Conveyor Systems

— Conveyor is a mechanical system that has a function to move goods from one place to another. The purpose of the use of conveyor, which is to transport goods with a large number and sustainable. In 2015 PLTU Indramayu menngalami an accident causing C6 conveyor system suffered a fatal damage. This causes the C6 conveyor system to not work automatically. In this case, C6 connectoror serves to transport coal from C5 conveyor to coal bunker. In practice this field work authors perform recovery C6 conveyor system. Prior to the recovery process, a literature study was conducted to find out the working principle of conveyor, conveyor mapping process, control panel working principle on TT3 (Transfer Tower 3), and other supporting components. By doing the process of recovery system C6 conveyor it will produce a system that can work automatically back with added some upgrades of the security system.

This paper reviews the PLC applications in the industry of cutting machines. This paper also reviews the PLC properties, different types of hacksaw used for cutting purposes. Today, there is lot of advancements in these fields as every industry is getting automated. For cutting materials for mass production conveyor systems are widely used. There are two types of conveyor: Belt type and Roller type. Feed of cutting materials is also done with the help of conveyor. Pneumatic System is used for smooth operation of hacksaw.

The conveyor belt is one of the most operational critical equipment's in the mining industry, they are mostly used in the transportation of crushed materials from the crushing station to where there'll be further processed. Due to the increasing complexity of belt conveyor systems, managing their integrity has become even more difficult, as they are now used across various industries, environments and carry materials of different weight variations, leaving them susceptible to failures (1). This paper provides an industry specific knowledge on belt conveyor systems, their respective components, and how they are configured using fault tree analysis to predict the different branches of event that can contribute to the failure of a belt conveyor system. The use of fault tree analysis sheds more light on how cascading failures can occur, where the failure of one component leads to the failure of the overall system.

Objectives: From an industry specific perspective, there is continuous pressure on manufacturing companies to reduce the operating expenditure by reducing the electricity cost by developing the energy efficient equipment and products especially conveyor systems. Methods/Statistical Analysis: Conveyor belts are the material handling equipment that is widely used in industry to move the material from the one place to another or from one process to next process. Conveyors
are generally driven with electric motors. Conveyor systems are the one of the major consumers of electricity industries, which consumes up to 40% electricity of the total operating cost, while the remaining 60% is due to operational costs and maintenance. Findings: In this work, efficiency of a conveyor system is evaluated by integrating all the factors that have
an influence on the electricity costs of the conveyor system. Using variable speed drive mechanism, an energy efficient conveyor system is developed by physically modeling the speed of the belt and conveyor loading dynamics mechanism under no load, marginally loaded and full loaded conditions. For the energy efficient conveyor system, different start-up of conveyor methods are evaluated as a baseline reason of generating the motor torque in comparison to rated voltage as
an optimal energy management tool to develop a relationship across the power consumption, conveyor belt speed and belt loading dynamics. Application/Improvements: The design of energy efficient conveyor system model by controlling multiple drive units in industrial units.

Conveyor systems persist in being a source of injuries and fatalities in the mining industry. To reduce these incidents, better methods are needed to enhance the monitoring of probable hazards and improve situational awareness during the normal operation and maintenance of conveyor systems. To address these issues, researchers from the National Institute for Occupational Safety and Health (NIOSH) continue to investigate emerging technologies that show the potential to improve miner safety around conveyors. This paper presents a feasibility assessment by NIOSH researchers of a fully integrated, commercially available wireless Internet of Things (IoT) system to improve situational awareness around conveyor systems. Included are discussions of a full-scale laboratory test bed that was designed to simulate a working conveyor system as well as the challenges and successes of integrating the IoT system with the test bed.

A systematic approach is essential for modeling and determination of optimum operating conditions which helps in process
quality improvement. Moreover it attempts to provide the user with flexibility to adopt appropriate techniques based on their
inherent potential. The designed solutions considering desired production requirements for intended studies can be helpful in
increasing the productivity. It can be achieved by adopting lean principles and standardized processes which thereby leading to
fulfillment of customer needs. The present study encompasses the different techniques for a case of set-up time reduction of
conveyor pulley manufacturing. Five different techniques and a specific Mechatronics approach are considered.

The technological advancements in process monitoring, control and industrial automation have played a decisive role in increasing the industrial productivity and manufacturing at faster pace even than been dreamed. An ultimatum requirement is an accurate and precise data acquisition mechanism which can be executed through diverse sensors especially for collecting, analyzing and sorting the objects and elements. In this work, an energy efficient conveyor system model is proposed and implemented which not only recognizes and sorts the objects by sensing its colour and place these objects to its destination by using Robotic vehicle but also smartly adjusts the speed of conveyor belts by recognizing the weight of object(s). The variable speed drive (VSD) based an optimal belt speed control mechanism is proposed by smartly sensing the object weight and optimally adjusting the belt speed. The proposed system optimally switches the conveyor system to on/idle/off status to minimize the energy consumption of conveyor belts. In this work, a mathematical model of the energy efficient conveyor system is also derived by considering the different dynamic parameters. When conveyor belt is fully loaded with objects, the belt moves around with its maximum potential speed, but when conveyor belt is partially or marginally loaded or unloaded, the speed of belt is adjusted accordingly. In this way, a significant amount of energy and cost of energy can be saved. It is anticipated that, the developed intelligent energy efficient conveyor system model will not only modernize the industrial manufacturing and distribution process but will significantly reduce the energy consumption and cost and will lead to increase the life time cycle of conveyor belts.

Purpose Large-scale belt-conveyor systems are extensively used in open mines to continuously transport bulk material. Conveyor pulleys are critical components and failures have significant financial consequences due to extended downtime. Aiming at increasing their durability, two critical spots are identified: the drum and the welds between end-plates and drum. Alternative designs have been evaluated. The paper aims to discuss these issues. Design/methodology/approach Loads on the driving drum are determined from measurements of the bearing force and the motor power. The friction interaction between belt and drum is described by the creep model and its impact is evaluated by comparing the results obtained for low and typical values of friction coefficient. Alternative designs are analysed using finite element method with optimised variable density mesh. The stress field and the deformations are calculated and evaluated. Findings Friction affects the torque transmission capacity and ...

The philosophy of efficient energy consumption is vitally crucial to profitable production cost in manufacturing industries. This is because the unit production cost is largely determined by the cost of unit energy supply; which is quite higher than the cost of raw materials in Nigeria. It has been established that the Nigerian industrial sector is responsible for 8.7% of the total energy consumption in the nation. Out of this chunk, the food and beverage industry appropriates approximately 2%. Meanwhile, it is observed that the energy consumption trend in most industrial electric motors is always high due to continuous operation even during the idle time/period in production. In this study, data gathered has a coefficient of determination of 99.7%. This is, thus, subjected to regression analysis which assists in predicting the energy consumption trend for a period of one year. Further to this, the capacity of control principles in efficient energy consumption is demonstrated by practical real time implementation of a smart energy saving in the food industries using PLClogicx software. In this sense, the developed programmable logic control (PLC) ladder diagram was further designed and implemented using fuzzy logic control (FLC). This is simulated using MATLAB/Simulink toolbox. By this arrangement; it is observed that there was a significant reduction in energy consumption. This is obviously revealed in the obtained results. In this case, there was an average electrical energy savings of 65.59% in the plant's case sealing section while an energy saving of approximately 0.13% was achieved in reference to the overall energy consumption of the industrial plant's processes. Finally, based on the mathematical calculations obtained from observations of typical production processes in the multinational food and beverage company, the FLC is discovered to provide 99.83% efficiency in optimizing energy consumption.

Large scale belt conveyor systems have a lot of unique characteristics, such as long conveying distance, large capacity and high efficiency, continuous transportation of bulk materials as well as central control and management. The motion of the belt conveyor system is controlled by a driving station, which consists mainly of two driving pulleys and one pre-tensioning pulley. The pulley drums are thin walled structures produced by rolling a thick steel sheet and welding it with two end plates. Decreased service life has been observe in the open mine of Amyntaion Greece, resulting in frequent break downs. Drum replacement in the harsh muddy conditions stalls the operation of the belt systems up to two days. In addition to the cost of the drum, it results in a dangerous and financially cumbersome repair. The drums are subjected to variable loads depending on weather, pretension and mined material. Therefore a methodology for modelling, which would take all these into consideration was...