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| MMF Uluslararası Mühendislik, Tasarım ve Teknoloji Dergisi, 2024, 6(2), Sayfa: 45-52

MÜHENDİSLİK-MİMARLIK FAKÜLTESİ International Journal of Engineering, Design and Technology, 2024, 6(2), Page: 45-52
Araştırma Makalesi
Research Article

Computer aided design of chain elavator


Zincirli elevatörün bilgisayar destekli tasarımı

Onur Güven1* , Mehmet Ali Altunbaşak1


Mersin University, Faculty of Engineering, Department of Mechanical Engineering, 33343, Yenisehir, Mersin, Türkiye

Abstract: In this study, a computer program has been developed for the computer-aided design of single-strand
chain elevators, which carry powder, bulk, and piece materials and have a wide range of applications. In industry or
other usage areas, the most common single-strand chain, gravity tensioned, pre-bedded, bucket elevator is dimen-
sioned using accepted coefficients, tables, catalogs, and formulas. The drive system includes an electric motor,
gearbox, bearing, shaft, sprocket, sprocket hub, chain, bucket, and drive upper and lower body enclosure. Brands
such as Nord, Yılmaz, Remas, and Flender are used as gearboxes, while brands such as SKF and FAG are used for
bearings. In our calculations, a computer program has been developed based on the technical specifications of Re-
mas for the gearbox and SKF for the bearings. Through the use of computer-aided design for the chain elevator,
time loss and the burden of the design process were significantly reduced. This study has led to the identification
of optimal design values, which in turn has lowered design costs. Operating costs were also minimized by avoiding
design errors.
Keywords: Elevator, Design by Classical Method, Bucket Conveyors

Özet: Bu çalışmada, toz, dökme ve parça malzemeleri taşıyan ve geniş bir uygulama alanına sahip olan tek sıra zin-
cirli elevatörlerin bilgisayar destekli tasarımı için bir bilgisayar programı geliştirilmiştir. Sanayi veya diğer kullanım
alanlarında en yaygın kullanılan tek sıra zincirli, yerçekimi ile gerilimli, önceden döşenmiş, kovalı elevatör, kabul
edilen katsayılar, tablolar, kataloglar ve formüller kullanılarak boyutlandırılmıştır. Tahrik sistemi elektrik motoru,
dişli kutusu, yatak, mil, dişli çarkı, dişli göbeği, zincir, kova ve tahrik üst ve alt gövde muhafazasını içerir. Dişli kutusu
olarak Nord, Yılmaz, Remas ve Flender gibi markalar kullanılırken, yataklar için SKF ve FAG gibi markalar kullanıl-
maktadır. Hesaplamalarımızda, dişli kutusu için Remas'ın teknik özelliklerine ve yataklar için SKF'nin teknik özel-
liklerine dayalı bir bilgisayar programı geliştirilmiştir. Zincir elevatörün bilgisayar destekli tasarımı sayesinde zaman
kaybı ve tasarım sürecinin yükü önemli ölçüde azaltılmıştır. Bu çalışma, optimal tasarım değerlerinin belirlenmesine
yol açmış ve tasarım maliyetlerini düşürmüştür. Ayrıca, tasarım hatalarından kaçınarak işletme maliyetleri de en aza
indirilmiştir.
Anahtar Kelimeler: Elevatör, Klasik Metot ile Tasarım, Kovalı Konveyörler

1. Introduction the process is far from simple. Designing chain elevators


An elevator is a mechanical conveying equipment used involves extensive use of charts, tables, experience, and
for vertically transporting materials from one point to predictions. A single incorrect value in these long and
another. It is particularly useful for conveying bulk ma- complex calculations can significantly alter the results,
terials such as dust and granules that need to be trans- and designing for a different material with the same ca-
ported vertically in large quantities. Elevators are high- pacity and height requires restarting the entire process.
ly efficient and widely used vertical conveying systems
for a variety of materials, making them one of the most
popular vertical transportation systems in today’s world.
2. Source Research
Therefore, their usage areas are very widespread. In Kurtboğan’s (2006) study, speed is stated as the most
important design criterion for bucket elevators. It is not-
The design of chain elevators may seem easy at first ed that speed causes both the dimensions and costs of
glance. Because it can be thought of as stretching the the elevator to increase excessively. The diameter of the
segments between two toothed segments of an endless drum or gear is also highlighted as a crucial factor in
chain, taking the material from the loading mouth, rais- elevator design. It is observed that while an increase in
ing it to the desired point and unloading the material the drum or gear diameter results in smoother transmis-
from the pouring mouth. However, as calculations reveal, sion, excessive growth in diameter leads to an increase in
*
İletişim Yazarı / Corresponding author. Eposta/Email : oguvenonur@gmail.com
Burdur
Geliş / Received: 30.06.2024, Revizyon / Revised: 25.07.2024 Mehmet Akif Ersoy
Kabul / Accepted: 01.08.2024 University Press

https://dergipark.org.tr/ijedt
Content of this journal is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
Computer aided design of chain elavator

the elevator’s volume. Therefore, experimental standard In the study of Güven (1997), a computer-aided design
tables are required to be used for the selection of both of rubber band conveyors was made. The history of rub-
speed and drum diameter in practice. ber belt conveyors, their applications from the past to
the present, the types of bulk materials they can trans-
It was mentioned that for the transmission of relative- port, and the various types of rubber belt conveyors were
ly hard, coarse-grained materials (such as ore) at high discussed. The benefits of using computer-aided design,
temperatures, a chain elevator should be preferred, while particularly with the Visual Basic 3.0 programming lan-
for the transmission of powdered materials (especially guage, for the ergonomic design of conveyors in terms of
grains) at high speeds, a belt elevator should be preferred workload and time efficiency were emphasized.
(Kurtboğan, 2006). The traction elements of elevators
were extensively examined in this study, and their char- In the study of Karagülle (2004) an effort was made to
acteristics were analyzed. It was stated that the correct generate interest in the language among programmer
selection of either chain or belt should be made based candidates by developing two very simple yet useful ex-
on environmental conditions and material properties. amples for an introduction to visual programming. The
Standards determine almost all elements in elevator de- structure of the programming language, variables, data
sign, and it was noted that smooth transmission would types, loops, program control expressions, operators,
be achieved by utilizing these values in the design. mathematical operations, functions, subprograms, ob-
ject-oriented programming, and debugging issues were
In the study by Gerdemeli (1996), the types and parts of explained.
bucket elevators were defined. Information on loading
and unloading the elevator based on the characteristics In the study of Demirli and İnan (2006) an attempt was
of the transported material was also provided. It was made to explain screen windows for an introduction to
mentioned that materials such as coal dust, cement, pow- visual programming, the basics of programming, rec-
der, soil, and slate, which have small particles, dust, and ommendations for programmer candidates, assignment
moderate abrasiveness, would not resist scooping during procedures, functions and procedures, loops, and error
loading, making the scooping method suitable for con- handling procedures.
veying such materials. However, for materials with large
particles, coarse and abrasive properties, such as gravel,
ore, and large coal, which would resist scooping during
3. Method
loading, it was emphasized that direct feeding to the For the computation of a single-strand chain elevator and
buckets, bypassing scooping, should be employed. Re- the dimensioning of its components in a computer envi-
garding the emptying of the buckets, different emptying ronment, Visual Studio C# (C Sharp) 2017 Programming
types were mentioned depending on material properties Language was utilized. This programming language is
and elevator speed. It was also stated that almost all el- designed for creating various applications running on
ements in the design of bucket elevators are determined the .NET Framework in the Windows environment. It is
by standards, and theoretical calculations can be made an object-oriented programming language (Aktaş, 2014).
using these values in the design process.

In the study of Cerit (1984) it was mentioned that various


4. Program Phases
types of powder, granular, and bulk materials (such as ce- The window created as the main menu, where program
ment, sand, soil, peat, coal, soda, refractories, chemicals, data is entered and outputs are obtained, serves as the
grain, flour, etc.) and building materials are conveniently entry page of the program. Figure 1 displays the main
transported using elevators. It was noted that elevators window that has been created.
are employed in chemical industry factories, foundries,
refractory material production, metallurgical factories, When the calculation icon is clicked on the main window
food industry, flour mills, grain silos, and similar set- of the program, it switches to the program writing page
tings. The characteristics of elevator components were where the desired information is calculated as blank spaces
described, and the calculation method for elevator design in the parts shown in the form of empty boxes in Figure 1.
was explained using tables with standards determined The command back-end, where the program calculation is
for elevator types and their components. performed, is where the desired program is created line by
line. After all the operations are completed, when the pro-
In the study of Demirsoy (1984) the elevator as a mecha- gram is executed, the window view appears on the screen.
nism that operates either vertically or inclined and includes The required inputs on this screen are: capacity, material
a band and a chain as the traction organs was defined. It to be transported, conveying distance, selection of one of
was mentioned that elevators are distinguished primar- the materials defined as AISI4140-AISI4340-AISI5140 for
ily by their methods of feeding and discharging buckets. the drive shaft material, and selection of one of the materi-
Types that use centrifugal force for rapid discharge and als defined as AISI1035-AISI1040-AISI1045-AISI1050 for
types that operate more slowly due to the weight of the the chain material.
conveyed material were discussed. Additionally, important
DIN standards related to elevator design were provided. In Figure 2, the result view of the main window is shown

46 Uluslararası Mühendislik, Tasarım ve Teknoloji Dergisi / International Journal of Engineering, Design and Technology, 2024: 6(2)
Onur Güven, Mehmet Ali Altunbaşak

at the top. Here, fundamental values such as capacity, elevator, and shaft sizing. When the shaft sizing button
shaft distance, bucket type and quantity, reducer type is clicked, the visual structure of the shaft along with nu-
and power, reducer shaft diameter, bearing type and merical values is displayed on the screen as shown in Fig-
shaft diameter, chain type and length, chain sprocket di- ure 3, which illustrates the drive system shaft sizing vi-
ameter and speed are displayed on the screen as output sualization. Clicking on the chain properties button will
results. Additionally, this screen includes icons showing display the chain characteristic values table on the screen
chain characteristic values, the overall appearance of the as shown in Figure 4. When the general appearance but-

Figure 1. Program main window

Figure 2. Microsoft visual studio c# program main window

Uluslararası Mühendislik, Tasarım ve Teknoloji Dergisi / International Journal of Engineering, Design and Technology, 2024: 6(2) 47
Computer aided design of chain elavator

ton is clicked, the parts constituting the elevator and the in this table have been incorporated into the program.
general appearance are displayed on the screen. Clicking The capacity values highlighted in yellow represent the
on the Project button, located next to the bucket type most suitable ergonomic capacity values created consid-
output, chain type output, and chain sprocket output, ering operating conditions and material properties. Se-
will display the project drawing details on the screen. lection can also be made from capacity values without
color, but here, the program prompts the selection based
4.1. Material Selection on the ergonomic capacity value. If the desired capacity
Computer-aided elevator calculations have been per- value exists, it is selected; otherwise, the closest higher
formed for materials such as clinker, coal, cement, fari- capacity value is chosen. If there are multiple capacity
na, ground limestone, slag, fly ash, limestone, sand, salt, values for the higher capacity, the program ensures the
and coke. By selecting the name of the material from the selection of the capacity value where the drum speed is
dropdown menu, the program obtains the specific grav- lower, considering the physical installation location of
ity value of the material from the table and includes this the elevator and, most importantly, the operating con-
value in the calculations. ditions. From the location of the selected capacity value,
the bucket type and volume, chain type and pitch; and
4.2. Capacity Selection from the vertical columns, chain sprocket diameter and
In the selection of capacity, the capacity table shown in speed parameters are selected. Based on these parame-
Figure 5, obtained through practical applications, expe- ters, the capacity is calculated in tons per hour (t/h) using
riences, and tests, has been utilized. The capacity values equation (1).

Figure 3. Drive system shaft dimensioning as a result of the calculation

Figure 4. Chain characteristic values used in the calculation

48 Uluslararası Mühendislik, Tasarım ve Teknoloji Dergisi / International Journal of Engineering, Design and Technology, 2024: 6(2)
Onur Güven, Mehmet Ali Altunbaşak

(1) gram. The reducer types and hydraulic coupling type


are selected by the program based on the reducer power
from the reducer catalog (Remas catalog, 2017). Bearing
The calculated capacity is compared with the desired type, bearing shaft diameter, bearings, sleeves, and cor-
capacity. If the result of the comparison is smaller than responding tensioning shaft diameters and tensioning
the desired capacity, then another capacity value, which bearings are obtained by the program from the SKF cat-
is the closest higher value, is selected. If the result of the alog (SKF catalog, 2017)
comparison is equal to or greater than the desired capac-
ity, the process proceeds to the next stage. 4.4. Chain Length Calculation
The calculation of chain length (CL) is done using equa-
4.3. Reducer Power Calculation tion (3). The accuracy of the chain length is verified
The reducer power Kw is calculated from the following through the calculation of the number of buckets. The
equation taking into account the selected capacity value number of buckets is calculated from equation (4).
and the entered shaft distance.
CL = Wheelbase x 2(mm)+Chain sprocket Circumfer-
(2) ence(mm)+Chain Bushing Circumference(mm) (3)

The coefficient expressed in equation (2), with values ChainLength(m )


ranging from 2 to 2.5, is selected by the program based Number of Buckets = (4)
BucketPitch(m )
on the applied capacity in practice. In the Turkish mar-
ket, there are reducer companies such as Nord, İmak, If the number of buckets turns out to be an odd or frac-
Yılmaz, Remas, and Öztekfen. Remas brand reducer data tional number, it is taken as the nearest even integer val-
has been used as the basis for the creation of the pro- ue. Then, the actual chain length is determined by multi-

CHAIN BUCKET CHAIN ​​GEAR DIAMETER AND SPEED


Weight Bushing diameter Volume Weight 1,04 1,16 1,25 1,4 1,56 1,67
Type Type Width Pitch Ø655 Ø730 Ø790 Ø890 Ø1005 Ø1115
(Kg/mt) (mm) (dm³) (kg)
200 3,7 5,8 280 37 41 45 50 56 60
250 4,6 6,6 280 46 51 55 62 69 74
280 5,2 7,3 280 52 58 63 70 78 84
CHAIN

22 38,2 210
A1

315 5,8 7,8 280 58 65 70 78 87 93


355 6,5 8,7 280 65 73 78 88 98 105
400 7,4 9,9 280 74 83 89 100 111 119
280 7,2 9 305 66 74 80 89 99 107
CHAIN

40 44,68 300 7,7 9,7 305 71 79 85 95 106 114


B3

315 8 10,2 305 74 82 89 99 111 118


355 9,1 11,1 305 84 94 101 113 126 135
250
400 10,3 12 305 95 106 114 128 142 152
CHAIN

45,5 50,68 450 11,6 13 305 107 119 128 144 160 172
B4

500 12,9 14 305 119 133 143 160 178 191


560 14,4 16,2 305 133 148 159 179 199 213
400 16,8 16,8 356 133 148 159 179 199 213
CHAIN

47,5 50,68
B5

450 18,9 18 356 149 166 179 201 224 240


500 21 19,9 356 166 185 199 223 249 266
CHAIN
Ş06

62,5 58,1 560 23,5 22,5 356 186 207 223 250 278 298
630 26,4 24,5 356 208 233 251 281 313 335
285
710 29,8 25,4 356 235 262 283 317 353 378
CHAIN
Ş13

65 58,9 800 33,6 32,6 356 265 296 319 357 398 426
900 37,8 33,3 356 298 333 359 402 448 479
1000 41,9 42,5 356 331 369 398 445 496 531
CHAIN
Ş15

82,5 70,9
1100 46,2 46,02 356 365 407 438 491 547 586
CAPACITIES ACCORDING TO BUCKET TYPE AND CHAIN ​​GEAR DIAMETER.
m³/ h (% 75 CONSIDERED AS FULL. )

Figure 5. Capacities by bucket type and sprocket diameter

Uluslararası Mühendislik, Tasarım ve Teknoloji Dergisi / International Journal of Engineering, Design and Technology, 2024: 6(2) 49
Computer aided design of chain elavator

Figure 6. A1 chain view and inner link section

plying the number of buckets by the bucket pitch. The bending moment Me (Nm) occurring in the shaft
is calculated from equation (5), where L represents the
4.5. Chain Link Section Calculation length in meters (m). The torsional moment Mb (Nm)
To select the chain material in the program, the mate- occurring in the shaft is determined from equation (6).
rial name is chosen from the dropdown menu on the
main window. This action allows the program to obtain
the material’s breaking strength value and include it in (5)
the calculations. In the program, chain views and inner
link sections for A1-B3-B4-B5-Ş06-Ş013-Ş15 chains have
been processed. Figure 6 displays only the A1 chain view (6)
and inner link section drawing detail.
The torsional moment Md (Nm) occurring in the shaft
Minimum total cross-sectional areas at pea-pin con- is calculated from the following equation. N is the pow-
nection of the chain types shown in the main window er transmitted by the motor (kW), n is the speed of the
result form are determined from the AutoCAD project motor (revolutions per minute, rpm), and η is the power
drawing for the pea cross-sectional areas of the select- transmission efficiency from the motor to the gearbox.
ed chain types. These values are taken by the program For the shaft to be able to perform the rotation process,
according to the chain types from the generated table. If Md must be greater than or equal to Mb.
a tensioning system weight project has been drawn, the
project weight is entered. If there is no project drawing, N
M d = 9550 (7)
an average weight should be entered into the program. n
4.6. Drive Shaft Diameter Calculation The shaft diameter D (m) under dynamic loads is calcu-
Figure 7 illustrates the forces acting on the drive shaft. lated from equation (8) considering the Maximum Shear
These forces cause shear, bending, and torsion in the Stress Hypothesis (MSSH). Equation (9) represents the
shaft. T1 represents the weight of the material-filled side shear safety stress.
(N), T2 represents the weight of the material-empty side
(N), and D represents the shaft hub diameter (m). (8)

τ*em = (σ*em)/2 (9)

The shear safety stress of the shaft is calculated from


equation (10) for infinite life under fully variable loading
due to dynamic loads during system start-up and shut-
down (continuous stress state).

Figure 7. Force distribution on the drive shaft


(10)

50 Uluslararası Mühendislik, Tasarım ve Teknoloji Dergisi / International Journal of Engineering, Design and Technology, 2024: 6(2)
Onur Güven, Mehmet Ali Altunbaşak

A working factor of 2 is taken for the dynamic effects


Table 1. Input preferences of design criteria
for the working factor S2. The program obtains the size
factor (K b) value from the table created according to the I Preference II Preference III Preference
diameter, the notch sensitivity factor (βk) value from the Capacity(m³/h) 99 101 106
table created according to the material, and the surface Chain type B3 B4 B4
factor (Ky) value from the table created according to the Sprocket Wheel(mm) Ø890 Ø790 Ø730
material’s tensile strength (Bozacı, 2005). The program
Chain speed(m/s) 1.4 1.25 1.16
obtains the impact (Km) and wear (Kt) coefficients ap-
plied to the bending and torsional moments for rotating Bucket type 250 x 315 250 x 355 250 x 400
shafts from the table created according to the loading
condition (Aşık, 1992).
the designer calculates values by relying on experience,
practical applications, tables, charts, and catalogs. When
5. Discussion and Conclusion selecting from Figure 5 for conveying cement with a spe-
In order to carry out the engineering design of a sin- cific gravity of 1 t/m3 at a capacity of 100 t/h and a height
gle-strand chain elevator using the classical method, of 30 m, the designer may make different choices. By se-

Table 2. Comparison of calculation results

Situations I Preference II Preference III Preference Program result


Capacity 99.21 t/h 101 t/h 106 t/h 100.76 t/h
Chain type B3 B4 B4 B4
Chain length 62.789 m 62.789 m 62.179 m 62.789 m
Sprocket wheel Ø 890 mm Ø 790 mm Ø730 mm Ø 790 mm
Chain speed 1.4 m/s 1.25 m/s 1.16 m/s 1,25 m/s
Bucket type 250 x 315 250 x 355 250 x 400 250 x 355
Number of buckets 206 Ad 206 Ad 204 Ad 206 Ad
Reducer power 16.22 Kw 17.29 Kw 17.29 Kw 18,5 Kw
Reducer type / K2A-225 / K2A-225 / K2A-225 / K2A-225
Distance between
L : 1035 mm L : 1075 mm L : 1120 mm L : 1075 mm
bearing
Drive shaft D : 14.72 cm D : 15.11 cm D : 15.83 cm
D : 160 mm
Drive of buckets ~150 mm ~150 mm ~160 mm

Figure 8. Calculation main window result form

Uluslararası Mühendislik, Tasarım ve Teknoloji Dergisi / International Journal of Engineering, Design and Technology, 2024: 6(2) 51
Computer aided design of chain elavator

lecting three different values from Figure 5, the designer perienced. If two different individuals were to design an
can make a choice from the design criteria in Table 1 for elevator with the same specifications using the classical
their design. These differences will lead to changes in the method without knowledge of each other’s work, they
elevator height, elevator length, and elevator weight. might arrive at different results. One of these results may
be more ergonomic than the other. Another scenario is
In this study, by inputting the operation data into the that designing for a different material at the same ca-
software implemented and running the program, the pacity and height would require starting all calculations
main window result form depicted in Figure 8 is ob- from scratch. Designing with computer assistance would
tained. minimize time loss and design workload, reduce design
costs by using optimal values, prevent erroneous designs,
The calculation results obtained by the classical meth- and consequently decrease operational and maintenance
od according to the preferences in Table 1 are compared expenses.
with the values calculated by the program in Figure 8 in
Table 2.
Orcid
As a result, during the design process, it is crucial to Onur Güven https://orcid.org/0000-0002-8101-4871
have a thorough understanding of operating conditions Mehmet Ali Altunbaşak https://orcid.org/0009-0000-2729-6532
and material properties, and the designer must be ex-

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