MAGENATIC BELT CONVEYER DESIGN

Chapter one

1.0 Background

1.1Introduction

Material handling is defined as the transportation or movement of raw materials semi-

finished products and finished products and finished articles of product through various
parts of production and housing is called as material handling in the history of material
handling it is not a concept rather than it is part of normal activity of formal work. Mostly
The people use some animals for transportation purpose like donkey, mule, and camels.etc.
but in the medieval period of time the people are faced to complicated way of transportation
of material. By this reason, they invent wheels, lorry, and makes material handling way of
transportation easier and easier. The recent time of material handling equipment history a lot
of material handling equipment were invented and improved the older models those which
is manual and automatics systems in order to save time and labor
In our project design magnetic belt conveyer is selected due to the problem that we seen
in industrial visit at Ethiopian crown cork and can manufacturing share company.

Fig 1 painting machine

1
 MAGENATIC BELT CONVEYER DESIGN
1.2 problem identification

We visited the company which is called Ethiopian crown cork and can manufacturing share
company to observe all activities that are being performed in the company concerning to material
handling. The problems are listed below as follow.

There are lack of safety and the way of handling the materials.
No modern conveyors to transport the cork and can, some of the machine stop working.
The working environment is not suitable for workers
The workers have no interest of their work
There is lack of supply raw materials for can and cork.

1.3 problem statement

As we seen in the company there is a lot of problems in material handling equipment mostly
they use labor force to carry all loads but they have two fork lift, one head crane and hand wheel
but they are not recent machines as a general in the company all machine are older and some of
them are stop working due to problem to maintain them. In this company, there is no modern
conveyer to transport the cork and can from machine to machine but they have an inclined
manual conveyer can and cork are used in the inclined surface of the conveyer. Therefore, in
order to solve this problem, we are interested to design magnetic conveyer and chain conveyer
that use electrical power and automatic system of control.

1.4 Objective
The main objective of this project is by visiting industries and observing how material
handling equipment is used in the factory. And based on the industrial visit identifying
problems concerning material handling equipment in the factory and lastly design the
problem solver material handling machines regarding the problem observed.

1.5 Methodologies

2
 MAGENATIC BELT CONVEYER DESIGN
The methodologies way of our project design information gathering about the problem,
types of material handling equipment that exist in Ethiopian crown cork and can
manufacturing share company are; -
. Observation
. Interview

1.6 scope of project

The scope of our project is as much as possible we are trying to observe problem of the
company and design a material handling equipment that can solve problem occurred in the
factory.

2. Literature review

2.1 Introductions to material handling equipment

A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor). A belt conveyor system is one of many types of conveyor systems. A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums), with an endless loop of
carrying mediumthe conveyor beltthat rotates about them. One or both of the pulleys are
powered, moving the belt and the material on the belt forward. The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley. There are two main industrial
classes of belt conveyors; Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials, such as grain, salt, coal, ore, sand, overburden and more.

Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials. The belt consists of one or more layers
of material. Many belts in general material handling have two layers. An under layer of material
to provide linear strength and shape called a carcass and an over layer called the cover. The
carcass is often a woven fabric having a warp & weft. The most common carcass materials are
polyester, nylon and cotton. The cover is often various rubber or plastic compounds specified by
use of the belt. Covers can be made from more exotic materials for unusual applications such as
silicone for heat or gum rubber when traction is essential. A conveyor belt can be a slide and be
controlled by the force of gravity. Material flowing over the belt may be weighed in transit using

3
 MAGENATIC BELT CONVEYER DESIGN
a belt weight. Belts with regularly spaced partitions, known as elevator belts, are used for
transporting loose materials up steep inclines. Belt Conveyors are used in self-unloading bulk
freighters and in live bottom trucks. Belt conveyor technology is also used in conveyor transport
such as moving sidewalks or escalators, as well as on many manufacturing assembly lines. Stores
often have conveyor belts at the check-out counter to move shopping items. Ski areas also use
conveyor belts to transport skiers up the hill. (https://en.wikipedia.org/wiki/Conveyor_belt)

2.2 History of belt conveyor

Primitive conveyor belts were used since the 19th century. In 1892, Thomas Robins began a
series of inventions which led to the development of a conveyor belt used for carrying coal, ores
and other products. In 1901, Sandvik invented and started the production of steel conveyor belts.
In 1905 Richard Sutcliffe invented the first conveyor belts for use in coal mines which
revolutionized the mining industry. In 1913, Henry Ford introduced conveyor-belt assembly lines
at Ford Motor Company's Highland Park, Michigan factory. In 1972, the French society REI
created in New Caledonia the then longest straight-belt conveyor in the world; at a length of 13.8
km. Hyacynthe Marcel Bocchetti was the concept designer. In 1957, the B. F. Goodrich
Company patented a conveyor belt that it went on to produce as the Turnover Conveyor Belt
System. Incorporating a half-twist, it had the advantage over conventional belts of a longer life
because it could expose all of its surface area to wear and tear. Mbius strip belts are no longer
manufactured because untwisted modern belts can be made more durable by constructing them
from several layers of different materials. In 1970, Intralox, a Louisiana-based company,
registered the first patent for all plastic, modular belting.
(https://en.wikipedia.org/wiki/Conveyor_belt)

2.3Belt conveyor systems

Conveyors are durable and reliable components used in automated distribution and warehousing.
In combination with computer controlled pallet handling equipment this allows for more efficient
retail, wholesale, and manufacturing distribution. It is considered a labor-saving system that

4
 MAGENATIC BELT CONVEYER DESIGN
allows large volumes to move rapidly through a process, allowing companies to ship or receive
higher volumes with smaller storage space and with less labor expense. Rubber conveyor belts
are commonly used to convey items with irregular bottom surfaces, small items that would fall in
between rollers (e.g. a sushi conveyor bar), or bags of product that would sag between rollers.
Belt conveyors are generally fairly similar in construction consisting of a metal frame with
rollers at either end of a flat metal bed. The belt is looped around each of the rollers and when
one of the rollers is powered (by an electrical motor) the belting slides across the solid metal
frame bed, moving the product. In heavy use applications the beds which the belting is pulled
over are replaced with rollers. The rollers allow weight to be conveyed as they reduce the amount
of friction generated from the heavier loading on the belting.

Belt conveyors can now be manufactured with curved sections which use tapered rollers and
curved belting to convey products around a corner. These conveyor systems are commonly used
in postal sorting offices and airport baggage handling systems. A sandwich belt conveyor uses
two conveyor belts, face-to-face, to firmly contain the item being carried, making steep incline
and even vertical-lift runs achievable. Belt conveyors are the most commonly used powered
conveyors because they are the most versatile and the least expensive. Product is conveyed
directly on the belt so both regular and irregular shaped objects, large or small, light and heavy,
can be transported successfully. These conveyors should use only the highest quality premium
belting products, which reduces belt stretch and results in less maintenance for tension
adjustments. Belt conveyors can be used to transport product in a straight line or through changes
in elevation or direction. In certain applications, they can also be used for static accumulation or
cartons. (https://en.wikipedia.org/wiki/Conveyor_belt)

2.4Manufacturers and service providers of belt conveyor

The major global conveyor belt manufacturers and service providers are Fenner plc, Kale
Conveyor, Terra Nova Technologies, ThyssenKrupp, HESE Maschinenfabrik GmbH and Tenova
Takraf. (https://en.wikipedia.org/wiki/Conveyor_belt

5
 MAGENATIC BELT CONVEYER DESIGN
2.5 Ethiopian manufacturers that use belt conveyors

They are CGF Crown Cork and Aluminum Cap Manufacturing Factory, Peniel Industry Plc.,
Daylight Applied Technologies Plc and Metal crown.addisbiz.com/ethiopian-business

Fig 2 working environment

Chapter 3

3.1 Company profile

3.2 Establishment and Development of the Company

6
 MAGENATIC BELT CONVEYER DESIGN
Ethiopian crown cork and can manufacturing Share Company is a decade old company and it is
planted at 1964. Even though this company was the first country to manufacture cork, it has not
become a successful company. This is due to lack of not recent machines and some of them are
stop working due to problem of maintenance. Even In this company there is no modern
conveyer to transport the cork and can from machine. But they have an inclined manual conveyer
that is used in the inclined surface of the conveyer for can and cork. Ethiopian crown cork and
can manufacturing Share Company is a mid-sized organization in the metal can companies
industry located in Addis Ababa, Ethiopia. it has approximately 180 full-time employees and
generates an estimated $80 million in annual revenue. It has launched its 1.8-millionBr crown
cork manufacturing plant in kality on September 13, 1964 by the government. It manufactures
bottle cork and cans. It was the first company launched in Ethiopia since 1964, which was landed
on 600sqm area. Once the customers were St. George beverage factory, Harer beverage factory,
Bedele beverage factory, Moha soft drinks beverage factory.

The company which was started operations, had a capacity of 100 thousand crown corks per
year, with production, it was expected to grow its capacity with the installation of more
machinery over the past decades. But due to financial crisis and inability to service, repair, the
company is now undergoing failure and insolvency.

3.3 Organizational Structure of the Company

In order to perform a best result at the end of the annual budget, the factory have prepared an
internal structure in which the job division is carried among the workers. This helps for easy
management of the workers in their position of work.

Board guidance

Audit service
7
Manager General
Human resource
Workersand
safety and General ProductTechnic
technical General
Marketing Salesadministration
property
administration guidance
General service
health service Finance
accountant guidance
Plan
classservice and guidance
Product information
sales class of property
administration
 MAGENATIC BELT CONVEYER DESIGN

Quality assurance

3.4 Main Products/Service of the Company

The main products of the company were crown corks and cans. But now due to old worn out
machines, they are now only producing cans.

3.5 Manufacturing Process

The main raw materials used for the production of caps is metal (steel and Aluminum) that is
used in the shape of sheets that are varnished, lithographed and then converted into caps and
capsules.

The manufacturing of crown cork has the following processes:

The tinned sheet metal is cut into sizes to fit the table of the punching, blanking press;
The sheared section of the sheet is fed into the offset printer to be covered with the
necessary design;
The printed sheet is fed into the blanking press to punch out the discs;
The punched-out discs are fed into the forming machine press to acquire its final shape;

8
 MAGENATIC BELT CONVEYER DESIGN
The interior of the crown cork is pasted with the adhesives for attaching the plastic
interior cover;

The manufacturing of can procedures: -

(1) Raw Material Coil

(2) Cutting into sheets

(3) Lacquer

(4) Heating

(5) Slitting to smaller sheets

(6) Rolling

(7) Welding

(8) Spraying & Curing

(9) Flanging

(10) Seaming

(11) Sidewall beading

(12) Testing

(13) Packaging

3.6 production process

9
 MAGENATIC BELT CONVEYER DESIGN
3.6.1 Production process of can;.

Production process of can in the company starts from the raw material of sheet metals that are
imported to the country mostly from Italy, Germany at the size of four by four sizes which is
suitable for production process. After reaching to the company this sheet metal is transported to
machine by using fork lift machine and then the operators put single sheet to the Newcan press
machine having of standard die and a load presses 70 tons hydraulic press system when the
operator press the pedal, the new can press machine applies a 70-ton load on the sheet and cutoff
the bottom parts of the can. and then the next process is liming compound which is done by
liming machine in which the machine has heat to attach the rubber to the cutoff part of can in
order to protect the can from leakage then forging process will continues and after liming process
the last finishing process of can is done by the worker and packed to the customer.

3.6.2 Production process of cork

In the 1st stage of cork production process, painting process on the sheet metal is done. In
ultraviolet ray room under dark working condition. In this ultra violet- ray machine operation,
process imprinting of the company product symbol on the sheet, the operator put out the finished
product symbol on the sheet. Then the output product of the stage pass to the roller and coloring
process will continue. Under this process large size rollers are applied in order to make the sheet
shinier and beautiful .the operator control the operation process by using different switch in order
to add or reduce amount of color entering to the printing valves.

After this process is done, the printed sheet metal is enter to the die machine through belt
conveyer in order to finish corking size by the process of blanking and by using some dies .the
end size of cork taken out, then the cork is transported by using lorry added to store. Then the
end process is adding of plastic inside of the cork in order to remove the connection between the
cork metal parts with soft drink.

3.7 material handling activities

10
 MAGENATIC BELT CONVEYER DESIGN
Material handling activity during production process is mostly done manually by using different
techniques. They use man power to carry sheet metal from the store the new can press machine
by using traditional system such as lorry and also the operator carrying some amount of sheet
from the store. It is one of time taking process, it have a great effect on the production rate and
loss of power of the operator

But some time they use fork lift machine in order to transport the bottom side of can to the
liming machine for the safety of the metal because the share company is the oldest in Ethiopian
industry all machine and instrument are older most of them are not working due to maintenance
problems and accessory to the older machines.

3.8 working environment

Working environment of the company is good regarding to the size of the house. because it is
more than enough for the operation process under very Hugh machine but they have a problem
of color indication in the working environment the color which is used to indicate the danger
place during machining operation time. Due to the duration, the color is removed from the
ground which it is not visible to other visitor and new workers.

They have good raw material store and finished goods of the company. And they have at the
outside area waste product are collected and packed to akaki kality metal industry and for other
metal industry as a raw material. The working environment of the share company is placed in
center for any customer for transportation purpose.

3.9 problems related to material handling activity

In our industrial visit to Ethiopian cork and can share company we visit problem related to
material handling activity in regarding to time wastage, loss of power of the operator. Most of the
material handling activity taken by manual system by the operator and worker in company.
Transportation of raw material for production process of can is carried out by the operator
therefore there is time lost and it has great effect on production time rate.

3.10 Bench Marking

11
 MAGENATIC BELT CONVEYER DESIGN
We suggest that the machines have to be get maintenance and service; the working environment
should be visible and clear. Since the machine in your company are not recent and due to this
your will not produce enough amount of product per day for the customer, in order to solve this
problem your company must change with the latest and modern machine.

3.7 Geographic Location

House No 1510 Woreda 27,

Kebele 11

Addis Ababa

Ethiopia

Chapter 4

12
 MAGENATIC BELT CONVEYER DESIGN
MAGENATIC BELT CONVEYER DESIGN CALCULATION

It provides excellent value for transportation of small ferrous metal chips and cork stoppers. It
totally enclosed system.

Magnetic belt conveyer design calculation

1. Material to be handle is cork stopper

2. Capacity of surge rate expressed in kg of cork stopper is 2.5kg

In order to determine capacity of belt of the conveyer

3. Path of travel in vertical motion of belts in order to puts the cork stopper in the reservoir of the
machine.

4. Feeding and discharging conditions

The feeding and discharging conditions of the belt conveyer is belt energy source is motor and
discharging methods is using pulley

5. Operating conditions at room temperature

Fig 1; magnetic belt conveyer

Standard for the design calculation

13
 MAGENATIC BELT CONVEYER DESIGN
N=300rpm

Belt width B=150mm

Driver pulley D1=200mm, N1=300rpm

Driven pulley D2=350mm

Belt speed

D1N 1 0.2300
v= = =3.14 m/s
60 60

Belt length

(( D 2D1 )2 )
L= ( D1 + D2 ) +2 x +
2 4x

Where x is the distance b/n the center of two pulley and determined by tilt angle of the belt
0
=6

r 1+ r 2 0.275
x= = =2.6 m
sin sin 6

0.152
L= 0.55+5.2+ =6.06 m
2 10.4

If the material conveyed in a unit load Q in ton per hour

Q=3.6qBV

Where q distributed load in kg/m2

V velocity of the belt in m/s

B belt width in m

Total load on the belt=2.5kg

2.5 2
q= =5.4957 kg /m
0.459

14
 MAGENATIC BELT CONVEYER DESIGN
62.12 kg
Q=3.65.49570.153.14= =22.369 ton /hr
s

0
The magnetic belt conveyor has an inclination angle =6 then the capacity Q will be
reduced by a factor P

Which p=0.98 from standard table then

Qs=P*Q=0.98*22.369 ton/hr=21.92 ton/hr

Cross sectional area of the material on the flat belt

( B+ 4 )B2 4.15 2 4 2
Af = = 0.15 =8.4810 m
110 110

Cross sectional area of the material on the troughed belt

Ac= 2Af = 2*8.48*10-4 =1.69*10-3m2

We select roller with ball bearing having of f=0.05

Resistance force

r 1=fqsl

qs from the value 2.5kg/3.03m=0.825kg/m

r 1=0.050.8252.6=0.1 N

Friction for due to material transported

r 2=fqml m=0.050.8253.03=0.124 N

Force required overcoming the level of difference

r 3=qmH=0.8252.6=2.145 N where qm=0.825kg/m

H=elevation difference=2.6m for vertical magnetic belt conveyor

Total resistance to motion R

R=r 1+r 2+r 3=0.1+0.124+ 2.145=2.369 N

15
 MAGENATIC BELT CONVEYER DESIGN
Belt tension calculation

Belt design and its consideration

In order to design the belt of the conveyer the material of the belt must be strong, flexible and
durable. Its must full fill high coefficient of friction in our design belts we select leather belts
due to having behavior of good contact between belt and pulley and places the greatest tensile
strength of the section on the outside

Width of the belt B=150mm

Thickness t=5mm

Stress on tight side =2 MPa

kg
=980
Density m
3

0
Wrap angle =22 =0.384rad

Coefficient of friction =0.38

T1
Maximum tension in the tight side of the belt

T 1 =A=21067.5103=1500 N Where

A=Bt=0.150.005=7.5104 m 2

Mass of the belt per meter length m

16
 MAGENATIC BELT CONVEYER DESIGN
7.51041980 kg
m= Al= =0.735 kg /m
m3

T2
Tension in the slack side

T 1
=e
T2

T1 1500 N
T2=
= =1297.5 N
e e0.145

Motor power

The power required at the driving pulley just for driving the belts is given by

Effective tension Te=T1-T2 =1500-1297.5=202.5N

T ev 202.53.14
Pd = = =635.8 W
1000 1000

Selection of idler

Depending on the type of belt conveyor, maximum belt speed and type of material to be
conveyed

Type of belt conveyor..magnetic

Maximum belt speed..V=3.14m/s

Material to be conveyed..cork stopper

We can select idler diameter d= 60mm

Design summary for pulley and belts

Diameter of driven pulley =350mm

17
 MAGENATIC BELT CONVEYER DESIGN
Diameter of driver pulley=200mm

Width of both pulley=150mm

Length of belt=6.06m

Thickness of belt=5mm

Belt width=150mm

Magnetic behavior

To give magnetic behavior for the belt conveyer by applying magnetic rod in between the gap of
vertical belts in order to control the cork escaping out from the leather belt, then at the end air
blowing system is used in order to remove the cork from the leather magnetic belt that ll be
collected to the machine reservoir .

Selected magnetic rod length 300mm

We select flat shape of magnetic rod in order to match with150mm width of the leather belts.

Additional way of giving magnetic behavior by the system of electromagnet

Magnetic field are produced when all electrons in a metal object are spinning in the same
direction either as a natural phenomena, in artificially created magnet or when they are induced
to do so by an electromagnetic field.

We develop the simple electromagnet by the following steps

1. Get magnet supplies. To make an electromagnet an electric current is run through a piece of
metal. Which create a magnetic field.
2. Strip insulation from the ends of the wire in order for the wire to effectively conduct
electricity its ends must be stripped of their protective insulation. The stripped ends will be
wrapped around the two ends of the motors.
3. Set up your supplies in small bowl made of plastic or wood.
4. Wrap the large rod metal.
5. Connect the wire ends to the motor.
6. Attach the mechanical switch use a regular mechanical switch to make this electro magnet.
7. As we ON the switch the belt will have a magnetic property, OFF the switch it lost magnetic
property.

CHAPTER FIVE
Conclusion and recommendation

18
 MAGENATIC BELT CONVEYER DESIGN
Conclusion

We have concluded that, in order to design the magnetic belt conveyer, the material of the belt
must be strong, flexible and durable. The selected material leather belt must have a behavior
of excellent contact between belt and pulley and also ought to have the greatest tensile strength
of the section on the outside. In designing the belt conveyor, we have to consider the width of the
bet, thickness of the belt, the stress on the tight side and slack side, wrap angle, coefficient of
friction, driver pulley diameter, speed of the belt, belt length. We have also known that to give
magnetic behavior for the belt conveyer, applying magnetic rod in between the gap of vertical
belts control the cork from escaping out of the leather belt, then at the end air blowing system is
used to remove the cork from the leather magnetic belt which that can be collected to the
machine reservoir .

Recommendation

We recommend that the company should provide and teach safety handling of material
equipment. The working environment for the workers should be suitable. The machines have to
be get maintenance and service; the working environment should be visible and clear. Since the
machine in your company are not recent and due to this your will not produce enough amount of
product per day for the customer, in order to solve this problem your company must change with
the latest and modern machine.

19
MAGENATIC BELT CONVEYER DESIGN

20