HAWASSA UNIVERSITY
INSTITUTE OF TECHNOLOGY
FACULITY OF MANUFACTURING
ELECTROMECHANICAL ENGINEERING
A thesis submitted in partial fulfillment of the requirements for the
award of the degree of BSc in electromechanical engineering
DESIGN AND SOFTWARE IMPLEMENTATION OF
EXAM PAPER ATTACHING MACHINE
By:
1. Rahel Tesfaye -----------------------------------1509/08
2. Bidisha Birhanu --------------------------------0425/08
3. Hadush Kidanu --------------------------------0909/08
4. Hailu Halefom ----------------------------------0536/07
Advisor: Ms. Senait A.
Co-advisor: Mr. Henok T.
Dec, 2020
Hawassa
DECLARATION
We hereby declare that the thesis project entitled “DESIGN AND SOFTWARE
IMPLEMENTATION OF EXAM PAPER ATTACHING MACHINE” submitted for B. Sc.
Degree in electromechanical is our original work and the thesis project has not formed the
basis for the award of any degree, associate ship, fellowship or any other similar titles.
Signature of students
______________________________________________________
______________________________________________________
______________________________________________________
______________________________________________________
Place: ______________________
Date: _______________________
i
CERTIFICATE
This is to certify that the thesis project entitled “DESIGN AND EMPLIMENTATION OF
EXAM PAPER ATTACHING MACHINE” is the work carried out by ELECTRO
MECHANICAL ENGINEERING students of B.Sc. Degree, Hawassa University, institute of
technology, Hawassa, during the year 2012/2013 EC (2020 GC). In partial fulfillment of the
requirement for the award of the degree of B.Sc. degree of Electro Mechanical Engineering
that the thesis project has not formed the basis for the award previously of any degree,
diploma, associate ship, fellow ship or any other similar rule.
Signature of the Advisor: _______________________________________________
Place: ________________________________
Date: ________________________________
ii
ACKNOWLEDGMENT
First of all Our deep gratitude goes to the almighty GOD for everything he done to us in all
the way we path through, then after for our advisor Ms. Senait and electromechanical
engineering department staff members for their continues and progressive support, advice
and guides us to do better work and gave us a reference materials and initiated us for our
work and project. In addition, we would like to thank our classmates and friends for sharing
their ideas and materials to us. Finally, we would like to thank our families for understanding
and helping us with all our needs.
iii
Abstract
From the earliest time attaching action was done manually. This thesis project titled as
DESIGN AND SOFTWARE IMPLEMENTATION OF EXAM PAPER ATTACHING
MACHINE is aimed to avoid manual attaching system of exam paper. The design of this
exam paper attaching machine consists of actuator and slide mechanism, conveyor belt, dc
motor, stepper motor, bearings and other design and control soft wares. And by pressing start
push button the whole system starts to do its specific function. Since the function of this
machine is attaching exam paper we analyzed four mechanisms. The result of these
mechanisms we found are, feeding piece of exam paper through first belt conveyor, attaching
of feeded paper using solenoid actuator, slide attached exam paper using lead screw driver
and unloading the attached exam paper using second belt conveyor to the final storage. Even
if this thesis project is automatic it has some limitations. These limitations are: the machine
attaches only A4 sized paper, changing staples, and feeding piece of exam paper is by human.
Therefore some researcher can do further analysis on this project to minimize these
limitations. This designed machine can be used in universities, school and colleges for
attaching an exam paper. Generally as our machine is automatic to attach exam paper works
efficiently and effectively by reducing time consumptions and human effort.
Key words: attaching, design, exam paper, machine, software
iv
TABLE OF CONTENTS
Contents
Page No
DECLARATION........................................................................................................................i
CERTIFICATE......................................................................................................................... ii
ACKNOWLEDGMENT..........................................................................................................iii
Abstract.....................................................................................................................................iv
List of acronomys and abbreviations..................................................................................... viii
List of figures........................................................................................................................... ix
List of tables.............................................................................................................................. x
CHAPTER ONE........................................................................................................................1
1.1. Introduction and Background of the Project...................................................................1
1.2. Problem Statement..........................................................................................................3
1.3. Objectives....................................................................................................................... 3
1.3.1. General objective..................................................................................................... 3
1.3.2. Specific objectives................................................................................................... 3
1.4. Project Questions............................................................................................................ 3
1.5. Scope of the study...........................................................................................................4
1.6. Justification and Significance of the study..................................................................... 4
1.6.1. Justification..............................................................................................................4
1.6.2. Significance............................................................................................................. 4
1.7. Limitation of the study................................................................................................... 5
1.8. Benefits and Beneficiaries.............................................................................................. 5
1.8.1. Benefits.................................................................................................................... 5
1.8.2. Beneficiaries............................................................................................................ 5
1.9. Organization of the project............................................................................................. 5
CHAPTER TWO....................................................................................................................... 6
v
2. LITRATURE REVIEW........................................................................................................ 6
2.1. Background of Exam Paper Attaching Machine............................................................ 6
2.2. Components of staplers.................................................................................................. 6
2.3. Types of staplers based on their Style, description and their usage............................... 7
2.3. Literature review about belt conveyor..........................................................................11
2.4. Draw backs of the staplers............................................................................................12
2.5. Brief Summary of literature review..............................................................................12
CHAPTER THREE................................................................................................................. 13
3. METHODOLOGY AND MATERIAL SELECTION........................................................ 13
3.1. Methodology.................................................................................................................13
3.1.1. Problem specifying and data collection section.................................................... 13
3.1.2. Design section........................................................................................................13
3.1.3. Simulation section................................................................................................. 13
3.1.4. Flow chart of the project methodology......................................................................14
3.2. Material Selection.....................................................................................................15
3.2.1. Electrical Materials for attaching part....................................................................... 15
3.2.2. Electrical Materials for attaching part using Arduino........................................... 15
3.2.3. Electrical Materials for attaching part using PLC................................................. 23
3.3. Mechanical Materials of the Attaching Part................................................................. 26
3.4. Belt conveyor................................................................................................................27
3.4.1. Material Selection Used For Belt Conveyor..............................................................27
CHAPTER FOUR................................................................................................................... 28
4. DESIGN AND DATA ANALYSIS.................................................................................... 28
4.1. Design and analysis of paper support guide................................................................. 28
4.2. Design and analysis of the attaching table....................................................................28
4.3. Design and analysis of the screw driver....................................................................... 31
4.4. Design and analysis of Paper pusher............................................................................ 38
vi
4.5. Design and analysis of a belt conveyor........................................................................ 40
4.5.1. Design of flat belt area...........................................................................................41
4.5.2. Dimension, capacity and speed for belt conveyor one.......................................... 41
4.5.3. Roller diameter...................................................................................................... 44
4.5.4. Belt Power and Tensions for both belts.................................................................45
4.5.5. Idler Spacing..........................................................................................................47
4.5.6. Pulley drum Diameter for both belts..................................................................... 48
4.6. Electrical design for both belt conveyors..................................................................... 51
4.6.1. Motor selection for conveyors...............................................................................51
4.7. Gear design and selection............................................................................................. 52
4.8. Control of the machine................................................................................................. 55
4.8.1. Mechanical control machine..................................................................................55
4.8.2. Electrical control machine..................................................................................... 55
CHAPTER FIVE..................................................................................................................... 57
5. RESULT AND DISCUSION.............................................................................................. 57
5.1. Results.......................................................................................................................... 57
5.1.1. PLC simulation circuit diagram with LOGO software.........................................59
5.2. DISCUSSION...............................................................................................................62
CHAPTER SIX........................................................................................................................63
6. CONCLUSIONS, RECOMMENDATIONS AND FUTURE RESEARCH WORK......... 63
6.1. CONCLUSIONS.......................................................................................................... 63
6.2. RECOMMENDATIONS..............................................................................................63
6.3. FUTURE RESEARCH WORK....................................................................................63
Reference................................................................................................................................. 65
vii
List of acronomys and abbreviations
AC
- Alternating Current
CATIA - Computer Aided Three dimensional Interactive Application
DC
- Direct Current
I/O
- Input Output
LED
- Light Emiting Diod
PCB
- Progammable Circuit Board
PLC
- Programmable Logic Controller
viii
List of figures
Figure No.
Description
Page No.
Figure 2.1 Parts of stapler.........................................................................................................7
Figure 2.2 Desktop stapler........................................................................................................7
Figure 2.3 : Hand held.............................................................................................................. 8
Figure 2.4 . Heavy duty............................................................................................................. 8
Figure 2.5 Long reach..............................................................................................................8
Figure 2.6 Petite/ Mini..............................................................................................................9
Figure 2.7 : Upright.................................................................................................................. 9
Figure 2.8 Electric stapler......................................................................................................10
Figure 2.9 Reduced effort stapler........................................................................................... 10
Figure 2.10 : carton closing and packaging stapler................................................................. 11
Figure 2.11 sample of belt conveyor...................................................................................... 12
Figure 3.1 : solenoid actuator................................................................................................. 17
Figure 3.2 : arduino Nano with................................................................................................18
Figure 3.3 : voltage regulator.................................................................................................. 19
Figure 3.4 : DC power jack..................................................................................................... 19
Figure 3.5 :
DC Power Jack Connectors...............................................................................20
Figure 3.6 : connector.............................................................................................................. 21
Figure 3.7 : push button..........................................................................................................22
Figure 3.8 : Male Female SIL Socket Row Strip PCB Connector......................................... 22
Figure 3.9 : jumper wires.........................................................................................................23
Figure 3.10 PLC..................................................................................................................... 24
Figure 3.11 proximity sensors................................................................................................ 24
Figure 3.12 : binary ripple Counter and Counter in digital circuit........................................ 25
Figure 3.13 solenoid actuator ................................................................................................ 26
Figure 4.1 . Paper support guide.............................................................................................28
Figure 4.2 : Attaching table..................................................................................................... 29
Figure 4.3 . screw driver..........................................................................................................33
Figure 4.4 paper mover support..............................................................................................33
Figure 4.5 solenoid actuator................................................................................................... 36
Figure 4.6 attaching stapler.................................................................................................... 37
ix
Figure 4.7 attaching system control box.................................................................................38
Figure 4.8 ; paper pusher......................................................................................................... 38
Figure 4.9 worm and gear.......................................................................................................53
Figure 4.10 design model of conveyor
[ own capture].......................................................55
Figure 4.11 plc and steeper driver.......................................................................................... 56
Figure: 5.1 final assemble.......................................................................................................57
Figure:5.2 . Exploded view......................................................................................................58
Figure 5.3 Plc ladder circuit diagram..................................................................................... 61
List of tables
Table No.
Description
Page No.
Table 3.1 Materials for electrical part of the attaching machine part ...................................15
Table 3.2 specification of solenoid ........................................................................................16
Table 3.3 specification of Arduino Nano ............................................................................. 17
Table 3.4 Description of regulators........................................................................................ 18
Table 3.5 Specification of power jack.................................................................................... 19
Table 3.6 electrical properties ............................................................................................... 20
Table 3.7 : Mechanical Properties........................................................................................... 21
Table3.8 : specification ...........................................................................................................21
Table3.9 : Specification button switch.................................................................................... 21
Table3.10 : Description .......................................................................................................... 22
Table3.11 : material selection for plc...................................................................................... 23
Table3.12 Mechanical materials of the attaching part...........................................................26
Table 3.13 Material selection used for two Belt Conveyors.................................................. 27
x
CHAPTER ONE
1.1.
Introduction and Background of the Project
In modern era, the world is developing rapidly in day to day life of the human machine;
system is changing as becoming vast rapidly. For small things to big ones are becoming
advance in our day to day life and taking it under consideration, but we looking till a day the
attaching action is done manually which is by using stapler.
A stapler is a mechanical device that joins pages of paper or similar material by driving a
thin metal staple through the sheets and folding the ends. Staplers are widely used in
government, business, offices, work places, homes and schools. [1]
The word "stapler" can actually refer to a number of different devices of varying uses. In
addition to joining paper sheets together, staplers can also be used in a surgical setting to join
tissue together with surgical staples to close a surgical wound (much in the same way as
sutures).[2]
Most staplers are used to join multiple sheets of paper. Paper staplers come in two distinct
types: manual and electric. Manual staplers are normally hand-held, although models that are
used while set on a desk or other surface are not uncommon. Electric staplers exist in a
variety of different designs and models. Their primary operating function is to join large
numbers of paper sheets together in rapid succession. Some electric staplers can join up to 20
sheets at a time. [3] Typical staplers are a third-class lever. The growing uses of paper in the
19th century created a demand for an efficient paper fastener. A McGill stapler in 1866,
George McGill received U.S. patent 56,587[5] for a small, bendable brass paper fastener that
was a precursor to the modern staple. In 1867, he received U.S. patent 67,665[6] for a press
to insert the fastener into paper. He showed his invention at the 1876 Centennial Exhibition
in Philadelphia, Pennsylvania, and continued to work on these and other various paper
fasteners throughout the 1880s. In 1868 an English patent for a stapler was awarded to C. H.
Gould, and in the U.S, Albert Kletzker of St. Louis, MO also patented a device. In 1877
Henry R. Heyl filed patent number 195,603 for the first machines to both insert and clinch a
staple in one step, [7] and for this reason some consider him the inventor of the modern
stapler. In 1876 and 1877 Heyl also filed patents for the Novelty Paper Box Manufacturing
Co. of Philadelphia, PA,[8] However, the N. P. B. Manufacturing Co.'s inventions were to be
used to staple boxes and books. The first machine to hold a magazine of many pre-formed
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staples came out in 1878. On February 18, 1879, George McGill received patent 212,316[9]
for the McGill Single-Stroke Staple Press, the first commercially successful stapler. This
device weighed over two and a half pounds and loaded a single 1/2 inch wide wire staple,
which it could drive through several sheets of paper. The first published use of the word
"stapler" to indicate a machine for fastening papers with a thin metal wire was in an
advertisement in the American Munsey's Magazine in 1901 .[4]
In the early 1900s, several devices were developed and patented that punched and folded
papers to attach them to each other without a metallic clip. The Clipless Stand Machine
(made in North Berwick) sold from 1909 into the 1920s. It cut a tongue in the paper that it
folded back and tucked in. Bump's New Model Paper Fastener used a similar cutting and
weaving technology.
In 1941 the type of paper stapler that is the most common in use today was developed: the
four-way paper stapler. With the four way, the operator could either use the stapler to staple
papers to wood or cardboard, or used to staple like pliers for bags, or the normal way with
the head positioned a small distance above the stapling plate. The stapling plate is known as
the anvil. The anvil often has two settings: the first, and by far most common, is the reflexive
setting, also known as the "primary" or "permanent" setting. In this position the legs of the
staple are folded toward the center of the cross bar. It is used to staple papers which are not
expected to need separation. If rotated 180° or slid to its second position, the anvil will be set
on the sheer setting, also known as "secondary", "temporary", or "straight". In this position
the legs of the staple are folded outwards, away from the cross bar, resulting in the legs and
cross bar being in more or less a straight line. Stapling with this setting will result in moreweakly secured papers, but a staple that is much easier to remove. The use of the second
setting is almost never seen, however, due to the prevalence of staple removers and the
general lack of knowledge about its use.[10] Some simple modern staplers feature a fixed
anvil that lacks the sheer position.
Modern staplers continue to evolve and adapt to the changing habits of users. Less-effort, or
easy squeeze/use staplers, for example, make use of different leverage efficiencies to reduce
the amount of force the user need apply. As a result, these staplers tend to be used in work
environments where repetitive, large stapling jobs are routine. Some modern desktop staplers
make use of Flat Clinch technology. With Flat Clinch staplers, the staple legs first pierce the
paper and are then bent over and pressed absolutely flat against the paper – doing away with
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the two-setting anvil commonly used and making use of a recessed stapling base in which the
legs are folded. Accordingly, staples do not have sharper edges exposed and lead to flatter
stacking of paper – saving on filing and binder space.
All the above systems are taking plenty of time to work and energetic. In order to reduce
such problems, considering time criteria, we thought to accept the challenge to make a
machine, which can attach an exam papers automatically. Some of the functions we had
successfully implemented on machine that it can auto attach an exam papers by using screw
driver and attaching machine. It consists of screw driver, electric motor, attaching arm and
other components.
1.2.
Problem Statement
The main problem that arises us to design exam paper attaching machine is the exam paper
attaching process in the universities were wider operation and time consuming with human
effort. This is because the process of attaching was manual. It was a human based operation
that consist a lot of mistakes and inaccuracy. That operation takes a lot of time and human
efforts. Development of an automatic exam paper attaching machine brings simplicity that
can attach exam paper automatically on a fixed position. So we are going to design an
automatic attaching machine for multi pages that prepared for the exams.
1.3.
Objectives
1.3.1. General objective
To design and software implementation of exam paper attaching machine which will use in
higher educational institutes and schools.
1.3.2.
Specific objectives
To Design mechanical parts of attaching machine
Analysis of each parts regarding the machine
To Model the mechanical parts using CATIA
Write programing using arduino or PLC to design controller
To control and simulate the system using CATIA and proteus software as well as
LOGO.
1.4.
Project Questions
What is the purpose of this exam paper-attaching project?
Where is its working areas?
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What is its role and how it can reduce human effort?
What type of software can we use to modelling each mechanical parts of the machine?
What type of software can we use to draw circuit diagram of this machine?
1.5.
Scope of the study
Scope of the study is to design and software implementation automated exam paper attaching
machine. The developed types of this machine is going to be designed by analysis, in this
section designs parts of the paper attaching machine by engineering calculation means, and
also draw each mechanical
part by CATIA and assembles the parts with electrical
components to operate the machine.
1.6.
Justification and Significance of the study
1.6.1. Justification
The reason that we will study this exam paper attachment is in order to overcome the
manually operated exam paper attachment in high educational institutes and colleges. When
we are design and prototyping this machine, we grasp a lot of practical knowledge. As this
machine is a combination of different mechanisms such as; sliding, extending and retracting,
rotating, driving, feeding and attaching mechanism, we will change our theoretical
knowledge about mechanism into practical knowledge.
In addition, as this machine is electromechanical machine that consists electrical, mechanical,
microcontroller and computer programing this leads us to know more about these parts
practically. For example, infrared sensor here we use to detect the objects is learned
theoretical in class, but we do not know practical. Then because of this thesis and the
machine for this thesis, we will know all materials we need to design and prototyping this
machine. Most important materials are stepper motor, stepper motor driver, solenoid,
Arduino Nano, male female header pins, and jumper wires.
1.6.2.
Significance
Primary significance of this thesis is we will build a practical knowledge on software (solid
work, arduino, proteus etc.), mechanical components, and electrical components. This thesis
will also consist different Significances for different universities in Ethiopia if they
manufacture and use this machine. Because in most universities and schools attaching is
manual using staplers. This is time consuming and needs large human power. Then, our
machine important to eradicate this problem. As well as it helps other researchers for farther
development of the machine. not only this but also this project can simplify their work, saves
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their time and Reduce human power of many organization as better than before which was a
manual. This all can lead an organization to get effective and perfect work.
1.7.
Limitation of the study
The limitation of our project is the machine can attach only A4 exam paper which are
different from other size papers. Another limitation of the project is, as the exam papers are
ordered first manually, then if the order of the papers are missed (or disordered) the machine
does not recognize the order of the later rather it only consider the first ordered paper.
1.8.
Benefits and Beneficiaries
1.8.1.
Benefits
1.8.2.
Reduce the human power
Save time
High quality
High accuracy
Beneficiaries
High schools
Universities
Other government offices
1.9.
Organization of the project
This thesis paper illustrates introduction of an exam paper-attaching machine, literature
reviews that define the meaning of exam paper-attaching machine, methodology, material
selection, design of each parts of selected materials, geometric analysis and design
calculation. It also gives result, conclusion and recommendation as well as reference.
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CHAPTER TWO
2. LITRATURE REVIEW
2.1.
Background of Exam Paper Attaching Machine
Stapler is a mechanical device joins pages of paper or similar materials by driving a thin
metal staple through the sheets and folding the ends. Staplers are widely used in government,
business, offices, workplaces, homes and schools. [32, 33]
Staplers are an iconic piece of office equipment that has withstood the test time and
solidified a unique place in history. The history of the stapler dates back to 18th century
France, when King XV thought an easy way to bind papers together. But with staples made
of gold and inscribed with Royal courts insignia, these were largely dinged for decorative
purposes. Before this, everything from sewing to clamping and combination of ribbon and
wax was tried to adhere pieces of paper together. And so the story goes, it wasn’t until the
1860s that the first functional stapler was invented for more practical use. George McGill
received a patent for a bend able fastener, but it was show to catch on because it required
continuous reloading. Staplers have come a long way since then, and there are now lots of
different staplers to choose from.[32,33]
2.2.
Components of staplers
1. Handle: exerts force to push a staple in to a stack of paper.
2. Pin: the pin allows the handle to sewing up and up to load staples.
3. Magazine: the piece that holds the staple and pusher.
4. Staple: the faster used to join papers together.
5. Pusher: a piece of metal that adjusts to accommodate stripes of sales. This keeps the
staples loaded in the magazine and to be inserted by the hammer.
6. Hammer: the part that drives staple into a stack of papers.
7. Crimp area and anvil: when the staple is forced through the paper, these two parts are
what bend the staple into the secure shape that keep the papers securely joined.
8. Throat: the section you slide stack of papers in to the deeper the throat the further into the
stack you can staple.
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9. Base: sturdy bottom that most often has nonskid properties.[32,33]
Figure 2.1 Parts of stapler
2.3. Types of staplers based on their Style, description and their usage
1. Desktop stapler: Most universally recognized style of stapler. A popular accessory for
any office or cubicle, this style usually placed on a work surface or tabletop and the
operator feeds paper into it. This type of stapler is inexpensive, light weighted, and
portable. It can join 15-20 papers and used to join Documents, Letters/memos, Home use
and Office use.[32, 33]
Figure 2.2 Desktop stapler
2. Hand held: A hand held stapler is picked up from a work surface and used in hand. They
most often feature a soft grip handle for comfortable use. One of the most common types
of manual stapler. This stapler uses at Documents, Letters/memos, Home use and Office
use.
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Figure 2.3 : Hand held
3. Heavy duty stapler
Typically staples through 100+ sheets at a time. This style also includes stapling pliers and
guns, which are frequently used for industrial application. It uses in Construction projects,
Copy rooms, Portfolios, Publications.
Figure 2.4. Heavy duty
4. Long reach
This stapler is designed for those hard to reach places that standard desktop staplers
just cannot get to. It uses in fastening tags, Cards, Booklets and Colanders.
Figure 2.5 Long reach
8|Page
5.
Petite/ Mini
Petite/ Mini staplers are Small, compact size and perfect for students or traveling consultants.
These are used in Small stapling projects, Home use, Letters/ memos and portable stapling.
Figure 2.6 Petite/ Mini
6. Upright
Typically, smaller in size, an upright stapler stands vertically on surface for
convenient storage. Are used in Small stapling projects, Documents, Letters/ memos
and portable stapling.
Figure 2.7 : Upright
7. Electric stapler
Electric staplers are ideal for busy offices that generate a lot of paper work. They simplify
and speed up the stapling process with a power drive in staple head. And are mainly used in
office.
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Figure 2.8 Electric stapler
8. Reduced effort stapler
As the name suggests, reduced effort staplers make stapling more comfortable and
ergonomic. Offices. And are used in Insurance contracts, Registration forms
Figure 2.9 Reduced effort stapler
10. Carton closing and packaging stapler in the industry
Since 1896, Bostitch has been designing and manufacturing tools and fasteners for a wide
variety of applications and industries. With over 500 million fasteners made every day,
Bostitch is one of the largest manufacturers of nailing & stapling tools and fasteners in the
world. The reassurance of global leadership BOSTITCH is part of the Stanley Black &
Decker organization, the global leader in tool manufacture across a wide range of industries.
[15]
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Figure 2.10: carton closing and packaging stapler
2.3.
Literature review about belt conveyor
Conveyor systems can help us create warehouse efficiency and optimize operations, it can be
achieved at different distances, different materials transportation. Conveyors are especially
useful in applications involving the transportation of heavy or bulky materials most of the
scientists are interested in research on optimization designing of belt conveyors and also
more risk free mechanism.[11] Pulley is heart of the bulk mining material handling. The
stability of cylindrical drum is very important S. P. Das and M.C. Pal considered the drum
buckling under variable loading. They considered the buckling of drum under exponential
load but not consider the variation along pulley face width. M. Ravikumar, Avijit
Chattopadhyay considered the both variation that is exponential and along the face width.
They analyze the pulley as integral that is pulley as whole. The studies using classical
analytical approaches have considered the pulley in parts as well as a single structure.[12] I
observed and studied from research paper of author Konakalla Naga Sri Ananth importance
of proper conveyor belt selection and effect of material characteristics on belt selection.[13]
Also studied design calculations and considerations of belt conveyor system for biomass
wood using 3 rolls idlers, in terms of power and tension, idler spacing, type of drive unit,
maximum loading capacity in order ensure fast, continuous and efficient movement of
crushed biomass wood while avoiding fatalities during loading and unloading.[14]
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Figure 2.11 sample of belt conveyor
2.4.
Draw backs of the staplers
The above-mentioned staplers have the same working principles and similar parts. These
staplers are working manually using human labor. Since these staplers are manual, not used
to attach many exam papers in a short period and the person who attach the papers will be
tired.
2.5.
Brief Summary of literature review
As we have seen from the above literature review the operation of attaching paper, tissue and
others is using different types of manual staplers. These staplers are small in size and
consume human powers and times. However, some staplers are electrically driven but these
staplers are also have many limitations by consuming time and due to some electric short
faced with it. Then, the research we study is automatic and has belt conveyor feeder as well
as belt conveyor used to transportation of joined exam papers in schools, universities and
colleges. As this machine is automatic, it reduces inaccuracy of attaching exam paper and
loss of human power as well as reduce consuming time for attaching in high institutions
during exam time.
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CHAPTER THREE
3. METHODOLOGY AND MATERIAL SELECTION
3.1.
Methodology
3.1.1. Problem specifying and data collection section
In our research paper we are planning on collecting different relevant data regarding the need
for an automatic attaching machine in order to solve problems that different educational
institutes are facing currently. This is done simply by observing our campus offices and
through other methods. Data also gathered from different internet websites, videos, journals,
and references. It is based on this collected information we are going to define and design the
workspace and the actual number of papers we are use.
3.1.2. Design section
This research paper is to be worked to design a paper-attaching machine, which can operate
in different organizations and educational institutes. So design is to be carried on based on
the information gathered from different sources. The design is to be computed by developing
a mathematical model which describes the system. The upward and downward motion of the
stapler will be done by using solenoid actuator. We choose PLC with some sensor and limit
switches for controlling the solenoid actuator by checking the number of papers with
proximity sensor.
3.1.3. Simulation section
In this section, we will deal the simulation of the actual product of our machine. The
simulation of an automatic attaching machine done using CATIA for mechanical parts and
Arduino or PLC LOGO soft comfort for electrical stimulation of a ladder program for
electrical part.
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3.1.4. Flow chart of the project methodology
Start push button is pressed
Conveyor one start rotating and unloading
each sheet of paper
1st proximity sensor detect the targeted exam
papers
solenoid actuator activated as counter
finishes number of sheet in an exam
Actuated solenoid will return at the end of its
actuation limit switch
The paper pusher activated due to return
llimit switch
Exam paper to the
conveyor will be
added
Counter to count
exam papers
It reaches
actuation Limit of
solenoid
Limit switch need for
solenoid to back to its
original position
Paper pusher
reach forward
Limit and return
to its position
2nd Conveyor start to unload attached paper
rotating
Proximity sensor to
detected attached paper
Counter starts counting attached paper
and stored at the storage
At the end attached paper stored at the
storage
14 | P a g e
As we see from the above flow chart of our project the method of the whole machine is Start
when start push button is pressed. After conveyor one start rotating Exam paper to the
conveyor will be added by human. Using first proximity sensor detect the targeted exam
papers which is counted by Counter. Timer also need for counter and to activate solenoid
actuator limiting switch. The limiting switch for Attaching solenoid is activated by the input
voltage. The paper pusher activated due to limiting switch for the paper pusher. After the
paper pusher slide the exam paper second conveyor start rotating and Proximity sensor
detected attached paper. At the end Counter starts counting attached paper and stored at the
storage.
3.2.
Material Selection
The materials used to design and software implementation of the exam paper-attaching
machine are listed below. The materials, which are selected and designed for our machine are
categorized in to two parts mechanical and electrical parts.
3.2.1. Electrical Materials for attaching part
The electrical parts of the attaching part are classified in two categories based on two soft
wares and related programs. The soft wares are Arduino and LOGO. Then our machine can
perform the attaching process using the two programs in real life.
Regarding the practical assumption we list the materials used in our thesis both Arduino and
PLC based.
3.2.2. Electrical Materials for attaching part using Arduino
The materials for electrical parts of attaching machine are assembled at control board circuit
or at PCB.
Table 3.1 Materials for electrical part of the attaching machine part
No Electrical materials
Numbers
1
Power transistor
2
2
5v regulator
3
3
Switch
1
4
100μf capacitor
3
5
Arduino Nano
1
6
Stepper motor drivers
3
7
Female header pins for stepper motors and Arduino Nano 11
15 | P a g e
8
Resistors
3
9
LED
2
10
Heat sink 40 voltages
4
11
Regulators
12
Power supply jack
1
13
proximity sensor
2
14
Solenoid Actuator
1
15
Dc motor for lead screw
1
16
Paper counter
1
Solenoid Actuator: is 12V 500mA 10mm Electromagnet Solenoid Actuator. We have one
solenoid in number. [30]
Description:
12V 500mA 10mm Electromagnet Solenoid Actuator
Specification:
Table 3.2 specification of solenoid
Model
HCNE1-1039
Color
Gold & Green
Voltage
12V
Current
500Ma
Stroke
10mm
Gravitation
25N
Size
40*20*25mm
Quantity
1pcs
Features:
Range of application:
Slot machine/one-arm bandit
Coin machine
Office equipment
16 | P a g e
Line Printer/Computer equipment/fax machine/punch-in time
clock/photocopier/typewriter/cash register/drawing machine/open drinking machines
Transporting equipment
Automatic door lock/safety belt lock/auto electromagnetic/mechanical parking equipment
Home appliances Tape recorder/video recorder/keyboard/automatic knitting machine and
Others
Packaging machine/manipulator/farming and stockbreeding machinery/stamping
equipment
Package Included:
1x Electromagnet Solenoid Actuator
Figure 3.1: solenoid actuator
Arduino Nano [34]
Specification:
Table 3.3 specification of Arduino Nano
Microcontroller
ATmega328
Operating Voltage (logic level)
5V
Input Voltage (recommended)
7V ~ 12V
Input Voltage (limits)
6V ~ 20 V
Digital I/O Pins
14 (of which 6 provide PWM output)
Analog Input Pins
8
DC Current per I/O Pin
40mA
Flash Memory
32KB (ATmega328) (of which 2 KB used by bootloader)
SRAM)
2KB (ATmega328)
EEPROM
1KB (ATmega328)
Clock Speed
16MHz
Chip
CH340G (CH340B is the update version of CH340G,
CH340B comes with crystal, but CH340G doesn't, and we
default sending CH340G version)
17 | P a g e
Package included:
1 x Nano V3.0 Board with pins
Figure 3.2: arduino Nano with
Voltage regulators [31]
Description:
Table 3.4 Description of regulators
Output Voltage
12 V
Output Current
1.5 A
Load Regulation
240 mV
Input Voltage MAX
35 V
Line Regulation
240 mV
Operating Temperature
0~+ 125℃
Mounting Style
Through Hole
Input Voltage MIN
14 V
Number of Outputs
1
Packaging
Tube
Polarity
Positive
PSRR / Ripple Rejection - Typ
55 dB
Series
L7812
Output Voltage
12 V
Output Current
1.5 A
Package included
18 | P a g e
10 x L7812CV L7812 KA7812 MC7812 Voltage Regulator
Figure 3.3: voltage regulator
DC power jack [35]
Figure 3.4: DC power jack
DC Power Male Solder Barrel Tip Plug Jack connector
Excellway® JP02 10Pcs 5.5x2.1mm DC Power Male Solder Barrel Tip Plug Jack Connector
Description:
Specification:
Table 3.5 Specification of power jack
Brand
Excellway®
Model
JP02
Material
Plastic, Metal
Type
5.5mm x 2.1mm Male
Outside Diameter
5.5mm
Inside Diameter
2.1mm
19 | P a g e
Length
4.5cm
Operating
temperature
-50 ~ 65 ℃
Connector Polarity + inside and outside Scope
DC power supply security, monitoring equipment, LED lights, switches
and other devices.
Features:
1.Fast and easy to install
2. Make of Plastic and Metal material, reliability, strong vibration resistance, good
mechanical and electrical performance.
Package include: [36]
Figure 3.5:
DC Power Jack Connectors
Connector [37]
Description:
As a kind of connector, the terminal block is an important module in the electric industry.
It is convenient to connect wires.
Electrical Properties:
Table 3.6 electrical properties
Rated voltage
300V
Rated current
16A
Contact resistance
Insulation resistance
20Mω
5000MΩ/1000V
Withstanding voltage
AC1500V/1Min
Mechanical Properties:
20 | P a g e
Table 3.7: Mechanical Properties
Temp. Range
-30℃~+120℃
Max Soldering
+250℃ for 5 Sec
Torque
0.5Nm
Specifications:
Table3.8: specification
Material Screws
Contact
Pin header
Housing
Pitch
Poles
Color
Quantity
M2.5 steel Zinc plated
phosphor bronze Ni plated or stainless steel
Brass, Tin plated
PBT, UL94V-0
5.08mm
2P
Blue
20
Package included:
20 x Terminal blocks
Figure 3.6: connector
20Pcs Tactile Push Button Switch Momentary Tact Caps [38]
Features:
Used in the fields of electronic products, household appliances and more.
This light touch switch is waterproof, prevent oil, anti-pollution, anti-static
interference.
High precision mechanism design offers acute operation and long service life.
Compact and lightweight, easy to carry and dismantling.
Good electrical conductivity.
Specification:
Table3.9: Specification button switch
Size
Life
Quantity
about 12x12x7mm
100000 times
20pcs
21 | P a g e
Color
Package included:
20 x Button Switches
Blue
Figure 3.7 : push button
10 Pair 40 Pin 2.54mm-Male Female SIL Socket Row Strip PCB Connector [39]
Description:
Table3.10: Description
Pitch
Gender of Connector
Number of Pins
Type of connector
2.54mm
Male & Female
40 PinType of Row: Single-Row
Straight
Package included:
10 x 40Pin Single Row Straight Male
10 x 40Pin Single Row Straight Female
Figure 3.8 : Male Female SIL Socket Row Strip PCB Connector
120pcs 20cm Male to Female Female To Female Male To Male Color [40]
Breadboard Jumper Cable Dupont Wire
Description:
40pcs chromatic male to male color jumper wire
22 | P a g e
40pcs chromatic color female-to-female jumper wire
40pcs chromatic male to female color jumper wire
Durable and reusable
Easy to install and use
a popular choice for construction or repair
be used for electronic project and genuine product
Specification:
Length: 20cm
Compatible with 2.54mm spacing pin headers
Package includes:
1 x a row of 40pcs male to male jumper wire
1 x A row of 40pcs female to female jumper wire
1 x A row of 40pcs male to female jumper wire
Figure 3.9: jumper wires
3.2.3. Electrical Materials for attaching part using PLC
Table3.11: material selection for plc
No.
Materials
Quantity
1
PLC block
1
2
Counters
2
3
Limiting switch
4
4
Proximity sensors
2
5
Stepper motor
1
6
Supper Solenoid actuator
1
23 | P a g e
Image of PLC
Figure 3.10 PLC
Proximity sensor
Figure 3.11 proximity sensors
24 | P a g e
Counters
Figure 3.12 : binary ripple Counter and Counter in digital circuit
Super solenoid
Characteristics of Super Stroke Solenoids:
Stroke up to 35mm (depending on type)
Optimized for long strokes
Holding force up to 24N (in end position, energized)
Life cycle up to >2 million cycles
25 | P a g e
Actuation time
Return time
Figure 3.13 solenoid actuator
3.3.
Mechanical Materials of the Attaching Part
Table3.12 Mechanical materials of the attaching part
No.
Materials
Material type
Quantity
1
paper support guider
Sheet metal
1
2
3
4
5
6
7
8
9
paper pusher
lead screw
Support legs
Beam support
Attaching table
Bolts and nuts
Bearings
Support and arm of actuator
Steel metal
Steel
Metal
Metal
Wood
Steel
Roller bearing
Metal
1
1
4
4
1
24
2
1
26 | P a g e
3.4.
Belt conveyor
In our software implementation and design of automatic attaching paper machine we use two
flat belts to feed paper to the attaching part of machine and to convey the attached paper to
the final receiver. These conveyors are called the first and second flat belt conveyor. The
difference between the two belt conveyors is the arrangement of the belts based on the
feeded exam paper and the attached exam paper. Then designs of these two belt conveyors
are similar except the area of these belts. The areas of the belts are different based on the
paper size arrangement.
3.4.1. Material Selection Used For Belt Conveyor
Table 3.13 Material selection used for two Belt Conveyors
No
mechanical Materials
Quantity
1
Drive unit(drum)
2
2
Bearing of drive drum
4
3
Gear box
2
4
Idle drum
2
5
Roller
22
6
Bearing of idle drum
4
7
Shaft
4
8
Electric motor
2
9
Return roller
22
10
Flat belt
2
27 | P a g e
CHAPTER FOUR
4. DESIGN AND DATA ANALYSIS
4.1.
Design and analysis of paper support guide
The area of paper setting part should have same area with the A4 paper. The reason we
designed this guiding area equal with A4 paper area is to guide and attach exam paper
accurately. We assume that the area of the paper guiding part will be equal to the area of the
exam paper, Therefore the length and width of the guiding part becomes;
䜘=297mm,
and
䜘 =210mm.
Using equation (4.1) area of paper support guide is calculated as:
AGP = LGp *WGp
(4.1)
=210mm*297mm
2
=62,370mm
Where;
: The total width of the attaching table
䜘
: The length of the guiding part
䜘:
The width of the guiding part
The model of paper support guide
Figure 4.1. Paper support guide
4.2.
Design and analysis of the attaching table
This table is designed in order to assemble the solenoid valve actuator, control box, lead
screw, attaching stapler and sliding parts to push the paper. In addition to this, the table has
two support legs. It receives the papers from the first belt conveyor, arrange and hold the
28 | P a g e
exam papers feeds to the second belt conveyor. Also it is useful to get accurate attaching
point on the paper. The model and analysis part for the table shown as follows;
Figure 4.2: Attaching table
Besides, we assume that the upper part of the attaching table is square, this implies that the
length and width of the attaching table are equal and we assign the individual dimension as
follows;
=500mm and the other dimension will be
=500mm.
Using equation (4.2) area of attaching table:
(4.2)
=
=500mm*500mm
=250000mm2
Where;
: Area of attaching table
The total length of the attaching table
The total width of the attaching table
Using equation (4.3) volume of attaching table is calculated:
The volume for the attaching table calculated as follows by considering the height of the
attaching table H=300mm to get total mass for the attaching part ;
29 | P a g e
= length * width* H =
*H
(4.3)
substituting equation (4.2) in equation (4.3) will be
R*H
=
Therefore, the volume can be determined as follow;
R*H
=7.5 *10-2m3 = 75,000,000mm3
Mass of attaching table will be calculated using equation (4.4)
Mass of attaching table= specific density of the table* volume
=
(4.4)
Where;
ρs : Specific density of walnut wood material
VAT : Volume of the attaching table
VAT : determined as follows; VAT=AAt *H
We take the Specific density of walnut wood table ρs = 490 kg/m3, (from kurmi design of
machine element) because the attaching table is made from walnut wood material.
The volume for the attaching table calculated above by using table height (H=300mm) is to
get total mass for the attaching part.
The mass for the attaching part will be determined as by multiplying its specific density with
its volume and this becomes
Therefore
7.5 *10-2m3*490 kg/m3
=36.75Kg
Load applied on the board= mass of all materials on the board * gravity
Mass of paper can be calculated using equation (4.5)
= N*Mp
(4.5)
30 | P a g e
We assume that the mass of each paper is as big as (<5g) and we consider that our belt
conveyor feeds three papers in order to convey a paper to attaching area at a time.
Therefore, the total mass of paper (
) is calculated as mass of paper multiplied by number
of paper (N), this implies;
= N*Mp= 5*3= 15gm.
The net weight for paper determined by using equation (4.6) multiplying its total mass with
gravity and it becomes;
t
(4. 6)
from equation (4.5)
=15gm and substitute in equation (4.6) weight
=3*5g*10kg/s =0.15N
Where;
WT: The total weight of paper
4.3.
MT : The total mass of paper and
g : Gravity
Design and analysis of the screw driver
Lead-screw drives are often used in high-performance linear motion systems because they
provide a transmission with a relatively high stiffness and an inherent drive reduction. For
design purpose mechanical analysis of lead screw affected by various parameters like
efficiency, torque requirement and load capacity. There are numerous important for
successful design of lead screw for drive system. Whenever sliding motion exists in machine,
system create vibration and which severally affects the function of system. The main
objective of analysis of lead screw is to determine various types of stress and deflection at
different mode shapes. The output needs from this work to investigate strength of lead screw
for various loading condition.
We just select Acme or trapezoidal thread. An acme or trapezoidal thread is a modification of
square thread. The slight slope given to its sides lowers the efficiency slightly than square
thread and it also introduce some bursting pressure on the nut, but increases its area in shear.
It is used where a split nut is required. Wear may be taken up by means of an adjustable split
31 | P a g e
nut. An acme thread may be cut by means of dies and hence it is more easily manufactured
than square thread.
Assumption; nominal (major) diameter(d)=20 mm
From mechanical design book, from Table 17.4. Basic dimensions for trapezoidal/Acme
threads.
Minor or core diameter(dc)=15.5 mm
Pitch(p) =4mm
Area of core(Ac) =189 mm2
tan α = p / π d
where; p = Pitch of the screw,
d = Mean diameter of the screw,
α = Helix angle,
tan α = p / π d =4/3.14*20= 0.06369
α= 3.640
Torque required to overcome friction between the screw and nut,
T1 =p* =W tan (φ − α)
where; W=load lifted
Φ= friction angle
W=mp*g
where; mp = mass of pusher ,g=gravity
W=1.02kg*10kg/s2 =10.2N
We assume as The efficiency given by the above equation will be maximum when sin (2α +
φ) is maximum, i.e. when
sin (2α + φ) = 1 or when
2α + φ = 90°
φ=900-(2*3.640)= 82.720
T1 =p* =10.2N* tan (82.72− 3.64)
=0.5287Nm
P=52.87N
Speed of lead screw, from machine design book; for screw material of Steel and nut material
of Bronze has Safe bearing pressure =1.05 – 1.7 N/mm2 and High speed > 15 m / min.
32 | P a g e
Modeling of screw driver
Figure 4.3. screw driver
Area of screw driver support
The total area will be determined as the summation of all these four each different parts.
Figure 4.4 paper mover support
(4.7)
*length*width=2* *
*length*width=2* *
=2*250mm*40mm=20,000mm2
=A0-A01
(4.8)
33 | P a g e
A =A0-A01 = (15mm*150mm) - (70*15) =1200mm2
Area of semi-circle
Area of semi-circle = t
(4.9)
=1/2*3.14*(35)2=1,923.25mm2
= A30-A31-A32
(4.10)
A = A30-A31-A32 = (15*150) - (70*15) - (1,923.25) =723.25mm2
=
(ro2-ri2)
A = π(ro2-ri2) =3.14*(452-352) =2,512mm2
Using the above equations (4.7,4.8,4.9, 4.10, 4.11)
(4.11)
=A1+A2-A3+A4
=A1+A2-A3+A4
=20,000mm2 +1200mm2+ 1,923.25mm2 + 723.25mm2 +2,512mm2
=22,988.75mm2
Where;
: Total area of screw driver support
Total volume will be calculated in equation (4.12)
(4.12)
=
Where;
: the total volume for the screw driver support
Since we have four different parts the total volume will be equated as the summation of the
volume of each all these four parts.
V1=1000, 000 mm3…….h=50mm
V2=60,000mm3……
h=50mm
V3= 36,162.5mm3…. .h=50mm
V4=37,680mm3………t=15mm
34 | P a g e
Substitute each volems in equation (4.12)
1,113,942.5mm3
Therefore, the total mass for the screw driver support will be calculated in equation (4.13);
(4.13)
= t
t
= 1,113,942.5mm3 and ρ= 7700(Kg/m3)
Using
=7700(Kg/m3) * 1,113,942.5mm3
t
Therefore,
t
Where;
=8.73Kg
t
: Mass of screw driver support
Weight of screw driver support calculated in equation (4.14)
t
=
t
*g
From equation (4.13)
t
(4.14)
t
=8.73kg
= 8.73kg*10kg/s2= 87.3N
Mass of attaching stapler;
We assume that atypical plastic stapler has a mass of 250g, where as a metal stapler has
a mass of 500g.
Mass of solenoid actuator=60g.
Modeling of solenoid actuator
35 | P a g e
Figure 4.5 solenoid actuator
The mass of the attaching stapler is the summation of both mass of plastic stapler and
solenoid actuator and it becomes;
MAS= MPS +MSA
(4.15)
Where;
MPS is the mass of plastic stapler
MAS is the mass of attaching stapler
MSA is the mass of solenoid actuator
Therefore, MAS = 250g+60g=310gm
From this result we can obtain the weight of attaching stapler as follows in equation (4.16);
WAS = MSA* g
(4.16)
Using equation (4.15) MSA=310gm and substitute in equation (4.16)
WAS =0.310kg*10kg/s2*=3.1N
36 | P a g e
Modeling of the attaching stapler
Figure 4.6 attaching stapler
We assume that the mass of control box will approximately be about one and half kilogram
(MCB =1.5kg, from this we can obtain the weight of control box as follows;
WCB= MCB * Gravity
(4.17)
WCB =1.5*10
WCB= 15N
37 | P a g e
Modeling of the control box
Figure 4.7 attaching system control box
4.4.
Design and analysis of Paper pusher
The paper pusher is made up of steel material and it is used to move attached exam papers to
the second conveyor.
Figure 4.8; paper pusher
Area of the paper pusher can be calculated in equation (4.18);
Since the paper pusher has three different geometrical parts we have to calculate the area of
individual parts and sum up them to get the total area.
Area =length x width =
= *
(4.18)
䜘䜘
(4.19)
=145*52=7540mm2
=
(4.20)
*
=38*12=456mm2
*
(4.21)
38 | P a g e
= 220*8=1760mm2
Using equation (4.18)
will be:
䜘䜘
=9756m
䜘䜘
12
A
28
2
52
145
Where;
䜘:
the total area of the paper pusher
= are the area of the first , second and third part, respectively.
The force applied due to the pusher on the paper obtained as follows using equation (4.22)
and (4.23);
∑
=W-Fn=0,
W=Fn
=0;
∑
*gravity
(4.22)
(4.23)
is frictional force and it is calculated as follow in equation (4.24):
ng g;
=µ*
(4.24)
, µ=0.277,
In order to get
=t=
䜘M ng
䜘M ng
Ͷ
t
䜘M ng
t And from this
=63.42
t=
䜘 䜘g
=63.42-62.4=1.02
following value
becomes;
t
浨
䜘M ng
(
t)
, substitute this value to the normal force and we get the
䜘M ng
Ͷt
t
tͶ N
39 | P a g e
Using
浨 µ we can calculate the frictional force acting in opposite direct to it which is
Fa and this becomes;
0.277*10.2=2.8254N ,
µ
2.8254N.
Load applied for the board can be obtained in equation (4.25)
Load applied on the board = (mass of materials on the table) * gravity
(4.25)
=WT+ Wl +Wsds + Was+ Wcb +wp
=0.15N+155.13N+87.3N+3.1N+15N +10.2 N
=270.9 N
Where;
WT: total paper weight
Wl: weight of lead screw
Wsds: weight of screw drive support
Was: weight of attaching solenoid
Wcb: weight control box
wp: weight of pusher
Total Weight of table found using equation (4.26)
Total weight of table = weight of attaching table +weight of materials on the table
(4.26)
=367.5N + 270.9N
= 638.4N
4.5.
Design and analysis of a belt conveyor
The design and analysis of belt conveyor system involves determination of the correct
dimension of the belt conveyor components and other critical parameter values so as to
ensure automatic efficiency during loading and unloading conditions. Some of the
components are: conveyor belt, electric motor, pulley, pulley idlers, rollers and etc.
The design of a belt conveyor system takes into account the followings
Area of the flat belts
Dimension, capacity and speed
Roller diameter
Belt power and tension
Idler spacing
Pulley diameter
Motor
40 | P a g e
Types of drive units
Control mode
Maximum loading capacity
4.5.1. Design of flat belt area
Flat belt are usually made up of leather and rubber. Flat belt that are made up of leather have
high coefficient of friction this implies that it can transmit high amount of power. The inside
layers are made up of canvas and fabric. These materials can transmit the majority of load
handled by the belt. To with stand the tensions created the belt material should have high
tensile strength. Flat belts have high load carrying capacity; in addition to this they produce
less noise compared to V belts. As we explain above we have two flat belts and area of these
belts are different based on the arrangement and size of exam paper.
Using equation (4.27) Area of the belt conveyor one can be calculated as:
Clearance of between each roller=20mm
Total clearance=20mm*15=300 mm
A1 = length *width
(4.27)
Total length of belt + (36mm*11) + (100mm*2) = 896 mm
Width of belt conveyor one equal to width of paper= 210mm
Therefore, A1 = length *width =890mm*220mm= 195,800mm2 =0.1958m2
Using equation (4.28) Area of the belt conveyor two can be calculated as:
Area of the belt conveyor two (A2):
A2=length*width
(4.28)
In our designed machine total length of belt two is equal to total length of belt one.
L2=300mm + (36mm*11) + (100mm*2) = 896 mm
Width of belt conveyor two equal to length of paper plus clearance =310mm
Therefore, A2=length*width
A2=890mm*310mm = 275,900mm2 = 0.2759m2
4.5.2. Dimension, capacity and speed for belt conveyor one
The diameter of the driver and driven pulley is determined by the type and dimension of
conveyor belt. The diameter of the pulley must be designed such that it does not place undue
stress on the belt. The length of a belt conveyor in meter is the length from a center of pulley
parallel to belt line. Belt length is dependent on both the pulley diameters and center
distances.
41 | P a g e
in equation (4.29) speeds of belt calculate as:
For both belts standard conveyor speed is 1.25m/s.
V1= d*Π =V2
(4.29)
From the above equation V1=0.415m/s will be substitute
D1 = V1/Π =D2
D1= 1.25/3.14
D1 =0.398m=398mm = D2
Roller diameter for each=398/11=36mm
Where:
V1=V2: speed of Belt conveyor one and two respectively
D1, D2: diameters of rollers; and
π: pi = 3.14
Capacity of belt conveyor one calculate as:
Capacity is the product of speed and belt cross sectional area
generally, belt capacity (kg/sec) is given as:
From equation (4.29) V1=1.25m/s substitute in below equation to calculate belt capacity.
B C1 = 3.6*Ac1* V1. * ρ
(4.30)
ρ= 1140kg/m3
Then,
B C1 = 3.6*Ac1* V1. *ρ
=3.6* 0.1958m2*1.25m/s*1140kg/m3
=1000kg/sec
Therefore,
From equation (4.29) V1=V2=1.25m/s substitute in below equation to calculate second belt
capacity.
B C2 = 3.6*Ac2* V2. * ρ
ρ= 1140kg/m3
B C2 =3.6* 0.2759m2*1.25m/s*1140kg/m3
Therefore,
Where:
=1000kg/sec
A= belt sectional area (m );
42 | P a g e
kg
ρ = material density ( ); and
V= belt speed (m/s)
m
The mass of material Mm (live load) per metre (kg/m) loaded on a belt conveyor is given as:
mass of material as follow:
Mm1
(4.31)
Ͷ
From equation (4.29) v2=v1= 1.25m/s
Therefore, Mm1
Ͷ
=1000/(3.6*1.25)
= 222.3kg/m
Where:
C1= Conveyor capacity and
V1= belt speed m
Mm for conveyor two
Mm2
Ͷ
=1415.4/(3.6*1.25)
=314.5kg/m
Where:
C2= Conveyor capacity and
V2= belt speed m
The capacity in tones/hr of a conveyor one and two consisting of 11 equal roll idler is given
as:
C= (CT*V* Cf *ρ)/ 1000
= (175*1.25*1.08*1140)/1000
=269.325 tones/hr
Where:
C=Capacity in tonnes/hr of a belt conveyor consisting of 11 equal
roll idler;
CT=Capacity of belts for 11 roll equal length idler (175);
ρ=material density in kg/m3 (1140);
Cf=Capacity factor (1.08); and
V=Belt speed in m/s (1.25)
43 | P a g e
Volumetric belt in equation (4.32) is calculated for both belts:
(4.32)
,
Where:
VL1, VL2=Volumetric belt load one and two respectively (m3/hr.)
LC1, LC2=Load capacity of the belt conveyor one and two (tones/hr.); and
W=W1=W2=Specific Weight of the conveyed material (tones/m3)
W=15*10-3N/m3 =5.4 tones/m3.
tͶ e
Therefore,
tͶ
Ͷh
tͶte 䁞
Ro
n
g
Ͷ
tͶ e
tͶte
eͶ
tͶ e *0.36=3.726 tones/hr.
=0.01 (m3/hr) and
=0.69 (m3/hr)
eͶ
4.5.3. Roller diameter
The roller support belt and facilitates easy as well as free rotation of the belt conveyor in all
direction. The correct choice of roller diameter must take into consideration the belt width.
The relationship between the maximum belt speed, Using equation (4.29) roller diameter and
the relative revolution per minute is given below for the two belts:
n=
V
Where:
ttt
DΠ
t
Ͷ e
Ͷe gͷ
t
ttt
Π
t
(4.33)
oMR䜘MR gͷg oRto
n= no of revolution per minute;
D= roller diameter (mm); and
V= belt speed (m/s)
Belt basic length equal for both belts which is given inequation (4.34) as:
Belt basic length= 2 *length along conveying route
Belt basic length= 2 *length along conveying route=2*890mm =1780mm
44 | P a g e
(4.34)
the length of a belt on roll is given as;
L= (d +
t 浨
L= (20 +
Where:
;
t
tt
(4.35)
)*3.14*2 =188.4mm
D=Outside diameter of the roll (m);
d=diameter of the roll center (m);
N= no of wraps of the belt
Over all diameter is given with L=188.4mm in equation (4.36)
D
D
䁞浨
䁞tͶtt
䁞 tt
䁞tͶtt
h
h
Therefore, D= 0.122m =122 mm
,
Ͷ
(4.36)
t
Where:
D= Overall diameter (m);
d= core diameter (m);
L= Belt length (m); and
G= Belt Thickness (mm)
4.5.4. Belt Power and Tensions for both belts
The longer the length of the belt, the more the power required for the conveyor and the
higher the vertical distance of the lift, the higher the magnitude of power required.
The power PP (kW) at drive pulley drum is calculated in equation (4.37):
䜘
殸
ttt
(4.37)
(KW)
=3*1.25/1000
=0.00375Kw=3.75W
Where:
FU: Total tangential force at the periphery of the drive pulley (N);
V: Belt speed (m/sec);
Fu=
䜘䜘 ttt
(4.38)
From equation (4.37) 䜘 =3.75W and substitute in equation (4.38)
45 | P a g e
=10.2=Fu*0.5*3.4
M 䁞tͶe
Therefore Fu=3N
Power required for the conveyor to produce sliding also equal
Ͷhe
P=
ttt
=Fu*V-(Mt*V3)
(4.39)
=3*1.25-15*1.253*10-3=3.72KW
Where:
P= power required for conveyor (KW);
Mt-total mass of moving material;
V is the belt speed;
C= conveyor capacity (tones/hr.); and
L=slide
The belt of the conveyor always experiences tensile load due to the rotation of the electric
drive, weight of the conveyed materials and due to the idlers. The belt tension must be great
enough to prevent slippage between the drive pulley and the belt. Belt tension at steady state
is given below is equal:
Tss = Ͷ he f
Where:
Mm
L
g[
MI
Mb
Mm cos θ
H g Mm
Tss=Belt tension at steady state (N);
f= Coefficient of friction (μ)
L=Conveyor length;
(Conveyor belt is approximately half of the total belt length)
g=Acceleration due to gravity;
Mi=Load due to the idlers;
Mb=Load due to belt;
Mm=Load due to conveyed materials ;
θ = Inclination angle of the conveyor ; and
H=Vertical height of the conveyor).
Mp g
Mm Mp g =0.015*10=0.15N;
mbelt
9t
t t䁞mm *1140(Kg/m3
(4.40)
(4. 41)
=2.33kg
Mb
mbelt g
Mb
mbelt g =2.33kg*10=23.3N
Mi=ρ*Vidler
46 | P a g e
(4. 42)
(4.43)
Mi=ρ*Vidler
Vidler=A*Lidler
2
=π (d /4)*
= 1140*4.12*10
Lidler
-4
=0.47 kg
= π*625*210
-4 3
=4.12*10 m
Mi=Mi*g=0.47*10=4.7N
MI
Mb
Mm cos θ
Tss = Ͷ he f L g[
H g Mm
=1.375*0.277*0.89*10*[(2*4.7+(2*23.3 + 0.15)1)] + 100*10*0.15
=340.3 N
During the start of the conveyor system, the tension in the belt will be much higher than the
steady state. The belt tension while starting is given in equation (4.44). This is equal for both
belts.
(4.44)
From equation (4.40)
340.3 N substitute in equation (4.44)
=340.3*1.08=367.5
=367N
Where:
Ts= Belt tension while starting (N);
TSS=Belt tension at the steady state; and
KS=Start up factor .
Belt tension of a conveyor system is of a varying value along the system flight and is
governed by the following influencing factors: length and track of the system, number and
arrangement of pulley, characteristics of the driving and braking equipment, type and
location of the belt take up devices and operating and loading state of the system .
4.5.5. Idler Spacing
Idlers are installed at graduated spacing to ensure that the sag as a result of load varies
inversely with the tension in the belt.
Total Live load obtained below is equal for all as;
TL
LL LC
Where;
LL
(4. 45)
tͶ 9
LC: conveyor length
47 | P a g e
: Live load
LL
Wdp
Wbe
Wro
Wro = 0.47*10=4.7N,Wbe=2.33*10=23.33N,Wdp=19.68N
TL =47.71*0.89=42.46N
LL
Ͷh
Ͷ
9Ͷ
hͶh N
Dead load is the load consisting of weight of roller, belt and drive pulley.
The idler spacing is equal for both belts conveyor at any point can be obtained in equation
(4.46) below:
T Sg
Mρ
IS
Where:
(4. 46)
M ρ = Mass of belt and live load (kg/m);
T= Tension at a particular point (KN); and
Sg=Percentage of the idler spacing
T is obtained as follows;
this implies that by substituting
=340.3N,we get
T=510.43. Sg =0.077 % and the mass of belt together with live load obtained as;
M ρ=
M ρ=
g
g
(4.47)
=5.43+2.33=7.768Kg
Where;
M ρ: total mass of belt and live load
g:
Mass of belt
: Mass of live load
4.5.6. Pulley drum Diameter for both belts
Pulleys are manufactured in a wide range of sizes. The selection of pulley takes into account the wrap
angle, belt speed , method of belt strain, belt tension T, belt width and type of splice of the conveyor
belt. The pulley diameter is obtained from standard value from the catalogue.
48 | P a g e
Once the pulley diameter is determined, the size of the coupling can also be decided from the
catalogue.
Pulley wraps length at terminals=2*π*D
(4.48)
N=2*3.14*0.122=0.766
Where:
D=Diameter of pulley
Drive pulley can be lagged to increase friction and improve transmission between belt and
pulley.
Elastic lagging helps to keep pulley clean so as to increase duration of friction while grooved
lagging helps in removal of moisture so as to improve friction.
The effective pull 殸 (N) is given as
M
t䁞
t
t䁞
=0.277*10(0.15+
=0.015Kg and
=2.33Kg,
From the above equations (4.41, 4.42, 4.3)
Therefore, M
(4. 49)
t
Ͷ
t
t
+0.3*10(11.65+4.7))
Fu =168.55N
Where:
µT : Coefficient of friction with support rollers
µR : Coefficient of friction with skid plate
g: Acceleration due to gravity
Mm: Total load of conveyed materials
MB : Mass of belt
Mi : Mass of roll idlers
Recall from equation (4.37), the power
殸
ttt
(kW) at drive pulley drum is
Ͷee Ͷ e
ttt
PP =0.21 Kw
49 | P a g e
t =0.47Kg
Where:
殸:
Total tangential force at the periphery of the drive pulley;
V: Belt speed;
The acceleration of the conveyor belt is given as:
are equal for both belts then acceleration is also equal.
浨
As
[
䁞
t
(4.50)
= (367-340.3)/[0.89*(2*4.7+2*23.3+0.15)]
= 0.54 m /s2
Where:
Ts = Belt tension while starting;
TSS =Belt tension at the steady state;
L=Conveyor length);
Mi =Load due to the idlers;
Mi =Load due to belt;
Mm=Load due to conveyed materials;
Belt breaking strength Bbs (N) parameter decides the selection of the two conveyor belts.
Belt breaking strength can be calculated in equation (4.51) as:
ͷ
䜘
(4.51)
=(15 *4.71*10-4) )/(0.75*1.25)=0.0075N
Where:
Cr=Friction factor; 4.71
Cv= Breaking strength loss factor;
Pp=Power at drive pulley; and
V= Belt speed.
50 | P a g e
4.6.
Electrical design for both belt conveyors
4.6.1. Motor selection for conveyors
From equation (4.54) the minimum motor power for sizing of the motor is below for the two
belt.
䜘
t
(4.52)
䜘
t
Where:
tͶ
tͶ9
tͶ
Pmin =Minimum motor power(kw);
Pp=Power at drive pulley (KW); and
η: Efficiency of the reduction gear;
The standard motor greater than Pmin can be sufficient.
Torsional moment for the two conveyors is given as
R
R
t
t
t
(4. 53)
t
= 0.5*122*(10.2+ 0.3*10*86.7)
=16488 N/mm
Where:
D= Diameter of pulley (m);
F= Force (N);
µ = Coefficient of friction;
W=Weight of material and Belt (kg/m); and
g=Acceleration due to gravity (m/s2)
The number of revolution per minute (n) of the motor is given as:
As power and torsional moment is the same for the two conveyors n is also the same.
9eet
ttt
(4.54)
R
= (9550*1000*0.475)/1648 =275rpm
51 | P a g e
Where:
P=Power (kW); and
Mt=Torsional moment (N/mm)
The cycle time of conveyor is given as:
(4.55)
R
= (2*0.89)/0.157
=11.34 sec
Where:
L=Length of conveyor; and
V= Belt speed;
Torque (KNm) for both conveyors is calculated as:
9Ͷee
(4.56)
= (9.55*0.475)/275
=0.0165 KNm
=16.5 Nm
In order to select the suitable motor for our belt conveyors
4.7.
Gear design and selection
We select Worm Gear Box, its Pitch Diameter of Worm Gear and Other Gear Design
Calculation using AGMA Formulae.
A worm gear box must contain a worm and a mating gear (helical gear) and normally the
axis of the worm is perpendicular to the axis of the gear. Look at the picture below:
52 | P a g e
Figure 4.9 worm and gear
Where,
D1 – Pitch Diameter of Worm
D2 – Pitch Diameter of Gear
C – Centre to Centre Distance between the Worm and the Gear
This worm gear design tutorial will discuss up to the selection of the module and pitch and
the calculation of the number of teeth, pitch circle diameter and centre to centre distance
between the worm and gear. We will use the AGMA formulae for doing the calculations.
Design calculations of the other aspects of the worm gear will be analyzed.
Steps of the Design Calculation
The axial pitch of the worm and the circular pitch of the gear must be same for a mating
worm and gear. We will use the term Pitch (P) for both the pitch.
Also, the module of the worm as well as the gear must be equal for a mating worm and gear.
Now, let’s say we have the following design input:
Speed of the Worm (N1) = 20 RPM
Speed of the Gear (N2) = 4 RPM
And, we have to find out the Module (m), Pitch (P), Number of helix of Worm (T1), Number
of teeth of Gear (T2), Pitch circle diameter of Worm (D1), Pitch circle diameter of Gear (D2),
Centre to centre distance(C).
Select the suitable module and its corresponding pitch from the following AGMA specified
table:
53 | P a g e
Module m (in MM)
Pitch P (in MM)
2 ———————6.238
2.5 ———————- 7.854
3.15 ——————— 9.896
4 ————————- 12.566
5 ————————- 15.708
6.3 ———————– 19.792
8 ————————– 25.133
10 ————————- 31.416
12.5 ———————– 39.27
16 ————————– 50.625
20 ————————– 62.832
We are going ahead with the Module as 2 and the Pitch as 6.238.
Use the following gear design:
N1/N2 = T2/T1
(4.57)
And, we will get:
T2 = 5 * T1
(4.58)
Now use the following AGMA empirical formula:
T1 + T2 > 40
(4. 59)
By using the two equations (Eqn 4.57. & Eqn.4.58), we will get the approximate values of
T1 = 7 and T2 = 35
Calculate the pitch circle diameter of the worm (D1) by using the below AGMA empirical
formula:
D1 = 2.4 P + 1.1
(4. 60)
= 16.0712 mm
The following AGMA empirical formula to be used for calculating the pitch circle diameter
of the gear (D2) :
D2 = T2*P/3.1
(4.61)
54 | P a g e
= 69.53185 mm
Now, we can calculate the centre to centre distance (C) in the following equation :
C = (D1 + D2)/2
(4.62)
= 42.80152 mm
The below empirical formula is the cross check for the correctness of the whole design
calculation:
(C^0.875)/2 <= D1 <= (C^0.875)/1.07
Observe that our D1 value is falling in the range.
Parts of description
1.
2.
3.
4.
Flat belt
Drum
Worm
Gear
5. Couple
6. Motor
Figure 4.10 design model of conveyor
4.8.
[ own capture]
Control of the machine
4.8.1. Mechanical control machine
These controllers can be used for time control and supervisory functions such as: conveyor
speed control, speed control of individual drives, speed and belt slip control, load
equilibration between two driving drum and speed difference control between two motors on
one driving drum. This is done by the worm gear we select.
4.8.2. Electrical control machine
The process of whole machine activity is controlled using the PROGRAM. The programs
will be both arduino and PLC using LOGO! Soft comfort. But for our machine to control
using PLC is more suitable than arduino. This is because the process is continuous and for
this process PLC is very important. From the following image we can understand controlling
system of lead screw driver. The PLC and the stepper motor are connected by program and
other important parts like limiting switch or internal coil.
55 | P a g e
Figure 4.11 plc and steeper driver
56 | P a g e
CHAPTER FIVE
5. RESULT AND DISCUSION
5.1.
Results
After selecting and designing specific parameter for all the part; i.e. the mechanical part and
electrical elements (components) those we used to assemble and control of the final exam
paper attaching machine, we reach at the final results. The result of every parts designed and
assembled for mechanical parts is using CATIA software
and for controlling and
implementing the machine is using PLC LOGO software.
Therefore the final result and exploded view of exam paper attaching machine is shown in
figures below.
Figure: 5.1 final assemble
57 | P a g e
Figure:5.2. Exploded view
As we see from the above figure (5.1), the designed machine has three distinct designed parts.
The first part is the first belt conveyor which is used to convey each sheet of exam paper to
attaching area. And the second part the attaching machine which attaches exam papers after
necessary exam paper ready to be attached. This attaching part has lead screw with paper
pusher, solenoid actuator and other parts. After attaching is completed the screw driver slides
to push the attached paper to the second conveyor. Finally the conveyed paper will be stored
to the final exam paper storage box. The storage box will be any local material which used to
store exam papers.
58 | P a g e
5.1.1. PLC simulation circuit diagram with LOGO software
From figure (5.3) below the plc ladder circuit diagram show the working and controlling of
our machine. This circuit diagram has nine inputs (I1-I9) and seven out puts (Q1-Q7) with
two counters. When start push button pressed the system starts its working process. If we
press stop push button the whole process will be stopped. Then simulation of the process will
be shown in LOGO soft comfort.
(a)
59 | P a g e
(b)
60 | P a g e
(c)
Figure 5.3 Plc ladder circuit diagram
61 | P a g e
5.2.
DISCUSSION
The purpose of our design is to attach exam papers automatically. To design this machine we
used different designing and modeling soft wares like CATIA, LOGO soft and others.
Materials like solenoid actuator, flat, plc and others are used to build this machine. Analysis
is done by considering the basic parameters which are used to assemble the exam paper
attaching machine. The component dimensions are expressed based on the value we got from
the calculation and from standard specification of components from different journals, books,
research gates and websites. The consideration of designing all part starts from considering
A4 sized exam paper. The design of attaching table and attaching area is also designed
precisely to attach exam paper effectively. We also used two proximity sensors at the end of
each conveyor to sense the coming exam paper by counting through PLC as we defined as
total number of pages for one exam and the second sensor to sense and count the attached
papers as we defined as a total number of students in the class. Finally the process ends after
finishing the attaching process. However, this machine is automatic the designed machine
has some limitations. The limitations of this machines are attaching part is sized only for A4
paper, and staples are changed by human beings as well as feeding system is also manual.
62 | P a g e
CHAPTER SIX
6. CONCLUSIONS, RECOMMENDATIONS AND FUTURE
RESEARCH WORK
6.1.
CONCLUSIONS
Since papers attaching are widely used in many application areas like universities, colleges,
schools and other areas the automatic paper attaching machine is critically designed to solve
simple attaching system. Now a day machines like Carton closing and packaging stapler,
Petite/ Mini, Long reach, Heavy duty stapler, Desktop stapler, Hand held etc, are used to
attach papers but they were not designed for using automatically attaching operation. By
considering this pneumonia, we designed and analyzed the software implementation and
design automatic attaching machine to solve the problems of attaching. The machine has
effective performance that reduces the faced problems. Generally we conclude that, the needs
of the customer will be solved as much as possible because of the machine has basic features
such as it increases mass production, reduces working time, wastage of papers and the
operation is safe. We believe the customers have been satisfied by this project.
6.2.
RECOMMENDATIONS
The field of attaching exam paper is very wide specially in universities, so the machine like
exam paper attaching machine designed in this thesis project have a valuable support to
advance the attaching process that all universities use manual staplers now a day. Our
machine minimizes such human efforts and eliminates error of attaching exam paper. So we
recommend for every universities to use our product by manufacturing as we designed in this
thesis project.
Finally we would like to recommend gladly for those who have need to modify or support
our design work in any case so as to achieve better value for colleges and universities.
6.3.
FUTURE RESEARCH WORK
After we design and simulate the machine there was some questions faced, which would
interesting for further modifications and improvement of machine attaching process. These
questions are presented below so as to improve the areas of proposed future research work.
63 | P a g e
It would be interesting to design paper feeding and unloading belt conveyor with another
way to reduce the power that belt conveyor uses to feed and unload exam paper. It would be
interesting to design and modify the paper attacher with pneumatic cylinder. It is also
possible to package attached papers for each section with the number of students in the class.
This will be done by designing package model at the end of attached paper receiver box.
64 | P a g e
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[34] https://www.banggood.com/atmega328p-nano-v3-controller-board-for-improvedversion development-module-geekcreit-for-arduino-products-that-work-with officialarduino-boards-p 1494102.html? akmclientcountr=et&rmmds=search&
cur_warehouse=cn&p=kz202343882 3201604s&custlixnkid=434464
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