Component Design Report - Group 3-Merged

COMPONENT DESIGN
(SEMM 3523)
SEMESTER II
2021/2022 SESSION
MAJOR PROJECT
SECTION 5
GROUP 3
GROUP MEMBERS MATRIC ID
MUHAMMAD SOFWAN BIN MOHD SHARIFUDDIN A19EM0327
KHAIRUL AZRI BIN KHAIRUL SALLEH A19EM0151
INDOK ZARITH SYUHADA BINTI DZOLKEPLI A19EM0129
LECTURER:
Ts. KHAIRUL ANWAR BIN HANAFIAH
DATE OF SUBMISSION:
13 JULY 2022
TEAM PICTURE
GROUP LEADER
MUHAMMAD SOFWAN BIN MOHD SHARIFUDDIN (A19EM0327)
(muhammadsofwan@graduate.utm.my)
KHAIRUL AZRI BIN KHAIRUL SALLEH (A19EM0151)

(khairulazri@graduate.utm.my)
INDOK ZARITH SYUHADA BINTI DZOLKEPLI (A19EM0129)

(indokzarithsyuhada@graduate.utm.my)
TABLE OF CONTENTS
1.0 ABSTRACT 1
2.0 PROBLEM DESCRIPTION 2
2.1 PROBLEM STATEMENT 2
2.2 DESIGN SPECIFICATION 3
3.0 ANALYSIS AND RESULTS 4
3.1 MOTOR SELECTION 5
3.2 V-BELT ANALYSIS 5
3.3 GEAR ANALYSIS 12
3.4 SHAFT ANALYSIS 18
3.5 BEARING ANALYSIS 22
4.0 CONCLUSIONS 29
5.0 APPENDIX 32
5.1 MOTOR SELECTION 33
5.2 V-BELT ANALYSIS 34
5.4 SHAFT ANALYSIS 53
5.6 ENGINEERING DRAWING 67
1.0 ABSTRACT
A conveyor system is a fast and efficient mechanical handling apparatus for

automatically transporting loads and materials within an area. This system minimizes human
error, lowers workplace risks and reduces labor costs. Conveyors provide ease of use in
applications such as transporting heavy or bulky items from one point to another. To get a
conveyor moving, a motor and a power transmission device must work together as a unit. In
this project, we are required to design a power transmission unit for a conv eyor system. The
main parts, including belt, gear, shaft and bearing, will be analyzed thoroughly to find the best
size for each component and, at the same time, can withstand the life cycle. Also, a compact
system structure will be designed as the lower cost is critical. Furthermore, this report is divided
into four sections: Problem Description, Analysis and Results, Conclusion and Appendix. For
the Problem Description section, the project specifications and design requirements are going
to be discussed. Next, the Analysis and Results section will discuss a detailed description of
analysis procedures and resulting design configurations. While in the Conclusions section, a
brief summary of what was done, the conclusions drawn from the analysis, and final
recommendations will be discussed. Finally, all the relevant calculations, figures and
engineering drawings of our design will be attached in the Appendix section.
Declaration:
I'm declare that my works done in this chapter:
Name % of contribution Signature Date

Muhammad Sofwan Bin Mohd Sharifuddin 100 13/7/2022
Khairul Azri Bin Khairul Salleh 100 13/7/2022
Indok Zarith Syuhada Binti Dzolkepli 100 13/7/2022
1
2.0 PROBLEM DESCRIPTION
2.1 PROBLEM STATEMENT
In this project, we were required to design a power transmission unit for a conveyor
system. Figure 1 below shows the schematic diagram of the conveyor system that is equipped
with the power transmission unit. The functions of this power transmission unit are to receive
power from an electrical motor through a rotating shaft and deliver the power to its output
component that ultimately drives the conveyor belt via pulley system.
Figure 1: Schematic diagram of conveyor system
2
2.2 DESIGN SPECIFICATION
The components used to design the power transmission unit play a vital role in
delivering a usable product and having a good life span. Thus, it is crucial to analyze and
consider the specification of each component like shaft, bearing, gear and belt to make sure the
power transmission unit is able to deliver the power to the output effectively. In this project,
there are four main components that we analyzed, which are belt, gear, shaft and bearing. All
these components are designed to fulfill the following specifications:
1. The speed (V) of the conveyor belt is 0.65m/s.

2. The diameter of the rollers is 350 mm.
3. The force (F) needed for driving the conveyor belt is 6500 Newton. ,
4. The gearbox output is connected to a pulley system (belt or chain driving system).
Moderate shock will be encountered.
5. The gearbox is bolted to a rigid steel frame on a horizontal surface.
6. The rotational speed of the motor is 1440 rpm.
7. Fatigue stress concentration factors for bending loading and torsional shear should be
properly considered.
8. Flexible couplings will be used on the input shaft to prohibit axial and bending loads
from being transmitted to the gearbox.
9. The system is expected to operate (5 days a week, 52weeks a year, and 8 hours a day)
with a design life of 10 years.
10. The space needed for it should be as small as possible, and a lower cost is critical.
3
Figure 2 below shows the overall design of the power transmission unit consisting of
the main components.
Figure 2: Overall design of the power transmission unit
Declaration:

4
3.0 ANALYSIS AND RESULTS
3.1 MOTOR SELECTION
Motor is an electromechanical device that converts electrical energy into mechanical

energy. Most often, the movement is rotary, with mechanical energy characterized by rotational
speed and motor torque. Although there are various types of motors available in the market,
we still need to consider some of the criteria before choosing the right one. In this project, the
motor was chosen from the BRANCO motor catalogue. Table 1 below shows the specifications
of the motor that we have selected.
Table 1: Specifications of selected motor
Type of motor BR2-112M-4
Rated output 5.5 HP (4 kW)
Rated speed 1440 rpm
Rated torque 26.5 Nm
Weight 52 kg
3.2 V-BELT ANALYSIS
A V-belt is the rubber belt that drives the alternator, air conditioning compressor, power
steering pump and water pump. It's called a V-belt because of its “V” shaped cross-section. All
belts wear out over time and need to be replaced. Grouped under the Power Transmission
banner, V-Belts have two main functions which is to transmit power from one shaft to another
and to either increase or decrease speed of a motion. Synchronous belts, also known as timing
belts, are the latest concept in power transmission belting evolution. In this V-Belt analysis,
The Mitsuboshi Selection Step has been applied in order to obtain the important information
and results for the V-belt design analysis which can be represented in Table 2.
Figure 3: B68 Classical V-Belt
5
Table 2: The Results for the V-Belt analysis
Analysis Information Results and Values
The type of belt Type B
The belt datum length 113.8 in
The center distance 16.7 in
The number of belts, Nbelt 5 pieces
In order to start our analysis, the Belting or V-Belt analysis should be executed first.
This is because the V-belt analysis is containing important information for the analysis of the
shaft for this Major Project. Firstly, there is some design specification that should be focused
on in order to proceed with the V-belt analysis. The important design specification in this V-
belt analysis is listed below:
1. The speed (v) of the conveyor belt is 0.65 m/s

2. The diameter of the rollers is 350 mm
3. The Force (F) needed for driving the conveyor belt is 6500 Newton
4. The rotational speed of the motor is 1440 rpm
5. The system is expected to operate (5 days a week, 52 weeks a year, and 8 hours a day)
From the information above, we can start to analyse the V-belt for this Major Project by
sketching the schematic diagram of the V-belt and stating the interim centre distance for both
small and the large pulley which has been found with the values of 2 4 inches (given in the
Major Project Question). The schematic diagram for the V-belt can be shown below.
Figure 4: Schematic Diagram of the V-belt system
6
In addition, This V-belt analysis was based on The Mitsuboshi selection step or
manual. The Power needed to move the conveyor belt is calculated using the basic power
equation which is shown below:
𝑃𝑜𝑤𝑒𝑟 = 𝐹𝑜𝑟𝑐𝑒 × 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 (1)
The power needed to move the conveyor belt with the velocity of 0.65 m/s or The
Transmission power is found to be 4.225 kW. This value of power is then converted into
horsepower using the equation below.
1𝑘𝑊 = 1.341 ℎ𝑝 (2)
After applying the equation above the value of power needed to move the conveyor belt
with the velocity of 0.65 m/s or The Transmission power (Ht) is found to be 5.6657 hp which
will be use later in the analysis. Next, the service factor (KS) has been determined for this V-
belt analysis the service factor formula can be stated as Eqn. 3 below.
𝐾𝑆 = 𝐾𝑂 + 𝐾𝑖 + 𝐾𝑒 (3)
where
KS: Service factor
KO : Service correction factor (Table 1-1)
Ki : Idler correction factor (Table 1-2)
Ke: Environment correction factor (Table 1-3)
The values for the K o, Ki and Ke can be referred to the Table 1-1, 1-2 and 1-3,
respectively according to the condition or the assumption that has been made such as for the
driving unit / motor having the max power is less than or equal to 300% of rated power and the
running time of 8-12 hours a day. The location of idler is assumed to be at the Belt slack side
and inside of belt. Meanwhile for the Environment condition is found to be normal. From this
assumption or the conditions that has been stated above the values for K o, Ki and Ke by referring
to the respective table is found to be 1.2, 0 and 0 respectively. In results, the value for Service
factor is found to be 1.2.
7
This service factor value is used in order to determine the design power (Hd) which can be
represented by Eqn. 4 below.
𝐻𝑑 = 𝐻𝑡 × 𝐾𝑠 (4)
where
Hd: The Design Power
Ht: The Transmission Power
Ks: Service factor
The Design Power, Hd in this analysis is found to be 6.7988 hp which has been used in
order to determine the type of belt will be used in the power transmission design. For the type
of belt analysis, there are two important parameters are used which is the small pulley speed
(rpm) and the Design Power (hp) which is found to be 240 rpm and 6.7988 hp respectively. By
referring to the Figure 1-1 which is the Cross section selection chart for V-belts, the type of
belts which will be used in the design is found to be the belt Type B.
After determining the belt type, the analysis of the pulley size can be proceeded and
from the type of belt obtained which is Type B, the minimum pulley datum diameter (in) can
be directly obtained from the Table 1-4. The minimum pulley datum diameter for belt type B
is found to be 5.4 inches. In order to obtain the large pulley datum diameter, the speed ratio
equation in Eqn. 5 and the large pulley datum diameter equation in Eqn. 6 has been used.
𝑛𝑑 𝐷𝑑
𝑆𝑅 = =
𝑛𝐷 𝑑𝑑
where (5)
SR = Speed ratio
nd = Small pulley speed
nD = Large pulley speed
Dd = Large pulley datum diameter
dd = Small pulley datum diameter
(6)
𝐷𝑑 = 𝑑𝑑 × 𝑆𝑅
Where
SR = Speed ratio
8
In order to use above equations, the speed of large pulley has been determined by using
speed of conveyor belt which is 0.65 m/s where has the same speed as the large pulley. The
large pulley speed is found to be 35.469 rpm and the speed ratio is found to be at the value of
6.766. The large pulley datum diameter is next can be determine using Eqn. 6 which to be at
the value of 36.539 inches. Furthermore, the belt length can be determined by begin with
obtaining the interim belt datum length which can be represented by the Eqn. 7 below.
𝐿𝑑 ′ = 2𝐶 ′ + 1.57(𝐷𝑑 + 𝑑𝑑) (7)
where
Ld’ = Interim belt datum length
C’ = Interim center distance
By using the Eqn. 7 above, the interim belt datum length is obtained to be at the value
of 113.844 inches which next the Table 1-10 is be used in order to determine the belt length.
For this V-belt analysis, by referring to the B type table which is Table 1-10, the closest and
most identical values for the datum length found from the Table 1 -10 is found to be 113.8
inches which represent the Outer length of the belt (115 inches) and Belt code (112). After that,
the center distance can be calculated using the Eqn. 8 stated below.
𝑏+ √𝑏2 −8(𝐷𝑑−𝑑𝑑) 2
𝐶= (8)
8
where
C = Centre distance
B = 2𝐿𝑑 − 𝜋(𝐷𝑑 + 𝑑𝑑)
𝐿𝑑 = Belt datum length
From the equation 8 above, the center distance value is found to be 16.7 inches with the
application of b value using the equation stated in the formula description which found to be at
the value of 95.845. The real value of center distance for our design now has been determined
by using equation 8 rather than the interim center distance with the values of 24 inches which
given in the schematic diagram of the major project question.
9
The last part for the V-belt analysis is to determine the required number of belts should
be used in the design. The required number of belts can be calculated using the Eqn. 9 stated
below.
𝐻𝑑
𝑁𝑏𝑒𝑙𝑡 = 𝐻𝑐 (9)
where
𝑁𝑏𝑒𝑙𝑡 = Required number of belts
𝐻𝑑 = Design power
𝐻𝑐 = Corrected power rating per belt
Before we can be calculated for the required number of belts using equation 9, there are
some additional steps in order to determine the corrected power rating per belt, Hc which can
be described by the Eqn. 10,11 and 12.
𝐻𝑐 = (𝐻𝑠 + 𝐻𝑎) × 𝐾𝑐 (10)
where
Hc = Corrected power rating per belt (hp)
Hs = Basic power rating per belt (hp)
Ha = Additional power rating for speed ratio (hp)
Kc = Power rating correction factor
𝐾𝑐 = 𝐾𝜃 × 𝐾ℓ (11)
where
Kc: Power rating correction factor
𝐾𝜃: Arc of contact correction factor
𝐾ℓ: Belt length correction factor
𝐷𝑑−𝑑𝑑
𝐾𝜃 = 𝐶
(12)
where
𝐾𝜃 = Arc of contact correction factor
Dd = Small pulley datum diameter
C = Center distance
10
In order to apply all the equation above, the value of 𝐾ℓ and 𝐾𝜃 should be determine
first using the equation 12 and Table 1-6 for Arc of contact correction factor, 𝐾𝜃 and using
Table 1-7 for Belt length correction factor, 𝐾ℓ which found to be at the values of 0.932 and
0.84 respectively. However, because of there is no values stated in Table 1 -6 after equation 12
has been applied, so Dr. has been advised us to modify the equation 12 by dividing with 2C
rather than dividing by C which resulting the values of 0.932 (the chat with Dr. is provided in
the Appendix section below). After obtaining the 𝐾ℓ and 𝐾𝜃 values the Kc can be determined
using equation 11, the value of Kc is found to be 0.89. For the Basic power rating per belt, Hs
and Additional power rating for speed ratio, Hs is obtained from the Table 1 -16 which is the
Table for B-Section Power Rating. Using the small pulley speed (240 rpm), the Hs and Ha
values is obtain using interpolation which the values is found to be 1.402 and 0.154,
respectively. Next, the value of Corrected power rating per belt can be obtained by using
equation 10 above which resulting the values of 1.385 hp. Lastly, the required number of belts
can be identified by using the equation 9 above which the number of the required belts is found
to be 5 pieces. This means that there are 5 pieces V-belt is required in our design in order to
execute the system flawlessly. All the table referred and the detailed calculation will be
provided in the Appendix section.
11
3.3 GEAR ANALYSIS
Gears are used to transfer motion and torque between machine components in
mechanical devices. Depending on the design and construction of the gear pair employed, gears
can change the direction of movement and increase or decrease the output speed or torque. In
this project, we used two spur gears to transmit the motion from one shaft to another. Also,
these two gears were used to reduce the speed from the motor (1440 rpm) to the small pulley
of the belt drive system, with a speed ratio of 6. Figure 5 below shows the design of our gear
system while Table 3 shows the results obtained from the analysis.
Figure 5: Design of the gear system
Table 3: Results obtained from the gear analysis
Gear 2 Gear 3
Gear teeth, N 24 144
Rotational speed, n (rpm) 1440 240
Tangential force (lb) 320.96 320.96
Radial force (lb) 116.82 116.82
Diameter, d (in) 1.5 9
12
Since lower cost is critical in this project, a pair of spur gears is designed as we want
the space of the gearbox to be small. These gears are connected to a 1440 rpm motor to a small
pulley of the belt drive system. The gears are used to reduce the speed produced by the motor
to a speed of 240 rpm, as required by the small pulley of the belt driv e system. This gear
analysis is carried out to determine the values of the tangential and radial forces that are going
to be further used in the shaft analysis. The other objective of this analysis is to determine the
safety factor against fatigue and also the safety factor of surface stress. The reason why we
need to calculate these safety factors is because we want to make sure the gears are safe and
have infinite life. To begin the analysis, some assumptions are made as follows:
1. 100% efficiency for power transmission

2. Number of teeth for gear 2 and 3 are 24 and 144, respectively
3. Pressure angle, 𝜙 = 20°
4. Gear material is steel with 450 Bhn
5. Gear will rotate in both directions
6. Gear has been hobbed (shaped)
7. Diametral pitch, P = 16 in -1
8. Both gears have the reliability of 50%
9. Load applied at highest point of single tooth contact (sharing)
10. The gears are accurate mountings, small bearing clearances, minimum deflection and
precision.
11. The source of power is moderate shock and there is moderate shock for driven machinery
12. The gear teeth have a machine surface
13. The operating temperature is less than 160 ℉
14. One-way bending for gears
The first step of the analysis is to check the interference and also the contact ratio. From
the assumption that has been made, the diameter of gear 2 and 3 are 1.5 and 9 in, respectively.
By using the values of these two diameters, we obtained the center to center distance, C value,
which is 18 in. Next, to check the interference for both gears, first, we need to determine the
radius of the addendum and the base circle of both gears. For gear 2, there is no interference
since the maximum radius of the addendum circle (1.929 in) is greater than the radius of the
addendum circle (0.8125 in). Similarly for gear 3, there is no interference since the maximum
radius of the addendum circle (4.594 in) is greater than the radius of the addendum circle
13
(4.5625 in). Before determining the value of the contact ratio, the base pitch needs to be
calculated first, and the value that we obtained is 0.185 inch. Furthermore, the equation below
is used to determine the contact ratio:
2 − 𝑟 2 + 𝑟 2 − 𝑟 2 − 𝑐 sin 𝜙
√𝑟𝑎𝑝 𝑏𝑝 √ 𝑎𝑔 𝑏𝑔
𝐶𝑅 =
𝑝𝑏 (13)
where
𝑟𝑎𝑝, 𝑟𝑎𝑔 = addendum radii of the mating pinion and gear

𝑟𝑏𝑝, 𝑟𝑏𝑔 = base circle radii of the mating pinion and gear
𝑝𝑏 = base pitch
By substituting all the values obtained into the Eqn. (13), the contact ratio that we obtained is
1.73 and this value is acceptable since it is within the range of 1.4 and 1.8.
The analysis is then continued with the fatigue failure analysis for the gear tooth. Since
both gears have the same type of materials, the analysis proceeds on the smaller gear (gear 2)
only. This analysis is performed to determine the safety factor against fatigue by using formula
𝑆𝑛
𝜂= (14)
𝜎
where
𝜎 = Bending stress
𝑆𝑛 = Endurance limit
14
To calculate the bending stress, the formula below is used
𝐹𝑡 𝑃
𝜎= 𝐾𝐾 𝐾 (15)
𝑏𝐽 𝑣 𝑜 𝑚
where
𝐹𝑡 = Tangential force
𝑃 = Diametral pitch
𝑏 = Face width
𝐽 = Spur gear geometry factor (Figure 15.23)
𝐾𝑣 = Velocity or dynamic factor (Figure 15.24)
𝐾𝑜 = Overload factor (Table 15.1)
𝐾𝑚 = Mounting factor (Table 15.2)
Since the power transmitted is known, which is 5.5 hp, we can determine other
parameters. The calculated values of the velocity, tangential, and radial force are 565.49 ft/min,
320.96 lb and 116.82 lb, respectively. Next, from the assumptions, the 𝐽, 𝐾𝑣 , 𝐾𝑜 and 𝐾𝑚 values
are 0.37, 1.471, 1.75 and 1.3, respectively. By using the face width of 0.875 inch, the bending
stress is 53.09 kpsi. For the endurance limit, it can be calculated using equation
𝑆𝑛 = 𝑆𝑛′ 𝐶𝐿 𝐶𝐺 𝐶𝑆 𝑘𝑟 𝑘𝑡 𝑘𝑚𝑠 (16)
where
𝑆𝑛′ = Standard R. R. Moore endurance limit
𝐶𝐿 = Load factor = 1.0 for bending loads
𝐶𝐺 = Gradient factor = 1.0 for P > 5, and 0.85 for P <=5
𝐶𝑆 = Surface factor (Figure 8.13)
𝑘 𝑟 = Reliability factor (Table 15.3)
𝑘 𝑡 = Temperature factor
𝑘 𝑚𝑠 = Mean stress factor.
15
From the assumptions that have been made, the values of 𝑆𝑛′ , 𝐶𝐿, 𝐶𝐺 , 𝐶𝑆 , 𝑘 𝑟, 𝑘 𝑡 and 𝑘 𝑚𝑠 are
obtained as in Table 3 below.
Table 4: The values of Sn′ , CL , CG , CS , k r , k t and k ms
𝑆𝑛′ 112.5 kpsi
Load factor, 𝐶𝐿 1
Gradient factor, 𝐶𝐺 1
Surface factor, 𝐶𝑆 0.63
Reliability factor, 𝑘 𝑟 1
Temperature factor, 𝑘 𝑡 1
Means stress factor, 𝑘 𝑚𝑠 1.4
By substituting all the values in Table 4 above into Eqn. (16), gives an endurance limit
of 99.225 kpsi. Next, by taking the ratio of the endurance limit to bending stress, the safety
factor for the bending stress is 1.87. Since the safety factor is greater than 1, gear 2 is safe and
will have infinite life.
Lastly, the analysis is continued by determining the safety factor of surface stress. The
safety factor of surface stress can be taken as the ratio of surface endurance limit to surface
stress. The surface stress of the gear can be determined using
𝐹𝑡 (17)
𝜎𝐻 = 𝐶𝑝√ 𝐾𝐾 𝐾
𝑏𝑑𝑝𝐼 𝑣 𝑜 𝑚
where
𝐶𝑝 = Elastic coefficient (Table 15.4a)
𝐼 = Geometry factor
In this case, the geometry factor that we obtained is 0.138 and since the material used
for both gears is steel, the value of the elastic coefficient is 2300 √𝑝𝑠𝑖. By substituting all the
parameters obtained into Eqn. (17), the surface stress of the gear is calculated to be 177.12
kpsi.
16
Next, the surface endurance limit is estimated from
𝑆𝐻 = 𝑆𝑓𝑒 𝐶𝐿𝑖 𝐶𝑅 (18)
where
𝑆𝑓𝑒 = Surface fatigue strength (Table 15.5)
𝐶𝐿𝑖 = Life factor
𝐶𝑅 = Reliability factor (Table 15.6)
From the assumptions that have been made, the values of 𝑆𝑓𝑒, 𝐶𝐿𝑖, 𝐶𝑅 are 170 kpsi, 1.1
and 1.25, respectively. By substituting all the values into Eqn. (18), gives a surface endurance
limit of 233.75 kpsi. Next, by taking the ratio of the surface endurance limit to the surface
stress, the safety factor of the surface stress is 1.32. Since the safety factor is greater than 1,
gear 2 is safe and will have infinite life. The detailed equations used, and calculations are
attached in the Appendix section.
17
3.4 SHAFT ANALYSIS
The analysis of shaft is required to be done in order to determine suitable size and type of
bearing need to be selected and choose. The shaft being used in the transmission unit is about
2 unit of shaft. First shaft is attached with pinion gear and togeth er with AC motor with the
combination of shaft coupling. Meanwhile for the second shaft, it is attached along with driven
gear. The usage of shaft in this analysis is quite significant due to its function to power from
one part to another part. So, in this case, the shaft being used to transfer power generated by
the AC motor to gear and end up at the pulley which consists of V-belt used for the conveyor
system. Before beginning the analysis, a few assumptions need to be considered as well. The
assumptions are stated as below:
1) The length of shaft is assumed to be 7 inches

2) The material used for shaft is AISI 4340 Hot Roll
3) Factor of safety for the shaft, 𝜂𝑓𝑠 is 30
From the assumption above, the shaft’s analysis can be proceeded as well. Begin with the free
body diagram of shaft which is important in determining the amount of force located at the
bearing. The free body diagram is divided into two view which are top and front view. From
the simple calculation solve in moment and y-direction, therefore the amount of force obtained
is stated in the table below:
Table 5: The amount of force located at each bearing from different views
Reaction Force (lb) Bearing A Bearing B
Top View 160.48 160.48
Front View 58.41 58.41
The value of forces obtained then being used in constructing the shear and moment
diagram for the further analyzed. The shear and moment diagram are used to determine at
which length did the moment will achieve the maximum value. The maximum value will be
used in calculating the alternative stress in fatigue strength analysis. The method is still same
by splitting the forces into two view which are top and front view as well. From the moment
diagram of both views, the values obtained is 240.72 lb.in (top view) and 87.62 lb.in (front
view), respectively.
18
The shaft’s analysis proceeds with the fatigue analysis as well. Since the shaft is
assumed to be AISI 4340 Hot Roll, therefore we can obtain the value of yield strength and
ultimate strength respectively from the Appendix-C2, Tensile properties of Metal. The yield
strength is about 𝛿𝑦 = 132 𝑘𝑠𝑖 and the Ultimate strength is, 𝛿𝑢𝑡 = 151 𝑘𝑠𝑖. The analysis
considered two type of load which are bending load and torsion. Therefore, the value of
bending moment and torsion need to be calculated respectively . In order to determine both
parameters, the calculation needs to be split into 2 parts which are pinion and gear. This is
because both shafts will be obtained different values of diameter, therefore by using the
information of gear as obtained in gear analysis. From, the radius of gear is taken as 0.75 in for
pinion in order to determine the value of torsion. By using the formula below:
𝑇 = 𝐹𝑇 𝑅 (19)
where
𝐹𝑇 = tangetional force exerted on gear pinion
𝑅 = Radius of gear pinion
The tangential force is given as 320.96 lb which was calculated in gear analysis as well.
From here, the value of torsion obtained is 240.72 lb.in. Since, we already have obtained the
maximum moment value for each view, thus it needs simplified by calculating the result of
maximum moment. The formula below is used to calculate the resultant of maximum moment:
𝑀𝑟𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 = √(𝑀𝑚𝑎𝑥1 )2 + (𝑀𝑚𝑎𝑥2 )2 (20)
From the calculation, the resultant of maximum moment obtained is about 256.17 lb.in.
As the parameters value obtained in fatigue analysis, we can proceed into the next step to find
the alternative stress, mean stress, alternative and mean shear.
Begin with calculating the value of alternative stress by using the formula below:
32𝑀
𝜎𝑎 = (21)
𝜋𝑑 3
where
𝑀 = Resultant of maximum moment
𝑑 = diameter of shaft
For mean stress and shear alternative is considered to be zero, 𝜎𝑚 = 𝜏𝑎 = 0,
19
Meanwhile for mean shear, it can be calculated by using the formula below:
16𝑇
𝜏𝑚 =
𝜋𝑑 3 (22)
where
𝑇 = Torsional forces
𝑑 = Diameter of shaft
All these parameter values obtained from the calculation above in term of d since
objective of shaft analysis is to determine what size of shaft need to be used so that size and
type of bearing also can figure out. The parameter values calculated value is used to determine
the equivalent stress in terms of alternative and mean. However, the result obtained still in term
of d since we need to find out what is the value of shaft diameter. By using the formula below
to determine the equivalent stress:
𝜎𝑒𝑎 = √(𝜎𝑎 ) 2 + 3𝜏𝑎 2 (23)
𝜎𝑚 𝜎𝑚 2
𝜎𝑒𝑚 = + √( ) + 𝜏𝑚 2 (24)
2 2
The analysis proceeds to next step which calculating the endurance limit with the
modifications factor. The endurance limit needs to be considered in this analysis as it will be
used back in equation of failure curve on the modified Goodman diagram. The endurance limit
can be calculated using the equation below:
𝑆𝑛 = 𝑆′𝑛 𝐶𝐿 𝐶𝐺 𝐶𝑆𝐶𝑇𝐶𝑅 (25)

where
𝑆′𝑛 = The endurance limit obtained from S-N curves (𝑆′𝑛 = 0.5𝑆𝑢𝑡)
𝐶𝐿 = Load factor
𝐶𝐺 = Gradient factor
𝐶𝑆 = Surface factor
𝐶 𝑇 = Temperature factor
𝐶𝑅 = Reliability factor
From here, the endurance limit obtained is 𝑆𝑛 = 45.3 ksi.
20
The analysis proceeds to the final step which is to determine the value of diameter for the shaft.
By using the formula below:
1 𝜎𝑒𝑎 𝜎𝑒𝑚
= + (26)
𝑛 𝑆𝑛 𝑆𝑢𝑡
where
𝑛 = Factor of safety is assumed to be 30
𝑆𝑛 = The endurance limit
𝑆𝑢𝑡 = Ultimate strength of AISI 4340 HR
𝜎𝑒𝑎 = Equivalent alternative stress
𝜎𝑒𝑚 = Equivalent mean stress
Since the value of equivalent mean and alternative stress in terms of d, therefore by using
the equation above, the value of d can be known as the value of shaft’s diameter. By solving
mathematically, the value of d which represents as diameter of driver shaft is 1.254 in. The
same step will used to determine the diameter of shaft the driven gear part. However, a few
changes was made which the value of Torsion since the radius of gear is d ifferent compared to
pinion. The value obtained for the diameter of driven shaft is about 1.32 in. The result can be
classified into the table below:
Table 6: The value of shaft diameter
Shaft Driver (Pinion) Driven (Gear)

Diameter (inch) 1.254 1.32
From the value of diameter obtained in table above, it will be used for determining the type
and size of bearing that also will attach at the shaft along with the consideration of reaction
forces calculated at the beginning. All details calculation for the shaft analysis can be referred
at the Appendix part for shaft analysis.
21
3.5 BEARING ANALYSIS
A bearing is a machine element that constrains relative motion to only the desired
motion and reduces friction between moving parts. The design of the bearing may, for
instances, provide for free linear movement of the moving part or for free rotation arou nd a
fixed axis or it may prevent a motion by controlling the vectors of normal forces that bear on
the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings
are classified broadly according to the type of operation, th e motions allowed, or to the
directions of the loads (forces) applied to the parts.
The bearing analysis for our design for the power transmission for the conveyor belt
machine is needed some critical information which provided during the shaft analysis. In the
simple word the bearing analysis has the connection with the shaft analysis. The important
information from the shaft analysis is the radial force, Fr and the tangential force, Ft which
found to be at the values of 713.850 N and 259.820 N respectively. From these forces values
we can determine the suitable type of bearing in order to support the system. Table 7 shows the
results obtained from the bearing analysis.
Figure 6: Types of bearings
Table 7: Results for the bearing analysis
Shaft Bearing Basic Number

Motor Shaft L06
Drive Shaft L06
22
To begin this bearing analysis, there are some information should be extracted from the
design specification given in the major project question as listed below.
1. Moderate shock will be encountered

2. The rotational speed of motor is 1440 rpm
3. The system is expected to operate (5 days a week, 52 weeks a year and 8 hours a day)
4. The space needed is small as possible and lower cost is critical
5. Consider a compact structure system.
From the design specification above, we can start to identify that our design should be
small, compact structured, lower cost importantly and etc. Thus, in order to begin the analysis,
there are some assumptions should be completed in order to simplify our design analysis for
the power transmission of the conveyor system.
The list of assumptions

a) A conservative design for light-to-moderate impact required
b) A conservative design for 8 hours per day continuous service required
c) A 90% reliability is required
d) The Analysis is covered both a radial (α=0°) and an angular ball bearing (α=25 °) for
the overall analysis
e) The Ball-Bearing life varies inversely with the 10/3 power of the total load (Equation
14.5b is accurate)
Noted that the reason why this bearing analysis only covered the ball bearing types which is
the radial and angular bearing is because both of this bearing is used at the higher speed than
the roller bearing.
23
From the Shaft analysis, we know that the radial force, Fr and the tangential force, Ft
which is at the value of 713.85 N and 259.82 N respectively. In order to find the Equivalent
Force for radial ball bearing and angular ball bearing in equation (14.3) 2 and (14.4)2 in the
textbook and the lecture note given which there is a set of equation to select from as shown in
the Figure 7 below.
Figure 7: The set of equations for the equivalent force for radial and angular bearing.
In order to determine which one equation that should be used, the ratio between the
tangential force and radial force is calculated using equation 1 shows below which found to be
at the value of 0.3639.
𝐹𝑡
= 0.3639 (27)
𝐹𝑟
Based on the value obtained in the equation 1, the set of equation for radial ball bearings
and angular ball bearings can be identified which stated below in Eqn. 28 and 29 below.
a) Radial Ball Bearings (α=0°)

For 0.35 < Ft/Fr < 10,
𝐹𝑡
𝐹𝑒 = 𝐹𝑟 [1 + 1.115 ( − 0.35)] (28)
𝐹𝑟
b) Angular Ball Bearings (α=25°)
For 0 < Ft/Fr < 0.68,
𝐹𝑒 = 𝐹𝑟 (29)
24
By using both equations above, the equivalent force for radial ball bearings and angular
ball bearings is at the value of 724.97 N and 713.85 N respectively. Next the objective is to
obtain the required value of C for the application (kN), C req. Firstly, the value of the application
factors, Ka is found by using Table 14.3 and the value of K a is found at 1.5 for the ball bearing
at the moderate impact. For the representative bearing design lives value, the Table 14.4 is used
in order to determine the design life. So, we know that the machine operate for 8 hours a day
service, every working day. Hence, the design life obtained from Table 14.4 is 30,000 -hour
life. However, the design life is converted in revolution resulting the life in revolution value is
2592 × 10 6 rev which can be represented by the Eqn. 30 below.
𝐿 = 1440 𝑟𝑝𝑚 × 30,000 ℎ × 60 𝑚𝑖𝑛/ℎ (30)
For the standard 90% reliability the K r value can be obtained using the Figure 14.13
which show the chart of the life adjustment reliability factor, K r against the Reliability, r (%).
Hence the Life adjustment reliability factor, K r found by standard 90% reliability is at the values
of 1 and the LR = 90×10 6 rev. The required value of C for the application (kN), C req for the
radial and angular bearings can be determine by using Eqn. 31 below which correlated with the
equation 14.5b in the textbook and the lecture note provided by lecturer.
𝐿 0.3
𝐶𝑟𝑒𝑞 = 𝐹𝑒 𝐾𝑎 ( ) (31)
𝐾𝑟 𝐿𝑅
After applying the equation above, the required value of C for the application (kN), C req
for the radial bearing and the angular bearing is found to be at the value of 2.98 kN and 2.93
kN respectively. Furthermore, the Table 14.2 (Bearing Rated Capacities, C for LR = 90 × 106
revolution life with 90% reliability) is referred in order to select the suitable bearing to handle
the value of Creq which in this case the bearing series selected should be able to withstand the
force more than the Creq values obtained using the Eqn. 31 above. The selection for the radial
and angular ball bearings can be shows as the Figure 8.
25
Figure 8: The selection of radial and angular ball bearing based on the series number and bore
size.
After the selection for the bearing series and bore size in mm has been done such has
been shown above, the bearing basic number can be identified by using the Table 14.1 (Bearing
Dimension). The selection for the bearing basic number can be shown in the Figure 9 which
has been provided as below.
Figure 9: The selection of the bearing basic number for the ball bearings
26
The list of the bearing selections of ball bearing and angular bearing from using Table
14.2 and 14.1 can be stated as Table 8 below.
Table 8: The list of the bearing selection of ball and angular bearings
Bearing Basic Number

Ball Bearing Angular Bearing
302 303
204 204
L06 L06
Lastly, in selecting the most suitable and the accurate ball bearing and the angular
bearing to be used in our conveyor system is the diameter size of shaft has been compared to
the bore size of the bearing. For this project, the lower cost is critical and becoming the top
priority which lead us to conclude that the type of bearing used in our design is ball bearing
due to its lower cost compared to angular bearing. Next the shaft diameter obtained from the
shaft analysis by using the Modify Goodman equations can be shown as Table 9 below.
Table 9: The Diameter of Shaft for Drive Shaft and Motor Shaft
Types of Shafts Diameter of Shaft (in) Diameter of Shaft (mm)

Drive Shaft 1.32 33.528
Motor Shaft 1.254 31.852
Since the diameter of drive shaft and motor shaft is found to be 33.528 mm and 31.852
respectively, hence the diameter of Shaft for the L06 is the most suitable for both diameter of
shaft because the diameter shaft for L06 (bearing basic number) is found to be 34.8 mm in the
Table 14.1. Both shaft for drive and motor need to be milled to the diameter of 30 mm which
is the bore size for the bearing L06. In conclusion, the selected bearing is the ball bearing with
the bearing basic number of L06 for motor shaft and drive shaft.
27
The Additional Explanation for the Bearing Selection
a) The ball bearing has been chosen due to roller bearing are not able to support the thrust
load or tangential force, Ft
b) The ball bearing can overcome and withstand the radial load, Fr and thrust load, Ft from
the analysis
c) The diameter size of shaft in the power transmission of the conveyor system should be
the closest and most suitable to the diameter shaft, d s for the bearing which has been
stated in the Table 14.1 with the bearing basic number. The diameter shaft, d s for the
ball bearing can be illustrated as figure below.
Figure 10: The dimension measurement for the ball bearing
Declaration:

28
4.0 CONCLUSIONS
In conclusion, the main objective of the project is achieved, whereby this project has been
encouraged the development of group interaction, independent thinking, decision-making, and
creativity, as well as the development of planning and problem-solving abilities. This statement
can be proved by our group has been successfully to design a power transmission unit for the
conveyor system by analyzing some important parts in the power transmission unit such as
Gearing, Bearing, Shafting and Belting. This analysis has been helped us in order to design the
power transmission unit which fulfil the design specification requirements. The other main
specification is to design the transmission unit for the conveyor belt with small as possible
space or dimension, lower cost is critical and the consideration for a compact structure of the
system has been applied to our final design of power transmission unit for the conveyor system.
The details of calculation and design for the analysis has been provided in the Appendix section
in order to explained more about our approach in designing the power transmission unit.
Furthermore, from the analysis that has been made, we can deduce that the final design
specification for our transmission unit which consist of Motor Selection, Belting, Gearing,
Shafting and Bearing can be represented in the Table below where the design specification has
been sorted by the type of analysis.
a) Motor Selection
Type of motor BR2-112M-4
Rated output 5.5 HP (4 kW)
Rated speed 1440 rpm
Rated torque 26.5 Nm
Weight 52 kg
b) V-Belt Analysis
Analysis Information Specification
The type of belt Type B

The belt datum length 113.8 in
The centre distance 16.7 in
The number of belts, Nbelt 5 pieces
29
c) Gear Analysis
Analysis Information Gear 2 Gear 3
Gear teeth, N 24 144
Rotational speed, n (rpm) 1440 240
Tangential force (lb) 320.96 320.96
Radial force (lb) 116.82 116.82
Diameter, d (in) 1.5 9
d) Shaft Analysis
Analysis Information Specification

The length of Shaft 7 inches
Material used AISI 4340 Hot Roll
Factor of Safety, ηfs 30
The amount of force located at each bearing from different views
Reaction Force (lb) Bearing A Bearing B

Top View 160.48 160.48
Front View 58.41 58.41
The value of shaft diameter
Shaft Driver (Pinion) Driven (Gear)
Diameter (in) 1.254 1.32
e) Bearing Analysis
Shaft Bearing Basic Number
Motor Shaft L06

Drive Shaft L06
30
Furthermore, during the completion of the project where the team has worked well with
each other. The team working effort shown by each member were very good and were effective
in ensuring the final outcome produced is satisfiable. The team also played their own part well,
from doing analysis, research, presentation and completion of the report. Other than that, the
team spirit to come out with the solutions was evident throughout the project. This ability
shown has managed to push one another and to not give up easily. Overall, the team is
impressed by each other’s abilities and contributions in the project. Th e experience gained in
this project will assist us in future projects to become a better team-player.
Lastly, there are some final recommendations that can be stated in order to improve the
accuracy and the efficiency of the analysis and also the design for the power transmission unit
for the conveyor belt system. The first recommendation or the improvement that can be made
is to change the material used for shaft in this power transmission unit of the conveyor belt
which is AISI 4340 Hot Roll to the high yield strength material such as S700MC and etc. This
high yield strength material will provide a long design life for the shaft. However, this can be
applied if the cost for this design can be increased because the high yield strength is mostly
high cost material. Other than that, the next recommendation for the design and the analysis is
for the gearing parts. The recommendation is to use more gears rather than use single pair of
gear but having the larger size. By using the more numbers of gears, it will allow smaller and
more economical motor to power the larger machine or improves the efficiency of the existing
transmission unit. The using of more gears will also be increasing the number of shafts use in
the gearbox in the power transmission unit.
Moreover, the recommendation that can be consider is to decrease the angle of the
platform in the conveyor system. This can decrease the power needed in order to move the load
on the conveyor belt which is can also decrease the number of V-belt needed and
simultaneously to decrease the cost for the power transmission unit for conveyor belt design.
Other than that, try to adjust the V-belt analysis in order to use the Type A belt rather that Type
B belt which have the higher cost compared to Type A. The main adjustment is to increase the
small pullet speed in order to obtain the specification for V-belt Type A.
31
Lastly, the recommendation is used the angular ball bearing rather than the radial ball
bearing. This is due to angular contact bearings have a much higher speed rating than radial
bearings because of the nonstop contact of the balls to both rings. Angular contact bearings can
carry both radial and axial loads. The weight of the load is transferred from one ring to the
other, through the balls, along a specific contact angle.
Declaration:

32
5.0 APPENDIX
5.1 MOTOR SELECTION
33
5.2 V-BELT ANALYSIS
34
35
36
37
38
39
40
Dr. Advised to modify the kθ equation
41
42
43
5.3 GEAR ANALYSIS
44
45
46
47
48
49
50
51
52
5.4 SHAFT ANALYSIS
53
54
55
56
57
58
59
5.5 GEAR ANALYSIS
60
61
62
63
64
65
66
5.6 ENGINEERING DRAWING
(Refer to the next page onwards)
Declaration:

67
18.19 13.84
1.00
20.94
UNIVERSITI TEKNOLOGI MALAYSIA Group 3 11/7/2022

Full Assembly of Power
FAKULTI KEJURUTERAAN MEKANIKAL Transmission Unit SEMM 3523 (SEC 05) SCALE 1:5
20.94
18.19
13.55
7.09
4.02 11.81
0
.0
R1
R1.08
R1.08
11.82
2.06
6.00
1.00
4.02 13.55

Base Plate for Transmission
FAKULTI KEJURUTERAANMEKANIKAL Unit SEMM 3523 (SEC 5) SCALE 1:5
ITEM NO. PART NUMBER QTY.
4
1 plate for power 1
transmission
11 2 Radial Ball Bearing 4
3 Spur gear 2 1
4 Shaft driver 1
5 Spur gear 3 1
2 6 Shaft driven 1
7 AC-Motor 1
5 8 Shaft 1
9 Coupling shaft 1
10 Coupling Key 1
6
11 Bolt 5
12 Nut 5
7
10
12

EXPLODED VIEW OF
FAKULTI KEJURUTERAANMEKANIKAL TRANSMISSION UNIT SEMM 3523 (SEC 5) SKALA 1:5
7.72
12.01
3.62
7.72
8.98
3.54
5.71
5.87
7.19

AC MOTOR
FAKULTI KEJURUTERAANMEKANIKAL SEMM 3523 (SEC 5) SCALE 1:1
0.88
1.70
0.11
1.70
1.70
1.40

Spur Gear (Pinion)
FAKULTI KEJURUTERAAN MEKANIKAL SEMM 3523 (SEC 5) SCALE 1:1
0.88
9.70
9.70
2.00
9.69

Spur Gear (Driven)
7.50 1.40
2.80 2.50
14.50 2.25
1.25
2.05
1.45

AC MOTOR SHAFT
2.00
3.00
2.00
7.00
2.00
1.32
1.32

Driven Shaft
2.00
3.00
2.00
7.00
1.40
1.25

Driver Shaft
2.60
1.00
1.6
30
3
0
.6 2.60
0.
R0
R0.10
2.81
2.00
3.01
1.80 1.00

Coupling Shaft
2.17
0.51
2.09
2.09
2.17
1.26
1.18
1.87 R0
.15

Radial Bearing (30mm)
0.50 2.60
0.15
2.60
0.50

Coupling Shafts's Key
0.30
03
0.
0.41
1.06
0.46
1.70
0.20
R0.20
0.40
0.20

Bolt
0.46
0.19
0.25
.20
R0
0.20
0.32
0.40
0.25
0.30

Nut

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COMPONENT DESIGN

GROUP MEMBERS MATRIC ID

MUHAMMAD SOFWAN BIN MOHD SHARIFUDDIN A19EM0327

KHAIRUL AZRI BIN KHAIRUL SALLEH A19EM0151

INDOK ZARITH SYUHADA BINTI DZOLKEPLI A19EM0129

KHAIRUL AZRI BIN KHAIRUL SALLEH (A19EM0151)

INDOK ZARITH SYUHADA BINTI DZOLKEPLI (A19EM0129)

A conveyor system is a fast and efficient mechanical handling apparatus for

Name % of contribution Signature Date

2.1 PROBLEM STATEMENT

Figure 1: Schematic diagram of conveyor system

1. The speed (V) of the conveyor belt is 0.65m/s.

Figure 2: Overall design of the power transmission unit

Name % of contribution Signature Date

3.1 MOTOR SELECTION

Motor is an electromechanical device that converts electrical energy into mechanical

Type of motor BR2-112M-4

Rated output 5.5 HP (4 kW)

Rated speed 1440 rpm

Rated torque 26.5 Nm

3.2 V-BELT ANALYSIS

Figure 3: B68 Classical V-Belt

Analysis Information Results and Values

The type of belt Type B

The belt datum length 113.8 in

The center distance 16.7 in

The number of belts, Nbelt 5 pieces

1. The speed (v) of the conveyor belt is 0.65 m/s

Figure 4: Schematic Diagram of the V-belt system

𝑃𝑜𝑤𝑒𝑟 = 𝐹𝑜𝑟𝑐𝑒 × 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 (1)

1𝑘𝑊 = 1.341 ℎ𝑝 (2)

𝐿𝑑 ′ = 2𝐶 ′ + 1.57(𝐷𝑑 + 𝑑𝑑) (7)

𝐻𝑐 = (𝐻𝑠 + 𝐻𝑎) × 𝐾𝑐 (10)

Figure 5: Design of the gear system

Table 3: Results obtained from the gear analysis

Gear teeth, N 24 144

Rotational speed, n (rpm) 1440 240

Tangential force (lb) 320.96 320.96

Radial force (lb) 116.82 116.82

Diameter, d (in) 1.5 9

1. 100% efficiency for power transmission

𝑟𝑎𝑝, 𝑟𝑎𝑔 = addendum radii of the mating pinion and gear

𝑆𝑛 = 𝑆𝑛′ 𝐶𝐿 𝐶𝐺 𝐶𝑆 𝑘𝑟 𝑘𝑡 𝑘𝑚𝑠 (16)

Table 4: The values of Sn′ , CL , CG , CS , k r , k t and k ms

𝑆𝑛′ 112.5 kpsi

Surface factor, 𝐶𝑆 0.63

Means stress factor, 𝑘 𝑚𝑠 1.4

1) The length of shaft is assumed to be 7 inches

Reaction Force (lb) Bearing A Bearing B

Top View 160.48 160.48

Front View 58.41 58.41

𝑀𝑟𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 = √(𝑀𝑚𝑎𝑥1 )2 + (𝑀𝑚𝑎𝑥2 )2 (20)

𝜎𝑒𝑎 = √(𝜎𝑎 ) 2 + 3𝜏𝑎 2 (23)

𝑆𝑛 = 𝑆′𝑛 𝐶𝐿 𝐶𝐺 𝐶𝑆𝐶𝑇𝐶𝑅 (25)

From here, the endurance limit obtained is 𝑆𝑛 = 45.3 ksi.

Table 6: The value of shaft diameter

Shaft Driver (Pinion) Driven (Gear)

Figure 6: Types of bearings

Table 7: Results for the bearing analysis