SYNOPSIS ON
DEVELOPMENT OF AN INTELLIGENT CONVEYOR
SYSTEM FOR PUMP ASSEMBLY
Submitted by
Mugesh R (18M230)
Nafees Abdul Azeez Z (18M231)
Nanta Gopal C (18M232)
Dissertation submitted in fulfilment of the requirements for the degree of
BACHELOR OF ENGINEERING
Branch: MECHANICAL
ENGINEERING
MAY 2022
PSG COLLEGE OF TECHNOLOGY
(Autonomous Institution)
COIMBATORE – 641 004
PSG COLLEGE OF TECHNOLOGY
(Autonomous Institution)
COIMBATORE – 641 004
INTELLIGENT CONVEYOR SYSTEM
FOR PUMP ASSEMBLY
SYNOPSIS
Submitted by
Mugesh R (18M230)
Nafees Abdul Azeez Z (18M231)
Nanta Gopal C (18M232)
Dissertation submitted in fulfilment of the requirements for the degree of
BACHELOR OF ENGINEERING
Branch: MECHANICAL ENGINEERING
MAY 2022
...……………………… …………..…………
Dr. N. Ganesh Kumar Dr.R.Velavan
Faculty guide Programme co-ordinator
Certified that the candidate was examined in the viva-voce examination held on
…………………….. …………………………
(Internal Examiner) (External Examiner)
ABSTRACT
A proper material handling is mandatory for any workshop or industry in
order to ensure the movement of products is done in a well-defined manner. In
PSG Industrial institute, especially in the pump assembly, the assembly of
multistage pump requires multiple parts including impellers etc., to be moved to
the assembly section. This Process is carried out by mini-trolleys or manual
operation, which may lead to human error, loss of productivity, damage to the
parts and economical loss. In order to rectify these problems, one of the method
is to introduce three proximity sensors, two light with a buzzer is implemented.
with this low-cost hardware, an attempt was made to build an intelligent
conveyor system enabled with IoT for pump assembly. For the design of the
conveyor system, there is a need for a conveyor stand which already exists in
Industry 4.0 Research LAB. On top of conveyor stand, conveyor mechanism has
to be implemented. The conveyor system has three stations. The first station is
LOADING where the pump is loaded on the pallet and the operator presses start
button. The pallet starts moving and it stops at ASSEMBLY station (second
station) automatically the buzzer creates noise. The operator assembles the
necessary components to produce 5hp 8 stage pump within speculated time.
Then the conveyor system moves to the next station automatically. It stops at the
third station called UNLOADING, here the operator unloads the Finished Goods
(FG) and the pumps are placed on a rack.
Conclusion
1. INTRODUCTION
Material handling has an impact on all aspects of the business, from forecasting to
production to after-sales service and support. In PSG Industrial Institute the pump is
manually carried out by a labor. There are some risks which include, the component
may get dropped while carrying, loss of productivity, damage to the parts. So, the
material handling must provide safe transportation, prevent economical and
productivity loss.
2. PROBLEM STATEMENT
Currently, the pump assembly is done in workshop manner at PSG Industrial
Institute. In PSG Industrial Institute, they spend an average time of about 114s to
transport a single pump from assembly area to testing area and this transportation
requires 4 labors. Since, all the material handling processes are manual, this
transportation results in loss of productivity, financial loss, human error, and part
damage.
3. OBJECTIVE DEFINITION
The aim of the project is to automate the handling of the pump along with the
elimination of the issue created by manual material handling of pump parts using
mini-trolley or labour. Below is a list of the overall objectives;
Transform the existing bed into a conveyor system which is IoT enabled
that automates the material handling process.
Provide to stop/start the conveyor system.
Design and develop Augmented Reality APP for the conveyor system.
4.METHODOLOGY
The existing testbed demonstrator is considered for the study. The detailed
methodology followed during the course of work is shown in Fig 4.1. The two-
dimensional sketch is to be obtained from the existing testbed demonstrator. The
design parameters like Sprocket diameter, chain length, shaft length motor HP and
torque required for drive are calculated. With the two-dimensional sketch the
CAD model has to be produced using a suitable design software. With the CAD
model simulation is to be performed and the results are compared with the numerical
results.
The process will be repeated if the numerical values failed to meet the
simulation results. The experimental setup is made with the suitable components and
results are again compared.
Fig 4.1- methodology
5. EXPERIMENTAL SETUP
5.1 MOTOR
The components must be transported via the conveyor system, which requires
a motor. The motor must also be capable of carrying the pump components for
assembly. It is decided to use a permanent magnet DC motor with a power rating
of 90 Watts and a speed of 2000 rpm. The output voltage can be as high as 180
volts. The speed will change depending on the supplied voltage. This DC motor is
powered by a battery with a 12-volt output.
5.2 SHAFTS
Two identical shafts of 65 cm in length and 15 mm in diameter are fitted into
the conveyor stand's holes. Two bearings at either end of each shaft are used to
secure it in the holes on the testbed. The shafts are additionally drilled on both
ends with two holes for locking with the sprockets.
5.3 SPROCKETS
The shafts are joined by four identical 7-inch-diameter sprockets with 43 teeth
each. At both ends of a shaft, two sprockets are linked. Each sprocket's hub is
bored with a hole. The holes on the shaft and the holes on the sprocket are
matched, and the holes are secured together by an M6 bolt and nut. As a result,
relative movement between the shafts and sprockets is halted.
5.4 INSTALLATION OF CHAINS
Each package contains 3m of fresh chains. Six fresh chains are purchased, and
three chains are connected to form a 9-meter chain loop. The chain is then
delinked and reduced to 8.3 metres using a hammer and punch. A second chain
loop is created for the other side of the conveyor. Both chains are put on the
sprockets and manually rotated to ensure that they are in good working order.
5.5 PALLET
The pallet must fit inside the confines of the conveyor bed. As a result, a
wood pallet with dimensions of 56x25 cm was chosen. They are fixed with four
rollers, each with a load capacity of roughly 80kg and sharing a load of 20kg. The
chain and pallet are held together by a steel plate with M6 nut and bolt. In the
chain conveyor system, the chain is also fastened by a nut and bolt, allowing us to
move the pallet along the conveyor.
5.6 COUPLING THE MOTOR WITH THE SHAFT
The coupling is responsible for transferring motion from the motor shaft to
the conveyor shaft. A 15mm diameter hole is bored on each side of the connection.
Then it's attached to a shaft, which transfers the torque from the motor to the
conveyor system. They are secured by a nut and bolt to prevent horizontal
movement along the axis. The coupling guarantees that the mechanism does not
move along the horizontal axis by connecting and transferring torque. The
conveyor is then run and verified for accuracy while the motor is powered by a
battery.
5.7 INTRODUCING ARDUINO AND SENSORS
Three sensors are mounted along the conveyor bed, with their outputs sent to
the ARDUINO UNO. When the sensors identify the pump parts on the pallet, a
programme is created to halt the motor. This pause will be used to assemble the motor
parts. The motor is then controlled by the Arduino for additional movement. When the
pallet reaches the end of the conveyor, the sensor stops the motor, the pump is
unloaded from the pallet, and the motor turns in the opposite direction, allowing the
pallet to return to its original position. This operation is done indefinitely until the
requirement is satisfied.
6.ARDUINO PROGRAMMING CODE
The objective of the programming language selection is to configure and
interface the IoT with the servo motor used. There are several programming languages
used for Arduino. They include C, C++, java and python. The programming language
selected is C++. C++ is better than C, since C is a low-level language, and not
objected oriented. C++ is chosen over java for its speed and performance. The IDE
(Integrated Development Environment) used is Arduino IDE.
The inputs of the sensors are given to the Arduino accordingly. Depending
upon that the void setup () function is programmed. The loop of the program is
designed such that it stops when reaches the sensor 1(Loading station) and moves and
waits for at 10 sec and sensor 2 (Assembling station) and then reaches and stops at the
end sensor 3. This pattern of pallet movement is programmed inside the Arduino.
7.FUTURE STUDY
It is planned to upgrade the conveyor system, improvise the features and
optimize the performance. The conveyor system will be subjected to various tests and
its performance will be analyzed. The augmented reality application that is developed
in this project will help to maintain its future scope and its self-explanatory function.
Thus, the conveyor system has a better future scope in the market, can perform its
own function and fulfill the requirements that are needed and can be further subjected
any research and development that are required.
8.CONCLUSION
• The Conveyor bed is altered and the Chain conveyor mechanism is
successfully implemented
• The CAD model of the conveyor is made for virtual simulation and for the
functioning of augmented reality.
• The workshop mode is replaced by station mode and the number of workers
involved in the process of assembly is reduced.
• The time delay and the errors occurring due to human nature is prevented.
Thus, the overall productivity of the PSG Industrial Institute will be improved.
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