BELT CONVEYOR DESIGN

Date: 11/9/18 7:24 AM

Knowns:
Belt Weight #/ft 6.7 Belt Width (BW) 18 in
Length of conveyor ft 13.25 Pulley Face Width (F) 20 in
Coeff. of friction 0.3 Bearing Centers (BC) 24 in
Belt speed fpm 210 B.C.M.F. 4 (Bearing Center Minus Face)
Total Material wt.# 1,469 P.I.W. Drive Pulley (#/in) 118 (Pulley Pounds per Inch of Belt Width)
Incline angle (deg) 5 P.I.W. Tail Pulley (#/in) 52 (Pulley Pounds per Inch of Belt Width)
Drive wrap angle (deg) 180 Drive pulley diam. (in) 24 24" Drive Pulley Diameter
Tail wrap angle (deg) 180 Tail Pulley diam. (in) 24 24" Tail Pulley Diameter
(see Dodge book, table 1, pg.PT 13-12

Carrying belt wt. 88.8 lbs Drive Pulley Resultant Load (R) (lbf) 3,064 (use 1/2 this to check bearing
Total "topside" weight 1,557.5 lbs Tail Pulley Resultant Load (R) (lbf) 1,886 load rating @ shaft rpm)
(see Dodge book table 3, pg.PT 13-13 for shaft sizes)
Horse Power Calcs:
Horizontal hp 3.0 HP Kb = 1.5 or 2.5 if overhug load 2.5
Vertical hp 0.9 HP Dodge Table 4 N value (BCMF / 2) 2
Dodge Table 4 addition to N value 1.75
Dodge Table 4, A value 3.75
Total HP 3.83 HP (Dodge pg. PT-13-15)
Service Factor 1.4
Design HP 5.36 HP Allowable Torsional Shearing Stress (S) 8,000 8,000psi for 1045 or 10,000psi for 4140, keyed shaft)
Selected Drive hp 7.5 Drive Pulley Shaft 37/16 43/16 Selected Drive Pulley Shaft Dia
Motor Selection: (formula from Dodge, Step 7, pg PT13-15) 31/16 Selected Tail Pulley Shaft
7 HP, 213T Frame, 1750 RPM
Motor RPM 1750
Tension Calcs: Calculated Gearbox ratio 52.36 :1
Te (Effective Belt Tension) 1,178.6 lbs Ave. Mechanical Efficiency of Gearbox (from Rex) 95% Actual gearbox selected:
Cw (Drive Factor) 0.8 Selected Gearbox ratio 31.63 Rexnord MARS 11 - Nom. Ratio 31.63:1
See Dodge book, table 7, pg.PT 13-52) Gearbox spkt rpm 55.33 RPM
T2 (slack side ten.) 942.9 lbs Gearbox Output Torque 8,116 in/lbs (Nominal)
T1 (tight side ten.) 2,121.4 lbs Equivalent Gearbox Output Torque (from Rex) 11,363 in/lbs (Max)

req'd chain ratio 1.6554 :1

Req'd final rpm 33.42
Gearbox (normally small) spkt teeth 22 Sprocket: Martin 100E22H
Large spkt teeth (calculated = 36) 35 Sprocket: Martin 100E35

Actual final RPM 34.78

Actual final Torque 13,592 in/lbs
FPM 218.51

Low Speed Shaft

Gearbox Over Hung Load OK
(from Rex, pg. H-9)
Gear Box spkt. P.D. 6.407 in
Load Connection Factor FC (from pg. H-9) 1
Load Connection Factor LF (from table 7, p. H-20) 1.3 (assumed 4 1/2" in)
O.L. = (126,000 * HP * FC * LF) / (P.D. * RPM) 3,466 lbs
Gearbox Load Rating (from table 8, pg. H-21) 3,860 lbs

RC100 Chain OK
(from Dodge, pg. PT12-30 to 39)
Small Sprocket No. of Teeth (from above) 22
Gear Box spkt. P.D. 6.407 in
RPM (from table) 50
Rated Hp (from table) 7.3
Required RPM (from above) 55
Interpolated HP rating 8.08
Reducer Output Chain FPM = 92.8 Check for slow drives
Chain Pull (Drive Spkt.) 2,667 lbs. see Dodge p. PT12-29

Shaft: (1045)
Allowable torsional shearing stress (Ss) 8,000 psi
Shock & Fatigue factor forTorsional Moment Kt 1
Shock & Fatigue factor for Bending Moment Km 1.5
B (1 for solid shafts) 1
Allowable bending stress (S) 16,000 psi
See Machinery Handbook pgs. 310-311

Drive Pulley Overhung Load:

Edge of hub to c/l brg. 4.5 inches
Bending moment (Mb) @ Drive Spkt. 13,789 in-lbs
Drive shaft tortional moment (Mt) 13,592 in-lbs
Min. Calculated Drive Shaft Diameter 40/16 inches

File: 401486097.xls
Belting Formulas
http://www.niba.org/beltingformulas.html
CONVEYOR BELT TENSION CALCULATION

Calculation F1 = .035" (Normal friction factor for average conditions (over 20 degree F) to move
s empty belt).

TC = F1 X L L = Belt length (feet).

X CW

CW = Weight of conveyor belt components (See Table A in Engineering Handbook).

TL= F2 X L F2s = .04" (Normal friction factor to move load horizontally).

X MW

L = Belt length (feet).

MW = Material weight (lbs. per lineal foot)

MW = 33.3 TPH / or MW = Total Material load in lbs. / L

Belt Speed
(fpm)

H = Difference between elevation of terminal pulleys (ft.)

TH= H X MW

TE = TC + TL + TH

Second, additional tension must be added to the effective Belt Tension (Te) to prevent slippage on
the drive pulley. This is called Slack Side Tension (Ts), or commonly called T2.

Ts = D X Te

D = Drive factor (See Table B in Engineering Handbook).

Next, the total tension To = Te + Ts

To is the total operating tension, or commonly called Allowable Working Tension, and is expressed
in PIW (pounds per inch of width). To is sometimes referred to as TL.