Design and development of omnidirectional industrial conveyor system

Ibrahim, Mohamad Ubaidah (2023) Design and development of omnidirectional industrial conveyor system. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The design and development of an omnidirectional industrial conveyor system represent a significant advancement in the fields of material handling and manufacturing automation, requiring careful consideration of factors such as material weight, width, and motor speed for optimal installation and maintenance. These conveyors, engineered for multidirectional movement, present unique challenges, including complex requirements and heightened maintenance costs, necessitating regular upkeep to prevent performance issues. In contrast to conventional conveyors, the omnidirectional system facilitates seamless movement, thereby optimizing space utilization and enhancing agility in manufacturing processes. This project adopts a comprehensive approach, encompassing initial design requirements through to actual development and functionality evaluation, utilizing 3D modeling software such as Catia V5 and integrating additive manufacturing techniques, including 3D printing for components like the Omni Wheel. Stress analysis conducted using ANSYS revealed maximum load capacities of 200N for a roller and 100N for an omni wheel. Testing involved evaluating load, speed, current, and energy consumption, demonstrating that the DC roller motor could not transport a 10kg load at low speed but could do so at high speed, while the DC omni wheel similarly failed to move a 10kg load at low speed and a 14kg load at high speed, highlighting the motors' dependence on elevated speeds for effective load mobility. Current draw increased with load, stabilizing at low speeds for loads that the motors could not move, with temperature assessments indicating that the DC omni wheel motor reached 44.5°C and the roller motor 41.1°C after 45 minutes, suggesting thermal stress and the need for cooling solutions. Load tests revealed significant performance variations, with the gap roller RPM decreasing from 256 to 205 (a 19.92% reduction) and current increasing from 0.92A to 2.65A (a 188.04% increase), while the omni wheel's RPM dropped from 661 to 0 (a 100% decrease) and current rose from 4.33A to 12.53A (a 189.38% increase). The prototype effectively moved a 14kg item, demonstrating satisfactory performance, thus confirming that omnidirectional delivery prototypes are effective and suitable for transporting items in all directions.

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