mPROK me gE PULLEYS, IDLER aE OH ia S Anp MATERIA rs anaes ALS Han, tee See SYSTems IS M. Sandvik Materials HandlingMPROK The object of this engineering reference is to develop guidelines toward the best engineered system through proper selection of the idlers. Further dasign and selection data is included in separate engineering references for the pulleys and other conveyor components, Engineering data is supplied toward developing a worksheet for common use and reference by engineers, operators and contractors. DESIGN CRITERIA FOR PRODUCT SELECTION AND GENERAL DATA Contents + Metric Conversion Factors 1-4 + Typical Conveyor installation 1-5 + Selecting idiers and Pulleys 4-7 + Design Criteria for Product Selection 1-8 + Conveyor Idler Selection 1-1 + Bulk Material Characteristics 1-44 + Material Class Description 1215 * Cross Sectional Areas for Beit Capacit 1-16 + Suggested Idler Spacing 1218 + Typical Belt Speeds 1-16 + Estimated Belt Weights 1219 + Dynamic Load Charts 1-20 + Static Load Charts 1-22 + Customer Idler Data Sheet 1-24 + Pulley Selection 1-26 + Recommended Storage and Handling Practices 1-27 + Recommendations for Belt Tracking 1-28 n INTEREST OF PRODUCT DEVELOPMENT, PROK GROUP RESERVES THE RIGHT TO CHANGE CRITICAL GAUSAT ANY TIME WITHOUT PRIOR NOTICE: DIMENSIONS SHOWIN ARE NOMINAL ONLY” CERTIFIED DRAWINGS ARE AVAILABLE ON REQUESTMETRIC CONVERSION FACTORS MPROK TO CONVERT inches (") feet (ft) feet per minute (ft/min) cubic feet (ft) pounds mass (Ib) Ibs per cubic foot (Wen) Short tons (st) ibs, per foot (lbitt horsepower (hp) pound force (bf) pound force feet {|bfft) mile (mi) pounds per square inch (psi) TO millimetees (mm) metres (m) metres per sec. (m/s) cubic metres (mn?) kilograms (kg) kg. per cubic metre (kgim?) metric tonnes (t) kg. per metre (kgim) Newtons (N) kilowatt (kW) Newton-metre (Nm) | kilometre (ken) Nim? Imperial to Metric multiply by 25.4 0.3048 9,00508 0,02832 0.4536 16.02 Metric to Imperial multiply by 0.0394 3.281 198.80 35.315Drive Pulley Belt (Lagged) ‘Scraper / Transition Idlers ‘Champion Skirt Trainer Emergency Pull Wire Switch Emergency \ Flat Return Rails Pull Wire Non Drive Pulley &PROK Typical Conveyor Installation Refer to page 2 - 85 (Uniagged) eWindguaris {or further details Trough Trainer Emergent “~ Puli cwach | Champion Skins . Trough Impact Idlers Symbols and Units or Impact Beds | Symbol Description Units Symbol Description Units Ty carry side tension KN # net lift of conveyor m qt, rotum side tension KN normal operating cross-sectional area m2 Ty; effective belt tension kN belt width mm K |_wrap-friction factor for carry side ~ | dimensionless B trough or return idler set spacing ™ 8 angle of wrap of belt around drive pulley degrees: Wy weight of belt per unit length kgim in coefficient of friction between belt and drive pulley dimensionless Wan ‘weight of conveyed material per unit length | kgim 3 idler vertical misalignment mm Wa | belt deviation load per unit length kgim A | degrees Poop belt deviation load kg d _| mm Ww, combined material and belt weight per unit length kgim v bell speed __| mis PB static load on each idler set kg | Bio | bearing life hours [Pa dynamic load on each idler set kg | B | troughing angie degrees USF dynamic speed factor dimensionless | Pp [minimum required motor power kw | [Bil dynamic bearing life factor dimensionless Pp | bulk material density — kgims u dynamic lump factor | dimensionless c | capacity of conveyer toh 5 arc of contact radiansSELECTING YOUR IDLERS AND PULLEYS process: | Description Symbol + Capacity of conveyor in TPH + Net lift of conveyor - metres + Idler vertical misalignment + Bulk density of material + Surcharge angle of material + Maximum lump size + Belt speed + Troughing angle + Required bearing life The following minimum data is required before commencing the idier/pulley s (c) (H) (8) () (A) (@ ) (B) (Bio) MPROKSa ZPROK DESIGN CRITERIA FOR PRODUCT SELECTION The engineering and selection procedures outlined on the fellowing pages will enable engineering and operations personnel to select the most appropriate idlers to suit their materials handling requirements, ‘On large and complex projects, we recommend that Prok design Engineers are consulted to ‘ensure that the optimum design is selected. Detailed checking by Prok Engineers may result in ‘small modifications which could substantially reduce the final cost to the consumer, This service is readily available on request. Please refer to the enclosed Prok idler / structure design data sheet ‘and pulley design data sheet. Complete these sheets with as much infarmation as possible to ensure a prompt and accurate selection is achieved. Please forward the design data sheets ta you nearest Prok office. To fully assess idler loads, charts and formula for Belt Deviation loads. and Convex Curve loads are included For carrect selection of idlers, it is essential that the allowable criteria for both static and dynamic loads be satisfied. The following step-by-step procedure shows the necessary steps in sequence, ‘with references to the appropriate tables and charts as indicated. it should be noted that the dynamic bearing selection procedures are in accordance with I.S.0. requirements, CALCULATION OF BELT TENSIONS USED FOR IDLER & PULLEY SELECTIONS To enable an accurate selection of idlers and pulleys, the conveyor belt tensions are required. This section details a method of how to determine the belt tensions. The Run tensions calculated T,(run) & T> (run) are to be used for the deviation load calculations for the idler selection, The Start tensions calculated T (star) & T, (start) are to be used for the selection of the pulleys. Start tensions are calculated by applying a start factor to the effective belt tension at the drive pulley. See table 3.0. Nomenclature used: yo F Tz = Drive slack side belt tension (kN) Ts Drive effective belt tension (kN) bh = Coefficient of friction between belt and drive pulley (See table 2.0) ® = Angle of belt wrap on pulley (degrees) = _—_Arcof contact (radians) v = belt speed (m/s) P1 = _ Installed motor power (kW) The factors used in table 1.0 are calculated from: K v 0 W y, = en t = ewSa ZPROK DESIGN CRITERIA FOR PRODUCT SELECTION TABLE 1.0K FACTORS (Single Pulley] ~—~Coafficient of Friction (up Weapangied | 0.710 [0.15 [020 | 0.25 [0.30 | 035 [o40 | 180 | 2.708 4.661 4.443 0.838 0.638 0.499 0.398 190 2543 [4551 | 1.062_| 0.7? _| 0.587 | 0.456 | 0.361 _| {200 2.393 4.453 0.990, 0.718 0.514 0.413 0.329 210 2.258 | 1.964 | 0.925 | 0.667 | 0.499 | 0.384 | 0.200 220 2136 | 1.284 | o8es | 0.020 | 0462 [053 [0274 TABLE 2.0 GENERAL PURPOSE CO-EFFICIENTS OF FRICTION (1) PULLEY | Wet Stee! | Moist Steel! Steel | Dry Stee! Dry | Wet Rubber] Geramic SURFACES | Rubber | Grooved VALUE 0.10 0.20 0.25 0.30 0.35 0.35 045 TABLE 3.0 TYPICAL CONVEYOR MOTOR START FACTORS (SF) Start Method ___ Start Factor [Fluid Coupling (Scoop contral) 12 Fluid Coupling (Delay Fill type) 14 Fluid Coupling (Traction type) 18 Direct on line (OL) 22 Using the appropriate formula and nominated tables, refer to the following warked example outlining the method of calculating the conveyor belt tensions: Worked Example No.1 20 KW Drive pulley wrap 2.5 ms Coefficient of friction Direct on line (OL) 180 degrees no 2 & Truny= PA ¥ 20 25 8.0 (KN) From table 1.0, § = 180° and y. = 0.35 K = 0.499 From table 3.0 Start Factor (SF) = 2. Tisiat) = SF xT, 228 17.8 (kN) T,(stan) K x T,(start) 0.499 x 17.6 8.78 (kN)MPROK DESIGN CRITERIA FOR PRODUCT SELECTION T (start) T, (start) + T,{start) = 16+ 878 = 26.38 (kN) T,{start) = Ti{run) ‘Ty{run) = T,(run) + T2{run) = + 878 = 16.78 (kN) {in Summar —_ TTi(start) 26.38 (KN) [T,(run), 16.78 (KN) Taster) Tefrun) = B.7B (kN) BELT DEVIATION ‘When a conveyor is constructed, ideally all idler sets are installed at the same level. If any idler set is at a higher level than its neighbours, the beit will impose additional loads to that idler. This additional load is referred to as the Belt deviation lead, With the advent of increasingly higher belt tensions, the effect of the idler misalignment in the vertical plane has become a significant factor in idler selection for a nominally straight belt. Tirun), Tirun) Normal installations should have a straightness allowance of 3.0 mm on the trough carry side and 6.0 mm on the retum side. If conveyors are installed without any vertical alignment checking then the misalignment 6 can be up to and beyond 15 mm. ‘The belt deviation load must be taken inte account when calculating the static and dynamic loads applied to the idiers. ‘CALCULATING BELT DEVIATION LOADS 0,204 x Tirun) x6 (kg) L Poe = Nomenclature used: Py, = Balt deviation load (kg) Tirun) = Belt Tensions ——T,(run) for trough carry side (kN) T,(run) for retum side kN) 6 = Idler vertical misalignment (mm) L—-= Trough carry or return idler set spacing (en) Note: Operating belt tensions vary greatly with conveyor loading and location within the: conveyor. i.e., head end tensions are generally much greater and subject to variations than tail end tensions, Therefore, each case should be considered individually.MPROK DESIGN CRITERIA FOR PRODUCT SELECTION CONVEX CURVES Loads on idlers in convex curves are greater than for normally straight belt lines. The follewing formula must be applied to establish whether or nat the idler spacing needs to be reduced from the normal spacing selected for the chosen idler series Where the calculated curve spacing exceeds the spacing selected for the normal fun of conveyor, then the normal spacing can be used in the curve area Where the calculated curve spacing is less than that for the normal run, then the calculated spacing must be used or a heavier idler series installed. DYNAMIC Sc = pk HORAT 4. (Wp # Wa) LE x SFX Bio Am) required spacing in curve (mm) = allowable dynamic load for series required (kg) bell tension in curve (kN) ‘curve radius (rm) mass of belt (kg/m) ‘mass of material on belt (kg/m) (Note: for return belt, W,, = 0) bearing life factor CURVE SPACING OF LENS cot Bee BR PT taker Ce wore Avera aS $ buenormcre RAB. inesor err bet Ws ister use STATIC Once the spacing has been finalized, it is advisable to check that the roller and frame structure is capable of carrying the static load. The actual static load is given by: 10247 « «wy + Wala P= Sox|02m The maximum static load is given by: {102 xT Plmax) = Sc x/*28T + (W, + Waa) KG These values must be less than those given. the relevant load charts. CONVEYOR IDLER SELECTION Please refer to the enclosed Idler Selection Worksheet to assist in selecting Prok products, TROUGH AND FLAT CARRY IDLERS STEP 1 CSA = (m2) BBxvxp) * Calculate the required design cross- sectional area (CSA) of material being conveyed as follows: STEP 2 * Using the above CSA and surcharge angle (A), determine a suitable beltwidth (w) and trough angle (ji) from Tables 5.1 to 5.6. STEP 3 * Check that the belt width selected above is suitable for the maximum lump size (d) using table 6.0. If not suitable select a wider beltMPROK CONVEYOR IDLER SELECTION STEP 4 + Select a suitable trough idler set spacing (Lc} from Table 6.0. STEP 5 * Obtain the weight of the belt per unit length (Wb) from the Bell Manufacturer , or if nat knawn table 9.0 may be used as a guide, STEP 6 Calculate the weight of the conveyed material per unit lengih as follows: - c Wa = waxy (kg/m) STEP 7 + Calculate the combined material and bolt weight per unit length as follows: We = W,, + W, (kgim) STEP 8 * Calculate the combined material and belt weight on each idler set using the selected trough idler set spacing (Lc) as follows Po = We x Le (kg) ‘STEPS + Calculate the belt deviation load as per the previous description: Poev = — 0.204x5xT,(run) (kg) Le ‘STEP 10 * Calculate the total static load on each idler set as follows: Ps=Pc + Pdev (ka) ‘STEP 11 * Determine the dynamic load per idler using the dynamic load factors as follows: Po = Ps x Sx Ly x Byof (ka) where Sf = Dynamic load factor for belt speed from table 10 Lf = Dynamic load factor for lump size from table 11 Bygf = Dynamic load factor for bearing life from table 12 STEP 12 * Using Pd, select a suitable trough roller series from the dynamic load chart 1,0 or 2.0. With this trough idler series, check that the static load given in chart 6.0 or 7.0 exceeds the stalic load Ps, calculated in step 10. If this is greater then select the next series of idler.MPROK CONVEYOR IDLER SELECTION RETURN IDLERS STEP 1 + Select a suitable return idler set spacing (Lr) from table 8.0 STEP 2 + Calculate the Beit deviation load (Pdev) as per step 9 for trough idlers and as per previous description puay 0.204% 5 xT AMUN) Ga) o STEP 3 * Calculate the total static load on each idler set as follows: Ps = (Wb x Lr) + Pdew (kg) STEP 4 + Determine the dynamic load per idler using the dynamic load factors. as follaws: Pd = Ps x S xBF, x Buf (kg) where Sf = Dynamic load factor for belt speed from table 10 BFF = Belt Flap factor = 1.25 for all return Idlers. Biof = Dynamic load factor for bearing life from table 12 (Note: 8F,= The Belt Flap Factor makes an allowance for the shock / impact loads attributed with excessive belt flap, This belt lap is generated by various sources including build up from carry back on the return side of the belt, the forcing frequency of the rollers and the balance and out of roundness of the roller) STEP 5 Using Pd, select a suitable return roller series from the dynamic load charts 2.0 to 5.0. With this, retum idler series, check that the static load given in the corresponding charts 8.0 {o 11.0 exceeds the static load Ps, calculated in step 3, if this is greater then select the next series of idler, IMPACT IDLERS Impact idler selection requires additional considerations. Please consult Prok for selecting Suitable impact idlers.MPROK Table 4.0 ed & | aeee x | wen MATERIAL Sy ee] oe MATERIAL gr cman | oO fn | eee | ee a stow ranaae Bis | Conrad ap wa [tos ‘ray ann 2 35 | Gonos | Bae se Sete ee ae Sees oa —] Coane ro a [3a = Comore 260 Es yas at 738 Gite Bs, = Tistenasens a aaa = [ee a Ear, ar exces 15 |-a0 fase, Eat cok coe cep 20a oae Faia (an wo eis Si Tew ie 15 [ too Fekeps 3 Wes o Fh rea Ee % ae | Bian | Fir wr “HT Taase Se a8 | Fe dt, boty Paws aE oso [is | “20-86 | Forapa t3er stecares He. Tae] “Hs [FF | a] Forapa aero Faroe] Die a3 3] Bat 1 Fay ah apne cue | Sei ‘aS | Fenay soe ese (i se) | ‘sara S| Aa | Fema fine, dsr cvs, WO 09 owe] Siseai = Furs th reise | 10 | roe Fat oath ot aoa 526 eee ad Fakes sath oF Wi Based [et | ee 962 Furs aah Ws ron sevaai | S| a eee tote ‘Garbage. Pexaahatd aa ea] ro “lass bch ase mm lowe | ot ‘na. Sn omer ——[ sa eH 8 ‘Grote. Jorm te Pm ump 183-1480 on) cures [es ‘ones ran aes 1 oa ana Dai? eave Ea jaas-1603 | 30 | a l andor. isk ede Ea Sane 8. a a 38-17 | Ba ‘Cortaruneun Simm aur —| eo ‘Grove pbs Fasano] Ws | we [ox] Carer, Porter sor ‘Gypmcm at nanos —— [a8 ‘Corer. Potand: eran | 2 1207 rma eed [wea-tia [0 [23 | ev ‘arr rok (oes isestone) | Tea 1764 ‘opm, Tana acreemnga [122-1283 | 20 —| 21 | oo Camaetcrtar asa | TESS | ES ‘Cjpmun, Soria Term orgs hades | 1s | Toa Conert rertr zie ie rites ssrr7t oe) Chat on rane aes Tanto ore Eros 527 Chak ON ras anes | 1001202 | iene ‘eas noe | 16 [8] “Oa Chee 505 EE) Tenors ced ise 208 posi as, pe pap al Soa ier nde pnt a7 Bs Tae ‘hie. papw mil stiwood | 1480 Haain day Tore andar [OO | #5 |_| Om ay (oe ala banancedaariaave ei Rae war ain it Ma) | Waa i. 100 rh 75-006 [30 | Z| aby [hip ening Tas a7 | Leg ores foosao| ie [is eaee iy fe eos i6ee | S| BE [CSF —] Leto: mel in 69, or sexta [1s | te] ae | Srumara unser 1000 zo_|ee Cosh arivacte rer ora | rine, eure Testes] 2 || cae 2 ed woe! as_| x6 | sien [Cinesne. aut as es | Aen Tat atncie Se tse | can a, eat sr76u1 es Cos mins. med | htangansse a vezi | 30 | ao oar Orv aed ura eczees | 20 | 20 | west [ricco siphaewore | ane 08 “Oar | est tineove, et andmaea| Fetes [v8] 8 ome Tar see eae Con, bumeoss. mired Paper io sack eae ia na rina mven_| 20 oso _| Phossnaie acc oir on feast [eet Prepare ipa mines warn t3irmand wow | canece | 20 | 22 | cast | gram temizer nize | 20 | 20 | eur est Baum, Phocpatn rock ewan ay | vaa-1963 | 15] 721 [8 siemeg et cared soos62 act | Presa ch, pions | 2s ew Coat Lorie fear —| 32 | oer —[ Pye rn 2m Fg | 10a 7525 eT Cane, ee Sea Ta | barat | Pyros. seis eet zr Conese chad BEIT wo bay | Guar ear Aa Cove, boaso, Garr ac nar [e086 [1530 | ao. Cary —| Guns een acme aa Tes x72 eo Trane ae | 0x8 | Os Sare a Timm nerf 1823 onz * May wary considerablyMPROK Tatas antl te [A] ran rrsee_ [Sucre rere rae | ye MATERIAL towne | ege. [ronan] MATERIAL say | ae | rar tnae) | saves | bee oe) | epee | eee oo. ate [aooezaes a6 | Sete. at weazsom | 35 [m0 _| wae eck a eceaied waar | Wes Tet [oe | Sarena Tamara nae Paes | 15 |e fem ube poled [pene [We | ae Ei, Hh Tener bps SRR | [eae [ora —[-15—1 8 Sagar pried 02.602 525607 ersoe—[ 10] 8 “Sopa pone aan. Teaser [sare Boge em rw aaa a TE [rzptaas| wo [11 oxoru | Supe et Car 1363 [20 [at [ eer | Sugarcane wed 240.200 ee EaeNT | Suasa,powsered oo a [iret zoet] “a0 [3032 sar | Sueraoe cused Timm under [a2.062 20 ars red [5 [Fe | B37 | Supa Tonem arcu TR TES ie Tze 24_[ oar [ae ponaer rn [ressseos| ao “22 [oar [ie tm scsannge Toa TaaT eso [B27 Tale rr Tr hina [385-18 Tse “ipl gat preaeras Wheat e [ateos Cape zr Bin Du T Be at ied os Sap furece pani ry a5 Sg. utc, paar wet | 143-105 ART Table 4.0 (continued) Material Characteristics cose Very ine «100 mesh ard unr A Site Fine -3mm and under a Granular - ure 13mm ¢ Lumpy enntaning lumps exer 13m o lrogulo- sty, icorking, mats together E Fiowabaty \Very trea towing - angle of repose ins than 20 dagraes 1 Angie af Froe flowing ~angle of repose 20 degrees a 30 degrees, 2 Repose ‘Average laning ange of repose 30 egrens to 45 deurees 3 Sliggsh - angle of pose 45 degrees and ever 4 Abranveness Nonabrasive 3 Abrasive ‘ Very abrasive 7 Very sharp cats or gouges bot cover 8 iscetianeovs Very sty i Chasers ‘Rertes ana develops Mud characters " {Somotenes more Goniaina exriosive dust N than one of hese Conamniatie affecting Use of satel P sharoctenetics (sgradable afecing use of saleabity a ray apeiy) Gives of harmful tunes or dust R Feghiy corres s iy cores t Hgroscone u Inderioeks or mats v ils or chemical present -may ate nubiber oducts w Packs under pressure x ‘Very taht an fly «ray be wind wept Y Elovoied temperature zSande Maer Haneing CROSS SECTIONAL AREA (m?) TABLES 'S = standard edge margin = 0.055 W + 20 mm (where W = belt width (mm) TABLES 5.0 - THREE ROLL TROUGH AND SUSPENDED IDLER Table 5-1 20° DEGREE TROUGH ‘SURCHARGE, ANGLE (A) Table 5-3 35" DEGREE TROUGH SURCHARGE ANGL ao aoe 30° Toor |e. wa 1S [oor | oor a [oats | cars| ors ms ‘anne ‘oat a.oea [oes om a. boas | 0086] O.oee ‘aa OE ‘ore, ‘ore [aust 0 ator 0.060 ‘ize ‘1a ‘tet 138 auras ‘Orr ‘Ozr O.iBe oa aan [0218 ‘287 O20 oe oar ‘ass ‘O87 496 [0557 oo Osa [0st | PE O76 507 Be DEGREE TROUGH DEGREE TROUGH SURCHARGE ANGLE (A) IURCHARGE ANGLE (A) we tos ‘aie aan ‘a0a0 038 ‘057 ‘07 ‘8 ‘aioe 138 ‘ae 0.190 ‘ons 036 ‘ans i 0387 az ast 52) ‘557 ‘aaa ‘7s ‘O78! Dee aa | OSfetta MPROK A CROSS SECTIONAL AREA (m2) TABLES (continued) Table 5.5 FLAT CARRY IDLER oy SURCHARGE ANGLE (Ai wnat * 2 fi et ‘oon B08 3/8}a/8)8)8|8|8|8 T I CROSS SECTIONAL AREA (m?) TABLES Table 5.6 45° - 5 EQUAL ROLL BASE MOUNTED AND SUSPENDED TROUGH IDLER ae SURCHARGE ANGLE (Ay wo a = te s zw |e a | aa asst aa aia a2 aaa [ ae av7a ae? ant a257 2m “88 ‘R07 ozs oe ‘ae See i aes ati re axe reo oat I a0? oa ars O10 oat ‘oan owe Biba O06 88 338 ron oe? Geis aie S76 ‘0.561 2.604 0.658 7am Get SEE 3882 a7 aga aa08 ane 2700 ‘arn aaet ‘a90 1.058 [ a7ae Co oe 0968 aa 120MPROK Sande Mater Haneing TABLE 6.0 TABLE 7.0 (MAXIMUM _LUMPSIZE (mm) TYPICAL BELT SPEEDS ( mis F TF MIRED GRAIN OR | RUN OF MINE | HARD ORES BeLTworh | UNIFORM vate BeLTWwOTH | FREE FLOW | GOAL AND em) uuWes | APPROX tim | maareiaL | crushed | STONE sonriNes_| AND EARTH Fa w | eA en 18 09 75 125 300 25, 22 1s 250 700 10 450 25 22 a 208 100 175 00 En} va az ca 123 200 [ 600 30) 25 22 ca 128 wo] 650) 3 = 75 150 300 750 35. a5. 21 200 150 300 ‘00 a7, 36 7 0 175 5 900, 40) 35. 30 7060 7200 338, 000 40 38 3 7080 200) 38 [ 1050 40 35. 30 7208 300) 50 1200 40. 40) 30 7350 300, s00___| 1350 45 40 30 “wc = 0 f 1a00 a5 a 3 "00 350) 00 1500 Fr 40. 30] 7600 378, 00 1600 45 30 7800 388 00 "ae a5 30 2000, cc it 000 45. 30 7200, 2200 80, 35 2400 ato 50 35 3500 2300 0. 35 TABLE 8.0 PROK SUGGESTED IDLER SPACING (METRES) TROUGH IDLER | RETURN eetr wor, |} TOLER feren) MATERIAL BULK DENSITY ¢ Kgim3 ) 0 we] aoe oe, 2x0] a +7 + 15 15 at a ts im 1 at Fr iF 1 13 15 wt 300 17 +5 1 te 12 500 cr ia i te @ a 18 ta i 1 12 750 15 ta 4 17 12 [a9 1 ia it 42 12 200 18 ta 1 12 10 1000 te ia 42 to ia 1050 Te tz tz 10 10 1200. 1a | 12 42 10 10 1350 1 1 tz +0 a9 00 18 12 [419 a8 1500, iz i2 [8 08 00 12 12 i a8 7] 700 12 ta oa a9 208 iz ia a ag 30 2200 ta a 3 a8 a8 2400 ia ia 3. oa 5 [a0 Fz +0 ia O as [aa 30MPROK TABLE 9.0 ESTIMATED AVERAGE BELT WEIGHTS (kg/m) BELT GENERAL MATERIAL BULK DENSITY (49?) BELT yee e000 FABRIC Si FABRIC at 39 6 Be 7 mn 365 12a 109, 1a ies 155. 134 105. we 186 208 0. 216 rr uF a} 30s r 305 36 330 mag “a 35.1 ST 408 ae STEELOORD, 58.0 8B STEELGORD Bis 78 sTeewcon | a2 357 STEELCGAD B15 100m TABLE 10.0 DYNAMIC LOAD SPEED FACTOR aT PD aT za [2s] 30-[ a5 [a0 | as 350 [as [75 SPEED FACTOR en [as | ten [106 | 10 | v8 tay [as [50 [139 TABLE 11.0 ; DYNAMIC LOAD LUMP ADJUSTMENT FACTOR ar WATERAL HULK DENSITY g/m Lunpsize a io a TO 7a TT e100 10 4.0 12 i) cE} a 1 sa io 7 a iT 7 77 [0 10 cs) ai it 32 3 10 if 7 z a “0 is i 32 12 13 20 i z 2 73 a ua TABLE 12.0 : DYNAMIC LOAD LIFE FACTOR (By) 5 HOURS LE semun_| 000 | Soo [-sooon | roo60 | ravoa | azow | soaoo | Toon URE FACTOR ax [080 | om om | oon | a0 [ton | tae] 10MPROK Sande Maer Haneing DYNAMIC LOAD CHART 1 35° DEGREE THREE ROLL TROUGH IDLER aay eROK SERIES or Zee ess | es eee pee 20 2] as 0 t_| 308 0 zat | 308 a0 Sot 3 So at 20 aot aa [ase 750_ 3a5_| 3s | a0, TH ca7_| 1045, war ma sts Bab Ezy ee_[ 15 ‘oa —] 00 sat 360 oa rt ees | tou ‘008 ioe si ssa 73 ae [nasa a0 sate 7 att [00s [aio 120 aa [ast_[ sae Tia zat [ om | aoe 70 sa [oa Hi eit [ee [ue 10 sae sae ri o_o [ae 4500 saz_|350_| a7, Ti e50_[ ott [338 | 000 | 406 10 saat Larr [oer [0 a0 [tonto ate ‘00 sat saa] ear [06] 709, ora sate 708 te 70 oe ‘ano DYNAMIC LOAD CHART 2 SINGLE ROLL FLAT CARRY AND RETURN IDLER eet = PROK SERIES : wit] —o5: ww] w w]e ls |e | | | Oo | | 50 | | so | 8 | oo Ev ae 00 208 “0 L208 i 2s |e [a 0 208 [ior | 407 [oem a zie 7 ae =f ao | ea] ore | ore 0 3 ‘ao_[ 53502 ort 00 a6 a ar st 510 | ean 7008 ate 1 ‘as sea_| ser | oon a8 “1 as | | os car a7 a eo [aa [esr an] sea [ oer [ast | «79 | sea] s07_| eso | arr a7] en are [sa [see | eas | 975 ae | 380 476 exa_| a8 “saa_T 350 a3 ou_| #72 ml M3 _| 353 | [ae [s can_| wes BtMPROK DYNAMIC LOAD CHART 3 10° DEGREE TWO ROLL VEE PLAIN RETURN BELT \yncra| a5 [ao [we too [ase [ai | a2 | oan re ee 750 ses [ar] set | a oo [ase | si] 321 | ast soo] a53 | 310] 20 | 30 ee me SSE /R/E |e BS Eas ig om ee a7] sao vaso | aso” aor [aw | sae as] vaon | 348 | 307 sie | a6 st4_| 5a ['tsoo | 340 [108 [aie [aa a73_| sar e00 | 3e8 | 305 | s4_| sea [asa | 72 | sar ‘aoe | oie | aan _| ao | vara | riae_| 7559 wooo | 3ae_[ soe [313 [ san [aur | seo | sa aoe |-o1s | aes [ear | vara [77 | veo0 2000 553) ‘ani | ore | 938 [se | vase [72 [ase 20 38 rar_| oe [ass [at | tase | ee | 1507 2400 si "rea o06 | a8 [28 [vast [ier | 1812 sao [asa [ise 08 "ras [asa [158 [ 507 0 Tarp ooo ane [ aa asa [sts {i taf esr [aie [sh [ra [er DYNAMIC LOAD CHART 4 DYNAMIC LOAD CHART 5 SINGLE ROLL RUBBER 10° DEGREE TWO ROLL VEE DISC RETURN RUBBER DISC RETURN mar OK SER ry PROX ERE oor) Te ra @ betora| — 3s a = 7 ‘a> 38 itor | #1 a8 ‘| 308 m7 ‘ame | 358 oe tt nH ata ‘ao | 351 1 mH ian | 60 tit tt iat | ss a me vo | 708 ie | 363 a He | — ae or aE m7 ‘aco |r zt oo a8 0 a si wal 70 00 tos aa a aoe oe 7 7800 co oo tseMPROK Sande Maer Haneing STATIC LOAD CHART 6 35° DEGREE THREE ROLL TROUGH IDLER PROK SERIES 6 Bee [Ss |e ps oe pe ee ee a0 ax] ast_| aa zat [ aaa] oar “a0_| 16a | iat | vow | ve8 | 80 | woo | vo0_| a00 au | zea | aan |zea [20s | 209 | ana | zoe | 269 ‘ai [ at] 2et | 24t ] 20r | aes [aes | 2a | 203 Sez] 387 | ar 8 ee] 388 saz 370) s70 am amt zan_| 308 | amr “sn_| 7a 405 | 205 azo | ar Ce 365 | ae wad] ace | eae | e02 | oie | 60a | 370] 370 wet] ost | oot | ger | ost | ost soo | aa "a6 | 708 | Tae | re6 | roe | 786. yous | voae [rare [rag [yao [ae on [aos [aan | vae0 | vaee | 3222 1651 165 Fisoe” [rene NOTE: I! the static oad, Ps is greater than that nominated in charts 6 ta 11 please consult your nearest Prok Office rok Engineering wil nominate an appropriaio spindle clameter ardor base size to meet your spectic operating conditions. STATIC LOAD CHART 7 SINGLE ROLL FLAT CARRY IDLER (peer PROK SERIES wore | oO >a pe Te Te Te pe Te | oT ae (50 17 [Ao [ase 500 al air_| sae “a00 2 wr _| ars (esa) 260) set_| 200 (ree a0 au [eae oa] 505 | ene [200 208, sar_| aue_| 337 esn_| s08_| ene 00 ire ser _[ as Hs 70 | 68 | 750) (0 zr vaa_[ ate [a2 o [eo | 1405 a Poe [iar [ea a8 1526. | 167 set_| aur | sae 57 Te} 1350 va [ar [550 ‘est cor sot | 156 24 eat 860_| <7 a5 558 7 55 | ae co Bs se a2 ar eaeSTATIC LOAD CHART 8 SINGLE ROLL FLAT RETURN IDLER STATIC LOAD 10° DEGREE TWO ROLL CHART 9 Z FE i a 1G LOAD CHART 10 LE ROLL RUBBER 10° DEGREE TWO ROLL VEE RETURN RUBBER DISC RETURN PROK SERIE? PROK SERIES _ a ri # he a 7 120) ia a i | iW i | 2 ia ii ae aa at co 20 | i a = a a0 Bt MPROK @ 01 He 103 Rr STATIC LOAD CHART 11PROK Sasi ater ting PROK IDLER / STRUCTURE DESIGN SHEET Client: Prepared By: Cony. No. Conv, No. Cony. No. Belt width mm Belt mis Belt type Belt mass kgim Material Bulk Density kgim? i Lump size mm Design capacity tph B10 life hours | Free fall height m ‘Surcharge angle “deg [Trough angle "deg (toler Sescie = Trough mm - Return: mm act mm ning beit tension 11 (Cary) kN _—[ T2 (Return) kN Belt deviation Carry side mm Retum side mm Convex curve radius m Nominal Quantities Rollo mm Trough ° tenet —— | Transition (5°/20") o _ Transition (15°/30") a I Flat camry ° | Fiat return o| a Meo return (Falls only) o 7 Return vainee . | Z Loadings Required YES| NO | (Please tok) 1) Convex eurve consiseredt 2) Flooded belt consigered 3) Deviation load considered, I 4) Assumptions if needed [ Checked By: FOR A PROK RECOMMENDATION ON IDLER SELECTION, COMPLETE THIS DATA SHEET AND FORWARD TO YOUR NEAREST PROK OFFICE,MPROK PROK IDLER SELECTION WORKSHEET Job to: Sheet! ——— # Date oy Cctient Dats: ont Project: — (Cet Spee Mo: = Gonweyor Data: Descrpior Capacity (2) ormesin ongth —————=—=== == ia unm — tm) Bet Speed (vr nis) Material Bata: Type SS Surcharge Ange 1X) {sogrv0s) Lamp Sizm (4) mm) ‘Deny 4p) —— fom) Motor Power: Minima Motor Power {P) ve) Bett Tensions: Balt Angie of Wrap (0) {sopraes) Balt Coumsient of Friction (p) a mensions) Wrap tetion Factor (K) omerscniess) Eneatve Tenska (12) Torson TY (Star ension T2 (Start unt: “Tension TT (Run) Rol Date: Trough Angle (3) tsgrss iO Basving Le Belt Date: Gross Sectional trea (CSA tw Batt wt = tm) Bat Type Batt Wao (Wb) 9m) ‘Trough Idlers: Lewdimeter (Win): bain) Combined Loadimeter (We) tai leer Spacing (L) i Batt Devaton (3) tm) Dievaton Load (Ws esi) State Load (Px): i ‘Speed Factor (Sh) — Idimensiontess) Lump Factor (Uf), {dimensionless} B10 Factor (810M, SS Idimensioniess) Dynamic Load (Pu a) ‘Selected Featers (dynamic) ‘Solocted Relers (static) ‘Saleet Raters Return Idlers: toed meter (Wb) (agin) Iie Spacing (Li ty Bat Devation () om) Devation Load (Wa ean) Stabe Load (Px tea) ‘Speed Factor (50) {dimansiontess) Bait Flap Factor (Bt) (dimensionless) B10 Factor (B10 {Gimensiontess) Dynaraic Load (Pa —— 7 Solocted ators (ynamic) Solocted Fells (static) ‘ler Rates — ‘pact idlers: Please conaull PROK fora detaled design selectionMPROK PROK RECOMMENDED HANDLING AND STORAGE PRACTICES IDLERS ‘Conveyor idler base frames and rolls packed separately. For project sites within Australia, base frames are packed on timber ppallets and rollers either in timber crates, ‘boxes or on pallets. Separate loose brackets (e.g. for flat return ‘idlers) are packed in boxes. ‘Goods for export are packed on pallets, crates ‘or in boxes and have provision for handling by a forklift, The steel straps securing the items should remain intact until the goods are ready to be unpacked Rolls must be stored horizontally, Rolls should be stacked on a pallet, if items are stored ‘outside and subject to weather during the pre- erection period, then they shall be kept well clear of the ground. Rolls must not be allowed to be immersed in pools of water. All rubber disc or lagged rolls must be stored under cover and out of direct sunlight to minimise UV damage PULLEYS ‘Conveyor pulleys should be lifted by the pulley ‘shell only. The recommended method is to use a spreader bar, lifting chain with hooks and ‘suitable attachment to securely support both ends of the pulleys shell rim overhand without damaging the end of the shell, lagging or speed sensing flags where fitted. (Refer Fig Fig 4 1). Alternataly, two (2) adequate textile slings with approprate end fittings, together with lifting chain and hooks may be used. The textile slings being placed under and around the pulley sheli so that it is securely supported Fig 2 (Refer Fig. 2) Under no circumstances shall chains be used on the pulley shaft as this will result in damage to the pulley shaft. The pulley assembly must not be lifted by the bearing housing cap eye bolts (where fitted). These are only fitted to lift the bearing housings. Lagged conveyor pulleys when delivered have the lagging protected by a galvanised steet sheet and heat resistant material wrapped around the pulley shell lagged surface. If the pulley isnot lagged, the circumferential pulley shell surface will be coated with a rust inhibiting compound (Castrol 108 fluid or equivalent). Exposed portions of the pulley shaft are also protectad with a coat of rust inhibiting compaund The complete pulley is strapped to timber battens to ensure stability during transport. When bearing assemblies are fitted, they are supported by timber battens to prevent movement and avoid brinelling during transpor. All packing and protection provided to the conveyor pulley should remain intact until the pulley is required far installation. The pulley should be stored in a horizontal position clear of the ground to prevent damage due to immersion in pools of water, Preferably conveyor pulleys should be protected from the weather during the pre-erection period and stored out of direct sunlight to minimise any heat effect upon pulley lagging.MPROK PROK RECOMMENDATIONS FOR CONVEYOR BELT TRAINING 1. When erecting the conveyor, special care should be taken to ensure that := a) All pulleys are set up with shafts parallel and square to the conveyor structure centre line 'b) All idlers are property aligned and square to the conveyor structure centre line c) The belt must be spiced straight and square at the joint 2. During commissioning of the conveyor, the belt may track off centre, even if the pulleys and idlers have been aligned reasonably well. Unsatisfactory tracking of the empty belt is usually due to a combination of errors in Item 1 above. Assuming that the pulleys and idlers have been reasonably aligned. then the tracking can be corrected by slewing the idlers sufficient to bring the belt back on centre: 8. To find aut where such a correction is to be made, look along the edge of the travelling belt in the direction of travel and observe where the curve along the bell edge occurs. Having ascertained where the curve exists, then correction can be made as follows, 4. Refer to Fig 3 With the observer located at Point A, sight along the direction of belt travel at belt edge and note curve occurring between idler marked 2 and 11, Mark the idler with chalk to highlight the extent of the curve, and also the position of belt edge on the rollers. {tis important to note that if the belt starts running off at idler 2, correction of idler setting will always be needed 1 or 2 idlers ahead of this point. In this case, idler + or even idler at paint B requires slewing To the belt towards the centre, Le from the left to the right side (as shown by the straight arrow), the idler B should be slewed as shown by the curved arrow, the left end should be brought forward and right end brought back. The amount of movement of the idler is small, and must be determined form the effect obtained. To start with, the distance either end of the idler is moved forward or back should not be more than about 2mm Having adjusted this first idler A, the effect should be noted on idlers 1 and 2 If the effect is insufficient or cannot be noted, idler 1 is adjusted in the same way followed by idlers 3, 4, 5 up to 10, If after having done sa, the belt has not shifted to the right out of centre at 11, a second adjustment is made starting again at idler B. If the second adjustment. proves again insufficient, a third and additional adjustment is made. ‘After each adjustment, it is desirable to ‘observe the effect for a sufficiently long period to permit the belt to travel at least ‘once right around the conveyor before the next adjustment is made. This is necessary as few belts are perfectly straight, Due to. this, there is always a certain amount of “weaving” of the belt edge at each idler and the position of the belt at any one idler must be judged as the average position of this weaving edge. Check the marks on the stringers to see which way the idlers were siewed and adjust any that are reverse slewed within a short distance, Having trained the empty belt, the belt should also run satisfactorily when it is loaded. If that is not so, it is due to the material not being fed centrally onto the belt. In such a case, the correct thing to do is to modify the feed chute so that the feed ‘onto the belt is well centered CENTERING ADJUSTMENT Fig 3. BELT TRAVEL