Abstract
A failure of conveyor chain links in a production process can cause unscheduled shutdowns, which increase the throughput time coupled with damaged buckets and chain links, which increase maintenance and repair costs. Since failures of conveyor chains are inevitable, this research aims to modify the design of the chain bucket elevator by incorporating a ratchet mechanism, which will prevent the chain bucket assembly from dropping to the bottom of the chain bucket elevator whenever there is a chain-link failure and also avoid the jamming of the bucket chain assembly against one another when dropping to the bottom of the elevator during failure. The number of damaged buckets and chains will be minimal, thereby reducing the maintenance and repair costs. Also, the time required for replacing the failed chain link will be reduced, which in turn, will reduce the down-time, thereby increasing the production rate. The ratchet mechanism, which can withstand a maximum load of 38.10 kN, comprises a toothed wheel, a pawl, and a spring. An analytical method was employed for the initial analysis and the results were verified using the FEM. Topology Optimization was carried out on the beam and lever with results showing a 20% and 26% weight reduction from the original, respectively. The stresses induced in the beam and lever increased significantly by 36% and 47 %, respectively, because of the optimization, however, they remained within the acceptable limits.
Highlights
The FE based design optimization (DO) is a welldeveloped and established method for determining design parameters that lead to the best measurable performance of a mechanical structure, device, or system under given constraints
The displacement was a function of the length and the angle subtended by the pawl whereas the velocity and acceleration were a function of length and the angle subtended by the pawl as well as the angular speed of the sprocket
The bucket elevator was modified by incorporating a ratchet mechanism for the purpose of preventing the bucket chain assembly from dropping to the bottom of the elevator when there is a chain failure, which is inevitable
Summary
The FE based design optimization (DO) is a welldeveloped and established method for determining design parameters that lead to the best measurable performance (optimal solution) of a mechanical structure, device, or system under given constraints. There is a rising demand for lower production cost, more efficient, less expensive and innovative methods to improve the performance of the existing systems. Optimization can be used to solve different engineering problems, including design of aircraft and aerospace structures aiming for minimum weight, vibration and noise optimization of automobiles for ride comfort, optimal design of electrical networks, analysis of statistical data and building empirical models from experimental results to obtain the most accurate representation of the physical phenomenon as well as optimal production planning, controlling and scheduling. Depending on the type of design variables, the finite element-based optimization may be classified as a parameter or size, shape and topology optimization. The topology optimization will be employed to optimize the components of the modified bucket elevator
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