.2 Experimental Splitting Force (Tons)
The force needed to split a stone block is fundamental for the sizing of the hydraulic
components. Relying on the results of the previous study and experiment, the
hydraulic unit will be designed on a 10 tons basis. Next, the hydraulic component
that generates this force will be designed.
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Chapter 2
Design Process
2.3- Hydraulic Cylinder

2.3.1- Introduction
Splitting is performed by squeezing the stone block between two blades. The force
exerted on the blades can be generated by several types of actuators. These actuators
can convert energy into a motion or a force and can be powered by pressurized fluid
or air, as well as electricity. Pneumatic, hydraulic and electrical actuators are
discussed in the next paragraph to determine which type of actuators will satisfy the
needed force and speed to cut the stone block.
2.3.2- Pneumatic, hydraulic and electrical/mechanical actuators
Pneumatic linear actuators (Figure 2.1) consist of a piston inside a hollow cylinder.
Pressure from an external compressor or manual pump moves the piston inside the
cylinder. As pressure increases, the cylinder moves along the axis of the piston,
creating a linear force. The piston returns to its original position by either a springback force or fluid being supplied to the other side of the piston.
While hydraulic linear actuators (Figure 2.1) operate similarly to pneumatic
actuators, an incompressible liquid from a pump rather than pressurized air moves
the cylinder.
The third type of actuators is the electric linear actuator (Figure 2.2). It converts
electrical energy into torque. An electric motor mechanically connected turns a lead
screw. A threaded lead or ball nut with corresponding threads that match those of the
screw is prevented from rotating with the screw. When the screw rotates, the nut gets
driven along the threads. [7]
Figure 2.1 Pneumatic and Hydraulic Actuators
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Chapter 2
Design Process
Figure 2.2 Electrical Actuator
2.3.3- Hydraulic actuator
The pneumatic actuator has a maximum operating pressure of 150 psi which
is very low compared to the pressure needed to generate the 100 000 N force
because this force needs a pressure of 2000 to 3000 psi.
The electric actuator offers the highest precision but its cost is very high and
a rapid wear will occur on the nut or the screw.
Hydraulic actuators are designed to carry out linear movements of all kinds
for forces from 10 kN to 250 kN and can operate in pressures of up to 4,000
psi.
Relying on the statements listed previously, a hydraulic actuator will be used to

deliver the 10 ton force. The hydraulic actuator will be a hydraulic cylinder (Figure
2.3). It is a hydro-mechanical device that extends and retracts providing a linear
force (Thrust) on the rod in proportion to its internal area multiplied by the pressure
potential of the fluid power system.
Figure 2.3 Hydraulic Cylinder
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Chapter 2
Design Process
2.3.4- Hydraulic cylinder specifications

In our application we need a fast splitting operation (fast extension and retraction
of the blade) so we cant rely on the spring of a single acting cylinder to return the
piston to its original position. So a double acting cylinder will be sized for the
splitting operation. The specifications that need to be considered while purchasing a
hydraulic cylinder are: [8]
Bore diameter: it is the diameter of the cylinder bore.
Maximum operating pressure: it is the maximum working pressure that a

cylinder can carry.
Rod diameter: it is the diameter of the piston or the rod that is used in
hydraulic cylinders.
Stroke: it is the distance traveled by a piston in a hydraulic cylinder.
Since the needed force is 10 tons, we assume that we have a cylinder bore
diameter of 100 mm, the maximum operating pressure during our application will be
calculated according to the equation 2.2. A bore diameter smaller than 100 mm will
induce a working pressure of approximatively 200 bars, which is very high and will
affect massively the size of the hydraulic unit.
=
=> P =
101000104
100100
(2.2)
= 12.73 MPa = 127.3 Bars ~ 130 Bars
The hydraulic actuator is the best actuator that will be able to deliver the needed
splitting force. The hydraulic cylinder to be purchased has a 100 mm bore diameter
and can withstand a pressure of 130 bars. The stroke of the cylinder can be sized
according to the mounting of the piston in the chassis (paragraph 2.4.4). Therefore,
the chassis of the machine will be discussed in the next paragraph.
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2.4- Chassis
2.4.1- Introduction
The chassis to be designed has to hold the hydraulic cylinder, so it should withstand
the 100 000 N force generated during the splitting operation. The chassis should be
designed to allow open access, the worker must be able to examine the splitting
operation and to interfere and stop the machine if something wrong occurred. We
should add that the chassis must accommodate the automatic feeding loading and
unloading of stone blocks.
2.4.2- Design
Two types of chassis were discussed in the previous chapter, the H-Frame chassis
and the C-Frame chassis. The C-Frame chassis will be used and designed in the
clat machine for the following reasons:
The C-Frame chassis offers three open access area for the operator while the
H-Frame offers two.
The hydraulic cylinder cannot be installed on the H-Frame chassis with the
automatic loading and unloading conveyor. Since the stone block must be
squeezed between the upper and lower blade until the splitting occurs, than
the belt of the conveyor will cover the lower blade even during the splitting
which is not possible.
The C-Frame opening will help us fix the lower blade and the conveyor can
pass through this opening to deliver the stone block under the blades.
The H-Frame chassis is suitable for the use of the multi-blade system which
will not be used in this machine for the reasons discussed in paragraph 2.5.
The chassis of the machine will be composed of two C-Frames separated by the
hydraulic cylinder. The distance separating the two C-Frames is chosen slightly
greater than the size of the outer diameter of the hydraulic cylinder.
o The outer diameter of the hydraulic cylinder is 115 mm, so the C-Frames will
be 180 mm distant one from the other.
o The dimensions of the C-Frame will be 1300 mm 500 mm
o
The opening of the C-Frame will start at 700 mm and will end at [700 mm +
320 mm (Table 2.3)] 1020 mm.
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C-Frame Opening
Lower blade support
Lower blade extension
Stone block
Free access
Upper blade extension
Upper blade support
Pistons flange
Piston rod Extension
Total C-Frame opening distance
C-Frame Opening
Chapter 2
Design Process
30
10
70
50
10
50
20
30
270
320
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
Table 2.3 C-Frame Opening
o The width of its opening will be 250 mm (Figure 2.4).
Figure 2.4 C-Frame Dimensions
o The thickness of the C-frame chassis, the fillet radius around the corners, and the
material type will be discussed in the next paragraph.
o The link between the two C-Frames will keep the chassis rigid and will keep a
distance of 180 mm between the two frames. Two 180 mm UPN (European
standard U channels) beams having a length of 250 mm are used at the bottom
and at the top of the two frames in the front, and two 30 mm hollowed cylinders
in the back (Figure 2.5).
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Figure 2.5 Chassis Assembly
2.4.3- Stress analysis

In this study, the material is assumed to be steel AISI 10201
The C-Frame is fixed at the bottom
The forces on the C-Frame are acting on the opening
The main objective of the stress analysis is to determine the thickness of the two
frames, the radius of the upper and the lower fillet. Using solid works simulation
express (Figure 2.6 on the next page), thickness was determined to be 20 mm, with
an 80 mm lower and upper fillet radius and 20 mm fillet radius on all the other edges.
The minimum safety factor is 1.7. This safety factor, equation 2.3, will increase since
we will use two adjacent C-Frames chassis instead of one to fix the hydraulic
cylinder.
Safety factor
=> =
(2.3)
410
1.7
237.6
2.4.4- Hydraulic cylinder Chassis connection

The hydraulic cylinder to be purchased has a 100 mm bore diameter and can
withstand a pressure of 130 bars. The stroke needed to perform the splitting operation
does not exceed 120 mm, so the hydraulic cylinder can be purchased having its inner
diameter, pressure and stroke.
The hydraulic cylinder found on the market has the following specifications:
100 BORE 250 STROKE 56 ROD HYDRAULIC PRESSURE: 233 Bars.
AISI 1020 is a low hard and low tensile carbon steel with Brinell hardness of 119 235 and tensile
strength of 410-790 MPa. It has high machinability, high strength, high ductility and good weld ability.
1
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Figure 2.6 Stress Analysis of the Chassis
The hydraulic cylinder is mounted on the chassis with a rectangular flange. The
rectangular flange is bolted on the two C-Frames on the upper part of the C-Frame
opening. The hydraulic cylinder will sit between the two C-Frames and it is fastened
to the rectangular flange. It is like a threaded shaft coupled to a threaded nut that is
the rectangular flange (Figure 2.7).
Figure 2.7 Hydraulic Cylinder Coupling
In summary, the chassis of the machine will be composed of two adjacent Cframes. The splitting force has to be transmitted to the block to cause it to shear, the
blade system is responsible of transmitting this force to the stone block. The next
section will discuss thoroughly the blade system to be used.
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2.5- Blade System

2.5.1- Introduction
Splitting is performed by squeezing the stone block between two blades, causing it
to shear in two halves along a surface between the blades. As said previously in
chapter two, different types of blade systems can be found in the machines sold on
the market:
1. Simple blade system
2. Hinged blade system
3. Multi-blade system
2.5.2- Simple blade system
The Multi-Blade system (Figure 2.9) has a very complex design, expensive and not
suitable for small stone block cutting so the machine will use the simple blade system
(Figure 2.8) that consists of two blades, the lower one is fixed and the upper one can
move. The simple hinged blade system is similar to the simple blade system but
adding the hinge adds complexity to the design. So the linear guidance system of the
blade will be designed to allow the blade to satisfy uniform force during the split if
the blocks surface is not ideal.
Figure 2.8 Simple Blade System
Figure 2.9 Multi-Blade System
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2.5.3- Blade design

The simple blade system to be used consists of two hardened steel blades, the lower
blade will be fixed to the chassis and the upper blade will move toward the lower
blade to perform the splitting operation.
Blades properties
Length : 220 mm
The stone blocks that are fed to the machine have a length that can vary
between 10 and 20 centimeters, therefore the length of the blade should be 22
centimeters to cover the stone blocks total length.
Thickness : 10 mm
Height : 40 mm
Material : Hardox 4002
The blade is chamfered with an angle = 45 to create a V cutting edge
(Figure 2.10).
This 45 angle was calculated and proved to be the best angle after a
theoretical study and finite element study made by a group of mechanical
engineering students in their final year project SPLITTING MACHINE
(150T).
The Blade is fixed to its housing with three threaded M8 screws.
Figure 2.10 V-Shape Blade End
The lower blade and the upper blade will have different heights and each one of
them will be fitted in its proper housing. The next section will expand the design of
the upper and the lower blade holders.
A Steel having a combination of hardness and toughness that makes it outstanding. Its extremely
resistant to wear, and able to perform as a load-carrying part in many applications. Yield Strength :
1200Mpa, Tensile Strength : 1400Mpa
2
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2.6- Blade system accessories

2.6.1- Introduction
The splitting force is transmitted from the hydraulic cylinder through the upper blade
to the stone block and then to the lower blade. This section will expand the design
of the upper and the lower blades housing, the connection between the upper blades
housing and the piston rod of the hydraulic cylinder, the linear guidance system of
the upper blades housing and the connection between the lower blades housing and
the chassis.
2.6.2- Upper blade housing
The housing of the upper blade is connected to the hydraulic cylinder, it has to
withstand the 10 tones force exerted on the stone block. The design of the upper
housing is very simple, it consists of a rectangular steel bar 40 mm 50 mm. It has
a length of 320 mm (Figure 2.11). A 10 mm slot, 20 mm deep will be cut to allow
the installation of the blade using the three M8 bolts.
Figure 2.11 Upper Blade Basic Design
*The length of this part was chosen after selecting the type of linear guidance system.
2.6.3- Piston rod connection
The 100 mm bore diameter hydraulic cylinder has a 56 mm standard rod diameter.
The connection between the rod and the housing of the upper blade will be similar to
the clevis-pin system. Since the standard size of a clevis-pin connection for a 56 mm
rod diameter is very large and will affect the available space in the C-Frame opening,
a custom made clevis, tang and pin will be designed and executed.
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Pin design
In order to determine the diameter of the pin we must calculate the shear stress acting
on the pin (Equation 2.4). There are no bending forces acting on the pin since the
new designed clevis will be a rectangular steel part having one top threaded hole for
the connection with the pistons rod and one side hole for the pin. The pin cannot be
subjected to bending inside the clevis because it is fully blocked inside the hole.
Pin shearing stress is shown in Figure 2.12 and calculated as follows:
2
= 2
(2.4)
F : Splitting Force, N : 100 000 N (10 Tones)

d : Pin Diameter : Assumed to be 20 mm
: Pin Shearing Stress, MPa
d : Allowable Shearing Stress 385 MPa
Figure 2.12 Shear Stress on Pin
=2
100 000
202
~ 160 < , so the pins diameter will be 20 mm and having a
total length of 80 mm. Two external C-clips are added after the installation of the pin
in its clevis (Figure 2.13).
Figure 2.13 Pin
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Tang design
As said before the tang has a rectangular shape with two holes, one that fixes the
pistons rod and the other fixes the pin. The hydraulic cylinder has a 250 mm stroke
since all we need is 100 to 120 mm stroke, 50 mm were cut from the rod and another
30 mm were threaded after reducing its diameter to 30 mm instead of 56 mm. The
tang has the following dimensions 40 40 75 (Figure 2.14), a 20
mm side hole and a 30 mm top threaded hole.
Figure 2.14 Tang
Clevis design
The upper housing of the blade is connected to the hydraulic piston via the clevis
system. Two clevis ears must be installed (welded) on the housing of the upper blade
and the pin will be fitted from one end to the other. The splitting force can now be
transmitted from the pistons rod to the blade. The thickness of the clevis ears a
is illustrated in Figure 2.15. a will be equal to 15 mm, this value was chosen since
the pin cannot be subjected to bending stress inside the tang. [9]
Figure 2.15 Clevis, Tang and Pin Connection
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The assembly of the piston rod connection with the upper blade housing is shown in
Figure 2.16.
Figure 2.16 Piston-Upper Blade Housing Connection
2.6.4- Linear guidance system

A linear guidance system besides the clevis connection system is needed to keep the
upper blade housing from rotating around the hydraulic cylinder (Figure 2.17).
Figure 2.17 Unwanted Rotations of the Upper Blade
The guidance system will ensure a vertical motion for the upper blade toward the
lower blade and will offer a small tilting angle for the blade to have the perfect contact
with the surface of the stone block since we are not using a hinged blade (Figure
2.18).
Figure 2.18 Tilting Angle Needed for Best Contact with the Stone block
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Linear guidance system study

The linear motion guidance must satisfy the following design criterions:
Reliable
Oil and Dust resistant
Low Cost
Allows a small tilting angle for the blade if the surface of the stone block is
not ideal
The linear motion guidance systems present on the market are of various types as
shown in Figure 2.19 but none of them are 100% oil and dust resistant. This machine
is exposed to sand, water, oil, and small residual stones so it operates in very bad
working conditions that affect the performance of seals and rubbers. A simple design
of the linear guidance system will be exposed in the next paragraph.
Figure 2.19 Different Types of Linear Guidance Systems
Linear guidance system design

The linear motion guidance system will be composed of two 400 mm long
rectangular bars 20 mm 20 mm bolted on each side of the blade and each one of
them is sliding between two other bars. The distance between the two C-Frames is
180 mm, the thickness of the two C-Frames is 40 mm so the total distance separating
the two guidance bars should be 220 mm. Since the linear guidance system should
allow the housing of the blade to tilt in order to perform the perfect split with a
uniform force on the stone blocks surface, the 220 mm separating distance will be
240 mm. Two fillet radius (Figure 2.20) were added to the tang of the clevis system
to allow the blades housing to tilt and two 3mm, 250 mm long folded metal sheets
are added to cover and protect the upper bars from dust, oil and dirt. Figure 2.21
shows the upper blade system with its linear motion guidance.
Figure 2.20 Modified Tang
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Figure 2.21 Upper Blade System with the Linear Motion Guidance
2.6.5- Lower blade housing
The lower blade is fixed to its housing with the three M8 screws as said
before.
The lower blade has a height of 32 mm
The housing of the blade should be fixed to the C-Frame Chassis to absorb
the splitting force from the stone block.
The housing of the lower blade will be a rectangular steel bar 30 mm 40 mm and
240 mm long (Figure 2.22). A 10 mm slot, 20 mm deep will be cut to allow the
installation of the blade using the three M8 bolts. Two 20 mm slots are cut in the
lower part of the housing, each slot is fixed onto one of the two C-Frames and these
slots will allow the lower blade to move inside the C-Opening to be adjusted directly
above the upper blade. Two bolts will be added on the sides to fix permanently the
lower blade in its place after the assembly of the machine.
Figure 2.22 Lower Blade Sub-Assembly
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Figure 2.23 shows the assembly of the C-Frames chassis, the piston, the upper
and the lower blade subassemblies.
Figure 2.23 C-Frame Chassis, Piston and Blade System Assembly
The chassis of the machine, the design of the blade system and the hydraulic
actuator were all designed. Next we discuss the stone delivery system and the stone
feeding technique.
2.7- Stone delivery system

2.7.1- Introduction
One of the design tasks that needs to be managed is to develop an automatic loading
and unloading device for stone blocks. The biggest benefit of automation is that it
saves labor and minimizes human intervention, thus optimizing quality, speed,
accuracy and precision. The stone delivery system will basically be a simple
conveyor that conveys stone blocks from the feeder to the blades and then into a
magazine after performing the split.
2.7.2- Study of existing technologies
Stone blocks are fed into various types of blade systems on chain (Figure 2.24), belt
(Figure 2.25) or roller (Figure 2.26) conveyors. Table 2.4 will compare the three
types of conveyors which will let us choose the type that will accommodate the
designed blade system and chassis.
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Chain Conveyor
Belt Conveyor
Roller Conveyor
Figure 2.24 Chain Conveyor
Figure 2.25 Belt Conveyor
Figure 2.26 Roller Conveyor
Comparison
- Complex design and parts - Simple design, easy to - Complex design and parts
install
- Needs lubrication
- No lubrication needed
- Needs lubrication
- Needs accurate mounting - Extremely Reliable

and careful maintenance
- Needs maintenance
- Noisy
- Quiet operation
- Noisy
- High cost
- Low cost
- High cost
Table 2.4 Study of Existing Conveyors
Relying on Table 2.4, belt conveyors will be used in this machine. It is simple, can
be configured to fit almost any application and requires less horsepower to operate than
other types of conveyors.
2.7.3- Belt design

There are two main types of belts, flat belts and v-belts. V-belts will be used to
convey the stone blocks. V-belts keep slip under control because of the wedging action
between the belt and the v-groove in the pulley and they are capable of transmitting more
power than flat belts. The stone blocks to be conveyed have a maximum length of 200
mm and a maximum width of 70 mm. Since each stone block will be squeezed between
the upper blade and the lower blade, two v-belts will pass slightly over the lower blade
to prevent the lower blade from entering the belt during the split and to avoid contact
between the stone block and the lower blade when the conveyor is running (Figure 2.27).
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Figure 2.27 Two Belt Concept
Various sections of V-belts can be found on the market. The section of the belt
A, B, C or D to be used is chosen depending on the maximum width of the stone
block to be conveyed which is 70 mm. So two type B v-belts will be used having
each 17 mm width and 11 mm height and distant 12 mm (Figure 2.28). The belts
length will be determined when the center to center distance between pulleys is
chosen.
Figure 2.28 V-Belt Configuration
The conveyor will have to convey the stone block on the two v-belts to the
blade system. Before the split occurs, the stone block is on the two belts with no
contact with the lower blade. When the upper blade actuated by the piston moves
toward the lower blade it will push the stone block against the lower blade and the
two v-belts will be slightly bent to allow the contact between these two. The lower
blade is 3 mm lower than the top of the belts surface (Figure 2.29).
Figure 2.29 Lower-Blade and Belt
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2.7.4- Pulley design

V-belt pulleys transmit power between axles by the use of a v-belt. Since we are
using two v-belts, there is a need for a two groove type B v-pulleys. Double groove
pulleys offer a 9 mm not the 12 mm needed separation distance between the two vbelts to be able to insert the lower blade between them, so two 1 groove SPB pulleys
shall be used on each side of the conveyor.
The two single groove pulleys will be fixed one next to the other on the rotating
shaft. Tapered bore or solid hub (Figure 2.30) pulleys can be found on the market
and in our application tapered bore pulleys with key tapered bushes are needed to fix
each pulley to its rotating shaft. [10]
Figure 2.30 Tapered Bore Vs. Solid Hub Pulleys
The specifications of these two parts (belt length, pulley diameter, center to center
pulley distance, chassis and shafts) will be discussed after the design of the feeder
that affects directly the design of the conveyor.
2.8- Stone block feeder

2.8.1- Introduction
The stone block to be split has a rectangular shape and its dimensions can vary from
one stone to another and according to the desired size of clat requested by the
client. The machine we are designing must have an auto feeder that accommodates
with the shape of the stone blocks and they must be fed on the conveyor automatically
without any human intervention. The next paragraphs will discuss the proposals we
came up with during the design process in order to choose the most passive and best
time and cost demanding design.
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2.8.2- Design proposals

Proposal A (Figure 2.31)
o Stone blocks are fed manually on a feeding slide and gravity moves each
stone block to the table level.
o A hydraulic, mechanical or pneumatic piston is responsible of delivering the
stone block from the tables feeder into the blade system.
o No need for a conveyor to deliver the stone block into the blade system.
o After the split, the two clat halves can slide on each side of the lower
blade into a container.
Figure 2.31 Feeder Proposal A
Proposal B (Figure 2.32)

o Stone blocks are fed into a box and a pusher connected to the belt will be
conveying the stone blocks into the blade system.
o An electric motor is used to drive the belts pulleys.
Figure 2.32 Feeder Proposal B
2.8.3- Proposals study

Proposal A
A piston pushes the stone blocks out of the feeder, the piston can be mechanically,
pneumatically or hydraulically actuated but still the design is not passive and
expensive and it will have many parts if it was mechanically driven.
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The sliding feeder will be a great idea if an experiment on the stone blocks can give
us the right angle of the feeder to the horizontal. Besides this, the change in length
of the stone blocks can cause a real problem for the piston because the stroke of the
piston must be varied every time the stone blocks length has changed. A conveyor
can be used in such a way that the blocks can be fed by the piston on the conveyor.
Proposal B
A pin connected to a moving belt pushes the stone blocks out of a box. The box that
contains the stone blocks can be designed to accommodate the change in size of the
stone blocks but this system will not be able of delivering the stone block into the
blade system. The stone block must be centered in length on the lower blade to obtain
a perfect split. A conveyor can be used after this system to deliver the block to the
blades.
2.8.4- Feeder design
An automatic feeding system without a conveyor cannot be installed on this type of
machine so it has been decided to design a feeder that will be a combination of the
two previously discussed feeder proposals. The feeder will benefit from the rotating
parts of the conveyor to push the stone blocks onto the belts out of a container or a
slider. The first step is to run an experiment on the stone blocks to find out if the
gravity can help the stone blocks slide on an inclined surface to the table level.
Several experiments have been made on different types of stone blocks with different
inclination angles of the slider to come up with the best angle to the horizontal that
wont cause problems during the feeding.
= 70, has been proven experimentally to be the best angle that will let
gravity bring the stone blocks to the table level (Figure 2.33).
Figure 2.33 Feeder's Preliminary Sketch
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Since the slider concept can be used as a container for the stone blocks, the next
step is to find a passive feeding technique that will be able to push the stone blocks
out of the sliders table onto the two belts.
1. To install a piston
The piston has to push one stone block at a time from the tables level on the
conveyors two belts. The retraction of the piston will cause a problem, while
the first stone block is being pushed out of the feeder, the next stone block is
sliding to get in the first stone blocks place. The cost of the piston and the
controllers besides the conveyor that should be installed is high so another
alternative solution must be found.
2. To benefit from the belts movement
This proposition suggests the use of a conveyor that has a pin connected to
its belt that pushes stone blocks out of the feeder onto the belts and not
directly into the blade system. This proposal is compatible with the design
of the two v-belt conveyor shown in section 2.7, but the pin on the belt will
interfere with the upper blade when it will be moving downward toward the
lower blade to squeeze the stone block.
3. To benefit from the pulleys rotation
If a pin or metal sheet pusher was inserted between the two v-pulleys, the
rotation of the pulley will let the pin get into a slot in the feeders table and
push a stone block. The two v-belts must be always tangent to the feeders
table to make it more possible to the stone block to get onto the belts once it
is out of the feeder. So the v-pulleys should be millimeters away from the
feeders table which will affect the diameter of the pulleys. This appears to
be the best solution for feeding.
While we have found the best technique for feeding it remains a design theory.
An experiment must prove that the stone blocks can be pushed out of the slider feeder
by a pin or a metal pusher without causing any feeding problems.
Slider design
The gravity can help the stone blocks get onto the feeders table once the first stone
block is pulled out of the feeder. The stone blocks to be split might have different
sizes (different length, height and thickness), so the slider of the feeder should be
customized to be able to contain the different sizes of stones.
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The slider will consist of two 2 mm galvanized steel metal sheets having a length
of 1250 mm. The first part will hold the stone blocks and the second can slide over
the first part to insure that different sizes of stone blocks can fit the slider (Figure
2.34). For medium to small stone blocks, an adjustable screw will be added at the
lower end of part # 2 to prevent the second stone block from leaving the feeder when
the pulling occurs. Two 10 mm 50 mm slots were cut in the two metal parts to let
the operator adjust part # 2 according to the size of the stone block.
Figure 2.34 Slider
To avoid the bending of the sliders parts due to the weight of the stone blocks
when the feeder is fully loaded, the two parts were bent as follows:
Part # 1: Z profile; Part # 2: U profile
The 70 needed angle of the feeder slider to the horizontal is provided by the
chassis of the feeder. The chassis of the feeder consists mainly of four 40 mm 40
mm rectangular hollowed beams and three reinforcement plates welded to the slider
feeder (Figure 2.35).
Figure 2.35 Feeder's Chassis
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Now a test shall be run to see if the proposal works. It should prove that the pin
is able to push stone blocks out of the feeder.
Slider Auto-feeder experiment
The pin pusher has to enter a slot in the feeders table and push a stone block out of
the feeder. This experiment has to be done to insure that the pin is able to push a
stone block out of the feeder without disturbing the other stone blocks on the slider.
The slider feeder (Figure 2.36) was executed and the experiment was held at La
Socit Libanaise des Marbres, SHERMEL on Tuesday, April 19, 2016.
Figure 2.36 Feeder Slider
To push the stone blocks out of the feeder, we used a screwdriver (Figure 2.37).
The screwdriver was pushing the stone blocks through a 10 mm slot we prepared
using two large stone blocks. This slot will be cut in the feeders table if the
experiment works fine.
Figure 2.37 Experiment Preparation
After multiple trials on the stone blocks, we had good results. Few changes
must be done on the design of the feeder to prevent some occasional problems from
occurring.
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The chassis of the feeder must be fixed on the feeders table but it should have
the possibility to be adjusted moving it forward or backward depending on
the thickness of the stone block to be split, to allow the stone block to exit the
feeder in a straight line directly on the two belts.
As seen in Figure 2.37, another part must be added in front of the slider
feeder. The stone block fixed by hands shown in the above picture, had an
incredible action when holding the stone blocks from falling and helping
them sliding to replace the stone blocks that are being pushed away by the
screwdriver. An L metal plate will replace this stone block and it should have
the possibility to be adjusted depending on the thickness of the stone block.
After the success of the experiment the design of the feeder can now be completed
as shown in Figure 2.38.
Figure 2.38 Feeder's Final Sketch
2.9- Conveyor
2.9.1- Introduction
The feeder of the machine has already been designed and the basic components of
the conveyor have already been introduced in section 2.7. The conveyor will use a
set of four v-pulleys, two coincident pulleys on each side. These pulleys will drive
two v-belts to deliver the stone block from the feeder into the blade system and then
into a container. This section will discuss the design of the pulleys, the length of the
belt, the torque needed, the rotating shafts and the chassis that will support the
pulleys, the conveyors motor and gearbox (if needed) and the feeder.
2.9.2- Pulleys diameter selection
The pulleys on the feeders side will have a pin that pushes the stone blocks as
discussed in the previous section. So the size of the pulleys should be sized according
to the path that the pin should travel to push the stone block out of the feeder.
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The maximum length that a stone block can have is 200 mm.
The pin should push the stone block smoothly without disturbing the other
stone blocks that lay above it. For this purpose, the pin should begin
pushing the stone block when it is close to its vertical position. To achieve
this, the center of the pulley must be shifted to the left.
The pulleys should be always at 15 mm from the stone block because the
belts should be tangent to the feeders table.
Multiple drawings were made to sketch the perfect path of the pin that will push
the stone block for 200 mm to get the stone block out of the feeder.
Figure 2.39 Pulley Design Sketch #1
Figure 2.39 shows the pin connected to its pulley and the stone block. The pin
as it rotates it will push the stone block along the path shown in the sketch and in this
scenario the pin is capable of pushing the stone block out of the feeder. In this sketch,
the diameter of the pulley is 250 mm but this diameter cannot be adopted. The center
of the pulley should be shifted to the left to allow the pin to push the stone block
when its parallel to its surface. Shifting the pulley to the left wont let the pin push
the stone block far enough to get the stone block out of the feeder.
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Chapter 2
Design Process
In the sketch of Figure 2.40, the diameter of the pulley is 400 mm. The center of
the pulley should be shifted to the left, so the pin should have a special end form to
push the stone block smoothly. So, shifting the pulley to the left by 30 mm and giving
the pin a special end profile will be the solution (Figure 2.41).
2.9.3- Pulley and belt specifications

Four SPB400 single groove pulleys are needed for the conveyor. The pulleys on the
feeders side should have a slot to receive the pin that pushes the stone blocks. A
cycle study of the machine will give information on the productivity of the machine,
the length of the belt which will let us choose the number of pins and their positions.
Cycle Study
The pin that pushes the stone blocks have a length of 60 mm. The position of the
stone block on the belts must be predicted, equation 2.5 will give the distance in cm
travelled by stone block according to the angular motion of the pulleys. In the cycle
studys sheet calculation prepared on Microsoft Excel, the distance traveled by the
stone block is an input and the angle of rotation of the pulley is given according to
equation 2.6. The time intervals for every step in the calculation is derived from
equation 2.7, having the angular rotation and the speed in rad/s the time can be
calculated. This cycle study is based on one pin connected to the pulley.
=
( 180 )
=
, deg
=
,
in rad, r and x in cm
(2.5)
(2.6)
(2.7)
Table 2.5 exposes the calculation made during the cycle study.
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Chapter 2
Design Process
Activity
Time
t=0
0.524
2.128
3.328
5.376
Total
5.485
Event
Start
Motor
Motor
on
stop
motor
Start
Motor
Motor
on
1 Cycle
Pulley
Radius, r
in cm
Pulley Angle of
Rotation, in
deg
RPM
, rad/s
26
44.096
14
1.465
20
0.524
44.096
20
20
134.713
14
1.465
x1 = 47
1.603
178.809
67
20
14
1.465
1.2
178.809
67
20
171.974
14
1.465
x2 = 60
2.047
350.783
127
20
9.216
14
1.465
0.109
360
127
Distance, x Tcumulative, Total Angle

in cm
sec
of Rotation
Total
Distance
Traveled
Table 2.5 Cycle Study
At i = 0; the first stone block travels 20 cm to get out of the feeder in t = 0.524 s and the angle of rotation of the pulley equals ~ 44.
At i = 1; the x1 distance is the distance separating the feeder from the blade system. It was assumed to be 47 cm to obtain a total angle of
rotation of 180, which will be explained next.
At i = 2; the block is being split, the time cannot be calculated, its given by an experiment done on the old clat machine.
At i = 3; the clat halves are delivered to the container. x2 must be around 60 to let the belt bent when the split occurs. Since it is hovering
over the lower blade housing, the distance from the feeder to the blade system must equal the distance from the blade system to the pulleys
on the container side.
At i = 4; no stone blocks are being pushed, the clat halves are in the container, the pulleys rotate freely to complete one revolution.
P.S: 14 RPM is based on 1400 rpm motor and 1/100 gearbox reduction ratio which is the most affordable.
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Chapter 2
Design Process
To maximize the productivity of the machine and benefit from the large diameter
of the pulleys, multiple pins can be inserted to push several stone blocks during one
revolution.
When the pin is at the feeder, the pulley has to rotate 44 to let the pin push the
stone block out of the feeder and another 136 to deliver the stone block into the
blade system. So at 180 (44 + 136) the conveyor will stop because the stone block
has reached the blades. If another stone block was fully launched out of the feeder
before the first block reaches the blade system, this will increase significantly the
productivity. The use of two pins separated with a 180 angle cannot be realized.
When the first stone block is being split the second pin is in the feeder which will
cause a problem during feeding.
To get a stone block out of the feeder, we need a 44 angle rotation, so 180 44 = 136. We can launch another stone block right after the first stone block by
inserting a second pin that is at 136 from the first pin (Figure 2.42). But by doing
this, we risk that the second stone block is not fully pushed out of the feeder so we
will consider that the angle needed to push a stone block out of the feeder is 60
instead of 44.
Figure 2.42 Pin Position
If 60 was the angle needed to push a stone block out of the feeder:
180 - 60 = 120, thus two pins can be inserted with a 120 separation angle.
If we divide 360 by three we will get 120, so three pins instead of two can also
be inserted without causing any feeding problems. After the first stone block is split,
a stone block will be under the blades and ready to be split every 120. Choosing the
distance x1 = 47 cm helped in simplifying the configuration of the pins.
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Chapter 2
Design Process
The pulleys on the feeder side will have three pins at 120 (Figure 2.43). The pin
is made of hard steel Hardox 400 and will have the following design shown in Figure
2.44. The threaded hole M6 is used to fix the pin to one of the pulleys. The pin has
a thickness of 9 mm to enter smoothly in the slot that will be cut in the tables feeder.
The SPB400 pulleys are tapered and their taper bushes have an inner diameter of 24
mm.
Figure 2.43 Feeders Pulleys Assembly
Figure 2.44 Pin or Stone Pusher
The conveyor of the machine will be composed of four SPB400 v-pulleys: two
pulleys on the feeder side and two on the other side coupled to the gearbox and motor
via their shaft. The center to center distance between the pulleys is equal to 127 cm,
its the distance traveled by the stone block (from the cycle study). We can choose
the belts length and complete the design of the conveyor.
Belt length calculation
Center to center Pulley distance, C = 127 cm
Diameter of large pulley, D = 40 cm
Diameter of other pulley, d = 40 cm
Length of the belt, L, will equal to: [11]
= 2 + 1.57 ( + ) +
()2
(2.8)
=>L = 379.6 ~ 380 cm

The two v-belts can now be purchased having the following specifications:
V-belts type B, outside length 3800 mm.
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Chapter 2
Design Process
A tensioning mechanism must also be designed to tension the belt but taking care
that the belt can bent when the split occurs. Since the center of the pulley should be
shifted to the left in order to push the stone block properly out of the feeder, we can
benefit from this to tension the belt. The pulley can be shifted to the left by moving
its shaft to the left by the use of a T bearing with rails. The T-bearing is the most
used on this type of conveyors, it facilitates the assembly of the belt and its pretensioning.
2.9.4- Conveyors Motor Selection
The selection of the gearbox and motor must take into consideration the torque
needed to drive the belt without slippage and to push the stone blocks out of the
feeder. The most important torque is then needed to push the stone blocks when the
feeder is fully loaded. For this purpose, the torque needed is calculated as follows.
Each stone block is subjected to the forces indicated in Figure 2.45:
F1: friction force between all the loaded blocks and the block to be pushed.
F2: friction force between the block and the L metal plate.
F3: friction force between the block and the feeders table.
P1: vertical force pushing the block down.
P2: projection of the load of all the stone blocks that lay above the first stone block.
Figure 2.45 Stone block Free body Diagram
The weight of one stone block is given by:

=
(2.9)
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Chapter 2
Design Process
The mass can be calculated from the density:

=
(2.10)
Where = 2.3 103 3

The largest stone block has the following dimensions: 20 mm 7 mm 7 mm, its
volume will equal: v = 980 cm3
The mass of this stone block will equal: m = 2.25 kg
The weight of the largest stone block will be w = 22 N
The feeders height is 1.25 m, the feeder can hold up to 17 large stone blocks so the
total weight of stone blocks when the feeder is fully loaded will equal W = 400 N.
This force is divided into two forces and :
= sin()
And
= cos()
(2.11)
(2.12)
Having W = 400 N and = 70;

is the force acting between the second block and the first block to be pushed.
= 346 N, Figure 2.46 shows the projections of Fd on the feeder.
1 = cos 30 = 346 cos 30 = 300 N.
2 = sin 30 = 346 sin 30 = 173 N.
Now that we have the normal forces we can find F1, F2 and F3:
=
(2.13)
Where F is the friction force, is the normal force, is the friction coefficient.
Figure 2.46 Forces acting on Stone block in the feeder
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Chapter 2
Design Process
Assuming that = 0.5

F1 = F3 = 1 = 300 0.5 = 150 N
F2 = 2 = 173 0.5 = 86.5 N
= 1 + 2 + 3 = 150 + 150 + 86.5 ~ 387
The required torque is given by:
=
(2.14)
Where r is distance between the center of the pulley and the stone block which is
equal to 0.2 m.
=> = 77.4 .
The motor of the conveyor should be chosen on an 80 N.m torque basis and on a
speed of 1400 rpm.
2.9.5- Gearbox selection
After the calculation of the torque needed to push a stone block out of the feeder via
the pin, the reduction ratio of the gearbox must be selected. The speed of the
conveyor affects the productivity of the machine, so depending on the cycle study
exposed in paragraph 2.9.3, we can estimate the productivity of the machine.
The speed of the motor is 1400 rpm

Cycle time t = 5.485 ~ 5.5 sec
If the pulley of the feeder has only one pin which means one stone block per
cycle, the machine would produce 3600 / 5 .5 = 654 stone blocks per hour. If the
machine operates 5 hours a day instead of 8 the productivity will be 3270 stone blocks
per day. If we add the two other pins to the feeders pulley, the productivity increases
enormously. The motor of the conveyor has an operating speed of 1400 rpm, the
gearbox should have a 1/100 gear reduction ratio to obtain a speed of 14 rpm. A
reduction ratio that is greater than 1/100 would affect the size and the price of the
gearbox. So it has been decided to go for the 1/100 reduction ratio gearbox with a
1400 rpm motor delivering an 80 N.m torque. The 14 rpm speed can be decreased by
the use of a VFD (variable frequency drive).
Using the TRAMEC catalogue (Appendix C), the gearbox and motor were
selected. 0.25 KW geared (XC) motor delivering 91 N.m torque with a 1/100
gearbox. The driving shaft will have a diameter of 25 mm according to the catalogue.
2.9.6- Conveyors chassis
The conveyor of this machine involves the pulleys, the motor and gearbox, the belt,
the bearings and the shafts. The chassis of the conveyor should be strong enough to
support the feeder, the pulleys and the geared motor. Two configuration of the
chassis came up during the design.
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Chapter 2
Design Process
The first, Proposal A (Figure 2.47):
Figure 2.47 Proposal A of the Conveyors Chassis
Proposal A of the conveyors chassis is cantilevered. The C-frame chassis that

was designed to hold the piston in its place and absorb the 100 kN generated during
the split, will also be used to support the pulleys, the feeder and the geared motor.
The chassis of the conveyor is composed of three main beams: two UPN beams and
one simple rectangular beam to support the gearbox. The C-frame chassis has now
two 80 mm UPN beams as supporting legs, these legs extend 400 mm from each side
of the chassis to distribute the weight and to give rigidity to the structure and an
opening was cut to allow the belt to pass through.
The second, Proposal B (Figure 2.48):
Figure 2.48 Proposal B of the Conveyor's Chassis
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Design Process
Proposal B of the conveyors chassis is composed of two independent HSS

(hollowed structural steel) structures. The C-frame chassis does not support any
weight and is not subjected to any forces that comes from the feeder or the rotation
of the pulleys and the geared motor. The C-frame chassis has four simple supporting
legs that have to be grounded and an opening was cut to allow the belt to pass through.
Comparison
Proposal A (figure 2.47)
Proposal B (figure 2.48)
- Simple design
- Complex design, lots of welding,

lots of parts
- Structural steel such as U beams

have high mechanical properties.
- Weak structure compared to

proposal A of the chassis
- U beams offer the opportunity to

use T bearings with rails to tension
the belt.
- Working with HSS is not simple as

working with U beams (especially
bolting)
- The height of the machine and its

calibration is much simpler with the
supporting U beam legs.
- Adjusting the height of all the

supporting legs to calibrate the
height of the machine is another
problem of a non-cantilevered
chassis.
Table 2.6 Comparison of Conveyor's chassis Proposals
Relying the statements listed in Table 2.6, proposal A appears to have the suitable
design for the conveyor.
Chassis design
The design of the chassis involves the sizing of the U beams that are used to fix the
pulleys.
The front U beam must fix the two front pulleys. The size of this beam will be
affected by the size of the T bearing used on the feeder side. The T bearing is used
for the assembly or disassembly of the belt and for the tensioning. So to proceed
with the design of the beam, the bearings of the conveyor must be selected.
The shaft of the gearbox will have a diameter of 25 mm (Appendix C). The taper
bushes of the pulleys have an inner diameter of 24 mm. So the shaft has to be
machined to be able to assemble the pulleys with their taper bushes. The gearbox
contains bearings inside its housing, by analyzing the forces acting on the shaft, the
shaft can be cantilevered there is no need for a bearing on the right side of the front
U beam.
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Chapter 2
Design Process
Figure 2.49 Radial Load On shaft
Figure 2.49 is extracted from the catalogue of the gearbox XC63, appendix C;
Fr2 is the radial force on the shaft of the gearbox, in our case this force is the weight
of the pulleys.
Each pulley weights 10 Kg,
So Fr2 = 2 10 10 = 200 N
y is the distance at which Fr2 is applied, y = 40 mm (from Solid works sketches).
a and b are given in the catalogue, a = 122.5 , b = 93.5, Fry2 calculated must be lower
than 5400 N (given by the datasheet of the gearbox, page 9).
Equation 2.15 gives the radial load on the shaft:
2 =
=> 2 =
2
+
200 122.5
93.5 + 40
(2.15)
= 183.52 N < 5400 N
The bearings inside the gearbox are capable of supporting alone the shaft.
A 20 mm UCF square roller bearing was added on the front U beam to avoid the wear
on the gearboxs bearings if any misalignment occurred. After starting the conveyor,
the bolts of the bearing can be fastened to prevent any misalignment between the
bearings inside the gearbox and the one on the front beam.
For the shaft on the feeders side, the back U beam will have a 25 mm UCT (pillow
block, Figure 2.50) bearing and the front U beam will have a 20 mm UCT bearing
similar to the bearings configuration on the gearbox side. The selection of the
bearings was made according to the catalogues shown in appendix C.
Figure 2.50 T bearing or UCT
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Chapter 2
Design Process
The size of the pillow block bearing (T bearing) is very important for selecting
the size of the U beams. The rails of the T bearing must be welded inside the U
beams so the U beam must be large enough to hold the T bearing and the two rails,
the upper and the lower one (Figure 2.51).
Figure 2.51 T bearing and rails
Referring to the catalogue (Figure 2.52), the T bearing has a height H of 89 mm,
so the U beams, front and back beams, should not be smaller than 120 mm UPN
beams. The rails for the T bearing have a height of 15 mm each, the T bearing has a
height of 76 mm (H1 in Figure 2.52) so the 120 mm UPN beam would be perfect:
76 +15 +15 < 120 mm
Figure 2.52 T bearing Catalogue, Appendix C
The front U beam must have each a slot to let the shaft of the feeder pulleys to be
shifted to the left. L metal plates are used to connect the front U beam to the C-frame
chassis (Figure 2.53). The front U beam has a length of 1500 mm.
The back U beam has also a slot to let the shaft of the feeder pulleys to be shifted
to the left. A simple 9 mm metal plate welded to the U beam connects it with the Cframe chassis (Figure 2.54). The back U beam has a length of 700 mm.
The beam that supports the geared motor cannot be a U beam. The gearbox must
be bolted to the beam and since the gearbox is larger than 120 mm, it cannot be
installed on the U beam. A reinforced simple thick metal plate (Figure 2.55), 580
mm length, 160 mm 10 mm, will be used and it is connected to the C-frame cassis
with a small metal plate.
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Figure 2.53 Front U beam Design
Figure 2.54 Back U beam Design
Figure 2.55 Gearbox Beam Design
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Chapter 2
Design Process
Since the conveyor will be carried by the C-Frame chassis, the supporting legs of
the chassis will be two 80 mm UPN beams connected to the chassis with L metal
brackets (Figure 2.56).
Figure 2.56 C-Frame Chassis with Conveyor
Force analysis on beams

Back U beam:
The back U beam, one of the two U beams used as feeder support, is cantilevered
(Figure 2.57), it has one fixed end (fixed to the C-Frame chassis) and one free
end. This beam is subjected to two main forces, the vertical force F (stones
weight resultant) and the Normal force N (stone push out force).
Figure 2.57 Cantilevered Back U beam
d = 525 mm
F= 375 N
N = 387 N
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Chapter 2
Design Process
The bending moment can be calculated as follows:

=
=> M = 375 0.525 = 197 N.m
(2.16)
The normal stress due to the Bending moment is given by:
1 =
(2.17)
The normal stress due to the Normal force is given by:
2 =
(2.18)
In the two above equations A, , y (Figure 2.58) are the U beam parameters, the
values of these parameters were selected from the table of UPN 80 mm.
The steel yield strength is assumed to be = 250 . [12]
The safety of factor can be calculated as follows:
(2.19)
Figure 2.58 U beam Parameters
Using the standard table for UPN beam 80 mm (see Appendix C):
= 11.02 2, = 19.4 4,
y = 40 mm.
1 = 40.62 , 2 = 35.11
is calculated from equation 2.20
= 1 + 2
=> = 75.73 ,
The safety factor will equal = 3.3
(2.20)
As shown in the previous calculations, an 80 mm UPN beam can support the

feeder and the pulley but due to the fact that the bearing housing should be insert
inside the U-beam, a UPN 120 mm cannot be replaced by the 80 mm U beam.
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Chapter 2
Design Process
Geared motor beam support:

This beam is also cantilevered, has one end fixed to the C-Frame chassis and the
other end is free. This beam is subjected to a normal force N (stone push out
force) and the moment M (motor torque), Figure 2.59. [12]
Figure 2.59 Cantilevered Geared Motor Beam
d= 580 mm
N=387 N
= 80 .
The normal stress due to the bending moment can be found from equation 2.17,
and the normal stress due to the Normal force from equation 2.18;
The total stress = 1 + 2 , equation 2.20.
For the rectangular section, the moment of Inertia is given by:
3
3
(2.21)
Having h= 160 mm, b=10 mm (Figure 2.60);

= 1365.33 4 .
Figure 2.60 Rectangular Beam Parameters
Equation 2.17 => 1 = 120 ;

Equation 2.18 => 2 = 0.24 ,
Equation 2.20 => = 120.24
This beam is safe, having a safety factor of 2, a reinforcement plate was added.
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Chapter 2
Design Process
Front U beam
The size of this U beam is the same as the size of the back U beam, UPN 120
mm. For esthetic reasons, the front side beam is fixed to the C-frame chassis and
it is subjected to the vertical force F (stones weight resultant) and the Normal
force N (stone push out force).
The study of this beam was made using solid works simulation see Table 2.7.
Fixture name
Fixed
Fixture Image
Fixture Details
Entities:4 face(s)
Type: Fixed Geometry
The U beam is fixed to the C-Frame Chassis
with L metal plates (Figure2.61).
Figure 2.61 Front Beam Fixture
Load Name
Normal force
Load Image
Figure 2.62 Normal Force on

Front U Beam
Vertical Force
of Feeder
Load Details
Entities: 1 face(s)
Type: Normal force
Value: 387 N
It is the force generated by the pin of the
pulley when it is pushing stone blocks (Figure
2.62).
Entities: 1 face(s)
Type: Vertical Force of Feeder
Value: 375 N
Figure 2.63 Feeder Load on

Front U Beam
It is the force generated by the weight of

stone blocks present in the feeder (Figure
2.63).
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Chapter 2
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Normal force
Entities: 1 face(s)
Type: Normal force
Value: 387 N
It is the force generated by the pin of the
pulley when it is pushing stone blocks but on
the gearbox side (Figure 2.64).
Figure 2.64 Normal Load on
Front U beam
Study Results
Type
Max Von Mises Stress
Factor of Safety
n
Value
16.28
Table 2.7 Stress Analysis of Front U Beam
2.9.7- Feeder connection

The feeders table is supported by the chassis of the conveyor. The two v-belts
should always be kept tangent to the feeders table to prevent any feeding problems.
Two 6 mm U bended sheet metals (Figure 2.65) will be used to fix the feeders table
on the chassis of the conveyor. The bended sheet metals will be fixed with bolts on
the front and back U beams and on the feeders table.
Figure 2.65 Feeder Connection to Conveyor
2.9.8 Shafts
The driving shaft and the idler shaft have the same diameter configuration:
25 mm (in the gearbox and T bearing back side), 24 mm (down the pulleys to
assembly the taper bushes), and 20 mm (in the front T bearing and square roller
bearing).
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Chapter 2
Design Process
The length of the driving shaft connected to the gearbox is: 320 mm (Figure
2.66)
The length of the shaft on the feeders side is: 240 mm (Figure 2.67)
The shaft are fixed axially using C-clips.
The rotational movement is transmitted from the gearbox to the shaft and then
from the shaft to the pulleys by keys.
Keys will slide inside the keyways cut in the shafts.
2 rectangular feather keys will be used on the driving shaft connected to the
gearbox and one key on the other shaft for the taper bushes of the pulleys.
Figure 2.66 Gearbox/Driving Shaft
Figure 2.67 Idler Shaft
2.10- Conclusion
This chapter discussed thoroughly the design of the clat machine. The specifications
and design of the blade system, the feeder, the conveyor and other hydraulic and
mechanical components were detailed after proper studies. The final sketch of the
machine is almost complete. The next chapter will cover the hydraulic unit to be used to
actuate the hydraulic cylinder.
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Chapter 3
Hydraulic Unit
Hydraulic Unit
3.1- Introduction
Hydraulic power units are the main driving components of hydraulic systems. Consisting
mainly of a motor, a reservoir and a hydraulic pump, these units can generate a
tremendous amount of power to drive most any kind of hydraulic ram. Hydraulic power
units are based on Pascal's law of physics, drawing their power from ratios of area and
pressure.
3.2- Hydraulic components

3.2.1- Hydraulic pump
A hydraulic pump is a mechanical source of power that converts mechanical power
into hydraulic energy. It generates flow with enough power to overcome pressure
induced by the load at the pump outlet. Various type of hydraulic units exist:
Gear pump
Radial piston pumps
Gear pumps (Figure 3.1) are simple and economical pumps. Radial piston
pumps are used especially for high pressure and relatively small flows, they are more
expensive than gear pumps. [13] For the simple blade system, gear pump will be used
since its economical and can deliver the required pressure. The piston was selected
having an inner diameter of 100 mm to deliver the required force at a lower pressure
so we can use the gear pump. A piston having an inner diameter of 80 mm can deliver
the force to split stone blocks but the pressure will be much higher than the one
required for the 100 mm bore diameter piston.
Figure 3.1 Gear Pump
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Chapter 3
Hydraulic Unit
3.2.2- Hydraulic motor

The hydraulic motor drives the gear pump. The operating pressure of gear motors is
usually quite low: between 100 and 150 bar. Torque output, running torque, motor
speed and slippage are taken into consideration in the motor sizing calculation. The
sizing of the motor and the other hydraulic components will be discussed in section
3.3.
3.2.3- Directional valve
Directional control valves (Figure 3.2) are one of the most fundamental parts in
hydraulic machinery as well as pneumatic machinery. They allow fluid flow into
different paths from one or more sources. They usually consist of a spool inside a
cylinder which is mechanically or electrically controlled.
An electrically controlled directional valve allowing three different paths: the
first path returns oil to the reservoir when the solenoid is not energized and the other
two paths to move the piston up and down by energizing one of the solenoid. Each
solenoid is responsible of moving up or down the piston. [14]
Figure 3.2 Directional Valve
3.3- Hydraulic unit sizing

Depending on the pistons speed of extend and retraction, the hydraulic unit will be sized
in Table 3.1.
The extend speed is calculated from the flow of oil and the cylinder area of the
hydraulic cylinder.
The retraction speed is calculated from the flow of oil and the cylinder net area
of the hydraulic cylinder.
The desired cycle time of extend and retraction must be below two seconds.
The cylinder net area is the inner area without the area of the pistons rod.
The cylinder bore diameter is 100 mm
The cylinder stroke is 200 mm
The pistons rod has a diameter of 56 mm
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Chapter 3
Hydraulic Unit
The study will be based on a 100 KN basis (10 tons force)

The displacement of the piston will be 20 mm (the piston is always at 20 mm
from the surface of the stone block to be split)
The pressure is 127 ~ 130 bars (from chapter 2, paragraph 2.3.5)
Cylinder area equals A = 7 853.98 mm2 (from chapter 2, paragraph 2.3.5)
Cylinder net area is calculated from equation 3.1, [8]
A = A S
(3.1)
Rod area:
(3.2)
d = 56 mm, S = 2463 mm2

Cylinder net area = 7 853.98 2463 = 5390.973 mm2
During the calculations the flow was varied to choose the best cycle time of
extend and retraction.
FLOW
liter/min
2.12
GPM
Cylinder Diameter =
Stroke =
Rod =
Displacement
Force needed
100
200
56
20
10
mm
mm
mm
mm
Tones
3.94
7.87
2.20
0.79
22046.2
Flow in GPM [US]
2.11
GPM
491.48
inch
inch
inch
inch
lb., Pound
cubic inch
per min
Pressure
1810.97
PSI
127.32
Bars
Rod Area
Cylinder Area =
Cylinder net Area
2463
7854
5390.98
mm2
mm2
mm2
3.82
12.17
8.36
Square inch
square inch
square inch
Extend Speed inch/sec

Retraction Speed
inch/sec
0.67
Extend Time, seconds

Retract Time, seconds
Cycle Time Sec
1.17
0.80
1.97
Effective HP
2.23
0.98
Table 3.1 Hydraulic Calculations
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Hydraulic Unit
Extend Speed is given by: [8]

Extend speed =
(3.3)
Retraction Speed is given:

Retraction speed =
(3.4)
The extend time is calculated as follows:
(3.5)
The retract Time is given by:
(3.6)
The horsepower is given by:

1714
(3.7)
By varying the flow, 8 L/min appears to be the flow that offers a cycle time of extend
and retraction that is below two seconds.
So we need a 3 HP motor delivering a flow of 8 liters/min.
The hydraulic unit will be composed mainly of a reservoir, the motor and the directional
valve. The hydraulic unit must be mounted near the hydraulic cylinder. Two L brackets
will be used along the length of the reservoir to fix the hydraulic unit to the supporting
legs of the C-Frame chassis as seen in Figure 3.3.
Figure 3.3 Hydraulic Unit on Chassis
3.4- Conclusion
After studying the different components of a hydraulic unit, the flow and power required
to actuate the hydraulic cylinder size were calculated. The mechanical design of the
machine is now completed, the next step is to automate the clat splitting operation.
Therefore, the next chapter will involve the electrical design of the machine.
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Chapter 4
Electrical Design
Electrical Design
4.1- Introduction
The two previous chapters reflected the common stages of the engineering design process
including the research, the design requirements, the preliminary design to get to the final
design and the execution of the machine. Since the machine must be fully automated, an
electrical system design is required to operate and control the machine. Various types of
electrical components and controllers were used for automation, they will be exposed
thoroughly in the next paragraphs.
4.2- Electrical Components

The main electronic automation components include a variable frequency drive (VFD),
a power supply, the programmable logic controller (PLC), an encoder, a proximity sensor
and a pressure switch.
4.2.1- The Programmable Logic Controller
The programmable logic controller is a digital computer used for automation of
typically industrial electromechanical processes, such as control of machinery on
factory. Different types of PLC can be found on the market according to their inputs
and outputs type. So in order to choose the suitable PLC for our application, a grafcet
is needed to determine both inputs and outputs. The machine runs in automatic or
manual mode.
For the automatic mode, the conveyor will start and pick up one stone block out
of the feeder onto the two belts to the blade system. A proximity sensor that measures
the length of the stone block is installed between the feeder and the blade system.
This input and the encoders input values will help the PLC stop the stone block right
under the upper blade and centered in length. Once the stone block is between the
two blades, the piston moves down and the stone block will be split in half. After
the split, the pressure switchs input into the PLC will move the piston up and the
conveyor to start again and convey the clat halves to a container and in the same
time to pick up again another stone block out of the feeder.
For the manual mode, the conveyor is at rest and the operator can only control
the valves of the hydraulic unit to lower or lift the piston via two push buttons (up
and down). The ladder program can be found in appendix B.
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Chapter 4
Electrical Design
IDLE
Auto switch
Manual switch
Automatic mode
Manual mode
UP push
Button pressed
Piston UP
Up push
Button released
U
P
Down push
Button pressed
Conveyor
on
Piston Down
Proximity
Sensor on
Down push
Button released
Block reached the

sensor
Proximity
Sensor off
Blocks length
obtained
Encoder counting
The distance traveled
By the block
Block reached the

blade
Conveyor off
Piston down
Pressure switch
Informing
If the block is split
Stone block split
Figure 4.1 Operations Diagram
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Chapter 4
Electrical Design
Based on Figure 4.1:

PLC inputs
1- One auto/manual switch
2, 3- Two push buttons (up and down)
4- One proximity sensor
5- One encoder
6- One pressure switch
PLC outputs
1- Piston up
2- Piston down
3- Conveyor on
The PLC to be used must have a minimum of six inputs and three outputs to automate
the machine. The 2nd generation DVP-SA2 series slim type PLC (Figure 4.2) will be
suitable for our application since this PLC offers eight inputs and four outputs.
Figure 4.2 PLC DVP SA2
4.2.2- Variable frequency drive

The VFD (Figure 4.3) is a type of motor controller that controls the speed of an
electric motor by varying both frequency and voltage. When the conveyors motor
was tested, we realized that we need to reduce much more the speed without changing
its torque delivery, so a VFD is required to achieve this function. Before using the
VFD the pulleys were turning at 14 rpm (1400 rpm on 1:100 reduction gearbox), the
use of the VFD will let us reduce much more the speed. The PLC will command the
VFD that will in turn supply the motor with the predefined frequency and voltage to
achieve the desired speed.
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Chapter 4
Electrical Design
Figure 4.3 Variable Frequency Drive
4.2.3- Encoder
An encoder (Figure 4.4) is an electronic device that converts information from one
format to another, for the purposes of standardization or speed when coupled to an
electric motor. It will provide closed loop feedback signals by tracking the speed
and rotation direction of a motor shaft. The feedback signals provided by the encoder
are collected by the PLC as inputs. We can track the position of the motor shaft by
inspecting these signals.
In our application the encoder is a must, it will be coupled to the conveyors shaft.
The information given by the encoder will be used to track the stone block on the
conveyors belt and with the signals collected from the proximity sensor we can
measure the length of the stone block in order to stop the conveyor right between the
blades. To obtain the distance traveled by the stone block we need to link the
encoders signals and the motors linear speed. The distance is given by:
= r
(4.1)
Where x is the linear distance traveled by the block and r the radius of the pulley
r = 0.2 m and = 2
x = 1256 mm
The encoder to be used must give a minimum of 1256 pulses/revolution which
means giving 1 pulse every 1 mm traveled by the stone block so we can have a perfect
and accurate information on the position of the stone block.
We have found on the market an encoder delivering 500 pulses/revolution, it has
three outputs:
123-
A
B
Z
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Chapter 4
Electrical Design
Terminals A and B both deliver 500 pulses but 90 degrees out of phase (Figure
4.4), terminal Z gives one pulse per motor revolution. If we merge A and B signals,
the 500 PPR encoder can deliver 2000 PPR (quadrature encoder). So using these two
outputs as inputs to the PLC, we can reach a 2000 PPR > 1256 PPR which is perfect.
Knowing the distance traveled by the stone block, the conveyor can be stopped when
the center of the stone block coincides with the center of the blade.
Figure 4.4 Encoder Outputs
4.2.4- Pressure switch

A pressure switch (Figure 4.5) is a sort of switch that closes an electrical
contact when a certain set pressure has been reached on its input. Squeezing the
stone block between the two blades will increase the oil pressure that will drop
rapidly when the block is split. This pressure fluctuation must be detected by the
pressure switch which will be one of the PLCs inputs.
Figure 4.5 Pressure Switch
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Chapter 4
Electrical Design
4.2.5- Proximity Sensor Photoelectric Sensor BPS Series

A photoelectric sensor (Figure 4.6), is an equipment used to discover the distance,
absence, or presence of an object by using a light transmitter, often infrared, and
a photoelectric receiver. This sensor is fixed 15 cm far from the blade system. Once
it detects the stone block, the PLC will reset the encoder in order to calculate the
stone blocks length. When the stone block passes the sensor, the PLC can calculate
now the distance needed to coincide the center of the stone block with the center of
the lower blade and stop the conveyor.
Figure 4.6 Photoelectric Sensor BPS Series
4.2.6- Power Supply

A power supply (Figure 4.7) is an electronic device that supplies electric energy to
an electrical load. The primary function of a power supply is to convert one form of
electrical energy to another and, as a result, power supplies are sometimes referred
to as electric power converters. The PLC, the encoder, the proximity sensor and
directional valves of the hydraulic unit, need a 24 V DC, so a power supply
converting from 220 V AC to 24 V DC is needed.
Figure 4.7 Power Supply
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Chapter 4
Electrical Design
4.3- Electrical Circuits

After choosing the main electrical components, we can start drawing the circuits and
sizing the components. Table 4.1 shows the electrical components to be used with their
corresponding quantities. Depending on current these components are sized.
The main circuit breaker current is 7.7 A (1.5 A conveyor motor, 5.2 A hydraulic
motor, 1 A power supply): a 20 A circuit breaker will be used.
VFD circuit breaker current 1.5 A: a 6 A circuit breaker will be used.
Power supply circuit breaker current 1 A: a 2 A circuit breaker will be used.
The electrical circuits were drawn on EPLAN electrical schematic design

software (Appendix B)
Electrical Component
Q1: Switch Disconnector
Q2: Motor Thermal Overload Protection
F1: Main Circuit Breaker
F2: VFD Circuit Breaker
F3: Power Supply Circuit Breaker
KA1: Hydraulic Motor Contactor
KA2:KA5 : Relays
KA6: Power Supply Relay
S1, S2
S3
S4, S5
S8, S9
Description
32 A, three pole
[4 - 7] A, three pole
20 A, three pole
6 A, two pole
2 A, one pole
20 A Coil: 220 VAC
24 V
220 V
Up, Down Push Buttons
On/off Switch
Pressure and Proximity
Start, Stop Push buttons
Quantity
1
1
1
1
1
1
4
1
1
1
1
1
Table 4.1 Electrical Components
4.4- Electrical Board

All the electrical controllers, relays, the VFD, the power supply, the contactors and
circuit breakers will be shielded in an electrical board. An electrical board panel is a
cabinet for electrical or electronic equipment to mount switches, knobs and displays and
to prevent electrical shock to equipment users and protect the contents from the
environment.
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Chapter 4
Electrical Design
The electrical components to be fitted inside the board panel as follows:
The components with high voltage usage are at the top.
The components with low voltage usage are at the bottom.
All the cables should pass through a cable tray. The cable tray should be
taken into consideration in sizing the electrical board.
The VFD, as listed in its manual, should be minimum 10 cm away from any
other electrical components for an optimal functionality.
The minimum enclosure height will be 100 mm, based on the VFD height since
it is the biggest electrical component to be fit in the electrical board. The size of the
electrical board panel was chosen after setting all the components on a drawing
(Figure 4.8) that simulates the area of an electric board using AutoCAD.
Figure 4.8 Eletrical Board Sketch
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Chapter 4
Electrical Design
So we need an enclosure having a minimum width of a 550 mm and a minimum

length of 770 mm and a height of 100 mm. The enclosures available on the market have
a width of 600 mm and a length of 800 mm and a height of 225 mm.
The enclosure user interface (Figure 4.9) have three light indicators the green one
indicate that the machine is working, the first red indicator indicate that the conveyor
motor is overheated and the second one that the hydraulic motor is overheated.
Concerning the push buttons, two push buttons for turning the machine on or off, an
auto/manual switch to choose between automatic or manual mode and finally two push
buttons up and down to control the piston. The push buttons that controls the piston are
not functional unless the machine is in manual mode.
Figure 4.9 Enclosures Operator Interface
4.5- Conclusion
The electrical components, the sensors and all the actuators were selected to operate and
control the machine via the programmable logic controller. The clat machine wont
be operational without the execution of the electrical circuits that will let the operator
control the machine with only push buttons. No further effort shall be made by the
worker to perform the clat splitting operation. The next chapter will present the
final sketch of the machine and the execution phase.
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Chapter 5
Final Sketch
Execution/Testing
5 Final Sketch Execution Testing

5.1- Final Sketch
After completing the mechanical design of the machine, the final sketch can now be
revealed (Figures 5.1, 5.2). The detailed drawings and sub-assemblies of all the parts can
be found in appendix A.
Figure 5.1 Final Sketch, drawing 1
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Chapter 5
Final Sketch
Execution/Testing
Figure 5.2 Final Sketch, drawing 2
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Chapter 5
Final Sketch
Execution/Testing
5.2- Execution
Figure 5.3 Photos from the execution process
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Chapter 5
Final Sketch
Execution/Testing
Figure 5.4 Photos of the "clat" machine
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Chapter 5
Final Sketch
Execution/Testing
5.3- Testing
During the execution process, testing is the most important part. Therefore several tests
were made to fulfill the realization of the machine. After the study of the feeder design,
a test was decided to be made. This test consists of loading the feeder and pushing out
the stone blocks using a screwdriver. Several successful tests on stone behavior were
made to make sure that a pin connected to the feeders pulleys can push the stone blocks
out of the feeder without causing any feeding problems (Figure 5.5).
Figure 5.5 Concept Feeder Test
After the successful test on the feeder, the design process of the machine has to
be completed. The conveyor was designed and executed. Once the conveyor and the
conveyors motor and gearbox were assembled, the feeder was again tested (Figure
5.6). The stone blocks were pushed by the pin connected to the feeders pulleys and
the test worked without complications. The stone blocks were successfully pushed
from the feeder onto the two belts but on their way to the blade system, some of the
stone blocks fell down. It was decided to design two fences or rails above the belts
to keep the stone blocks on the belt during the delivering.
Figure 5.6 Feeder Test
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Chapter 5
Final Sketch
Execution/Testing
Once all the mechanical and electrical components were assembled on the machine,
the PLC program should be tested. The PLC program test is the most important one. The
stone, leaving the feeder, passes through the proximity sensor and stops under the blade.
The blade must correspondingly go down until the splitting occurs. For this test the
proximity sensor was glued on two support blocks (Figure 5.7). Ergo, the distance
between these blocks and the blade was measured so that the value is entered in the PLC
program. Ultimately, the machine was ran. Various changes in the program were made
to accomplish all the tasks. The test was done on the machine with a pressure sensor that
can detect pressure up to 50 bars. This pressure sensor is used just for testing, the
electronic pressure sensor that senses pressures up to 130 bars didnt arrive yet from the
U.S.A. The machine will be ready to be operational and efficient when the sensor and
the rail guide of stone blocks will be installed on the machine.
Figure 5.7 PLC program Test
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Conclusion
Conclusion
In this project, we opened out on the making of a small clat with auto feeder,
detailing each step within the design and the execution processes. The clat splitting
operation on the conventional splitting machines, takes time and needs huge effort from
the worker to achieve the work. The new clat machine has to overcome these issues
and the solution was to automate the splitting process.
The desired solution requires building a new machine from scratch. The design tasks
involve the design of an automatic feeding technique and a conveyor system that delivers
stone blocks into the redesigned hydraulic splitters. After studying all the blade systems
used in the conventional hydraulic splitters, the simple blade system was selected and
designed. Another study on the chassis that has to withstand the splitting forces
generated during the split, revealed the design of a solid C-Frame Chassis.
The design of the feeder was challenging, none of the machines on the market offer
a feeding technique that accommodates with stones having different dimensions. Several
tests were made on stone blocks to come up with a slider feeder design that benefits from
the rotation of the conveyors pulleys to push the stone blocks on the conveyor.
Then, the torque needed to perform the push of stone blocks out of the feeder was
calculated and the motor and gearbox were selected accordingly once the mechanical.
Many proposals concerning the chassis of the conveyor were discussed in order to choose
the suitable chassis that will be carried by the C-frame chassis.
Once the mechanical design is ready to be executed, the electrical design takes place.
Since the machine must be fully automated the electrical design is necessary to operate
and control the machine. The electrical circuits and drawings were made after choosing
the convenient electrical components, sensors and the programmable logic controller.
Lastly: the last step is to test the different parts designed in the machine. Testing the
feeder, the PLC program and the stone splitting, made sure that all the mechanical parts
are working as intended. Also, this machine can be enhanced. The feeder can be
connected to the swing cutter that prepares stone work to the clat operation. The
machine can be equipped with a small screen that gives information on the productivity
of the machine.
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References
References
[1]
Granite City Tool Company, St. Cloud, Minnesota,

"http://www.stone.poplarheightsfarm.org/plug___feathers.HTM".
[2]
Natural
Stone
Council,
The
United
Voice
of
the
Stone
Industry,
"http://naturalstonecouncil.org/about-natural-stone/uses-of-natural-stone/".
[3]
"Chisel, n.1" def. 1.a. Oxford English Dictionary Second Edition on CD-ROM (v.
4.0) Oxford University Press 2009".
[4]
STONE project, Edinburgh College of Art, "http://www.stoneproject.org/toolstechniques.html#6".
[5]
Womack
Machine
Supply,
"http://www.womackmachine.com/engineering-
toolbox/formulas-calculations/hydraulic-cylinder-calculations.aspx".
[6]
Machine
design,
"http://machinedesign.com/linear-motion/what-s-difference-
between-pneumatic-hydraulic-and-electrical-actuators".
[7]
Hydraulic Mania, "http://www.hydraulicmania.com/hydraulic_cylinders.htm"
[8]
Autodesk,
Inventor
Products
articles,
"https://knowledge.autodesk.com/support/inventor-products/learnexplore/caas/CloudHelp/cloudhelp/2017/ENU/Inventor-Help/files/GUID5E9762E6-D09B-4136-BF64-AE0F2C4A9B7C-htm.html".
[9]
Machine design, "http://machinedesign.com/motion-control/making-right-shaftconnections".
[10]
Engineers Edge Solutions by Design,

"http://www.engineersedge.com/belt_design/belt_length_pulley_center_dist.htm".
[11]
Engineering Toolbox, "http://www.engineeringtoolbox.com/american-standardsteel-channels-d_1321.html".
[12]
"Hydraulics and Pneumatics a technician's and engineer's guide", p. 38. Elsevier".
[13]
"Facts 101, Fluid Power With Applications, 7th edition, Study guide".
[14]
E. Sabbagh and E. Antonios, "Final Year Project, Automatic Small Eclatee", 2012.
P a g e | 74
Appendix A
Drawings

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2015/2016

FINAL YEAR PROJECT

Small clat With Auto Feeder

Defended on 15 September 2016 in front of the jury:

Dr. HANNA Fady

CHAKHTOURA Anthony | HELOU Mario

CHAKHTOURA Anthony | HELOU Mario

Design Process ........................................................................................................ 8

2.1- Introduction ................................................................................................................ 8

Hydraulic Unit ...................................................................................................... 54

3.1- Introduction .............................................................................................................. 54

Electrical Design ................................................................................................... 58

4.1- Introduction .............................................................................................................. 58

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Final Sketch Execution Testing ...................................................................... 67

5.1- Final Sketch .............................................................................................................. 67

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Figure 2.28 V-Belt Configuration ................................................................................. 27

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Figure 3.3 Hydraulic Unit on Chassis ........................................................................... 57

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1.2- Splitting techniques Blade system

Figure 1.1 Plug and Feather

Figure 1.2 Chisels

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Figure 1.3 Semi-Automatic Simple Blade

Figure 1.4 Manual Simple Blade

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Figure 1.5 Hydraulic Multi Blade System

Figure 1.6 Mechanical Multi-Blade System

In 1999, a group of students from the mechanical engineering department- Lebanese

Figure 1.7 Semi-Automatic "clat" Machine

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1.3- Stone block feeding Conveying

Figure 1.8 Small Stone Block Feeder

1.4- Stone block centering

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Figure 1.9 C-Frame Chassis

Figure 1.10 H-Frame Chassis

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Table 2.1 Calculated Splitting Force (Kg)

Table 2.2 Experimental Splitting Force (Tons)

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2.3- Hydraulic Cylinder

Figure 2.1 Pneumatic and Hydraulic Actuators

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Figure 2.2 Electrical Actuator

2.3.3- Hydraulic actuator

Relying on the statements listed previously, a hydraulic actuator will be used to

Figure 2.3 Hydraulic Cylinder

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2.3.4- Hydraulic cylinder specifications

Bore diameter: it is the diameter of the cylinder bore.

Maximum operating pressure: it is the maximum working pressure that a

Stroke: it is the distance traveled by a piston in a hydraulic cylinder.

= 12.73 MPa = 127.3 Bars ~ 130 Bars

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