Belt conveyor example calculation

DESIGN SP
DETERMINE BELT WIDTH/DRIVE POWER/BELT TENSION/TAKE
BELT CONVEYOR
BASE ON
DESIGN SPECIFICATION
TRANSPORT CAPACITY, Qt =
MATERIAL BULK DENSITY,
SURCHARGE ANGLE = 20
BELT TROUGH ANGLE = 30
BELT SPEED, v =
HORIZONTAL LENGTH, L =
VERTICAL LIFT, H =
GRAVITY TAKE
CARRIER ROLLER SPACING, lc =1 m
RETURN ROLLER SPACING, lr = 3
DRIVE PULLEY WRAP ANGLE, θ = 210
FRICTION COEFFICIENT OF IDLER ROLLER, f = 0.022
FRICTION COEFFICIENT BETWEEN DRIVE PULLEY
DRIVE UNIT EFFICIENCY, η = 8
BELT CONVEYOR
BASE ON YOGOHAMA CONVEYOR BELT
CIFICATION: UPHILL CONVEYOR/
MATERIAL BULK DENSITY,
SURCHARGE ANGLE = 20
BELT TROUGH ANGLE = 30
BELT SPEED, v = 2.5 m/sec
HORIZONTAL LENGTH, L =
VERTICAL LIFT, H = 35 m
GRAVITY TAKE-UP DISTANCE FROM HEAD PULLEY
RETURN ROLLER SPACING, lr = 3
DRIVE UNIT EFFICIENCY, η = 8
BELT CONVEYOR EXAMPLE
YOGOHAMA CONVEYOR BELT
UPHILL CONVEYOR/
TRANSPORT CAPACITY, Qt = 2,400 ton/h
MATERIAL BULK DENSITY, γ = 1.80 ton/
SURCHARGE ANGLE = 20 degree
BELT TROUGH ANGLE = 30 degree (3 ROLLER)
m/sec or v = 150
HORIZONTAL LENGTH, L = 250 m
m
UP DISTANCE FROM HEAD PULLEY
RETURN ROLLER SPACING, lr = 3 m
DRIVE UNIT EFFICIENCY, η = 85%
EXAMPLE CALCULATION
UPHILL CONVEYOR/DRIVE AT HEAD
ton/h
ton/
(3 ROLLER)
150 m/min
DRIVE PULLEY WRAP ANGLE, θ = 210 degree
CALCULATION
DRIVE AT HEAD WITH GRAVITY TAKE
UP DISTANCE FROM HEAD PULLEY, Lt = 10 m
FRICTION COEFFICIENT OF IDLER ROLLER, f = 0.022 (good installation)
SURFACE AND CONVEYOR BELT, μ = 0.3
DETERMINE BELT WIDTH/DRIVE POWER/BELT TENSION/TAKE-UP WEIGHT
CALCULATION BY LION CAVE TEAM THAILAND
YOGOHAMA CONVEYOR BELTS TECHNICAL INFORMATION
WITH GRAVITY TAKE
(good installation)
AND CONVEYOR BELT, μ = 0.3
UP WEIGHT/SELECT BELT CARCASS
BY LION CAVE TEAM THAILAND
TECHNICAL INFORMATION
WITH GRAVITY TAKE-UP
AND CONVEYOR BELT, μ = 0.3
/SELECT BELT CARCASS
AND CONVEYOR BELT, μ = 0.3 (normal condition)
/SELECT BELT CARCASS
(normal condition)

STEP 1/SIZING BELT WIDTH
FROM TABLE 1.5
FROM TABLE 1.3
BELT CONVEYOR
FROM TABLE 1.5
CAPACITY REDUCTION RATE
FROM TABLE 1.3
COEFFICIENT OF SECTION AREA
TRANSPORT CAPACITY,
Qt = TRANSPORT CAPACITY
A = LOADED CROSS SECTIONAL AREA OF CONVEYING MATERIAL(
γ = CONVEYING MATERIAL BULK DENSITY(ton/
v = BELT LINEAR SPEED(m/min) = 150 m/min
i = CAPACITY REDUCTION RATE = 0.97
LOADED CROSS SECTIONAL AREA,
K = COEFFICIENT OF SECTION AREA = 0.1488
B = BELT WIDTH(m)
THEN
AND
CONVEYOR INCLINATION
FROM TABLE 1.5 INCLINATION ANGLE α = 8 degree
CAPACITY REDUCTION RATE
FROM TABLE 1.3 TROUGH ANGLE
COEFFICIENT OF SECTION AREA
TRANSPORT CAPACITY,
TRANSPORT CAPACITY
= CAPACITY REDUCTION RATE = 0.97
B = BELT WIDTH(m)
THEN Qt = 60*K*
D BELT WIDTH
ATION ANGLE
INCLINATION ANGLE α = 8 degree
CAPACITY REDUCTION RATE, i = 0.97
TROUGH ANGLE = 30 degree AND MATERIAL SURCHARGE ANGLE = 20
COEFFICIENT OF SECTION AREA, K = 0.1488
TRANSPORT CAPACITY(ton/h) = 2400 ton/h
Qt = 60*K*( .
BELT WIDTH =
ANGLE, = tan
INCLINATION ANGLE α = 8 degree
, i = 0.97
30 degree AND MATERIAL SURCHARGE ANGLE = 20
K = 0.1488
Qt = ∗ ∗
(ton/h) = 2400 ton/h
LOADED CROSS SECTIONAL AREA, A =
− . ) ∗
∗(
∗
tan ( ) = tan
∗ ∗
) = 1.8 ton/
∗ ( . −
∗ ∗ ∗
∗ ∗ ∗ ∗
.
.
tan ( )
A = LOADED CROSS SECTIONAL AREA OF CONVEYING MATERIAL( )
) = 1.8 ton/
− . )
)
=
) ; = .
∗(
∗ .
30 degree AND MATERIAL SURCHARGE ANGLE = 20 degree
∗ . ∗ ∗
.
.
. )

FROM TABLE 1.
FROM TABLE 1.
BELT WIDTH
ACTUAL
ACTUAL
MAXIMUM TRANSPORT CAPACITY
Qmax =60*0.1579*1.80*150*0.97 = 2
FOR THIS STEP
FROM TABLE 1.13 FOR BELT WIDTH = 1
BELT WEIGHT, W1 = 26 kg/m
FROM TABLE 1.12 FOR BELT WIDTH = 1
WEIGHT OF MOVING PART(CARRIER SIDE), Wc = 23.6 kg/set
WEIGHT OF MOVING PART(RETURN SIDE), Wr = 21.1 kg/set
BELT WIDTH B = 1000*
ACTUAL LOADED CROSS SECTIONAL AREA,
ACTUAL LOADED CROSS SECTIONAL AREA,
Qmax =60*0.1579*1.80*150*0.97 = 2
FOR THIS STEP SELECT BELT WIDTH = 1
FOR BELT WIDTH = 1
FOR BELT WIDTH = 1
B = 1000*(1.063/0.9
Qmax =60*0.1579*1.80*150*0.97 = 2
SELECT BELT WIDTH = 1
FOR BELT WIDTH = 1,200 mm
FOR BELT WIDTH = 1,200 mm
1.063/0.9) = 1,181
Qmax =60*0.1579*1.80*150*0.97 = 2
SELECT BELT WIDTH = 1,200 mm
200 mm
,200 mm
181 mm ROUND
LOADED CROSS SECTIONAL AREA, A = ∗ (0
LOADED CROSS SECTIONAL AREA, A = 0.1579
Qmax =60*0.1579*1.80*150*0.97 = 2,481 ton/h > Qt(2
ROUND UP TO BE
0.9 − 0.05)
0.1579
481 ton/h > Qt(2,400 ton/h)
ELT WIDTH 1
) = (0.1488
400 ton/h)
LT WIDTH 1,200 mm
1488) ∗ ((0.9 ∗ 1.2) − 0.05
05)

STEP 2/CALCULATE DRIVE POWER
REQUIRE POWER
P1 =
P2 = HORIZONTAL LOAD POWER
P3 = VERTICAL LIFTING POWER
f = FRICTION COEFFICIENT OF IDLER ROLLER =
= CORRECTED VALUE OF CENTER DISTANCE(m) =
Qt = TRANSPORT CAPACITY
V = BELT SPEED
L = HORIZONTAL LENGTH
H = VERTICAL LIFT
W1 = BELT WEIGHT(kg/m) = 26 kg/m (for belt width 1200 mm)
Wc = WEIGHT OF ROTATING PART(CARRIER SIDE) = 23.6 kg/set (for belt width 1200 mm)
Wr = WEIGHT OF ROTATING PART(CARRIER SIDE) = 21.1 kg/set (for belt width 1200 mm)
lc = CARRIER ROLLER SPACING(m) =1 m
lr = RETURN ROLLER SPACING(m) =
P1 =
P2 =
P3 =
REQUIRE POWER
REQUIRE
η = DRIVE UNIT EFFICIENCY
REQUIRE POWER
P1 = HORIZONTAL
ON COEFFICIENT OF IDLER ROLLER =
TRANSPORT CAPACITY
BELT SPEED(m/min)
HORIZONTAL LENGTH
VERTICAL LIFT(m) = 35
lr = RETURN ROLLER SPACING(m) =
P1 =
( . )∗(
P2 =
( . )∗(
P3 =
( )∗( )
REQUIRE POWER
REQUIRE DRIVE POWER
DRIVE UNIT EFFICIENCY
REQUIRE POWER(kw), P = P1+P2+P3
HORIZONTAL NO LOAD POWER
ON COEFFICIENT OF IDLER ROLLER =
TRANSPORT CAPACITY(ton/h) = 2
= 150 m/min
HORIZONTAL LENGTH(m) = 250 m
35 m
lr = RETURN ROLLER SPACING(m) = 3
( )∗ ∗
( )∗(
)
REQUIRE POWER P = P1+P2+P3 = 288.4
DRIVE POWER
DRIVE UNIT EFFICIENCY(%) = 85%
= P1+P2+P3
NO LOAD POWER(kw)
P2 = HORIZONTAL LOAD POWER(kw) =
P3 = VERTICAL LIFTING POWER(kw) =
∗
ON COEFFICIENT OF IDLER ROLLER = 0.022
(ton/h) = 2,400 ton/h
m/min
m
3 m
. .
∗
)
P = P1+P2+P3 = 288.4
Pd = =
%
(kw) =
∗( )∗
∗( )∗(
∗
0.022 (for good installation)
= CORRECTED VALUE OF CENTER DISTANCE(m) = 66 m (for f
400 ton/h
= 14.08
= 45.46 kw
= 228.88 kw
P = P1+P2+P3 = 288.4
=
.
.
= 339.3
)∗ ∗
)
(for good installation)
(for f =0.022)
08 kw
= 45.46 kw
= 228.88 kw
P = P1+P2+P3 = 288.42 kw
= 339.31 kw
∗
(for good installation)

STEP 3/CALCULATE
FROM TSUBAKI BACKSTOP CAMCLUTH CATALOG
STEP 4/CALCULATE
FROM DRIVE PULLEY
/CALCULATE BACKSTOP TORQUE
Pr = BACKSTOP POWER(kw)
P1 = HORIZONTAL NO LOAD POWER(kw) =
P3 = VERTICAL LIFTING POWER(kw)
BACKSTOP POWER,
IF DRIVE PULLEY DIAMETER
DRIVE PULLEY SPEED,
BACKSTOP TORQUE
BACKSTOP TORQUE,
USE THIS TORQUE DATA TO SELECT BACKSTOP SIZE FROM
/CALCULATE BELT TENSION
FROM DRIVE PULLEY
DRIVE FACTOR,
μ = FRICTION COEFFICIENT BETWEEN DRIVE PULLEY
θ = CONTACT ANGLE(ANGLE OF BELT WRAP) OF DRIVE
DRIVE FACTOR,
EFFECTIVE TENSION(kg),
P = REQUIRE POWER(kw) = 288.42 kw
BACKSTOP TORQUE
BACKSTOP POWER,
IF DRIVE PULLEY DIAMETER
DRIVE PULLEY SPEED,
BACKSTOP TORQUE SERV
BACKSTOP TORQUE,
BELT TENSION
FROM DRIVE PULLEY
DRIVE FACTOR,
DRIVE FACTOR,
BACKSTOP TORQUE
Pr = P3-(0.7)*(0.06*P1+P2)
BACKSTOP POWER, Pr = (228.88)
IF DRIVE PULLEY DIAMETER, ØD = 630 mm
DRIVE PULLEY SPEED, N = v⁄
SERVICE FACTOR,
BACKSTOP TORQUE, T =
BELT TENSION
DRIVE FACTOR, =
DRIVE FACTOR, = ( .
(0.7)*(0.06*P1+P2)
Pr = (228.88)-(0.7)*(
= 630 mm
⁄πD = 150⁄(π*0.63)
FACTOR, SF = 1.5 (for backstopping several time a day)
∗
∗
∗ . )
=
∗
P = REQUIRE POWER(kw) = 288.42 kw and v = BELT SPEED
(0.7)*(0.06*P1+P2)
P1 = HORIZONTAL NO LOAD POWER(kw) = 14.08 kw
P2 = HORIZONTAL LOAD POWER(kw) = 45.46 kw
P3 = VERTICAL LIFTING POWER(kw) = 228.88 kw
(0.7)*(14.08+45.46)
π*0.63) = 75.7
(for backstopping several time a day)
=
∗
.
USE THIS TORQUE DATA TO SELECT BACKSTOP SIZE FROM TSUBAKI BACKSTOP CAM CLUTH
μ = FRICTION COEFFICIENT BETWEEN DRIVE PULLEY SURFACE
θ = CONTACT ANGLE(ANGLE OF BELT WRAP) OF DRIVE PULLEY AND BELT = 210 degree or
= 0.4993
∗
BELT SPEED(m/min)
14.08 kw
45.46 kw
228.88 kw
14.08+45.46) = 187.20
= 75.79 rpm
.
∗ 1.5
TSUBAKI BACKSTOP CAM CLUTH
SURFACE AND CONVEYOR BELT
PULLEY AND BELT = 210 degree or
(m/min) = 150
20 kw
= 35,383 Nm
TSUBAKI BACKSTOP CAM CLUTH
AND CONVEYOR BELT =
PULLEY AND BELT = 210 degree or
150 m/min
Nm
TSUBAKI BACKSTOP CAM CLUTH CATALOG
= 0.3
PULLEY AND BELT = 210 degree or 3.665 radian
CATALOG
3.665 radian

EFFECTIVE TENSION(kg), =
∗ .
= 11,767 kg
SLAG-SIDE TENSION(kg), 2 = ∗ = 11,767*0.4993 = 5,875 kg
TIGHT-SIDE TENSION(kg), 1 = + 2 = 11,767+5,875 = 17,642 kg
SLOPE TENSION(kg), 3 = 1 ∗ = 26*35 = 910 kg (tension from belt self weight)
MINIMUM TENSION TO PREVENT BELT SAG BETWEEN IDLER ROLLER TO MUCH(SAG =2 %)
CARRIER SIDE, 4 = 6.25 ∗ ∗ (
. ∗
+ 1)
RETURN SIDE, 4 = 6.25 ∗ ∗ 1)
Qt = TRANSPORT CAPACITY(ton/h) = 2400 ton/h
lr = RETURN ROLLER SPACING(m) = 3 m
V = BELT SPEED(m/min) = 150 m/min
CARRIER SIDE, 4 = 6.25 ∗ 1 ∗ (
. ∗
+ 26) = 1,829 kg
RETURN SIDE, 4 = 6.25 ∗ 3 ∗ 26 = 487.5 kg
USE LARGER VALUE OF F4 THEN MINIMUM TENSION, F4 =1,829 kg
RUNING RESISTANCE OF RETURN SIDE BELT, = ∗ ( + ) ∗ ( 1 + )
= (0.022) ∗ (250 + 66) ∗ (26 +
.
) = 230 kg
BELT TENSION AT DRIVE PULLEY(DRIVE AT HEAD)
CARRIER-SIDE TENSION(kg), T1
CASE1 T1 = Fp+F2 = 11,767+5,875 = 17,642 kg
CASE2 T1 = F4+F3+Fp- = 1,829+910+11,767-230 = 14,276 kg
MAXIMUM TENSION(kg), T1 =17,642 kg
RETURN-SIDE TENSION(kg), T2
CASE1 T2 = F2 = 5,875 kg
CASE2 T2 = F4+F3- = 1,829+910-230 = 2,509 kg
RETURN SIDE TENSION(kg), T2 = 5,875 kg

BELT TENSION
BELT TENSION
STEP 5/BELT CARCASS SELECTION
BELT TENSION AT TAIL P
RETURN-SIDE TENSION(kg), T3 EQUAL TO CARRIER
CASE1
CASE
TAIL PULLEY BELT TENSION(kg),
BELT TENSION AT TAKE
WEIGHT OF
CASE1
CASE
L = HORIZONTAL
Lt = GRAVITY TAKE
WEIGHT OF COUNTER WEIGHT(kg),
TAKE-UP PULLEY BELT TENSION(kg),
MAXIMUM BELT TENSION(kg),
BELT CARCASS SELECTION
CONVEYOR BELT SPECIFICATION
BELT WIDTH
MAXIMUM BELT TENSION,
BREAKING STRENGHT
BREAKING STRENGHT
SELECT POLY
AT TAIL PULLEY
SIDE TENSION(kg), T3 EQUAL TO CARRIER
CASE1 T3=T4 = F4 = 1,829 kg
CASE2 T3=T4 = F2
TAIL PULLEY BELT TENSION(kg),
AT TAKE-UP P
WEIGHT OF COUNTER WEIGHT(kg), Wt
CASE1 =
CASE2 =
HORIZONTAL LENGTH(m) = 250
Lt = GRAVITY TAKE-UP DISTANCE FROM HEAD PULLEY
WEIGHT OF COUNTER WEIGHT(kg),
UP PULLEY BELT TENSION(kg),
BELT TENSION(kg),
CONVEYOR BELT SPECIFICATION
BELT WIDTH, B = 120 cm
MAXIMUM BELT TENSION,
BREAKING STRENGHT OF ONE PLY FABRIC,
BREAKING STRENGHT OF
POLYESTER FABR
LLEY
T3=T4 = F4 = 1,829 kg
T3=T4 = F2-F3+ = 5,875+230
TAIL PULLEY BELT TENSION(kg), T3=T4 = 5,195 kg
UP PULLEY
COUNTER WEIGHT(kg), Wt
2 + ∗ (
4 +
LENGTH(m) = 250 m
WEIGHT OF COUNTER WEIGHT(kg), Wt = 5,848 kg
UP PULLEY BELT TENSION(kg),
BELT TENSION(kg), Tmax = T1= 17
CONVEYOR BELT SPECIFICATION : POLY
cm(1200 mm)
MAXIMUM BELT TENSION, Tmax = 17
OF ONE PLY FABRIC,
OF POLYESTER F
RIC BELT TYPE :
T3=T4 = F4 = 1,829 kg
= 5,875+230-910 = 5,195 kg
T3=T4 = 5,195 kg
COUNTER WEIGHT(kg), Wt
( − 3) =
∗ ( 3 − )
m
Wt = 5,848 kg
UP PULLEY BELT TENSION(kg), T5=T6 =
Tmax = T1= 17,642 kg
POLYESTER FA
/ NO.PLY, n =
Tmax = 17,642 kg
OF ONE PLY FABRIC,
ESTER FABRIC BELT
TYPE : EP 500 X
SIDE TENSION(kg), T3 EQUAL TO CARRIER-SIDE TENSION(kg), T4
910 = 5,195 kg
T3=T4 = 5,195 kg
= 5,875 +
) = 1,829 +
UP DISTANCE FROM HEAD PULLEY(m) =10 m
Wt = 5,848 kg
=
,
=
642 kg
ABRIC BELT
n = 4 PLY / SAFETY FACTOR,
=
∗
∗(
BELT TYPE EP 500
X 4 PLy
SIDE TENSION(kg), T4
910 = 5,195 kg
∗ (230
+ ∗
10 m
= 2,924 kg
/ SAFETY FACTOR,
∗
)
=
,
∗(
500 = 500 kg/cm.ply
SIDE TENSION(kg), T4
− 910) = 5,848
(910 − 230
/ SAFETY FACTOR, SF = 12(ordinary)
∗
)
= 452.4
= 500 kg/cm.ply
= 5,848 kg
230) = 2,482 kg
(ordinary)
452.4 kg/cm.ply
kg
kg/cm.ply

RE-CHECK MAXIMUM
BELT CONVEYOR
BELT CONVEYOR
TRANSPORT CAPACITY
BELT CONVEYOR EXAMPLE
TRANSPORT CAPACITY
EXAMPLE CALCULATION
CALCULATION FROM APPLICATION
FROM APPLICATION
FROM APPLICATION

STEP 3/CALCULATE
/CALCULATE BACKSTOP TORQUE
BACKSTOP TORQUE
BACKSTOP TORQUE

STEP 4/CALCULATE
STEP 5/BELT CARCASS SELECTION
/CALCULATE BELT TENSION
BELT TENSION
BELT TENSION

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