Conveyor

Introduction
Material transportation/handling methods are
normally classified into 3 main groups ( from the
standpoint of mechanics involved);

Continuous methods

Semi-continuous, or small batches methods and

Batch methods

 Some example of material transportation/handling

equipments and techniques:

Belt conveyor (penghantar tali sawat)

Chain conveyor (penghantar rantai)
Screw conveyor and feeder (penghantar skru dan penyuap)
Suction pipe (paip sedutan)
pressure pipe (paip tekanan)
suction pneumatic
pressure pneumatic
Monorails
bucket elevator
aerial ropeway
Chute
shaker conveyor
Locomotive
Hoists and lift

Belt Conveyor (penghantar tali sawat)

Chain conveyor (penghantar rantai)

Bucket elevator (pengangkat timba)

Shaker Conveyor (penghantar bergetar)

Suction Pipe (paip sedutan)

Screw Conveyor (penghantar skru)

Locomotive Haulage

Hoist

Mine Winder (pengangkat lombong)

Chute

Lecture 2

Belt Conveyor (Talisawat Penghantar)

Belt conveyor is basically an endless strap stretched

between two drums.

Suitable for very short distances and low outputs.

It is necessary to support the top strand of the

conveyor at regular intervals to prevent undue

sagging and to reduce the spillage of material which
may occur if the belt does not run truly, while
maintaining a high carrying capacity.

these requirements usually met by trough idlers.

 Idler (Pemelahu)
Consist of three separate rollers to support the belt
and also bend it into a trough shape.

The two
outer rollers are tilted upwards at an angle
o
o
of 25 to 30 .

For very wide belts a design using five separate

rollers is sometimes used.

For narrow belts two angled idlers only may be

used.

impact idlers = Pemelahu hentaman

trough idlers = Pemelahu paluh
return idlers = Pemelahu kembali

Top strand
(Lembar
atas
)

Bottom strand
(Lembar
bawah
)

Idlers for small conveyor belt

Material

Belt Conveyor
(Talisawat Penghantar)

Normal Trough Idler (three idlers)

Pemelahu paluh yang biasa (tiga pemelahu)

Belt Conveyor

Trough idler

Idler for wide belt conveyor (five idlers) Pemelahu untuk

talisawat yang lebar (lima pemelahu)

Feed Chute
(Pelongsor suapan)

Top Strand
(Lembar atas )

Trough Idler
(Pemelahu Paluh)

Impact Idler
(Pemelahu
Hentaman )

Drive Drum
(Gelendung Pemacu)

Idler Drum (Gelendung

Pemelahu )
Return Idlers
(Pemelahu Kembali )

Bottom Strand
(Lembar bawah)

Exercise 1

Lecture 3

 The driving drum relies on the friction between drum and belt to
provide the drive to the belt.
If the two tensions in the belt at the driving drum are P1 and P2 with
P1 the bigger tension in the top strand, the limiting ratio of tensions
when about slip is about to occur is given by:
P1
P2

P1 / P2 = e
Log10 P1 / P2 = 0.434
is coefficient of friction or coefficient of grip between the belt & drum
Is the angle of wrap

 For a long conveyor with a large hauling duty P1 requires to be

large.
Value of P1 possible is obtained by three method:
Increasing by lagging the driving drum with a suitable
rubber-like material.
Increasing the value of
Increasing the value of P2
No slip P1/ P2

The value of can be increased by:

=1 +2

o 450
=40~

=o250

1
=1 +2 +;
3

o 0
1. Using a snub pulley
= ~6

2.

2
3

Using more than one

. driv

The value of P2 can be increased by

3. pre
-tensioning
belt

By a screw
tightening device at the tail end o
conveyor

Tension

Driving
drums

Rail mounted carriage

2. Take
-up loop
as part ofstorage
a belt or
uptake
loop

Driving
drums

Weighted roller

3.

Gravity tensioning device

For higher powered conveyors a gravity oper

used, either by pulled via steel
-upcables
carriage
on t
or by a heavy roller mounted in a frame

Pelongsor suapan
(feed chute)

Lembar atas
(top strand)

Pemelahu
Hentaman
(impact
idler)

Pemelahu Paluh
(trough idler)
Gelendung Pemacu
(Drive drum)

Gelendung Pemelahu
(Idler drum)
Pemelahu Kembali
(Return Idlers)
Lembar bawah
(Bottom strand)

Kapi ambil
(take-up
Pulley)
Berat
Pengambang
(Counter weight)

Factors affecting the use of belt conveyors

1.

2.

A straight line plan is usually required (some small deviations of a few

degrees are possible). If the line of the conveyor system must be angled
it is often necessary to use separate conveyors but some systems have a
complex belt lacing which permits a fix angle at some point in the
conveyor, the material being discharged from one section of the belt to
the other as if the two sections were separate conveyor.
The angle of inclination of the conveyor is limited by the friction of the
material on the belt, to about 25o. The maximum gradient used for a
conveyor must allow for restarting with the belt loaded on the incline
and sufficient frictional grip must be provided to overcome the
component of the weight tending to pull the material down the belt
and also to accelerate the material.

3. The maximum lump size is limited to about half the

belt width.
4. The carrying capacity of the belt depends on how the
material can be piled up on the belt width. As the belt
is continuously passing over sets of supporting idlers,
the materials is slightly disturbed all the time and
tends to spread out on the belt. The carrying capacity
of the conveyor is given by the equation;
T= a (m2) b (t/m3) v (m/s) = abv (t/s)
where T is the carrying capacity, a is the average crosssectional area of material, b is the bulk density and v
is the speed of the conveyor belt.

For a belt of width W the value of the area a varies approximately between
w2/10 (high loading) and w2 /12 depending on the nature of the material. A
blocky type material such as coal, broken rock, or ore can be piled onto the belt
as shown in Fig.(a) whereas a smooth material such as particle tends to run out
over the belt as shown in Fig.(b).

(a
)

(b)

The value of b the bulk density in t/m3 is numerically equal to the relative
density (g/cm3) but it relates to the density of broken material including air
spaces, and not to the solid relative density

Material

Density (t/m3)

Coal
Solid coal
Gravel
Dry ashes
Wet ashes
Broken sandstone
Solid sandstone
Broken limestone
Slag
Dry sand

0.8
1.35
1.4 1.7
0.55 0.65
0.7 0.8
1.35
2.4
1.45
1.35
1.6

5. Thb
eelt strength affects the maximum force w
belt, and the value of the maximum force depe
and the drive head frictional grip. The power
can be divided into three components.
i. power for the We
empty belt,
ii. Power to conveyWmthe material,
iii. Power to raiseWrthe material,

The total power requiredWT =

by
We a
+belt
Wm
Wr
is then

 The value of Wr is written as plus or minus as if the material is being lowered

and help to run the belt thus the power requirement for this is negative.
The power as calculated above is the power required at the driving drum of the
conveyor, and so the motor power required will be greater because of power
losses in the gearing at the drive head.
Assuming an efficiency of 90% for this gearing the otor power is then given by
W = WT / 0.9
The power required to drive the empty belt depends on the total force
required to move the empty belt, and on the belt speed.
The force required : Ne = total weight on idlers x friction coefficient
Ne = Mi g e
= mi ( l + lx ) g e
And then the power required We = Ne v
We = mi ( l + lx ) g ev
Note: l the length of the conveyor is increased by lx = 45 m to allow for end pulley
friction

The power required to convey the material; Wm =mml g mv

The value of mm the mass of material per unit length is obtained from
mm = T tan/s
v m/s
Therefore,
Wm = T l g m v
v

Or

Wm = T l g m

the value of m the friction coefficient is again 0.03 for well maintained conveyors
but sometimes raised to 0.04 if the conditions are unfavourble.

 The power required to raised the material at the rate T

through height h is obtained directly as
Wr = T g h kW
Effective belt tension Pe =

WT

kN
v
The maximum tension P1 is obtained from the formula
Pe = P1 P2
For no slip to occur P1 < e = n
P2
P2 = P1/n
P1P2 = P1 P1/n = P1 (n-1)/n
P1= (n/n-1) Pe

The calculated value of P1 is then used to find the belt stree f (kN/m per ply).

Fabric

Density (kg/m2)

Stress (kN/m ply

U.S. cotton

0.814
0.930
1.043
1.220
1.395
1.744

4.25
5.25
5.75
7.0
8.75
10.5

Rayon and cotton

1.19
1.63

12.25
15.8

Rayon, cotton, nylon

0.930
1.02

7.0
9.65

Nylon and cotton

3.0

35.0

Steel reinforced
(Steel cords in rubber and
fabric belt)

16.4 42.3

80-450

 Exersice 2
A conveyor is 600 m long and conveys coal of bulk density 0.8 t/m3
up a gradient of 1 in 60 at the rate of 220t/h. Determine suitable
speed and strength for the installation.
(Note: assume the area of the material is w2/11, width of the belt
conveyor for transporting coal is 0.75 m, total mass acting on the
idlers 60 w = 45kg/m, m =0.04, = 440o)

 Sampun .
Matur Nuwun.