Report on:

Gravity Roller Conveyor Design

A report submitted for the partial fulfilment of the subject ‘Design of a Mechanical System’ for the course of
Bachelor of Technology in Mechanical Engineering

22nd May, 2017

Submitted to:

Department of Mechanical Engineering

Heritage Institute of Technology
Prepared by:

Sudipto Shekhor Mondol

College Roll number: 1357024
Department of Mechanical Engineering
Heritage Institute of Technology
University Roll Number- 12600713052
Registration Number- 131260110613 of 2013-2014

Under the Guidance of

Dr. Siddhartha Ray

Professor, Heritage Institute of Technology
 Acknowledgment
I am indebted to a number of people, who helped and motivated me to bring out
this project. I would like to thank Dr. Siddhartha Ray who always guided me in
my endeavours and it has been an honour working under his guidance. I also want
to thank other members of the department of mechanical engineering of Heritage
Institute of Technology especially Dr. Sukanta Sarkar and Prof. Sankar Nath
Mukhopadhyay for their kind support and aid.

Sudipto Shekhor Mondol

Department of Mechanical Engineering
Heritage Institute of Technology
 List of Figures
Figure Description Page
Number Number
1 General view of an unpowered roller conveyor 2
2 Types of unpowered conveyor rollers 3
(a) cylindrical; (b) double tapered; (c) wheel
3 Rollers of (a) heavy and (b) extra heavy type 4
4 Unpowered roller conveyors with curved section1, turn-table 2, hinged 5
section 3
5 Velocity diagram of a roller 6
6 Gravity Roller GA Drawing 13
7 Gravity Roller Drawing 14
8 Gravity Roller Component Drawing 15
 Contents
Description Page Number

Abstract 1

Introduction 1

Literature Review 2

Aspects of Gravity Roller Conveyor Design 6

Design Considerations 8

Calculations 9

References 12
1|Page

Abstract
Wooden boxes of size 300 x 500 x 250mm weighing 200 kgs are to be conveyed by a gravity
roller conveyor up to a distance of approximately 4 meters. At the entry end, the boxes are
loaded by a crane with tong mechanism, at the roller top height of 700mm. In the present study,
the roller conveyor is designed and GA & detailed drawing for the conveyor is prepared.

1. Introduction
Conveyors are gravity or powered equipment commonly used for moving bulk or unit load
continuously or intermittently, unidirectionally from one point to another over fixed path,
where the primary function is conveying of the material by the help of movement of some
parts/components of the equipment. The equipment as a whole does not move.
A roller conveyor supports unit type of load on a series of rollers, mounted on bearings, resting
at fixed spacings on two side frames which are fixed to stands or trestles placed on floor at
certain intervals. A roller conveyor essentially coveys unit loads with at least one rigid, near
flat surface to touch and maintain stable equilibrium on the rollers, like ingots, plates, rolled
stock, pipes, logs, boxes, crates, moulding boxes etc. The spacing of rollers depend on the size
of the unit loads to be carried, such that the load is carried at least by two rollers at any point
of time.
Roller conveyors are classified into two groups according to the principle of conveying action.
These are:
1. Unpowered or Idle Roller Conveyor.
2. Powered or Live Roller Conveyor.
In an unpowered roller conveyor, the rollers are not driven or powered from an external source.
The loads roll over the series of rollers either by manual push or push from an endless moving
chain or rope fitted with pusher dogs, rods or clamps. Generally these conveyors operate at
horizontal plane, but at times a gentle slope is given to these conveyors to aid motion of the
loads. An inclination of 1.5% to 3% ensures that the load will roll by gravity. Such conveyors
are termed “gravity roller conveyor’’.
In a powered roller conveyor, all or a selected number of rollers are driven by one or a number
of motors depending on the selected drive arrangement. The driven rollers transmit motion to
the loads by friction. The powered roller conveyors may be installed at a slightly inclined
position, up to 10° up or up to 17° down. The load can be moved in either directions by
changing the direction of rotation of the rollers, where these are called reversing conveyors.
Roller conveyors are used for conveying almost any unit load with rigid riding surface that can
move on two or more rollers. These are particularly used between machines, buildings, in
warehousing as storage racks, docks, foundries, rolling mill plants, manufacturing, assembly
and packaging industry. They are also used for storage between work stations and as segment
of composite handling system. However, the limitations of rollers conveyors are that they can
2|Page

be best used for objects with rigid flat surfaces, and for movement to relatively short distances.
Needs side guards to retain the loads from falling off. Gravity roller conveyors have the risk of
accelerating loads.

2. Literature Review
An unpowered roller conveyor consists of series of rollers, the frame on which the rollers are
placed and the stands on which the framework rests. Because of simplicity of design,
competitive cost and trouble free operation, these conveyors are used extensively in handling
unit loads in workshops or process plants to convey articles from one working station to
another. Unpowered roller conveyors are often used as a storing platform and as such are often
termed as roller table. These are also used in stores as storing racks and in loading bays for
loading / unloading materials from carriages. A gentle slope may be provided in the conveyor
to aid movement of the loads on idle rollers. These gravity roller conveyors are used to convey
load in one direction only. The conveyors can have a curved section to change direction.
Material movement between two levels may be done by an inclined or a spirally formed gravity
roller conveyor. The spiral form increases the length of the conveyor and thereby controls the
velocity of the articles moving down the conveyor. A typical unpowered roller conveyor is
shown in Fig. 1.

Figure 1: General view of an unpowered roller conveyor

Parts of unpowered roller conveyor
(i) Rollers: Cylindrical rollers are generally used which are made from ERW steel pipes with
cast or fabricated end flanges to accommodate the antifriction bearings (usually ball bearings).
The through axles are stationary and roller barrels can rotate freely. These rollers are called
idler rollers.
3|Page

For conveying cylindrical objects (drums, pipes, round steel bars etc.), double tapered rollers
or wheel rollers are used (Fig. 2).

Figure 2: Types of unpowered conveyor rollers

(a) cylindrical; (b) double tapered; (c) wheel
The diameter of the rollers depend on the diameter of standard steel pipes available, and vary
from about 20 mm to max 155 mm. Heavier the load to be conveyed, larger diameter and
heavier wall thickness of the rollers are chosen. Typical sizes of some of the rollers and their
weight carrying capacities are given in the following table:

Roller pitch depends on the length and weight of the load handled. The unit load should be
supported at least by two rollers, thus the maximum pitch should be ≤ ½ of the load length. For
goods vulnerable to jerks/ shaking, roller pitch equal to ¼ to 1/5 of length of load to be
considered.
(ii) Frame: Frame is that part of the conveyor on which the roller axles rest and are fixed to.
The conveyor frame is fabricated from angle or channel sections. The roller axles are held in
slots cut in the flanges of the frame. The axles are flat machined at the ends so that the axles
do not rotate in the slots. Axial movement of the axles are prevented by using split pins or lock
plates. For heavy rollers, the axles may be fixed on the frame by clamps. Side guards may be
provided along two edges of the frame to prevent movement of the loads beyond the roller
span. Side guards are particularly necessary at the curved sections of a conveyor. Typical idle
rollers with bearing fittings and their attachment to the frame is shown in Fig. 3.
4|Page

Figure: 3: Rollers of (a) heavy and (b) extra heavy type

(iii) Stands or Trestles: Stands or trestles support the conveyor frames with roller assemblies,
from the ground. Stands are generally fabricated from pipes or structural sections, with
provision for grouting on the floor. Height of stands are chosen to keep the articles at a
convenient level on the conveyor. Small portable conveyors often have telescoping legs for the
stands, such that the inclination of the conveyors can be suitably adjusted in situ.
Special designs/features
A number of features can be incorporated in an unpowered conveyor to satisfy different
functional requirements. Some of these are described below.
(i) Double-row roller conveyor: This design is used to convey wide and heavy loads. In place
of one long and proportionately large diameter roller, two smaller diameter rollers with lengths
less than half of the larger roller are used. To support the inner ends of the pair of rollers,
additional support frame is required. This design works out to be cheaper than the same width
conventional single row conveyor with longer and larger rollers.
(ii) Curved sections: These are used for changing direction of the conveyor in the horizontal
plane. In this section rollers are arranged radially. Two or more number of cylindrical rollers
are used in place of one roller to reduce sliding action of the load on rollers (Fig. 4). Minimum
sliding action of the load on rollers can be achieved by using single tapered roller (V-roller),
but as these are to be made from solid casting or forged section, are costly and seldom used.
5|Page

(iii) Switches: Devices used in a roller conveyor to change the normal direction of the load or
divert the load from the conveyor are called switches. Different types of switches are employed,
some of which are as follows:
A turn-table (Fig 4) is used for transferring a load from one roller conveyor to a sliding runway
or to a perpendicular roller conveyor. This consists of a small length (equal or slightly smaller
than the width of the main conveyor) of roller conveyor mounted on a base frame which is
fixed on a vertical shaft mounted on bearings. Once the load comes on the turn-table, the turn
table can be rotated (manually or by proper mechanism) to the desired angle and the load can
be rolled over to the desired runway.
A hinged section (Fig. 4) is a small section of the conveyor which is hinged at one end with the
frame/stand of the main conveyor, and can be lifted up to make a passage way through the
conveyor line.
An array of wheel rollers on swiveling heads (castor wheel) are used independently or as a part
of a roller conveyor where it is necessary to move the load in many directions.
Deflector is a flat or angle like section placed longitudinally over the conveyor making an angle
(may be adjustable or fixed) with the conveyor axis. This acts as an obstruction to the
movement of the load and deflects them to one side of the conveyor axis. Manipulator consists
of one pair of deflectors to bring the loads at the middle section of the conveyor axis. Deflector
or manipulator is used on idle conveyors and more commonly with powered roller conveyors
with chain/rope pushing facility.

Figure 4: Unpowered roller conveyors with curved section1, turn-table 2, hinged section 3
(iv) Stops: These are placed at the end of the conveyor to physically stop the moving loads
from falling off the conveyor end. Disappearing stops may be placed at desired intermediate
points in the path of a roller conveyor to stop the moving articles at such points, if required.
The stops are simple flat steel plates fixed on rigid legs or fixed to conveyor structure.
Disappearing stops may be moved up or down from the top level of the roller by suitable
mechanism.
6|Page

3. Aspects of Gravity Roller Conveyor

Design
The major design calculations involved are to determine the force required to overcome the
resistance to motion of the loads and the angle of inclination required for a gravity conveyor.
Total resistance to motion is made up of:
(i) Resistance to rolling of the load on rollers due to friction.
(ii) Frictional resistance in the roller bearings.
(iii) Resistance due to sliding of the load on the rollers and force required for imparting
kinetic energy to rollers.
(i) Resistance to rolling of the total load ‘‘G’’ on the rollers is given by
F1 = Gk/R ...(i)
where k = rolling friction factor also called coefficient of rolling resistance, mm
R = roller radius, mm
(ii) Frictional resistance on roller journals is expressed by
F2 = (G + wn′) μr/R ...(ii)
Where, w = weight of rotating part of each roller.
n′ = number of rollers supporting total load, and hence in motion.
μ = coefficient of friction at the journal.
r = journal radius.
(iii) When a moving load comes over a static roller, it slides over the roller and starts
accelerating the roller till the roller attains the surface speed equal to speed of the load. When
the load leaves the roller, it starts decelerating and eventually stops until it is accelerated by
the next load. This phenomena is shown in Fig. 5.

Figure 5: Velocity diagram of a roller

7|Page

O is the point of time when a moving load touches a static roller. Till time t; the load rolls and
slides over the roller. The surface or rotational velocity of the roller is under acceleration,
expressed by line OA. From A up to B, the load rolls over the roller, and at B it leaves the
roller.
If the conveyor is conveying Z pieces of load per hour, then the cycle period will be
t1 = 3600/ Z seconds.
If G′ is part of weight of each load carried by each roller and μ 0 the kinetic coefficient of
friction, the frictional sliding force between the load and roller during time t′ is = G′ μ0 and the
work done by the load = G′μ0vt′ where v linear velocity of the load, and vt′ is the distance
moved by the load in time t′, represented by the area OEAF in Fig. 5.
The distance travelled by any point on the periphery of the roller during this time will be
vt′/2(area OAF), which is also the sliding path. This shows that half of the work done by load
is spent in overcoming the friction, and the other half is used in imparting kinetic energy to the
roller.
If ‘w’ is the weight of the rotating part of the roller, then its kinetic energy = (1/2)(w/g)(v2q).
Where q is a factor of value between 0.8 to 0.9, because not all the mass of the roller moving
parts is on the periphery, and thereby not moving with velocity v.
Therefore, the work done due to sliding and acceleration of one roller is given by
2 ×1/2 × (w/g) × v2q = wv2q/g
If there are ‘n’ number of rollers in a total length of ‘L’, then the total work done in ‘n’ number
of rollers will be = nwv2q/g for moving one load throughout the length of the conveyor. Hence
the average resistance to motion on one load due to sliding and acceleration will be given by,
F3′ = nwv3q/gL ...(iii)
If there are Z0 numbers of loads moving simultaneously on the conveyor, then average total
resistance due to sliding and acceleration will be,
F3 = Z0 nwv2q/gL ...(iv)
Therefore, total resistance to motion of the loads, which is the force required to move the loads
on a horizontal unpowered conveyor is
F = F1 + F2 + F3 = (G × k/R) + {(G + wn′) μr/R} + {q × (Z0 nwv2/gL)}...(v)
We can define the equivalent resistance to motion factor ‘f’ by an equation, F = Gf.
∴ f = F/G = (2k/D) + [{1+ (wn′/G)} × (μd/D)] + {q × (Z0 nwv2/gLG)} ...(vi)
where, D = roller Diameter = 2R
d = journal diameter = 2r
However, for calculating the minimum inclination angle ‘β’ of a gravity conveyor, which will
allow movement of a load due to gravity only, resistance to only one load need to be considered,
8|Page

which should be overcome by the component of the gravitational force on the load along the
inclination of the conveyor. Thus,
f = tan β = F/G′= (2k/D) + [{1+ (wn′′/G′)} × (μd/D)] + {q × (nwv2/gLG′)}...(vii)
where, n′′ = number rollers supporting each load =n′/Z0
G′ = weight of each load =G/Z0
Therefore, n′′/G′= (n′/Z0)/( G/Z0) = n′/G
tan β = (2k/D) + [{1+ (wn′/G)} × (μd/D)] + {q × (Z0nwv2/gLG)}...(viii)

4. Design Considerations
 The first three rolls will be designed for impact loading. The G will be considered to
be 400Kg. The entire weight may impact directly on one of the first 3 rollers. So, for
safety point of view, they will be heavy duty rollers (OD 105mm)[1] with axle
diameter 30mm.
 Pitch is 200mm. At any time, a minimum of 3 rollers will be in contact with the load.
 For maximum stability, the load was made to sit on the 500x300mm face
(length=500mm & breadth=300mm).
 The width of the conveyor should be larger than the width of the load (300mm). A
width of 500mm was considered for standardization.
 Jindal Pipes Limited’s Seamless and ERW Pipes & Tubes brochure is used for
selection of the black pipes.
 Jindal pipes do not manufacture OD 105 mm pipes. The next higher size is 113.1mm.
The 113.1 mm should be given a skin-cut to get 110mm as the final OD.
 The rest of the rollers should be medium duty rollers with OD 73 mm[1] with axle
diameter 20mm. Jindal pipes produce 75.3mm rough OD pipes. This pipe will be
skin-cut to 73mm OD.
 For standardization, all the axles taken should be 30mm. This will constrict the
necessity of different bore diameter bearings.
 As the OD of the bearings is less than the ID of the pipes, a bushing will be required
to keep the outer race of the bearing in place.
 Machining has to be done along the inner diameter of the pipe in order to push the
bearing inside.
 The part of the axle which is between the two bearings on either sided will be given a
rough surface finish and can have a diameter of more than 30mm. This will reduce
machining costs. The part of the axle in contact with the bearing will be given a good
surface finish and will have an exact diameter as the bore of the bearing. There will be
an interference fit between the inner race of the bearing and the axle. The part of the
axle outside the bearing will have a smaller diameter than 30mm. This will ensure that
when the bearing is fitted there is no rubbing between the axle and the bearing.
9|Page

 A cover will also be provided at the end of each roller. This will keep the outer race in
its required position and also protect the bearing from outside dust and dirt. The cover
is screw to the bushing.
 A grease nipple enclosed within the cover lubricated the bearings.
 A M24 nut holds the inner race in its place.
 An oil seal is also provide so that the oil doesn’t leak out.
 Medium duty roller diameter (OD 73mm) was taken into consideration for calculation
of the minimum inclination angle ‘β’ of a gravity conveyor because the smaller OD
corresponds to larger β. If the β is chosen to be large it will also roll for the heavy
duty rollers.
 The angle of inclination was taken slightly more than the minimum inclination angle
‘β’ and this will give rise to an acceleration. The last rollers were kept flat so that it
deaccelerates the load.
 To fix the axles to the frame, rectangular grooves will be made on the angle iron and
the opposite sides of the stepped axle will be flattened. This will restrict any rotational
motion. A groove is also made on the axle and a clip which fits the groove is screwed
on the angle iron. This restricts any vertical motion.
 MS C-sections will form the stands of the rollers. Both ends of the C-sections will be
welded to a steel plate. This steel plate will be bolted to the angle iron.
 The steel plate at foot of the C-sections will be bolted to the foundation using
foundation bolts.

5. Calculations
5.1 The minimum inclination angle ‘β’ of the gravity conveyor:
Pitch = 200mm
Total length of the conveyor = 4 metres = 4000mm
Number of rollers necessary = 4000/200 = 20
Volume of the 73OD pipes = π/4 × h × (D12-D22)
= π/4 × 500 × (732-652)
= 433539.79mm3 = 433.5398cm3
Weight of the rotating part of the roller = density of steel × Volume
= 7.8 × 433.5398
= 3381.61g = 3.382 kg
tan β = (2k/D) + [{1+ (wn′/G)} × (μd/D)] + {q × (Z0nwv2/gLG)}
k = rolling friction factor (wood-steel) = 0.0012m = 1.2mm
D = roller diameter = 73mm
10 | P a g e

w = weight of the rotating part of the roller = 3.382 kg

n′= 3
G = total load = 200kg
μ = coefficient of friction at the journal = 0.5
d = journal diameter = 30mm
q = factor of value between 0.8 to 0.9, because not all the mass of the roller moving parts is
on the periphery, and thereby not moving with velocity v = 1 (assumed)
Z0 = numbers of loads moving simultaneously on the conveyor = 1 (assumed)
n = number of rollers= 20
v = linear velocity of the load = 0.2 m/s (assumed)
g = acceleration due to gravity = 9.81 m/s2
L = total length = 4m
tan β = (2k/D) + [{1+ (wn′/G)} × (μd/D)] + {q × (Z0nwv2/gLG)}
= (2×1.2/73)+[{1+(3.382×3/200)}×(0.5×30/73)]+{(17×3.382×0.22)/(9.81×3.5×200)}
= 0.249
β = 13.98 ° ≈ 14 °
5.2 Bearing Selection:
For simplicity, deep groove roller bearing is used.
The relationship between the dynamic load carrying capacity, the equivalent dynamic load
and the bearing life is given by,
L10 = (C/P)p
P = equivalent dynamic load
L10 = rated bearing life (in million revolutions)
p = 3 (for ball bearing)
The relationship between life in million revolutions and life in working hours is given by,
L10 = 60nL10h/106
L10h = rated bearing life (hours)
n = speed of rotation (rpm)
P = (Wt. of load +Wt. of rollers) × 9.81 = (400+6.43) × 9.81 = 3987.07 N
v = πDn/60
=) 0.2 = (π × 0.105 × n)/60
11 | P a g e

=) n = 36.38 rpm
L10h = 20000
L10 = 60 × 37 × 20000/106 = 44.4
C = 3987.07 × (44.4)1/3 = 14118.27 N
From SKF bearing catalogue, a bearing is chosen with the nearest C value:
Bore Diameter = 30mm, Outer Diameter = 62mm, Width = 16mm, C = 19500 N,
Designation=6206
12 | P a g e

References
[1] Dr. Siddhartha Ray, “Introduction to Materials Handling”, New Age International
Publishers, 2013 ed.
[2] “Design of Machine Elements” by V B Bhandari, McGraw Hill Education, Third edition.
[3] “Machine Design Data Book” by V B Bhandari, McGraw Hill Education, 2014 edition.

Data References:
[4] The value of k, rolling friction factor, is taken 0.0012m from this webpage:
http://www.roymech.co.uk/Useful_Tables/Tribology/co_of_frict.htm
[5] Kinetic coefficient of friction, μ, is taken to be 0.5: http://www.tribology-
abc.com/abc/cof.htm
[6] The ID of the 73mm pipe is taken to be 2.469 inches:
http://www.mcnichols.com/?pageCode=pipedims
[7] Density of Steel: http://www.thyssenkruppaerospace.com/materials/steel/steel-sheet-
plate/weight-calculations.html
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