By Naveen kumar.H.

S (4JC10MMT07)

Under the guidance of 1. Prabhuswamy.S

Associate Professor Dept. Mech, SJCE Mysore

2. Mohammad Mujahid Baig

Engineer,TKM Bidadi Bangalore

 Reduce

the down time . Increase the machine availability. Avoid the major line stop. Reduce the maintenance time and cost

Conveyor is a mechanized device used to move materials in relatively large quantities between specific locations over a fixed path.

Fig : 1 conveyor system

 Roller Chain Portable Vibrating Screw/Spiral Belt Overhead

 Value

conveyor problems. Pallet conveyor problems. Part conveyor problems.

Fig: 2 value conveyor

Fig : 3 steel belt

Fig : 4 side Wings

cleet
Fig: 5 cleet Fig :6 Apron Plates

Accumalation

of scrap at bottom side of

conveyor Scrap getting struck between the side guard Frequently damaging of cleet and wings

140

120

T I M E I N M I N

100

VALU E CONVEYOR 1

80
VALUE CONVEYOR 2

60

40

20

0 DECEMBER JANUARY FEBRUARY MARCH APRIL

Fig:7 Different size scrap

SCRAP AND SCRAP SIZE DETAILS

SL NO: PROCESS SCRAP SCRAP SIZE YES NO BIG SMALL

1/2 FRAME 1 2/2 FRAME

2
1/4 BODY PANNEL 3 2/4 BODY PANNEL 4 3/4 BODY PANNEL 5 4/4 BODY PANNEL 6

 Check

the speed of conveyor Width of steel belt Size of scraps Orientation of wings Bin replacment time Distance between two cleets in conveyor belt Cleets height

 Orientation

of the wings reversed.

Fig: 8 wings

 Bin

replacement
Bin replacement time is 45sec.
In 2/4 process 4 times the bin is filled.

Fig :9 scrap bin

 Cleet

spacing

762mm

Fig :10 steel belt

 Cleet

width and height:

Fig :11Steel belt

Fig : 12 pallet conveyor

Dog
Chain link

Fig: 13 dog and chain

Fig: 14 half process pallet

Fig : 15 draw process pallet

Fig : 16 pallet conveyor

 Frequent

damage of dogs Tripping of motor Chain link break

180 160

140
120 100 80 60 40 20 0 DECEMBER JANUARY FEBRUARY MARCH PALLET CONVEYOR

MONTHS

Welding of dogs to chains Load of pallet on dogs Rollers misalignment Bent pallets Fork lift opration Motor specifiction Random placement of dogs

Fig : 17 Pallets corrections

Fig : 18 damaged dogs

Fig :19 dog and chain link

Fig :20 pallet conveyor

 Roller

misalignment correction by providing shins properly. Parallel dogs alignment after dogs reduction as per needed. Rewelding or replacing of damaged dogs links. Providing proper guidways and guide links for forklift movement. Automation.

Fig :21 before correction

Fig :22 after correction

Fig :23 guide ways

dogs

Limit switches Fig : 24 automation arrangement

Fig : 25 part conveyor

The shaft of conveyor is cut. The shaft cut problem is accord every 15 days once. The shaft replacement time is 2 hours.

Fig : 26 parts of part conveyor

Fig : 27 shaft drawing

 Design

of shaft to be check Gear box arrangement Motor suitability Bearings Alignment of shaft Alignment of roller drum Sensor operation Shaft material

Sensor operation is to NO/OFF of the conveyor. For one minute the ON/OFF is almost 12 times means in one minute 12 parts flow from one machine to other machine. By this ON/OFF process the sudden load is acting on shaft.

EN8D is carbon steel The composition is

C = 0.40 to 0.45% Si = 0.o5 to 0.35% Mn = 0.70 to 0.9% S = 0.06% P = 0.06%

EN8D mechanical properties

Maximum stress 700-850 N/mm2 Yield stress 465N/mm2 0.2% proof stress 450N/mm2 Elongation 16% Impact KCV 28jouls Hardness 201-255 BHN

CMM inspection

Initially the CMM origin is to be set according to shaft and drum. The horizontal axis as taken as X axis (X+ to left and X- to right). The vertical axis as taken Y axis(Y+ to upper and Y- to lower). As we can see in fig.
Fig : 28 part conveyor

Fig : 29 roller drum

Schedule Sl.No. 1 Activity Feb Mar Apr May June

Pallet conveyor problem in A Study the present situation. press machine

Set counter measures.

Root cause for problem. Analysis of problem 2 Scrap conveyor problem in A press machine Carry out counter measures. Result Study the present situation Root cause for problem Analysis of problem 3 Shaft cut in part conveyor in CC press machine Set counter measures Carry out counter measures Result

Study the present situation Root cause for problem Analysis of problem

Set counter measures Carry out counter measures Result