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INTRODUCTION
1.1 GENERAL
moving bulk material and consist primarily of a conveyor screw rotating in a stationary
trough.
transportation is fairly of continuous and uniform character, the individual loads being very
high.
can be mounted horizontally, vertically and inclined. Their supports are simple and easily
installed.
stirrer to mix and blending dry or fluid ingredients provide crystallization or coagulation
escaping or dirt or moisture from entering. They can be jacketed to serve as a dryer or
Screw conveyors are used as a earth augers to dig past holes or to bore
under highways for installation of culverts. They are also used extensively on threshing
machines hay balers fodder blowers and many other farm machines.
1.2 SCOPE
units.
With the help of conveyors more work can be done with a given floor space, blocks are
avoided.
Conveying plant enables two or more detached building to be connected together and
The enclosing trough can be made tight enough to contain toxic dust and vapours.
1.3 OBJECTIVE
The aim of this project is to "design and fabricate a screw conveyor" to convey cement
LITERATURE REVIEW
MATERIALS
Belt conveyors are the most versatile and widely used of all conveyors.
They are capable of handling higher tonnages over greater distances at lower costs per ton
then any other type of conveyor – and often at lower cost per than any other means of
transportation. Yet, they are used extensively for small and moderate capacity systems
because of their ability to handle practically any kind of material economically and
dependably. Since the material is carried on the belt, tees conveyors are suitable for
handling certain corrosive materials that would quickly attack the vital parts of all metal
conveyors.
The range of the sizes, which may be handled on belt conveyors limited
Materials may vary from extremely fine Chemicals to lumpy ore, stone,
coal or pulpwood logs. Since belt conveyors are relatively self cleaning to or more
Belt conveyor systems are capable of operating around the clock without
loss of time for empty return trips or delays for loading and unloading. Belt conveyors are
adaptable to the parts of material flow in any plant. They occupy comparatively little space
and can avoid existing equipment and structure. Long distance belt conveyors systems will
negotiate terrain and paths of travels that are not practical or economical for more other
method of transportation.
C.O.E. & T.,Akola
3
Design & Fabrication of Screw Conveyor
conveyors may be used to perform many other functions such as weighing, blending,
sampling and stock piling. Also belt conveyors may be supported and housed at lower cost
belt conveyors systems are low power requirements, long life of wearing parts, low lab
our cost of replacing parts, low cost of inspection and attendance, low cost of loading and
BELT CONVEYOR
OSCILLATING CONVEYOR
reactor legs. This conveyors are ideal for handling all granular, free flowing materials as
well as hot, abrasive, dusty, stringy and other difficult- to- handle materials or where
heating and drying. They have leak proof trough in which there are no moving parts, and
Oscillating conveyors can be modified for many special uses. Trough can be
made in a special widths or they can be constructed of tubes or pipes; they may also be
conveyors can also be use on modify to suit many process applications such as drying,
BUCKET ELEVATORS
or belt operating overhead and foot wheels. Take-ups are provided as a means to
atmospheric conditions, or wear. A steel casing usually encloses the bucket line and the
head and put machinery. The type of elevator and material handled determine the bucket
selection.
Chain is used on elevators caring heavy loads, hot materials, or those, which
pack between the buckets and a belt. Rubber covered or treated fabric belts are used an
elevators handling grains, cereals, and many other, free - flowing, abrasive materials. The
head and the foot machinery components have been selected to best suit the service
fine and loose materials with small to medium size lumps. Buckets, mounted at spaced
intervals, are loaded by scooping up materials from the boot or by feeding the material into
them.
head wheel. These elevators are made in several types and are suitable for many
requirements.
Elevators of this design operate at low buckets speeds suitable for handling
light, fluffy, fragile materials and those having a tendency to stick in the buckets. Buckets,
at spaced intervals, are loaded by scooping up material from the boot or by feeding the
material into them. After passing over the head wheels, the buckets are inverted over the
Elevators of this design are made in a number of types for handling many
bulk materials ranging from light to heavy and from fines to large lumps. Buckets are
spaced continuously and loaded by direct feeding. Their close spacing prevents spillage
between buckets. As buckets discharge, the material flow over the preceding bucket, who's
gentle handling in bulk of relatively small articles such a stampings, castings, plastic chips,
pallets, bolts, nuts, rivets, granule chemicals, seeds, shelled nuts and similar materials.
bulk materials in vertical, or combination of horizontal and vertical paths. It derives its
name from the fact that material discharges from the buckets by gravity. Gravity conveyor
discharge conveyor- elevator is primarily intended for use where breakage or degradation
relatively large capacities and many other applications where comparatively economical
equipment is desired.
shaped buckets rigidly mounted at regular intervals between two strands of long pitch steel
roller chain, operating over suitably located comer sprockets and in open troughs or
fed into the conveyor at any point along a lower horizontal run-in the latter instance the
buckets act as a scrapers, pushing the material forward to a corner where it is carried
Upon reaching an upper comer the conveyor line again assumes a horizontal position and
the buckets operate as scrapers. Material is restrained from spilling at corner by specially
where opening occur in the trough bottom. Gates can be provided or the trough bottom
omitted to properly distribute material along the line of travel of the upper run.
carrying properly spaced scrapers or flights for moving material along the length of a
stationary trough. Material fed into this trough is there by pushed along its length for
conveyor, are those, which are granular; lumpy; very free flowing; non-abrasive, and
mildly corrosive.
Flight conveyors are used for either horizontal or inclined paths and are
Single strand flight conveyors with scraper flights are ideal for conveying
Double strand flight conveyors with sliding chain –suspended flights are
used for larger capacities and longer paths than single strand flight conveyors and can be
made to convey on both runs. The chain operates on flat renewable steel bars attached to
the trough.
SKIP HOIST
Skip hoists are particularly adaptable to very high lifts and may be used to
elevate any bulk materials that can be handled in batches, including materials with large
lumps.
The skip hoist will convey virtually all materials with the exception of those
which are very fine, light or fluffy, contaminable, highly corrosive, or those having
The skip hoist consists of a bucket with or without counter weights or two
buckets balancing each other, a winding machine, wire rope, a steel structure with tracks,
means for loading and unloading the buckets and the necessary electrical apparatus and
lead sheaves.
especially applicable to high lifts. The sip hoist is suitable for various combinations of
vertical and inclined paths of travel. It has few moving parts and the material being carried
does not contact these parts; therefore, maintenance is infrequent and simplified.
The link -belt hoist is known for its simplicity of construction, its
automatic.
There are three general types of skip hoist- the single non-counter-weighted
bucket, the single counterweighted bucket, and the type with balance buckets.
in horizontal screw conveyors. Being compact, say contained and fully enclosed they can
be readily applied in congested areas. Feature insuring sanitation and ease of cleaning are
available.
operating in troughs are usually employed. Inclines above 20 degrees ordinarily require the
units can satisfy many conveying problems and have the further advantage of being
These units find it difficult to handle materials containing large lumps and
The capacity of a given screw conveyor decreases with the increase of incline.
As the angle of inclination increases, there is reduction of flight (i.e. effective angle) as
it pushes against the material. Depending on angle of incline a certain portion of helical
flight does not urge the material forward. This causes material turbulence and
tumbling.
The 'U' shape of the conveyor trough is such that the material is allowed to fall back on
the top of the rotating screw. Again this increases the turbulence and cross sectional
loading.
Due to turbulence and tumbling of material, more horsepower is required than the
Due to the above -mentioned factors we select Horizontal Screw Conveyor, which
This consists of a series of cut and folded flights mounted on the central
revolving shaft or pipe. In this the material is intentionally tumbled and sheared as it is
advanced along the casing by the pitch of the screw at every revolution. Friction between
the material and the revolving spiral tends to carry the material up one side and around
The capacity averages about 15% less than that of standard screw
conveyors, due to retarding action. Adjusting the angle of paddles can control conveying
action. They are used for mixing, blending, or stirring dry or fluid materials.
In this type of conveyor screw a steel bar rolled to form a continuous helical
ribbon flight fastened to the pipe or shaft by steel supporting lugs welded at spaced
intervals.
Also, this screw can be furnished with either continuous or sectional flights, lap or butt
welded together.
These are recommended for handling, sticky materials such as molasses, tar
or substances likely to build upon screw. The tendency of materials of this nature to adhere
and build up at the juncture of solid flight with the pipe is over corned by the open
operation and reduces power consumption when handling materials which tend to pack or
trowel between flights and troughs. Consequently, beveled edge ribbon flight conveyor
accordingly heavy loads and construction is extremely accordingly heavy and rugged. The
ribbons are supported on the pipe or shaft by steel lugs, generously proportional to resist
bending.
paddles can be furnished, spaced at intervals and set to partially oppose the forward flow,
called ribbon flight conveyor screw with paddle. Paddles are adjustable and may be set at
any angle, to produce the desired degree of agitation. They are used for light or medium
In multiple ribbon flight conveyor screw, the screw consists of two or more
ribbon flights of different diameter and opposite hand, mounted one within the other on the
same pipe or shaft by rigid supporting lugs. The other, thereby inducing positive and
blanked from a flat steel plate and formed into helix. The flights are butt welded together
and fastened to the pipe, or shaft by intermittent or continuous welds with or without
formed steel end lungs. Sectional flights are formed with regular pitch approximately equal
to the diameter.
The pipe of a size carefully selected for adequate torsion strength and
resistance to excessive deflection, has internal collars at each end. These collars are
permanently inserted and have appropriate inside diameter to accept coupling or end
shafts.
thickness. When desired, sectional flights may be continuous welded to the pipe on one or
both sides, thus providing exceptionally rugged construction for the most severe conveying
application.
4. Helicoids type:
The helicoids flight conveyor screw is made of a helix, formed by flat steel
bar and mounted on a pipe or shaft. The helix, formed by special rolling equipment to the
required diameter, pitch and thickness, is a smooth, continuous one- piece flight.
absence of laps, rivets or welds on the carrying face of the flight promotes and maintains
cleanliness and reduces wear. The rolling process affects a hardening and smoothing of the
flight surface, which increases resistance to wear and reduces friction and power
consumption.
C.O.E. & T.,Akola
17
Design & Fabrication of Screw Conveyor
welds and with or without formed steel end lungs. The pipe, of a size carefully selected for
adequate torsion strength and resistance to excessive deflection, has internal collars at
each end. These collars are permanently inserted and have appropriate inside diameters to
exceptionally sturdy, and inherent balance permits operation at high speeds. Its distinctive
diameter. It can also be furnished with other than regular pitch and in a wide range of
diameter, thickness and lengths to meet the most exacting requirements. For extremely
heavy duty the flighting may be continuous welded to the pipe or shaft on one or both
sides.
METHODOLOGY
The key to any successful screw design is, firstly through a thorough under
most important to have thorough knowledge of, and understanding of the way material
Capacities are usually given in TPH. Also the apparent density in the
material could vary. The conveyor size and speed must be based on maximum volume and
2) Material Class: A 2 7 Y
Taking the lower value of bulk density and converting it into tons per meter cube.
7- Mildly abrasive
Table no 2
For converting TPH into cubic feet per hour we divide the capacity by the
Therefore,
Therefore,
For finding the diameter of screw conveyor we refer the graph G-5
C = 3.142/4*[(D*D-d*d)*p*k*B.D*(r.p.m.)*60
0.3*1.0404*60*60
Therefore d = 0.039m
= 39mm
A -class pipe. (Since the pipe is being used for light- duty work)
Standard available pipe outer diameter is "42.5" with 2.5mm wall thickness.
Adding the distance between the trough end inlet and outlet centers (i.e. pitch)
We get,
=1000mm
We assume 100% loading and thus calculate the capacity. Using this
C=3.142/4*[(D*D)-(d*d)]*p*k*r.p.m*60
C=8.48 TPH
C=8.48 *2205
C.O.E. & T.,Akola
21
Design & Fabrication of Screw Conveyor
D = Bearing factor
H.P. = 0.046
Since the length of conveyor c/c is one meter therefore no hanger bearing is required and
B.H.P. = H.P. * P
B.H.P. = 0.046*2
= 0.092
= 0.092/0.85
= 0.108
motor.
The Frame size is 71 for 0.5 H.P. Motor as seen from table no. 3 Looking in
motor dimensions for frame 71 we get the input diameter of motor " d " =9mm. As seen
We have got motor r.p.m. = 1380 and required speed =60 r.p.m (max)
We reduce the speed from 1380 r.p.m to 60 r.p.m or lesser in two stages.
We use a gearbox.
We select the size of gearbox unit as 112 based on the reduction ratio required 25/1
Screw conveyors are limited in overall length by the amount of torque that
=716*0.25 *l.5/1320
= 0.203 kg-cm.
COUPLING TYPE - L
The selected coupling should fit on the shafts of motor and gearbox.
The dimensions of type -L love joy flexible coupling are as given in the table no: 8
3.6 FLIGHTS
“sectional” flights. Helicoids flights are formed from a flat bar or strip into a continuous
helix. This flighting is thinner on the outer edge then on the inner edge. This process
provides a continuous one – piece construction with a work hardened, smooth finished
flighting surface. Sectional flights are formed from a flat disc and the thickness of the
flight is uniform. The lead of a sectional flight is slightly greater then one pitch. A joining a
number of sectional flights together on a piece of pipe and butt-welding them together
flighting is formed .The hand of the screw may be clearly and easily ascertained by looking
The screw pictured to the left has the helical flighting wrapped around the
pipe in a counter- clockwise direction. This is arbitrarily termed a Left- hand screw.
The screw pictured to the right has the helical flighting wrapped around the
A conveyor screw viewed from either end will show the same
configuration. If the end of the conveyor screw is not readily visible, then by merely
imaging that the flighting has been cut and the cut end exposed, the hand of the screw
The arrows in the Fig. 4.7 indicate which way the material will move if
conveyor screw. Once a screw conveyor is built and installed with a certain hand,
direction of the rotation is fixed for the desire direction of material transport. Any
If the hand of the screw isn't specified, the screw manufacture will normally
We select sectional flights with both RIGHT HAND and LEFT HAND
"CALCULATIONS"
The screw shaft with the profile of the helix of flight and is development is
as shown in figure –
Therefore we get,
= 182.84
= 60 mm
= 125 + 42.5
= 167.5
= 168
= 225.7
= 226
This disc internal diameter 60mm and outer diameter 226mm will be cut
radically and then bent in the form of flight over the pipe. This flight section will be butt-
=750+2 * 125
= l000 mm.
= 8 flights
We take five right handed flights from inlet end of trough to outlet, and one
left handed flight from the end plate of trough at outlet side to discharge.
TROUGHS
The trough not only confines and guides the flow of material, but also
serves as the housing in which all operating components are supported and held together in
qualities that make stainless steel and non-ferrous metals well adapted to this service. In
general, any type of troughs that can be fabricated of mild steel also be made of stainless or
FLANDED TROUGH
By forming the top flanges integrally with the trough sides from a single
steel sheet, ad equal strength and rigidity is obtained without super fulvous bulk or wait.
This trough is identical in construction to the flanged trough; accept that top
flanges are obtained by securely welding structural steel angles to the troughs.
RECTANGULAR TROUGH:
C.O.E. & T.,Akola
28
Design & Fabrication of Screw Conveyor
Rectangular trough may be made from a single steel sheet or with sides and
bottom of separate pieces, dependent on size and gauge of metal .It is frequently used to
handle abrasive materials capable of forming a layer of material on the bottom of the
trough. The material thus move on it's self, protecting the trough from undo wear.
TROUGH COVERS
(1) The personal are not protected by the Inaccessible location of moving parts of a
conveyor, to protect personal from contact with the rotating screw and
(2) To keep the conveyed material and dust within the conveyor housing, and to exclude
foreign materials there from. The degree to which the cover feeds the trough depends
upon circumstances attending the particular conveying problem and so thus the means
trough cover so that the different components are usually visible for better understanding
We take a clearance of 25mm between trough cover plates and screw flight.
= 25 +125 + 3 + 3 = 156mm
C.O.E. & T.,Akola
29
Design & Fabrication of Screw Conveyor
Normally the trough cover plate is of 5.8mm thickness material mild steel.
Based on experience the spacing between the boards provided on troughs is 150mm.
= Pitch +2 *clearance
= 125 +2 *3 = 131mm.
The inlet and outlet centers are at a distance of 0.75m and are pitch distance
Most screw conveyor can be design with little thought given t<thrust as the
thrust force in an ordinary screw conveyor is moderate and commonly used screw
conveyor drives will accommodate thrust in either direction. However, in screw feeders
with long inlet opening and in screws used to compressed materials (either by design or by
accident when discharge openings are plugged). Thrust can be very severe. Sever thrust
forces can strip the flights from the pipe, stall the drive, and result in sheared coupling
The thrust force is a function of the weight of the product in the trough, the
Due to the clearance between the flighting o.d and inside of the trough, the
product mostly slights on itself and therefore the friction factor for the product on itself
is more significant than the fraction then the friction factor of the product sliding on steel.
For screw feeders the thrust forces results both from reaction of product
friction on the trough and also from the reaction of the product friction against itself in the
C.O.E. & T.,Akola
30
Design & Fabrication of Screw Conveyor
area over the screw at the inlet. For short conveyor it is not significant but for the long
conveyor it is not significant but for long conveyors it is usually not advisable to have the
screw section in compression, as at every connection there could be a side force that would
The most common dives in use today are so called screw conveyor drives
that are adaptation of shaft mounted reduces. This includes drive shafts that are secured in
the reducer so to take thrust in either direction and transfer the thrust force to one of the
Usually when selecting the end bearing for screw conveyor that has a large
amount of thrust it may be necessary to consider the overhung load in using a roller chain
device.
However, if longer than standard sections of screw are to be used, without intermediate
hangers bearings, care should be taken to prevent the screw flights from contacting the
Very often using a conveyor screw section with the large diameter pipe can
solve a problem.
BEARING SELECTION
Bearing are deep grove ball bearing 2 bearings of dia.20mm are selected i.e.
2 bearings of SKF6204 are selected based on shaft dia. = 20mm & checked as follows:
= 10,000*60*52.5/100000
= 31.5mR
x*Fr*S
= 1*140*1.2 (Fr=Ra=Rb)
= 168N
= 16.8kg.
= (31.5)*25
=78.95
~80kg.
Bearing of SKF6204 are selected be reducing shaft dia from 37mm 20mm.
Let V=volume in which cement loads acts down wards (i.e. on center pipe) i.e. cement of
V= [(width of trough * height of end plate above center pipe)] - [0.5*volume of hollow
pipe)]
= 9.094* *1040.4=9.461kg
WI~10kg = 100N.
= 3.142/4*(0.142*0.142-0.060*0.060)*0.0125
= 1.626*
Where Do, Di >> dist O.D & I.D from which flights are made .
W2 = 8*7800*1.628*
=1.0147kg.
= 11 kg/m.
C.O.E. & T.,Akola
33
Design & Fabrication of Screw Conveyor
Adding l& 2
udl=1.5*111=166.5N/m.
W3 = volume* density
= [3.142*(0.020)*(0.020)*0.075]*7800
= 0.184kg.
= 2 Newton. (Approx)
W4 = 3.142[(0.037)*(0.037)*0.050]*7800
= 0.41kg = 5N.
Let, load due to shaft of dia 20mm be 5N & load due to shaft of dia 20mm be 10N.
w5 = volume * density
= [(do*do-di*di)*length]*7800
= [(0.0424*0.0424-0.037*0.037)*l]*7800
C.O.E. & T.,Akola
34
Design & Fabrication of Screw Conveyor
= 2.6266 kg.
W5 = 5kg.(approx)
M = 140*0.525-10*(0.525-0.05)-[((0.525-0.025)^2)/2)*10
M = 67.5 Nm.
fs = 21.47 N/mm^2
Deflection = (5*W*L^4)/(384*E*I)
Deflection = (5*0.25*1000^4)/(384*2.1*100000*66.65*1000)
Deflection = 0 232573 mm
are usually complete units, shop assembled and match marked before shipping, or as
individual components to be aligned and assembled in the field. When the manufacturer
SAFETY
a manner as to comply with the occasional safety and health act, all state and local
or all of the following safeguards may be required to protect the operators and those
1. COVERS AND GRATINGS use rugged gratings in all open loadings areas and the solid
covers in other areas. Covers guards gratings at the inlet points must be such that the
followed when a conveyor is stopped for maintenance or repairs and before conveyors or
guards are removed .all safety devices, conveyors and guards shall be replaced before
3.GUARDS. For protection of the operator and other persons in the working area,
purchaser should provide guards for all exposed equipment such as drives, gears, shafts,
couplings.
are not equipped to operate under conditions, which may be hazardous, nor with hazardous
materials. The manufacturer should be consulted if there is any indication that a hazardous
condition or material is involved. Several situations may create these conditions. A few of
Hazardous conditions
provided with jackets for heating or cooling, special precautions are required. Standard
Hazardous materials
4.4 ELECTRICAL
equipment to control the conveyors. In the conveyor installation, the purchaser must used
with any conveyor installation, the purchaser must use equipment confirming to the
All devices such as those listed below are intended the safety and/or overall
safety devices as they might present a false sense of security to the operator or other
personnel safety precaution around the equipment .in no case are they intended to replace
1. Overload protection. Devices such as shear pins, torque limiters, etc to shut off power
2. No-speed protection. Devices such as zero speed switches to shut off power in the
3. safety shut off switch with power lockout provision at conveyor drive.
conveyor stops.
4.5 INSTALLATION
1. All assemblies and parts are checked against the bill of materials.
2. place the screw inside the trough .Fix the trough end plates with bolts provided . A thin
lining of rubber is placed between the trough and it's end plates. Do not tighten the
bolts. Align trough bottom and centerline, and then tighten the bolts.
5. slide the Plummer block on the screw shaft and rest it on the base plate using bolts.
Ensure that the Plummer block slides smoothly over the plate.
7. place the acrylic cover on the trough and fix it using bolts.
4.6 OPERATION
operate the conveyor. The operator should thoroughly understand these instructions before
WARNING
Guards, access doors, and covers must be securely fastened before operating
this equipment. Lock out power before removing guards, access doors and covers. Failure
4. Do not put conveyor to any other use than for which it is designed.
5. Avoid poking or prodding material in the conveyor with bar or stick inserted through
openings.
6. Always have a clear view of conveyor loading and unloading points and all safety
devices.
7. Keep area around conveyor drive and control free of debris and obstacles.
8. NEVER operate conveyor without covers, grating, guards and other safety devices in
position.
1. REMEMBER - Screw conveyor drive is generally shipped without oil. Add oil to drive
2. MAKE SURE before initial start-up that conveyor is empty, that end bearings and
lubricated, and that all cover guards, safety equipments are properly installed.
3. If conveyor is part of a material handling system, make certain that conveyor controls
5. Operate conveyor while empty for several hours, making a continuous check for
heating of bearings, misalignment of drive, and noisy operation, if any of these occur
proceed as follows:
a. If anti-friction bearings are used, check supply of lubricant. Either too much or too less
b. Lock out power supply and check for misalignment in trough ends, screws and
3. Stop & start conveyor several times & allow to operate for several hours.
4. Shut off conveyor and lock out power supply. Remove covers and check coupling bolts
for tightness. Check hanger bearings, realign if necessary and retighten mounting bolts.
5. Replace covers.
C.O.E. & T.,Akola
41
Design & Fabrication of Screw Conveyor
permit it to operate for a period of time after the feed has been cutoff in order to discharge
as much as possible from the trough. However there is a nominal clearance of 1/2
"between the screw & trough and this procedure will allow amount of material to remain in
harden or setup, the trough should be cleaned completely after the4 conveyor is shut down
4.7 MAINTENANCE
continuous maximum operating performance. Keep the area around the conveyor drive
clean and free of obstacle to provide easy access and to avoid interference with the
1. lock out power to motor before doing any maintenance work preferably with a padlock
on control.
2. Do not remove padlock from control nor operate conveyor until covers and guards are
securely in place.
replacement. The installation procedures are outlined in the section entitled ERECTION.
opposite the drive. Remove trough end, conveyor screw sections, coupling shafts, and
sections.
COUPLINGS
Replace couplings when wear exceeds 1/8 inch. Replace coupling bolts
LUBRICATION
application, bearing materials and operating conditions. Weekly inspection and lubrication
DRIVE.
speed for the speed reducer and other drive components requiring lubrication speed
CONCLUSION
CONVEYOR " explains the design and manufacturing of a screw conveyor, basic
This project gives detailed information about the various factors that me
taken into account before designing and selecting different components, which form a part
of screw conveyor, it also gives the details of be assembly as per the standard procedure
Moving ahead from designing stage this project gives a detailed count of
the fabrication of the screw conveyor, its installation and its maintenance for a better
Finally the project highlights the major advantages of the screw conveyor
BIBLIOGRAPHY
MISSISSIPPI-38801
2. Stephen-Adamson
4. www.theshathigears.com
5. www.rediff.com
6. www.google.com
7. www.howstuffworks.com
8. www.altavista.com
3) Bearings 02 0175.00
4) Hub 02 0100.00
6) Trough 01 0225.00
7) Coupling 02 0300.00
Total 4750.00
APPENDIX
This gives a program in C++, which calculates the various proportions for the screw conveyor for
the given input capacity desired. The program also gives the assembly of screw conveyor in pictorial view.
# include<stdio.h>
#include<conio.h>
#include<graphics.h>
#include<math.h>
#include<iostream.h>
#include<stdlib.h>
void draw();
void design();
void start();
void main()
{
start();
design();
draw();
}
void start()
{
int gd=DETECT,gm;
initgraph(&gd,&gm,"C:\\TC\\bgi");
setbkcolor(BLACK);
setcolor(2);
settextstyle(7,HORIZ_DIR,3);
outtextxy(180,20,"WELCOME TO PROJECT");
outtextxy(280,50,"OF");
outtextxy(0,80," DESIGN AND FABRICATION OF SCREW CONVEYOR");
settextstyle(7,HORIZ_DIR,2);
outtextxy(30,240," ....SUBMITTED BY....");
outtextxy(30,260,"1)SHASHANK KAPLE");
outtextxy(30,280,"2)ANANT NAGNE");
outtextxy(30,300,"3)RAKESH RODE");
outtextxy(30,320,"4)SHAHID FAIYAZ");
outtextxy(30,340,"5)VINOD JAYLE");
outtextxy(30,360,"6)DEBASIS BARUA");
outtextxy(200,180,"*GUIDED BY....");
outtextxy(220,200,"PROF. P.R. WADNERKAR");
outtextxy(200,140,"*H.O.D.....");
outtextxy(220,160,"PROF. C.V. DESHMUKH");
outtextxy(0,380,"***********************************************************************
");
outtextxy(0,220,"***********************************************************************
");
outtextxy(0,120,"***********************************************************************
");
outtextxy(0,10,"************************************************************************");
outtextxy(5,400,"PRESS ENTER <---- FOR FURTHER CALCULATION");
getch();
closegraph();
}
void design()
{
clrscr();
int inc,cd,j,d,t,f,n2,did,did1;
f=1;
long n1,fs;
float d1,d2,n,p,c,x,y,l,rr,c1,cdf,hp,bhp,c2,dod,pid;
float stdpitch[]={100,125,160,200,250,315,355,400,450,500,560,630};
clrscr();
cout<<"ENTER THE CAPACITY DESIRED IN TONS PER HOUR:"<<endl;
cin>>c;
c=c*35.28/1.0404;
cout<<"ASSUMING CENTRE TO CENTRE DISTANCE=1000 MM:"<<endl;
cd=1000*1;
cout<<"SELECT THE SCREW DIAMETER FROM FOLLOWING STANDARD SIZES:"<<endl;
cout<<"6,9,10,12,14,15,16,20:"<<endl;
cin>>inc;
//////////////////////////////////////////////////////////////////////
switch(inc)
{
case 6:
{
cout<<"YOU HAVE SELECTED A 6 INCH CONVEYOR FOR WHICH FROM
GRAPH";
n=c*6.66*0.1;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
case 9:
{
cout<<"YOU HAVE SELECTED A 9 INCH CONVEYOR FOR WHICH FROM
GRAPH";
n=c*1.75*0.1;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
case 10:
{
cout<<"YOU HAVE SELECTED A 10 INCH CONVEYOR FOR WHICH
FROM GRAPH";
n=c*1.25*0.1;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
case 12: {
cout<<"YOU HAVE SELECTED A 12 INCH CONVEYOR FOR WHICH
FROM GRAPH";
n=c*0.08;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
case 14:
{
cout<<"YOU HAVE SELECTED A 14 INCH CONVEYOR FOR WHICH
FROM GRAPH";
n=c*14/30;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
case 15:
{
cout<<"YOU HAVE SELECTED A 15 INCH CONVEYOR FOR WHICH
FROM GRAPH";
n=c/30;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
case 16:
{
cout<<"YOU HAVE SELECTED A 16 INCH CONVEYOR FOR WHICH
FROM GRAPH";
n=c/45;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
case 20:
{
cout<<"YOU HAVE SELECTED A 20 INCH CONVEYOR FOR WHICH
FROM GRAPH";
n=c*0.017;
cout<<",FOR THE GIVEN CAPACITY , THE VALUE OF RPM IS:"<<n;
cout<<endl;
break;
}
default:
{
cout<<"YOU HAVE NOT SELECTED A STANDARD VALUE "<<endl;
break;
}
}
cout<<endl;
///////////////////////////////////////
cout<<"MATERIAL CLASS MEANS FOLLOWING:"<<endl;
cout<<"A-VERY FINE ,100MESH:"<<endl;
cout<<"2-FREE FLOWING ANGLE:"<<endl;
cout<<"7-MILD ABRASIVE:"<<endl;
cout<<"Y-AERATED AND BECOMES FLUID:"<<endl;
cout<<"*************************************************************************"<<endl;
cout<<"c=3.142/4*(d2*d2-d1*d1)*p*k*BD*RPM*60"<<endl;
x=((d2*d2)/(1000*1000))-((4*c)/(3.142*p*0.001*0.3*1.0404*n*60));
d1=sqrt(x);
d1=d1*25.5;
cout<<"HOLLOW SHAFT OUTSIDE DIAMETER="<<d1;
cout<<endl;
cout<<"'k'IS 0.3 FOR 30%LOADING "<<endl;
cout<<endl;
cout<<"'d1' IS SHAFT DIAMETER"<<endl;
cout<<endl;
cout<<"'BD' is BULK DENSITY"<<endl;
cout<<endl;
cout<<"WE SELECT AN ELECTRIC RESISTANCE
WELDED(E.R.W.)PIPE"<<endl;
cout<<"TYPE :'C' CLASS BECAUSE IT HAS MORE THICKNESS,WHICH
WILL AVOID BENDING"<<endl;
cout<<"SELECT STD VALUE OF THE PIPE O.D. WITH THE HELP OF
FOLLOWING TABLE:"<<endl;
cout<<"PIPE O.D. * THICKNESS "<<endl;
cout<<"33.7 * 2.5 "<<endl;
cout<<"42.4 * 2.5 "<<endl;
cout<<"48.3 * 3.5 "<<endl;
cout<<"60.3 * 4.0 "<<endl;
cout<<"76.1 * 5.0 "<<endl;
cout<<"88.9 * 5.0 "<<endl;
cout<<"114.3 * 5.5 "<<endl;
cout<<"139.7 * 6.0 "<<endl;
cout<<"152.4 * 7.0 "<<endl;
cout<<"#######################################################"<<endl;
cout<<endl;
cout<<"NOW , GIVE THE VALUE OF STANDARD PIPE O.D. FROM ABOVE
TABLE:";
cin>>y/1000;
cout<<endl;
d1=y;
cout<<"SELECT THE STANDARD WALL THICKNESS FROM THE
TABLE:";
cout<<endl;
cin>>t;
pid=d1-2*t;
cout<<"PIPE INSIDE DIAMETER IS"<<pid;
cout<<endl;
l=2*p+cd;
cout<<"CONVEYOR OVERALL LENGTH WOULD BE ="<<l;
cout<<endl;
///////////////////////////////////
cout<<"ESTIMATING THE HORSE-POWER REQUIRED:"<<endl;
cout<<"***********************************"<<endl;
cout<<"IN ORDER TO CALCULATE THE POWER REQUIRED WE SHALL
ASSUME 100% LOADING"<<endl;
c1=3.142/4*(d2*d2-d1*d1)*0.125*l*n*60;
cout<<"CAPACITY AT 100% LOADING ="<<c1;
cout<<endl;
cout<<"CONVERTING INTO LBS/HOUR"<<endl;
c1=c1*2205;
cout<<"SO,THE VALUE OF CAPACITY IN LBS/HOUR IS ="<<c1;
cout<<endl;
cout<<"H.P. =l*(c1*F)/100000"<<endl;
cout<<"'l' IS THE LENGTH OF CONVEYOR IN FEET"<<endl;
cout<<"'f' IS THE H.P. FACTOR=1 FOR PORTLAND CEMENT"<<endl;
cdf=0.003268*cd;//cross section distance in feet
hp=(cdf*c1*f)/100000;
cout<<"H.P. IS ="<<hp;
bhp=hp/0.75;
cout<<"REQUIRED MOTOR H.P. IS BHP="<<bhp;
clrscr();
/////////////////////////////////
cout<<"MOTOR SELECTION";
cout<<endl;
cout<<"***************";
cout<<endl;
cout<<"FOLLOWING TABLE SHOWS STANDARD HP,FRAME SIZE
& RATED RPM OF MOTORS"<<endl;
cout<<"FRAME H.P. RATED RPM"<<endl;
cout<<"#######################################"<<endl;
cout<<"56 0.125 1320 "<<endl;
cout<<"56 0.16 1340 "<<endl;
cout<<"63 0.25 1350 "<<endl;
cout<<"71 0.33 1370 "<<endl;
cout<<"71 0.50 1380 "<<endl;
cout<<"80 0.75 1400 "<<endl;
cout<<"80 1.00 1400 "<<endl;
cout<<"90S 1.50 1410 "<<endl;
cout<<"112 5 1440 "<<endl;
cout<<"132 7.5 1440 "<<endl;
cout<<"132 10 1450 "<<endl;
cout<<"160 15 1450 "<<endl;
cout<<"160 20 1455 "<<endl;
cout<<"#######################################"<<endl;
cout<<"SELECT STANDARD FRAME SIZE FROM ABOVE TABLE: "<<endl;
cin>>fs;
cout<<"FRAME SIZE SELECTED ="<<fs;
cout<<endl;
cin>>n1;
rr=n1/n;
cout<<endl<<"REDUCTION RATIO IS ="<<rr;
cout<<endl;
cout<<"WE USE THE GEAR BOX TO REDUCE THE SPEED FROM "<<n1;
cout<<" RPM TO "<<n;
cout<<" RPM ";
cout<<endl;
getch();
///////////////////////
cout<<"FLIGHT SELECTION"<<endl;
cout<<"****************"<<endl;
cout<<"FLIGHT IS MADE FROM A HOLLOW DISC WHICH IS RADIALLY
CUT AND PULLED TO FORM A FLIGHT"<<endl;
cout<<"SEVERA SUCH FLIGHT ARE BUTT WELDED TO FORM THE
COMPLETE SCREW"<<endl;
cout<<"THE PROPORTIONS FOR THIS HOLLOW DISC ARE AS FOLLOW
:"<<endl;
did1=(d1*d1*3.142+0.125*p)/3.142;
did=did1^(1/2);
cout<<"DISC INSIDE DIAMETER="<<did;
cout<<endl;
cout<<"CONSTANT =SCREW DIAMETER+PIPE O.D."<<endl;
c2=d1+d2;
cout<<endl;
cout<<"CONSTANT="<<c2;
dod=c2+did;
cout<<endl;
cout<<"DISC OUTSIDE DIAMETER="<<dod;
cout<<endl;
n2=1000/p;
cout<<"NUMBER OF FLIGHTS="<<n2;
cout<<endl;
cout<<"WE TAKE ONE HANDED FLIGHT"<<endl;
cout<<"THEREFORE NUMBER OF RIGHT HANDED FLIGHT="<<(n2-1);
cout<<"THICKNESS OF FLIGHT :2 TO 5 MM"<<endl;
cout<<"MATERIAL OF FLIGHT IS MILD STEEL"<<endl;
/*getch();*/
///////////////////////////////
cout<<"TROUGH SELECTION:"<<endl;
cout<<"*****************"<<endl;
cout<<"WE SELECT A FLANGED TROUGH."<<endl;
cout<<"THE TOP FLANGES ARE FORMED INTEGRALLY FROM A SINGLE
STEEL SHEET."<<endl;
cout<<"WE SELECT SQUARE INLET AND OUTLET POINTS ON THE
TROUGH."<<endl;
///////////////////////////////////////////////////
cout<<"BEARING SELECTION:"<<endl;
cout<<"*******************"<<endl;
cout<<"DEPENDING UPON THE END SHAFT DAIMETER'SKF' BEARINGS
MAY BE SELECTED."<<endl;
cout<<"UNTILL THIS WE HAVE BEEN DISCUSSING THE DESIGN"<<endl;
cout<<"NOW WE SWITCH ON TO THE GRAPHICS FUCTION WHICH
WILL GIVE US THE VIEW OF THE CONVEYOR."<<endl;
getch();
}
void draw()
{
int gd=DETECT,gm;
float i,j,k=0,l=0,midy,x=35,y,od,id,t;
float sd,sd1;
char sdc[15];
clrscr();
cout<<"ENTER THE SCREW DIAMETER SELECTED IN INCHES(in betwee 1 to 50) :"<<endl;
cin>>sd1;
cout<<"ENTER THE STANDARD SHAFT DIAMETER SELECTED IN mm :"<<endl;
cin>>od;
cout<<"ENTER THE STANDARD THICKNESS IN mm :"<<endl;
cin>>t;
sd= (sd1* 25.5)/4;
initgraph(&gd,&gm,"C:\\TC\\bgi");
setbkcolor(BLACK);
setcolor(WHITE);
midy=getmaxy()/2;
line(x,midy-5,x+39,midy-5);
line(x,midy+5,x+39,midy+5);
rectangle(x+35,midy-(sd+12),x+535,midy+(sd+12));
line(x+35,midy-(sd+14),x+35,midy+(sd+22+25));
line(x+35,midy-(sd+14),x+17,midy-(sd+14));
line(x+17,midy-(sd+14),x+17,midy-(sd+10));
line(x+17,midy-(sd+10),x+32,midy-(sd+10));
line(x+32,midy-(sd+10),x+32,midy+(sd+19+25));
line(x+32,midy+(sd+19+25),x+17,midy+(sd+19+25));
line(x+17,midy+(sd+19+25),x+17,midy+(sd+22+22));
line(x+17,midy+(sd+22+25),x+35,midy+(sd+22+25));
line(x+535,midy-(sd+14),x+535,midy+(sd+22+25));
line(x+535,midy-(sd+14),x+535,midy+(sd+14));
line(x+535,midy-(sd+14),x+535,midy-(sd+10));
line(x+535,midy-(sd+10),x+538,midy-(sd+10));
line(x+538,midy-(sd+10),x+538,midy+(sd+19+25));
line(x+538,midy+(sd+19+25),x+535,midy+(sd+19+25));
line(x+553,midy+(sd+19+25),x+535,midy+(sd+22+25));
line(x+553,midy+(sd+22+25),x+535,midy+(sd+22+25));
line(x+531,midy-5,x+570,midy-5);
line(x+531,midy+5,x+570,midy-5);
line(x+17,midy-(sd+14),x+535,midy-(sd+14));
line(x+32+27,midy-(sd+12),x+32+27,midy-(sd+35));
line(x+32+97,midy-(sd+12),x+32+97,midy-(sd+35));
rectangle(x+32+12,midy-(sd+37),x+32+112,midy-(sd+35));
rectangle(x+32+12,midy-(sd+18),x+32+112,midy-(sd+20));
rectangle(x+17,midy-(sd+17),x+553,midy-(sd+14));
line(x+531-27,midy+(sd+12),x+531-27,midy+(sd+15+12));
line(x+531-97,midy+(sd+12),x+531-97,midy+(sd+15+12));
rectangle(x+531-12,midy+(sd+12),x+531-112,midy+(sd+14));
rectangle(x+531-12,midy+(sd+12+15),x+531-112,midy+(sd+12+17));
setlinestyle(2,1,1);
line(x+32+17,midy-(sd+43),x+32+17,midy-(sd+29));
line(x+32+107,midy-(sd+43),x+32+107,midy-(sd+29));
line(x+32+17,midy-(sd+26),x+32+17,midy-(sd+11));
line(x+32+107,midy-(sd+26),x+32+107,midy-(sd+11));
line(x+531-17,midy+(sd+8),x+531-17,midy+(sd+20));
line(x+531-107,midy+(sd+8),x+531-107,midy+(sd+20));
line(x+531-17,midy+(sd+22),x+531-17,midy+(sd+34));
line(x+531-107,midy+(sd+22),x+531-107,midy+(sd+34));
id=(od-4*t)/4;
od=od/4;
rectangle(x+531,midy-id,x+506,midy+id);
rectangle(x+39,midy-id,x+64,midy+id);
line(x+64,midy-id,x+506,midy-id);
line(x+64,midy+id,x+506,midy+id);
line(x+38,midy-od,x+531,midy-od);
line(x+38,midy+od,x+531,midy+od);
rectangle(x+32,midy-13,x+24,midy-5);
rectangle(x+32,midy+13,x+24,midy+5);
line(x+32,midy-13,x+24,midy-5);
line(x+24,midy-13,x+32,midy-5);
line(x+32,midy+13,x+24,midy+5);
line(x+24,midy+13,x+32,midy+5);
rectangle(x+546,midy-13,x+538,midy-5);
rectangle(x+546,midy+13,x+538,midy+5);
line(x+546,midy-13,x+538,midy-5);
line(x+538,midy-13,x+546,midy-5);
line(x+546,midy+13,x+538,midy+5);
line(x+538,midy+13,x+546,midy+5);
line(x+532-62,midy+sd,x+532-62,midy+(sd+35));
line(x+532-62,midy-(sd+37+35),x+532-62,midy-(sd+37+20));
line (x+532-62,midy-(sd+37+20),x+532-62,midy-(sd+37+15));
line(x+532-62,midy-(sd+37+15),x+532-62,midy-(sd+37));
line(x+532-62,midy-(sd+37),x+532-62,midy-(sd+37-5));
line(x+532-62,midy-(sd+37-5),x+532-62,midy-(sd+37-20));
line(x+532-62,midy-(sd+37-20),x+532-62,midy-(sd+37-35));
line(x+32+62,midy-(sd+37+35),x+32+62,midy-sd);
i=sd/3;
line(x+38,midy-od,x+38+i,midy-sd);
line(x+38+i,midy-sd,x+38+4*i,midy+sd);
l=4;
for(i=sd/3;k<=510-(4*i);k=l*i)
{
line(x+38+l*i,midy+sd,x+38+(l+3)*i,midy-sd);
line(x+38+(l+3)*i,midy-sd,x+38+(l+6)*i,midy+sd);
l=l+6;
}
if(sd1>5)
{
setcolor(0);
setfillstyle(0,1);
fillellipse(580,midy,4,4);
fillellipse(587,midy,4,4);
fillellipse(592,midy,4,4);
fillellipse(595,midy-26,20,20);
fillellipse(592,midy+25,15,19);
fillellipse(595,midy+51,20,20);
fillellipse(615,midy+50,35,35);
}
setcolor(WHITE);
if(sd1==10)
line(x+38+22*i,midy+sd,x+531,midy+od);
if(sd1==8)
line(x+38+28*i,midy+sd,x+531,midy+od);
arc(x+2,midy-2,90,270,3);
arc(x,midy+2,90,360,3);
arc(x+568,midy-2,270,90,3);
arc(x+571,midy+2,90,360,3);
setlinestyle(0,1,1);
rectangle(x+12,midy-21,x+32,midy-5);
rectangle(x+12,midy+21,x+32,midy+5);
rectangle(x+538,midy-21,x+558,midy-5);
rectangle(x+538,midy+21,x+558,midy+5);
setcolor(2);
settextstyle(1,HORIZ_DIR,3);
outtextxy(120,20,"ASSEMBLY OF SCREW CONVEYOR");
line(x+39,midy+(sd+22+35),x+531,midy+(sd+22+35));
line(x+39,midy+(sd+22+30),x+39,midy+(sd+22+40));
line(x+531,midy+(sd+22+30),x+531,midy+(sd+22+38));
settextstyle(2,HORIZ_DIR,4);
outtextxy(x+40,midy+(sd+22+29),"<");
outtextxy(x+527,midy+(sd+22+29),">");
line(x-25,midy-sd,x+38+i,midy-sd);
line(x-25,midy+sd,x+38+4*i,midy+sd);
line(x-15,midy-sd,x-15,midy+sd);
line(x+32+62,midy-(sd+37+15),x+531-62,midy-(sd+37+15));
settextstyle(2,HORIZ_DIR,5);
outtextxy(x+230,midy+(sd+60),"OVERALL LENGTH");
outtextxy(x+250,midy+(sd+40),"1000 mm");
outtextxy(x+200,midy-(sd+70),"CENTRE TO CENTRE LENGTH");
outtextxy(x+250,midy-(sd+50),"750 mm");
outtextxy(x+32+68,midy-(sd+37+23),"<");
outtextxy(x+531-65,midy-(sd+37+23),">");
settextstyle(2,VERT_DIR,4);
outtextxy(x-35,midy-30,"SCREW DIA.");
sprintf(sdc," %3.2f mm ",4*sd);
outtextxy(x-15,midy-30,sdc);
getch();
closegraph();
}
NOW, GIVE THE VALUE OF STANDARD PIPE O.D. FROM ABOVE TABLE:
NOW, GIVE THE VALUE OF STANDARD PIPE O.D. FROM ABOVE TABLE:
42.4
MOTOR SELECTION
***************
FOLLOWING TABLE SHOWS STANDARD HP,FRAME SIZE & RATED RPM OF
MOTORS
FRAME HP RATED RPM
#############################
56 0.125 1320
56 0.16 1340
C.O.E. & T.,Akola
57
Design & Fabrication of Screw Conveyor
63 0.25 1350
71 0.33 1370
71 0.5 1380
80 0.75 1400
80 1 1400
90S 1.5 1410
112M 5 1440
132S 7.5 1440
132M 10 1450
160M 15 1450
160M 20 1455
##################################
SELECT STANDARD FRAME SIZE FROM ABOVE TABLE:
56
FRAME SIZE SELECTED = 56
ENTER THE SELECTED RPM:
1340
REDUCTION RATIO IS = 22
WE USE THE GEAR BOX TO REDUCE THE SPEED FROM 1340 RPM TO
59.938156 RPM
FLIGHT SELECTION
******************
FLIGHT IS MADE FROM A HOLLOW DISC WHICH IS RADIALLY CUT AND
PULLED TO FORM A FLI
GHT
SEVERAL SUCH FLIGHTS ARE BUTT WELDED TO FORM THE COMPLETE
SCREW.
THE PROPORTIONS FOR THIS HOLLOW DISC ARE AS FOLLOWS:
DISC I.D. = 103
CONSTANT-SCREW DIA+PIPE O.D.
CONSTANT = 202.399994DISC O.D. = 305.399994
NUMBER OF FLIGHTS = 8
WE TAKE ONE HANDED FLIGHT
THEREFORE NUMBER OF RIGHT HANDED FLIGHTS = 7THICKNESS OF
FLIGHTS: 2 TO 5 MM
MATERIAL OF FLIGHT IS M.S.
TROUGH SELECTION:
*******************
WE SELECT A FLANGED TROUGH.
THE TOP FLANGES ARE FORMED INTEGRALLY FROM A SINGLE STEEL SHEET.
WE SELECT SQUARE INLET & OUTLET POINTS ON THE TROUGH.
BEARING SELECTION:
*****************
TABLE NO. 1
TABLE 2