Chapter III

Design of vertical carousal system

3.1 Design Concept Criterion:

In the process of designing the VCSS there is some limitation and criterion the decision
is affected by and the limitation and criterion are as the following:
Customer Needs:
- Customer needs resemble the primary objective in the project as the
customer needs must be satisfied so that the project is profitable.
- Customer needs might vary greatly between industrial or pharmaceutical
and the different variety that can be offered by the VCSS so
customization and variation must be available in the production line that
will produce the product.

Space Limitation:
- Space decides the size of the VCSS and the model where it can be three
meter high or 30 meter high and with multi-access platforms

Configuration:
- The arrangement of the system and configuration is varying primarily
because of the customer needs size, shape and functionality required is
the main factor in changing configuration of the system.

Access Rate:
- Based on the number of items to be stored and retrieved and the
utilization of the system the access rate must be considered to be higher
or lower, response of the system and the speed of the retrieval process.

Power Drive :
- Power of the drive is determined and selected by the number of the items
stored and their weight and the speed of the systems response.

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 Appearance:
- The appearance of the system is determined by the category and the use
of the VCSS. the customer requirement of the color and logo to be added
and instructions to be printed on the system

Safety:
- The device must be have to the highest degrees of safety and is
ergonomically designed to prevent any human injury while using and
maintain the system.
Next Generation Modification:
- Expandable data acquisition system to handle the data between the main
store and the system
- New generation of the same type with different scales can be managed
for market as market demands
- Expandable height to accommodate more cylinders and multiple access
points
- Alternative power sources can be used such as the wind or solar energies
for green factories

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3.2 Design Calculations:

Selection of Drive:
The driving power of the system consisting of an AC motor, chain and pulley
connected to 10 cylinders. The cylinder dimensions is 1400 mm of length and 300
mm of diameter and its weight is equal to 10 kg. The total weight of cylinders is 100
kg as of 10 cylinders. Assuming maximum allowable add on weight is 50 kg. Then
total weight is 60 20 =1200 kg. Then torque due to weight is equal to weight of
single side multiplied by half distance to pulley. As W is weight of the shelf and
adds on weight, g is gravity, N is number of shelves and r is the radius then,
equation is
=
= 60 9.81 5 0.15
= 441.45 .
The power needed form motor is equal to = , where = as V is the
velocity
is the radial velocity rad / sec.
=
0.10 = 0.15
= 0.6667 /
=
= 441.45 0.667
= 294.44
Compensation of Chain is, ch=0.7 and compensation for frication fr=0.9, then

total compensation factor t =0.70.9=0.63

The power effective needed form motor is equated through.

=

294.44
= 467.37
0.63
P =0.62 H.P
The available motor selected is 1.5 H.P and it is preferred to increase the power of
the motor so it does not breakdown more frequent and it is not desired to increase

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 the power by much so that the efficiency of the system does not drop due to the
increase consumption of electricity.
Gear box ratio determination:
The gear box needed was calculated by the number of R.P.M produced by the motor
Divided by the R.P.M needed for the system. The motor has a R.P.M of 1400
rev/min and the desired R.P.M is 13 rev/min so the gear ratio needed is 107. the
motor purchased has 1400 rev/min with gear ratio of 106 which suffice in our
system.

Design of Frame:
the design of the frame is fairly simple we need to know the load a certain structure
will fail at and determine the amount of forces applied on the structure and choose
the dimensions that makes the structure rigid, resilient and does not buckle against
forces.

To calculate the load to avoid buckling we use the formula

2
=
2

is the critical load in which if reached the column will buckle, E is the modules
of elasticity, I is the second area moment of inertia, and is the effective length.

Substituting in the formula with the used dimension in the system to check its
safety as the size of the frame was considered in the assembly the length of the
column, the thickness ,its shape and size so the length of the column chosen was 2.5
m and the dimension of the L shaped steel angel equal leg bar is 80 80 6 mm .
to check it safety and reliability substituting in the formula.

2 200 103 0.558 106

=
(0.65 2500)2

= 416693.5 N

= 41.6

As the critical load is very high the structure is proved to be very safe and it is
concluded that any extra enforcing to the structure is money and effort wasted. if the
assembly didnt need the specific size and dimensions of the steel angle bar we
could have used a smaller ize. the increase in safety might proof useful in case a
higher VCSS with multiple access points is required.

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And the selected frame design of vertical storage carousel will be drawn with
dimention next time and here is a general frame of vertical storage carousel.

Fig. 3.1 Frame of VCSS

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 Shaft Design:
A shaft is the component of a mechanical device that transmits rotational motion
and power.
It is integral to any mechanical system in which power is transmitted from a prime
mover, such as an electric motor or an engine, to other rotating parts of the system.
The drawing and the dimention will be drawn next time.

Fig. 3.2 general shape of shaft

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Calculation of Shaft:
As the shaft is subjected to bending, torsion and axial loads to know the material
and the dimension of the shaft we need to calculate the tensile stress due to direct
load and bending and the shear stress due to torsion .
.
= +

P is the axial load, A is the expected area of the shaft, M is the bending moment, I is
the moment of inertia and the c is the radius if the expected radius.

.
=

T is the torque applied to the shaft; J is the polar moment of inertia.
To know the maximum allowable shear stress applied on the shaft we need to use
the following formula:
1
= 2 + 4 2
2
The same is applied to the maximum allowable tensile stress on the shaft from the
following formula.
1
= + 2 + 4 2
2 2

Assuming the shaft diameter is 40 mm, P = 1000 N which is assumed to be 10% of

the forces applied on the shaft, the area of the shaft is calculated from =
2
(4)( ) , M is calculated from the bending moment diagram, I is calculated

from the formula = ( 4 ) , T is calculated from = where P is the power
4 2

of the motor and f is the frequency of the motor,and = ( 4 ).
2

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 0.1 m 0.1 m

(5000+5595) / 2 (5000+5595) / 2

Shear Force
Diagram
5297 N
+

5297 N -

Bending Moment 526 N.m

Diagram

=
=1119/0.2
=5595 N
The bending moment M=526 N.m , = 1.17 107 4 ,and A=0.0125 2 .

to calculate the tensile stress due to direct load and bending from the formula

.
= +

Substituting in the formula with the information

1000 526 0.02

= +
0.0125 1.17 107

t = 90 MPa

=
2

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 1119
=
2 13
60

T=821

to calculate the shear stress due to torsion

.
=

821 0.02
=
2.51 107
= 65MPa

The maximum allowable shear stress

1
= 2 + 4 2
2
1
= 902 + 4(65)2
2
= 79

maximum allowable tensile stress

1
= + 2 + 4 2
2 2
90 1
= + 902 + 4(65)2
2 2
= 124

Comparing the results the material selected which is ASTM-A709 Grade 345 and
having a = 450 and a = 265. To calculate the safety factor of
the tensile stress of the shaft
450
= = 3.62 .
124

It is noticed that the safety factor is a little higher than expected that is because the
shaft should not deflect under the weight carried and the power applied . the
structure might stand under smaller diameter but it will deflect which is not allowed
in the design of the whole system . the safety factor of the maximum shear stress.

265
= = 3.35
79
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 Design of the cylinder group configuration:

The cylinder group system consists of four parts flange, pin, arms and the cylinder .it is
a crucial design concept because it holds the carriage and the cylinder should rotate
swiftly without any problems .and to do so the design of the cylinder group must be
done by the outmost accuracy and technique. the cylinder group parts design is as the
following:

- The Flange:

The flange is the part that is attached to the cylinder and holds the bearing to
give the cylinder a free gravity fixed rotation around the bearing, it should be
designed to have the strength to hold the weight of the cylinder. The design of
the flange is merely simple, the drawing and the dimentions will be drawn next
time.

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- The Pin :

The pin the connection between the arms and the cylinder. The pin is
inserted in the bearing to give the cylinder a free movement while rotating
around the sprocket keeps the center of gravity of the cylinder down. And it
will be drawn with dimention next time.

Fig. 3.3 Pin

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- The Arms:

The arms are steel plate that will be connected to the cylinder from one side
and to the chain from the other side. the arms should be imbedded in the
chain and connected to the pin to allow the lifting of the cylinder .and the
arm will be drawn with dimentions next time.

- The cylinders:
The Part where carried and stored, and its drawings with dimention will be
drawn next time

`
Fig. 3.4 stored cylinders

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