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DOI101007/S0017000318433ORIGINALARTICLEINTJADVMANUFTECHNOL200525551559SHMASOODBABBASESHAYANAKARAANINVESTIGATIONINTODESIGNANDMANUFACTURINGOFMECHANICALCONVEYORSSYSTEMSFORFOODPROCESSINGRECEIVED29MARCH2003/ACCEPTED21JUNE2003/PUBLISHEDONLINE23JUNE2004SPRINGERVERLAGLONDONLIMITED2004ABSTRACTTHISPAPERPRESENTSTHERESULTSOFARESEARCHINVESTIGATIONUNDERTAKENTODEVELOPMETHODOLOGIESANDTECHNIQUESTHATWILLREDUCETHECOSTANDTIMEOFTHEDESIGN,MANUFACTURINGANDASSEMBLYOFMECHANICALCONVEYORSYSTEMSUSEDINTHEFOODANDBEVERAGEINDUSTRYTHEIMPROVEDMETHODOLOGYFORDESIGNANDPRODUCTIONOFCONVEYORCOMPONENTSISBASEDONTHEMINIMISATIONOFMATERIALS,PARTSANDCOSTS,USINGTHERULESOFDESIGNFORMANUFACTUREANDDESIGNFORASSEMBLYRESULTSOBTAINEDONATESTCONVEYORSYSTEMVERIFYTHEBENEFITSOFUSINGTHEIMPROVEDTECHNIQUESTHEOVERALLMATERIALCOSTWASREDUCEDBY19ANDTHEOVERALLASSEMBLYCOSTWASREDUCEDBY20COMPAREDTOCONVENTIONALMETHODSKEYWORDSASSEMBLYCOSTREDUCTIONDESIGNDFADFMMECHANICALCONVEYOR1INTRODUCTIONCONVEYORSYSTEMSUSEDINTHEFOODANDBEVERAGEINDUSTRYAREHIGHLYAUTOMATEDCUSTOMMADESTRUCTURESCONSISTINGOFALARGENUMBEROFPARTSANDDESIGNEDTOCARRYPRODUCTSSUCHASFOODCARTONS,DRINKBOTTLESANDCANSINFASTPRODUCTIONANDASSEMBLYLINESMOSTOFTHEPROCESSINGANDPACKAGINGOFFOODANDDRINKINVOLVECONTINUOUSOPERATIONSWHERECARTONS,BOTTLESORCANSAREREQUIREDTOMOVEATACONTROLLEDSPEEDFORFILLINGORASSEMBLYOPERATIONSTHEIROPERATIONSREQUIREHIGHLYEFFICIENTANDRELIABLEMECHANICALCONVEYORS,WHICHRANGEFROMOVERHEADTYPESTOFLOORMOUNTEDTYPESOFCHAIN,ROLLERORBELTDRIVENCONVEYORSYSTEMSINRECENTYEARS,IMMENSEPRESSUREFROMCLIENTSFORLOWCOSTBUTEFFICIENTMECHANICALCONVEYORSYSTEMSHASPUSHEDCONVEYORMANUFACTURERSTOREVIEWTHEIRCURRENTDESIGNANDASSEMBLYMETHODSANDLOOKATANALTERNATIVEMEANSTOMANUFACTUREMOREECONOMICALANDRELIABLECONVEYORSFORTHEIRCLIENTSATPRESENT,SHMASOODA117BABBASESHAYANAKARAINDUSTRIALRESEARCHINSTITUTESWINBURNE,SWINBURNEUNIVERSITYOFTECHNOLOGY,HAWTHORN,MELBOURNE3122,AUSTRALIAEMAILSMASOODSWINEDUAUMOSTMATERIALHANDLINGDEVICES,BOTHHARDWAREANDSOFTWARE,AREHIGHLYSPECIALISED,INFLEXIBLEANDCOSTLYTOCONFIGURE,INSTALLANDMAINTAIN1CONVEYORSAREFIXEDINTERMSOFTHEIRLOCATIONSANDTHECONVEYORBELTSACCORDINGTOTHEIRSYNCHRONISEDSPEEDS,MAKINGANYCHANGEOVEROFTHECONVEYORSYSTEMVERYDIFFICULTANDEXPENSIVEINTODAYSRADICALLYCHANGINGINDUSTRIALMARKETS,THEREISANEEDTOIMPLEMENTANEWMANUFACTURINGSTRATEGY,ANEWSYSTEMOPERATIONALCONCEPTANDANEWSYSTEMCONTROLSOFTWAREANDHARDWAREDEVELOPMENTCONCEPT,THATCANBEAPPLIEDTOTHEDESIGNOFANEWGENERATIONOFOPEN,FLEXIBLEMATERIALHANDLINGSYSTEMS2HOANDRANKY3PROPOSEDANEWMODULARANDRECONFIGURABLE2DAND3DCONVEYORSYSTEM,WHICHENCOMPASSESANOPENRECONFIGURABLESOFTWAREARCHITECTUREBASEDONTHECIMOSAOPENSYSTEMARCHITECTUREMODELITISNOTEDTHATTHERESEARCHINTHEAREAOFIMPROVEMENTOFCONVEYORSYSTEMSUSEDINBEVERAGEINDUSTRYISVERYLIMITEDMOSTOFTHEPUBLISHEDRESEARCHISDIRECTEDTOWARDSIMPROVINGTHEOPERATIONSOFCONVEYORSYSTEMSANDINTEGRATIONOFSYSTEMTOHIGHLYSOPHISTICATEDSOFTWAREANDHARDWARETHISPAPERPRESENTSARESEARCHINVESTIGATIONAIMEDATIMPROVINGTHECURRENTTECHNIQUESANDPRACTICESUSEDINTHEDESIGN,MANUFACTURINGANDASSEMBLYOFFLOORMOUNTEDTYPECHAINDRIVENMECHANICALCONVEYORSINORDERTOREDUCETHEMANUFACTURINGLEADTIMEANDCOSTFORSUCHCONVEYORSAPPLYINGTHECONCEPTOFCONCURRENTENGINEERINGANDTHEPRINCIPLESOFDESIGNFORMANUFACTURINGANDDESIGNFORASSEMBLY4,5,SEVERALCRITICALCONVEYORPARTSWEREINVESTIGATEDFORTHEIRFUNCTIONALITY,MATERIALSUITABILITY,STRENGTHCRITERION,COSTANDEASEOFASSEMBLYINTHEOVERALLCONVEYORSYSTEMTHECRITICALPARTSWEREMODIFIEDANDREDESIGNEDWITHNEWSHAPEANDGEOMETRY,ANDSOMEWITHNEWMATERIALSTHEIMPROVEDDESIGNMETHODSANDTHEFUNCTIONALITYOFNEWCONVEYORPARTSWEREVERIFIEDANDTESTEDONANEWTESTCONVEYORSYSTEMDESIGNED,MANUFACTUREDANDASSEMBLEDUSINGTHENEWIMPROVEDPARTS2DESIGNFORMANUFACTURINGANDASSEMBLYDFMAINRECENTYEARS,RESEARCHINTHEAREAOFDESIGNFORMANUFACTURINGANDASSEMBLYHASBECOMEVERYUSEFULFORINDUSTRIESTHATARECON552SIDERINGIMPROVINGTHEIRFACILITIESANDMANUFACTURINGMETHODOLOGYHOWEVER,THEREHASNOTBEENENOUGHWORKDONEINTHEAREAOFDESIGNFORCONVEYORCOMPONENTS,ESPECIALLYRELATEDTOTHEISSUEOFINCREASINGNUMBERSOFDRAWINGDATAANDREENGINEERINGOFTHEPROCESSOFCONVEYORDESIGNBASEDONTRADITIONALMETHODSAVASTAMOUNTOFPAPERSHAVEBEENPUBLISHEDTHATHAVEINVESTIGATEDISSUESRELATEDTODFMAANDAPPLIEDTOVARIOUSMETHODOLOGIESTOACHIEVERESULTSTHATPROVEDECONOMICAL,EFFICIENTANDCOSTEFFECTIVEFORTHECOMPANIESUNDERINVESTIGATIONTHEMAINCLASSIFICATIONSOFDFMAKNOWLEDGECANBEIDENTIFIEDAS1GENERALGUIDELINES,2COMPANYSPECIFICBESTPRACTICEOR3PROCESSANDORRESOURCESPECIFICCONSTRAINTSGENERALGUIDELINESREFERTOGENERALLYAPPLICABLERULESOFTHUMB,RELATINGTOAMANUFACTURINGDOMAINOFWHICHTHEDESIGNERSHOULDBEAWARETHEFOLLOWINGLISTHASBEENCOMPILEDFORDFMGUIDELINES6DESIGNFORAMINIMUMNUMBEROFPARTSDEVELOPAMODULARDESIGNMINIMISEPARTVARIATIONSDESIGNPARTSTOBEMULTIFUNCTIONALDESIGNPARTSFORMULTIUSEDESIGNPARTSFOREASEOFFABRICATIONAVOIDSEPARATEFASTENERSMAXIMISECOMPLIANCEDESIGNFOREASEOFASSEMBLYMINIMISEHANDLINGDESIGNFORHANDLINGPRESENTATIONEVALUATEASSEMBLYMETHODSELIMINATEADJUSTMENTSAVOIDFLEXIBLECOMPONENTSTHEYAREDIFFICULTTOHANDLEUSEPARTSOFKNOWNCAPABILITYALLOWFORMAXIMUMINTOLERANCEOFPARTSUSEKNOWNANDPROVENVENDORSANDSUPPLIERSUSEPARTSATDERATEDVALUESWITHNOMARGINALOVERSTRESSMINIMISESUBASSEMBL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USEDELAYSINDELIVERIESTHEDELAYISUSUALLYCAUSEDBYSOMEOFTHEPARTSNOTARRIVINGFROMOVERSEASSUPPLIERSONTIMETHEMOSTCRITICALSPECIFICATIONSREQUIREDFORTHECONVEYORLEGSARE554STRENGTHTOCARRYCONVEYORLOADSTABILITYEASEOFASSEMBLYEASEOFFLEXIBILITYFORADJUSTINGHEIGHTFIGURE2INDICATESALLTHEPARTSFORTHEEXISTINGDESIGNOFTHECONVEYORLEGTHEINDICATEDNUMBERSARETHEPARTNUMBERSDESCRIBEDINTABLE2,WHICHALSOSHOWSABREAKDOWNOFCOSTANALYSISCOMPLETEWITHTHELABOURTIMEREQUIREDTOASSEMBLEACOMPLETESETOFLEGSTHEEXISTINGLEGSETUPCONSISTSOFPLASTICLEGBRACKETSORDEREDFROMOVERSEAS,STAINLESSSTEELLEGTUBES,WHICHARECUTINTOSPECIFIEDSIZES,LEGTUBEPLASTICADJUSTMENTS,WHICHARECLIPPEDONTOTHELEGTUBEATTHEBOTTOMASSHOWNINFIG2LUGS,WHICHARECUTINSQUARESIZES,DRILLEDANDWELDEDTOTHELEGTUBETOBOLTTHEANGLECROSSBRACINGANDBACKINGPLATETOSUPPORTLEGBRACKETSBOLTSTHEOFPARTSINTABLE2SIGNIFIESTHENUMBEROFCOMPONENTSINEACHPARTNUMBERANDTHEQUANTITYISTHECONSUMPTIONOFEACHPARTINTHELEGDESIGNCOMPANIESHAVEUSEDTHISDESIGNFORMANYYEARSBUTONEOFTHECOMMONCOMPLAINTSREPORTEDBYTHECLIENTSWASOFTHEINSTABILITYOFLEGSFROMANINITIALINVESTIGATION,ITBECAMECLEARTHATTHECONNECTIONBETWEENTHESTAINLESSSTEELTUBEANDPLASTICLEGSBRACKETPARTFIG2EXISTINGLEGDESIGNASSEMBLYWITHPARTNAMESSHOWNINTABLE1TABLE2COSTANALYSISFOROLDLEGDESIGNASSEMBLYPARTNOPARTDESCRIPTIONOFPARTSQTYCOSTSOURCE1PLASTICLEGBRACKET223000OVERSEAS5,6LEGTUBEPLASTICADJUSTMENT422800OVERSEAS4LUG22400INHOUSE7ANGLECROSSBRACING11500INHOUSE2BACKINGPLATE22400INHOUSE3LEGTUBE222500INHOUSE8BOLTS66300INHOUSETOTALASSEMBLYCOSTWELDING1500INHOUSETOTAL1917114001ANDPART3INFIG2WASNOTRIGIDENOUGHTHECONNECTIONSFORTHESEPARTSAREONLYASINGLE6MMBOLTATTIMES,WHENTHECONVEYORSYSTEMWASCARRYINGFULLPRODUCTLOADS,ITWASOBSERVEDTHATTHECONVEYORLEGSWEREUNSTABLEANDCAUSEDMECHANICALVIBRATIONONEOFTHEMAINREASONSFORTHISWASDUETOASINGLEBOLTCONNECTIONATEACHENDOFTHELUGSINPART3ANDPART7THESTABILITYOFTHECONVEYORISCONSIDEREDCRITICALMATTERANDREQUIRESRECTIFICATIONIMMEDIATELYTOSATISFYCUSTOMEREXPECTATIONSCONSIDERINGTHEPROBLEMSOFTHEEXISTINGCONVEYORLEGDESIGNANDTHECLIENTSPREFERENCES,ANEWDESIGNFORTHECONVEYORLEGWASDEVELOPEDGENERALLYTHESTABILITYANDTHESTRENGTHOFTHELEGSWERECONSIDEREDASTHEPRIMARYCRITERIAFORIMPROVEMENTINTHENEWDESIGNPROPOSALBUTOTHERCONSIDERATIONSWERETHESIMPLICITYOFDESIGN,MINIMISATIONOFOVERSEASPARTSANDEASEOFASSEMBLYATTHEPOINTOFCOMMISSIONINGFIGURE3SHOWS,THENEWDESIGNOFTHECONVEYORSLEGASSEMBLY,ANDTABLE3GIVESADESCRIPTIONANDTHECOSTOFEACHPARTFIGURE3SHOWSTHATTHENEWDESIGNCONSISTSOFONLYFIVEMAINPARTSFORTHECONVEYORSLEGCOMPAREDTOEIGHTMAINPARTSINTHEOLDDESIGNINTHEOLDDESIGN,THEPLASTICLEGBRACKET,THELEGTUBEPLASTICADJUSTMENTANDTHELEGTUBEWERETHEMOSTEXPENSIVEITEMSACCOUNTINGFOR72OFTHECOSTOFLEGASSEMBLYINTHENEW555FIG3NEWDESIGNFORLEGASSEMBLYWITHPARTNAMESINTABLE3TABLE3COSTANALYSISFORNEWDESIGNLEGASSEMBLYPARTNOPARTDESCRIPTIONOFPARTSQTYCOSTSOURCE1STAINLESSSTEELANGLE50503MM222400INHOUSE3LEGPLASTICADJUSTMENT221000OVERSEAS4CROSSBRASSING11700INHOUSE5BOLTS84400INHOUSE2BACKINGPLATE22400INHOUSETOTALASSEMBLYCOST1000INHOUSETOTAL15115900DESIGN,THOSEPARTSHAVEBEENREPLACEDBYASTAINLESSSTEELANGLEANDANEWPLASTICLEGADJUSTMENTREDUCINGTHECOSTOFLEGASSEMBLYBYALMOST50THUSTHETOTALNUMBERSOFPARTSINTHELEGHAVEBEENREDUCEDFROM19TO15ANDTHETOTALCOSTPERLEGSETUPHASBEENREDUCEDBY55INTHENEWDESIGNTHENEWCONVEYORLEGDESIGN,WHENTESTED,WASFOUNDTOBEMORESECUREANDSTABLETHANTHEOLDDESIGNTHEELIMINATIONOFPARTNUMBER1AND5FROMOLDCONVEYORDESIGNHASMADETHENEWDESIGNMORESTABLEANDRIGIDINADDITION,THEWIDTHOFTHECROSSBRACINGHASALSOBEENINCREASEDWITHTWOBOLTSMOUNTINSTEADOFONEINOLDDESIGNTHISHASPROVIDEDTHEENTIRECONVEYORLEGSETUPANADDITIONALSTRENGTH6REDESIGNOFTHESIDEFRAMESTHESIDEFRAMEISTHEPRIMARYSUPPORTOFACONVEYORSYSTEMTHATPROVIDESPHYSICALSTRENGTHTOCONVEYORSANDALMOSTALLTHEPARTSAREMOUNTEDONITTHESIDEFRAMEISALSOEXPECTEDTOHAVEARIGIDSTRENGTHTOPROVIDESUPPORTTOALLTHELOADSCARRIEDONTHECONVEYORITALSOACCOMMODATESALLTHEASSOCIATEDCONVEYORCOMPONENTSFORTHEASSEMBLYTHECRITICALCONSIDERATIONSOFSIDEFRAMEDESIGNARESIZEOFSIDEFRAMEDEPTHSTRENGTHOFTHEMATERIALEASEFORASSEMBLYEASEFORMANUFACTURINGFIGURE4SHOWSTHESIDEFRAMEDIMENSIONANDPARAMETERSTHESIDEFRAMEUSEDINEXISTINGDESIGNAPPEARSTOBEOFREASONABLEDEPTHINSIZEDIMENSIONHINFIG4FROMTHEINITIALINVESTIGATION,ITWASFOUNDTHATTHEDISTANCEBETWEENSPACERBARHOLESANDRETURNSHAFTDIMENSIONSGANDFINFIG4COULDBEREDUCED,ASTHEREWASSOMEUNNECESSARYGAPBETWEENTHOSETWOCOMPONENTSTHEIMPORTANTPOINTTOCHECKBEFOREREDEFININGTHEDESIGNPARAMETERSWASTOMAKESURETHATAFTERBRINGINGTHOSETWOCLOSER,THERETURNCHAINSWOULDNOTCATCHTHESPACERBARWHILETHECONVEYORISRUNNINGTHEMODELOFTHENEWSIDEFRAMEDESIGNWASDRAWNONCADTOENSUREALLTHESPECIFICATIONSARESOUNDANDTHEPARTSAREPLACEDINTHEPOSITIONTOCHECKTHECLEARANCESANDTHEFITSUSINGTHEPRINCIPLEOFDESIGNFORMANUFACTURINGTHENEWSIDEFRAMEDESIGNWASMADESYMMETRICALSOTHATITAPPLIESTOALLTYPESOFSIDEFRAMESTHISCHANGEISEXPECTEDTOREDUCETHESIZEOFSIDEFRAMESIGNIFICANTLYFORALLSIZESOFCHAINSTABLE4SHOWSACOMPARISONOFDIMENSIONSINTHEOLDDESIGNANDTHENEWDESIGNOFSIDEFRAMESFORTHESAMECHAINTYPEIT556FIG4SIDEFRAMEDIMENSIONSTABLE4NEWANDOLDSIDEFRAMEDIMENSIONPARAMETERSOLDDESIGNCHAINTYPEABCDEFGHIJKL325PRIMEPRIMELF/SSSTR/LBP/MAG319271196651052112411365885196TAB2283621875696202232127NEWDESIGNCHAINTYPEABCDEFGHIJKL325PRIMEPRIMELF/SSSTR/LBP/MAG/TAB311007317367107167199925885152ISNOTEDTHATTHEOVERALLSIZEDEPTHOFTHECONVEYORHASBEENREDUCEDFROM241MMTO199MMDIMENSIONH,WHICHGIVESASAVINGOF42MMOFSTAINLESSSTEELONEVERYSIDEFRAMEMANUFACTUREDTHUS,FROMASTAINLESSSTEELSHEET15003000MM,THEOLDDESIGNPARAMETERSALLOWEDONLYSIX3MLONGSIDEFRAMESBUTWITHTHENEWDESIGNPARAMETERNOWITWASPOSSIBLETOPRODUCESEVENSIDEFRAMESOF3MLONGFROMTHESAMESHEETSIZETHEAMOUNTOFMATERIALUSEDFORSIDEFRAMESWASALSOREVIEWEDFORFURTHERINVESTIGATIONITISESTIMATEDTHATABOUT55OFTHETOTALCOSTOFTHECONVEYORSYSTEMISSPENTONMATERIALSTHECURRENTMATERIALUSEDFORSIDEFRAMESIS25MMTHICKSTAINLESSSTEELFOODGRADE304CURRENTLY,THEREAREOTHERMATERIALSAVAILABLEINTHEMARKETWITHALTERNATIVETHICKNESSTHATCOULDBECONSIDEREDASANOPTIONFORTHIS,ADEFLECTIONANALYSISHASBEENCONDUCTEDTOESTIMATEIFTHEREWASANYOTHERTYPEOFMATERIALSUITABLETOREPLACETHEEXISTINGMATERIALSOTHATITDOESNOTFAILITSSTRENGTHCRITERIA61DEFLECTIONANALYSISFORSIDEFRAMESFIGURE5SHOWSTHEEXPERIMENTALSETUPTODETERMINETHEDEFLECTIONOFNEWSIDEFRAMEINXANDYDIRECTIONUNDERDIFFERENTLOADINGCONDITIONSWITHTHENEWDESIGNPARAMETERSASETOFSIDEFRAMESWEREMANUFACTUREDTOINVESTIGATETHEDEFLECTIONON16MMTHICKSTAINLESSSTEELSIDEFRAMESASECTIONOFSIDEFRAMEBOLTEDWITHSPACERBARANDRETURNSHAFTWASASSEMBLEDFORTESTINGWITHTHEEXPERIMENTTHERESULTSFORDEFLECTIONWEREOBTAINEDBYAPPLYINGVARIABLELOADSONASECTIONOFTHESIDEFRAMEVIAAHYDRAULICPRESSASSHOWNINFIG5,THEDEFLECTIONGAUGESAREPLACEDONVERTICALYANDHORIZONTALXAXESTOMEASUREANYREADINGOBSERVEDONTHESIDEFRAMESTHELOADSAREAPPLIEDONSIDEFRAMEVIATHEHYDRAULICPRESSINDOWNWARDDIRECTIONTHESIDEFRAMESARESUPPORTEDBYSTANDSFROMTHESAMEPOSITIONWHERETHELEGSAREMOUNTEDONTHESIDEFRAMESTHREESETSOFEXPERIMENTSARECONDUCTEDONFOUR,SIXANDEIGHTTRACKSOFCONVEYORSECTIONSTOOBSERVEANYABNORMALITIESUNDERBIGLOADSTHELOADSAPPLIEDONTHEEXPERIMENTALCONVEYORSECTIONSAREOVERESTIMATEDANDAREHIGHERTHANACTUALLOADCONDITIONSFORCONVEYORSYSTEMINREALAPPLICATIONSTHECONVEYORSAREUSUALLYDESIGNEDTOCARRYLOADUNDERONETONNEPERMETREFORINDUSTRYAPPLICATIONINTHEFOODANDBEVERAGEINDUSTRYTHEPURPOSEOFAPPLYINGABIGLOADWASTOESTIMATETHEPOINTOFDEFLECTIONFORSIDEFRAMEUNDERHIGHLOADSFIGURES6AND7SHOWTHERESULTSOFTHEEXPERIMENTSFORTHECONVEYORSECTIONSOFFOURTRACKSANDSIXTRACKS,RESPECTIVELYFROMTHERESULTSOBTAINED,ITISOBSERVEDTHATUNDER2KNOFLOADS,THEDEFLECTIONVALUESAREALMOSTUNDER2MMFORALLFIG5EXPERIMENTALSETUPTOINVESTIGATEDEFLECTIONONNEWSIDEFRAMEDESIGN557FIG6DEFLECTIONRESULTSFOR4TRACK16MMSTAINLESSSTEELSIDEFRAMEFIG7DEFLECTIONRESULTSFOR6TRACK16MMSTAINLESSSTEELSIDEFRAMETYPESOFSECTIONSUNDERTHEGIVENCIRCUMSTANCES,THE16MMSTAINLESSSTEELSIDEFRAMEDESIGNCANBEAPOSSIBLEALTERNATIVETOTHEEXISTINGCONVEYORSIDEFRAMEDESIGNITISEXPECTEDTHATWITHWIDERCONVEYORSECTIONS,THEDEFLECTIONSONSIDEFRAMEWILLSTAYWITHINTHEALLOWABLELIMITS,THATIS,5MMTHEMAINREASONWHYTHISEXPERIMENTWASCONDUCTEDISTOENSURETHATTHESIDEFRAMESDONOTBUCKLEUNDERHIGHLOADSTHUSTHEREWASNOEVIDENCEOFBUCKLINGOCCURRENCEFORANYOFTHETYPESOFCONVEYORSECTIONSUSEDITISALSOEXPECTED,BASEDONTHEEXPERIENCESOFENGINEERSANDTHEINVESTIGATIONDURINGTHECURRENT
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