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Belt Conveyor Pulley Design - Why the Failures

BELT CONVEYOR PULLEY DESIGN - WHY THE FAILURES?

TERRY KING Pr. Eng. B.Sc Mech Eng (Hons) M.S.A .I.M.E. A .S.S.A .I.M.M. Design Engineer to the Bosworth Group of Companies

1. SUMMA RY A syste m for the de sign and dim e nsioning of conve yor be lt pulle ys, in a m anne r which pe rm its use at drawing office or com putational le ve l, is laid out. The the ore tical m ode l is use d to e x plain the re ason for som e com m on failure s and to place in conte x t som e of the pulle y construction fe ature s se e n in re ce nt ye ars. Lastly, an account is give n of the factors which lim it the life of a pulle y and a de sign is propose d for the ne x t ge ne ration of long-life , low cost pulle ys for the South African m ark e t. 2. INTRODUCTION 2.1 Historical Context Gre at stride s have be e n m ade in re ce nt ye ars in the provision of low m ass be lts with e ve r highe r te nsion ratings. In m any case s the se low m ass be lts pe rm it the use of sm all diam e te r pulle ys, whilst the te nsion ratings de m and sim ilar or incre ase d shaft diam e te rs. O fte n the conve yor de signe r ne e d not re strict him se lf to the lim its of the be lt. Howe ve r, in situations such as in-se am unde rground conve yors, whe re the transfe r points, te nsion se ction and drive are all of re stricte d he ight, the optim um size is re quire d. Sim ilarly, in the pulle y construction fie ld, wide acce ptance has be e n e arne d for the conne ctions originally introduce d by R ingfe de r. The se have k e yle ss shaft

re sulte d in a ne w ge ne ration of pulle y

constructions be ing adopte d, de signe d large ly by the use r com pany or m ine . It has also le d to a confusion of diffe re nt pulle y style s, back e d by conflicting claim s as to the ir value . 2.2 Design Standards The situation of de signs be ing produce d at m any place s in South Africa and use d to and in som e case s be yond the ir lim its has le ad to the re quire m e nt of a practical de sign standard against which the lim itations of a give n pulle y construction can be de te rm ine d. Such inform ation is available pie ce m e al but is not in a re adily usable form . It is the purpose of this pape r to supply such a de sign syste m , the syste m be ing justifie d both analytically
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Belt Conveyor Pulley Design - Why the Failures

and by com parison with failure s re corde d in re ce nt ye ars. It is a spe cific aim of this pape r to avoid analytical te chnique s unsuite d for use at drawing office le ve l. W he re this has re quire d sim plifications it is note d in the te x t. C le arly, not e ve ry aspe ct of de sign is stre ss-base d. W he re this is the case . note s on succe sse s and failure s are give n for your guidance . Lastly, an atte m pt has be e n m ade to place in conte x t som e of the construction fe ature s that have be e n appe aring and disappe aring in re ce nt ye ars. This is aim e d at im proving consiste ncy and providing a basis for standardisation and ne w de sign think ing. 3. A NA LYTICA L SYSTEM 3.1 Background A num be r of authors (1, 2, 3, 12, 13) work ing in Ge rm any be twe e n 1963 and 1973 have contribute d m uch to the study of pulle y stre sse s. Unfortunate ly, the disse rtations re sulting have only re ce ntly be e n translate d and are at a le ve l not conve nie ntly use d in the de sign office . The y de scribe syste m s which diffe r from local practice in a num be r of im portant re spe cts. 3.1.1 Shaft and drum e nd m ate rials are of significantly highe r te nsile stre ngths. 3.1.2 Pulle y proportions are diffe re nt, drum diam e te rs be ing in the range 1000 to 1750 m m , drum widths are sim ilar to local practice . 3.1.3 Manufacturing m e thods are aim e d at low m ass. Locally, m ass has re m aine d se condary to m anufacturing e conom y due to a lack of standardisation and the unde m anding conditions our pulle ys have work e d in. The work s re fe rre d to have the re fore be e n adapte d to form m uch of the basis for the m e thod which follows. The m ain value of this m e thod be ing that e ach part of the pulle y can be tre ate d individually with m inim al re pe tition re quire d. 3.2 Common Constructions Figure s 1 (a to d) show som e com m on pulle y constructions use d locally, all of which can be analyse d by the syste m de scribe d. Variations such as asym m e trical e nd plate s are adm issible and have be e n shown (3) not to affe ct the stre ss patte rn significantly. The shading of pulle y se ctions indicate s the stre ss le ve ls e ncounte re d, dark are as be ing highly stre sse d, and will be re fe rre d to in the te x t.

Fig.1a - W e ld-in-hub C onstruction

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Belt Conveyor Pulley Design - Why the Failures

Fig.1b - Plate End C onstruction

Fig.1c - R e fine d Plate End C onstruction

Fig.1d - Forge d Hub C onstruction 3.3 System of A nalysis 3.3.1 Shaft Sizing The shaft m ust be size d both for the stre sse s at its point of e ntry to the hub and for its de fle ction. Find Drive Torque T, if any, and shaft be nding m om e nt M in the usual way m ak ing allowance for duty factors. From the se find the following: C om bine d Torsion Mom e nt Te = T + M C om bine d Be nding Mom e nt Me = (M + Te ) (Equation 1) (Equation 2)

Using the se m om e nts in the Torsion and Be nding Equations give s the first two possible diam e te rs (4). Torsion Base d Diam e te r:

__________ dr = 3

Te x 16000 s x PI

(Equation 3.)

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Belt Conveyor Pulley Design - Why the Failures

Be nding Base d Diam e te r:

__________ db = 3

Me x 32000 s x PI

(Equation 4.)

Note s and s are tak e n to be e qual since the allowable dire ct principle stre ss s is a fatigue case and the she ar stre ss s is not. Value s for the principle stre sse s can be found from BS 153 Parts IIIb and IV : 1972 or any sim ilar authority. O the rwise value s in the range 41,5 to 45 Mpa(5) have be e n found satisfactory for BS 970 : 1972 070M20 (EN3A) ste e l, the m ost com m on shaft m ate rial. A third possible diam e te r should always be de te rm ine d from the "fre e " shaft de fle ction as be low: De fle ction Base d Diam e te r:

_________ dd = 4

W .a.L.1600 E.PI.

(Equation 5.)

W he re : W = Ne tt Te nsion without duty factor a = Be aring ce ntre to hub distance L = Hub spacing E = Youngs m odulus for shaft = Allowable de fle ction

KN mm mm N/m m radians

C onve nie nt de fle ction lim its are in the re gion of 0,001 radians for shaft conne ction hubs and 0,01 radians (8) for shrink fit hubs. The large st of the thre e possible diam e te rs should now be chose n or a re asonable com prom ise re ache d. If it is a drive pulle y the shaft conne ction can be se le cte d using the drive torque . For non-drive pulle ys any appropriate conne ction can be chose n using a suitable guide (11). 3.3.2 Hub Diameter

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Belt Conveyor Pulley Design - Why the Failures

In this syste m the hub is first size d by m ax im ising the circum fe re ntial stre ss at the inne r e dge , using Lam s e quations (10) suitably transpose d as follows:

______ do = di

fc + q fc - q

mm

(Equation 6.)

W he re :

d i = hub inside (conne ction outside ) diam e te r

mm

f c = m ax hub stre ss allowable (e g 80% of yie ld) N/m m q = conne ction to hub pre ssure from catalogue N/m m

This e stablishe s the m inim um hub size d o. It is now ne ce ssary to che ck the circum fe re ntial stre ss at the outside of the hub to e nsure that e x ce ssive stre ss is not applie d to the ne x t com pone nt, whe the r it is a we ld or a diaphragm . For this, apply the e quation:

Ex te rnal circum fe re ntial hub stre ss = f

1 c

1 c

= 2 qd i/(do - di) N/m m

(Equation 7.)

Now one of se ve ral situations will occur. The hub will alre ady be too large to fit the pulle y. In this case use one of the spe cial low pre ssure conne ctions (se e (11)) and start 3.3.2 again or use a large r pulle y. The hub will fit in the pulle y but the oute r e dge of the hub approache s the drum attachm e nt we ld. This is a good re ason for adapting a construction such as Fig lb. Note that the allowable e x te rnal tange ntial stre ss m ust be re duce d to allow for we ld im pe rfe ctions. A low pre ssure conne ction can be advisable to assist in this. Note also that for this construction, the hub stre sse s are additional to the diaphragm stre sse s de alt with be low. The hub is an acce ptable proportion of the pulle y diam e te r and a construction such as 1a, 1c or 1d is appropriate . 3.3.3 Construction Choice C hoice be twe e n 1a, 1c and 1d de pe nds large ly upon shaft attachm e nt m e thod. Sche m e s 1a and 1d have e x te nde d hubs in orde r to distribute the ve ry high radial attachm e nt force s from shrink fits along the shaft without local m ate rial collapse . The se are unne ce ssary whe n using shaft conne ctions, pure ly se rving to add cost. In this case 1c is indicate d or 1b for e conom y. If shrink fits are re taine d, as the y should be for m ax im um e conom y, the n a construction such as 1a is indicate d and for he avie r pulle ys 1d, the m ajor
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Belt Conveyor Pulley Design - Why the Failures

value of 1d is to e lim inate the diaphragm to hub we ld from a ve ry highly stre sse d are a. 3.3.4 Shrink Fit Hubs It will be note d that no atte m pt has be e n m ade to size shrink fit hubs, this topic could be a pape r in itse lf. Shrink fits are e x tre m e ly se nsitive to m anufacturing tole rance s and cannot practicably be de alt with without the collaboration of the m anufacture r. It is sugge ste d the re fore that the ide ntical proce ss de scribe d in 3.3.2 be use d to size the se hubs or that a particular m anufacture rs data be adopte d. 3.3.5 Hub Width C hose n, in the case of shaft conne ctors as the m inim um hub width that will se cure the e le m e nt. This is sufficie nt. If the pulle y is of a construction having no se parate hub such as Figure 1b the n ignore this se ction and proce e d to 3.3.6. 3.3.6 Diaphragm Stress Components The diaphragm of a pulle y is subje ct to a num be r of loads. The se can be sum m arise d as follows: R adial Be nding Mom e nts due to shaft de fle ction. R adial dire ct stre ss due to pulle y load. Tange ntial she ar stre ss due to drive torque . In addition the re m ay be a radial dire ct stre ss due to shaft conne ction loads. The first sim plification is to ignore the Tange ntial she ar com pone nt. The se have be e n found to be ne gligible for the m ate rial thick ne sse s involve d, as in Figure 2a. Se condly, the approach sugge ste d by som e authors for radial dire ct stre ss (12,3) was adopte d afte r che ck ing against e x pe rim e ntal re sults (3). It e quate s to a sim ple proje cte d are a approach, thus;

R adial Dire ct Stre ss f d =

W 2d ot

N/m m

(Equation 8.)

W he re : t = diaphragm thick ne ss This stre ss is e qual com pre ssive and te nsile on opposite side s of the pulle y (3). R adial Be nd Stre ss is de rive d as follows: Firstly re lative stiffne ss' of shaft and drum are e stablishe d. PI x d 4 32(L-200)

Shaft Stiffne ss C onstant K6 =

mm

(Equation 9.)

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Belt Conveyor Pulley Design - Why the Failures

W he re : d = shaft diam e te r. Diaphragm Stiffne ss C onstant = K5

K5 =

2,73 PI

1 - R 1 + R

+ log (R ) ) m m

(Equation 10.)

W he re : R = ratio of diaphragm diam e te rs =

di do

The n, a suitable thick ne ss is chose n by se tting radial dire ct stre ss to one third of the allowable fatigue stre ss and finding an e stim ate d t value from Equation 8. Ne x t the actual diaphragm stiffne ss is calculate d, for this t value as be low:

Diaphragm Stiffne ss K7 =

t K5

(Equation 11.)

If the drum is assum e d infinite ly stiff com pare d with shaft and diaphragm (re asonable since stiffne ss is the fourth powe r of diam e te r, as supporte d by e x pe rim e ntal re sults (1)). The n the Be nding Mom e nt is distribute d in pulle y e nd and shaft in proportion to stiffne ss, as follows:

Diaphragm Be nding Mom e nt Md =

K7 . M K7+K6

Nm

(Equation 12.)

Now the pulle y e nd can be tre ate d as a flat plate having rigidly supporte d e dge s (3,2,13) with good accuracy.

Flat plate constant K8 =

(1 - R )

PI.R (1 + R )

(Equation 13.)

and finally

Diaphragm radial be nd stre ss f b =

M d.K8.2000 d ot

(Equation 14.)

Max im um fluctuating stre ss occurs on the pulle y e nd at the diaphragm /hub joint, he re the pe ak stre ss is as follows: Pe ak Stre ss f max = f r + f b + f c W he re : f r = shaft conne ctor pre ssure , if appropriate . Minim um Stre ss f min = f r - f b - f d (+ve or -ve ) From the se stre sse s and the fatigue table s the thick ne ss use d can be asse sse d and e quations 8. and 11. to 14. re vise d if ne e de d.
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Belt Conveyor Pulley Design - Why the Failures

The thick ne ss of the diaphragm m ay be incre ase d at will, since the e ffe ct of diaphragm thick ne ss on stre ss le ve l is shown in figure 2a work e d in the m anne r above for a pulle y of typical proportions. The socalle d "fle x ible " e nd pulle y doe s not e x ist e x ce pt in drum s of the proportion of m ine -winde rs, e .g. Figure 2b whe re a significant low stre ss at low thick ne ss re gion is visible . The re fine d profile shown in Figure 1c is de rive d by using the calculation syste m above to find a m inim um thick ne ss at the hub and the n re ducing this in the ratio of the diam e te rs outward toward the drum . Toge the r with large ble nd radii at the hub diam e te r, this achie ve s the m ost e ve n stre ss distribution fe asible . 3.3.7 Pulley Drums Se ve ral authoritie s (1,3,10) have de vise d syste m s for asse ssing the stre ss le ve l in the drum surface . Howe ve r, the data provide d whe n e x te nde d for local pulle y proportions, re sults in drum thick ne sse s that are im practically thin from the we ar p oint of vie w. For e x am ple , 4m m plate for an 1100 m m wide pulle y with 304 KN re sultant te nsion. Both te st re sults and obse rvations of pulle ys afte r se rvice confirm that the the ory is corre ct. It is re com m e nde d that drum thick ne ss is the re fore conside re d care fully toge the r with lagging and inne r diaphragm s in the light of the points m ade in 4.3

4. FA ILURES A ND SUCCESSES During 1982/83 all pulle ys re turne d to Bosworth Ste e l Structure s for re furbishing and re place m e nt we re e x am ine d for m ode of failure . Som e typical e x am ple s are give n be low in the light of the fore going analytical syste m , with com m e nts on construction tre nds in the industry. 4.1 Shaft and Shaft Connection Related Failures 4.1.1 Shafts Many authoritie s are te nding to frown on use of re duce d journal diam e te rs to the shaft e nd. The practice of "journaling" arose from the significant be aring housing cost savings which can be achie ve d on large shafts. The se savings are still available at no cost in be aring life . The argum e nt against journaling is one
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of practice not principle , the following faults still arising fre que ntly: Journals place d too close to the hub, so that the re duce d diam e te r and incre ase d stre ss as de scribe d by Pe te rson (7), apply in Equations 3. and 4. R adius and surface finish re quire d are not spe cifie d by the de signe r. Manufacturing le ave s significant stre ss raise rs on the ste pdown radius. Ste p downs are use d on shafts whose be aring costs are ne gligible . Figure s 3 a and b de m onstrate good and bad practice in this fie ld. W e sugge st that journaling m ay be not only an e conom ical practice but also a possible m e ans of standardising pulle y m ountings across a conve yor sche m e without e x ce ssive capital cost and are the re fore a use ful practice . 4.1.2 Shaft Connections Pulle y shaft conne ctions are ofte n haile d as the answe r to a m aide ns praye r.

FIG 3a A W ELL R ADIUSED SHAFT AND HUB

FIG 3b A FAILED SHAFT W ITH SMALL R ADIUS AT THE STEP-DO W N This is justifie d provide d the following points are born in m ind: Shaft conne ctions de pe nd totally on friction for the ir e ffe ct. The y de m and the sam e re spe ct as be arings in the ir application. Machining tole rance , surface finish and contam ination are all pote ntial cause s of failure . Shaft re m oval afte r se rvice is ofte n possible (11) but the shaft and e le m e nt are lik e ly to re quire re ne wing, since corrosion se ve re ly affe cts the ope ration of the e le m e nt. Shaft size s m ust ofte n be incre ase d up to 12% due to the de fle ction lim itation. Spe cification of
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Belt Conveyor Pulley Design - Why the Failures

high stre ngth ste e l, doe s not im prove this. (Se e e quation 5). Sm all size conne ctions, up to 120 dia. have high shaft to conne ctor pre ssure as appropriate to the Europe an shaft m ate rials. C om pare d to EN3A the se pre ssure s of up to 250 Mpa(I6) be fore pulle y loading are e x ce ssive and incre ase the risk of dam age as in Figure 4 whe n fitting the shaft. C onne ctions are far too loose ly spe cifie d without re gard to the ir prope rtie s. If all this is tak e n into account failure s such as that in Figure 5 can be avoide d. It is sugge ste d that the shrink -fit not be abandone d too re adily, particularly for light pulle ys, as this is still the m ost e conom ical conne ction m e thod and conside rable e x pe rie nce has be e n built-up in its use . As one authority (17) says "For highly stre sse d shaft-hub conne ctions the shrink -fit is unsurpassable ..... re garding fatigue stre ngth unde r alte rnating torsional stre ss". FIG 4 SHAFT DAMAGE DUE TO SHAFT C O NNEC TIO N

FIG 5 SHAFT C O NNEC TIO N DAMAGE DUE TO PO O R APPLIC ATIO N

4.2 Drum End Influences The the ory advance d by som e com m e ntators (14) that a thin "fle x ible " diaphragm is appropriate , re sults from tak ing the radial be nding stre ss out of conte x t. Figure 2a de m onstrate s that a re gion whe re stre ss incre ase s with thick ne ss doe s e x ist, but is insignificantly sm all e x ce pt in ve ry large diam e te r pulle ys with e x traordinary be aring ce nte rs (Figure 2b). This is born-out in practice by Figure s 6 and 7a which show two typical case s of ve ry light diaphragm pulle ys, failure having occurre d at the inside and outside diaphragm we lds re spe ctive ly, due to radial fatigue stre sse s. Failure in Figure 7a m ay have be e n haste ne d by shrink age stre sse s in the we ld. Shrink age stre ss is k nown to be a hazard particularly in sm all diam e te r pulle ys. Stre ss re lie ving is re com m e nde d to off-se t this proble m in critical applications. The opposite e nd of the scale is shown by Figure 7b, one of a range of pulle ys with inte rm e diate diaphragm thick ne sse s. W e are not aware of a single re porte d failure of such a pulle y.

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Belt Conveyor Pulley Design - Why the Failures

FIG 6 FAILED HUB/DIAPHR AGM W ELD IN THIN DIAPHR AGM PULLEY

FIG 7a FAILED DIAPHR AGM/SHELL W ELD IN THIN DIAPHR AGM PULLEY (Arrow shows line of we ld fracture )

FIG 7b A MEDIUM-HEAVY DIAPHR AGM DUR ING PULLEY ASSEMBLY 4.3 Drum Surface Phenomenon W he n talk ing of drum surface we ar, "failure " is a contradiction in te rm s. The tim e at which a drum surface be com e s unusable due to we ar le gitim ate ly de te rm ine s the use ful life of the pulle y. If we assum e that the re m aining structure of a pulle y can be m ade sound, the n it be com e s ve ry im portant to unde rstand the way the drum be have s in orde r to im prove pulle y pe rform ance . Sadly our unde rstanding is ve ry incom ple te . A fe w ge ne ral points can howe ve r be m ade as outline d be low: 4.3.1 The ve ry low le ve l of stre ss m e ntione d in 3.3.7 is a re al phe nom e non. This has be e n de m onstrate d e x pe rim e ntally (1, 3, 18) and is de m onstrate d practically in Figure 9. To the be st of our k nowle dge , this pulle y was re place d due to be aring failure , both e nds. The the ory also te lls us that the drum fatigue stre ss unde rgoe s thre e cycle s pe r re volution, not one . This is shown in Figure 8 re produce d from (3). 4.3.2 Inne r diaphragm s have a m ark e d e ffe ct on pulle y we ar, Figure s 9 and 10 and 11a are pulle ys with none , one and two inne r diaphragm s re spe ctive ly, In e ach instance the "saddle back " be twe e n diaphragm s can be cle arly se e n. In our atte m pt to de te rm ine why a stiffe ne r should affe ct the rate of we ar we disse cte d som e use d drum s. Figure 11a and 12a show two of the se drum s, be twe e n se ve n and te n ye ars old. O n m e asuring the dim e nsional change s of the drum we produce d the re sults shown in Figure s 11b and 12b.
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Belt Conveyor Pulley Design - Why the Failures

W e conclude d as follows:

Fig 8 : Ax ial stre sse s in the pulle y she ll

FIG 9 A W ELL W O R N DR UM SHO W ING HO W LITTLE MATER IAL IS NEEDED IN A FUNC TIO NING PULLEY

FIG 10 W EAR PATTER N IN A SINGLE INNER DIAPHR AGM PULLEY

FIG 11a W EAR PATTER N O N A PULLEY SHELL (two inne r diaphragm s)

FIG 12a W EAR PATTER N O N A PULLEY SHELL (one inne r diaphragm ) FIG 11b PLO T O F DIAMETER S O F USED PULLEYS SHO W ING SHELL W EAR AND DISTO R TIO N

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Belt Conveyor Pulley Design - Why the Failures

FIG 12b PLO T O F DIAMETER S O F USED PULLEYS SHO W ING SHELL W EAR AND DISTO R TIO N

W e ar rate is asym m e trical due to une ve n be lt te nsion. The visible distortion is due in approx im ate ly e qual parts to we ar (m e tal loss) and to plastic de form ation of the surface . The latte r ite m e x plains the e ffe ct inne r diaphragm s have . The distortion is due to fatigue at low stre ss 4.3.3 W e can now arrive at som e guide line s. Firstly, poor be lt track ing is a prim ary cause of rapid drum we ar. Se condly, inne r diaphragm s do he lp to distribute drum we ar e ve nly. Thirdly, since the purpose of inne r diaphragm s is one of support (stiffne ss) and not one of stre ngth, thick ne ss is unlik e ly to be im portant. A fe w thin diaphragm s are thus be tte r than one thick one . Fourthly, the succe ss of your chose n drum thick ne ss is de pe ndant on we ar rate , for your carrie d m ate rial. Not on any stre ssing te chnique now available . It is strongly re com m e nde d that all drum s are lagge d in orde r to pre ve nt m e tal we ar. If this is done e x tre m e ly thin she lls with inne r diaphragm s to pre se rve the ir shape can be utilise d safe ly. R e m aining plastic de form ation is not of any conse que nce on its own. This saving in the she ll has a large e ffe ct on pulle y cost and m om e nt of ine rtia. Lastly two cautions are appropriate : He avy diaphragm we lds, un-stre ss re lie ve d, have be e n a cause of drum failure and should be avoide d. If you still wish to abandon inne r diaphragm s conte m plate the re sults of the loose pie ce in Figure 10 or 13 e nte ring your be lt syste m . An inne r diaphragm would pre ve nt this sort of occurre nce .

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Belt Conveyor Pulley Design - Why the Failures

FIG 13 A FAILED SHELL C R EATING R ISK-O F SEVER E BELT DAMAGE 5. CONCLUSION If we in South Africa are to m ove ahe ad of the Europe an pulle y produce rs a num be r of ite m s are re quire d: Shaft conne ction m e thods be tte r suite d to the m ild ste e ls we corre ctly favour using. An im prove d unde rstanding of the com pone nt which de te rm ine s the life of a pulle y. The Drum . Manufacturing te chnique s which are e conom ical unde r our conditions. A m ore wide spre ad appre ciation of the cost of we ar in our ope rations. Be arings of acce ptable life -span. Figure s 14 shows a possible ne x t-ge ne ration pulle y which de m onstrate s m ost of the se fe ature s. Shaft conne ction is by k e y-le ss close control fit, allowing a 15% sm alle r shaft without risk of fre tting corrosion in the asse m bly. Shaft m ate rial is still m ild ste e l and the whole is we ll suite d to sm all diam e te r large shaft pulle ys since it is com pact. Drum e nd is turne d from plate with m inim um wastage and giving e x ce lle nt stre ss distribution. Pulle y we ld is m ade in a position of low stre ss, whe re autom atic te chnique s and non-de structive te sting can be applie d re liably. Inne r diaphragm s are use d to control plastic de form ation cause d by low stre ss high cycle fatigue .

Fig.14 NEW GENER ATIO N BELT C O NVEYO R PULLEY -C O MPAR ED W ITH C UR R ENT EQ UIVALENT H7 - to 1 thou/inch All pulle ys would be cove re d in a low cost high we ar re sistant two-color lagging. Ex ce ssive we ar is indicate d by change of color in tim e for re -lagging.
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Such a pulle y is be twe e n twe nty and thirty pe rce nt che ape r than the curre nt e quivale nt and would last inde finite ly or until the be arings saw through the shaft. In closing m ay we in the pulle y industry m ak e a ple a in the inte re st of sim plifie d m anufacture . In one nine m onth pe riod re ce ntly, one pulle y com pany m anufacture d 47 diffe re nt pulle y diam e te rs, 41 diffe re nt face widths and 25 diffe re nt shaft diam e te rs. More than 10 diffe re nt constructions we re e m ploye d, m ak ing a total of m ore than 480,000 diffe re nt pote ntial pulle y de signs, not counting shaft variations. W he n drawing up your ne x t com pany standard m ay we ask that you talk to a m anufacture r, or be tte r still, use ISO 1536 (19) as a guide so that we can he lp you by m ak ing m ore e conom ical pulle ys in a rational range of size s. A CKNOWLEDGEMENT The author wishe s to thank all the m e m be rs of staff of Bosworth Ste e l Structure s (Pty) Lim ite d and in particular Mr. Ge rald Bosworth, also m e m be rs of the Engine e ring faculty of the Unive rsity of the

W itwate rsrand for the ir invaluable assistance in the pre paration of this pape r. REFERENCES

1. SC HMO LTZI W . De signing drum s with transve rse shafts for be lt conve yors. The sis for Doctorate in
Engine e ring, Hannove r, 1974.

2. LHR G. C alculation work on plate e nds for we lde d te nsion and drive pulle ys. Forde rn and He be n
14 (1964), No. 2 p. 102-104.

3. LANGE H.- Inve stigation in stre ssing of conve yor be lt drum s. The sis for Doctorate in Engine e ring,
Hannove r 1963.

4. INC O EUR O PE LIMITED. De sign Data for shafts, 2nd Ed, W ightm an Mountain Lim ite d, London,
1950.

5. C EMENT SER VIC ES (PTY) LIMITED. C onve yor pulle y shafts spe cial re quire m e nts in conne ction with
work ing stre sse s. PD.411. Nov. 1972.

6. ASA B17c. C ode for the de sign of transm ission shafting. 7. PETER SO N R .E. Stre ss conce ntration factors. W ile y Inte r-Scie nce , 1974. 8. C O NVEYO R EQ UIPMENT MANUFAC TUR ES ASSO C IATIO N. Be lt conve yors for bulk m ate rial, 2nd Ed.,
C BI, Boston, 1979.

9. R O AR K R .J. AND YO UNG W .C . Form ulas for stre ss and strain, 5th Ed., McGraw-Hill, 1975. p504 10. TIMO SHENKO S.P. AND W O INO SKY-KR IEGER S. The ory of plate s and she lls, 2nd Ed., McGraw-Hill,
1955.

11. KING T.J. Use rs guide to shaft conne ctions. Bosworth Ste e l Structure s, Johanne sburg, 1982. 12. BAHR J. Ne ue Proble m e de r Bandte chnik , Frie be rge r Forschungs - He fte A207, Acade m i - Ve rlag
Be rlin, 1962, p. 55 - 72.

13. HASSELGR UBER

H. Zur Be re chnung de r durch Konstruction 6 (1954), No. 5 p. 194 - 197. 1982.

e in

Bie ge m om e nt

be laste te n

k re isringplatte ,

14. LLO YD B.E. De sign of conve yor pulle ys, pape r pre se nte d at Be ltcon 1 C onfe re nce , Johanne sburg, 15. BIKO N 4000 MANUAL. No. 2003, W ie se ngrund, 1979. 16. R INGFEDER . R fu 7012 MANUAL. No. S79E, Kre fe ld, 1980. p 4. 17. C HILDS T.H.C . The contact and friction be twe e n flat be lts and pulle ys. Int J of Me ch.Sci, Vol 22,
1980 pp 117 - 126.
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Belt Conveyor Pulley Design - Why the Failures

18. ISO

1536-1975(E). C ontinuous Me chanical handling. Equipm e nt for loose bulk Troughe d be lt conve yors (othe r than portable conve yors) - Be lt pulle ys, lst Ed., 1975.

m ate rials -

O ffice rs: C .W . Ne lson, M.G. C ohe n, A.E W ock e , W . Stobbs, S. He rholdt, J.R Brie rle y, P.N.J. W hite , R .P. Hannon, G.A. Frangs and D. McArthur.

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