1-Mini Project 1- gearbox last stage

2-Mini Project 2- Spur Gear Reverse Engineering

3-Main Project – Conveyor Belt System

Faculty of Engineering
Cairo university

Cairo university - Faculty of engineering

Mechanical Engineering department
Second year

mini project

No. Name Section B.N. ID

1 ‫مايا محمد احمد محمد الصاوي‬ 4 7 9230721

2 ‫محمد سامي حسين سعد‬ 4 22 9230766

3 ‫محمد صالح محمد الهادي عطيه‬ 4 25 9230776

4 ‫هاجر علي حسين علي خليل‬ 6 17 9230971

5 ‫يوسف حسن محمد علي‬ 6 22 9231008

Calculations

𝑃𝑚𝑎𝑥 + 𝑃𝑚𝑖𝑛 16.5 + 8

𝑃𝑚 = = = 12.25 𝐾𝑁
2 2
𝑃𝑚𝑎𝑥 − 𝑃𝑚𝑖𝑛 16.5 − 8
𝑃𝑎 = = = 4.25 𝐾𝑁
2 2

𝑀𝑚 = 𝑃𝑚 . 𝑙 = 12.25 ∗ 50 = 612.5 𝑁. 𝑚
𝑀𝑎 = 𝑃𝑎 . 𝑙 = 4.25 ∗ 50 = 212.5 𝑁. 𝑚

𝑇𝑚𝑎𝑥 + 𝑇𝑚𝑖𝑛 2. .2 + 1.1

𝑇𝑚 = = = 1.65 ∗ 103 𝑁. 𝑚
2 2
𝑇𝑚𝑎𝑥 − 𝑇𝑚𝑖𝑛 2. .2 + 1.1
𝑇𝑎 = = = 0.55 ∗ 103 𝑁. 𝑚
2 2

𝛿𝑒 = 0.5𝛿𝑢𝑙𝑡 = 0.5 ∗ 670 = 335𝑀𝑝𝑎

𝛿̀𝑒 = 𝐾𝑠 ∗ 𝐾𝑓 ∗ 𝐾𝑟 ∗ 𝐾𝑡 ∗ 𝛿𝑒

𝐾𝑠 : 𝑆𝑖𝑧𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
➢ 𝐾𝑠 = 1.248𝑑0.112

𝐾𝑓 : 𝑆𝑢𝑟𝑓𝑎𝑐𝑒 𝑓𝑖𝑛𝑖𝑠ℎ 𝑓𝑎𝑐𝑡𝑜𝑟

➢ Not enough information ∴ 𝐴𝑠𝑠𝑢𝑚𝑒 𝐾𝑓 = 1

𝐾𝑟 : 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟
➢ Not enough information ∴ 𝐴𝑠𝑠𝑢𝑚𝑒 𝐾𝑟 = 1

𝐾𝑡 : 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑓𝑎𝑐𝑡𝑜𝑟
➢ Not enough information ∴ 𝐴𝑠𝑠𝑢𝑚𝑒 𝐾𝑡 = 1

𝐾𝐹 : 𝑆𝑡𝑟𝑒𝑠𝑠 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟

𝐷/𝑑 0.2 𝑟/𝑑 0.05

Stress concentration factor for bending 𝐾𝑐𝑚 = 1.9

Stress concentration factor for torsion 𝐾𝑐𝑡 = 1.55
• For bending:

𝐾𝑓 = 1 + (𝐾𝑐 − 1 )𝑞𝑛
𝑞𝑛 = 0.7
𝐾𝑓 = 1 + (1.8 − 1) ∗ 0.7 = 1.59

• For torsion:

𝐾𝑓𝑠 = 1 + (𝐾𝑐𝑠 − 1 )𝑞𝑛

𝑞𝑛 = 0.8
𝐾𝑓𝑠 = 1 + (1.55 − 1) ∗ 0.8 = 1.44

√ 2 3 2
√(𝐾𝑓𝑚 𝑀𝑚 )2 + 3 (𝐾𝑓𝑚 𝑇𝑚 )
2
32𝑁𝑠 (𝐾𝑓 𝑀𝑎 ) + 4 (𝐾𝑓𝑠 𝑇𝑎 ) 4
𝑑= [ + ]1/3
𝜋 𝛿𝑒 𝛿𝑢𝑙𝑡

Assume 𝐾𝑓𝑠 = 𝐾𝑓𝑠𝑚 , 𝐾𝑓𝑚 = 𝐾𝑓

√ 3 2 3 6 2
32 ∗ 2.5 1/3 (1.56 ∗ 212.5 ∗ 10 ) + 4 (1.44 ∗ 0.55 ∗ 10 )
𝑑=( ) [
𝜋 418.08𝑑−0.112
√1.56 ∗ 612.5 ∗ 103 )2 + 3 (1.44 ∗ 1.65 ∗ 106 )2
4
+ ]1/3
670

𝛿𝑒 = 1 ∗ 1.248𝑑−0.112 ∗ 1 ∗ 1 ∗ 335 = 418.08𝑑−0.112

𝑑 = 57.676 ≅ 58 𝑚𝑚
• Key design
N.s 2 𝜔 16mm
d 58mm h 10mm
𝛿𝑦 490Mpa 𝛿𝑢𝑙𝑡 590Mpa

𝛿𝑦 𝐴𝑠 𝑑 4𝑇𝑛. 𝑠
𝑇= ∴ 𝐴𝑠 =
4𝑛. 𝑠 𝛿𝑦 𝑑
𝐴𝑠 = 619.282 = 𝜔𝐿 ∴ 𝐿 = 38.7𝑚𝑚

• Bearing design
𝛿𝑦 𝑑𝑙ℎ 4𝑇𝑛. 𝑠
𝑇= ∴𝑙=
4𝑛. 𝑠 𝛿𝑦 𝑑ℎ

∴ 𝑙 = 61.928𝑚𝑚 ∴ From standard 𝑙 = 63𝑚𝑚

𝑙 63mm 𝑤 16mm ℎ 10mm

• Welding design

Assume electrode (E60XX), 𝛿𝑦 = 345𝑀𝑝𝑎, full rectangular weld

35mm
3𝑏𝑑2 + 𝑑3 3 ∗ 230 ∗ (35)2 + (35)3
𝐼𝑢 = = = 148020.833
6 6

(𝑏 + 𝑑)2 (230 + 35)2 230mm

𝑑𝑢 = = = 3101604.167
6 6

𝑙𝑤 = (35 + 230) ∗ 2 = 530𝑚𝑚, 𝑁. 𝑠 = 2

 𝐽 = 0.707ℎ𝑒 𝐽𝑢
First: Shear, Primary
1.414𝑃 1.414𝑃
𝜏𝑠 = ∴ ℎ𝑒 =
ℎ𝑒 𝑙𝑤 𝜏𝑙𝑤

𝑇𝑟 2.2 ∗ 106 ∗ 50
𝜏𝑠 = =
𝐽 0.707ℎ𝑒 𝐽𝑢

0.5 ∗ 𝛿𝑦
𝜏𝑚𝑎𝑥,𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 = = 86.25𝑀𝑝𝑎
2

2
2.2 ∗ 106 ∗ 17.5 1.41 ∗ 16.5 ∗ 103
√
86.25 = ( ) +
0.707ℎ𝑒 562500 300ℎ𝑒

ℎ𝑒 = 1.22𝑚𝑚
 8 7 6 5 4 3 2 1

F A
F
589.99
1

150.00
5

H7
10.00 2 16.00
k6
E 56.87 69.60
H7
4 E
f6 452.00

452.00 10.00
H7
R29.00
g6
7

D 6
D
3
SECTION A-A
SCALE 1 : 5 A
300.00
Exploded view

Side view

C C
589.99 ITEM
NO. Part Name Material QTY.
380.00
1 Handle AISI 316 stainless steel sheet SS 2
2 Key AISI 1040 CD 2
3 Frame AISI 1045 CD 1
4 Shaft AISI 4130 Normalized 1
300.00 5 Crank AISI 4130 Normalized 2
6 Gear AISI 4130 Normalized 1
B 7 Ball Bearing AISI 52100 2 B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
Cairo University 2nd Year
LINEAR:
ANGULAR: Faculty of Engineering Mechanical Department
NAME SIGNATURE DATE Section B.N TITLE:

Top View
Gear box Output
DRAWN

CHK'D

APPV'D

MFG

A Q.A MATERIAL: DWG NO.

A3 A
WEIGHT: SCALE:1:5 SHEET 1 OF 7

8 7 6 5 4 3 2 1
 4 3 2 1

F +0.01
16.00+0.00
F
62.00
+0.01
10.00 10.00+0.00

front view side view

E E

D D
62.00

16.00

C Top view Isometric view

C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: Cairo University 2nd Year
LINEAR:
ANGULAR:
Faculty of Engineering Mechanical Department
NAME SIGNATURE DATE Section B.N TITLE:

Key
DRAWN

CHK'D

APPV'D

MFG

A Q.A MATERIAL:

AISI 1040 CD
DWG NO.
A4 A
WEIGHT: SCALE:1:1 SHEET 2 OF 7

4 3 2 1
 4 3 2 1
80.00 64.00
F R8.00
F
B

25.00 50.00

30.00 30.00

E 230.00 230.00
E

+0.02 6.13
16.00 0.00 64.00

56.87 63.00

D +0.02 D
B R29.00 0.00

Front view SECTION B-B

SCALE 1 : 2.5

80.00

C C
64.00

Top view

B Isometric view B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: Cairo University 2nd Year
LINEAR:
ANGULAR:
Faculty of Engineering Mechanical Department
NAME SIGNATURE DATE Section B.N TITLE:

DRAWN

CHK'D

APPV'D
Crank
MFG

A Q.A MATERIAL:

AISI 4130 Normalized

DWG NO.
A4 A
WEIGHT: SCALE:1:2.5 SHEET 3 OF 7

4 3 2 1
 4 3 2 1

F F
30.00
100.00

30.00

E Front view Side view E

D D

100.00

30.00

C C
Top view Isometric view

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: Cairo University 2nd Year
LINEAR:
ANGULAR:
Faculty of Engineering Mechanical Department
NAME SIGNATURE DATE Section B.N TITLE:

Handle
DRAWN

CHK'D

APPV'D

MFG

A Q.A MATERIAL:

AISI 316 stainless steel sheet SS

DWG NO.
A4 A
WEIGHT: SCALE:1:2 SHEET 4 OF 7

4 3 2 1
 4 3 2 1

F C
F
200.00
R126.00
20.00
251.49

70.00 240.00 85.00 70.00 85.00

E E

C R112.50
13.25
SECTION C-C
Side view

D D
240.00
200.00

20.00

251.49 85.00
C C

Top view
Isometric view

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: Cairo University 2nd Year
LINEAR:
ANGULAR:
Faculty of Engineering Mechanical Department
NAME SIGNATURE DATE Section B.N TITLE:

Gear
DRAWN

CHK'D

APPV'D

MFG

A Q.A MATERIAL:

AISI 4130 Normalized

DWG NO.
A4 A
WEIGHT: SCALE:1:5 SHEET 5 OF 7

4 3 2 1
 4 3 2 1
310.00 220.00
F 15.00 35.00 D
F

150.00
240.00 150.00

355.00 350.00
355.00

E 1.97mm 1.97mm
E
5.00 5.00

D
380.00
300.00
SECTION D-D
SCALE 1 : 6 side view

D D

380.00

35.00

310.00
300.00
C 222.00 C

Top view

Isometric view
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: Cairo University 2nd Year
LINEAR:
ANGULAR:
Faculty of Engineering Mechanical Department
NAME SIGNATURE DATE Section B.N TITLE:

Frame
DRAWN

CHK'D

APPV'D

MFG

A Q.A MATERIAL:

AISI 1045 CD
DWG NO.
A4 A
WEIGHT: SCALE:1:10 SHEET 6 OF 7

4 3 2 1
 4 3 2 1

F F
510.00
350.00 +0.02
16.00 0.00
R6.00 56.00 69.60 3.87

-0.03 38.00 38.00

69.60-0.05

10.00 -0.01
58.00

64.00 R29.00-0.02
E E
Front view Side view

D D
510.00
350.00
59.70

38.00 69.60 58.00

64.00
C 16.00
C
Top view Isometric view

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES: Cairo University 2nd Year
LINEAR:
ANGULAR:
Faculty of Engineering Mechanical Department
NAME SIGNATURE DATE Section B.N TITLE:

Shaft
DRAWN

CHK'D

APPV'D

MFG

A Q.A MATERIAL:

AISI 4130 Normalized

DWG NO.
A4 A
WEIGHT: SCALE:1:6 SHEET 7 OF 7

4 3 2 1
Faculty of Engineering

Cairo university

Cairo university
Faculty of engineering
Mechanical Engineering department
Second year

Gear Analysis Report

No. Name Section B.N. ID

1 ‫مايا محمد احمد محمد الصاوي‬ 4 7 9230721

2 ‫محمد سامي حسين سعد‬ 4 22 9230766

3 ‫محمد صالح محمد الهادي عطيه‬ 4 25 9230776

4 ‫هاجر علي حسين علي خليل‬ 6 17 9230971

5 ‫يوسف حسن محمد علي‬ 6 22 9231008

Abstract:
Gear reverse engineering is a fundamental process within mechanical
engineering, essential for unraveling the intricacies of gear mechanisms across
diverse industries. This methodical approach involves the systematic
deconstruction and analysis of existing gear systems to unveil their design,
functionality, and performance attributes. Through meticulous dimensional
analysis, material scrutiny, and computational modeling, engineers gain profound
insights into the underlying principles governing gear dynamics. Such insights
extend to deciphering gear tooth profiles, scrutinizing surface characteristics, and
understanding the interplay of components within the system.

The applications of gear reverse engineering are widespread and profound,

impacting manufacturing, automotive engineering, aerospace, and robotics. By
optimizing gear design for enhanced performance and durability, engineers elevate the
efficiency and reliability of mechanical systems. Additionally, gear reverse
engineering serves as a conduit for innovation, facilitating the integration of advanced
materials and manufacturing techniques into traditional gear systems .
Contents
Abstract: ........................................................................................................................................................ 2
1. Introduction............................................................................................................................................... 4
2. Gear Measurement Using Vernier Caliper ............................................................................................... 4
2.1 Measurement Process ........................................................................................................................ 4
3. Chemical Composition Analysis ................................................................................................................ 5
3.1 Chemical Testing Method ................................................................................................................... 5
3.2 Infrastructure Test .............................................................................................................................. 6
4. Hardness Test ............................................................................................................................................ 7
4.1 Testing Method ................................................................................................................................... 7
4.2 Hardness Results ................................................................................................................................. 7
5. CAD Modeling in SolidWorks .................................................................................................................... 8
5.1 Purpose of CAD Modeling ................................................................................................................... 8
5.2 Steps for CAD Modeling ...................................................................................................................... 8
5.3 CAD Model Output .............................................................................................................................. 8
6. References ................................................................................................................................................. 8
 1. Introduction
Gears are essential components in mechanical systems, enabling motion transmission with high
efficiency and precision. The objective of this study was to measure the physical dimensions of a
gear using a vernier caliper, analyze its chemical composition and hardness, and create a 3D
CAD model in SolidWorks. These analyses provide insight into the gear's material properties,
structural integrity, and overall performance in mechanical applications.

2. Gear Measurement Using Vernier Caliper

2.1 Measurement Process
A vernier caliper was used to measure the key dimensions of the gear.

Outer Gear
Parameter Symbol Measured Value (mm)
Outer Diameter Do 81
Pitch Circle Diameter Dp 76.5
Inner Diameter Di 70.875
Number Of Teeth Z 34
Tooth Thickness t 3.7
Module m = Dp/Z 2.25

Inner Gear
Parameter Symbol Measured Value (mm)
Outer Diameter Do 68.25
Pitch Circle Diameter Dp 58
Inner Diameter Di 63
Number Of Teeth Z 29
Tooth Thickness t 2.8
Module m = Dp/Z 2

Keyway

Parameter Symbol Measured Value (mm)

Width W 7.8
Depth H 4.85
Length L 11
3. Chemical Composition Analysis
3.1 Chemical Testing Method
The chemical composition of the gear was analyzed. The results were recorded as follows:

Element Percentage (%)

Carbon (C) 0.2404
Iron (Fe) 96.9552
Chromium (Cr) 0.9795
Manganese (Mn) 1.1508
Silicon (Si) 0.3105
Phosphorus (P) 0.0227
Sulphur (S) 0.0417
Nickel (Ni) 0.0834
Copper (Cu) 0.1596
Molybdenum (Mo) 0.0132
Vanadium (V) 0.006
Titanium (Ti) 0.0008
Aluminum (Al) 0.0078
Boron (B) 0.0006
Niobium (Nb) 0.0007
Tungsten (W) 0.0004
Arsenic (As) 0.0045
Tin (Sn) 0.0132
Cobalt (Co) 0.0125
Lead (Pb) 0.0018
Antimony (Sb) 0.0014
Bismuth (Bi) 0.0016
Calcium (Ca) 0.001
Zinc (Zn) 0.0000
3.2 Infrastructure Test
 Based on the attached chemical composition analysis, we have determined that the material of
our gear potentially similar to AISI 1141 or 1144 due to the absence of significant lead content.
Instead, the composition is more in line with a low-alloy carbon steel,which are known for their
strength and machinability.
The composition includes elements such as manganese, silicon, nickel, chromium, and
molybdenum, which contribute to desirable properties like strength, hardness, and wear
resistance. However, the sulfur content (0.0417%), while not excessively high, could still impact
machinability and might pose concerns such as hot shortness during manufacturing.
While this steel composition offers certain advantages, its suitability for gear applications
must be carefully evaluated. Factors such as load capacity, operating speed, environmental
conditions, and manufacturing constraints should be considered. Additionally, rigorous testing
and validation are essential to ensure the material meets the necessary performance standards for
gear applications.

4. Hardness Test
4.1 Testing Method
We conducted Vickers hardness testing on the gear at three distinct points to ensure
comprehensive analysis, obtaining an average value for accurate assessment of its resilience and
durability. This methodical approach, utilizing the Vickers method, allowed for a thorough
evaluation of the gear's hardness profile, facilitating informed decisions regarding its suitability
for various mechanical applications.

4.2 Hardness Results

Test Location Hardness Value (HV)
Point 1 336
Point 2 347
Point 3 340

We will take the average value of (H.V) which is 341, and it is a suitable hardness for steel gears
5. CAD Modeling in SolidWorks
5.1 Purpose of CAD Modeling
Creating a 3D model of the gear in SolidWorks allows for accurate visualization, dimensional
verification, and potential stress analysis.

5.2 Steps for CAD Modeling

• Sketching the Base Circle: Defined using the measured pitch circle diameter.
• Defining Gear Parameters: Entered in SolidWorks using the "Equation Driven Curve" method.
• Creating Teeth Profiles: Used the standard gear generation tools.
• Extrusion of the Gear: The gear was given thickness based on the measured values.
• Final Refinements: Filleting edges, ensuring manufacturability.

5.3 CAD Model Output

• 2D Technical Drawings (Include images if applicable).
• 3D Rendered Model (Include screenshots).

6. References
Relevant textbooks, AGMA/ISO standards, and research papers used in the analysis.
 8 7 6 5 4 3 2 1
A
14.60
11.00
F 10.90 F
7.80

24.90
4.85

E R2
0.
68
E

68.25
55.10
D D
External Module 2.25 mm
External pitch diameter 76.5 mm

External outer diameter 81 mm

A
External root diameter 70.875 mm
C FRONT VIEW Section Side view at A-A
External Number of teeth 34
C
Internal Module 2 mm
68.25
Internal pitch diameter 58 mm

Internal inner diameter 63 mm

Internal number of teeth 29 mm

B Pressure angle 20 ° B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
Spur Gear
TOP VIEW
MFG

A A
Q.A MATERIAL: DWG NO.
A3

WEIGHT: SCALE:3:2 SHEET 1 OF 1

8 7 6 5 4 3 2 1
Faculty of Engineering

Cairo university

Cairo university - Faculty of engineering

Mechanical Engineering department
Second year

Design of a Belt Conveyor System

No. Name Section B.N. ID

1 ‫مايا محمد احمد محمد الصاوي‬ 4 7 9230721

2 ‫محمد سامي حسين سعد‬ 4 22 9230766

3 ‫محمد صالح محمد الهادي عطيه‬ 4 25 9230776

4 ‫هاجر علي حسين علي خليل‬ 6 17 9230971

5 ‫يوسف حسن محمد علي‬ 6 22 9231008

Abstract
Belt conveyor systems play a vital role in industrial material handling, offering efficient transportation for
bulk materials like wet clay. This project focuses on designing a belt conveyor system specifically optimized
for wet clay (Group 25), which has a bulk density of 1,800 kg/m³ and an angle of repose of 38°. The system is
designed to transport 175 TPH
(tons per hour) over a horizontal distance of 47 meters at a belt speed of 1.0 m/s, ensuring stable and
reliable material flow while minimizing spillage and wear.
Key design considerations include:
Selection of a heavy-duty rubber belt with high abrasion resistance to handle wet clay’s adhesive and
cohesive properties.
Proper idler spacing and pulley configuration to support the material load and reduce belt stress.
Integration of cleaning blades and side skirts to prevent material buildup and maintain operational
efficiency.
The design adheres to CEMA (Conveyor Equipment Manufacturers Association) standards, ensuring
durability and safety in industrial applications. By addressing the unique challenges posed by wet clay, this
conveyor system provides a robust solution for industries such as ceramics, construction, and mining.
Contents
Abstract .......................................................................................................................................................................... 2
Introduction .................................................................................................................................................................... 4
Belt Conveyor System components .................................................................................................................................. 5
Project Objective and Its Relation to the Course ................................................................................................................ 6
Calculations ................................................................................................................................................................... 7
1. Capacity Conversion .......................................................................................................................................... 7
2. Belt width .......................................................................................................................................................... 7
3. Belt tension calculations .................................................................................................................................... 8
4. Belt Idlers .......................................................................................................................................................... 8
5. Drum, Tail & Shaft Design ................................................................................................................................. 10
6. Shaft Design .................................................................................................................................................... 10
Shaft calculations ................................................................................................................................................. 11
7. Bearing design ................................................................................................................................................. 12
8. Coupling design ............................................................................................................................................... 13
9. Belt Thickness.................................................................................................................................................. 13
10. Motor Selection ........................................................................................................................................... 14
11. Gear reduction ............................................................................................................................................ 15
12. Saub pulley ................................................................................................................................................. 16
Shaft Material Selection: AISI 1060 ( Q , T ) [1.1221] .................................................................................................. 16
Roller material selection: Q235 Carbon Steel [ASTM A36 Steel] ................................................................................ 16
13. Saub Bearing ............................................................................................................................................... 17
14. Drum bearing............................................................................................................................................... 17
15. Saub & Shaft Spline...................................................................................................................................... 17
16. Power screw ................................................................................................................................................ 18
17. C Beam ....................................................................................................................................................... 19
Load Calculations ................................................................................................................................................. 19
Live Load (Dynamic) .............................................................................................................................................. 20
Stress Analysis ...................................................................................................................................................... 21
Maximum Moment: ............................................................................................................................................... 21
Deflection Check .................................................................................................................................................. 21
Verification Summary ............................................................................................................................................ 21
Dynamic Load Considerations ............................................................................................................................... 21
Final Specifications ............................................................................................................................................... 21
Cost Analysis ................................................................................................................................................................ 22
Material Costs....................................................................................................................................................... 22
Labor and Assembly Costs......................................................................................................................................... 22
Miscellaneous Costs ............................................................................................................................................. 22
Final Technical Specifications ........................................................................................................................................ 23
System Overview ....................................................................................................................................................... 23
Safety Considerations ................................................................................................................................................... 24
Conclusion ................................................................................................................................................................... 25
References ................................................................................................................................................................... 25
Introduction
A belt conveyor system is a common material handling mechanism that utilizes a continuous belt to
transport materials or goods from one place to another. It consists primarily of two or more pulleys (also
known as drums), with a closed loop of carrying medium—the conveyor belt—that rotates around them.
One or both pulleys are powered, moving the belt and the material on the belt forward.

Belt conveyors are widely used in various industries, including mining, manufacturing, logistics, agriculture,
and food processing, due to their ability to efficiently move bulk materials over long distances with minimal
energy consumption. They are ideal for transporting both lightweight and heavyweight materials, and their
design can be customized for horizontal, inclined, or even curved paths.

The key components of a belt conveyor system include the drive unit (motor), pulleys, idlers, belt, and
supporting structure. Modern systems may also integrate sensors, automated controls, and safety
mechanisms to enhance performance and ensure operator safety.

The simplicity, scalability, and cost-effectiveness of belt conveyor systems make them an indispensable
part of many industrial operations, contributing significantly to productivity and operational efficiency.
Belt Conveyor System components
1. Conveyor Belt
The continuous loop that transports materials. Typically made from rubber, PVC, or fabric-reinforced
composites, it moves over rollers and pulleys to carry loads.
2. Head Pulley (Drive Pulley)
Located at the discharge end, this pulley is powered by a motor to drive the belt forward. It often
features a rough surface (lagging) to enhance grip.
3. Tail Pulley
Situated at the loading end, it guides the belt and may assist in tensioning.
4. Take-Up Pulley
Adjusts belt tension to compensate for stretch and ensure smooth operation.
5. Idler Rollers
Support the belt and the load it carries. They come in various types:

• Carrying Idlers: Support the loaded belt.

• Return Idlers: Support the empty belt on its return.

• Troughing Idlers: Shape the belt into a trough to center the load.
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6. Drive Unit
Comprises the motor and gearbox that provide power to the head pulley.
7. Belt Support Structure
The framework that holds all components in place, ensuring stability and alignment.
8. Loading and Discharge Chutes
Direct materials onto and off the belt, minimizing spillage and wear.
9. Safety and Control Devices
Include emergency stop switches, belt misalignment sensors, and speed monitors to ensure safe
operation.
Project Objective and Its Relation to the Course
The objective of this project is to design and analyze a belt conveyor system capable of efficiently
transporting materials within an industrial or manufacturing environment. The project aims to apply
fundamental engineering principles to develop a reliable, cost-effective, and mechanically sound conveyor
system, considering real-world constraints such as load, speed, efficiency, and safety.

This project is directly related to the Machine Design 2 course, as it integrates key concepts covered in the
curriculum, including:

• Shaft design and analysis: Designing the conveyor's drive shaft and pulleys.

• Bearing and gear selection: Choosing suitable components to support rotational elements.

• Belt and pulley mechanisms: Applying principles of friction, tension, and power transmission.

• Failure analysis and safety factors: Ensuring mechanical integrity under expected loads.

• Material selection: Choosing appropriate materials for structural and wear resistance.

By working on this project, students gain practical experience in applying theoretical knowledge to a real
engineering system, enhancing both their design skills and problem-solving abilities in line with the learning
outcomes of Machine Design 2.
Calculations
This section covers the core theoretical calculations that define the design of the conveyor system for
transporting wet clay.

Parameter Value
Bulk Density 112.37 𝑓𝑡 3 (1800 𝑚3)
𝑙𝑏𝑠 𝑘𝑔

Repose Angle 38°

Conveyor Length 154.2 ft (47m)
Capacity Required 175 TPH
Belt Speed 196.85 fpm (1m/s)

1. Capacity Conversion
175 ∗ 103 𝑘𝑔
∵𝑄= = 48.61
60 ∗ 60 𝑠

2. Belt width

𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 48.61
∴ 𝐴𝑟𝑒𝑎 = = = 0.027 𝑚2 = 0.2906 𝑓𝑡 2
𝐵𝑒𝑙𝑡 𝑠𝑝𝑒𝑒𝑑 ∗ 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 1 ∗ 1800

Surchage angle=0.5~0.9 Repose angle (cema refrence)

0.5 ∗ 38° = 19° ≅ 20°

from table 4.3 (cema refrence)

𝐵𝑒𝑙𝑡 𝑊𝑖𝑑𝑡ℎ = 24 𝑖𝑛𝑐ℎ = 609𝑚𝑚

from Janson & heuning standards

𝐵𝑒𝑙𝑡 𝑊𝑖𝑑𝑡ℎ = 650𝑚𝑚 = 25.59 𝑖𝑛𝑐ℎ

 3. Belt tension calculations

𝑇𝑒 = 𝐿(𝐾𝑡 𝐾𝑥 + 𝐾𝑦 𝑊𝑏 + 0.015𝑊𝑏 ) + 𝑊𝑚 (𝐿𝐾𝑦 + 𝐻) + 𝑇𝑝 + 𝑇𝑎𝑚 + 𝑇𝑎𝑐

Assume H=0

From cema reference - table 6.1

𝑙𝑏𝑠 𝑘𝑔
𝐵𝑒𝑙𝑡 𝑊𝑒𝑖𝑔ℎ𝑡 (𝑊𝑏 ) = 5.5 ≅ 8.19
𝑓𝑡 𝑚

𝑄 48.61 𝑘𝑔 𝑙𝑏𝑠
𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡(𝑊𝑚 ) = = = 48.61 = 32.67
𝑉 1 𝑚 𝑓𝑡
𝐴𝑖
∵ 𝐾𝑥 = 0.0068(𝑊𝑏 + 𝑊𝑚 ) +
𝑆𝑖
1.04
∴ 𝐾𝑥 = 0.0068(8.19 + 48.61) + = 0.90529 → (1)
1.2

4. Belt Idlers
According to table 5.2
 𝑆𝑖 = 4 𝑖𝑛𝑐ℎ = 1.2𝑚

𝑁𝑜. 𝑜𝑓 𝑟𝑒𝑡𝑢𝑟𝑛 𝑖𝑑𝑙𝑒𝑟𝑠 = 10

According to table 5.4

𝑟𝑜𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 4 𝑖𝑛𝑐ℎ

𝐴𝑖 = 2.3 = 1.04 𝑘𝑔

𝑇𝑎𝑚 = 𝑓 = 𝑀𝑉𝑐

𝑄 ∗ 2000
𝑙𝑏𝑠
∵ 𝑊 = 3600 = 𝑇𝑃𝐻 , 𝑔 = 32.2 𝑓𝑡⁄𝑠 2
𝑠𝑒𝑐
𝑤 𝑄 ∗ 2000
∴𝑀= =
𝑔 3600 ∗ 32.2
𝑉 − 𝑉0
∵ 𝑉𝐶 =
60
𝑄 ∗ 2000 𝑉 − 𝑉0
𝑇𝑎𝑚 = ∗
3600 60
175 ∗ 2000 196.85
𝑇𝑎𝑚 = ∗ = 9.9 𝑙𝑏𝑠 = 44.06 𝑁 → (2)
3600 ∗ 32.2 60

𝑇𝑎𝑐 = 0 → (3) (we don’t have accesorien)

𝑇𝑝 = (𝐶𝑟 𝑊𝑏 + 𝐶𝑚 𝑊𝑚 ) ∗ 𝐿

Range Value
C𝑚 = 0.03~0.04 0.035
C𝑟 = 0.015~0.018 0.0165

𝑇𝑝 = (0.0165 ∗ 5.5 + 0.035 ∗ 32.2) ∗ 154.2

𝑇𝑝 = 87.777 𝑙𝑏𝑠 = 835.27 𝑁 → (4)

𝐾𝑦 = 0.03 → (5)

𝐾𝑥 = 1 → (6)
 𝑇𝑒 = 47 ∗ (0.90529 ∗ 1 + 0.031 ∗ 8.19 + 0.015 ∗ 8.19) + 48.61(47 ∗ 0.031) + 835.27 + 44.06

𝑇𝑒 = 972.116 𝑁

𝑃𝑜𝑤𝑒𝑟 = 𝑇 ∗ 𝑉 = 972.116 ∗ 1 = 972.116 𝑊𝑎𝑡𝑡 = 1.3 ℎ𝑝

According to Janson & heuning standards

𝑃𝑜𝑤𝑒𝑟 = 1.5 𝐾𝑊

5. Drum, Tail & Shaft Design

To make wrap angle = 180° let Diameters of drum and Tail be = 250 𝑚𝑚
𝑇𝑒 = 𝑇1 − 𝑇2 → 𝑇1 = 𝑇𝑒 − 𝑇2
𝑇1 + 𝑇2
𝑇𝑖 =
2
𝐹𝑐 = 𝑊𝑏 ∗ 𝑉 2 = 80.34 𝑁
𝑇1−𝐹𝑐 𝑇𝑒+𝑇2−𝐹𝑐
= = 𝑒 𝜇𝜃𝜋/180° Assume 𝜇 = 0.3
𝑇2−𝐹𝑐 𝑇2−𝐹𝑐

972.116 + 𝑇2 − 80.34
= 𝑒 0.3∗180∗𝜋/180°
972.116 − 80.34
𝑇2 = 1396.82 𝑁
𝑇1 = 2368.94 𝑁
𝑇𝑖 = 1882.87 𝑁
𝑃𝑜𝑤𝑒𝑟 = 𝑇𝜔 = 𝑇𝑒 ∗ 𝑟𝑑𝑟𝑢𝑚 ∗ 𝜔
𝜔 = 12.3 𝑟𝑎𝑑/𝑠 = 118 𝑟𝑝𝑚

6. Shaft Design

𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑆ℎ𝑎𝑓𝑡 = 𝐵𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ + 2 𝑝𝑢𝑙𝑙𝑦 𝑒𝑥𝑡𝑒𝑛𝑠𝑖𝑜𝑛 + 2 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑤𝑖𝑑𝑡ℎ 𝑡𝑎𝑙𝑙𝑜𝑤𝑛𝑎𝑐𝑒

Assume that pully face width is a bit more than belt width

𝑃𝑢𝑙𝑙𝑦 𝐹𝑎𝑐𝑒 𝑊𝑖𝑑𝑡ℎ = 650 + 75 = 725 𝑚𝑚 ≅ 28.54 𝑖𝑛𝑐ℎ

From cema table 8.1
𝑤 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑢𝑙𝑙𝑦 = 38.554 𝑘𝑔

Assume

• pully extensions = 50 𝑚𝑚 from each other

• bearing to be spherical roller bearing (psd)
• width = 100 𝑚𝑚 on each side
• allowance for coupling to be 50 mm

𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑆ℎ𝑎𝑓𝑡 = 725 + 2 ∗ 50 + 2 ∗ 100 + 50 = 1225 𝑚𝑚

Shaft calculations

𝑃 1500
𝑇𝑜𝑟𝑞𝑢𝑒 = = = 121.95 𝑁. 𝑚
𝜔 12.3
Assume distributed load for 𝑇1, 𝑇2

576.631 ∗ 103 𝑁. 𝑚𝑚

Σ𝑀1 = 0
1225 𝑇1 = 3765.756 ∗ 612.5
𝑇1 = 𝑇2 = 1882.878 𝑁

𝑀𝑎𝑥 𝑀𝑜𝑚𝑒𝑛𝑡 = 576.631 ∗ 103 𝑁. 𝑚𝑚

Assume Shaft material AISI 1060 (Q&T)

Tensile strength 965 Mpa

Yield strength 669 Mpa

Using Suderberg for cyclic loading

2 2
32𝐹. 𝑠 𝛿 𝛿
𝑑=[ √(𝑀𝑚 + 𝑦 𝐾𝑓 𝑀𝑚 ) + (𝑇𝑚 + 𝑦 𝐾𝑓𝑆 𝑇𝑎 ) ]1/3
𝜋𝛿𝑦 𝛿𝑒 𝛿𝑒

Assume load varies bet + ve and – ve

𝑀𝑚 = 0 , 𝑀𝑎 = 576.631 ∗ 103 𝑁. 𝑚𝑚 , 𝑇𝑎 = 𝑇𝑚 = 187.5 ∗ 103 𝑁. 𝑚𝑚

𝛿𝑒 ′ = 0.29𝛿𝑢 = 0.29(965) ≅ 280 𝑀𝑝𝑎

𝛿𝑒 = 𝐾𝑓 𝐾𝑠 𝐾𝑟 𝐾𝑡 𝐾𝑚 𝛿𝑒 ′

Assume machining (Cold Drawing)

𝑒 = 4.51 , 𝑓 = −0.265

𝐾𝑓 = 𝑒𝛿𝑢 𝑓 = 4.51 ∗ 965−0.265 = 0.73

Assume reliability factor (𝐾𝑟 ) = 0.9

Assume 𝐾𝑡 , 𝐾𝑚 = 1

𝛿𝑒 = 0.73 ∗ 0.9 ∗ 280 = 183.96 𝑀𝑝𝑎

Assume 𝐹. 𝑠 = 3

2 2
32 ∗ 3 669 669
𝑑=[ √ ( 3 3
∗ 576.631 ∗ 10 ) + (187.5 ∗ 10 + ∗ 187.5 ∗ 10 ) ]1/3
3
𝜋 ∗ 669 183.96 183.96

𝑑 = 110 𝑚𝑚

7. Bearing design

Bearing No. 22210E

Adapter sleeve H311
Bune Diameter 50 mm
Width 25 mm
Outer Diameter 90 mm
Dynamic load rate (C) 106 Km
Static load rating (𝑪𝟎 ) 102 KN
 8. Coupling design

Table 2 in psg reference

1.5 𝐾𝑤 ∗ 1.5 ∗ 100
𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝐾𝑤 𝑟𝑎𝑡𝑖𝑛𝑔 = = 2.945 𝐾𝑤 ≅ 3 𝐾𝑤
76 𝑟𝑝𝑚
We will choose coupling no. 5

Check shaft fit, A 45~56 ∴ 𝑆ℎ𝑎𝑓𝑡 𝑠𝑎𝑓𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 50 𝑚𝑚

9. Belt Thickness

Based on EMEA conveying solutions and givens, It is a transcant belt ( 630/1)

Carcus gauge = 3.3 mm

Our material is wet clay, which is abrasive and sticky but harsh as crushed rocks

It’s a standard duty application

Top cover = 5~6 𝑚𝑚

Bottom cover = 5~6 𝑚𝑚

This will protect against

• Wear due to sticky minor impacts from loading points

• Potential damage from return rollers

Belt thickness = carcus gauge + top cover + bottom cover

B y taking the average of top and bottom covers

belt thickness = 5.5 + 3.3 + 2.5 = 11.3 mm
 10. Motor Selection

CONTI Titan motor

For heavy duty applications suitable for wet clay
FEATURES
• High abrasion resistance
• Excellent load support
• Ideal for harsh conditions

𝑀𝑜𝑡𝑜𝑟 𝑠𝑝𝑒𝑒𝑑 = 3000 𝑟𝑝𝑚

𝑚𝑜𝑡𝑜𝑒 𝑠𝑝𝑒𝑒𝑑 3000
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 = = = 25.423 ∶ 1
𝐷𝑟𝑢𝑚 𝑠𝑝𝑒𝑒𝑑 118
11. Gear reduction

Objective: Reduce motor speed from 3000 RPM to drum speed of 118 RPM.
Key Parameters
• Total Gear Ratio:

• Design Approach:
o Equal ratio distribution across 3 stages (∛25.42 ≈ 2.94:1 per stage).
o Standard gear teeth (min 17T to avoid undercutting).
Gear Train Specifications
Driver Gear Driven Ratio Output
Stage (Pinion) Gear Speed
1 17 Teeth 50 Teeth 2.941:1 1020 RPM
2 17 Teeth 50 Teeth 2.941:1 347 RPM
3 17 Teeth 50 Teeth 2.941:1 118 RPM

Verification:
Total Ratio = 2.941×2.941×2.941= 25.42:1 (Exact)
Advantages of This Design
1. Precision: Matches the target 118 RPM exactly.
2. Standardization: Uses identical 17T : 50T pairs for all stages (reduces part variety).
3. Reliability:
• 17T pinions meet the minimum tooth count for 20° pressure angle (no undercutting).
• 50T gears are widely available per AGMA/ISO standards.

Technical Drawing
Motor (3000 RPM)
│
├── Stage 1: 17T → 50T (1020 RPM)
│
├── Stage 2: 17T → 50T (347 RPM)
│
└── Stage 3: 17T → 50T (118 RPM → Drum)
 References
1. AGMA 9002-B17: Standard for Gear Tooth Proportions.

Notes for Implementation

• Lubrication: Required for high-speed stages (Stage 1 operates at 1020 RPM).
• Material: Case-hardened steel (AGMA Grade 2) recommended for durability.
• Tolerance: Ensure gear alignment within ±0.05mm to minimize noise.

12. Saub pulley

Shaft Material Selection: AISI 1060 ( Q , T ) [1.1221]

𝐓𝐞𝐧𝐬𝐢𝐥𝐞 𝐬𝐭𝐫𝐞𝐧𝐠𝐭𝐡 965 Mpa

𝐲𝐢𝐞𝐥𝐝 𝐬𝐭𝐫𝐞𝐧𝐠𝐭𝐡 669 Mpa
𝐃𝐞𝐧𝐬𝐢𝐭𝐲 7850 𝑘𝑔/𝑚3
𝐄 190 Gpa
Shear modulus 80 Gpa
Bulk modulus 140 Gpa

Roller material selection: Q235 Carbon Steel [ASTM A36 Steel]

𝐓𝐞𝐧𝐬𝐢𝐥𝐞 𝐬𝐭𝐫𝐞𝐧𝐠𝐭𝐡 400 Mpa

𝐲𝐢𝐞𝐥𝐝 𝐬𝐭𝐫𝐞𝐧𝐠𝐭𝐡 250 Mpa
Density 7850 𝑘𝑔/𝑚3
 13. Saub Bearing

𝐁𝐞𝐚𝐫𝐢𝐧𝐠 𝐧𝐮𝐦𝐛𝐞𝐫 22222-E

Bore diameter 110 mm
width 56 mm
Outer diameter 200 mm
Dynamic load rate 491 KN
Static load rate 560 KN

➢ For bearing housing (From shaffler catelouge):

LOE 222 – N – AF - L LOE 222 – N – AL - L

14. Drum bearing

𝐁𝐞𝐚𝐫𝐢𝐧𝐠 𝐧𝐮𝐦𝐛𝐞𝐫 22228 – CC – W33

Bore diameter 140 mm
width 68 mm
Outer diameter 250 mm
Dynamic load rate 743 KN
Static load rate 900 KN

➢ For bearing housing (From shaffler catelouge):

LOE 228 – N – AF - L LOE 228 – N – AL - L

15. Saub & Shaft Spline

𝑃 1500
𝑇𝑜𝑟𝑞𝑢𝑒 = = = 121.95 𝑁. 𝑚
𝜔 12.3
For such a heavy duty work, the spline need a number of keys = 9

For a 110 mm diameter

𝝎 28 mm
𝒉 16 mm
Material AISI 1060 Q&T
Tensile strength 965 Mpa
Yield strength 669 Mpa
Safety factor 3

For shear stress

𝛿𝑦 ∗ 𝐴𝑠 ∗ 𝑑𝑛
𝑇=
4 ∗ 𝑛𝑠
𝐴𝑠 = 𝜔 ∗ 𝐿
 4 ∗ 𝑇 ∗ 𝑛𝑠 4 ∗ 107.5 ∗ 106 ∗ 3
𝐿= = = 121.33 𝑚𝑚
𝛿𝑦 ∗ 𝑑𝑛 ∗ 𝜔 669 ∗ 110 ∗ 28 ∗ 9

For bearing/ crushing stress

𝛿𝑦 ∗ 𝑑 ∗ ℎ ∗ 𝑙 ∗ 𝑛
𝑇=
4 ∗ 𝑛𝑠
4∗𝑇∗ 𝑛𝑠 4∗187.5∗106
𝑙𝑛 = = = 212.325 𝑚𝑚 ≅ 212 𝑚𝑚 (safe choice)
𝛿𝑦 ∗𝑑∗ℎ∗𝑛 530∗110∗16∗9

For drum shaft

𝛿𝑦 ∗ 𝑑 ∗ ℎ ∗ 𝑙 ∗ 𝑛
𝑇=
4 ∗ 𝑛𝑠
4∗𝑇∗ 𝑛𝑠 4∗187.5∗106
𝑙𝑛 = = = 166.89 ≅ 167 𝑚𝑚 (safe choice)
𝛿𝑦 ∗𝑑∗ℎ∗𝑛 530∗140∗16∗9

16. Power screw

It’s function is to keep the belt at tension by moving the drum

since there are two power screws
𝑇𝑒 972.116
𝑓= = = 486.058 𝑁
2 2
Specifactions single – start, ACME
Thread factor of safety 4
material 4140 steel annealed
Tensile strength 417 Mpa
Yield strength 555 Mpa

𝛿𝑦 𝑓
=𝜋
𝑛𝑠 2
4 ∗ 𝑑𝑖𝑛

𝑓 ∗ 𝑛𝑠
𝑑𝑖𝑛 = √𝜋
4 ∗ 𝛿𝑦

486.085 ∗ 3
𝑑𝑖𝑛 = √ 𝜋 = 2.4365 𝑚𝑚
4 ∗ 417

For more safety (from the table)

𝑑𝑐 = 1 𝑖𝑛𝑐ℎ = 25.4 𝑚𝑚, 𝑝𝑖𝑡𝑐ℎ = 5.08

Then

𝑑𝑝 = 𝑑𝑐 − 0.5 𝑝𝑖𝑡𝑐ℎ − 0.254 = 22.606 𝑚𝑚

𝛽 = 29°, 𝑙 = 𝑛𝑝 = 1 ∗ 5.08 = 5.08 𝑚𝑚

 𝑙 5.08
𝛼 = tan−1 ( ) = tan−1 ( ) = 4.0914°
𝜋𝑑𝑝 𝜋 ∗ 22.606

𝑑𝑟 = 𝑑𝑝 − 𝑝𝑖𝑡𝑐ℎ − 0.508 = 19.812 𝑚𝑚

Since the load on the screw will be tension only (No buckling)

17. C Beam

Design Parameters

Parameter Value Unit

Material Yield Strength 250 MPa
Safety Factor 3.0 -
Allowable Stress 83.33 MPa
Beam Span 6,000 mm
Number of Beams 2 -
Impact Factor 1.5 -

Load Calculations
Dead Load:

Component Qty Unit Weight (kg) Total (kg)

Idlers 6 56.5 339

Rollers 4 8 32

Total 371

Conversion:

Distributed Load:
Live Load (Dynamic)
Material Flow:

Dynamic Load Intensity (50% Impact):

Total Design Load:

Structural Analysis
Section Properties

Proposed Section: C180×90×18×6 *( for SF=3)*

Dimension Value (mm)

Total Height (H) 180
Width (B) 90
Flange Thickness (t) 18
Web Thickness (t_w) 6

Moment of Inertia:

Section Modulus:
Stress Analysis
Maximum Moment:

Bending Stress:

Deflection Check

Allowable Deflection:

Verification Summary
Check Calculated Allowable Status

Bending Stress 79.38 MPa 83.33 MPa Pass

Deflection 9.92 mm 16.67 mm Pass

Dynamic Load Considerations

Natural Frequency Check:

Fatigue Analysis:
o Stress range (Δσ) = 29.26 MPa (from static) × 1.5 = 43.89 MPa

o Endurance limit (for S235): 80 MPa > 43.89 MPa (Safe)

Final Specifications

Section C180×90×18×6 mm

Material ASTM A36 Steel

Inspection Ultrasonic Testing for Critical Welds

 Cost Analysis
Material Costs
Component Material Quantity Unit Cost Total Cost
(USD) (USD)
Conveyor Belt (650mm Heavy-duty rubber 47 m 150/m 7,050
width) (630/1)
Head/Tail Pulleys AISI 1060 (Q&T) 2 800/each 1,600
Idler Rollers Q235 Carbon Steel 10 120/each 1,200
Drive Shaft AISI 1060 (Q&T) 1 1,500 1,500
Bearings (22210E, 22222- Spherical roller 4 200/each 800
E) bearings
Gearbox (3-stage Case-hardened steel 1 3,000 3,000
reduction)
Motor (1.5 kW) Industrial-grade 1 1,200 1,200
C-Beam Support Structure ASTM A36 Steel 6m 100/m 600
Subtotal 16,950

Labor and Assembly Costs

Activity Hours Rate (USD/hr) Cost (USD)
Mechanical Assembly 80 25 2,000
Electrical Installation 20 30 600
Safety Compliance Testing 10 50 500
Subtotal 3,100

Miscellaneous Costs
Item Cost (USD)
Transportation 500
Contingency (5%) 1,003
Total Project Cost 21,553
Final Technical Specifications
System Overview
• Application: Transport of wet clay (Bulk density: 1,800 kg/m³, Angle of repose: 38°).

• Capacity: 175 TPH (48.61 kg/s).

• Conveyor Length: 47 m (horizontal).

• Belt Speed: 1.0 m/s.

Key Components
Parameter Specification

Belt Width: 650 mm; Thickness: 11.3 mm (3.3 mm carcass + 5.5/2.5 mm covers).

Pulleys Diameter: 250 mm; Material: AISI 1060 (Q&T).

Drive Unit Motor: 1.5 kW, 3000 RPM; Gearbox: 3-stage (25.42:1 ratio).

Idlers Troughing idler spacing: 1.2 m; Roller diameter: 4 inches.

Shaft Diameter: 110 mm; Material: AISI 1060 (Q&T).

Bearings Spherical roller bearings (22210E, 22222-E).

Support Structure C180×90×18×6 mm (ASTM A36 Steel).

Performance Metrics
• Power Consumption: 1.5 kW (2 HP).

• Belt Tension: 972.116 N (T1 = 2,368.94 N, T2 = 1,396.82 N).

• Shaft Torque: 121.95 N·m.

• Deflection Limit: 9.92 mm (<16.67 mm allowable).

Safety Considerations
Safety is a critical aspect of belt conveyor system design, operation, and maintenance. Conveyor systems
involve moving parts, high speeds, and heavy loads, which can pose serious hazards if not properly
managed. Below are key safety considerations:

1. Emergency Stop Mechanisms

Emergency stop switches should be installed along the length of the conveyor to allow immediate
shutdown in case of an emergency.

2. Belt Alignment and Tracking

Misaligned belts can cause material spillage or equipment damage. Sensors and automatic belt
trackers help prevent accidents due to belt misalignment.

3. Guarding of Moving Parts

All rotating parts such as pulleys, gears, and shafts must be properly guarded to prevent contact
with clothing or limbs.

4. Overload Protection
Systems should include torque limiters or overload sensors to prevent mechanical failure due to
excessive load.

5. Start-up Alarms and Warning Systems

Audible and visual alarms should alert workers before the system starts to ensure they are clear of
danger zones.

6. Safe Access and Maintenance

Proper walkways, handrails, and lockout/tagout procedures should be in place to protect
maintenance personnel.

7. Fire and Dust Hazard Controls

In some environments, conveyor systems can create fire risks due to friction or carry combustible
dust. Regular cleaning, anti-static belts, and fire detection systems help mitigate this risk.

8. Training and Operational Procedures

Operators and maintenance staff should be thoroughly trained in safe usage practices, emergency
procedures, and equipment-specific risks.

9. Regular Inspections and Maintenance

Scheduled inspections help identify wear, misalignment, and other hazards early to avoid
breakdowns or accidents.

10. Compliance with Standards

The system should comply with relevant safety standards such as ISO, OSHA, or local industrial
safety codes.
Conclusion
The designed belt conveyor system effectively transports wet clay at 175 TPH over 47 meters, combining
robust engineering (AISI 1060 shafts, 650mm heavy-duty belt, and 1.5 kW motor) with cost-efficiency
($21,553 total project cost) and safety compliance (CEMA standards, emergency stops). Future upgrades
like automated cleaning and predictive maintenance could further optimize performance, making this
system a reliable, scalable solution for industrial applications in ceramics, construction, and mining.

References
• Cad Model

https://drive.google.com/drive/folders/1tza4Nvrh0DIuq31OGXinD1szWqvOZ0d7?usp=drive_link

• Convey_solutions_EMEA_en
• PSG Design Data Book For 7 Sem Mech
• Conveyor Equipment Manufacturers Association. Engineering Confer - Belt conveyors for bulk
materials (1997, CEMA)
 8 7 6 5 4 3 2 1
R2 H7
F 40
.0 140.00 k6
0
F 1 F
G G
3

4
5
E E
F SECTION SIDE VIEW AT F-F
FRONT VIEW
ISOMETRIC
SCALE: 1:20
1570.00

D D
ITEM PART NUMBER MATERIAL QTY.
NO.
1 Drum pulley (with rubber AISI 304 1
coating)
7
2 2 Ring with blade (drum) AISI 304 1

3 Hub (drum) AISI 304 1

6
C 4 Shaft (drum) AISI 1060 1 C
H7
280.00 p6

5 Bearing housing (drum) Gray cast iron 2

H7
400.00 p6

600.00
6 Drum Bearing SAE 52100 2
9 (22228_cc_w33_01)
7 Drum Bearing SAE 52100 2
(22228_cc_w33_02)
8 Drum Bearing SAE 52100 2
(22228_cc_w33_03)
B 8 9 Drum Bearing SAE 52100 2 B
(22228_cc_w33_04)
SECTION TOP VIEW AT G-G UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
Drum
A MFG A
Q.A MATERIAL: DWG NO.
A3

WEIGHT: SCALE:1:10 SHEET 1 OF 6

8 7 6 5 4 3 2 1
 4 3 2 1
R2
40
.0 440.00
0
F F
40
0.0
0 +0.0
0.0 6
0

E E

FRONT VIEW SIDE VIEW

1000.00
D D

C C
ISOMETRIC
TOP VIEW SCALE : 1:20

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Drum Pulley

A MFG A
Q.A MATERIAL: DWG NO.

AISI 304 with A4

Rubber coating
WEIGHT: SCALE:1:10 SHEET 2 OF 6

4 3 2 1
 4 3 2 1
280.00
500.00
28.00
F F

C C

86.00
E E

R7
FRONT VIEW SIDE VIEW

0 .0
+0 0.0
0

.0 0
3
D D
167.00 30.00
+0.09
280.00 +0.06
155.00

C C
SECTION TOP VIEW AT C-C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
Drum Hub
A MFG A
Q.A MATERIAL: DWG NO.
A4
AISI 304
WEIGHT: SCALE:1:7 SHEET 3 OF 6

4 3 2 1
 4 3 2 1
23.00
.08
+0 .05
F +0 F
R1 .00
40 00
.00 +0 R2 8.50
.
0.004
0
6.00

E E
0
7.0

FRONT VIEW SIDE VIEW

D D

TOP VIEW

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

Ring
DRAWN

CHK'D

APPV'D

A MFG A
MATERIAL: DWG NO.

AISI 304
Q.A
A4

WEIGHT: SCALE:1:7 SHEET 4 OF 6

4 3 2 1
 4 3 2 1

+0.03
140.00 +0.00
F 1462.00 F
167.00
28.00

FRONT VIEW SIDE VIEW

E E

D D
TOP VIEW

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
Drum Shaft
A MFG A
MATERIAL: DWG NO.

AISI 1060
Q.A
A4

WEIGHT: SCALE:1:12 SHEET 5 OF 6

4 3 2 1
 4 3 2 1
327.89 190.00

305.02 185.00

F R17 F
5.0 180.00
0

D D

25
0.
00
125.00
R5
.0

E E
0

80.00
600.00
FRONT VIEW SIDE VIEW
54.00

D 5 D
M4

50.00

SECTION TOP VIEW AT D-D

C C

ISOMETRIC
B SCALE: 1:8 B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Bearing House

A MFG A
GRAY CAST
Q.A MATERIAL: DWG NO.
A4
IRON
WEIGHT: SCALE:1:6 SHEET 6 OF 6

4 3 2 1
 8 7 6 5 4 3 2 1

1200.00
F F
1

371.96
E E

SIDE VIEW
FRONT VIEW

D D
2
101.60

C C

TOP VIEW
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 roller ASTM A36 with rubber coating 3
B B
2 idler frame ASTM A36 1
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D IDLER
A MFG A
Q.A MATERIAL: DWG NO.
A3

WEIGHT: SCALE:1:7 SHEET 1 OF 3

8 7 6 5 4 3 2 1
 4 3 2 1

1200.00
F 5.0 F
0

184.58
202.42

301.08
45.69

175.00
5°

60
.9

4.65
.34
60

° 69.00
E 127.26 E

FRONT VIEW SIDE VIEW

D D
12.00

TRUE R7.50
240.00
2 HOLES M12x1.5

TOP VIEW
C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Idler Frame

A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:10 SHEET 2 OF 3

4 3 2 1
 4 3 2 1
15.00

F F

101.60

245.00
E E

D D
76.20

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D ROLLER
A MFG A
Q.A MATERIAL: DWG NO.
ASTM A36 with A4
rubber coating
WEIGHT: SCALE:1:3 SHEET 3 OF 3

4 3 2 1
 8 7 6 5 4 3 2 1

F F

101.60
55.35

1143.00
E E

FRONT VEIW 2
1
SIDE VEIW
D D

C C

TOP VEIW ITEM NO.

1
PART NUMBER
return roller holder
MATERIAL
ASTM A36
QTY.
2
B B
2 return roller ASTM A36 1
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D

A MFG A
MATERIAL: DWG NO.

Return Roller
Q.A
A3

WEIGHT: SCALE:1:5 SHEET 1 OF 3

8 7 6 5 4 3 2 1
 4 3 2 1

105.00 99.00
F F

20.45
94.90

64.00

60.00
.5 0

E E
R7

65.00

30.00

FRONT VEIW SIDE VEIW

M1 2x1.5
D OLES D
2H

5.00
30.00

C C
105.00

TOP VEIW

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Return Roller Holder

A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:2 SHEET 2 OF 3

4 3 2 1
 4 3 2 1

F F

101.60

E E

965.00
D D

FRONT VEIW SIDE VEIW

C C
0
.2
76

15.00

B TOP VEIW B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Return Roller

A MFG A
Q.A MATERIAL: DWG NO.

ASTM A36 with A4

rubber coating
WEIGHT: SCALE:1:8 SHEET 3 OF 3

4 3 2 1
 4 3 2 1

18.00
R2
140.00 30x2. 0 0.
F 8H OLES M 165.00 00
F

180.00
6000.00
6.00

FRONT VEIW SIDE VEIW

E E

90.00
D D
TOP VEIW

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D C beam (6 metre)

A MFG A
MATERIAL: DWG NO.

ASTM A36
Q.A
A4

WEIGHT: SCALE:1:50 SHEET 1 OF 3

4 3 2 1
 4 3 2 1

165.00 R2

18.00
0x2.0 0.
F 8H OLES M3 140.00 00 F

180.00
3938.83

6.00

FRONT VEIW SIDE VEIW

E E

90.00
D D
TOP VEIW

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
C beam)
A MFG A
MATERIAL: DWG NO.

ASTM A36
Q.A
A4

WEIGHT: SCALE:1:50 SHEET 2 OF 3

4 3 2 1
 4 3 2 1

890.00
20.00
F 165.00 F

280.00 140.00

120.00
.0
30x2
LES M

E E
FRONT VEIW SIDE VEIW
8 HO

D D

TOP VEIW

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

C beam link
NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D

A MFG A
MATERIAL: DWG NO.

ASTM A36
Q.A
A4

WEIGHT: SCALE:1:6 SHEET 3 OF 3

4 3 2 1
 8 7 6 5 4 3 2 1

1253.83 129.00

F F

E E

FRONT VIEW SIDE VIEW

D 4 3 5 1 D

2 6
ITEM PART NUMBER
C NO. MATERIAL QTY. C
1 Base (Screw) GRAY CAST IRON 1
2 C channel for ASTM A36 1
124.33

screw
3 Cover (screw) GRAY CAST IRON 1
4 Eye Screw AISI 4140 1
ISO 2340 - B -
5 27 x 120 x 6.3 - GRAY CAST IRON 1
St
B TOP VIEW 6 ISO 1234- GRAY CAST IRON 2
B
6.3x40-C
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Power Screw

A MFG A
Q.A MATERIAL: DWG NO.
A3

WEIGHT: SCALE:1:5 SHEET 1 OF 5

8 7 6 5 4 3 2 1
 4 3 2 1

ACME THREAD
Dc=25.4mm
F pitch=5.08mm F

400.00
m=1
Dp=22.606mm
Dr=19.812mm
330.38

E E
445.00

40.40
D D
40.00

20.00
R40.
00

FRONT VIEW SIDE VIEW

C C

TOP VIEW

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D EYE SCREW

A MFG A
Q.A MATERIAL: DWG NO.
A4
AISI 4140
WEIGHT: SCALE:1:4 SHEET 2 OF 5

4 3 2 1
 4 3 2 1

162.50
F F

5
M4

180.00
44.00

E E

800.00

27

50.00
M
100.00

17.00
D 5.00 D

15.00
83.00

C C

B ISOMETRIC VIEW B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D SCREW BASE

A MFG A
Q.A MATERIAL: DWG NO.
A4
GRAY CAST IRON
WEIGHT: SCALE:1:7 SHEET 3 OF 5

4 3 2 1
 4 3 2 1
328.24
104.00
447.57
F F

58.00
58.00

64.00

84.00
200.00

E E

30.67
. 35
R51

D D

40.00

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
COVER
A MFG A
Q.A MATERIAL: DWG NO.
A4
GRAY CAST IRON
WEIGHT: SCALE:1:5 SHEET 4 OF 5

4 3 2 1
 4 3 2 1
100.33
180.00

F F
10.00
107.33

60.00

95.33
E E

7.00
FRONT VIEW SIDE VIEW

90.00
M27

D D
107.00

C TOP VIEW C

ISOMETRIC VIEW
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D C Channel
A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:2 SHEET 5 OF 5

4 3 2 1
 8 7 6 5 4 3 2 1
B
1480.00

F F

400.00
E E

FRONT VIEW SECTION SIDE VIEW AT B-B

B

H7
D 110.00 j6 D
ISOMETRIC
SCALE: 1:9
ITEM PART NUMBER MATERIAL QTY.
NO.

1 Bearing housing GRAY CAST 2

(snub) IRON
325.00

C 2 Pulley (Snub) AISI 304 1 C

3 Shaft (snub) AISI 1060 1

4 Drum Bearing SAE 52100 2

(22222_e_02_01)

5 Drum Bearing SAE 52100 2

(22222_e_02_01)
6 Drum Bearing SAE 52100 2
(22222_e_02_01)
B SECTION TOP VIEW AT A-A
7 Drum Bearing SAE 52100 2 B
(22222_e_02_01)
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Snub
A MFG A
Q.A MATERIAL: DWG NO.
A3

WEIGHT: SCALE:1:6 SHEET 1 OF 4

8 7 6 5 4 3 2 1
 4 3 2 1

C 250.00
F 234.00 100.00 F
0
3 7.5 105.00
R1

0
D D 110.00

0.0
20
100.00

297.50
E E

CFRONT VIEW
SECTION SIDE VIEW AT C-C
10.00

D 37.50 D
9
M3

SECTION TOP VIEW AT D-D

C C

ISOMETRIC
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Bearing Hosue

A MFG A
Q.A MATERIAL: DWG NO.
A4
GRAY CAST IRON
WEIGHT: SCALE:1:5 SHEET 2 OF 4

4 3 2 1
 4 3 2 1

1460.00

+0.01
110.00 - 0.01
F F
414.47
212.00 28.00

71.00
FRONT VIEW SIDE VIEW
E E

TOP VIEW

D D

C C

ISOMETRIC VIEW

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Snub Shaft

A MFG A
Q.A MATERIAL: DWG NO.
A4
AISI 1060
WEIGHT: SCALE:1:11 SHEET 3 OF 4

4 3 2 1
 0. .03
4 3 2 1

00
0 0
5 .0 +
R5
F 28.00 F
304.00

71.00
E E

325.00
E E
FRONT VIEW SIDE VIEW

1000.00
69.50

200.00

D D
304.00

212.00

SECTION E-E

C C

B ISOMETRIC VIEW B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Snub Pulley

A MFG A
Q.A MATERIAL: DWG NO.
A4
AISI 304
WEIGHT: SCALE:1:11 SHEET 4 OF 4

4 3 2 1
 8 7 6 5 4 3 2 1
6
1940.00 3
2
F F

1915.00
E 6 E

ITEM NO. PART NUMBER Material QTY.

4
D 1712.80 D

5 FRONT VIEW SIDE VIEW 1 Front paw (Leg) ASTM A36 2

2 Side bone (Leg) ASTM A36 2

3 Longer Side ASTM A36 2

bone (Leg)
C C
4 Back Leg ASTM A36 2

5 Front Leg ASTM A36 1

6 Triangular Rib ASTM A36 6

(Leg)

B 7 Back bone (Leg) ASTM A36 1 B

UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Leg structure

A MFG A
TOP VIEWE Q.A MATERIAL: DWG NO.
A3

WEIGHT: SCALE:1:20 SHEET 1 OF 8

8 7 6 5 4 3 2 1
 4 3 2 1

F F

400.00
100.00
E E

FRONT VIEW SIDE VIEW

D D
R8
.5

95
0

C C
20.00

TOP VIEW

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Front Paw

A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:5 SHEET 2 OF 8

4 3 2 1
 4 3 2 1

F F

E 70.00 E
1310.00
160.00

D D

FRONT VIEW SIDE VIEW

C C
95 20.00
°

R8
.50
B TOP VIEW B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Side bone

A MFG A
Q.A MATERIAL: DWG NO.

ASTM A36 A4

WEIGHT: SCALE:1:10 SHEET 3 OF 8

4 3 2 1
 4 3 2 1

F F
160.00 70.00

E E
1350.00

D D

FRONT VIEW SIDE VIEW

C C
20.00

95°
R8.
50

TOP VIEW

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Longer Side bone

A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:10 SHEET 4 OF 8

4 3 2 1
 4 3 2 1

F F

70.00

E E
1568.99

D D

200.00
200.00
4H

C C
ole
s

FRONT VIEW SIDE VIEW

30.00
30
.00

30.00

B TOP VIEW B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
Back leg
A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:10 SHEET 5 OF 8

4 3 2 1
 4 3 2 1

F F
160.00

E E
100.00

D 1915.00 D
15.00

200.00

C C
FRONT VIEW SIDE VIEW
30.00
30.00

95
°
4
HO
0

LE
.5

TOP VIEW
S
R6

B B
30
.0
0

UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND

DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D Front Leg

A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:12 SHEET 6 OF 8

4 3 2 1
 4 3 2 1
15.00
200.00
F F

°
90
200.00

E E

FRONT VIEW SIDE VIEW

D D

C C
TOP VIEW

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D

A MFG A
MATERIAL: DWG NO.

Leg structure
Q.A
A4
ASTM A36
WEIGHT: SCALE:1:3 SHEET 7 OF 8

4 3 2 1
 4 3 2 1

F F

160.00
E E

1570.00 70.00

D D

C C
FRONT VIEW SIDE VIEW
95
°

8 .50
B R TOP VIEW B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN

CHK'D

APPV'D
Back Bone
A MFG A
Q.A MATERIAL: DWG NO.
A4
ASTM A36
WEIGHT: SCALE:1:10 SHEET 8 OF 8

4 3 2 1
 12 11 10 9 8 7 6 5 4 3 2 1

10
29 10 16 25 3 8 27 28 7 17 2

2329.94
47000.00
H H
1712.80
18
16

24 23
19 17
9 22
26 FRONT VIEW
14 15 12 30 SCALE:1:300 SIDE VIEW
G G
30 7 11
26
25 24

ITEM NO. PART NUMBER DESCRIPTION QTY.

27
F 23 14 12 TOP VIEW 8 1 Drum 2
F
4 C channel 14
1000.00 5 Complete Leg 2
Strucure
740.00 6 Hinge (Leg) 4
7 C beam 5m 2
8 c beam link 28
E 1 9 return idler 2 E
10 Ideler 20 degree 1
11 belt 1
12 return idler2 23
10 12 13 return idler 4 1
DETAIL D 14 return idler 5555555 1
5 SCALE 1 : 15
15 ISO 4014 - M12 x 55 100
D x 55-N D
6 4 ISO 4014 - M30 x 110
16 x 66-N 16

17 ISO 4014 - M12 x 120 78

x 120-N
18 ISO 4014 - M24 x 90 8
x 90-N
19 ISO - 4161 - M12 - N 100
CROPPED FRONT VIEW SIDE VIEW 20 ISO - 4034 - M30 - N 120
C SCALE:1:25 21 ISO - 4034 - M42 - N 8 C
22 ISO - 4034 - M36 - N 8
23 ISO 4018 - M30 x 60- 8
WN
24 ISO 4018 - M42 x 8
160-WN
25 ISO 4018 - M36 x 8
150-WN
26 ISO - 4035 - M30 - N 8
B B
27 ISO 7411 - M30 x 120 112
--- 72-WN
28 ISO - 4033 - M12 - W 156
-N
29 ISO - 4032 - M24 - W 8
-N
30 Leg support ASTM A36 16
TITLE:

A Belt Conveyor System A

TOP VIEW
WEIGHT: DWG NO.
A2
16554.269710862
Kg
SCALE:1:300 SHEET 1 OF 1

12 11 10 9 8 7 6 5 4 3 2 1