2. The process flow charts will be provided by the manufacturing engineer or the process engineer, depending on the type of installation the conveyor is serving.

3. Determine the path of the conveyor on a scaled layout of the plant.

4. Draw a plan and elevation of the conveyor as shown in the figure above, on a scaled layout of the plant. Show obstructions the conveyor will encounter, such as columns, walls, machinery, and work aisles. Indicate the loading and unloading zones, probable drive location, and passage through walls.

5. Develop a vertical elevation to determine inclined and declined dimensions.

6. Show the inclines and declines, and their dimensions. A three-dimensional view of the installation can be prepared at this point to help people better visualize the final installation and the various routes of the conveyor.

7. Determine the material movement rate, unit load size, spacing, and carrier design for the conveyor.

8. Information for these variables can be obtained from the flow chart and the personnel in charge of the process being served by the conveyor. It is important that the conveyor be designed for the maximum anticipated load and material size.

9. Modify turn radii to provide adequate clearances.

10. Prepare drawings showing needed load spacing on turns. Without adequate clearances, the conveyor may not provide the desired transportation capability needed to serve properly the process for which the conveyor is being designated.

11. Design the load for clearances on inclines and declines.

12. As inclines and declines get steeper, load spacing has to be increased to provide a constant clearance or separation between loads. The table below gives selected clearances on inclined track for overhead conveyors for a given separation at various inclined angles.

13. Redraw the conveyor path and vertical elevation views using newly determined radii and inclined information.

14. Show the new radii and inclined information as determined by the redesign of the system layout.

15. Compute the chain pull in the conveyor.

16. The chain pull is the total weight of the chain, trolleys, and other components, plus the weight of the carriers and load. Thus, the chain pull is given by:

17. CP=LPL(f)

18. Where: CP = tentative chain pull, in kg

19. L = length of the conveyor, in m

20. PL = chain load, in kg/m

22. Again, work with the standard radii available from the manufacturer, if possible. This will reduces installation costs and time.

23. Determine the conveyor power requirements and drive locations.

24. Make point-to-point calculations of the chain pull around the complete path of the conveyor. For the point-to-point chain pull:

26. Where: PT = pull for each traction wheel or roller turn, in kg

27. X = 0.02 for standard ball-bearing trolleys

28. W = total moving weight, in kg/m, empty or loaded as the case may be

29. S = horizontal span of vertical curve, in m

30. H = total change of level of conveyor, in m

31. + when the conveyor is travelling up the curve

32. - if the conveyor is travelling down the curve

33. Y = 0.02 for traction wheel or roller turn

34. Z = 0.03 for 30 deg incline, 0.045 for 45 deg incline, 0.06 for 60 deg incline, 0.09 for 90 deg incline

35. P = pull at start of curve, in kgs

36. For the drive horsepower,

37. HP=Fv0.6(33,000)

38. Where:HP = drive horsepower, in hp

39. F = drive capacity, in lbs

40. F = PH + PT + PV

41. v = maximum belt speed, in ft/min

42. Design the conveyor supports and superstructures

43. Design guards required by laws and codes

44. The general procedures presented here is valid for overhead conveyors handling a variety of materials: manufactured goods, parts for assembly, raw materials, etc., in plants in many different industries. Since conveyor layout, sizing and safety design are a specialized skill, the engineer should consult carefully with the conveyor manufacturer. The manufacturer’s wide experience will be most helpful to the engineer in achieving an economical and safe design for the installation being considered.

45. Reference: Handbook of Mechanical Engineering Design and Calculations by Tyler G. Hicks, 10.5 – 10.9

46. (Some values and nomenclatures were changed)