Screw Conveyor Design and Developement

Screw conveyor Design
ME 5390-Design for Manufacture
Submitted By
Kevin Nichols
Rohit Sengar
Siddarth Shetty
Pinak Upadhyay
Table of Contents
1. Abstract 3
2. Introduction 3
3. Design Requirements and Assumptions 3
4. Conceptual Design 3
5. Embodiment Design
6. Reliability
7. Bill of Materials
8. Safety Analysis 15
9. Detail Design 15
10. Ergonomics 16
11. Conclusion 16
12. Appendix 17
12. A. Conceptual Design 17
12. B. Embodiment Design 21
12. C. Detail Design 23
12. D. Calculations 24
12. E. Part Drawings 29
12. F. Safety Labels 35
13. References 36
Design Of Screw Conveyor Page 1

List of Figures
1. Fig 3.1 Basic Screw Conveyor 6

2. Fig 3.2 Functional Decomposition 7
3. Fig 3.3 Concept 1 9
7. Fig 3.7 Product Architecture 12

1. Abstract:
Screw conveyors are widely used for transporting materials at controlled and steady rates. They
are used in many bulk material applications in industries ranging from industrial minerals,
agriculture, chemicals, pigments, plastics, cement, sand, salt and food processing. The purpose of
this project was to design a screw conveyor for Martin Sprocket. The screw conveyor needs to be
able to move recycled sand having temperature 560oF to their foundry which is located 45 ft far
from the intake. This conveyor is replacing their current belt conveyors that measures 250CFH
flow rate.
2. Introduction:
A screw conveyor uses a mechanism of rotating screw blade, called a "flighting", within a tube,
to move granular materials like sand. They are used in many bulk handling industries. Screw
conveyors in modern industry are often used horizontally or at a slight incline to facilitate the
transportation of the material. As the angle of inclination increases, the capacity of a given unit
rapidly decreases.
3. Design Requirements and Assumptions
For this project there are several design requirements that must be met. The first requirement
is that it must be cost effective. The second is that it must flow a minimum of 250 cubic feet per
hour. The engineering design process used was the one defined in Engineering Design. In this
book the design process is split into three main sections; Conceptual Design, Embodiment Design,
and Detail Design (2).

4. Conceptual Design
The first portion of the design process was Conceptual Design. The first part of concept
generation performed was to build a House of Quality. The house of quality is very important. It
allows customer wants, which tend to be subjective, to be converted into engineering
characteristics, which are quantifiable. It also allows the engineers to identify and focus on the
more important aspects of a project.
Table 3.1 The engineering Characteristics

Direction of
Engineering Characteristic Units
improvement
Motor Characteristics HP/RPM Increase
Flow Rate ft3/hr Increase
Surface Hardness HB Increase
Thermal Expansion ΔL/L Decrease
Screw Geometry N/A N/A
Conveyor Loading % Increase
Trough Design N/A N/A
Stiffness lb/in Increase
Material Selection N/A N/A
Efficiency % Increase
In order to build the house of quality the customer wants had to be identified for the first
room and weighed according to their importance. The customer wants that were chosen for the
house of quality were Low cost, temperature resistance, safety, reliability, ease of maintenance,
long life, sealed, high performance, and wear resistance. These wants were chosen based on the
information provided by Martin Sprocket. The engineering characteristics that were chosen to
compare the customer requirements can be found in Table 3.1 along with the direction of
improvement and the units that are being considered.
Once The House of Quality was constructed and filled out it was determined that the most
important engineering characteristic was material selection followed by Trough design and
efficiency. The complete House of Quality, HOQ, can be found in Appendix A. The roof of the
house of quality determined that most of the engineering characteristics have a positive effect of

no effect on each other. The only engineering characteristics that were determined to have a
negative correlation were conveyor loading and stiffness.
Once the HOQ was constructed the Product Design Specifications, PDS, were determined. The
complete PDS can be found in appendix A.
The physical Decomposition was then performed to get a better idea about the screw
conveyor and the parts that are in it and how they go together. The physical Decomposition can be
found in Appendix A. Figure 3.1 shows a basic diagram of a screw conveyor. It was determined
form research and the catalog that the screw conveyor is made up of four main assemblies. The
assemblies are the Screw, the trough, the shaft drive, and the hanger. These assemblies were then
broken down into sub-assemblies and components.
Figure 3.1 Basic Screw conveyor diagram [1].
Once the physical decomposition was performed it allowed was used to create a functional
decomposition. For this it was needed to determine how the screw functioned, which was helped
by producing the physical decomposition. The screw conveyor is a mechanical system in which
sand and electrical energy are inputted and the output is sand that has been moved to another
location. Figure 3.2 shows the complete functional decomposition.

Figure 3.2 The functional decomposition of the screw conveyor.
In order to generate concepts from the analysis a morphological chart was generated. This
chart included possible components to be used with a conveyor that met the design specifications.
The categories/assemblies that were put into the morphological chart were screw, Trough,
Reducer, hanger, and trough ends. These were considered to be the most logical choices to generate
some concepts. The morphological chart can be found in Table 3.2.
Table 3.2 Morphological Chart

Screw Trough Reducer Hanger Trough Ends
Standard Pitch, Formed Flange Outside Trough
Screw Drive Reducer Style-216
Single Flight U-trough Ends with Feet
Outside Trough
Half Pitch, Angle Flange
Gear Motor Drive Style-220 Ends without
Single Flight U-trough
Feet

Formed Flange
Inside Trough
Ribbon Flight Rectangular Style-226
Ends
Trough
Cut Flight, Angular Flange
Style-316
Standard Pitch Tubular Trough
Solid Tubular
Style-326
Trough
Once some likely components were chosen for a screw conveyor several concepts could be chosen.
From the morphological chart there was a possibility of 600 concepts to be generates. Using the
information learned it was narrowed down to four likely candidates. These 4 concepts can be found
in Table 3.3 and Figures 3.3-6.
Table 3.3 Concept Chart

Concept Screw Trough Reducer Hanger Trough Ends
Standard Pitch, Formed Flange Gear Motor Outside Trough
1 Style-220
Single Flight U-trough Drive Ends with Feet
Outside Trough
Half Pitch, Angle Flange Screw Drive
2 Style-316 Ends without
Single Flight U-trough Reducer
Feet
Outside Trough
Half Pitch, Angular Flange Screw Drive
3 Style-226 Ends without
Single Flight Tubular Trough Reducer
Feet
Formed Flange Outside Trough
Half Pitch, Screw Drive
4 Rectangular Style-216 Ends without
Single Flight Reducer
Trough Feet

Figure 3.3 Concept 1


The four concepts that were generated were put into a weighted matrix to determine which
concept would be the most viable. From the weighed matric concept 3 had the highest score. The
weighted matrix can be found in Table 3.4. And concept 3 can be found above in Figure 3.5.
Concept 3 consists of a single flight half-pitch screw, an angled flange tubular trough, style-316
hanger, and outside trough ends without feet.
Table 3.4 Weighted Matrix for Concepts
Concept-1 Concept-2 Concept-3 Concept-4
Design Criteria
Weight Factor
Magnitude
Magnitude
Magnitude
Magnitude
Rating
Rating
Rating
Rating
Score
Score
Score
Score
Units
Hp/
Motor
0.03 V.good 8 0.24 Good 7 0.21 Good 7 0.21 Good 7 0.21
Characteristics Rpm
3 Excell
Flow-Rate 0.10 Ft /hr Good 7 0.7 Good 7 0.7 9 0.90 Poor 3 0.3
ent
Surface
0.08 HB Good 7 0.56 Good 7 0.56 Good 7 0.56 V.Good 8 0.64
Hardness
Thermal
0.08 (Dl/l) Good 7 0.56 Good 7 0.56 Good 7 0.56 Good 7 0.56
Expansion
Screw HPS
0.11 n/a SPSF 4 0.44 8 0.88 HPSF 8 0.88 HPSF 8 0.88
Geometry F
Conveyor
0.09 % 15% 10 0.9 15% 10 0.9 15% 10 0.9 15% 10 0.9
Loading
A-F
A-F F-F
F-F U- Tubul
U- Rectang
Trough Design 0.13 n/a 7 0.91 7 0.91 ar 9 1.17 4 0.52
Trou ular
trough Troug
gh Trough
h
V.Go V.Goo
Stiffness 0.09 Lb/in Good 7 0.63 8 0.72 8 0.72 Good 7 0.63
od d
Material
0.18 n/a Good 7 1.26 Good 7 1.26 Good 7 1.26 Good 7 1.26
Selection
GSF Excell
Efficiency 0.12 % GSFD 6 0.72 6 0.72 9 1.08 Poor 3 0.36
D ent
Total 6.92 7.42 8.24 6.26

The last part that was done for the concept generation portion of the project was to create
the product architecture chart. This chart can be found in Figure 3.6.
Figure 3.7 Product Architecture

From Above function analysis we know that –Drive, screw and hanger have Modular
Architecture. Trough have an Integral architecture Therefore, Screw conveyor is Mixed
Architecture product.
5. Embodiment Design
The next step of the design process is the embodiment design. For this portion the
Manufacturing processes and materials were selected, the Design for Manufacture (DFM) analysis
was performed, the Design for Assembly (DFA) analysis was performed, and the parametric
design and the Tolerance analysis was performed.

The first part of preliminary design was to start sizing the screw conveyor and to perform the
tolerance analysis. In order to perform the tolerance analysis the screw lengths needed to be
determined along with the lengths of the trough sections. The drawing produces for this can be
found in Appendix B and the tolerance analysis calculations can be found in Appendix D.
Table 3.5 Weighted Material Property Index
Material Weighting Candidate Material

Property Factor 304SS A36 AR225 AR400
Abrasion
10 70 70 80 90
Resistance
Thermal
5 70 80 90 90
Expansion
Fatigue 7 70 80 70 80
Fracture
8 90 80 80 80
Toughness
Weighted Property Index 2260 2300 2380 2550
The process of choosing materials started by choosing four materials that were suitable to
be used. The candidate materials that were chosen were 304 stainless steel, ATSM A36 Steel,
AR225 steel, and AR400 steel. Table 3.5 shows the weighted property index that was used to
determine the candidate materials. The weighted material property index is a rational way to select
the materials to use for the screw conveyor. Each material property is weighted with an importance
factor and then each material is given a rating for each of the materials properties. From there each
candidate material received a score based on how well it meets the material properties that are
needed. The material with the best score meets is the best materials based on the combined material
properties. In the matrix AR400 received the top score. Hence AR400 was selected for the trough
material and 304SS for the Shaft material and screw flight. Additional hardness of the shaft will
be achieved through hardening the shaft and applying various types of ceramic coatings.

The manufacturing processes were selected using data found in chapter 13 of Engineering
Design (2). This data was put into Table 3.6 to determine the best manufacturing process for each
of the major components of the screw conveyor. For each component three manufacturing
processes were selected and they were compared to each other based on cycle time, process
flexibility, material utilization, quality, and equipment and tooling cost. Each manufacturing
process received a score for each category and the scores were summed to give the process an
overall score.
Table 3.6 Process Selection Table
From Table 3.6 it was determined that the trough should be manufactured using centrifugal
casting. The screw shaft should be manufactured with closed die forging. The screw flights will
be manufactured with a sheet metal forming operation. Table 3.7 shows the final manufacturing
process and material selected for the major components.

Table 3.7 Manufacturing Processes and Materials to be used for the major components.
For the trough Centrifugal Casting was selected since the shape of the trough is tubular and
in this process high mechanical along with less inclusions and impurities can be obtained. Then
some machining will be performed to create the mounting flanges and the mounting locations of
the inlet, discharge, and hanger pockets. The inlet, discharge, and hanger pockets will all then be
welded to the trough to make the final trough design. AR400 is used as a material for trough, and
all the components that will be welded to the trough since it has very good abrasion wear property.
The screw that has been chosen for this project is a sectional screw, which requires that the flights
are made individually as many pieces rather than helicoid, which all the flights are manufactured
as one piece. For the Screw Shaft Forging process was selected since it can reduce the weight of
the shaft and obtain high strength at an economical price. For the Screw Flight a Sheet metal
forming process selected since it can produce versatile shapes. Screw shaft and screw flight will
be manufactured from 304SS due to its good weldability, longer life, and low cost. Once the screw
shaft and flights are manufactured they will be welded together to create the screw assembly.
The screw conveyor that has been designed will require some parts that can be bought and some
parts that will be custom made, and some parts that are standard but will require dimensional
changes to make them fit. Table 3.8 contains a full list of the components to be used along with
the information on whether or not they will need to be custom ordered or if they can be bought.
The full assembly analysis can be found in Appendix B.

Table 3.8 Parts List
Part Martin Sprocket Part Number Custom
Tubular Trough* 14CHT3-A X
Screw* 14SF624 X
Coupling Shaft X
Conveyor Inlet X
Discharge Spout 12TSD7
End Plate 14CHTE6BB-P
End Bearing (Ball Bearing) TEB6B
Drive Shaft* 1CD6BB-P X
End Shaft X
Hanger Pocket* 14CPH12 X
Hanger (style 226) 14CH2266
Hanger Bearing CHB2206C
Thrust Washer CTW6
*See Drawings in Appendix E to see how the component varies from Martin Sprocket part
From Table 3.8 the parts that have a part number and a mark for it being custom then there have
been some modifications from Martin Sprockets’ specs listed in their catalog. The parts with no
part number are one off custom parts that need to be manufactured specifically for this screw
conveyor. Among these parts are the connecting shafts (drive, end, and coupling), which are
designed differently due to the half-pitch flight configuration chosen. Martin Sprockets’ design
would cause interference between the bolt holes and the flight. The inlet is also custom designed
to work with the screw conveyor. The bolt pattern for the top of the inlet is the specified pattern
for a 14” trough on page H-42 of the catalog provided by Martin Sprocket (1).

6. Reliability:
Safety Factor=𝑆𝐹𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 × 𝑆𝐹𝑠𝑡𝑟𝑒𝑠𝑠 × 𝑆𝐹𝑡𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 × 𝑆𝐹𝑓𝑎𝑖𝑙𝑢𝑟𝑒 𝑡ℎ𝑒𝑜𝑟𝑦 × 𝑆𝐹𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦
Safety factors of critical parts is given by:
As trough is a structural part it is having the highest safety factor of 1.54.
System reliability
𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = 1 − 𝑝𝑟𝑜𝑏𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒
Components are arranged so that the failure of any component causes the system to fail. Hence
the designed screw conveyor has series reliability.
It can show as below:

FIGURE 1 : SERIES RELIABILITY OF SCREW CONVEYOR SYSTEM
And reliability of over all system can be given by :
𝑅𝑠𝑐𝑟𝑒𝑤 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟 = 𝑅𝑇 × 𝑅𝑆 × 𝑅𝐶 × 𝑅𝐻 × 𝑅𝐻𝐵 × 𝑅𝐸𝐵 × 𝑅𝐸𝑃
7. Bill of Material:

8. Safety Analysis:
For safety it was determined that inspection doors should be placed in several locations along
the trough. These inspection doors will allow access to critical components. The hanger bearing
housings double as the inspection doors since they are located throughout the trough and allow
access to the bearings without the removal of the trough covers. Along with the inspection points
Bearing Temperature sensor, zero speed sensor, and speed switch are installed for better
maintenance and safety.
9. Detail Design
For the detail design the reliability, ergonomics and safety, and failure mode and effects
(FMEA) analyses were performed. The CAD models and assemblies were also generated. All of
the final drawings can be found in Appendix E.
For the FMEA the major possible points of failure were determined. Once they were determined
it was determined how these components would fail. From there they were assigned a value of 1
through 10 for the categories of severity, occurrence, and detection. These values were used to
calculate the risk priority number (RPN). The RPN is used to detect the greatest risk and ranges
from 1 to 1,000 (2). The component that received the highest RPN, 175, for the screw conveyor is
the seals, which is logical because if the seals fail it will eventually cause more parts to fail. The
lowest RPN, 7, went to the screw shaft. By using the FMEA it is possible to determine if there is
any issues with the design so that the issues can be properly addressed. The full FMEA table can
be found in Appendix C.

10.Ergonomics:
Ergonomics is an applied science concerned with designing and arranging things people use
so that the people and things interact most efficiently. Ergonomics along with risk factor
assessment and intervention and decrease the risk of injury/illness, enhance worker productivity
and improve quality of work life. Some of the human engineering factors that need to be considered
in a screw conveyor as follows: The controls are provided at arm’s length of the user i.e. around
40cm .Hence providing easy reach to the user resulting in better productivity and safety. All the
major operation controls are provided at the right of the user so as to avoid ambiguity and ease the
operation process for the user. The operator will be informed about every operation he performs
in the form light signal at the control interface.
11.Conclusion:
The screw conveyor was designed to fulfill the customer requirements. Here the main focus
was to use as standard parts as possible for the cost reduction. Some parts like Screw shaft, Shaft
Coupling were custom made for the ease of assembly of the screw conveyor.
Thus the proposed design of the screw conveyor is cost effective, efficient, standard and
fulfilling the customer requirement with the optimum performance.

12. Appendix
A—Conceptual Design
Figure A.1 House of Quality

Table A.1 Product Design Specifications (PDS)

Table A.1 (continued)

Figure A.2 Physical Decomposition

Appendix B—Embodiment Design
Figure B.1 Screw Conveyor Preliminary Drawing.

Table B.1 Design for Assembly Evaluation.

Appendix C—Detail Design
Table C.1 Failure Modes and Effects Analysis (FMEA)

Appendix D —Calculations
Tolerance Analysis
Horse Power and Screw Diameter Calculations
Step 1: Screw Diameter Calculations

Material to be conveyed: Silica Sand
Material Properties:
Material Weight Material Bearing Component Material Trough
Lb/ft3 code Series Factor (Fm) Loading
Silica Sand 100 B-6 2 7 H 3 2.0 15

 Material Code Interpretation
B-6 : Material having Fine Particles of size (0.132”) and under
2 : Free Flowing Material
7 : Extremely Abrasive Material
Required Capacity (ft3/hr) : 250 ft3/hr
𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = (𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦) × 𝐶𝐹1 × 𝐶𝐹2 × 𝐶𝐹3
Where CF1= Special Conveyor Pitch Capacity Factor = 2.0

CF2=Special Conveyor Flight Capacity Factor =1.0
CF3=Special Conveyor Mixing Paddle Capacity Factor =1.0
∴ 𝐶𝐹 = 250 × 2.0 × 1.0 × 1.0

∴ 𝐶𝐹 = 500 ft3/hr
Selecting the diameter as per the CF from the Design Catalogue,
Diameter Capacity ft3/hr Max RPM
(Inch) 1 RPM Max RPM
14 10.40 520 50
Hence, Screw having 14 inch diameter is selected.
𝑓𝑡 3
𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 ( )
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑆𝑝𝑒𝑒𝑑 (𝑅𝑃𝑀) = ℎ𝑟
𝑓𝑡 3
𝑖𝑛 1 𝑅𝑃𝑀
ℎ𝑟
500
𝑆𝑝𝑒𝑒𝑑 = = 48 𝑅𝑃𝑀
10.40
Step 2: HP required to drive the Screw Conveyor
𝑯𝑷 = 𝑯𝑷𝟏 + 𝑯𝑷𝟐 + 𝑯𝑷𝟑
Where HP1=Horse Power to run an Empty Conveyor

HP2=Horse Power to run the loaded Conveyor
HP3=Extra Horse Power Required due to inclination

𝐿 𝑁 𝐹𝑑 𝑓𝑏
𝐻𝑃1 =
1000000
Where, L=Total length of the conveyor = 45.17’

N=Operation Speed = 48 RPM
Fd=Conveyor diameter Factor = 78
fb= Hanger Bearing Factor=4.4
45.17 × 48 × 78 × 4.4
∴ 𝐻𝑃1 =
1000000
∴ 𝑯𝑷𝟏 = 𝟎. 𝟕𝟒 𝑯𝑷
Now,
𝐶 𝐿 𝑊 𝐹𝑚 𝐹𝑓 𝐹𝑝
𝐻𝑃2 =
1000000
Where C= Capacity (ft3/hr) = 500 ft3/hr

W= Weight of the material = 100 lb/ft3
Ff = Flight Factor = 1.0
Fp= Paddle Factor = 1.0
Fm=Material Factor = 2.0
500 × 45.17 × 100 × 2 × 1 × 1

∴ 𝐻𝑃2 =
1000000
∴ 𝑯𝑷𝟐 = 𝟒. 𝟓𝟏 𝑯𝑷
Now
𝑙𝑏
× 𝐻𝑒𝑖𝑔ℎ𝑡 (𝑓𝑡)
𝐻𝑃3 = 𝑚𝑖𝑛
33000
𝑙𝑏 𝐶𝐹𝐻×𝑊𝑒𝑖𝑔ℎ𝑡 250×100 𝑙𝑏
Where = = = 417 𝑚𝑖𝑛
𝑚𝑖𝑛 60 60
Height = 45 × tan 5 = 3.94 𝑓𝑡

417 × 3.94
𝐻𝑃3 = = 𝟎. 𝟎𝟓 𝑯𝑷
33000
∴ 𝐻𝑃 = 𝐻𝑃1 + 𝐻𝑃2 + 𝐻𝑃3

∴ 𝐻𝑃 = 0.74 + 4.51 + 0.05 = 𝟓. 𝟑 𝑯𝑷
Now
𝐻𝑃×𝐹0
𝑇𝑜𝑡𝑎𝑙 𝐻𝑃 = 𝑒
Where F0 = Overload Factor = 1.0

E= Screw Drive = 0.88
5.4 × 1
∴ 𝑇𝑜𝑡𝑎𝑙 𝐻𝑃 =
0.88
= 𝟔. 𝟏𝟒 𝑯𝑷
Step 3: Calculating Torque
63025 × 𝐻𝑃
𝑇𝑜𝑟𝑞𝑢𝑒 =
𝑅𝑃𝑀
63025 × 6.14
=
48
= 𝟖𝟎𝟔𝟐 𝒍𝒃. 𝒊𝒏
Step 4: Expansion of Screw Conveyor Handling Hot Materials
∆𝐿 = 𝐿(𝑡1 − 𝑡2 )𝐶
Where ∆𝐿= Increment of change in length (in)=45.17 ft

t1= Upper limit of temperature (oF)=560oF
t2= Ambient temperature (oF) = 110oF
C= Coefficient of Linear Expansion = 10.4 x 10-6
Expansion of Screw Handling Hot Sand (560oF) in summer (110oF)

∆𝐿 = 10.4 × 10−6 × 45.17 × (560 − 110)
∴ ∆𝑳 = 𝟎. 𝟐𝟏𝟏 𝒊𝒏

Appendix E—Part Drawings
(All Dimensions in inches unless specified otherwise.)
Figure E.1 Labels all of the trough and screw sections for the drawings.
Figure E.2 Bolt pattern on all screws for intermediate shaft mounting.

Figure E.3 Screw Section S1
Figure E.4 Screw Section S2
Figure E.5 Trough Section U1

Figure E.8 Trough Section B1

Figure E.11 Coupling Shaft

Figure E.12 End Shaft
Figure E.13 Drive Shaft

Figure E.14 Hanger Pocket
Figure E.15 Inlet (Flange dimensions and bolt pattern specified in Martin Sprocket catalog, pg. H42) (1)

Appendix F: Safety Labels:[3]

Appendix G: CAD Parts

13.References:
[1]Martin Sprocket Catalog.
[2] Dieter, George E. and Schmidt, Linda C., “Engineering Design,” 5th edition, McGraw-
Hill, United States, 2013. Print.
[3] CEMA Screw Conveyor Safety Operation and Maintenance Manual.352-2012,1-3

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Screw conveyor Design

ME 5390-Design for Manufacture

Design Of Screw Conveyor Page 1

1. Fig 3.1 Basic Screw Conveyor 6

Design Of Screw Conveyor Page 2

3. Design Requirements and Assumptions

Design Of Screw Conveyor Page 3

Table 3.1 The engineering Characteristics

Design Of Screw Conveyor Page 4

Figure 3.1 Basic Screw conveyor diagram [1].

Design Of Screw Conveyor Page 5

Table 3.2 Morphological Chart

Design Of Screw Conveyor Page 6

Table 3.3 Concept Chart

Design Of Screw Conveyor Page 7

Figure 3.4 Concept 2

Design Of Screw Conveyor Page 8

Figure 3.6 Concept 4

Design Of Screw Conveyor Page 9

Table 3.4 Weighted Matrix for Concepts

Concept-1 Concept-2 Concept-3 Concept-4

Total 6.92 7.42 8.24 6.26

Design Of Screw Conveyor Page 10

Figure 3.7 Product Architecture

Design Of Screw Conveyor Page 11

Table 3.5 Weighted Material Property Index

Material Weighting Candidate Material

Weighted Property Index 2260 2300 2380 2550

Design Of Screw Conveyor Page 12

Table 3.6 Process Selection Table

Design Of Screw Conveyor Page 13

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Safety Factor=𝑆𝐹𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 × 𝑆𝐹𝑠𝑡𝑟𝑒𝑠𝑠 × 𝑆𝐹𝑡𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 × 𝑆𝐹𝑓𝑎𝑖𝑙𝑢𝑟𝑒 𝑡ℎ𝑒𝑜𝑟𝑦 × 𝑆𝐹𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦

Safety factors of critical parts is given by:

As trough is a structural part it is having the highest safety factor of 1.54.

𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 = 1 − 𝑝𝑟𝑜𝑏𝑎𝑏𝑖𝑙𝑖𝑡𝑦 𝑜𝑓 𝑓𝑎𝑖𝑙𝑢𝑟𝑒

It can show as below:

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Figure A.1 House of Quality

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Figure B.1 Screw Conveyor Preliminary Drawing.

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Table C.1 Failure Modes and Effects Analysis (FMEA)

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Horse Power and Screw Diameter Calculations

Step 1: Screw Diameter Calculations

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Required Capacity (ft3/hr) : 250 ft3/hr

𝐸𝑞𝑢𝑖𝑣𝑎𝑙𝑒𝑛𝑡 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = (𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦) × 𝐶𝐹1 × 𝐶𝐹2 × 𝐶𝐹3

Where CF1= Special Conveyor Pitch Capacity Factor = 2.0

∴ 𝐶𝐹 = 250 × 2.0 × 1.0 × 1.0

Hence, Screw having 14 inch diameter is selected.