bp BRIDGE STONE CONVEYOR BELT "DESIGN MANUAL ) PT. DWWJAYATEK ERATEKNII MATERIAL HANOLING DIVISION “ GUNUNG SAHARI CENTRE JL GUNUNG SAHARIBAYA BHCOK B No.3 JAKARTA 10720, PHONE 6002248 - 6007250 Fax. 62908064. CONTENTS PREFACE ‘Typical Belt Conveyor Arrangements Drive Arrangements Belt Take-up System Conveyor Belt Analysis Sheet & Comeyor Balt Record ‘Transport Material Size and Minimum Belt Width Angle of Incline or Decline of Belt Conveyor 1-7, Belt Speed TRANSPORT CAPACITY 2-1, Caleulation Formula 2-2, CrossSeetional Area of Load (A) 2-3. Surcharge Angle of Material Apparent Specific Gravity of Material (7) 2-5, Coefficient of Angle of Incline (s) 3.6. Caleutation Rests for Cross-Sectional Area of Land & Transport Capacity CONVEYOR BELT DRIVING POWER CALCULATIONS 4:1, Calenlation Formulae 32. Additional Data Friction Gooflcien of lets (2) & Adjisted Llonzontal Length of Conveyor () Tripper Driving Power (PX) Weight of Moving Parts other than Transport Material (W) Weight of Rotating Parts of Carrier and Retum Rollers (We & Wel Pitch of Carrier and Return Llers Standard! Belt Weights BELT TENSION CALCULATIONS 4-1, Conveyors in General 4-1-1, Hffective Tension (Fp) - 4.1.2, TightSide Tetsion and SluckcSide Tension (Fy & F) 4-1-3, Tension due 19 Incline (F;& Py) 4.14, Minimum Tension (Fy, & Pa.) 1-5, Maximum Tension (Prax) 1-6, Additional Data 1, Weap Angle (0) 4-1-6-2, Friction Coefficient (1) 4-1-6-3. Drive Factor 41-2, Axle Power and Tension: Example of Caleulation 42, Calculation Formulae for Multiple Pulley Dsves (Single Drive at Head and Tail) 4-2-1. Theoretical Distribution of Effective Tension 4-2-2. Distribution of Eifective Tension oetween Moters 4-2-3, Caleulation Examples. 4-2-4, Comparison of Tensions Generated by Varios Drive Systems 21s 3 4 6 6 7 B 4 4 14 15 16 164-3, Diagrams of Belt Tension Distribution... . * : . oo 8 43-1, Horizontal Conveyor - . 5 a Head Drive. " e 25 | b Tail Drive 7 26 © Head and Tail Drive 26 Uphill Slope Conveyor eneeanennee 2 i, Head Drive b, Tail Drive Head and Tall Drive 4.3.3, Downhill Slope Conveyor | 4.3-3-1. When Braking is Not Required . i ag a Head Deve B b. Tail Drive : 8 ce. Heal and Tail Drive . » 4:3-3-2, When Braking 1s Required 9 4. Nead Drive 29 b, Tail Drive : 29 fc. Mead and Pail Drive . 29 4.4, Overland Conveyor : 30 4-4-1, Calculation Procedures 30 4-4-2. Calouation Example . 32 4.5. Acecleration Tension and Acceleration Time .4 Horizontal Conveyor Taran 34 Upiuill Conveyor oh Downhill Conveyor : 34 46, 12 Tension and Braking Time 4 4-6-1. Broking Time (0) 5 34 4-6-2, Determination of Braking Capacity 35 4-6-2-1, When Fn 0 : 35 4-6-2:2, When Fp <0 35 4-7. Additional Resistance . 35 4-Te1. Pullout Resistance from Hopper (Fh) 35 4-7-2. Skirthoard Friction Resistance (Fk) . 36 4-8. Design of Bucket Elevator Belt 36 4.8-1, Caeulation Formule for Transportation Volune 36 4-8-2, Caloulation of Maximum Belt Tension : us . 36 4.83. Additional Data : : 37 4-8-3-1. Lift Adjustment due to Scooping Force (bo) 3 4-8-3-2, Drive Coefficien ‘ 37 4.8.3.3. Bucket Loading Efficiency (¢) . 37 5, DETERMINATION OF BELT SPECIFICATIONS 5-1, Calculation of Tensile Strength of Carcass 3 : . 38 5-1-1. Steel Cord Belt : 38 5-}-2. Fabric Belt eran 8 5-2, Selection of Carcass... <-> . : ee 5.2.1, Tension Ratite A : = : & 2 §-2.2, Minimum Number of Plies in Relation co Load Sunport . -- 4 | 2.3, Troughabllily ...- 662 sees ee . 41Balt Safety Factors 5-3-1. ChissiNication of 8: 2) Primary Safety Factor (SPs) 5) Tertiary Safety Factor (SF) ©) Minimum Safety Factor (SFmin) 53-2, Standard Safety Factor Values for Designin a) Steel Cond Belt b) Fabric Bolt 5-4, Determining the Thickness of the Rubber Cover 5-4-1, Thickness of the Top Rubber Cover 8) Steel Cord Belt 1b) Fabre Belt 5-4-2, Determining, the Thickness of thy Botiom Rubber Cover Factors : n of Approximate Weight of Conveyor Belt 5-5-1, Steel Cord Belt 5-5-2. Fabric Belt 5-6. Splicing $61, Steel Cond Belt 56:2. Fabrie Belt 5-6-3. Splicing Length 5-7, Packing 7-1. Dimension: of Packing Dram 5-7-2. Drum Markings CONVEYOR BELT DESIGN 6-1. Determination of Pulley Diameters 6-1-1. Stel Cord Belt 6-1-2. Pabrie Belt 6-2. Troughing Transition Distance 6-2-1, When the Pulley Face is at One-Half the Depth of Troughing 6-2-2. When the Pulley Face is on the Same Level as the Cartier Roller 63. Minimum Bending Radius 6-3-1, Convex Conversion 6-3-2. Conewe Conversion 6-3-3. 6-4, Determination of Tamover Distance (length) 6-4-1, Supporting the Intermediate Section with a Flat Roller 6-4-2, Supporting the Whele Length of Tumover Distance with Support Rollers 6-5. Determination of Take-up Length 65.1. Steel Cord Belt 6-5-2. Fabrie Belt 6-6, Determination of Take-up Counterweight (WD) Fension at Conversion Point CONVERSION TABLES 43 44 4 44. 45 45 46 46 46 48 49, 49, 49. 30. 50 31 53 33 33 55 55 55 56 57 7 58 38. 58. 59) 60.1. PREFACE ‘The belt conveyor system is the most vonrenient and evonomical means of transporting matertals in. bulk As the conveyor belt alone takes up 15 SO% of the total cost oF the belt conveyor, wrest atiention must be pid to the design and selvetion of the eorweyor bet 0 that it will be perfectly suited te its tusk and he <4 economical as possible in. ope Hexcessne emphasis is placed on safety measures, the conveyor will not only. tie considerably in cost, it will sso fail to justify: this higher cost in teims of performance. On the other hand, if to0 much emphasis is placed on economy, there is the danger of shostening the life of the ewnveyor belt 14. Typical Belt Conveyor Arrangements Te aot Consequently, it is most important that the design and selection of 2 suitable belt arrangement be studied and scrutinized ftom every angle. And the basis for achieving an ideal design is thorough knowledge of felt conveyor design methods. With this in mind we have produced the Bridgestone Conveyor Belt Design Mans This manual explains step by step and in simple terms, the conveyor belt design concepts adopted by Bridgestone Tue Company. We hope that our customers will find it a useful tool in the design and selection of conveyor belts that are perfectly suited to their neds. Tripper Dioshorge chute Tal ee = — Scraper “ emt les” roughing A Snub pulley at lowtg paint garyingilers** Return lors Bend pulley | |Snab ond a : AE: bend pulley lepact ater, requiced °° Fraiing ers as ‘equiv veins Tikep Higure 1- Supporting Structure Designed to Sui the Normal ements of a Beli Conveyor 2. Drive Arrangememts ingle Drive (0 = 180") (oethou stub pulley) (b) Single Drive with Snub Pulley A smub pulley is used to enlarge the Wrapping angle (0 = 190° ~ 240°. oo rim puny @) ~ Snub pulley(©) Tandem Type Single Drive Although two pulleys are used, only fone acts as the drive pulley (@ = 190° ~ 240"), @—Tanlem Drive Of the two drive pulleys placed adja: cent ta each other, only one drives fone of the shafts directly. The other pulley-shalt is driven by gears or hain or by VeBelt ( 0"). (©) Dust Dive This 6 a system In whch ovo drive pulleys are used, each of which is dlriven by separate motors (Multiple drive It is possible to drive a belt conveyor at more than one place along its length. Two or more pulleys driven by a separate motor, can tured. This arrangement is. most appl cable to long-distance and yolume hhauling as i reduces the comveyor's maximum tension and saves th tors fom overstraining oO w (6) Primary five oulley f , ie C ‘ive pulley (a) Primary drive pulsy Teetary sive pulley Mp... din ptey Tertiary drive pulley Primary drive pulley Secondary drive pulleyCONVEYOR BELT ANALYSIS SHEET (Soparate Sheet Required for Each Conveyor) NEW OR REPLACEMENT. = RATE z company i : BELT DESIGNATION Location Salonge GENERAL CONVEYOR DATA TAKE-UP DATA, "Belt with, a rm STVPE: serow or counterweight ‘Horigonta! C6 distance |) 1 > eter Travel : ‘netor ‘Max ani incline : enrens Wcountarwaighe, weight i Max angledcine omens Location an conveyor Overall itt rete’ or érop. | neior — MerHop or uoimine “Bett speed Seer 2 Reto pat ate "Vuleantzed ape, “Tripper hoight <2 | meter *Festaners ere fe sie MATERIAL DATA intent Tyee . sconieyariensiom z “Weight er cubic moter || DRIVE DATA “Mas loacion conveyor metic TPH “Location of drive 2 a pat “Humber of driv pulays ot Porcent tines “Aref contact in degrees : Temp: avy... deqrass | Max arene “Are chive pulleys lage! ? : Abrasve’ character A Motor :ype and horsapowe a "Destine any oll condition “Type of maven siting ss | u " CARRYING IDLERS Other canaitions Equal lang : : 4 LOADING CONDITIONS Leng exntee ort ey | Number of loading points Other : : Lacatone oar “Spacts ‘ ee racer Incline angle of elt latina doin stooroes Diameter 2m Overall vertieal drop of marl Om belt RETURN IDLERS 0 loading chutes: : *Soacing - eter Discharge in irecion uf bu visto?” Diamar Seeeaseinaec tn Discharge material close to belt speed? PULLEY DIAMETERS: Center ou om be. + : SMa ee . en Lox! fines an bet iret? Tale EE aren Snub tm Take-up ‘ wm Otter. one Simm PREVIOUS BELT HisToRY Bolt description: Size... Type Spacing Motor Present oett specication | 2) : Present belt has handled tens in ‘yoors Describe completely present condition of belt ‘ ‘box prentoussenrce 21 teat in veers Mate are specification af best bale Describe now thisbel aed : en ‘Aatitional information earn nantes ‘ BRIDGESTONE BELT RECOWMENDATION “Minimum information required: however, in order to provide the best recommendation, ie, lowest ultimate belting eos, all tem Shout! be complated, {This information is absoluiety indimensible in making the best possible recommendation for a replacement conveyor belt Radiusof Concave — Loatng Poin ‘ — = oo —— -4DESIGW CALCULATIONS E Horsepon be ke CONVEYOR BELT RECORD1-8, Transport Material Size and Minimum Belt Width ‘The width of the conveyor belt varies in accordance with the tarsportation capacity of the conveyors as well as the lump sizos of the materials to be trang ported. This means that if the lump sizes of the materials to be transported are lange, the belt widih must be pro portionally wider, and vice versa Table 1 shows the minimum widths of belts for specific lump sizes of materials to be Column A indicates lamps of approximately unisorm size and Colunin B incicates lumps of mixeil sizes. In I belt widths Lave been calculated on the assumption That maximum ump sizes make up no more than 10% of the whole ransported, TABLE | Transport Material Size and Minimum Batt With ] Taamp Sizes te Minium Bete Width < a) Uniform Miset +00 oe [av os san Bs 00 no ssi 15 | wo | is? ll 900 Isa Fs.000 203 i 1050. us as | 1,200 250 so 1400 27 a0 1.400 MS 0 380 800 440, 900 | sao 1,000 2400 se ico | 2.600 oon 1300 650 1230 [3.000 a0 i400 | 3,150. 70 so 1-6. Angle of Incline or Decline of Belt Conveyor The angle of incline or dectine ig govemed by the characteristics and shapes of the materials (0 be trans. ported, For example. » comparatively steep slope ean be sifely adopted for transporting granular and other sich stable materials, whereas a gentler slope is prefer- able fy Warsporting unstable materials sich a5 coal Phe maximum permasible angles of ineline or decline ‘or Gansporiing matectals of diflerent-charaeteristics and shapes. on smootl-surfaced conveyor belts are in Table 2 Note the following points 1. When a weigher is used. it is prefershle for the inctine/decline angle to be lined 19 less than 18°, Feyaruless of Lae figures gwen wt Table 2. 2, When conditions at the site of installation or other Factors make i impossible to keep within the max mum allowable incline'dectine tp. cleated or finned conveyor belt should be employed. ngle value, 4 rough The incline/dlectine angle values given in Table 2 apply to operation under conditions where the belt tained! it a comparatively clean com sition, If the surface is wer or ditty, incline! deciine angles should be reduced ay 23° from the given viesTABLE 2. ‘Angle of Incline oF Dacline of Rel Conveyor Coat Rock one Limestone time omens Salpnue Phosphate Ore Grae Sane sant Wow Lump Size Ove 10m Noweunalorin Dry fine Wels 50mm $0Rme ver 10 an = 10 der 10 over 10 naw ater 100m Over 110) mi Trae 100 mn bine Pie Over 160 ma Vine Washo, unsfor Unwashed, son-untocn Nomarilorn Dy Wet For casting @ouuudey) Wet hips I~ 18 is 14. Belt Speed Tine speed of the belt is limited wo! only by the trans: port capacity of the conveyai, but also by the belt width and the characteristics of the materials carned It is most economical 10 use @ marrow Yell ai high speeds, but generally it is easier to operate wide belt al high speeds than narrow belts, Tables 2 and 4 give the wyaximism belt speeds in relation to specific transport materials and belt widths respec tively TABLE 3. Gelt Speed ~ Mavimum Belt Saeed under Special Conditions Se una ackanes 15~69 Lulpsood Coes w Patpwood 90~ 10 sap Slow Discharge eet: Doven Operation Jot Slinger Timumers Chataces sa 1.900 Parable Convessiew g0~ 144 Whee Factors 270 ~ 460 Picking Bets Is~ 0 1,600 360 | TABLE 4. Belt Speed — Maximum Belt Speeds A Grainsand other feoftowing marerials 1B, Qverburden Gun of ni Galland 1 mach moderately abrasive eters) Hard ore, rock and other very abrasine mater2. TRANSPORT CAPACITY ‘The transport capacity of a conveyor belt per uni time is governed by the belt speed, type of carrier, angle of incline/lecline, characteristics and shapes. of materials to be transported, ete, But for general pur poses the capacity can be calculated oy the formule given belove 24, Calculation Formula Q= 60 Avs Where Qe Transnomt capacity Clons pee lhown) (eonshe) A: Cros+sectional area of load (in?) Vo: Belt speed (m/min) of mates (onfm) YY} Appsrsnt specific grav + Coefficient by angle of inctine/dectine (table 8) 22. Cross-Sectional Area of Load “A’ The cross-sectional area of load is as shown in the diagrams below. Its usually calculated from the top section of tho load, called the “ass,” and the bese section called the “trapezoid,” bul as this system of calculation is very complicated, » simpler formula is sven here A=K(O9B 0.05)? Where A: Sectional area of load (im?) K = Coefficient of sectional area B: Width of belt (im) Diagrams Fiat belt L 0.8-005m ——— | Surcharve Angle (0.9-0.057 Trouahed bet Trough Anal The following table gives namesieal values iu relation to the arrangement of the carrier rollers and Ge suc charge angle of the transport material TABLE 5, Coefficient of Sectional Area "K" een | ee Sarelusye Angle (destee) ee 4) ae uw » | » Hy » | naa | asst | o.pm6 w | coor | ars | oars av | noes | airs | masse as | is | ose | oreo | | urase | auass | natsa suns | voll as | utsas | ouses | 04837 0 | ata | assay | o.ras2 4s | cise | autos ome so | utsse | auras | ono "ss | taste | airse | o.tv07 | uises | naste oas69 wo | ue | aise | ones sae [|_| aaa | eusus | ows. | ras so | oraos | ours | 0.1046 oust | eases | aire | o.tgs9 w | cress | vison | otzas. Surcharge Angle of Material Ty surcharge angle i meant the angle of the material 10 de amsported when il is in epose. Generally, the surcharge angle of a material during transportation ts less than when it is at a standstill The values are given belovs TABLE 6, Surchaige Angle of Material Suchare MN ype & Conaition of Moers Dr fine miter Wren bulk: muerias (coal, gravel, most ows, Ste) use teamported ty sriloaey.egripment Uuniee ordinary conaltions Wher the materials comparatively rge an the ati faey 1 property arranged 9 that the material constany ade oe the Feit Inu uniform sn Ful manner 24, Apparent Specific Gravity of Material “y” ‘The apparent specifis grivity of any bulk material is Ais weight per unit volume, including the space between: the individual lumps of the material hemg transported, Note that the appacent specitie gravity differs from the actual specific gravity of the material The sppurent specific gravities “y” (Lonfir) of vaikous bulk materials are as shown in Table 7 below TABLE 7, Apparent Specifie Gravity of Material “"y"" Weight per Material Gon) Acid phosphate fersaer 096 shun Lamp 08 ~ 0.95 Plverbet an~08 Amir nitrate on Ammonia sults We 128 Asbesios Ore os. Shredded 032~ Ash Wood ti ~ 0.98 Sots eva fet = 0.72 Agphaltum 13~ 139 sry es, tose 2a~ 28s laste ‘minor ore 088 ~ 0.93 Crashed, dry 121.36 tine. Common and hard tor ~ a6 Fie 219~23 Caliche 16 Carbon black pallets 038 ~ 0.45 Cone Poland, ary 141 ~ 16 Clinker 128 ~ 1.32 hate 136 at harooal Gis~04 Cinders 64» 0.72 chy Dw twa We 132~ Les Coal Anthracite 083 ~ 09 Bhumious 175 ~ 083 Breeze va ~ 04 Laase asi 0st Refine, 056 ~ 0.64 Concrete mis, wes Vad~ 2 Conpst one 192 ~ 2.56Weight 2 fae ee lor 4 Te Peat | mare pe Wes | os ‘ Maa 1 Vebbh | Hie ee Pumice stone, geound mbt Hoe we | Pyrites fave fimestone and tae aided 50 peweent) poe shovel) 16-17% Granite, besker | sai re | Obl Sand and gravel ae | oan 0.22 vr Oe el 056~ 044 Saweist Hl ieee 45~ 012 Shale, broken ie : 4d Shells, oyster raven i Ceased } 2 0 ‘Slate, broken i Cake Uda 08 i ee | tise | ome | | tee Soapstone tak \ 2a | | i Mo, ee | 12 ‘Suwur, refined nr aw | a » sommetcial 1,12 wo 1.8 ~ 0.96 Trap rock, broker 1 ee anon ‘Chips ars) | 40. Hydrated | Q: V1 ae ' ee a | ee oe cteenines, 1S | Las~ 149 a | Naa h28 | ‘Marl | 1,26. ‘Carkonates and lime | sk | 1ag~ 2.24‘Transport capacity varies in relation to the imetine/ Coefficient by Angle of Incline/Dectine “Ss” TABLES, Coefficient by Angle of Incline/Dectine "S' decline angle, The steeper the slope, the less the amount Incline /Decline Angle | Dinwii : i‘ 26, Calculation Results tor Cross-Sectional Area at | Lad "A" ad Taner Capacity "OH" “Copeaion ane of wa (en ay n TAME Trews Anas] T ] lin 400 ST 120 33 143 153, so | 74 1s? | m4 137, 200 a sou 7 9S 194 2 238 254 on aa 20 382 357 38h 0) 169 356 426 - 44 (i 0 a | bee 28 765 if 0 79 8 | ase | one 1000 4227 900 98 Lots 1231 ft Last an i 997 1192 1365 [eno | 865 2179 2495, hse ave [aos | as |e sa2_| ec AED 3 4229 4557 in| 330 2.21 4,638 eyes 5543 L. Daan 2431 5,543 ene 6025 7070 [aa 3099) as 7.02 aoa 4308 ta 2.800 3606 7.596 8ars 9078 9.688 [ son “4,150 3.743 968 10449 11S 3150 4584 9.656 10,710 11,541 12,317 u2) Transport capacity (Table. 10) Note: a) Apparent specific by S:coller carte } Bel: speed 100 avai, 1s = 10 ton/m® d) Incline/dectine angle = 0" TABLE 10, Transport Capacity “0” ve wae ie » 2 “0 is ‘ et Wain in [aoe # pw % e a “0 # ™ 104 » ey sew 7 1 me) ta 18 ra 600 ne | 199 24 220 24s. 650 101 nd 27 | 286 22 23 ™ | 19 m2 | | 349 372 400 800 [459 335, 372 401 428 as | 900 205 aan 479 515 | 1.000 286 wo [sts 88 7 oso | a 4 as v63 8 1208 6 7 un 1085 1.400 oo] 1,307 1,395 1.497 1,600 685, 1443 son | 1a. 184) 1975 [uso Sd waa 702 | aan 2 2520 [ 200 | iam baw | 28 | 298 | 2200 1a] anes) Re 3306 3509 2.400 ism | 3326 | eos | amis | aze 2,600 1850 | 435 4082 ov asm |e ee ee san 3,000 2,490 $819 6.209 6591 3.56 21 tan | 93s 7398 R The a DY is a1.CONVEYOR BELT DRIVING POWER CALCULATIONS The axle power required for diving & conveyor belt ss caleulated according th the following formulae 34. Calculation Formulae P=P) +P; + Py Pr p, = EU od We 16,120 7, = MERLE _ (E+ J Wmv 267 6.120 pal. Where P : Calculated axle power of crive puliey (kw) P. : Horizontal no-load axie power (kw) P.: Horizontal axle power umfer Ind (kw) Ps: Yertical axle power under load (k4) GF the conveyor #8 inning downhill, the value will be negative! Pc: Driving power of upper or stacker (kw) T+ Coetfeient af friction af idler hearings W > Weight of moving parts other than material transported (kg/m) Wine Weiekt of uaterial per meter leaded on conveyor (kg/m) ¥ Belt speed (ra/min) H Lift Finchiding ising cripper height) (an) © + Horuontal length of conveyor (m) G+ Adjusted horizontal length of conveyor (m) Q : Transport eapaetty om essmier side (Gon/hr) oa Auilary calculation formulae’ ve, We te ty 72M = bane ee 0.06 6 of belt per meter (kel) We > Weight of revolving parts of one set of carrier rollers (hg) Wr © Weight of revolving parts of one set of return roles (kx) e > Piteh of earrier roller (1m) > Piteh of retuen roller (m) @ = Inelinefdceline angle af slant comeyor {legree)3:2, Additional Data 3-22, Tripper Driving Power “Pt’” ; “rippers canbe stationary (Fixed) or movable, axd 324, Friction Coofficiont of Idlers "Mand Adjusted cys cepted standard values for tipper driing power : Horizontal Length of Conveyor “go” “Pr are giver: in Table 12. However, it must be noted that tripper Iii power is not inckided in the given Factors ©) and th" are related to one another and values; this shoulé he incorporated. into the vertical 4 standard values ate piven: below, in Table 1 power undo load : TABLE 11, TABLE 2 Friction Coefficient of Idlers “F” and Adjusted i epee Cantino ower: PR Units kw Horizontal Lenath of Canwayor "a" aae f | Convevor Contitions Ga) Stationary | owon | 003 | a) Conveyors with poor alignments tem 0 parson paras enevees au ) Capesors operating i extrmety 5 07s 12s Sal dns wh eso ap ‘i | fim snl sare toni pe Hs 0.022 | 66. | Permanent or wiher conveyors with gonad a A eco ee ee a 29 Tn 8012 | 156 | in case here the braking power of 4s downhill conteyor must be caleulated. 10a ats. al ‘Note: When (f) tas vues otter is tose given sbow. the aa ea (G2) ean 66 Cowie ham ihe oii tov 5 oousaze *199* 2.000 “ o“ ay) San 40 a aa won 250 aay 60 van 432:3, Weight of Moving Parts other than Transport Material °W" When designing 9 conveyor, the values given in Table 13 are generally used tor obtaining the weight of moving parts othe than ue materials transported “W". When more accurate values are reeuived, refer to the formal siven on page 13, TABLE 18, Weight of Moving Part other than Transport Material WW" wet Walt orm) Wikre so 1M foo 6 eon 41 50 33 100 56 00 63 1,00 oo 1.050 aw saat tsa 2 m4 en 2 240 247 2.800) 28 3,0 aw 5150) 2 224. Weight of Rotat Return Rollers “Vh”™ Parts of Cartier “We” and Standard values Tor the weight of the rotating parts of one set of carries and return solkrs are giver in Table 14, TABLE 14. ‘Weight of Rotating Parts of Carrier "We" and Return Rollers “We Note: a) For steel rollers only b) Woighis given are average weights and these my vary. Actual weights given. in man: facturer’s catalogues or technical data should be used in Final design calculations, bth Width (my (kyle) We Geum 4 66 so 45 a sa 0 28 | On 83 6a 03 oo a so ro | goo | ast = ee ee 105i a3 1K8 20 236 | Lan 36.6 L500 41 | so a4 425 2000 sae 465 ano si 0 20 te n 2.801 i) 100 3.00 bt toot Ast =|32:5. Pitch of Cartier “2c” and Return Idlers "Qi" ‘The values given in Table 15 for the pitch of cartier and return idlers are aceepled as standard, TAaLe ts ‘sy mt qo] tas | tas 300 go | i | io i00 we | ia) ate | ae too | to | mo vaoe | im | 1 30 isto | 1am is 500 fo) ty | aan two | tao a 3-2-6, Standard Belt Weights "W," The values given in Table 16 are generally used for Dell weights when desigainy ordinary conveyor bells For hells of other thicknesses, add or subtract from the designated weight values accordingly Etro Bia | wae riebnes(m) [a i= as a si isin i 780 130 | 8010 be 13 ox t 155 | [iso 460 | Dann so | |. [ase no 16—| 4, BELT TENSION CALCULATIONS 41. Conveyors in General 41-1, Effective Tension (Fp) ‘The effective tension of the belt is caleulated from the dive axle power. The calculation formula is given below: _st20P Where Fp: Effective tension (kx) P : Bott drive axle power (kw) + 5 Belt speed (hain) 44-2. TightSide Tension “F,”"and Slack Side Tension “Fs” Fie Fras Note: The relationship between Fp, Fy and Fy Js as follows: rer F Effective tension (ka) Fy): Tightside tension (ke) Fx Slikeside tension (kp) 1: Friction costficent hetween pulley surface and the belt + Contact angle (angle of belt wrap) of drive pulley and belt (rasan) Diagram of Tension Distribution at Drive Section 0 41-3. Tension due to Incline “F&F,” In an inclined conveyor, the belt constantly develops tension die to its own weight; the belt tends to slide hack, creating resistance, Tension due to incline can be calculated from the Following formulae Fy=Wy-R (tana 1 Fy'= Wy -@ (ana +9) Where Fy Incline tension of uphill slope (ke) Fy’: Incline tension of downhill slope (ke) W, = Woigit of belt por meter (kg/m) £ Horizontal conveyor length (m) a: Incline angle (*) F + Rotating Friction costfieient of idler rolls Note: fo, Wr ant tr are ignored inthe above 41-4, Minimum Tension “Fac & Fy," The minimum tension is the tension necessary to limit sag between the iWkers to 2% of the interval ween the To obtain this aorior or relusn idlers, salue, the folowing formulae are generally adopted Pag =6,25t6 (Wy 484) Bq, =6.2560.W, Where Fae > Minimum: tersion of carer site (kg) Ege + Minianim torsion. of rotam side (kg) Gos Carrie idler piel: (m) + Return iar pitch (mp Waa Woigtt ecr tcten ob alec ttanpponed (gin) Wy © Weight per meter of belt (kg/m) When it is preferable to keep the inter-idler hell sag al 1% as an added safety measure, the following for Fac = 12.50 Wy Wi) Fae = 12.58,44-5, Maximum Tension “Fma The maximum tension necessary: in determining the carcass of the conveyor belt is obtained by using the Fp. Fa, Fa, Fas Fae and Fay factors in the following formulae, The largor of the results obtained from these formulae should be adopted. ‘TABLE 17. Maximum Tension “Fm: Type at Conveyor | _AtHead Drie AU Tall Dive Horizontal Epi Pa Conveyor Feta Fr Ept kay Uphit Conveyor Tptly Enea tFa rear —t Newbie, | SAE a Town | Bp tae With fake eco} Where By PLU) Oy Wye) 441-6, Additional Data 41-61. Wrap Angle of Belt “0” The angle of wrap (the angle of contact between the drive pulley and the belt) ording (0 the type of belt conveyor drive. values given. below (Tele 18) are generally used The name TABLE 18. ‘Wrap Angle of Bett “0” Type at Drive Ange of Wrap lear) (A) Sinek Dre 180 0 Single Deve wth srub pre aae ples x ay ~ 240, {by Tandem Drive aor~ayo | (1). Dual Deve Piimary 170 ~ Secondary 19 ™ o Fax wy 1841-62. Friction Coefficient “u” ‘The friction coefficient between the drive pulley and the belt varies according to the surface conditions of the pulley and the material of which the pulley is made. The values given in Table 19 are generally used. TABLE 19, Friction Coefficient Types | Safe Condition | __ Filaion Drive Paley af Drive Pulley” | Caet tient basal | DHYeveL a oe Moist 0.1~0.2 Prey Dry a Groord ant | Dirty & Wot 02 RabverLagged | Mom 02-03 Paley Dey ons @ Tent 163. Drive Factor pas Values of the drive fietor (49! >) ae ehen below in Table 20. . Where € + The base of Naperian fogarithms (2.718) us Coetticient of tretion between pulley sur: face-and helt TABLE 20. Drive Factor "1 i a naan . Sa . at 0.20 0.28 0.30 0.35 1941-7. Axle Power and Tension: Example of Calculation Operating conditions Output data by Computor ao OTP) CBR 00min joo tons 50 m/min, W=2020+ = 80.2 2S Calculations ,022(234 + 66) 86.2 150 5y Bap tear i = eat 2139 ky sey ck oe . ea py = O06) 200 ae = 302.400 1969 mor ea usr, gute Py = OREO § 196.2 kw em eta wel Tage P= 13.94 83.2 4 19622533 kw . ee san ut 10.335 ke Fy = 10,335 «0.499 =5,157 Fy = 26430 0.022.034 4 66) (264 = 780 241 = 539 ke ( [Simple method: 26 « 30 - 0.022 x 26 x23 = 180 — 134= 646 kg] l| Fac = 6.25% 1(26 # 266.7) 1.829 Bay = 6.25% 2x26 25 ke 10,585 + 5157 15492 1592512 i Ty, = e297 #400 keenly Belt Spee. = NF400 1,200 x 4P x 8 x 3 (Assumed cover thickness) | -20-42. Colculation Formulae for Multiple Pulley Drives (Single Drive at Head and Tail When the calculations for scandard belt designing are mae using the Formulae provided so far, there is 2 tendency for the miximum tension or motor eapacity (in some cases both) to become excessively large. When designing a belt Yor fong distance and large capacity, the answer to this problem lies in the multiple drive system, The formule Cor 4 two single crives system are as folbws emary ore Pauley Section Stcondary Drive Pulley Secton HEHE) 0H + Berges ON) Be nergy Bey F, + =F, + py Fp Noe: For 2 downhill slope conveyor, reverse the plus and minus (hb factors above, substituting thein with WOW, + Wm) and + h-W, respectively 421, Theoretical Distribution of Effective Tension Yee™ Taiatan 7 Art hee 3) ty = uu). 01-23 @) 1g Fea tee een) ery 42-2. Distribution of Effective Tension hetween Motors When When The calculation of Fy, and Fp, is the same as in para 42+1., where My: Motor capacity at primary drive pulley (kw) Ms: Motor capscity at scan a) Total motor capacity (kw) ‘Total effective tension (lee) Effective tension at primary drive pulley Ly drive pulley (kg) Fy ¢ Effective tension at secondary drive pulloy (kg) yy} Tightsde tension at printary drive pulley kg) Fla! Tightside tension atsecondary drive pulley ke) 12 Slack side tension at primary drive pulley (a) Faas Slick-side tension at secondary drive pul ley (key Fe | Caierside tension due to munning, resist: ance (kg) F, © Returnside tension due to nnning resist ance (kg) 4, > Friction coefficient at primary drive pulley U, : Friction coefficient at secondary. dive pulley O) 5 Angle of wap at primary drive (radtan) ; : Angle of wiap at secondary drive pulley (radian)42.3. Caleubstion Examples B= 1,400.am Qt = 6,000 TH 028 Vo = 250m/min 210 = 3,900 my G67 ratian) h = 0m = 400 kafm A Tension Fe = 0.022 (3,900 + 66) (33 + 36.6/1 + 400) = 40,974 Fp = 0,022 (3,900 + 69) (33 + 32.612) = 4.302 Fy = 40,974 + 4,302 = 45,276 Ey = 0 G Fac 6.25 x 1(33 4400) = 2,706 = gig (45,276 + 2.176% 15) = 13,869 kg Fp, = 45,276 — 13,809 = 31.407 kg 424, Fy = 314075 3 31407 x 20,938 ke 13.869 x SagsesaT y= 13.809 Fa 240 ky 2) Tension Distribution (between Motos) (Fy, =p, = 121 Mr=M, 15,092 keB c Tension Diagram (1) ‘Theoretical Method Q)_Diseibution between Mowoss Comparison between Theoretical Method and Distribution Method Effective tension (Axle power) Min, requited ‘rotor power Motor power for primary drive pulley Motor power for secondary pulley Max. working tension Comparison of Tensions Generated by Various (Operating conditions are the same es ix-4-2-3) B= 1400.0, 1. Hoad F-34490 oar ‘s.3021 Uy =uy = 0.25, =A, = Theoretical Method 2.000 kw 1.400 kw 1500 kw 345 ky Systems 22210" 36.066 45.276 ke (1,850 kw) a) Distribution Method 45,276 ke (1 2.000 ki 1,000 kaw 1.000 kw 56,003 ky sT40003 4, 5 Tail Single Drive Fas + 90178 1a) PD 4a02) Fis = 75894 Heaé Tandem Drive —< ae NU ago Fs 12.008 Hood Dial Brive \ a Ly aan Hoad Single & Tail Single Drive (1 ‘0.9701 iano) Head Dual & Tail Dual Drive (1: 1) aor) ora anata » ae = 60276 eee uM ora Frmax = 75454 kg st-4000 Fax = 52.878 ko st=3150 ix = 80.376 4 13 Fax = 86.066 ke s-729 st-674-3. Diagrams of Bolt Tension Distribution ‘An understanding of the tension to whic a belt is subjected can be best achieved through the use of & tension distribution diagram, ‘The diagram below shows the tension originating at each section of a general uphill slope conveyor. Where Fp: Effective tension (kg) Fp = Foti Fe: Running tension on carrier idler side (kp) Fy, = Ept Py orkp+ Fa + Fa Fr: Running tension on return iller side (kg) F) + Tihtide tension (kg) F, = Fy gaa ors Py Fy Slick-side tension (kg) c Fy + Bell inline tension (kg) B= Woh 2 Minti nas al Pe = Paces Par 43-1, Horizontal Conveyor fp + Fete Fe = Fr qr on MS B= rere eX) 8. Haut iva (Ge unecoeea Ty= Fie Fp+Fy Ty= Ty Fat hybe Tail Drive Head & Tail Drive Ty= Ty= Ft Fe= By Fp = Fou \Fpa t= Rey pr e,su.8, 1 Far = Fpa* Say © When Fy Fra Fr Ty= Fra Ib Ty= Fra = Fo tps Ty Faro Fae *Fps Ths Fa Fr T= Fu — Fe Tr= Fras Fpe tT T3= Fat Fp 43-3. Downhill Slope Conveyor et Fr Ie = Fer ean + ME + Wan) hWnd For = £(UE VW FRE 4 Wend F, = FOE R ON ARE) Fey For — F¢e# te) we MEY € & When the conveyor i being operated without Inad and the effective tension (Fyo) becomes grester than Ep, tala th belt tenon by subslutng Hy Wi pp » (r= 0,022). Fpo > Fen Fr Feo = PEF GYM, ANE) Prterov wie ey cw; i Fy = FQ 8) (Ws 1G) Hho 434-1. When Braking is not Required (Fp > 0) a. Head Drive sem mes Fpt hs a m: ins Bote ey me TH Hs > HT © When's < Fag 0 Par MMe Ty = Ta = Fae Fe T= Ts Fy Ty = FptF ve pth bh, Tail Orive = hy= Ree Tr= Fae Fy Goo} Ti= FL= Fpths 1)" Tas Fi Fr © When Ts < Fae oF Far How, Eye T= Fa @ Ppt P Fr renHead & Tail Drive 43-3-2, When Braking is Required (Fy <0) Wher the result becomes Fy <0 EF = 9.029). use F= G1? in order to vbtain the braking tension and a tae vo ahsobite value a Head Drive 4. Tail Drive ©. Head & Tail Drive When braking is necossary fir a downhill conveyor, bead and tail drive 16 not very alfactive (pte eh%—p) ot Fos © When ay

Fit Fp When Ty < Faye oF Fay Fac or Bay Ft Fp Tam Fat Py Ts= e oy 7 =Fy Vy By When Ty <4. oF Pep Ts =e = yy or Ry, T= Fae Ty +h Ty= Fs +hp44, Overland Conveyor 44-1, Calculation Procedures When there ate both uphill and downhill sections within one span of a conveyor, caleulate the belt ten sion in the following way Procodure 1. Caleulate Ry, Ray Ry, and Re for each section (Caluulate Ry and Re at the carrier side and the retum shle) Ree = Fy bet tee Rye = OM HE) K Ry 252) Way K Rs = Hi Win Roe = 1 Wy Rye = HW a reat Where {= Horizontal length af conveyor (an) {gj ¢ Adjusted horizontal length of conveyor (mn) Ry: Horental re-load tersion of carrier si (lg) Ry: Horvental nodoad tersion of return si (2) Ry: Horizontal underlead tension (0 R + Vertical underioad tension (ky) Vertical bell tension of carrier side (ke} Ray: Ver uta side ( 8): Horizontal conveyor length per section (a Hy = Lift of each section (x) K _: Corrected conveyor length coefficient f= Coefficient of friction oF téler bearings (0.022) (VWhen the belt is downhill overall, alst ate using the value O12) cal belt tension of Wy = Belt weight (kx/en) We 5 Carvier idler weight (kg) Wy = Return idler woight (kz fe = Casier idler pitel (mt) & + Roturn idler piteh (sn) Wh Weight of load with conveyor on fillers 30— 8 z 7 ~ 4 aS Procedure 2. Caleulate Re, Rey Roy Rey Re and Ryo according to under-loal conditions, as follows Re: Total value of sectional horizontal no-load tension (R)), horvaontal under (R.) and vertical undertoad tension (Ry), Ry * Use the value of Re when all scetions of the conveyor are under Toad, and use Ry value i the opposite case (all sections are under sio-load conditions). Ry: bie tot plus the tension created: by the belt isell (Ra). Ry Indicate al each point 1e per section (Moke 1 z210). Ry :Caleulate 9 that the minimum, value he- comes gero when the value of Ry 1s mints, ‘ewn if at one poial only. Calculate so that the minimum tension (Ryu c) becomes adequate al the carrier side 1 well as at the rolurn side (Ry..). in expec! of the minimum, value of Ry | salue of the values Rs persection, the weight of A pul Ryo 12.58 OW, + Wind 2.5 W,Undor-Load Conditions Procedure 3. Noload, underload, loading and discharge condi- The effective tension (Fp) occurs on uaderoad tions must all be taken fully into consideration conditions when the total value of Ry in each and calculations should be made under all these table reaches its maximum, The highest value of conditions, as indicated in Table 21 and 22 Ry equals Epmax. below 2) A tentative value for maximum tension (Pinax) ‘oewurs at Ryq in each table. In this case, however, calculation is applicable only to tail drive, The ‘TABLE 21, Seaton | Netost [Laing [Under toad real maximum tension is obtained by taking into ae loo jili 1 [alo ‘consideration the slack-side tension (Rz) and mo oe ilo the effective tension (Fy) co o [folo r[a]| 3) When a drive system other than tail drive is cae rer) adopted, i! is necessary to caleulate Fax through the useof tables indicating the tentative maximum tension. The seal maximum tension can be cal culated in the following manner: Calculate Fys trom the Fy of each drive section in ofder to salisty Ry and in order tw acumalate the value of Ry between each section, TABLE 22, 7 Section STAT R TR | R | PR, UE | | | Pome L | t |_ a ae : 8 caer Sie +— 1 } =f e ca a © ep 0 D file Total Return Site = = a E | a 31442, Calculation Example by Computor Conveyor Layout TABLE 23 Operating Conditions Material transported ] Nickel tron Ore Specific gravity ym? Laump size nme Temperature fc Teamoort quantity fun [rane [ iota: horepower kw [90 elt width ~ fom | 1.000 [ itortzonta ength ofsomeyor [1m a [in | Me ett slope av 25 al lel speed __4t 20 Angle of wap 20 | Type of drive ou inate [ Lani: petey 7 Lagrot (a= 0.31 | Drive pulley diameter rm | 1250 [stead putey diameter ron ‘Tal pulley diameter ssn | Siu pulley diomoter | un Tiowshingangle of carrying Wes |deg, | 30. Spacing of carving ders m [oo | Spuving oF return les na [30 Typeof skew curiae130 100) Bell Spee ST-2000 1000 x 6.26 x8 x6 (Assunned cover thickness) 3B45. Acceleration Tension and Acceleration Time ‘The tension requited for starting 4 conveyor in repose is approximately 135% of the maximum under-load sunning tension, The following formulae should be ‘used in adjusting the acceleration time (1) so that the total tension on starting is 135% of the maximum uunderload running tension (Fmax). VR £9) OW + Wind S88 Fa (ky) 45-1. Horizontal Conveyor PA” S88 Gk 588 Pa kl 45-2. Uphill Conveyor WAGER WE Wi) FAB EK [PCH &) OW 4 Wn) + Win bi] ¥ (C+ bo) V+ Wm) a LCENGIW EW) | Way bd 453. Downhill Conveyor é ¥ (G4 0) (W# Win) 8 Sen oR [FCRH 86) OWE Wind —W (G4 o) W# Won) BPA [TCH (WS Hy) Where Fa ¢ Avovleration tension (38) Fy = 0.8 ii, ts Acceleration time (s8¢.) 1 | Rotanng roller friction eootth y= Belt speed (mimir.) © + Horizontal conveyor lemeth (an) Bo + Adjusted horvontal length of conveyor (0) W = Weight of moving parts other than material lo be transported (kelm) Wp © Weigil of transport material (kw/m) bo Lift (nm) 46. Braking Tension and Braking Time 46-1, Braking Time ‘The braking time (1) of & conveyor is calculated from the Kinetic energy (F) of all moving parts according (© the following formulae: rb = Fpt Pn: E Wile Q-t-v x 1,000 2g » 3,600 x 60 (2mm? Where W_: Woight of belt and rollers’ rotating parts Ckgfn) © Horizontal sonveyor tema (1) v= Belt speed (infrnin,) 2 + Acceleration gravity (9.8 in/see.*) OL: Transport quantity Gonihry Py: Eflectise tension due to braking (xe) Fp: Effective tension due to axl> horsepower (ke S: Moving distance (m) {+ Reposing time (see) P Axle power (Ke) My: Braking toque at drive pulley (km) D-_ : Diameter of drive pulley (m) GD* + Elywheel effect (km?) N+ Revolutions (rev.see.) 34546-2, Determination of Braking Capacity 46.2.4. When Fp > 0 a) When the arrangement of the conveyor itself places ne restriction on stopping time, the con seyor at a whole can be stopped by switeh-off at the power source, b) When there i no need for brakes but 2-3 con veyors are used successively, the stopping time (0) is established frst and the braking capacity 's determined from (0). 46-2-2. When Fp <0 a) When 2-3 conveyors are employed suecesively, the braking capacity should be determined from «. b) The braking capacity should be fixed and (1) be Uetermined. The excess capacity due to extra (0) should be absorbed by providing the conveyor with a. hopper. ©) When: Py 1.25 (Fp Ler Fp-pe) Consideration of connte-weieht 's unmeces: Py > 1.25 (Ep or Ep-pa) Consideration of counterweight is necessary 35 47. Additional Resistance 47-41, Pull-Out Resistance from Hopper When there is a need to consider resistance from a hopper (as in the case of + feeder hell), the following formula is used 1,000 Bowes wboh-r Where Fh: Pullout resistance trom hopper (kg) u * Fretion coefficient between transport mate- rial and belt b= Width of hopper bottom (m) Length of hopper bottom (m) f+ Apparent specific gravity of material to be transported (ton/o ) h > Height of hopper Gm) Note: b= 3b47-2. Skirthoard Friction Resistance When a skirt i provided throughout the length of the conveyor belt, the friction resistance of the skittbourd must be allowed for. In such cases, calculate this resistance using the following formula’ W QE be 6007 For Fk = Where Fk : Skirtboard friction resistance (kg) 11 Friction coefficient between material to be transported ané belt (04) 4 : Voluine of load (tons) fk = Length of akin (om) v= Belt speed (m/min) T+ Apparent speciic gravity of material to be transported (tonfn) b+ Fifectve width of skiet (mm 48. Design of Bucket Elevator Belt 48-1, Calculation Formula for Transportation Volume 60 vere tae 48-2. Calculation of Maximum Belt Tension max pris Fs or Fiax = Fp+ Fi When QU(h tho) 0.06V Where QL + Trasportation volume (ton{hn) & + Bucket capacity (a8 each) 1 + Apparent specitic gravity of material to be transported (g/m!) ee ¥ Bele speed (m/min) sive eapacity of loxd per Bp: Bucket fitting pitch (m) Prax © Maxiznumn cension (kg) h Lift (m) ho + Liffadjustment due to scooping foree (m) F, + Slack side tension (ke) F,' > Lifting tension due to belt weight (ke) W, =: Bell weight (kg/m) Fy" = Lilie tension due to weight of bucket itso (ks) Be: Bucket weight (kgjeach)