ENGINEERING DESIGN

Cover Page

Engineering Design

TABLE OF CONTENTS

Cover Page 1

TABLE OF CONTENTS 2

A8120 Conveyor Series System 3

Introduction 3 1.0.

Report Analysis 3 2.0.

Task 1-The Requirements to be used in PDS 3 2.1.

Discussion 8 3.0.

Task 2- Major Design Parameters 8 3.1.

Task 3-Comprehensive PDS 9 3.2.

General comprehensiveness of A8120 9 3.2.1.

Comprehensive A8120 PDS 11 3.2.2.

Task 4: PDS Meets Original Customer Requirements and are in Accordance with the BS7373 12 3.3.

Conclusion 14 4.0.

References 15 5.0.

A8120 Conveyor Series System

  1. Introduction

The A8120 series belt conveyors are considered a heavy duty conveyor that have the capability to deal with a number of applications in different industries based on its robustness. The A8120 are manufactured through the usage of the extruded aluminium steel with skid beds and 113dia drive drums. The materials are of higher quality based on the resistance to corrosion, abrasion among others such as how easily they are maintained. The tension ends are seen housing the idler rollers and the drives, which can be removed easily for routine maintenance or changes simply. The belts have an ad-track that improves the lifecycle of the conveyor. Thus, it makes it safer for operations. It is perceived as the best for superior conveyor series and the mechanized assembly lines, such as the company in London, where the system has just been installed. The A8120 versatility and robustness brands the system as a perfect choice for applications that have lengthy downtimes. The A8120 conveyor belt systems can be manufactured with bespoke frames, which will be used for adjusting the height. Other elastic components included castors, flexible/fixed side guides, stop ends and other control options.

  1. Report Analysis

    1. Task 1-The Requirements to be used in PDS

The product design requirements are provided during the initial stage of designing a system. The requirements are beneficial in documenting and tracking the necessary information that defines the development of a system. The PDS requirements should all be met in that development of a product, for successful usage in industrial applications. The main important requirements that the product should meet include:

Target: The target of the product is the production line through packaging and dispatching at the end of the production line. The conveyor belt installed is flexible since it will be used in the horizontal transportation of materials, while packaging and dispatching them. The transport units perceived in the conveyor cover the entire unit. The nominal width of the conveyor as requested by the customer includes 120mm high, heavy duty aluminium belt conveyor. Available with a 113mmdiameter motorized drive drum either end mounted or underslung. It reflects the standard measurements from 280mm to 1230mm in 50mm increments. It also has 113mm, 80mm and 38mm diameter terminal rollers as standard. Therefore, the component size is 200mm long x 50mm high x 125mm wide. These sizes are effective in meeting the responsibilities of the conveyor in the company through the packaging and dispatching functions. The bespoke frames will also be installed. They will help through adjusting the length which is dependent on the weight of the materials loaded on the conveyor. The terminal rollers will be beneficial since they will help avoid a collision when some materials on the conveyor experience a jamming. The roller is powered by the belt.

Customer Needs: The main need the customer requested is the installation of the A8120 conveyor belt system to be used at the end of the production line through packaging and dispatching. The conveyor had to provide safe transportations of the materials and unloading during the dispatch part. More importantly, the system should meet the anticipated size and weight, speed, life cycle of the product and other power requirements. Presented below, presented how all these requirements of the customer have been met including the color of the product.

Performance: The conveyor belt system was developed for a company in London that would focus on packaging and dispatch throughout the end of the production line. Thus, the performance demanded by the customer will be considered. For instance, the customer presents that the A8120 will be used automatically in the products end line. Thus, the customer (London Company) needs the conveyor to have a very high speed. The A8120 conveyor system installed has a variable speed control that helps the company to reduce the operating and production costs that are reliant on the process of moving materials efficiently. The conveyor will help the business benefit highly since the belt will continuously run at a fair speed despite the bulk the conveyor carries. The conveyor uses electrical actuators, which ensure that it can operate at a zero pressure conveyor accumulation. The drive powers the actuators.

Operating Environment: the requirements that should be met including defining the operating temperature of the product. For instance, the aluminium extrusion material used in the A8120 conveyor belt system can withstand temperatures of 1,200 F and 600 C, which is why the Polyurethane/PVC materials are used. Materials such as polyester when used for the aluminium extrusion can only withstand temperatures of 300 F and 150 C. Thus, the product will work efficiently in high temperatures, as well as low temperatures. The materials used are effective for the company since they support packaging and dispatching loads from one position to another. The main important factor is that the conveyor belt and drive are major parameters in ensuring the packaging and dispatching of these loads through the logistics are met. The A8120 installed for the company has steel skid beds that help the belt withstand shock loadings. The skid beds mainly protect the conveyor belt improving its life cycle while supporting the conveyor belt width. The maintenance of the idler is them eliminated since the replacing of idler frames and shafts does not occur frequently.

The conveyor belt has two main pullers identified as the drive pulley and the idler. The drive pulley is powered as the belt moves the material forward. The industry/ customer will benefit from using the installed belt conveyor since it will help move loads for long distances at a cost effective price. The height of the belt can be changed, and with the added trippers it will be capable of unloading materials at different positions. The A8120 belt conveyor installed has a high tensile strength, and resistance to scratch, gouging and cutting. More importantly, the product is anti-corrosive, they resist wear and tear and have a robust construction process.

Reliability: The reliability of the A8120 conveyor belt system is related to the modular automation of the product, which makes it effective and suitable for different industries. Thus, the flexibility of the product is a key factor that ensures it can be relied upon in the company for effective packaging and dispatching. The conveyor’s flexibility makes it more effective for the company’s production line environment. More importantly, the A8120 can operate around bends that occur either horizontally or vertically. Therefore, the product can be relied upon in the company to accomplish its roles.

Safety Requirements: When dealing with the A8120 or any other conveyor belt system, potential hazards exist. For instance, the employees should have training when shoveling and cleaning around the conveyor. That is; when one is shoveling or cleaning around a conveyor that is poorly guarded or not guarded at all, there is the possibility that the individual may get harmed.

Safety can also be ensured through training the employees through maintaining and lubricating the conveyor. That is; the employees should be taught on how to operate the pulleys when removing materials or loading materials. More importantly, the conveyors should not be overloaded (Hulman, n.d., 2).

When checking the conveyor, hazards may also occur. The individuals should learn to check the conveyors such as ensuring the stalled conveyor belt is not blocked since it can store potential energy. They should learn to check the falling materials and other issues that help avoid hazards including possible electrocution challenges. Hazards may occur when dealing with components such as the drive belt, the pulley, and the shafts. Thus, all elements must be evaluated as expected.

Ergonomic Requirements: The most desirable features of the conveyor belt A8120 include the guards. The guards protect the employees by sealing all moving parts that may critically harm the employees working the conveyor or around the conveyor.

Maintenance: The maintenance of a product is also a key factor in ensuring its success in an industry or facility. In this case, the A8120 series belt can be maintained and serviced easily. That is; assembling of its components is easy, maintaining and requires fewer replacements within the life cycle of a conveyor belt. Additionally, like other machinery in different industries, the product has to undergo check-ups frequently. The check-ups are also perceived as inspection or servicing a product, which increases its lifecycle. The servicing occurs as a process of identifying areas or components that need repairing worn out or torn belt and replacing guards among others. The resilience of the A8120 conveyor belt series leads to a low maintenance cost, which also brands it as the most suitable product and design for the company. More importantly, routine check-ups can be done by the company authorized individuals who will help to maintain the product. Consequently, the costs will be low when professional maintenance is needed. Additionally, the components used for the development can be purchased, but the A8120 systems have a high quality in the market.

Material: The A8120 conveyor belt system has a high strength and durability, which is why it is used in the many industries. It can withstand both high and low temperatures. More importantly, the materials can take on any weight of the loads without tearing or wearing out easily. The A8120 meets the demand of materials that have the capacity of displacing heavy loads. The use of Polyurethane helps in dissipating electrical charges that may be experienced.

Recycle/Disposal: A8120 aluminium conveyor is made through the application of components that are heavy duty. Thus, when parts of the conveyor are not usable anymore, they can be used to process steel and other electronic wastes. The materials of the A8120 will lead to the development of plants such as the discharge conveyors, showing the successful recycling of its components to uses plants or systems.

Manufacturing: During the construction of the A8120 conveyor belt series, it does not need environmental protection since it does not pollute the environment. The customer requested for the provided color and other preferences such as the materials used, and dimensions of the components. The materials used are environmentally friendly.

  1. Discussion

    1. Task 2- Major Design Parameters

The main design parameters of the A8120 conveyor belt include:

Consumer needs: The consumer presented requirements regarding size, color, materials and the roles that the conveyor should meet. In developing the product all these factors were considered and met during the final product construction.

Aluminium conveyor: it is the main product. It is assembled easily, and the tensile strength of the product brands it an excellent material for the company. The material has low weight, which brands it an effective product due to low transportation costs also related to the low environmental factors of transporting the product.

Belt: The parameters of the belt are important since they represent the angle of fiction that the conveyor can undertake. The A8120 has the capacity to carry numerous loads irrespective of weight, and maintenance of the conveyor. Thus, the important belt parameters to include are the speed of the belt, width, power and the drive pulley shaft (Ananth, et al., 2013, 43).

Materials: The material used for the construction should be of high quality and strength. A8120 uses aluminium materials, which are considered to have high strength, tensile strength, and ductility, which allows it to support heavy loads and tensions. More importantly, the guards used to cover the rotating parts of the conveyor are heat resistance among other characteristics that help protect the carcass leading to an increase in the life cycle of the conveyor.

Size: The sizes used in the production of the conveyor are the standard dimensions that are acceptable for different kinds of industry. The company in London will benefit through this dimension and the construction of the product since it is flexible and allows changes. For instance, the bespoke frames allow height adjustments to meet the current need at hand while considering the weight of the load. The size of the conveyor is 200mm long x 50mm high x 125mm wide (Advance, 2017).

    1. Task 3-Comprehensive PDS

      1. General comprehensiveness of A8120

The development of products through BS7373 PDS is important since it influences the success of the product in the market (Syan & Menon, 2012, 110). The comprehensiveness of the PDS is a key factor in ensuring the success of the product, as will be presented below.

The belt of the product is perceived as a major parameter. The belt success is influenced by a number of factors such as speed. Thus, the main factors one ought to consider is generally the capacity of the belt so it can handle the maximum load available. The comprehensive PDS of the belt may start with the width of the belt. The standard widths begin from 280mm to 1230mm in 50mm increments. The customer requested the standard belt widths be used since they are influenced by the loading unit requirements. The speed of the belt as described earlier is variable, which is important to control the discharge, transfers, and loading of the conveyor among other factors (Fenner Dunlop, 2009, 2-2). The capacity of belts should be calculated using the formula below.

Capacity – the tonnes loader per hour =

3.6 * the cross section load area (m2) * speed of the belt (m/s) * the density of the material been loaded (kg/m3).

The diameters of the terminal rollers used as standard measurements include 113mm, 80mm and 38mm diameter. The terminal friction should be expressed in terms of metres, which are measured from the centre. These include measuring the elevating conveyor heights among others.

The idler spacing is also a key factor that should be comprehensively evaluated since it influences the success of the product. The graduated idler spacings are important when the conveyor experiences tension or is loaded heavily (Reicks & Myers, 2004, 98). Thus, tension is dependent on the belt length among others. The A8120 shows that when it is used in the production line returns can be transferred for dispatch and packaging effectively.

Idler spacing should be attained through the formula below

Idler spacing = 8 * T * sag / Mϧ * (9.81 * 10-3)

Mϧ = the belt mass or live load (kg/m)

Live load = C / 3.6 s

C = Capacity of the belt (t/h)

S = speed of the belt (m/s)

T = point of tension (kN)

Sag = Idler percent spacing provided in decimal points (Fenner Dunlop, 2009).

The A8120 conveyors will be powered by the stainless drive drums installed, though occasionally, the shaft motors can be used. The belt width will be met to meet the conveyors lengths. The construction of the product will consider all these factors since accurate measurements are important to meet the role of the product. Other comprehensive requirements include:

Target market: The product focuses on packaging and dispatching in the end of company’s production line. Thus, the A8120 is considered the ideal conveyor for production lines that need large, strong and reliable conveyors. It can withstand high loads, different temperatures and can accommodate changes to suit the customers’ needs as they change. As a result, it meets the function it was installed to meet through success in transporting loads from the different units in the company.

      1. Comprehensive A8120 PDS

Cost: The cost is high, more than $200

Quantity: 1 conveyor will be installed (was installed)

Maintenance: Minimal

Materials: Heavy loads, transportable and cannot be damaged easily

Aesthetics: strong and highly reliable

Shelf life: 10 years without high costs of maintenance

Customer: London Company

Specification: Provided in task four

Safety: safety measures such as guards are provided among other standards to help meet the safety measures.

    1. Task 4: PDS Meets Original Customer Requirements and are in Accordance with the BS7373

Target: It is a version of A8120 series conveyor systems. It is the best suitable product for large industries since it conveys tranquillity in packaging and dispatching processes in the production line. The production costs, when compared among other existing conveyors, is slightly high, which can be attributed to the quality of materials and components used in the construction of the A8120 (BS 7373, 1991).

Function: the product meets its main function in the product line. It is effective for large companies dealing with heavy loads mainly since it can withstand tension and shock loads. Thus, it is the most suitable product for the set functions in the company.

Material: The A8120 series conveyor belts are considered the most durable due to the tensile strength, versatility and duct-ability. Thus, the materials used meet the needs and specifications according to the regulating bodies since they are reliable and will increase efficiency in the company.

Inspection: It includes the visual inspection of the product and its auditory inspection through reviewing how the product operates in different environments. The inspection of the product at the company will be liable to inspections when operational and when it is not operating. If inspections should occur when the conveyor is operational, the inspector should and will remain at a safe zone since the guard measures of the product are operational (bs 7373, 2001). The inspection will find that the conveyor does not clog or jam. More importantly, the inspection also proves that the employees have received sufficient training in operating the conveyor. For instance, the authorized employees should know how to safely interrupt operations of the conveyor, start the conveyor, shut it down normally, and on using emergency shutdown devices. How to load the conveyor properly and how to restart it safely after an emergency power cut.

Safety: This is met through the training the employees in the company are undergoing to have the relevant information to operate the conveyor belt. The information includes operating around/ near the belt among other factors that must be met (bs 7373, 2001). Any stored energy is dissipated, and locks among other tags are used during any hazards or as normal procedures for shutting down. The provided training ensures the employees understand that despite the elimination of electrical energy, when the tension of a belt is removed it would lead to the conveyor movements that may be harmful to the employee. The training will ensure the moving parts of the conveyor system are guarded properly as presented in the BS 7373, (1991).

More importantly, the materials used for the products development, maintenance or replacement should be evaluated thoroughly for any potential hazards. The regulations and other standards as provided by the BS 7373 (1991) and others should be followed for the equipment’s replacements and usages in the design of such products.

Test: The products operations should undergo several tests the manufacture of the product to ensure it meets all needs of the customer, the legal and other safety needs as expected. The first test done is ensuring that all rotating/ moving parts of the conveyor are guarded as needed such as the shafts and pulleys of the system (BS 7373, 1991).

The belt also needs some tests to ensure some hazards such as abrasion or friction are not encountered. Thus, the belt tests will find that the installed A8120 belt conveyor has a guard, which protects it from the potential exposures.

The rollers also pose a hazard of return rollers. However, the test shows that through the return roller device, the risk is minimized since it helps reduce the threat of impact on the rollers.

Moving loads test was also completed. Some of the vulnerabilities it poses include the individual load or conveyor obstacles. It may lead to dangers such as loads crushing with fixed objects on the conveyor, shearing and other impacts. However, through the fixed guard, the loads have a safe distance from each other, which eliminates obstacles and crushing of loads.

Handling: The A8120 conveyor belts like other equipment’s in the engineering field are handled through the application of rollers with shafts that are mainly for handling the loads, frictions and other protruding tines. When handling the belt component of the conveyor, spreader bars come in play where they guard the belt edges against wear, abrasion or any other possible hazard. The company received the spreader bars and rollers during the installation among other guards that should be purchased to increase safe handling of the product.

Maintenance: The product is to be regularly evaluated or often as required by the regulatory bodies. It is important to check the product through the authorized individuals in the company. This will ensure during professional maintenance, the costs are low, and the life span of the conveyor increases. Though the product does not need frequent maintenance, it is important it is often checked to clean where necessary, lubricate or replace worn out components.

Disposal: The materials used in developing the conveyor A8120 series are steel, which when they are no longer usable for the conveyor, they will be recycled for other product developments. Since the product components do not pollute the environment, they will be perfect for recycling.

  1. Conclusion

The A8120 conveyor series belts are the most used and applicable in different industries. The A8120 is best suited for the company since occasionally it will deal with large loads, where only the A8120 can manage such shock load. The development of the conveyor is dependent on the function of the product in the company and the needs of the customer. Therefore, prior to developing a product, one must identify the needs of the customer, and the intended function of the equipment. Consequently, the design of the product will be developed to meet specification such as the disposal of the product, safety, maintenance and others as presented above.

References

Advance, 2017. A8120 — Modular Aluminuim Belt Conveyor. Available at:
[Online] https://www.findtheneedle.co.uk/companies/advance-automated-systems-ltd/products/a8120-modular-aluminium-belt-conveyor [Accessed 20 3 2017].

Ananth, S. N. K., Rakesh, V. & Visweswarao, K. P., 2013. Design and Selecting the Proper Conveyor-Belt. International Journl of Advanced Engineering Technology, pp. 43-49.

BS 7373, 1991. Guide to the preparation of specifications.pdf. BS 7373:1991 .

bs 7373, 2001. Guide to the preparation of specifications Guide to preparation. BS 7373-1:2001 .pdf.

Fenner Dunlop, 2009. Conveyor Handbook. Fenner Dunlop: Conveyor Belting Australia, pp. 1-10.

Hulman, R., n.d. Design Core: The Product Design Specification. Chapter 3; Total Design, pp. 45- (1-17) Retrieved from: https://www.rose-hulman.edu/~voltmer/EC460F00/pds.pdf.

Reicks, A. & Myers, T. M., 2004. Bulk Material Handling by Conveyor Belt 5. Illustrated ed. USA: Society for mining , Metallurgy, and Explorationn.

Syan, C. & Menon, U., 2012. Concurrent Engineering: Concepts, Implementation and Practice. New York: Springer Science & Business Media.