AUTOMATIC SPEED CONTROL OF LAMINATED

CONVEYOR

A PROJECT REPORT

Submitted by

MURALIDHARAN. B (71602114021)
RAGHAVENDRAN. V (71602114031)
SIVA KUMAR. R (71602114040)
SRIJITH. N (71602114046)

in the partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING

PARK COLLEGE OF ENGINEERING AND TECHNOLOGY

COIMBATORE

ANNA UNIVERSITY::CHENNAI 600 025

MAY 2006

1
 ANNA UNIVERSITY::CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “AUTOMATIC SPEED CONTROL OF

LAMINATED CONVEYOR“ is the bonafide work of “ B.MURALIDHARAN,

V.RAGHAVENDRAN, R.SIVA KUMAR, N.SRIJITH “ who carried out the

project work under my supervision.

SIGNATURE SIGNATURE

Prof. S. Paranjothi B.E, M.Sc (Engg) Mr. K. S. Sathish Kumar B.E, M.S (RES)
Head of the Department Supervisor
Park College of Engineering and Technology Park College of Engineering and Technology
Kaniyur, Coimbatore - 641 659 Kaniyur, Coimbatore - 641 659

INTERNAL EXAMINER EXTERNAL EXAMINER

2
ACKNOWLEDGEMENT
3
 From the idea to the act, from the conception to the reality, from the
emotion to the response we were led by those, about whom to write all words
seem meek.

We wish to express our sincere thanks to our beloved CHAIRMAN Dr.

P.V. RAVI, for providing an opportunity to work on this project.

We wish to express our deep sense of gratitude to our Principal, Dr.

K.SIDDAPA NAIDU Ph.D., and our VICE PRINCIPAL Prof. R.
GOVINDAN KUTTY. B.Sc (Engg), M.Tech, for their valuable support and for
providing us all the facilities required to build up this project work.

We express our sincere thanks to Mr. VICTOR, (MANAGER

MAINTAINENCE) and Mr.KIRAN KUMAR (CRUSHER INCHARGE),
ACC MADHUKARAI CEMENT WORKS, Coimbatore, for giving us the
opportunity to work in company environment.

We are grateful to our HEAD OF THE DEPARTMENT

Prof.S.PARANJOTHI, B.E, MSc, (Engg) for providing his help and
cooperation throughout the course.

We also express our deep heartfelt thanks to our SUPERVISOR and

PROJECT COORDINATOR, Mr. K.S.SATHISH KUMAR. B.E., M.S
(RES) and all the faculty members of our department for their valuable
information to complete the project.

We also thank our PARENTS and FRIENDS who had been responsible
for their support throughout the project.

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 Dedicated to

the Almighty

and

Our Beloved Parents

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 CONTENTS

S.No CONTENTS PAGENO

1. INTRODUCTION 8

2. LITERATURE SURVEY 10

3. PROCESS FLOW SHEET 21

4. CRUSHER PROCESS 23

5. DIAGRAMS 25

6. SPECIFICATIONS 29

7. NOMENCLATURE 35

8. DESIGN OF JAW PLATE 37

9. DESIGN O GEAR BOX 40

10. DESIGN OF SHAFT 47

11. SENSORS 52

12. ADVANTAGES 58
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13. DISADVANTAGES 58

14. LIMITATIONS 58

15. BIBLIOGRAPHY 59

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 INTRODUCTION

8
Associated Cement Companies (ACC) is one of the leading Cement

producers in India. They excavate lime stones from the Madukkarai Limestone mines.

The initial stage in cement production is crushing the larger limestones into smaller

ones.

When too many stones from the Quarry approach the crusher through the laminated

conveyor, there may be accumulation in the hopper section of the Jaw Crusher due to

continuous flow of stones. This accumulation of stones may at times damage the Jaw

plates and the laminated conveyors. due to which, the crusher control room has to

monitor the jaw crusher and manually adjust the laminated conveyor speed.

To eliminate such problems,we have placed sensors at three levels in the hopper area

of the Jaw Crusher which will sense the level of accumulation in the Jaw Crusher and

gives the feedback to the Crusher Controller. Thus the speed of the laminated

conveyor is controlled according to the accumulation of the limestones in the hopper.

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LITERATURE SURVEY

10
ABOUT THE COMPANY
11
 Associated Cement Companies (ACC), one of the leading Cement producers in
India came into existence consequent to the amalgamation of ten cement companies in
1936. Manufacturing and marketing of cement, redymix concrete, refractories and
refractory products are the main business of ACC. Further the company is also into
consultancy and engineering services.ACC's manufacturing base consists 14 cement
plants spread well all over India, two refractory plants one each at Maharashtra and
MP and 6 RMC plants near to four metros of India and Bangalore. The total cement
capacity of ACC stands at 161.47 lakh tonnes at March 31, 2003.

In Jan. 1999, the company came out with a rights issue to fund its capex
projects involving modernisation/ expansion of existing plants and creation of new
capacity at Wadi. The company meets around 83% of its power requirements from its
captive power plants. The captive power plant at Jamul and Kymore with a capacity
of 25 MW each was commissioned in Nov 1999. The 15 MW capitive powerplants at
Chanda, Tikaria and Madukkarai were commissioned during the year 2002-03.In
2000, Tata group has exited from the company by divesting their 14% equity stake in
favour of Gujarat Ambuja group.

Notably, Gujarat Ambuja group is the most efficient and aggressive cement
group in India. The disinvestment was done in phases at Rs 370 per share.

ACC has completed the modernization and expansion of the Chanda and
Madukkarai cement plants for increasing their capacities to around 1 MTPA each.
These plants started production from 1 September 2000 and 1 October 2000
respectively. The de-bottlenecking at Chanda, Gagal and Madukarrai plants have
added 1 MT to ACC's installed capacity. The 2.6 MTPA Cement plant at Wadi with
largest Kiln in the country has started its commercial production from Oct 2001.The
Company has decided to exit from the non-core businesses in an optimal manner. The
company has completed divestment of its stake in Float glass India Ltd (13% stake in
2001-02), International Ferrites Ltd. (35% stake in 2002-03) and Bridgestone ACC
India Ltd. (19% stake in 2002-03). Further it has also sold its stake (5,00,000
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E.Shares) in Tata Industries in 2001-02. The company is making all efforts to hive off
the ACC Nihon Casting, a 100% subsidiary of ACC manufacturing alloy steel casting
but has not met success yet. At the same time of existing from non-core businesses the
company has not failed to invest in core activities it has acquired 76.01% stake in
Eternit Everest from Etex Group in Feb 2002. Consequent to the acquisition the
Eternit Everest became the subsidiary of ACC w.e.f from Feb 12, 2002.

In 2005, Holcim group of Switzerland enters strategic alliance with Ambuja

Group by acquiring a majority stake in Ambuja Cements India Ltd. (ACIL) which at
the time held 13.8 % of the total equity shares in ACC. Holcim simultaneously makes
an open offer to ACC shareholders, through Holdcem Cement Pvt. Limited and ACIL,
to acquire a majority shareholding in ACC. Pursuant to the open offer, ACIL’s
shareholding in ACC increases to 34.69 % of the Equity share capital of ACC.

Today, the company's operations are spread throughout the country - with 14
cement factories, 11 regional marketing offices, 21 area offices, and a dedicated
employee band of about 9000 people from all corners of India.
As part of its expertise, ACC has acquired rich experience in mining, being the largest
user of limestone, and it is also one of the principal users of coal. As the largest
cement producer in India, it is one of the biggest customers of the Indian Railways,
and the foremost user of the road transport network services for inward and outward
movement of materials and products.

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MANUFACTURING PROCESS

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LIMESTONE QUARRY AND CRUSHING PLANT
The major raw material for cement production is limestone. The limestone most
suitable for cement production must have some ingredients in specified quantities i.e.,
calcium carbonates, silica, alumina, iron, etc. Typically, cement plants locations are
based upon the availability of good quality limestone in the vicinity. The cement
producer using the open cast mining process does the quarrying operations.
Quarrying is done through drilling and subsequently, using heavy earth moving
equipment such as bulldozers, pay loaders and dumpers.
The quarried raw material is then transported to the cement plant, using mechanical
conveying equipment such as ropeways or belt conveyors, or by vehicles like wagons
and trucks.
The quarried limestone is normally in the form of big boulders, ranging from a
few inches to meters in size. These varying sizes of limestone need to be crushed to a
size of about 10 mm in order to be prepared for finish grinding.
There are mainly two types of crushers available for this purpose- compression type
or impact type crushers. There are many types of compression type crushers such as
jaw crusher, gyratory crusher, cone crusher, and roll crusher. The impact technology
is used in hammer crusher/impact crusher.
Crushing is done either in two stages or in a single stage. In the two stage
crushing system, a compression type crusher is used in the first stage for raw crushing,
followed by impact/hammer crusher in the second stage. In single stage crushing, an
impact type crusher is used.
The selection of the crusher depends mainly on the characteristics of the raw
materials. This selection is further guided by the particle-size distribution
requirements of the down-stream equipment such as raw mills and lastly by financial
considerations.

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LIMESTONE STOCK PILE
The raw material is stored at either the quarry or at the plant. Typically, circular
or longitudinal stockpiles are used to store the material.
A number of layers are stacked in circular or longitudinal piles and are reclaimed in
transverse, cross-sectional slices.
The stockpiles consist of separate layers/piles of different kinds of raw material.
This is used in segregating the raw material quality-wise. The required quantity of the
various raw materials is thus easily extracted for use.
The extraction of different qualities of raw material is monitored and controlled
in order to maintain the desired composition of raw meal, suitable for feeding into the
kiln.

ADDITIVES STORAGE HOPPER

In order to get the required composition of raw material, certain additives such
as iron ore, bauxite, laterite, quartzite and fluorspar are added in required quantities.
These additives are stored at the plant in separate hoppers and are extracted
using belt conveyors in conjunction with belt-weighing equipment. This ensures that
only the required quantities are extracted and added to the raw material.

RAW MILL BUILDING

The raw material is finish-ground before being fed into the kiln for clinkering.
This grinding is done using either ball mills or vertical roller mills (VRM). The raw
material is simultaneously dried.
Ball mills use impact with attrition principles for grinding the raw material.
Inside the ball mills, various sizes of balls are used and classifying liners are used to
maintain the position of different sizes of balls. The larger sized balls are utilized for
impact grinding and the smaller balls for attrition. VRM uses the compression
principle to grind the raw material.
The choice between a ball mill and VRM is governed by many factors such as
the moisture content of the raw material, the size of the plant, and the abrasiveness of
16
the material, the energy consumption levels, reliability, and finally financial
considerations.
Ball mills are suitable for low and medium moisture content in the range of five
to six per cent and are preferred for abrasive material. The main advantage of VRM is
higher grinding efficiency and ability to accept material with higher moisture content.
Normally the energy consumption level in VRM is 10 to 20 percent lower than
in ball mills.

BLENDING AND STORAGE SILO

Normally there are various sources of limestone, each with different qualities,
which are added with various additives to get the required composition of raw mix. As
there are various sources of raw materials, it becomes necessary to blend and
homogenize these different materials efficiently to counteract fluctuation in the
chemical composition of the raw meal.
The variations in the composition of kiln feed have very adverse impacts on the
efficiency of the kiln. It results in undesired coating and ring formation inside the kiln.
In order to blend and homogenize the raw materials properly, continuous blending
silos are used.

PREHEATER
The most important activity in cement manufacturing is clinkering (or burning)
of raw material. Clinkering takes place in the kiln and the preheater system.
Preheater systems offer heat transfer from the hot kiln gases.
GAS CONDITIONING TOWER AND ESP
The conditioning tower is used to reduce the temperature and to increase the
moisture level of the dusty exhaust gas from the kiln, before it is passed through the
bag house and ESPs. It is called a conditioning tower because it conditions the hot
gas, thus making it more suitable for the ESP and bag house to extract dust from it.
The Electrostatic Precipitators are used in cement plants particularly for
removal of dust from the exit gases of cement kilns and from the exhaust air

17
discharged by dryers, combined grinding and drying plants, finishing mills and raw
mills through water injection.
Through ESPs, the dust-laden gas is made to flow through a chamber usually
horizontally, during which it passes through one or more high voltage electric fields
formed by alternate discharge electrodes and plate type collecting electrodes.
By the action of electric field, the dust particles, which have become electrically
charged by negative gas ions, which are formed at the discharge electrodes and attach
themselves to the particles, fly to the collecting electrodes and are deposited there.
The dust is dislodged from these electrodes by rapping and thus falls into the
receiving hopper at the base of the precipitator casing.

KILN
A kiln is the heart of any cement plant. It is basically a long cylindrical-shaped
pipe, and rotates in a horizontal position. Its internal surface is lined by refractory
bricks. Limestone and additives are calcined in this. The output of the kiln is called
clinker.

COOLER
The clinker coming out of the kiln is hot. It is cooled in a set-up called a cooler.
In the cooler, cold air is blown to effect heat exchange between hot clinker and cold
air.

DEEP BUCKET CONVEYOR

The deep bucket conveyor is essentially an equipment to lift material vertically.

CLINKER/GYPSUM STORAGE
The output of the kiln is stored before it is fed to the cement mill for conversion
to cement. This storage is called clinker storage, if it is used for clinker storage
purpose. If the storage space is used for gypsum storage, it is called gypsum storage.
The storage may be of silo type or covered stacker reclaimer type or simply a
gantry type. Silo type clinker storage has the advantage that there is no dust pollution
18
and spillage of clinker. Same advantage can be achieved through stacker reclaimer
type as well. However, there is a little bit of dust generated. Gantry type is not used in
modern cement plants because of its environmental unfriendly nature.

GYPSUM STORAGE
The output of the kiln is stored before it is fed to the cement mill for conversion
to into cement. This storage is called clinker storage, if it is used for clinker storage
purpose. If the storage space is used for gypsum storage, it is called gypsum storage.
The storage may be of silo type or covered stacker reclaimer type or simply a
gantry type. Silo type clinker storage has the advantage that there is no dust pollution
and spillage of clinker. Same advantage can be achieved through stacker reclaimer
type as well however, there is a little bit of dust generated. Gantry type is not used in
modern cement plants because of its environmental unfriendly nature.
Limestone coming out of quarry is crushed in multiple stages in a sizing plant before
it is put in limestone stockpile. Crushers are mainly of two types viz. Jaw crusher and
Hammer crusher. Jaw crusher is basically a simple mechanism having two plates one
fixed and another moving. This is also called primary crusher. Hammer crusher has
got metallic hammer mounted on the axes and the sizing achieved by the impact of the
hammer.

COAL MILL BUILDING

The coal mill building houses the mill for grinding lumpy coals. This fine
ground coal is used for burning in the kiln.The mills used for coal grinding and drying
are either trumbling mills (tube mills) or roller mills.

CEMENT MILL AND BAG HOUSE

Clinker, along with additives, is ground in a cement mill. The output of a
cement mill is the final product viz. Cement. In a cement mill, there is a cylindrical
shell lying horizontal which contains metallic balls and as it rotates, the crushing
action of the balls helps in grinding the clinker to fine powder.

19
 The term bag house is applied to large filters containing a number of tubular
bags mounted in a usually rectangular casing. The dust-laden air is drawn through
them by suction.
The bag house is used to remove dusty particles from discharge of different
equipment such as cement mill, coal mill and kiln. In a bag house system discharge
gas containing dusty particles is passed through a series of bags made of strong
fabrics.

CEMENT STORAGE SILO

The cement storage silo is used for storing the finished product - cement.

PACKING AND DISPATCH

The cement is packed with the help of a rotary packer and finally dispatched to
the market.

CENTRAL CONTROL ROOM

It is the nerve center of the cement plant since all equipment is controlled from
this place. It is the place from where all the process parameters are controlled

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PROCESS FLOW SHEET

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22
 CRUSHER PROCESS

DEFINITION:
Crusher is defined as the crushing of big stones in to small stones . It
can be achieved by two steps. The output size of limestone from the crusher is 20 mm.

FIRST STEP:
The stones from the quarry is poured in the primary crusher dumper.
From the dumper it is taken to jaw crusher hopper through laminated conveyor. The
disintegration of limestones is mainly due to the movement of movable jaw plate
attached eccentrically with the motor shaft of the primary crusher. One jaw plate is
fixed and the other is movable. The gap maintained at the end of the two plate is
200 mm. the gap can be varied. The output size of stone from primary crusher is
200 mm. Then it is transferred to secondary crusher through belt conveyor.

SECOND STEP:

The input to the secondary crusher is the output of primary crusher. Secondary
crusher has 48 hammers arranged in 12 rows, each row containing 3 hammers. It is
rotated at high velocity to break the stones into small pieces(<20 mm). Then it is
moved to vibratory screen, from the vibratory screen the rejection is again send to
secondary crusher and remaining is transferred to ball mill through belt conveyor. The
stones lessthan 20 mm is the product from the crusher and it can be transferred to
ballmill.

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 DRAWINGS

24
3-D MODEL OF LAMINATED CONVEYOR AND JAW PLATE

25
FIXED JAW

26
MOVABLE JAW

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28
 SPECIFICATIONS
LAMINAR PLATE CONVEYOR:
• Main Structure
• Foundation Bolt
• Tail shaft Assembly  1
• Head shaft Assembly  1
• Lamellae Assembly  43
• Counter shaft Assembly  1
• Coupling Assembly  1
• D.B.Radicon gear box  1
• 3 – piece coupling Assembly  1
• Commutator motor  1

LAMINATED CONVEYOR :
• Size : 1800 mm X 12000mm
• Inclination : 25°
• Speed : 3.3 – 6.6 ft/min
• Sprocket wheel speed : 0.64 – 1.28 rpm
• Capacity : 150 TPH @ maximum speed
• Lamella size : 1800 X 320 mm
• No of lamella : 86
• Sprocket wheel shaft diameter : 180 mm
• Sprocket wheel pitch diameter : 490 mm
• No of teeth on sprocket wheel : 6
• Chain length : 60000mm

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 • Drive : Gear

MOTOR DETAILS:
• Make : SIEMENS
• Type : Induction , Slip ring
• Speed : 986 rpm
• Power : 415 V , 227 amps

GEAR BOX:
• Make : SHANTHI GEARS LTD
• Type : SCH 280F
• Size : 17 RHU
• Power : 15 HP
• Speed ratio : 31.5 : 1
• RCC dumping hopper capacity  50 T

PRIMARY CRUSHER:
• Make : TRF
• Type : Single Toggle Jaw Crusher
• Size : ( 48" X 42" )
• Capacity : 300 TPH
• Feed size : (-) 1000 mm to (+) 900 mm , 5 to 10 %
: (-) 900 mm to (+) 500 mm, 40 %
: (-) 500 mm, 50 %
• Output size : 125 mm
• Feed openings : 1050 wide X 1240 mm
• M/C Weight : 42 T approx

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MOTOR DETAILS:
• Make : SIEMENS
• Type : Squirrel cage induction
• Kw / Volts : 132 / 433 V
• Mode of Power transmission : Fluid coupling pembri / FCU 23
• Speed : 1000 rpm
• Drive : V – Belt drive 7 Nos

LUBRICATION DETAILS:
• Multiline Grease
Pumping Station : AFMC Lubrication Pvt LTD
• Hydraulic remote : Model ‘ LSP ‘ Plain Ram
control jack BEMCO - JACK & ALLIED `
PRODUCT LTD
• Hand Pump : Model SPR 12/2

CONVEYOR DETAILS :
CONVEYOR – 1
• Size : 900 mm c/c
• Inclination : 20°
• Speed : 1.5 m/min
• Belt size : 900 mm X ply X grade
• Total belt length : 28 m
• Idler space : 1.25 m
• Belt weight : 10.8 Kg / m
• Coupling : Bush
• Through angle : 20°
• Capacity : 150 TPH

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 TENSIONING DEVICE :
• Head pulley diameter : 750 mm
• Head pulley shaft diameter : 100 mm
• Tail pulley diameter : 600 mm
• Tail pulley shaft diameter : 85 mm

DRIVE MOTOR DETAILS:

• Make : Kirloskar
• Type : Induction
• HP / KW : 10 / 7.5
• Speed : 1440 rpm

GEAR BOX DETAILS:

• Make : RADICON
• Type : U 700
• Speed Ratio : 40 : 1

CONVEYOR – 2
• Size : 900 mm c/c
• Inclination : 35°
• Speed : 1.5 m / min
• Belt size : 900 mm X ply X grade
• Total Belt Length : 16000 mm
• Idler space : 1250 mm
• Belt Weight : 10.8 Kg / m
• Coupling : Bush

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TENSIONING DEVICE:
• Head pulley diameter : 750 mm
• Head pulley shaft diameter : 115 mm
• Tail pulley diameter : 600 mm
• Tail pulley shaft diameter : 115 mm

DRIVE MOTOR DETAILS:

• Make : ELECON
• Type : Induction
• HP / KW : 35 / 25
• Speed : 1460 rpm

GEAR BOX:
• Make : RADICON
• Type : U 1200
• Speed ratio : 40 : 1

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34
 NOMENCLATURE

L = Length (mm)

t = Thickness (mm)

W = Width (mm)

A = Area (mm2)

V = Volume (mm3)

P = Load (N)

M = Mass (Kg)

D = Density (Kg/m3)

σ = Stress (N/mm2)

Z = Teeth

T = Torque (N-m)

b = Face Width (mm)

N = Speed (rpm)

35
a = Centre Distance (mm)

m = Module (mm)

ds = Diameter Of Shaft (mm)

Ls = Length Of Shaft (mm)

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 DESIGN OF JAW PLATES

MOVABLE JAW: FIXED JAW:

MATERIAL: MnSteel Gr 3 MATERIAL MnSteel Gr3
L = 2620mm L = 2279 mm
t = 170mm t = 200 mm
W = 1205mm. W = 1316 mm

CALCULATION OF AREA:

AREA 1 = (1000 X 200) + (0.5 X 343 X 1000)

= 371000 mm2
AREA 2 = (1500 X 200) + (0.5 X 516.40 X 1500)
= 687367.5 mm2
AREA 3 = (2000 X 200) + (0.5 X 688.655 X 2000)
= 1088655 mm2

CALCULATION OF VOLUME:

VOLUME 1 = A1 X W = 371000 X 1205

= 447.06 X 106 mm3
VOLUME 2 = A2 X W = 687367.5 X 1205

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 = 828.27 X 106 mm3
VOLUME 3 = A3 X W = 1088655 X 1205
=1311.82 X 106 mm3

CALCULATION OF LOAD:

DENSITY OF LIME STONE : 2560X10-9 Kg/mm3 (High Density)

D = Mass / Volume Kg/mm3

LOAD AT A1:
2560 X 10-9 = M1 / 447.06 X 106
M1 = 1144.32 Kg.
P1 = 11225.78 N
LOAD AT A2:
2560 X 10-9 = M2 / 828.27 X 106
M2 = 2120.4 Kg
P2 = 20801.13N

LOAD AT A3:
2560 X 10-9 = M3 / 1311.82 X106
M3 = 3358.3 Kg
P3 = 32944.9N
STRESS CALCULATION :

σ = LOAD / AREA (N/mm2)

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STRESS AT A1:
σ1 =11225.78 / 371000
= .03025 N/mm2
STRESS AT A2:
σ2 =20801.13 / 687367.5
= .03025 N/mm2
STRESS AT A3:
σ3 =32944.9 / 1088655.5
= .03025 N/mm2
THE DESIGN IS SAFE

39
 DESIGN OF GEAR BOX

z = P1(X1) . P2(X2) . P3(X3)

Here number of speeds z = 12

Nmax / Nmin = Φz-1

Φ12-1 =1000 / 31.5

Φ = 1.369

From P.S.G design data book Pg.No: (12.3)

For Shaft Speed Series 1.12 We get (1.12)6 = 1.40

The following speeds are obtained:

31.5,45,63,90,112,1690,224,315,450,630,900,1200.

Therefore we get

z = 3(1) . 2(3) . 2(6)

CONDITIONS:

40
Nmax / Ninput >= 0.25

Nmin / Ninput <= 2

For SET: 3

Nmax / Ninput = 0.28

Nmin / Ninput = 2

(So the speed selected is 112rpm)

For SET: 2

Nmax / Ninput = 2

Nmin / Ninput = 0.7

(So the speed selected is 160rpm)

For SET: 1

Speed selected is 1000 rpm (Input speed)

TEETH CALCULATION:

For SET: 3

(1) Assume Z13 = 20 (Smallest Fixed Gear)

Z14/Z13 = N13/N14

Z14/20 = 112/31.5

Z14 = 72

41
Z14 = 72 and Z13 = 20

(2) Z11/Z12 = N12/N11

Z11/Z12 = 224/112

Z11 = 2Z12

We know that Z11+Z12 = Z13/Z14 = 92

We get Z12 = 30

Z11 = 92 – 30 = 62

Z12 = 30 and Z11 = 62

For SET: 2

Assume Z9 = 20 (Smallest Fixed Gear)

(1) Z9/Z10 = N10/N9

20/Z10 = 112/160

Z10 = 28

Z9 = 20 and Z10 = 28

(2) Z7/Z8 = N8/N7

Z7/Z8 = 315/160

Z7 = 1.96Z8

We know that Z7+Z8 = Z9/Z10 = 48

We get Z8 = 16

Z7 = 48 – 16 = 32
42
 Z8 = 16 and Z7 = 16

For SET: 1

Assume Z5 = 20 (Smallest Fixed Gear)

(1) Z5/Z6 = N6/N5

20/Z6 = 160/1000

Z6 = 124

Z5 = 20 and Z6 = 124

(2) Z3/Z4 = N4/N3

Z3/Z4 = 224/1000

Z3 = 0.224Z4

We know that Z5+Z6 = Z3+Z4 = 144

We get Z4 = 118

Z3 = 144 – 118 = 26

Z4 = 118 and Z3 = 2 6

(3) Z1/Z2 = N2/N1

Z1/Z2 = 315/1000

Z1 = 0.224Z2

We know that Z5+Z6 = Z3+Z4 = Z1+Z2 = 144

We get Z2 = 110

Z1 = 144 – 110 = 34
43
Z2 = 110 and Z1 = 34

KINEMATIC DIAGRAM

44
RAY DIAGRAM

45
46
 DESIGN OF SHAFT

MATERIAL SELECTION:

For i >= 4 , 40 Ni 2Cr1 Mo28

CACULATION OF MODULE:

1) To find torque:

T14 = (P X 60) / (2 π N)
= (415 X 227 X 60) / (2 X π X 31.5)
T14 = 28558.46 Nm
To find tangential force on gear 14

Ft14 = T14 / r
= (2 X T14) / (Z14 X m)
= (2 X 28558.46) / (72 X m)
= 793.29X103 / m
We know that
Module m = √(Ft / (ψm X m))
ψm = b / m = 10
M = Material constant
For 40 Ni 2Cr1 Mo28 M = 100
m = √ ( (793.29X103 / m ) / 100 X 10 )
m3 = 793.29

47
m = 9.25 mm
Nearest standard module , m = 10 mm

CALCULATION OF CENTRE DISTANCE :

STAGE 1:
a1 = (Z1+Z2 / 2) m
= (34+110 / 2) 10
= 720 mm

STAGE 2
a2 = (Z7+Z8 / 2) m
= (16+32 / 2) 10
= 240 mm

STAGE 3
a3 = (Z11+Z12 / 2) m
= (62+30 / 2) 10
= 460 mm

CALCULATION OF FACE WIDTH :

b =ψXm
= 10 X 10
= 100 mm

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CALCULATION OF LENGTH OF SHAFT :

L = 25 + 10 + 7b +20 + 4b + 20 + 4b + 10 + 25
= 110 + 15 b
= 110 + 15 (100)
= 1610 mm

DESIGN OF SHAFT :

i ) Design of spindle, (o/p shaft)

To find maximum bending moment (M)
M =(Fn X L) / 4
Fn - Normal load on gear, = (Ft / cosα)
= (79.33X103 / cos 20°)
Fn = 84421.22 N
M = (84421.22X1610) / 4
M = 339.8X105 Nmm

To find Teq = √ (M2 + T142)

Teq = 44.4 X 106 Nmm.

Diameter of the spindle

ds = [(16 X Teq ) / (π X τ )] ⅓ (τ = 55 N/mm2)

ds = 160 mm. (R40 Series)

ii) Design of other shafts

SHAFT 1:

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I/P Speed = 1000 rpm

T = 0.2 ds13 (τ)

T = [(415 X 227 X 60) / (2π X 1000)]

T = 899.59 Nm

899.59 X 103 = 0.2 X ds13 X 55

ds1 = 42.5 mm (R40 Series)

SHAFT 2:

T = [(415 X 227 X 60) / (2π X 160)]

= 5622..44 Nm

ds2 = 79.95 mm ; ds2 = 80 mm (R40 Series)

SHAFT 3:

T = [(415 X 227 X 60) / (2π X 112)]

= 8032..06 Nm

ds3 = 90.04 mm ; ds3 = 90 mm (R40 Series)

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51
 SENSOR

LASER SENSOR(LV-H1300)

LV-H1300-100 WIDE AREA THRUBEAM LASER

SENSORS

52
DESIGN OF SENSOR

53
54
SPECIFICATION OF SENSOR

LV-H300/100 HIGH-POWER THRUBEAM LASER SENSOR

55
 Sensor
LV-H100 LV-H300
Model head
Amplifier LV-51m, 51MP, 52, 52P
Visible red semiconductor laser, Wavelength: 650 nm, 3 mW max., Pulse
Light source
duration 3.5 ms
FDA class Class II
IEC class Class 2
FINE
Detecting
78.74" 2000 mm 78.74" 2000 mm
distance TURBO
SUPER

Area width: approx. 0.39" 10 mm Area width: approx. 1.18" 30 mm

Smallest detectable object: 0.003" 0.1 Smallest detectable object: 0.01" 0.3
Beam spot shape
mm dia. opaque material (Detecting mm dia. opaque material (Detecting
distance: 19.69" 500 mm max.) distance: 19.69" 500 mm max.)

Laser ON alarm indicator: Green LED,Label indicator: Green x 2, Red x 1

Indicator
(label indicator displays excess gain from 90 to 110%.)
Ambient light Incandescent light: 10,000 lux max. Sunlight: 20,000 lux max.

Ambient temperature-10 to +55°C (14 to 131°F), No condensation

Relative humidity 35 to 85%, No condensation

10 to 55 Hz, 0.06" 1.5-mm double amplitude in X, Y, and Z directions: 2
Vibration resistance
hours per direction

Case: Reinforced glass plastic, Lens cover: Polyarylate (Glass for

Materials transmitter of LV-H37, LV-H100, LV-H300 only, Acryl for transmitter of
LV-H32/H35)

LADDER DIAGRAM :

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ADVANTAGES:

• Man power is reduced.

• Wear of jaw plate is reduced.

57
 • Efficiency of the jaw crusher has been improved.

• Overloading of stones inside the jaw crusher is avoided.

• Installation of the equipment made simple.

• Application of the equipment may be changed by altering the program.

• Maintenance cost is very low.

• It cannot affected by dust.

LIMITATIONS:

• Kept away from vibratory parts.

DISADVANTAGES:

• Initial investment is high.

• It cannot be repaired.

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 BIBLIOGRAPHY

REFERENCE BOOKS AUTHOR

DESIGN OF TRANSMISSION SYSTEM R.S.KHURMI

STRENGTH OF MATERIALS S.S.RATTAN

59
P.S.G.DESIGN DATA BOOK

WEBSITES

www.keyence.com

www.sensorpack.com

www.acc.co.in

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