ADAPTIVE DESIGN AND

DEVELOPMENT OF
CONVEYOR FOR CHIP
DISPOSAL SYSTEM
ADAPTIVE DESIGN AND DEVELOPMENT OF
CONVEYOR FOR CHIP DISPOSAL SYSTEM
Submitted by

G.RAM KUMAR 511813114030

H.ASHOK KUMAR 511813114007

K.KRISHNAMOORTHY 511813114016

INTERNAL GUIDE EXTERNAL GUIDE

Dr.J.S.SENTHILKUMAAR Mr. SANJAY RAO

TTC/RWF
principal,
Podhigai College of Engineering
& Technology
 ABTRACT
Our proposal is to modify this belt
conveyor setup by extending the
automatic machine shop conveyor
up to the manual operated machine
shop conveyor so that chips from
both machine falls on the wagon.
This proposal increases the
productivity and reduces the
maintenance expenses.
 OBJECTIVE
Modification chip disposed conveyor
system
Both automatic machine conveyor
and manual machine conveyor will
be integrated
 RAIL WHEEL FACTORY PROFILE

Rail Wheel Factory

Rail wheel factory plant is the only in Asia to employ the

controlled pressuring process to cast wheel. WAP has achieved
the unique distinction of distinction of becoming the first
production unit of railway to secure the prestigious ISO-9002
and ISO-14001 certification for quality management. It is
approved by the association of American railway for supply of
wheel and axles to North America railroads.
Land area
The Rail Wheel Factory extends over an area of 117.77 hectares.

Plant Area Factory & Building 77.30

Colony area East colony 13.36
West colony 27.11
Total 117.77
MACHINE SHOP
 CONVEYORS

A conveyor system is a common

piece of mechanical handling
equipment that moves materials from
one location to another.
Conveyors are especially useful in
applications involving the
transportation of heavy or bulky
materials.
Conveyor systems allow quick and
efficient transportation for a wide
variety of materials, which make them
very popular in the material handling
EXISTING
 DISADVANTAGES
1. cost is high
2. more size
3. maintenance is high
4. travel distance is high
PROPOSAL
 PROPOSAL
The A shop and B shop are 12.17m
apart. The conveyors of the manual
lathe and automatic CNC lathe are not
at the same line.
The 305 width conveyor is 0.45m
apart from the 381 width conveyor
which means the mea the two lathes
are at 1.5ft apart.
This make the modification of both
chip conveyors more complicated. .
This makes the 305 width conveyor
and 381 width conveyors on the same
DIAGRAM
 ALTERNATIVES
ALTERNATIVE 1
(533 * 6 pitch chip conveyor is heavy duty)
(the big trough for installation)
ALTERNATIVE 2
(the 381x6" pitch chip conveyor)
(the gradient for lifting the chips into the wagon)
ALTERNATIVE 3
(305x6" pitch chip conveyor)
(It need not to run continuously)
CONCLUSION ALTERNATIVE
(the 305x6" pitch may be kept as it is because it can
provide heavy duty work by carrying the load of both
station lathe machines.)
(The 381x6" pitch conveyor shall be extended for
15m from the B shop to the A shop chip conveyor.)
DESIGN
 CALCULATION
Chip weight for each 10 min received = chip
weight per axle *2.8
= 5.7 kg *2.8
=16.52kg
3816 chip conveyor move 5.18m for every 10min
cycle an it bears a weight of 2.8 axles.
So the 36m length conveyor bears a total number
of n axles.
n = length of conveyor/distance of conveyor moves
for 10m cycle.
= 36/5.18
= 6.97~7 set will be on the conveyor.
 Our proposed new conveyor length
will be 25m.
Load on 25m length conveyor =
(110/36)*25
= 76.38kg which is within the
permissible load.
 COST ESTIMATION
The chain cost of 533x6" pitch per
meter is
Rs.19482/-
The trough cost of 533x6" pitch per
meter is
Rs.169939/-
For this 60m length trough, the cost will
be
Total trough cost=60*Rs.169939/-
=Rs.10196340/-
For the length of 120m chain, the cost
 OUR PROPOSAL
Chain cost per meter for 381x6" chip conveyor is
Rs.11566/-
Trough cost per meter for 381x6" chip conveyor is
Rs.121476/-
So for the 25m trough the cost will be
Trough cost=25*121476=Rs.3036900/-
Chain cost=50*11566=Rs.578300/-
For the installation of 381x6" pitch conveyor (25m
length), the total cost will be,
Total cost=Trough cost + chain
cost=Rs.3615200/-
Cost of 12m length of 381x6" pitch chip conveyor
trough=12*Rs121476/-=Rs.1457712/-
Purchase cost= trough cost +chain
cost=Rs.1573372/-
Direct labor cost = construction work + installation
work
= (wage * no of worker * no of
days) + (wage * no of workers * no of day)
= (Rs. 300 * 4 *5 day) + (RS. 500 * 4 *4)
=Rs. 14000/-
Total estimation = purchase cot + direct cost
= purchase cost + (direct labor +
direct material)
=Rs. 15, 73,372 + (Rs. 14,000 + Rs.
50,000)
Total estimation = Rs. 16, 37,732/-
Economic advantage = approved cost estimation on
our proposal
= Rs. 1, 25, 34,180 Rs. 16,
37,732 = Rs. 1, 08, 96,448/-
Thus, through our proposal the
railways can save Rs. 1, 08,
96,448/- on the modification of chip
conveyor in between the station 1
and station 1 CNC.