Material Handling Systems

Material Handling System
ATILIM UNIVERSITY
Manufacturing Engineering Department
Lecture 10 – Automated Material Handling Systems
Fall 2005/2006
Dr. Saleh AMAITIK
Types of loads
1. Bulk Loads
2. Unit Loads
• Bulk Loads : consists of large homogenous particles or lump material.

• Ex. Coal, mineral ore, sand, stone, clay, cement etc.
• Unit Loads : single rigid mass handled and transported as one piece
• Ex. Machines, boxes, containers etc.
Containerization :
The process of converting the bulk loads or small loads into a unit
load by using the containers
Unit Load Containers
(a) Wooden pallet, (b) pallet box, (c) tote box

Principles in selecting Material Handling Equipment
Direction of Load
Length of Load
Type and Properties of Loads to be handled
Required Load Moving Capacity of Unit
Characteristics of Production Processes
Local Condition
Initial and Operating Cost
Method of Stacking Loads at initial and final points

Objectives of Material Handling System
Accuracy in Transporting Loads to Destination
Precision in Pick-up
Scheduled Time
Required Quantity
Without Damage
Minimum Manpower
Low Cost
Easy Maintenance
Operational Safety
Classification of Material Handing
Equipments
1. Hoisting Equipments
Hoisting Machines
Cranes
Elevators
2. Surface and Overhead Equipment
Trackless Trucks
Narrow-Gauge Car
Conveyor Systems
• Conveyors are used when material must be moved in relatively large
quantities between specific locations over a fixed path.
• Conveyors divided into two basic categories:
1. Powered conveyors
2. Non-powered conveyors.
• In powered conveyors, the power mechanism is contained in the fixed path,

using belts, rotating rolls, or other devices to propel loads along the path.
They are commonly used in automated material transfer systems.
• In non-powered conveyors, materials are moved either manually or by
human workers who push the loads along the fixed path.
Nonpowered Industrial Trucks
(Hand Trucks)
(a) Two-wheel hand truck, (b) four-wheel dolly, (c)

hand-operated low-lift pallet truck
Powered Trucks:
Walkie Truck
Powered Trucks: Forklift Truck
Powered Trucks: Towing Tractor
Types of Conveyors
• A variety of conveyor equipment is commercially available. The following
are the major types of powered conveyors:
• In roller conveyor, the pathway consists of a series of tubes (rollers) that
are perpendicular to the direction of travel.
• The rollers are contained in a fixed frame that elevates the pathway
above floor level from several inches to several feet.
• Flat pallets carrying unit loads are moved forward as the roller rotate.
• Roller conveyors are used in a wide variety of applications, including
manufacturing, assembly, and packaging.
Types of Conveyors
2. Belt Conveyors consist of a continuous loop: Half its length is used for
delivering materials , and other half is the return run.
Types of Conveyors
Chain Conveyors : Consists of Endless chain running over the drive
or head sprocket
Screw Conveyors : consists of a screw or worm, in the form of helix,

rotating in a trough or tube.
Troughed Belt Conveyors
Elements of Belt Conveyor System
1. Conveyor Belt
2. Drive or Head Pulley
3. Tail Pulley
4. Snub Pulley
5&6. Idlers
7. bend Pulleys
8. Take-Up Pulley
9. Counter Wts.
10&11. Belt Cleaner
12. Feeder
13. Hooper
Capacity of Belt Conveyors (Q)
The Volumetric Capacity for Horizontal Belt Conveyors
Q  Cb 2 v m m3/s
Q  C 0.9 B  0.005 v , m3/s
2
Q  C 0.9 B  0.005 v  3600, m3/hr

2
Mass Capacity… M    Q
Where, C = Surcharge Factor
B = Width of Belt, m
b = Effective Belt Width, m
= (0.9B-0.05), m
v = Belt Speed, m/s
ρ = mass Density of bulk material
Surcharge Factor
Capacity of Belt Conveyors (Q)
The Volumetric Capacity for Inclined Belt Conveyors
Q  kb 2 v , m3/s
Q  k 0.9 B  0.005 v , m3/s
2
Q  k 0.9 B  0.005 v  3600, m3/hr

2
Mass Capacity… M    Q
Where, k = flowability Factor
B = Width of Belt, m
b = Effective Belt Width, m
= (0.9B-0.05), m
v = Belt Speed, m/s
ρ = mass Density of bulk material
Flowability Factor
Conveyor Belt Speeds ‘v’
Standard Belt Widths (B) : 400, 450, 500, 600, 650, 750, 800, 900,
1000, 1200, 1400, 1600, 1800, 2000, 2200 and 2400 mm
Head (Drive) and Tail Pulleys
The minimum diameters of drive pulley and tail pulley,
Dmin  K1  K 2  Z p
Where, Zp = Number of plies
K1 = Material factor for plies
K2 = Belt tension and arc of contact factor
Material Factor K1
Material Factor K2
The length of pulley (lp) is given by,

F  Ftight  Fslack l p  B  2s
Where, S = Side margin
= 60 to 75 mm
IDLERS
Impact idlers
Roller type idlers with ball bearings
Roller type idlers with roller bearings
Disc type idlers

Spring type idlers
Belt Take-Up Devices
Horizontal Gravity Type

Vertical Gravity Type
Screw Type Winch Operated Type

Methods of Discharge to Flat Belt
Conveyor
Head Pulley Discharge Both End Discharge
Tripper Discharge Plow Discharge

Different Resisting Forces on Conveyor Belt
1. Load Resistance due to Lifting of Material (Fm)
Component along belt,
Fm  Wm Sin  mm lg sin   mm gh
2. Frictional Resistance due to idlers(Fr)
 mz 
Fcr  f c  mm  mb  i c  gl
 l 
 mi z r 
F rr  f c  mb   glr
 l 
Power Requirement of Belt Conveyors
Power Required for Lifting Load

(Pl) in KW
Qgh
Pl 
1000
Power Required for Overcoming

Frictional Resistance (Pf) in KW
C0 QgL
Pf 
1000
Total Power Required :
P  P l  Pf

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Material Handling System

Lecture 10 – Automated Material Handling Systems

• Bulk Loads : consists of large homogenous particles or lump material.

(a) Wooden pallet, (b) pallet box, (c) tote box

Type and Properties of Loads to be handled

Required Load Moving Capacity of Unit

Characteristics of Production Processes

Initial and Operating Cost

Method of Stacking Loads at initial and final points

2. Surface and Overhead Equipment

• In powered conveyors, the power mechanism is contained in the fixed path,

(a) Two-wheel hand truck, (b) four-wheel dolly, (c)

Screw Conveyors : consists of a screw or worm, in the form of helix,

Q  C 0.9 B  0.005 v  3600, m3/hr

Where, C = Surcharge Factor

Q  k 0.9 B  0.005 v  3600, m3/hr

Where, k = flowability Factor

The length of pulley (lp) is given by,

Disc type idlers

Horizontal Gravity Type

Screw Type Winch Operated Type

Head Pulley Discharge Both End Discharge

Tripper Discharge Plow Discharge

2. Frictional Resistance due to idlers(Fr)

Power Required for Lifting Load

Power Required for Overcoming

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