1.

CONVEYOR DATA:
BC01
Qo =
Working Capacity:
40.00
Design Capacity:
Q=
50.00
Conveyed Material:
Mix
Material Density:
d=
1.20
Belt Width:
B=
500.00
Belt Speed:
v=
0.90
=
Troughing Angle:
20.00
Conveyor Length (distance between pulleys):
L=
28.50
Elevation between pulleys:
H=
2.90
Conveyor inclination:
slope = H/L
=
asin(slope).180/
Inclination angle:
L =
Highest Inclination Angle (local):
15.00
2. CAPACITY CONTROL:
Belt width coefficient:
b=
(0.9xB/1000)-0.05
Capacity reduction coefficient due to inclination ; Given for different inclination angles in DIN 22101.
Capacity reduction coefficient:
k=
0.90
Material crossection coefficient:

ck =

0.122

Theoretical volume flowrate:

Theoretical capacity:
Conveyor filling ratio (normal operation):
Conveyor filling ratio (design operation):
3. MOTOR POWER CALCULATION:
Belt weight:
Carrying idler weight:
Return idler weight:
Total weight of belt and idlers:
Friction coefficient:
C coefficient: (DIN 22101)
Total friction coefficient:
Drive system efficiency:

Qm =
Qt =
kdor =
kdord =

ck.b .3600.v
Qm.d.k
Qo/Qt
Q/Qt

Gb =
Gt =
Gd =
Gm =
f=
C=
ftop =
=

9.20
9.00
3.00
2.Gb+Gt+Gd
0.025
2.90
f.C
0.85

Fu =
Pv =
Pb =
Pyol =

ftop.L.(Gm+(Q/(3.6.v)))+(Q.H)/(3.6.v)
(Fu.v)/(102)
Q.v2/3600
Pv+Pb.1.1

a) Power Calculation:
Drive pulley peripheral force:
Full load inertia power:
Acceleration power:
Movement power:

t/h
t/h

1.25
3

t/m
mm
m/s
deg
m
m

slope = 0.10
=
15.00

deg

b=

0.4

Qm =
Qt =
kdor =
kdord =

63.24
68.30
0.59
0.73

m /h
t/h

Gm =

30.40

kg/m

ftop =

0.073

Fu =
Pv =
Pb =
Pyol =

139.45
1.23
0.01
1.24

kg
kW
kW
kW

kg/m
kg/m
kg/m

Scrapper and loading hopper power losses should be added to movement power.
Quantity of scrappers:
Length of loading hopper:

ns =
Lyk =

Power loss due to scrapper:

Psy =

Psy =

1.35

kW

Power loss due to loading hopper:

Pyk =

0.075.Lyk.v

Pyk =

1.08

kW

Motor power:

Pmot =

(Pyol+Psy+Pyk).(1/)

Pmot =

4.32

kW

3.32

rad

Te =

685.41

kg

T1 =

1087.57

kg

T2 =

402.17
400.05
420.05

kg
kg
kg

b) Determination of the motor power:

Required motor power:
Selected motor power:
3. BELT CALCULATION:
Drive pulley wrap angle:
Friction coefficient between drive pulley and belt:
Factor of safety :
a) Belt Tension:

1
16.00

m
ns.v. 1.5

Nmotr = 1.4.Pmot
Nmotr = 6.05
Nmot = 7.50

kW
kW

=
=
Kb =

190.00
0.30
12.00

Effective tension:

Te =

Nmotr.(101.9716)/v

Drive side belt tension:

T1 =

Te.(e /(e -1)

T2 =
Tail side belt tensions:

T3 =
T4 =

deg

Te.(1/(e -1)
T2-H.Gb+ftop.L.(Gb.cos+Gd)
T3+20

T3 =
T4 =

b) Belt selection:
Max. belt tension:

Tmax =

(T1/B).10

Tmax =

21.75

kg/cm

Belt tension:

Bg =

Tmax.Kb

Bg =

261.02

kg/cm

Selected belt type:

Top cover thickness:
Bottom cover thickness:
Belt thickness:
4. PULLEY CALCULATION:
a) Selection of pulley diameter:
Drive pulley diameter (including lagging):

EP315
tt =
tb =
t=

3xEP100
3 mm
2 mm
8 mm

Bmax =

31.50

kg/cm

Dt =

400.00

mm

Weight of the drive pulley:

Tail pulley diameter:

Wt =

260.00
320.00

kg
mm

n=

42.97

rpm

R=

1512.26

kg

Weight of the tail pulley:

Dk =
Wk =

170.00

kg

Take-up pulley diameter:

Dg =

n/a

mm

Weight of the take-up pulley:

Wg =

n/a

kg

Drive snub pulley diameter:

Dts =

n/a

mm

Weight of drive snub pulley :

W ts =

n/a

kg

Tail snub pulley diameter:

Dks =

n/a

mm

Weight of the tail snub pulley:

W ks =

n/a

kg

Take-up snub pulley diameter:

Dgs =

n/a

mm

Weight of the take-up snub pulley:

W gs =

n/a

kg

b) Rotational speed of drive pulley:

n=

(v.60.1000)/(.Dt)

c) Material properties of the pulley shafts:

Pulley shaft material
Safety shear stress for the shaft material:
Factor of safety for bending:
Factor of safety for torsion:
d) Drive pulley shaft diameter calculation:
Shaft loads and shaft diameters:
Resultant load on the pulley:
Distance between hub and bearing:

SAE 1040
em =
500.00
Ceg =
1.50
Cb =
1.10

kg/cm

2 1/2

Bending moment:

R=
e=
Meg =

18903.25

kg.cm

Mb =

(R/2).e
97376.Pmot/n

Meg =

Torsion:

Mb =

13708.19

kg.cm

Bigger diameter of the drive pulley shaft:

(at the point where loads applied to)

dth1 =

(16/(.em).((Ceg.Meg)2+(Cb.Mb)2)1/2)1/3

dth1 =

6.89

cm

dth2 =
dth2 =
Smaller diameter of the drive pulley pulley shaft:
(16/(.em).(Cb.Mb))1/3
(at the point where the shaft driven)
Determination of shaft diameters and selection of the bearings (selected according to gear hollow shaft):
dt1 =
Selected bigger shaft diameter :
80.00
mm

5.36

cm

R=

837.53

kg

Meg =

10469.12

kg.cm

dkh1 =

5.43

cm

((T1+T2) +W t )
25

cm

Selected shaft smaller diameter:

dt2 =

70.00

mm

Selected shaft bearing diameter:

dty =

75.00

mm

R=
e=
Meg =

((T3+T4) +W k )
25

e) Tail pulley shaft diameter calculation:

Shaft loads and diameters:
Resultant force on the pulley:
Distance between hub and bearing:
Bending moment:

2 1/2

(R/2).e

dkh1 = (16/(.em).(Ceg.Meg))1/3
Tail pulley shaft diameter:
(at the point where the loads applied to)
Determination of shaft diameters and selection of bearings:
dk1 =
Selected shaft diameter :
60.00
Selected bearing diameter:

dky =

cm

55.00

mm
mm

5. DETERMINATION OF DRIVE EQUIPMENT:

a) Motor:
Required motor power:
Selected motor power:
Rotational speed of the motor:
b) Gear reducer:
Gear reducer service factor:
Rotational speed of drive pulley:
Selected output rotational speed :
Selected gear reducer :

Nmotr = 6.05
Nmot = 7.50
nmot = n/a

ired =
n=
nr =

kW
kW

2.6
42.97
43
KA97DRE132MC4

rpm
rpm