Client Name

Project Name
Conveyor Name
Location
Description

Designer
Company
Filename
Date

System Information

Material Properties
Type .............................................................. Concentrado
Design Tonnage ..................................................... 800 t/h
Density ............................................................ 2000 kg/m3
Maximum lump size ................................................ 1 mm
Surcharge angle ......................................................25 deg

Belt Properties
Type ............................................................ Fabric (3-Ply)
Width ................................................................... 914 mm
Rating............................................................. 1000 N/mm
Speed ................................................................... 1,50 m/s
Top / bottom cover thickness ....................... 9,0 x 4,0 mm
Total thickness ....................................................... 19 mm
Weight (new / worn) ............................... 19,7 / 13,7 kg/m
Modulus ......................................................... 8.657 kN/m
Tape length ............................................................. 266 m
Belt cycle time ...................................................... 177 sec
Running
83,5
10,94
34,0
0,55

febrero 11, 2013

Idler Set Data

Calculation method .......................................... CEMA 6th

Conveyor Length / Height ............................ 124 / 26,4 m
Material lift ............................................................ 24,9 m
Ambient temperature ................................................... 4 C
Kt factor at minimum temperature ............................. 1,01

Tension Summary
Maximum tension (kN)
Minimum safety factor
Minimum tension (kN)
Maximum belt sag (%)

ABB

Momentary
106
8,66
29,7
0,65

Cross Sectional Loading

Material mass (wm) ......................................... 147,8 kg/m
Combined mass (wm + wb) .............................. 167,5 kg/m
Edge distance (required / actual)................... 73 / 117 mm
Cross sectional area ............................................ 0,074 m
Cross sectional loading (utility / total) ........... 75 % / 52 %
Bed depth ............................................................. 166 mm

Series name
Number of rolls
Trough angle (deg)
Type
Idler spacing (m)
Number of idler sets
Roll diameter
Roll rpm
Total drag (N)
Drag range (N)
Roll length
Shaft diameter (mm)
Rating (N)
Calc Idler Load (N)
L10 life1 (1000 hrs)
1

Carry
E6
3
35
Inline
1,00
124
152
188
12,5
27,6 - 28,9
336
25,0
8.007
3.129
350,0

Return
E6
1
0
Inline
3,00
40
152
188
4,2
9,6 - 9,7
1003
25,0
4.448
2.188
350,0

L10 life above which 95% of idlers exceed

Drive Station
Type ............................................................. Squirrel cage
Synchronous RPM ........................................... 1500 RPM
Motor quantity / rating ................................... 1 / 90,0 kW
Total installed power ........................................... 90,0 kW
Empty / full power .................. (14 / 82%) 13,0 / 73,7 kW
Motor Voltage ......................................................... 400 V
Efficiency ................................................................ 95,5%
Maximum starting torque ......................................... 150%
Inertia - Motor .................................................... 2,0 kgm
Pulley lagging type ................................................ Rubber
Motor wrap angles....................................................... 180
Lagging friction factor (run / accel) ................. 0,30 / 0,34
Reducer ratio .......................................................... 33,940
Pulley shaft rpm ......................................................... 43,7

Take-up Data
Type ...................................................................... Gravity
Location ................................................. Head / Pulley #3
Required belt line tension..................................... 37,1 kN
Counterweight mass .......................................... 7,6 tonnes
Required pulley displacement ................................ 2,94 m
Dynamic displacement (incl thermal) .............. 0,32 m
Permanent elongation ...................................... 1,73 m
Splice length (1 included) ................................ 0,54 m
Clearance ......................................................... 0,35 m

Backstops
Backstop type ............................................. None installed
Flooded belt tonnage........................................... 1.538 t/h
Flooded (wm + wb) .......................................... 303,8 kg/m

Brakes
Brake type .................................................. None installed

Sidewinder Plus v4.84 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 1 / 7

Client Name
Project Name
Conveyor Name
Location
Description

Designer
Company
Filename
Date

Fully Loaded Motor Torques

100% Motor Torque - High Speed...................... 582 Nm
Motor Shaft Torque - Running ........................... 475 Nm
Motor Shaft Torque - Starting............................. 872 Nm
100% Motor Torque - Low Speed ................. 19.742 Nm
Low Speed Shaft Torque - Running .............. 15.305 Nm
Low Speed Shaft Torque - Starting ............... 22.914 Nm

Starting and Stopping

Start control ............................................. Constant torque
Start time...................................................... 0,7 to 2,0 sec
Operational stop control.............................................Drift
Operational stop time ................................... 1,6 to 6,2 sec
Emergency stop control .............................................Drift
Emergency stop time ................................... 1,6 to 6,2 sec
Material buildup in chute ........................................ 0,1 m

ABB

febrero 11, 2013

Minimum Case Belt Tensions (kN)

Case
Empty - Normal Frict.
Full - Normal Frict.

Running
34,0
34,0

Dynamic
32,9
29,7

Maximum Belt Sag

Case
Empty - Normal Frict.
Full - Normal Frict.

Running
0,21
0,55

Dynamic
0,22
0,65

Demand Power (kW)

Case
Empty - Normal Frict.
Full - Normal Frict.

Demand
power (kW)
13
74

% Nameplate
14
82

Din Factor and Total Equivalent Mass

Tension Ratios
Allowable (running)................................................... 2,57
Running tension ratio ................................................. 2,20
Allowable (dynamic) ................................................. 2,91
Starting tension ratio .................................................. 2,82

Case

Din factor

Empty - Normal Frict.

Full - Normal Frict.

0,0535
0,0297

Belt line
mass (kg)
34.492
52.391

Transition Lengths
Tail transition length (full trough) ......................... 1,54 m
Head transition length (full trough) ....................... 2,44 m
Head transition length (elevated 91 mm) ............... 1,12 m

Estimated Splice Data

Splice type .............................................................. 2-Step
Splice step length ..................................................... 0 mm
22 degree bias angle............................................. 370 mm
Splice length & bias ........................................... 1070 mm

Other Information
Loaded beltline mass (excluding motors) ......... 31.083 kg
Total inertia (ref HS shaft) ............................... 2,92 kgm2

Maximum Case Belt Tensions (kN)

Case
Empty - Normal Frict.
Full - Normal Frict.

Running
43,8
83,5

Dynamic
68,8
106

Belt Safety Factor

Case
Empty - Normal Frict.
Full - Normal Frict.

Running
20,86
10,94

Dynamic
13,29
8,66

Splice Safety Factor

Case
Empty - Normal Frict.
Full - Normal Frict.

Running
13,91
7,30

Dynamic
8,86
5,77

Sidewinder Plus v4.84 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 2 / 7

Client Name
Project Name
Conveyor Name
Location
Description

Designer
Company
Filename
Date

ABB

febrero 11, 2013

Conveyor Profile - Overall length = 124 m - Overall height = 26,4 m

Tail Arrangement

Head Arrangement

Maximum Pulley Tensions for any Load Case & Maximum Resultant Force
Steady State Tensions (kN)
Shaft Shaft Shaft
Wrap
Hub
stress Center
Pulley
Type Angle
Resultant
Slope safety
Def.
T1
T2
(deg)
Force
(min) factor (mm)
Motor 1
1
180
3,08
1,72
0,45
83,5
38,0
122
Pulley 2
3
90
5,80
1,66
0,72
38,0
53,8
Take-up Pulley
2
180
4,57
1,81
0,58
37,1
74,5
Pulley 4
2
90
3,63
2,29
0,46
38,3
54,4
Tail Pulley
2
181
5,26
1,58
0,66
34,0
68,5

Momentary Tensions (kN)

T1

T2

106

38,7
38,6
37,1
40,0
44,6

Resultant
Force
144
54,3
75,9
57,7
91,1

Note: T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

Pulley Geometry Details (Pulley Types)

Type

1
2
3

Diameter
Lagging
with
Lagging Diameter
Thickness
Lagging
Type
(mm)
(mm)
(mm)

Face
Width
(mm)

Shaft
Material

Rubber
Rubber
Rubber

1050
1050
1050

SAE 1018
SAE 1018
SAE 1018

630
400
400

10,0
10,0
10,0

650
420
420

Shaft
Bearing
Bearing
Pulley &
Center
Center Plummer
Shaft
Diameter
Diameter
Distance Block
(mm)
Mass (kg)
(mm)
(mm)

170
125
110

135
100
90

1365
1285
1275

530
522
520

741
349
322

Sidewinder Plus v4.84 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 3 / 7

Client Name
Project Name
Conveyor Name
Location
Description

Designer
Company
Filename
Date

ABB

febrero 11, 2013

Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures). Additionally they must include any other external loads
(wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the required live
load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes for the project.
The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and other
details. These forces must then be multiplied by the required dead load structural design safety factor requirements (typically
1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together to obtain the
total structural design forces.
The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for the
high friction case with 947 t/h have also been included. This specific load case results in 101% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 150% for this case. The maximum tension values have been
multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum tensions have
been reduced by 10%. The resultant force values include the vertical weight of the pulley.
Structural Live Loads - Includes case with 947 t/h under high friction steady state and dynamic conditions + 110% multiplier

Shaft
Wrap Hub
Pulley
Type
(deg) Slope
(min)
Motor 1
1
180
3,61
Pulley 2
3
90
5,87
Take-up Pulley
2
180
4,66
Pulley 4
2
90
3,84
Tail Pulley
2
181
5,79

Shaft
stress
safety
factor
1,68
1,66
1,81
2,29
1,58

Shaft
Center
Def.
(mm)
0,52
0,73
0,59
0,49
0,73

Minimum Tensions (kN)

T1

T2

37,1

32,6
32,7
33,4
33,9
26,5

Resultant
Force
70,0
49,6
63,1
50,2
52,0

Maximum Tensions (kN)

T1

T2

125

42,7
42,6
40,8
44,0
49,1

Resultant
Force
168
62,1
80,0
65,9
99,4

Bearing Reaction Forces (excluding any overhung loads)

Bearing X-Direction (kN)
Bearing Y-Direction (kN)
Pulley
Entry Exit
Shaft Structural
Wrap
Structural
Structural Structural
Pulley
Type
Angle Angle
FL-N
FL-N
Mass
(deg)
Max
Max
Min
Min
(deg) (deg)
Case
Case
(kg)
Tension
Tension Tension
Tension
Motor 1
1
180
180
180
831
-69,6
-122
-168
-8,16
-8,16
-8,16
Pulley 2
3
90
0
270
349
32,7
38,0
42,6
-37,5
-41,5
-45,5
Take-up Pulley
2
180
90
90
386
0,00
0,00
0,00
62,7
70,7
79,7
Pulley 4
2
90
270
180
386
-33,6
-38,5
-45,8
-37,7
-42,1
-47,7
Tail Pulley
2
181
15
14
386
51,1
66,3
97,0
9,44
13,4
21,3

The idler stringer loading should be based on the flooded belt surge capacity of 1.538 t/h and 303,8 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.

Sidewinder Plus v4.84 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 4 / 7

Client Name
Project Name
Conveyor Name
Location
Description

Designer
Company
Filename
Date

ABB

febrero 11, 2013

Sidewinder Plus v4.84 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 5 / 7

Client Name
Project Name
Conveyor Name
Location
Description

Designer
Company
Filename
Date

ABB

febrero 11, 2013

Element Tension Breakdown - (EM) Empty - Normal

Individual drag components per element
Pulley
Feeder
Extra
Running Running Element
Wm+Wb
Lift
Belt
Idler
Drag
Pt. Force Accessory
#
Tension Ten Diff Tonnage
(kg/m) Force (N) Force (N) Force (N)
Force (N)
(N)
Force (N)
(N)
(N)
(t/h)
1
34.435
469
19,7
295
3
171
2
34.904
774
19,7
155
1
346
272
3
35.678
3.308
19,7
2.083
20
1.205
4
38.986
3.308
19,7
2.083
20
1.205
5
42.294
659
19,7
370
5
284
6
42.953
413
19,7
124
5
284
7
43.365
445
19,7
7
438
8-M
43.810
-5.820
19,7
-155
208
800
9
37.991
5
19,7
5
10 - P
37.996
64
19,7
-77
141
11
38.060
-960
19,7
-966
6
12 - T
37.100
254
19,7
254
13
37.354
973
19,7
966
6
14 - P
38.327
220
19,7
77
142
15
38.546
5
19,7
0
5
16
38.551
52
19,7
10
4
38
17
38.603
-75
19,7
-124
5
44
18
38.528
-321
19,7
-370
5
44
19
38.208
-1.875
19,7
-2.083
20
188
20
36.333
-1.875
19,7
-2.083
20
188
21
34.458
-140
19,7
-155
2
14
22
34.318
-226
19,7
-249
2
21
23
34.092
-45
19,7
-50
0
5
24 - P
34.047
388
19,7
150
238

Sidewinder Plus v4.84 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 6 / 7

Client Name
Project Name
Conveyor Name
Location
Description

Designer
Company
Filename
Date

ABB

febrero 11, 2013

Element Tension Breakdown - (FL) Fully Loaded - Normal

Individual drag components per element
Pulley
Feeder
Extra
Running Running Element
Wm+Wb
Lift
Belt
Idler
Drag
Pt. Force Accessory
#
Tension Ten Diff Tonnage
(kg/m) Force (N) Force (N) Force (N)
Force (N)
(N)
Force (N)
(N)
(N)
(t/h)
1
34.435
469
19,7
295
3
171
2
34.904
2.589
800
167,4
1.320
15
379
875
3
37.493
20.026
800
167,4
17.699
670
1.658
4
57.519
19.955
800
167,4
17.699
599
1.658
5
77.475
3.667
800
167,4
3.142
134
391
6
81.142
1.577
800
167,4
1.053
133
391
7
82.719
806
800
167,4
204
602
8-M
83.526
-45.535
19,7
-155
340
800
9
37.991
5
19,7
5
10 - P
37.996
64
19,7
-77
141
11
38.060
-960
19,7
-966
6
12 - T
37.100
254
19,7
254
13
37.354
973
19,7
966
6
14 - P
38.327
220
19,7
77
142
15
38.546
5
19,7
0
5
16
38.551
52
19,7
10
4
38
17
38.603
-75
19,7
-124
5
44
18
38.528
-321
19,7
-370
5
44
19
38.208
-1.875
19,7
-2.083
20
188
20
36.333
-1.875
19,7
-2.083
20
188
21
34.458
-140
19,7
-155
2
14
22
34.318
-226
19,7
-249
2
21
23
34.092
-45
19,7
-50
0
5
24 - P
34.047
388
19,7
150
238

Sidewinder Plus v4.84 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 7 / 7