iLenSys - Material Handling Equipment Design and Application Engineering

Overview

iLenSys provides a range of design engineering services to meet customer requirements for both unit and bulk material handling equipment design. We offer end-to-end product design services from conceptualization to the final product. Our design solutions consist of broad applications of solid-state electronic control, scanners and other control devices to provide on-line or “real time” data on the status of equipment and materials in an operation.

Sectors

Steel Plant

Power Plant

Cement Plant

Aggregate & Quarry

Shipping Industry

Stockyard

Services to EPIC

Food and Packaging

Standards

CEMA, IS 11592 (Conveyor design).
ISO:3684 – Conveyor belts (Determination of pulley diameters).
BS:2573 I, II – Crane Design.
ISO:5048, ISO:5049 (Mobile equipment continuous handling).
DIN 22261 & AS4324.1 – Mobile Equipment for Continuous Handling of Bulk
Equipment (Excavators/spreaders).
FEM Standards 2.131/2.132 – Rules for the design of Mobile Equipment for Continuous
handling of Bulk Materials.
AWS D1.1 – Structural Welding.
Mechanical / Structural / Hydraulic / Pneumatic / Electrical and Electronics Engineering.
Analytical Modeling and FEA – (Static/Dynamic).
Progressive Computer-aided Design, Development, And document support.
Product Optimization.
Control Designing & PLC , HMI Automation.
Field Failure Analysis And Design Support.
Digital Manual Preparation.

Conveyor Design

Designing of Troughed Belt Conveyor.
Design Components used for Horizontal Conveyor, Inclined (Uphill) Conveyor, Steep Conveyor & Declined (Downhill) Conveyor.
Design of Conveyor drive power, Gearbox and Coupling for Conveyors.
Design of Head and Tail Pulley, Belt Scrapper, selection of Idler sizes, their location & bearings.
Selection of Belt for Conveyor as per Material Characteristics like Lump size, Density etc.
Design of inlet and outlet chute with Skirt Board.
Provide Conveyor with all Safety Switches like Belt Sway, Speed Switch, Protection, Track Metal Detector etc.

Apron Feeder

Design of Impact tray, Carrying Rollers, Return Rollers as per Material Characteristics.
Frame Design through FEA and Manual Calculations.
Selection of Bearings Sealed for life, Purgeable dust seal & spherical roller bearings with Cast steel Plummer block, high precision link chain/ crawler chain, Manganese alloy sprockets.
Variable speed Hydraulic Pump Drive & Hydraulic Power pack for Pulley & Dribble Drag Chain.
Overload Safety Device, Speed Sensor, Apron weigh Feeder and Automation control.
Centralized or Manual Lubricating System.

Tripper

Design of Tripper Structure to support Conveyor components, Long travel Drive, Cable Reeling Drum etc.
Design of tripper components as per Material Characteristics like Head/Drive Pulley, Bend Pulley, Take-ups, Scrapper, Belt alignment.
Design of Chutes and Flap Gate with Actuators.
Design for Long Travel Drive Power, Gearbox, Brake & Coupling Wheel, Axle, Plummer Block.

Stacker

Design of heavy Structure like:
- Equalizer beam & bogies
- Undercarriage
- Superstructure & Pylon
- Reversible boom
- Counterweight arm and tie arm
- Counterweight structure
- Electrical machine air-conditioned platform
- Operator’s cabin with hydraulic & mechanical controls
- Bucket wheel
- Maintenance Walkway and access to platforms etc.
Design of balancing of machine

Belt Feeder

Designing the sizes and shapes of Vibrating Feeders and recommended frequencies with corresponding range of amplitudes.
Design of weld free bootable steel Structure as per material characteristics like Fabricated Plate Framework mounted on either base or Suspension spring mounted.
Selection of Screen Openings for Single or Multiple Deck, wire Cloth or Polyurethane Screen Media, etc., & Tensioning rails.
Selection of drive, helical springs, suspended or cable, air mount, eccentric mass, shaft, flywheel, “V” belt, sheave or pulley and special heavy-duty taper roller antifriction bearings.
Entire assembly securely locked with tightly fitting SAE machined huck bolts.

Bucket Elevator

Designing and Selection of bucket sizes, Bucket Spacing for centrifugal discharge & high-speed elevators as per material characteristics.
Selection of Drive Head, Bottom Head Pulley and Chain or belt.
Design of inlet and outlet chute with supporting frame and Casing.
Drive Calculations, selection of Motor and Gearbox.
Design of rigid structure & take-up.

Crusher

Selection of Appropriate Crusher for given application, size and Gradation of Feed, Material Characteristics, Surge or peak loads.
Selection of Optimum drive power required for crushing application
Selection drive component and its mounting on structure.
Design of heavy reinforced structure for crusher through FEA.

Other Industries

Medical Devices & Equipment
Our solutions addresses regulatory compliances right from product ideation to marketing in the volatile market
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Scientific Instruments
Leverage our deep expertise in hardware, firmware and software design for instruments.
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Life Sciences
Our understanding on technologies helps in reducing manufacturing costs, improving robustness in design.
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Static & Mobile Equipments
We specialize in considering critical safety aspects during the design of static and mobile equipment.
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Material Handling Equipment
We prioritize critical usage conditions, applications, and standards in our material handling equipment designs.
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Services

Mechanical Engineering
We work on Core Disciplines and follow an agile approach and add value in our engagements
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Embedded Systems
We offer small form factor designs to multi-board system designs.
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Industrial Automation
Services for PLCs, HMI, Motion Controllers, Servo Amplifiers, VFD and Plant automation is offered.
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Regulatory Compliance
Services from compliance management, risk mitigation for medical device manufacturers to meet global market regulations
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3D Immersive Tech
Virtual reality (VR), augmented reality (AR) and Mixed reality connect the virtual and physical worlds. They allow you to visually absorb information
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Technical Documentation
Reach us for a comprehensive product/process documentation to different stakeholders.
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Early Engineering Talent (EET)
We engage with Global Captive Centre’s by addressing Talent Crunch in Electronics and Mechanical Engineering domains.
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News & Updates

The "News & Updates" section features the latest developments and innovations in our services and solutions, including engineering services, product compliance, environmental regulations, Obsolescence Management, and regulatory & product safety.

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iLenSys Obsolescence Manager 21 Oct 2024

IIOM International Symposium United States 2024 conference

iLensys is excited to announce our participation in IIOM 2024! Join us as we explore our comprehensive obsolescence

iLenSys Compliance Manager 21 Oct 2024

FORUM24 | EHS & Sustainability Management Forum

Drive greater business value for your EHS and Sustainability programs with innovative solutions

iLenSys Compliance Manager 14 Oct 2024

PSX 2024 Product Stewardship Society

Join us at PSX 2024 for an enlightening session on the latest updates in global product regulatory changes and PFAS reporting.

Resources you might be interested in

Blogs

Benchmarking and Value Analysis

Product benchmarking is a valuable tool in value analysis and value engineering (VE) that involves

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Whitepapers

Global Trade Meets Climate Change: Carbon Border Adjusted Mechanism (CBAM)

The Carbon Border Adjustment Mechanism (CBAM) is a transformative EU policy designed to curb global emissions

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Webinars

Design-Led Supply Risk Management

Join our webinar, “Design-Led Supply Risk Management,” to discover how design plays a pivotal role in High-Mix, Low-Volume (HMLV) manufacturing. Gain insights into the unique challenges HMLV manufacturers encounter and learn how strategic design decisions can enhance supply chain resilience and support the product lifecycle. We’ll also explore how design collaborates with other functions to drive innovation and improve efficiency.

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Videos

Understanding PFAS - The Forever Chemicals

Explore the pervasive presence of PFAS, their impact on our homes and environment, health risks, and the regulations in place to control them.

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Case Studies

Hydrogen City

The global leader in CO2 products and services aimed to promote their hydrogen infrastructure by

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iLenSys Technologies Pvt. Ltd.

8-2-293/82/L/231/ABC,
MLA Colony, Road No: 12, Banjara Hills,
Hyderabad, Telangana 500 034
Phone: 040 – 66998246, 040 – 66998234
Email: info@ilensys.com

Efficient Material Handling Solutions