Finite Element-Based Design and Performance Evaluation of a Chain Conveyor Grid Feeder for Non-Value-Added Reduction in Battery Manufacturing

Timotius Anggit Kristiawan; Rosyadul Muzzaqi; Farika Tono Putri; Mochammad Ariyanto

doi:10.22441/ijimeam.v8i2.38756

Authors

Timotius Anggit Kristiawan Politeknik Negeri Semarang, Indonesia http://orcid.org/0009-0008-4054-4586
Rosyadul Muzzaqi Politeknik Negeri Semarang, Indonesia
Farika Tono Putri Politeknik Negeri Semarang, Indonesia http://orcid.org/0000-0002-3563-6389
Mochammad Ariyanto Universitas Diponegoro, Indonesia http://orcid.org/0000-0001-8125-6742

DOI:

https://doi.org/10.22441/ijimeam.v8i2.38756

Keywords:

ANSYS, chain Conveyor, FEA, Line Balancing, NVA, Solidworks

Abstract

Non-value-added (NVA) waiting time in the grid-feeding process of battery manufacturing is caused by the limited capacity of the existing paster machine input conveyor, resulting in production flow interruptions and reduced operational efficiency. Although finite element analysis (FEA) has been widely applied for structural verification of industrial equipment, limited studies have integrated structural validation with operational performance evaluation to address production inefficiencies in battery manufacturing. To address this gap, this study proposes a chain conveyor grid feeder and introduces a cross-platform FEA approach by combining ANSYS Workbench and SolidWorks Simulation with in-situ industrial validation, thereby providing both numerical verification and practical evidence of production performance improvement. This study proposes and evaluates a chain conveyor grid feeder by integrating cross-platform FEA using ANSYS Workbench and SolidWorks Simulation with in-situ operational validation. The methodology includes CAD-based design, linear-static structural analysis under the maximum loading condition using ASTM A36 material properties, followed by fabrication, production-line implementation, and before–after performance evaluation. The FEA results indicate maximum von Mises stresses of 55–57 MPa for the frame subsystem and 60–73 MPa for the conveyor subsystem, both remaining below the ASTM A36 yield strength (250 MPa). The corresponding maximum deflection ranges from 0.41 to 1.09 mm, with minimum safety factors ranging from 2.30 to 4.54, confirming adequate structural reliability. Operational validation further demonstrates that NVA waiting time was reduced from 124.33 s to 0 s, while operator requirements decreased from two to one across two production lines. These findings demonstrate that integrating cross-platform FEA with industrial implementation provides an effective framework for achieving both structural reliability and measurable improvements in production efficiency.

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