ALTERNATIVE MECHANISM FOR UNLOADING

PRODUCTS FROM TRUCKS

ABSTRACT
In an alternative way of approach towards the Unloading of all kinds of products from
Lorries currently operating either on the Hydraulic Lifting mechanism or manual efforts, a yet
another rapid and reliable process of Unloading of products is proposed in this paper.
The Floor of the truck body is divided into number of Slabs with rollers under them
similar to the trolleys. Trolleys carrying products are mounted over the Conveyor chains. The
proposed method utilizes the method of Conveyors which receives its Work input from the
Engine through the TRANSFER CASE, connected to the Engine which continuously drives the
Conveyor Chains down to the ground. The Conveyor Chains are also capable of moving in the
reverse direction once the Unloading process is over, by the engagement of the Reverse gear.
This method is Economical and can be applied to Load and Unload any product with high
degree of safety. The mechanism is relatively fast as the Lifting Mechanism and also provides
safer method of Unloading. The detailed Design of the System is discussed in this paper.

CONSTRUCTION OF THE MECHANISM

TROLLEYS : The Trolleys are mounted over the Conveyor Chains through small rollers or
wheels and they are arranged much closer as possible to prevent the leakage of sand through
gaps. They may be kept in a slightly higher number inorder to make them get down easily at the
bent portions.The Trolleys are interconnected by metal strips or chain links as in Train
compartments. This enables the system to return to its original position once the Gears are
reversed.
CONVEYOR SYSTEM

Conveyors are used as components in automated distribution and warehousing. It is

considered a labor saving system that allows large volumes to move rapidly through a process,
allowing companies to ship or receive higher volumes with smaller storage space and with less
labor expense
Chain conveyors are generally fairly similar in construction consisting of a metal frame
with rollers at either end of a flat metal bed. The Chain is looped around each of the wheels and
when one of the wheel is powered by the Motor Drive. The Chains slide across the solid metal
frame bed, moving the product. In heavy use applications the beds which the Chain is pulled
over are replaced with rollers. The rollers allow weight to be conveyed as they reduce the amount
of friction generated from the heavier loading on the Chains. The required size of the Conveyor
systems is designed in the later part of the paper.
MOTOR DRIVE
The Motor drive is essentially of the Gear-Box type which allows it to be connected to the
Engine whenever required and also enables reverse movement. It runs the Driving wheel of the
arrangement. It consists of Bevel Gears and all essential gears so as the Engine output is
transmitted to it effectively with minimized losses .It utilizes the Transfer Cases inorder to obtain
power from the Engine.
REAR RELEASE DOOR
The door is also provided with rails inorder to guide the Trolleys down to the
ground. The door is usually of high lengths capable of touching the Ground to provide stability.
The door is mounted in such a way that the Trolleys immediately after leaving the Conveyor
Chains slips into the rails of the Rear door. It is also fairly made of the same material of floors to
take care of the loads.
CONSTRUCTION OF THE SYSTEM
(Wheels are not shown and only the platform of the Truck is indicated)

OPERATION OF THE SYSTEM

The entire operation starts with opening of the release door at the rear side of the
Lorry. The Door is opened fully such that its lower end touches the ground.

REAR RELEASE DOOR OPENED AND THE TROLLEYS ARE READY TO MOVE
DOWN
Then the Motor drive is connected to the Engine by the Transfer case and hence the
Sprocket wheels are rotated and the Trolleys are moved on the track. Hence the Trolleys will be
moving over the conveyor chain until the end of platform i.e the Lorry Body and the rollers
begin to travel on the rails in the release door once the platform end is reached. The rear door is
mounted carefully to ensure this engagement of rollers.
Hence the slope provided enables the evacuation of the products in the Trolleys. It is to
be noted that atleast a part of first Trolley needs to be attached to the Conveyor Chain so that
they can be reversed. Once the product is unloaded the Motor Drive is reversed and the Trolleys
return to the initial position.

TROLLEYS DOWN TO THE GROUND

PROOF OF CONCEPT:
SPECIFICATIONS OF THE TRUCK
Capacity

21 Tonnes

Wheel Base

2600mm

Front Overhang

1275mm

Rear Overhang

400mm

Centre Line of the Front Axle

150mm

Frame Height from ground

1100mm

Cab Height

3200mm

Width across Rear Tyres

2500mm

to back of Cab

ENGINE:
240 BHP , 6.9 L
Expected Performance : 240 BHP at 2400 rpm
925Nm at 1200-1750 rpm
FRAME:
Material

High Tensile Steel

Section

270*85*25 mm

Width

920 mm

WHEELS and TYRES:

295/80R 22.5
BODY COMPARTMENT:
Dimensions

2800*2500*2400mm

Maximum Volume that can be utilized

2.4*2.5*2.2m

13.2 m^3

Base Plate

: 20 mm Thick ST-52

Height of Rear Door

: 2400mm

LAYOUT OF THE TRUCK

SIDE WALLS NOT SHOWN

VEHICLES BOTTOM VIEW WITHOUT WHEELS

TRANSFER CASE:
As the trolleys are pushed forward the Repulsive force might not be sufficient to keep the
momentum going on. Hence a Motor Drive, run by the Lorry Engine is needed to keep moving
the Trolleys by running the Conveyor. Here the Motor Drive is the Transfer case.
Transfer Case are usually used in Four Wheel Drive (FWD) Vehicles and it delivers
power to the both the Front and Rear Axles. The interesting fact of the transfer case is that it
provides the option to switch between 4WD and FWD whenever required. By making use of
this capability of the Transfer case, the output energy that is supposed to be given to the FWD
can be utilized to run the Conveyor thereby making use of the powerful 240BHP Engine
effectively.
There are two different types of "internal workings" found in most transfer cases

Chain

Driven and Gear Driven. Our purpose can be served by the GEAR-DRIVEN TRANSFER CASE
inorder to cope up with the High Power and Torque to be transmitted from the 240 BHP engine.
Gear-driven transfer cases use sets of gears to drive either the front or both the front and rear
driveshafts.
PROPOSED STRUCTURAL MODIFICATION FOR TRANSFER CASE:
Usually Transfer cases are built in RWD platform so that only the Front Axle is
disconnected optionally whereas the Propeller shaft remains connected always. But for our
purpose the Propeller Shaft has to be disconnected temporarily so that the Vehicle is does not
move while unloading and the Motor Drive of the Conveyor is connected to the Engine by
Transfer Case. The engagement of the Conveyor Drive could be achieved by means of
ELECTROMAGNETIC CLUTCH and this option is given in the Driver Compartment.But the
target of disconnecting the Propeller Shaft can be achieved by means of AXLE SHIFT MOTOR

fixed to the Rear end of the Transfer Case.

AXLE DICONNECT SYSTEM VACUUM OPERATED

The axle shaft on the long side of the axle is actually in two pieces. The two shafts come
together where the vacuum motor and shift fork are located. One shaft has a small hole in the end
that has a small needle bearing inside. The other shaft has a little "nub"/ bearing race, which fits
into the hole of the other shaft. The ends of the shafts have large splines where two meet and has
a shift collar that slides on the splines to connect/disconnect the two shafts together. The collar is
connected to the vacuum motor via the shift fork.
So the inclusion of the Axle Shift Motor to the Propeller Shaft and Engagement of the
Electromagnetic Clutch is proposed while Unloading Sand from the Truck.
CONVEYOR DESIGN
Let us assume that Dry sand of density 1602 kg/m^3 is filled upto a volume of
2.3*2.5*2m. Then the Total load of sand in the Truck is

18423 kg

The Conveyor chain design is done with above assumption and a overall capacity of 21
Ton is considered. With the input reduced speed as 200 rpm and let us assume the engine delivers
60kW power.
Centre distance of the Conveyor Chain Drive be
a=2400mm
Let

a=49 p

Where p is the pitch

Therefore

p=2400/49=48.97mm

Nearest available pitch is 50.8mm ,

The Transmission ratio of the Conveyor is 1, as both wheels move with same speed

i=1

Let the number of teeth on the Driving Sprocket wheel be taken as Odd number
Z1 = 29 teeth
Driven Sprocket

Z2 = 29 teeth

Load on the Chain

Where

Q = P*Ks*Kn /V

P= Power to be transmitted kW
Ks= Service Factor =1.875 (from Data Books)
Kn=Factor of safety=14.625
V= Velocity of Chain=Znp/60000=4.91m/s

Sub the Values,

Q=335094 N+210000N=545094N
The Chain capable of withstanding this load is ISO 32A-3 (ANSI 160).
ISO 32A-3 (ANSI 160)
(Triplex chain)
From the Nomenclature of Chains,
Approximate Centre distance in multiples of Pitch ap = a/p= 47.24
No of links

N= 2ap+((Z1+Z2)/2)

Sub the values

N= 124

Length of Chain Lp = N * p = 50.8*124=6299.2mm=6300mm

Centre Distance after allowing 2% sag = 2408.17mm=2409mm

Sprocket Diameter D= p/sin(180/Z)

D

= 470mm

From data Book ,

Total weight of Chain =190kg

SPECIFICATION CHART FOR THE CONVEYOR DRIVE

ISO 32A-3 (ANSI 160)

Number of Links
Length of Chain
Weight of Chain
Centre Distance
Sprocket Material
Sprocket Teeth
Sprocket Diameter
Root Diameter
Roller Seating Radius
Sprocket Width
Weight of Sprocket

=
=
=
=
=
=
=
=
=
=
=

124
6300mm
190kg
2409mm
Medium Carbon Steel
29
470mm
441mm
15mm
152mm
190 kg

MOUNTING OF THE CONVEYOR SYSTEM

The Driving end of the Conveyor can be fitted to the frame of the truck by means of
Bearings. The Shaft runs transversely with TAPER ROLLER BEARINGS on both the ends.
The Sprocket wheel are mounted on the Shaft. By Calculations Shaft of 75 mm Dia is
required to take on the Loads. The Driven end is also mounted on the same manner at the
Rear end.
ADVANTAGES
In addition to Soil and Sand other products such as Cement bags, Bikes, Cars and any other
product can be LOADED as well as UNLOADED safely with high degree of care and
smooth transitions.
Unloading even under Steep slopes
Low maintenance cost involved as only Lubrication of the Conveyor Chains and movable
parts is required

 The Truck may be unloaded at even slanting positions and Non-Level grounds, as the
system avoids the danger of ROLLING which is more prevalent in Tipper Trucks and
hence avoids Fatal Accidents

As the Transfer Cases are used the Truck may be converted into a FOUR WHEEL
DRIVE Truck with less additional cost
Noiseless unloading and Transmits less shocks to the products
Very rapid process of unloading
As there is no conversion of Energy from Mechanical to Hydraulic and again Hydraulic
to Mechanical as in the current systems the overall efficiency of the system increases
considerably
CONCLUSION
Thus this mechanism can be used efficiently under all conditions to perform Unloading
of all kinds of products with suitable provisions. It is also as economical as compared to the
currently available Trucks. The effort towards this method of Unloading will be also very much
useful for transportation within the Factories and industrial areas in addition to other Fruitful
products for unloading.
REFERENCES
AUTOMOTIVE TECHNOLOGY by Jack Erjavec
THE MOTOR VEHICLE - Thirteenth Edition T.K. GARRETT
INSTALLATION MANUAL - Field practices for Escalators by National Elevator
Manufacturing Company

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