BELT CONVEYOR

CONVEYOR SPECIFICATION

Material to conveying : Gravel

Capacity ( Cap ) : 5 m³/min

Distance ( L ) : 30 m

High of material hill (H) : 7 m

Location : Out-door

A. MATERIAL

Material name : Gravel

Mass density ( ɣ ) : 1920 kg/m^{3 ( wet )}

Surcharge angle ( δ ) : 20 ^o

Trough angle ( β ) : 30^o

Elevating high ( H ) : 7 m

Incline angle ( α ) : 15^o

Repose angle ( ρ ) : ( 30^{o -}45^o)

Speed ( V ) : 2.25 m/s

: 135 m/min

Notes : See Table-...

B. BELT SELECTION

Belt construction : Carcass & Cover
Carcass : PN-500/2 ( Polyurethane & nylon, 2 plies )

Thick : 3.3 mm

Allowable tension : 37 kN/m

Specific weight : 4.4 kg/m2

: 2.64 kg/m length

Cover : NR ( Natural rubber ),

suitable for mining, quarrying, general service.

Top cover : 6 mm

Bottom cover : 3 mm

Specific weight : 930 kg/m3
: 5 kg/m length

Carcass + Cover = Rubber belt conveyor

Rubber belt conveyor

Width ( B ) : 600 mm

Thick ( Tb ) : 12.3 mm

Belt load ( Qb ) : 7.64 kg/m length

Section area ( A ) : 0.0413 m2

Capacity factor ( Cf ) : 0.94 ( δ : 20^o , β : 30^o )

Capacity ( Cap ) : Cf . A . V

: 0.94 x 0.0413 x 2.25

: 0.0873 m3/sec ( 5.24 m3/min ) ⇒ Ok

Material load ( Qm ) : A . L . ɣ
: 0.0413 x 1 x 1920
: 79.3 kg/m

Notes : See Table-...

Cross section area of material ( A )

Drive pulley - A

Da : 450 x 650, mm
d : 90 x 1040, mm
Q'ty : 1 unit
W : 209 kg

Tail & Tension pulley - B

Db : 360 x 650, mm
d : 70 x 900, mm
Q'ty : 4 unit
W : 470 kg

Snub pulley - C

Dc : 280 x 650, mm
d : 60 x 890, mm
Q'ty : 1 unit
W : 85 kg

Idler pulley - D

Dd : 114 x 650, mm
d : 30 x 880, mm
Q'ty : 13 unit
W : 214 kg

Trough roller

D : 60 x 200 x 3, mm
d : 12 x 220, mm
Q'ty : 29 unit
W : 130 kg

Total weight of Pulleys : 209 + 470 + 85 + 214 + 130

: 1108 kg

Pulleys Load ( Qp ) : 1108 / L ( Conveyor length )

: 1108 / 30

( Qp ) : 36.93 kg/m length

D. BELT RESISTANCES

Resistance load ( F ) :

Principal Resistances ( Fp )
Scondary Resistances ( Fs )
Special Principal Resistances ( Fsp )
Special Secondary Resistances ( Fss )
Inclination Resistances ( Fi )

F = Fp + Fs + Fsp + Fss + Fi

Principal Resistances ( Fp )

Resistances of belt, pulley & material load

Fp = f . Lb . g [ Qp + ( 2. Qb ) + Qm ] cos α

= 0.02 x 63 x 9.81 x [ 36.93 + ( ( 2 x 7.64 ) + 79.3 ) x cos 15^o ]

= 1570.3 N

Where is Lb, total length of belt

Lb = ( 30 x 2 ) + ( 𝜋 x ( Da/2 + Db/2 ) + ( 𝜋 x Db ) + 2h = 63 m

g = 9.81 m/sec2

Bearing type	State	f
Ball / Roller	Good	0.018
	Normal	0.02
	Not good	0.023-0.03
Sliding		0.05

Secondary Resistances ( Fs )

Length correction factor

Fs = ( Cl . Fp ) - Fp

= ( 2 x 1570.3 ) – 1570.3
= 1570.3 N

Cl : Length correction factor
Belt length : 63 m

L belt - m	3	4	5	6	8	10	13	16	20	25	32	40
Cl	9	7.6	6.6	5.9	5.1	4.5	4	3.6	3.2	2.9	2.6	2.4

L belt - m	50	63	80	100	125	160	200	250	320	400	500
Cl	2.2	2	1.8	1.7	1.6	1.5	1.4	1.3	1.2	1.1	1.05

Special Principal Resistances ( Fsp )

Resistances of Trough roll

Fsp = ct . μ . Lt ( Qb + Qm ) . g . cos α . sin β

= 0.4 x 0.35 x 27 x ( 7.64 + 79.3 ) x 9.81 x cos 15^o x sin 30^o

= 1512.6 N

ct : Trought angle coefficient ( 0.4 ) ( 30^o = 0.4 / 45^o = 0.5 )
μ : Friction coefficient belt - trough roller ( 0.35 ) ( 0.3 – 0.4 )

Lt : Length of trough roller area ( 27 m )

Special scondary resistance ( Fss )

Resistance of chute sidewalls – material ( Fsc ) & Scraper – belt ( Fsx )

Fsc = Wc . k

= 0.46 x 1500
= 690 N

Fsx  = As . P . μ₂
= 0.014 x 30 x 0.5
= 0.216 N

As : Contact surface cleaning tool - belt

: ( 0.6 x 0.012 ) x 2 = 0.0144 m2

P : Pressure cleaning tool - belt

: 30 N

μ2 : Friction coefficient (cleaning tool – belt )

: 0.5

Wc : Width of belt ( Chute area )

: 0.46 m

k : Scrap factor ( Chute are )

: 1500 N/m

Fss = 690 + 0.216

= 690.2 N

Inclination resistances ( Fi )

Inclination resistances of materials

Fi = Qm . H . g
= 7.93 x 7 x 9.81
= 5445.5 N

TOTAL RESISTANCES ( F )

F = Fp + Fs + Fsp + Fss + Fi

= 1570.3 + 1570.3 + 1512.6 + 690.2 + 5445.5

F = 10,789 N

E. BELT TENSION

Tight side tension ( T1 ) & Slack side tension ( T2 )

T1 = F + T2 T1 / T2 = e^μ^.ϕ

T1 = T2 . e^μ^.ϕ

= T2 x e ^{0.3 x 210}

T1 = T2 x 9.151

9.151 x T2 = T2 + F

9.151 = 1 + ( F / T2 )

( F / T2 ) = 9.151 - 1

T2 = F / 8.151

= 10789 / 8.151

T2 = 1323.6 N

T1 = 1323.6 + 10,789

T1 = 12112.6 N

T max = T1 / B

= 12112.6 / 0.6

T max = 20187.6 N/m Allowable belt tension ( Ta ) : 37000 N/m

T max < Ta --> OK

F. GEARED MOTOR & SPROCKET

POWER : Sf . F . V . 10^-3   Sf : Safety factor
  : ( 1.5 - 2 )
: 1.5 x 10,789 x 2.25 x 10^-3

   : 36.41 kW

ROTATION ( n )

V x 60 = π x Da x n

n = ( V x 60 ) / ( π . Da )
= ( 2.25 x 60 ) / ( π x 0.45 )

n = 95.54 Rpm --> 100 Rpm

Geared motor : 37 kW / 100 Rpm

Chain

Chain tension = F

= 10.789 kN

Chain selection : RS-80 ( allowable tension, max 14.7 kN ) --> OK

Sprocket

n1 / n2 = t2 / t1

t2 = ( n1 / n2 ) x t1
= ( 100 / 95.54 ) x t1

t2 = 1.04 x t1

Shaft of geared motor d = 80 mm

Sprocket-1 : RS-80B / 40t

t2 = 1.04 x 40

= 41.6 ---> 42
= 42

Sprocket-2 : RS-80B / 42t

n2 actual = ( 40/42 ) x 100
= 95.23 Rpm

V actual = 3.14 x ( 0.450 + ( 2 x 0.0123 ) ) x 95.23
= 142 m/min ( 2.36 m/sec )

Cap actual = 0.94 x 0.0413 x 142 --> ( Cap : Cf . A . V )
= 5.512 m3/min --> OK

Geared motor : 37 kW / 100 Rpm
Chain selection : RS-80
Sprocket-1 : RS-80B / 40t
Sprocket-2 : RS-80B / 42t

G. BEARING UNIT

NO	PULLEY	DIMENSION	SHAFT Ø	Q'TY	BEARING TYPE	Q'TY	WEIGHT (kg)	REMARKS
1	A-Drive pulley	D-406 x L-650	85	1	CMUCF-317	1
					CUCF-317	1		Drive side
2	B-Tail pulley	D-318 x L-650	60	3	CMUCF-312	6
3	Tension pulley	D-318 x L-650	60	1	CMUCT-212-30	2	20 x 2	Tension range 300 mm
4	C-Snub pulley	D-267 x L-650	50	1	CMUCP-310-D1	2
5	D-Idler pulley	D-114 x L-650	25	13	CMUCP-305-D1	26
6	E-Trough roller	D-60 x L-200 x 3	12	29	6201-LLU	174

BELT CONVEYOR

BELT CONVEYOR - TROUGH TYPE

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