DESIGN & ANALYSIS OF SUPPORT STRUCTURES AND MATERIAL

TRANSFER CONVEYOR

TEAM M.SAIKIRAN SINGH P.KRANTHI KUMAR

R.ADITYA

Background Pioneer Hi-Bred, a DuPont business headquartered in Des Moines, Iowa, is

the world's leading developer and supplier of advanced plant genetics, agronomic support, and services to farmers.

Basic Facts Founded in 1926 by Henry A. Wallace Business operations in more than 90 countries More than 70 production locations More than 100 research locations More than 10,000 employees worldwide

Pioneer Hi-Bred and its employees share a responsibility to create a safe and healthy workplace by performing to the highest standards of safety – every time, everywhere.

PHI Medchal - India Multi crop seed processing plant – Corn, Rice, Millet, Mustard and Sunflower High speed and automated machinery for seed drying, conditioning, treating and packaging Annually over 30000 MT of seed is handled Over 100 workers are engaged for daily operations

Problem and challenges Seed handling is a manual process, needing several casual workers

and hamalies. There is a challenge to effectively move the large quantities of seed for regular operations.

Safety is utmost priority and one of the core value of the company. Due to manual handling few accidents occurred in the plant in the

past while loading and unloading the seed bags to the trucks. So, for improving the safety efficiency few support structures are

needed Reducing manual intervention through effective material conveying

system is needed.

Objectives Support structures are to be designed for safety of the personnel

working on the trucks [like loaders / unloaders – hamalies]. This requires structural designing and calculation of all the loads that are required to design the support structures.

Design an unloading structure for transferring the seeds from jumbo bags of capacity 1.5 MT to a metal bin for effective material handling

Design a conveyor belt for the transportation of corn into the conditioning plant.

Assessment and study

Initially we differentiated the work space from the available space.

Then the clearance is provided to the work space and the total measurements are taken exactly.

Detailed study is done on present unloading system.

Process mapCurrent

Corn receipt from field

Corn dump from truck

Manual conveying to dryer

Corn unloading from dryer

Shelling in small bags

Seed bulking in small bags

Seed bulking in metal bins

Transfer to conditioning, treating and packing

Proposed new process

Corn receipt from field

Support structures for safety of the personnel working on the trucks

Corn dump from truck

Mechanical conveying to dryer

Corn unloading from dryer

Shelling in jumbo bags

Unloading structure for transferring the seeds from jumbo bags to metal bin

Seed bulking in metal bins

Transfer to conditioning, treating and packing

Analysis

Analysis for unloading structure of jumbo bags

a. Load analysis

Analysis for support structures for safety personnel working

a. Load analysis

b. Beam analysis

c. Column analysis

Mechanical conveyor

a. Material to be carried

b. Speed of the belt

c. Dimensions of the belt

d. Power of the motor

Load analysis of beams

/FOS=F/A

where =yield tensile stress of mild steel W =Load acting on beam (1200*10 N) A =Cross sectional area of the beam From this formulae we calculated the area of the beam and

checked the availability of the beams in the market The beam matching our requirement is ISMB 100

Analysis of columns

Crippling Load (Fcr) = (* *E*I)/(L*L) For columns also load analysis is carried out and it is

decided to be ISSC 100 Slenderness ratio and EULERS formula is considered to

prevent buckling of column. Fcr = Fc/(1+a*(L/K)2) Slenderness ratio=(L/K)

where L=effective length of column

K= Radius of gyration=(I/A)^0.5

Now crippling load is calculated using the RANKINE’S FORMULA

(1/Fcr)=(1/Fc)+(1/Fe)

Where Fcr=crippling load

Fc=crushing load

Fe=Eulers load

The crippling load is less than the force (Fcr < F).So, the design is safe

The complete designing of this model is done in the designing software CATIA and analyzed in ANSYS.

The first iteration carried out is :

The deflection obtained through this structure is about 40 cm which is beyond limits. So to minimize the deflection an another iteration is carried out

In the second iteration cross beams are introduced by which the deflection is reduced to 6 mm

To increase the safety of the structure a truss is added.

The analysis of the support structure is carried out in ANSYS , a load of 1200 kg is applied and the maximum deflection obtained is 1.31 mm.

Drafting:

The main purpose of this support structure is to become a platform for the unloading of jumbo bags.

A number of iterations were used for the final design of the support structure

The load applied on these rods is about 2000 Kg. A solid base was selected for the support structure to be designed

and for the assembly of the hollow rods.

SUPPORT STRUCTURE FOR HANDLING 2 TON WEIGHT:

Base

Analysis of first iteration:

The thickness provided for the plate is approximately 18mm.Due to the high thickness the weight and the cost of the material are increased so, to decrease the weight and as well as to optimize cost another iteration is carried out by removing the plate and adding some hollow rectangular beams and cross beams for the support .

Design of second iteration:

All the rods are hollow rectangular sections with a standard dimension 120*80 mm

Analysis of second iteration:

The load applied on this structure is 2000 kg and the deflection obtained is 0.06 mm.

Drafting

Conveyor

STEPS INVOLVED IN THE DESIGNING PROCESS

1. Material to be conveyed: Corn

2. Bulk density of material to be conveyed :0.75

3. No of tons to be conveyed :10 tons per hour

4. Length of the conveyer : 10 meters

5. Number of cubic meters conveyed per hour : 13.3 cubic meters

6. Efficiency

7. Material repose

8. Conveyor speed : 1 meter per second

9. Width of conveyor belt :300 mm

10. Free zone

VELOCITY OF BELT MATERIAL TRANSFER RATE

WIDTH OF CONVEYOR BELT

1 m/sec 3 kg 200 mm

0.75 m/sec 3.75 kg 250 mm

0.5 m/sec 6 kg 300 mm

0.3 m/sec 9 kg 600 mm

•The different situations considered as per manufacturer’s point of view are tabulated below.

Conclusion The support structures were prepared and analyzed in

ANSYS. Key observations are as follows – The deflection of support structure to hold people after

applying a load of 1200 kg is 1.3 mm The deflection of support structure to hold 1.5 MT jumbo bag

after applying a load of 2 ton is 0.06mm. A conveyor system to transport seeds at a rate of 3kg/sec

with a velocity 1m/s is designed.

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