Professional Documents
Culture Documents
Alforque Conveyor
Alforque Conveyor
Alforque Conveyor
INTRODUCTION
Conveyor systems are used widespread across a range of industries due to the numerous
benefits they provide. Conveyors are able to safely transport materials from one level to
another, which when done by human labor would be strenuous and expensive. They can be
installed almost anywhere, and are much safer than using a forklift or other machine to move
materials. They can move loads of all shapes, sizes and weights. Also, many have advanced
safety features that help prevent accidents. There are a variety of options available for running
conveying systems, including the hydraulic, mechanical and fully automated systems, which are
equipped to fit individual needs.
One of the known conveyors that is generally used is the chain conveyor. A conveyor
comprising one or two endless linked chains with crossbars or flights at intervals to move the
coal or mineral. The loaded side of the conveyor runs in a metal trough, while the empty side
returns along guides underneath. The material is transported on the conveyor partly by riding on
the chain and flights and partly by being scraped along in the trough. The chain conveyor is
widely used in coal mines with heavy loads.
Conveyor Types
There are, in general, nine types of chain conveyors. The material being handled and
the service environment typically determined which type is chosen.
1|Page
INCLINED CHAIN CONVEYOR 2014
2|Page
INCLINED CHAIN CONVEYOR 2014
DESIGN CONSIDERATION
3|Page
INCLINED CHAIN CONVEYOR 2014
Material Classification
4|Page
INCLINED CHAIN CONVEYOR 2014
5|Page
INCLINED CHAIN CONVEYOR 2014
Chain Sliding and Its Advantages
6|Page
INCLINED CHAIN CONVEYOR 2014
7|Page
INCLINED CHAIN CONVEYOR 2014
8|Page
INCLINED CHAIN CONVEYOR 2014
DRAWINGS
9|Page
INCLINED CHAIN CONVEYOR 2014
10 | P a g e
INCLINED CHAIN CONVEYOR 2014
11 | P a g e
INCLINED CHAIN CONVEYOR 2014
DESIGN COMPUTATIONS
M = 50 lbs./ft
• Determine W:
W = (CW) (N) + Ws
N = No. of chain strands = 2
Ws = Wt. of slats = 22.8 lbs/ft
CW = Wt. of Chain (lbs./ft.)
12 | P a g e
INCLINED CHAIN CONVEYOR 2014
From Table 6:
fr = .20 (Rolling Chain)
• Conveyor Speed:
(s)= 100 ft./min.
• Determine Sideboard Friction (J) from Table 9:
𝐶ℎ2
J= 𝑅
50(6)2
J= 14
J = 128 lbs.
• Determine Service Factor (V) from Table 10:
V = (Frequency of Shock)( Character of Loading)( Conditions of Operation)( Daily Operating
Period)
V = (1.0) (1.2) (1.4) (1.2)
V = 2.02
Calculate Conveyor Pull (P)
From formula:
For Chain Rolling
P = [(Mfs + Wfr) COSa + (M + W) SINa] C + (WfrCOSa - W SINa) C
P = [((50) (.55) + (32.8) (.2)) .8 + (50 + 32.8) .6] 50 + [(32.8) (.2) (.8) - 32.8 (.6)] 50
P = 3,850 lbs. - 720 lbs.
P = 3,130 lbs. (rolling)
Select Sprocket Size
From Table 11 we obtain 12-tooth sprocket as best selection choice.
E = .990
Calculate Design Conveyor Pull (DP)
For Chain Rolling
DP = (P) (V) (E)
DP = (3130) (2.02) (.99)
DP = 6,260 lbs. (rolling)
13 | P a g e
INCLINED CHAIN CONVEYOR 2014
Calculate Chain Tension
For Chain Rolling
T = (DP) (1.2)/2
T = (6,260) (1.2)/2
T = 3,760 lbs. (rolling)
G-29 or G-19 attachments are convenient for bolting scraper flights. Since attachment spacing is
every 12”, choose either 4”, 6”, or 12” pitch chain. Select 1131R with G-29 every 2nd pitch.
Since the maximum allowable working load rating of 1131R is 5,900 lbs., the selection is
satisfactory. We could, however, economize by selecting a smaller chain (for example, 627R). To
do this, recalculate chain tension by repeating Steps 2, 3, 4, and 5. For 12 tooth sprocket,
sprocket number 1131R, for union chain number 1131R with 6 in. chain pitch,
14 | P a g e
INCLINED CHAIN CONVEYOR 2014
Max bore = 5.440 in.
Hub diameter = 8.0 in.
Pitch diameter = 23.182 in.
Roller diameter = 3.0 in.
Plate thickness = 1.250 in.
Approximate weight = 216.0 lbs
15 | P a g e
INCLINED CHAIN CONVEYOR 2014
Required power to drive the conveyor
HP = DP x S x 1.1 / 33,000
Where:
DP = total conveyor pull
= 6260 lbs
S = conveyor speed, ft/min
= 100 ft/min
1.1 = compensates for motor efficiency
Therefore,
HP = (6260x 100 x 1.1) / 33,000
HP = 20.86666667 Hp
Transmitted Power on Spur Gears= Required power to drive the conveyor/ (0.97)
= 20.86666667 / ( 0.97)
=21.51202784 Hp
Transmitted power on V-belt = transmitted power on the first step gear reduction / 0.95
Transmitted power on V-belt = 21.51202784 Hp / 0.95
16 | P a g e
INCLINED CHAIN CONVEYOR 2014
Transmitted power on V-belt = 22.64423983 Hp
The nearest capable driving is: From: Machine Design Materials and Shop Practices
(Subaran).From: Machine Design Materials and Shop Practices (Subaran)
Power output: 25 hp
RPM: 400 rpm
From table17-3, Standard V-belt Lengths, Horsepower and Stock Sheave Diameter(Faires, p.458),
I select the minimum diameter from section D, 13in for the small or driving sheaveand 58in for
the big or driven sheave.
N2= N1D1/D2
= (13)(400) / 58
N2= 89.65517241 rev/min
17 | P a g e
INCLINED CHAIN CONVEYOR 2014
From Table 16-1, Drive Election Data (Doughtie and Vallance, p.378), the minimum speed ratio
per step of standard V-belt is 8 and the assume diameters of small and big sheave is satisfactory.
From equation (p) by Faires, p. 457, if the size of smaller sheave is assumed and velocity ratio is
known, choose a minimum center distance (c) as:
Note: The center distance is made adjustable so that the belts can be mounted into the grooves
without harmful stretching and so that initial tension can be maintained (Faires, p. 457).
𝜋 (D₂−D₁)²
L = 2 (D₂+D₁) + 2C + 4𝑐
𝜋 (58−13)²
L = 2 (58+13) + 2(58) + 4(58)
L = 236.2549875 in.
From Table 17-3, Standard V-belt Lengths (Faires, P.458) at Section D, I choose D240 with pitch
length equal to 240.8 in.
18 | P a g e
INCLINED CHAIN CONVEYOR 2014
Solving for the V-belt Speed
πD₁N₁
νm = 12
π(58)(400)
νm = 12
0.09
103 c νm² νm
Rated Hp = [a ( νm ) − Kd D₁ − e 10⁶ ] 103
Where:
0.09 (3769.9111842 )
103 5.326 3769.911184
Rated Hp = [2.684 (3769.911184) − 1.14 x 4 − 0.0136( )]
106 103
Rated Hp = 4.930591382 Hp
19 | P a g e
INCLINED CHAIN CONVEYOR 2014
Where:
Nsf = Service Factor Table 17.7(Faires, p.466), 1.4 for driven machine arecrushers,
jaw, hammer mills and driving machine is AC Normal Torque Squirrel Cage,
subtract 0.2 if the operation is quite intermittent.
Therefore,
Design Hp = 1.4(22.64423983)
Design Hp = 31.70193576 Hp
𝐵 + √𝐵 2 − 32(𝐷2 − 𝐷1 )2
𝐶=
16
𝐵 = 4𝐿 − 6.28(𝐷2 − 𝐷1 )
𝐵 = 517.32
𝐶 = 60.47971223 𝑖𝑛.
20 | P a g e
INCLINED CHAIN CONVEYOR 2014
Where:
D₂−D₁ 58−13
= 60.47971223= 0.7440511593
𝐶
By interpolation,
0.70 0.89
0.7440511593 K
0.80 0.87
Kѳ =0.8811896814
Therefore,
Design Hp
No. of Belts = Adjusted Rated Hp (Faires, p.461)
31.71093576
= 4.344786249
21 | P a g e
INCLINED CHAIN CONVEYOR 2014
= 7.298618147 say 8 belts
1 3
For Section D, 𝑏 × 𝑡 = 1 4 × 4
F1
𝝎
F2
𝐹1
= 𝑒 𝑓𝜃
𝐹2
Where:
22 | P a g e
INCLINED CHAIN CONVEYOR 2014
Computing the Angle of Contact
D₂− D₁ 𝜋
θs =[ 180 - 2sinˉ¹ ( )] 180
2c
Where:
58−13 𝜋
θs= [180 - 2sinˉ¹(2 x 60.47971223)] 180
θs = 2.379212089 rad
F₁
= 𝑒 (0.25)(2.379212089)
F₂
F₁ = 1.812673853 F₂ (eq. 1)
Power transmitted on the V-Belt, Hp from the eq. 16.7 (Doughtie and Vallance, p. 383)
(F₁−F₂) x νm
Hp = 550
Where:
23 | P a g e
INCLINED CHAIN CONVEYOR 2014
550 x 22.64423983
F₁-F₂ = 22.68928028
F₂ = 675.4347934 lb
F₁ = 1224.342989lb
1
= 1 4 (8) + 1
= 11 in
The pulley face should be about 1 in. wider than the belts up to 12 in. (Doughtie and Vallance,
p.389)
𝜋
W₁ = D₁² t ρ
4
Where:
24 | P a g e
INCLINED CHAIN CONVEYOR 2014
t = thickness of small sheave, 11in.
ρ = density of pulley material used, 0.256 lb/in³ for ordinary cast iron from Table 2-1
General Properties of commonly used materials (Doughtie and Vallance, p.11)
𝜋
W₁ = 4 (13)²(11) (0.256)
W₁ = 373.7741276lb
𝜋
W2= D2² t ρ
4
Where:
ρ = density of pulley material used, 0.256 lb/in³ for ordinary cast iron from Table 2-1
General Properties of commonly used materials (Doughtie and Vallance, p.11)
𝜋
W2= 4 (58)²(11) (.256)
W2= 7440.09561lb
25 | P a g e
INCLINED CHAIN CONVEYOR 2014
DESIGN CONSIDERATIONS
Material Used: ordinary cast iron for both gear and pinion
Pressure Angle: 14 ½ degrees
Type of Load: Medium shock
Type of Service: 24 hours
RPM of Pinion: 89.65517241 rev/min
RPM of Gear: 16.47708841 rev/min
Design condition:
Material used: ordinary cast iron, for both pinion and gear
Pressure angle: 14 ½ degrees
Type of load: medium shock
Type of service: 24 hrs/day
26 | P a g e
INCLINED CHAIN CONVEYOR 2014
Solving for pitch line velocity, v
𝜋𝐷𝑝 𝑁𝑝
𝑣=
12
Where:
π x 12 x 89.65517241
ν= 12
ν = 281.660031 ft/min
Where:
Ng = 16.47708841 rpm
NpDp= NgDg
NpDp 12 x 89.65517241
Dg = =
Ng 16.47708841
Dg = 65.29442837 in
Dg ≈ 65 in
33000 Hp
Ft = Fsν
Where:
27 | P a g e
INCLINED CHAIN CONVEYOR 2014
Fs = service factor, 0.55 from Table 11-4 Service Factors with steady load and 24 hr/day
service. (Doughtie and Vallance, p.270)
33000 x 21.51202784
Ft = 0.55(281.660031 )
Ft = 4582.551759 lb
From Table 16-1 Drive Selection data, the computed values are within the range in the table
therefore the speed reduction is satisfactory. (Doughtie and Vallance, p. 378)
Sw fY 600
Ft = eq. 11-2 (Doughtie and Vallance, p.270)
P 600+ν
Where:
Sw= Safe stress, 8000 psi from Table 11-3 Safe beam stress or static stress of materials
for gears , ordinary cast iron (Doughtie and Vallance, p.269)
Y = Lewis form factor from Table 11-2 Factors for the Lewis equation (Doughtie and
Vallance, p.268), 0.3 for trial
P= Diametral pitch
28 | P a g e
INCLINED CHAIN CONVEYOR 2014
ν= pitch line velocity, 281.660031 ft/min
Sw 10Y 600
P² = Ft 600+ν
P = 3. 564133478
Diametral pitch varies by increments of 1/2 from 2 to 5(Doughtie and Vallance, p.262)
This value suggests the use of a standard diametral pitch of 3.5,with 42 teeth on the
pinion 228 teeth on the gear. From Table 11-1 Gear Tooth proportions, the recommended
smallest pinion that will operate without interference with all gears at 14 ½ deg full-depth, 32
teeth. (Doughtie and Vallance, p.262).
It is customary to limit the reduction to 6:1 for spur gears (Doughtie and Vallance,
p.255)and the above solution will satisfy this statement.
To determine the smallest involute pinion that will operate without interference, use:
4m(Tg+m)
Tp² + 2TpTg = from eq.11-3 (Doughtie and Vallance, p.260)
sin²ф
Where:
m = product of diametral pitch and addendum, 1 from Table 11-1 Gear Tooth
proportion, Addendum is 1/P; hence, m =1 (Doughtie and Vallance, p.262)
(4x1)(228+1)
Tp² + 2(228)Tp = sin²14.5
29 | P a g e
INCLINED CHAIN CONVEYOR 2014
Tp² + 456Tp – 14611.54666 = 0
−b ± √b²−4ac
Tp = 2𝑎
−456 ± √456²−4(1)(−14611.54666)
Tp = 2(1)
𝑁+2
𝐷=
𝑃
D = (42 +2)/3.5
D = 12.57142857 in.
𝑁+2
𝐷=
𝑃
D = (228 +2)/3.5
D = 65.71428571 in.
Solving for the pitch line velocity, v, using actual diameter of the pinion
𝜋𝐷𝑝 𝑁𝑝
𝑣=
12
ν = (𝜋 x 12.57142857 x 89.65517421)/12
ν = 295.0724134 ft/min.
30 | P a g e
INCLINED CHAIN CONVEYOR 2014
To get Y, from the Table 11-2 Form Factors for the Lewis equation with Np = 42. (Doughtie and
Vallance, p.268)
38 0.335
42 Yp
43 0.345
Yp = 0.343
Ft P(600+𝜈)
fp = SwY(600)
4582.551759 (3.5)(600+295.0724134)
fp = 8000(0.343)(600)
fp = 8.719633636 in.
For gear:
From Table 11-2 Form factors for the Lewis equation with Ng = 171. (Doughtie and Vallance, p.
268)
150 0.376
228 Yg
300 0.383
Yg = 0.37964
4582.551759(3.5)(600+295.0724134)
fg = 8000(0.37964)(600)
fg = 7.878080121 in.
31 | P a g e
INCLINED CHAIN CONVEYOR 2014
Since both gears are made of the same material then the pinion is the weaker which should be
the one considered to approximate dimensions.
0.05ν ( Cf + Ft )
Fd = Ft + Fi = Ft + 0.05ν +√Cf + Ft
Where:
From Fig. 11-12 Maximum Permissible error in gears at various speed, error in gear = .003555
for pitch line velocity equal to 295.0724134 ft/min.
Thus class 1, industrial gears cut with formed cutters will be used from Table 11-5 Maximum
Error in action between gear; e= 0.0029 for diametral pitch equal to 3.5.
From Table 11-6 Values of the dynamic factor, C the materials are both cast iron, error in gear is
equal to 0.0029 through interpolation, we get
0.002 1600
0.0029 C
32 | P a g e
INCLINED CHAIN CONVEYOR 2014
0.003 2400
C = 2320
Therefore
0.05(295.0724134){(2320)(8.719633636 )+2361.307581}
Fd= 4582.551759 +
0.05(295.0724134) +√ (2320 x 8.719633636 ) + 4582.551759
Fd = 6707.494578 lb.
The load limit for wear is expressed by the eq. 11-20 (Doughtie and Vallance, p.275)
Where:
Sew = surface endurance limit, 90000 psi from Table 11-7 Fatigue limits of gear materials
for gray cast iron. (Doughtie and Vallance, p. 275)
Ep = modulus of elasticity for pinion, 12x10⁶ psi from Table 2-1 General properties of
commonly used material for cast iron. (Doughtie and Vallance, p.11)
33 | P a g e
INCLINED CHAIN CONVEYOR 2014
The value of Fw is not less than the value of dynamic load Fd, therefore it is ok.
Solving for the actual transmitted force or tangential load required for power
transmission.
𝐹𝑟
𝐹𝑛
𝐹𝑡
34 | P a g e
INCLINED CHAIN CONVEYOR 2014
33000 Hp
Ft = Vm
33000 x 21.51202784
Ft = 295.0724134
Ft = 2405.839674 lb.
𝐹𝑡
Fn = cosф
2405.839674
Fn=
cos14.5
Fn = 2484.99255 lb.
Fr= Fttanф
= 2405.839674 tan14.5
Fr = 622.1924448 lb
Weight of pinion
πD²fρ
Wp = 4
Where:
ρ = density of the pinion material, 0.256 lb/in³ for ordinary cast iron
𝜋
Wp= 4 x 122x 8.719633636 x 0.256
Wp = 252.4588367 lb.
35 | P a g e
INCLINED CHAIN CONVEYOR 2014
Weight of gear
πD²fρ
Wp = 4
Where:
ρ = density of the pinion material, 0.256 lb/in³ for ordinary cast iron
𝜋
Wp= 4 x 652x 8.719633636 x 0.256
Wp = 7407.212397 lb.
Design condition:
36 | P a g e
INCLINED CHAIN CONVEYOR 2014
Design for Shaft 1
D₂−D₁
Cos α = from eq. by Spotts, p.293
2C
Where:
18−4
α = cosˉ¹ 2 𝑥 60.47971223
37 | P a g e
INCLINED CHAIN CONVEYOR 2014
α = 68.15940562o
F₁= 1224.342989 lb
F₂= 675.4347934 lb
Fx₁ = 1136.462683 lb
Fx₂ = 626.9537574 lb
Fx = 1136.462683 + 626.9537574
Fx = 1763.41644 lb
Ws = 7440.09561 lb
38 | P a g e
INCLINED CHAIN CONVEYOR 2014
Total load at D section,
FHA = 1763.41644
Wp = 373.7741276 lb
FHD = 622.1924448 lb
39 | P a g e
INCLINED CHAIN CONVEYOR 2014
FVD = 2405.839674 - 373.7741276
ΣMC = 0
RVB = -551.476843 lb
ΣFV = 0
RVC = 5007.750761 lb
40 | P a g e
INCLINED CHAIN CONVEYOR 2014
ΣMA = 0
41 | P a g e
INCLINED CHAIN CONVEYOR 2014
ΣMC = 0
45(622.1924448)+15(1763.41644)
RHB = 30
RHB = 1814.996887 lb
ΣFV= 0
RHC = 570.6119978 lb
42 | P a g e
INCLINED CHAIN CONVEYOR 2014
43 | P a g e
INCLINED CHAIN CONVEYOR 2014
Resultant Moment at Section B and C.
MB =√(41694.207032 ) + (9332.8866722 )
MB =42725.93859 in-lb
MC =√(108538.31582 ) + (26451.246592 )
MC = 111714.9696 in-lb
Load
Section Resultant
Vertical Horizontal
2023.05546lb 622.1924448 lb 2848.39793 lb
A
551.476843lb 1814.996887 lb 1896.929205 lb
B
5007.750761lb 570.61198 lb 5040.155329 lb
C
7235.88772 lb 1763.41644 lb 7447.664643 lb
D
Moment
Section Resultant
Vertical Horizontal
44 | P a g e
INCLINED CHAIN CONVEYOR 2014
C 108538.3158 in-lb 26451.24659 in-lb 111714.9696 in-lb
2𝜋𝑇𝑁
Hp=33000
33000 x 21.51202784HP
T= 2𝜋𝑥 89.65517241𝑟𝑝𝑚
0.5𝜎𝑦𝑝 16
𝜏max = = 𝜋𝑑3 √(𝐶𝑚 𝑀)2 + (𝐶𝑡 𝑇)2
𝐹𝑠
Where:
Fs = factor of safety, 2
Cm = shock and fatigue factor due to be applied for the computed bending moment, 1.5 form
Table 3-1 constants for ASME Code or rotating shafts with gradually applied or steady load
(Spotts, .157)
Ct = shock and fatigue factor due to be applied for the computed torque, 1.0 from Table 3-1
constants for ASME Code or rotating shafts with gradually applied or steady load (Spotts, .157)
45 | P a g e
INCLINED CHAIN CONVEYOR 2014
From ASME Code B17C -1927, Section 21, p.171
Recommended working stress, τma x for the commercial shafting is 8000 psi in any
materials , if there is a key way at the section for which the stress calculation are made,
the working stress calculation is to be reduced to 75% of the value for the solid circular shaft.
Solving:
Therefore:
16
6000 = 𝜋𝑑3 √(1.5 x 111714.9696 𝑖𝑛 − 𝑙𝑏)2 + (1 𝑥15122.4208in − lb)2
D = 4.575018338 in.
15
The nearest value for standard machinery shafting by Faires, p.269 is 4 in. (4.9375 in.)
16
15
Therefore, I use4 16in. (4.9375 in.) for diameter of shaft 1.
Computing for the maximum actual radial load of the bearing at B section.
RVB = 7235.88772lb
RHB = 1763.41644 lb
Fr=√(7235.88772)2 + (1763.41644)2
Fr=7447.664643 lb.
46 | P a g e
INCLINED CHAIN CONVEYOR 2014
Solving for catalog rated force, FC
Fc = (KaKl) Ko Kp Ks Kt Fr
Where:
Ka= application factor taking into account the amount of shock (Table 9-4), 1.3 for moderate
shock and using roller bearing
𝐻𝑎
Kl =∛𝐻𝑐𝐾𝑟𝑒𝑙, life factor
Ha = 24(365) (3)
Ha = 26280 hrs.
Hc =10,000 hrs.
26280
Kl = ∛1.0 𝑥 10000 = 1.3799887397
𝐾𝑟𝑁𝑎
Ks =∛ , speed factor
𝑁𝑐
47 | P a g e
INCLINED CHAIN CONVEYOR 2014
Nc = catalog rated rotational speed, 500 rpm
Kr = rotational factor, 1.0 for fixed outer race and rotating inner race
1.0(89.65517241 )
Ks = ∛ = 0.563899594
500
Therefore,
Fc = (1.3)(1.3799887397)(1.0)(1.0)(0.563899594)(1.0)(7447.664643 lb)
Fc = 7534.263235 lb
From Table 9-7 Typical radial capacity Fc of Straight Cylindrical Roller Bearing (Doughtie and
Vallance, p.212) for the shaft diameter of 4.9375 in., I select SAE 224roller ball bearing with F c
of 12160lb and bearing bore of 4.7244 in. The shaft may be machined so bearing can be
inserted.
Design Condition :
Su = 62,000 psi
Sy = 40,500 psi
1 7
b = 1 4 in t = 8 in
48 | P a g e
INCLINED CHAIN CONVEYOR 2014
Design for Shearing Stress, Ss
0.5 𝑆𝑦
Ss= 𝐹𝑠
Where:
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one direction, gradual
mild shock (Faires, p.20)
0.5 𝑥40,500
Ss = = 6750 psi.
3
𝑆𝑦
Sc= 𝐹𝑠
Where:
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one direction, gradual
mild shock (Faires, p.20)
40,500
Sc = 3
= 13500 psi.
𝑇
F=𝑟
15122.4208
F= 4.7244
𝑖𝑛
2
F = 6401.837609 lb.
49 | P a g e
INCLINED CHAIN CONVEYOR 2014
Solving for the Length of the Key
𝐹
Sc= 𝐴
6401.837609 lb.
13500 = 7
8𝐿
2
L = 1.083909013 in.
𝐹
Ss =𝐴
6401.837609 lb
6750= 1
1
4𝐿
2
L = 1.517472618 in.
1 7
Therefore, I use L = 1.517472618 in. and 14 𝑖𝑛 x 8 𝑖𝑛 key.
Design Condition:
50 | P a g e
INCLINED CHAIN CONVEYOR 2014
Horizontal Component:
Fx = Fr = 622.1924448 lb.
Vertical Component :
Fy = Ft = 2405.839674 lb.
51 | P a g e
INCLINED CHAIN CONVEYOR 2014
Wg = 7407.212397 lb.
52 | P a g e
INCLINED CHAIN CONVEYOR 2014
T1 = 1.35 × m × L1 × (g / 1,000) (kN)
T2 = (L - L1) × m × f1× (g / 1,000) + T1(kN)
T3 = 1.1 x T2(kN)
Where:
Tma x = Maximum chain tension (kN).
T = Static chain tension at each part of conveyor (kN).
L = Horizontal center distance between sprockets (m).
= 50ft or 15.24390244m
L1 = 1.5ft x (1m/3.28ft) = 0.4573170732 m
m = Mass of the working portion of the chain (kg/m).
= 32.8 lbs./ft. (0.4536kg/1lb x 3.28ft/1m)
= 48.8001024 kg/m
M = Mass of the conveyed object in conveying section (kg/m).
= (50 lb/ft) x (0.4536 kg/lb) x (3.28 ft/m)
= 74.3904 kg/m
f1 = Coefficient of friction between the chain and the guide rail when conveying.
= 0.33 from Table 4, Appendix A
53 | P a g e
INCLINED CHAIN CONVEYOR 2014
T3= 1.1(1.852885584)
T3= 2.038174142 KN
T3= 458.1997746 lbs
T = Tmax+ T1
T = 3550 lb + 66.44380702 lb
T = 3616. 443807 lb
54 | P a g e
INCLINED CHAIN CONVEYOR 2014
FVA = 5001.372723 (downward)
FVC = 216 lbs + T sin β
= 216 + 3616.443807 sin 36.8699˚
FVC = 2385.866403 lb (downward)
FVE = FVC
FVE = 2385.866403 lb (downward)
ΣMB = 0
10FVA + 25 RVD = 10FVC + 40FVE
25RVD = -10(5001.372723) + 10(2385.866403) + 40(2385.866403)
RVD = 2771.183717 lb (upward)
ΣFy = 0
RVB = 5001.372723 + 2(2385.866403) – 2771.183717
RVB = 7001.921812 lb
55 | P a g e
INCLINED CHAIN CONVEYOR 2014
56 | P a g e
INCLINED CHAIN CONVEYOR 2014
FHC = T cos β
FHE = T cos β
ΣMB = 0
57 | P a g e
INCLINED CHAIN CONVEYOR 2014
ΣFy = 0
58 | P a g e
INCLINED CHAIN CONVEYOR 2014
For bending moment:
Resultant Moment:
MB =√(50013.727232 ) + (6228.396742 )
MB =50400.05791 in-lb
MC =√(30008.23236342 ) + (3737.038042 )
MC = 30240.03475 in-lb
MD=√(35787.996062 ) + (43397.324342 )
Load
Section Resultant
Vertical Horizontal
5001.372723 lb 622.839674 lb 5040.005791 lb
A
7001.921812 lb 871.975544 lb 7056.008107 lb
B
59 | P a g e
INCLINED CHAIN CONVEYOR 2014
Moment
Section Vertical Horizontal Resultant
The shaft diameter is equal to the maximum bore of the hub of the sprocket, 5.440 in.
The standard shaft diameter available for the sprocket is 5 7/8 in which is less than the
maximum bore. Keyset: width = 1 ¼; depth = 5/8.
2𝜋𝑇𝑁
Hp=33000
33000 x 20.866667HP
T= 2𝜋𝑥16.47708841𝑟𝑝𝑚
60 | P a g e
INCLINED CHAIN CONVEYOR 2014
T=79815.62611 in-lb
Computing for the maximum actual radial load of the bearing at B section.
Fr=√(7001.92182)2 + (871.975544)2
Fr=7056.008107 lb.
Fc = (KaKl) Ko Kp Ks Kt Fr
Where:
Ka= application factor taking into account the amount of shock (Table 9-4), 1.3 for
moderate shock and using roller bearing
𝐻𝑎
Kl =∛𝐻𝑐𝐾𝑟𝑒𝑙, life factor
61 | P a g e
INCLINED CHAIN CONVEYOR 2014
Ha = 24(365) (3)
Ha = 26280 hrs.
Hc =10,000 hrs.
26280
Kl = ∛1.0 𝑥 10000 = 1.3799887397
𝐾𝑟𝑁𝑎
Ks =∛ , speed factor
𝑁𝑐
Kr = rotational factor, 1.0 for fixed outer race and rotating inner race
1.0(16.47708841 )
Ks = ∛ = 0.3206049002
500
Therefore,
Fc = (1.3)(1.3799887397)(1.0)(1.0)(0.3206049002)(1.0)(7056.008107 lb)
Fc = 4058.333187lb
From Table 9-7 Typical radial capacity Fc of Straight Cylindrical Roller Bearing (Doughtie and
Vallance, p.212) for the shaft diameter of 5.440 in., I select SAE 226roller ball bearing with F c of
23720lb and bearing bore of 5.1181 in. The shaft may be machined so bearing can be inserted.
62 | P a g e
INCLINED CHAIN CONVEYOR 2014
Design Condition :
Su = 62,000 psi
Sy = 40,500 psi
1 7
b = 1 4 in t = 8 in
0.5 𝑆𝑦
Ss= 𝐹𝑠
Where:
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one direction, gradual
mild shock (Faires, p.20)
0.5 𝑥40,500
Ss = = 6750 psi.
3
𝑆𝑦
Sc= 𝐹𝑠
63 | P a g e
INCLINED CHAIN CONVEYOR 2014
Where:
Fs = factor of safety, 3.0 from Table 1.1 Factors of Safety for repeated, one direction, gradual
mild shock (Faires, p.20)
40,500
Sc = = 13500 psi.
3
2𝜋𝑇𝑁
Hp=33000
33000 x 20.866667HP
T=2𝜋𝑥 16.47708841𝑟𝑝𝑚
T= 79815.62611 in-lb
Hence,
𝑇
F=𝑟
79815.62611
F= 5.1181
𝑖𝑛
2
F = 31189.5532 lb.
𝐹
Sc= 𝐴
64 | P a g e
INCLINED CHAIN CONVEYOR 2014
79815.62611 lb.
13500 = 7
8𝐿
2
L = 5.280770912 in.
𝐹
Ss =𝐴
79815.62611lb
6750 = 1
1
4𝐿
2
L = 7.393079277 in.
1 7
Therefore, I use L =7.393079277 in.and 14 𝑖𝑛 x 8 𝑖𝑛 key.
Since the same sprocket size is to be used from the shaft 2 (headshaft), the same material and
diameter of the shaft is to be used.
The shaft is equal to the maximum bore of the hub of the sprocket, 5.440 in. The standard shaft
diameter available for the sprocket is 5 7/16 in and from Table 2, Standard keyways and set
screws, keyset: width = 1 ¼ in.; depth = 5/8 in.
Design Condition:
Sy = 55 000 psi
65 | P a g e
INCLINED CHAIN CONVEYOR 2014
Su = 90 000 psi
Fs = 3.0, from Table 1.1 Factors of Safety, based on yield strength of steel, ductile metals
(Faires, p. 20)
I will use the same size of bolts for all the bearing caps for the three shafts. And to
compute the size of the bolt, I will use the maximum value of the horizontal reaction for
shearing of the three shafts divided by the number of bolts. The vertical reaction has no effect
on the bolt because all the vertical forces are in downward direction.
Solving for the size of the bolts Based on the Shearing Stress
0.5𝑆𝑦
𝑆𝑠 = 𝐹𝑠
Where:
𝐹
𝑆𝑠 = 𝐴
Where:
66 | P a g e
INCLINED CHAIN CONVEYOR 2014
A = Cross sectional area of the bolt
Therefore,
0.5𝑆𝑦 𝐹
= 𝜋
𝐹𝑠 2 (4 𝐷2 )
0.5(55000) 6047.038175
= 𝜋
3.0 2 (4 𝐷2 )
D = 0.6480457952 in.
From Table 6-1 Unified & American National threads, coarse, fine, and extra-fine series
(Doughtie and Vallance, p.130), I select ¾ in. UNC bolt with Ar= 0.334 in² and minor diameter of
0.6273 in. The bolt being screwed into the part is the threaded part.
67 | P a g e
INCLINED CHAIN CONVEYOR 2014
DESIGN SUMMARY
68 | P a g e
INCLINED CHAIN CONVEYOR 2014
Shaft 3 (tailshaft) AISI C117 Annealed Carbon Steel @ section D,
D = 5.4375 in Mmax= 56250.40819 in-lb
L = 50 in Tmax = 79815.62611 in-lb
69 | P a g e
INCLINED CHAIN CONVEYOR 2014
REFERENCES
Books:
Doughtie, V.L., &Vallance, A. (1978).Design of Machine Members(4thed.).New York: McGraw- Hill, INC.
Faires, V.M. (1969). Design of Machine Elements (4thed.). New York: MacMillan Company.
Spotts, M.F. (1991). Design of Machine Elements (6thed.). Singapore: Simon & Schuster (Asia) Pte Ltd.
Subaran, G.C. (1985). Mechanical engineering board reviewer: Machine design materials and shop
practices (2nd ed., Vol.1). Manila: 24K Printing CO., INC
Internet:
http://www.ustsubaki.com/eng_chain_cd/images/pdf/c_sprselecguidelns51-59.pdf
http://en.wikipedia.org/wiki/Chain_conveyor
70 | P a g e
INCLINED CHAIN CONVEYOR 2014
APPENDICES
71 | P a g e
INCLINED CHAIN CONVEYOR 2014
72 | P a g e
INCLINED CHAIN CONVEYOR 2014
73 | P a g e
INCLINED CHAIN CONVEYOR 2014
74 | P a g e
INCLINED CHAIN CONVEYOR 2014
75 | P a g e
INCLINED CHAIN CONVEYOR 2014
76 | P a g e
INCLINED CHAIN CONVEYOR 2014
77 | P a g e
INCLINED CHAIN CONVEYOR 2014
78 | P a g e
INCLINED CHAIN CONVEYOR 2014
79 | P a g e
INCLINED CHAIN CONVEYOR 2014
80 | P a g e
INCLINED CHAIN CONVEYOR 2014
81 | P a g e
INCLINED CHAIN CONVEYOR 2014
82 | P a g e
INCLINED CHAIN CONVEYOR 2014
83 | P a g e
INCLINED CHAIN CONVEYOR 2014
Table 9-4 Typical Values of application factor for roller and ball bearings
84 | P a g e
INCLINED CHAIN CONVEYOR 2014
Table 9-2 SAE and International Standard dimensions for ball and Roller Bearings
85 | P a g e
INCLINED CHAIN CONVEYOR 2014
86 | P a g e
INCLINED CHAIN CONVEYOR 2014
Table 6-1 Uniform and American National Threads, coarse, fine and extra-fine
87 | P a g e
INCLINED CHAIN CONVEYOR 2014
88 | P a g e