1. ABSTRACT
Material handling involves short-distance movement within the confines of a
building or between a building and a transportation vehicle. Material handling
can be used to create time and place utility through the handling, storage, and
control of material, as distinct from manufacturing, which creates form utility by
changing the shape, form, and makeup of material.
The main advantage of material handling system is that material is transferred in
close loop thereby preventing the environmental effect on the material and vice
versa. In this project different parameters like pressure, distance to be conveyed
and shape which governs the design of system are described.
2. INTRODUCTION
A Pneumatic material handling system is a process by which bulk materials of
almost any type are transferred or injected using a gas flow as a conveying
medium from one or more sources to one or more destinations. Air is the most
commonly used gas but may not be selected for heavy loads.
A well designed pneumatic material handling system is often a more practical
and economical method of transporting materials from one point to another due
to the following reasons :
1. Pneumatic systems are relatively more economical to install and operate.
2. Pneumatic systems are totally enclosed and if required can operate
entirely without moving parts into contact transported material.
3. They are flexible in terms of rerouting and expansion. A pneumatic
system can convey a product at any place a pipeline can run.
Material handling system is divided into the following categories :
1. Manual Handling system –
Manual handling refers to the use of a worker’s hands to move individual
containers by lifting, lowering, filling, emptying, or carrying them. It can
expose workers to physical conditions that can lead to injuries.
2. Automated Handling system –
Whenever technically and economically feasible, equipment can be used
to reduce and sometimes replace the need to manually handle material.
Most existing material handling equipment is only semi-
automated because a human operator is needed for tasks like
loading/unloading and driving that are difficult and/or too costly to fully
automate, although on going advances in sensing, machine intelligence,
and robotics have made it possible to fully automate an increasing
number of handling tasks.
3. Literature Survey
1. Base papers :
1.1 Author Name – Anthony Esposito
Book title – Fluid Power with Applications
Publication – Pearson
1.2 Author Name – Kai Huang
Paper title – Model of the Equipment selection of Material
Handling system
Publication – ATLANTIC PRESS
2. Reference Websites :
nptel.ac.in
www.ijirset.com
4. SYSTEM DESIGN AND CIRCUIT
The following components have been used in the construction of our Material
Handling system prototype :
1. Double acting cyclinders (3.5cm bore , 4cm stroke) – 2nos
2. 5/2 DCV lever operated – 2 nos
3. FRL unit
4. Flow control valve – 1 nos
5. T-joint – 1nos
6. Hose (2m length)
7. Wooden ply mount – (54×16cm sq.)
8. M seal
9. Container
10. Wooden test piece – (2.5×2.5×2 cm cube)
11.Nails(1in.)
CONSTRUCTION DETAILS :
1. The mount for the system was designed by cutting the wooden ply into
two pieces with the cross section of 24×16cm sq. and 30×16 cm sq.
2. The two wooden bases were clamped at an angle of 90 deg.
3. Each DA cylinder was then attached to the respective wooden base using
M seal at the co-incident axis at proper locations.
4. The M seal was left to dry for 30min.
CIRCUIT DESIGN :
1. The DA cylinders were connected to the each of the 5/2 DCVs using hose
connectors.
2. The DCVs were then connected to the FRL unit using a T-joint to provide
equal air pressure to both the DCVs .
3 The FRL unit is connected to the DCVs via a Flow control valve where
we adjusted the optimum pressure for the cylinders to lift and push the
weight.
6. WORKING OF DESIGNED CIRCUIT
1. Firstly we operate the vertical DA cylinder which is used to lift the load
kept on the platform.
Fig 1.2 Extension of vertical load carrying DA cylinder
2. Then the horizontal cylinder is extended which pushes the load into the
container.
Fig 1.3 Extension of horizontal cylinder to push the test load off the platform.
3. After that the process repeats continuously as we operate the DCVs.
7. FUTURE ENHANCEMENTS
While carrying out the testing , we found some discrepancies in the
working of the system. Due to stipulated budget , we could not fabricate a
better prototype but we can try to troubleshoot the following arising
problems :
1. The system we designed has to be controlled manually by the lever
operated DCVs. Using a system with roller operated valves (2 nos)
and one pilot operated DCV can make the continuous sequencing of
the circuit possible.
2. Due to shortage of funds , we could not use a DA cylinder with
cushioning mechanism in order to protect the test piece from impact
damage
3. Better cylinders can be used to increase the load capacity of the
system.
8. OBJECTIVES OF MATERIAL HANDLING
The primary objective of a material handling system is to reduce the unit cost of
production. The other subordinate objectives are:
1. Reduce manufacturing cycle time
2. Reduce delays, and damage
3. Promote safety and improve working conditions
9. 4. Maintain or improve product quality
5. Promote productivity
i. Material should flow in a straight line
ii. Material should move as short a distance as possible
iii. Use gravity
iv. Move more material at one time
v. Automate material handling
6. Promote increased use of facilities
i. Promote the use of building cube
ii. Purchase versatile equipment
iii. Develop a preventive maintenance program
iv. Maximize the equipment utilization etc.
LIMITATIONS OF AUTOMATED MATERIAL HANDLING SYSTEMS:
A good management practice is to weigh benefits against the limitations or
disadvantages before contemplating any change. Material handling systems also
have consequences that may be distinctly negative. These are:
1. Additional investment
2. Lack of flexibility
3. Vulnerability to downtime whenever there is breakdown
4. Additional maintenance staff and cost
5. Cost of auxiliary equipment.
6. Space and other requirements:
