Professional Documents
Culture Documents
Conveyor Design
Conveyor Design
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Announcements
• Emergency Doors
• Bathrooms
• Security
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Conveyor 101
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Conveyor 101
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OUR GOAL
• 1. History of Conveyors
• 2. Safety History of Conveyors
• 3. Design Concepts
• 4. Conveyor Components Selection
• 5. Good Conveyor Practices
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Our Goal
• 1. History of Conveyors
• 2. History of Safety for Conveyors
• 3. Design Concepts or Rules
• 4. Conveyor Components Selection
• 5. Good Conveyor Practices
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History
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History
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History
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History
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History
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OUR GOAL
• 1. History of Conveyors
• 2. Safety History of Conveyor
• 3. Design Concepts or Rules
• 4. Conveyor Components
• 5. Good Conveyor Practices
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Safety
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Safety
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Our Goal
• 1. History of Conveyors
• 2. History Conveyor Safety
• 3. Design Concepts
• 4. Conveyor Components Selection
• 5. Good Conveyor Practices
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Basic Common Rules
(There are exceptions)
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Basic Common Rules
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Basic Common Rules
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Basic Common Rules
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DESIGN CONCEPT - FORCES
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Design Concept - Forces
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Design Concept - Forces
• From a Design point of view, the most difficult
part is determining the Forces or Tensions in the
system.
• Tension is developed by the Motor that defines
the maximum forces to be generated on the
conveyor system.
• HP calculation addresses the necessary forces
for overcoming: Parts Friction, and Horizontal
and Vertical forces necessary for the movement
and elevation of materials.
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Design Concepts - Forces
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Design Concepts - Forces
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Design Concepts - Forces
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Design Concepts - Forces
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Design Concepts - Forces
• PIW = TT / PIW
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Design Concepts - Forces
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Design Forces
• Some Root Cause or Reasons that cause
Conveyors problems:
– Not Enough Information Provided or Gathered
– Erroneous Information Obtained
– Poor Engineering Analysis
– Fictitious Savings
– Pushing Manufacturer’s Limits or Specs Out of
Range.
– OTHER
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Design Concepts - Forces
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OUR GOAL
• 1. History of Conveyors
• 2. Safety History of Conveyors
• 3. Design Concepts
• 4. Conveyor Components Selection
• 5. Good Conveyor Practices
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Conveyor Components
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Conveyor Components Selection
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Conveyor 101
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Pulleys & Shafts
As mentioned before:
• The pulley(s) is a rotating structural component
that has minor influence on the conveyor
resistance to movement. However, the friction
contribution is transmitted through the pulley as
torque. (CEMA 6 Edition Ch. 5)
th
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Pulleys & Shafts
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Pulleys & Shafts
On Crown Faced Pulley the
Belt is stretched on the
center (as is a longer
distance than to the edge)
due to the rim curvature.
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Shaft Deflection
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Pulleys & Shafts
DEFLECTION
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Pulleys & Shafts
Alternating End Disc Stresses
(Stress from shaft deflection)
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Pulleys & Shafts
Static Bending Stress
(Stress from bushing installation)
Installation Sequence
1. Bushing to shaft grip > Bushing to hub grip
2. Therefore bushing locks to shaft first
3. Further tightening moves discs apart (Bellows)
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Pulleys & Shafts
CAPACITY COMPARISON
16 X 32 PULLEY WITH 2-15/16" SHAFT AND 40" BEARING CENTERS
CEMA SHAFT LOAD RATING - 6000 LB (3000 LB Tension at 180 Degrees)
END DISC RIM OVERALL CAPACITY ABOVE COST FACTOR
PULLEY TYPE CAPACITY (LB) CAPACITY (LB) CAPACITY (LB) SHAFT LOAD RATING PULLEY ASSEMBLY
HEAVY DUTY 6570 6780 6570 10% 1.00 1.00
MINE DUTY 7610 26750 7610 27% 1.73 1.14
MINE DUTY EXTRA 30630 26750 26750 346% 1.85 1.16
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Pulleys & Shaft
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Pulley Specifications
• Customer Supplied
– Can vary from no specifications to hundreds of pages
– Establishes expectations, durability and warranties for
product(s) ordered.
– Always use deflection factor to differentiate and
compare pulleys among manufacturers.
• Manufacturers can:
– recommended pulley specifications
– Help in understating what is being used by the mining
industry for projects they are involved in.
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Pulley Specifications
CLASS IV III II I
Belt Type Fabric Fabric Fabric, Steel, Kevlar Fabric, Steel, Kevlar
Recommended kN/m up to 140 kN/m up to 218 kN/m above 218 kN/m above 437 kN/m
Recommended PIW up to 800 PIW up to 1,250 PIW above 1,250 PIW above 2,500 PIW
Design Welded Hub Integral Hub / Profiled Turbine T-Section
Hub to Disc Weld Fillet None None None
Disc to Rim Weld Fillet Fillet Fillet Groove
Locking Assembly HE HE / Keyless Keyless Keyless
LAGGING
Drive Pulley Type Herringbone Herringbone Herringbone Diamond
Drive Pulley Thickness 13mm (0.5 in.) 13mm (0.5 in.) 13mm (0.5 in.) 25mm (1.0 in.)
Non-Drive Pulley Type Plain Plain Plain Plain
Non-Drive Pulley Thickness 10mm (0.375 in.) 10mm (0.375 in.) 10mm (0.375 in.) 13mm (0.5 in.)
Shore A Durometer 60 60 60 60
Compound SBR SBR SBR D-LAG
KB Factors
Drive Pulleys w/ OHL 2.5 2.5 2.5 2.5
Drive Pulleys w/o OHL 1.5 1.5 1.5 1.5
Non-Drive Pulleys 1.5 1.5 1.5 1.5
KT Factor 1 1 1 1
Deflection (mm/mm or in/in) 0.0023 0.0015 0.0015 0.001
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Pulley Specifications
Class IV Class III Class III (Engineered) Class II Class I
NOTE: Only drive pulley shafts with HE locking assemblies are key
seated.
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Pulleys & Shafts
• Heavy Duty and Mine Duty
– Welded hub design
– Drums and wings
– DF = .0023 in/in
• Mine Duty Extra
– Integral hub design
– Drums and wings
– DF = .0015 in/in
• Engineered Class
– Welded hub design
– Integral hub design
• Rigid
• Profiled
• Turbine
• T-section
– DF = .0010 in/in
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Pulleys & Shafts
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Heavy Duty Wing Pulleys
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Pulleys & Shafts
Exclusive HE
(High Endurance)
14˚ Taper Bushing System
XT
9.5˚ Taper Bushing System
Taper Lock
8˚ Taper Bushing System
Q.D.
4˚ Taper Bushing System
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5
Engineered Class Pulleys
FROM CEMA “BELT CONVEYORS FOR BULK MATERIALS”
• Engineered pulleys are specifically designed to meet load
conditions of a particular conveyor.
• Common reasons for using engineered pulleys are:
1. Belt tensions and resultant loads exceed CEMA standards
B105.1 and B501.1.
2. Pulley diameter, face width, and shaft diameter combination
falls out of size ranges defined in CEMA standards B105.1
and B501.1.
3. Conveyor belt uses steel cable, steel mesh, aramid, or other
high modulus carcass.
4. It is desired to control project costs by optimizing pulleys for
their intended use.
5. Conveyors operate at high speeds with nearly continuous
service.
6. Transient belt tensions greater than 50% more than steady
state running tensions.
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Pulleys & Shafts
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Pulleys & Shafts
Plain Herringbone
Ceramic Diamond
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Pulleys & Shafts – Suggested Pulley
Diameter per HP
HP Head Lag Snub Bend GTU Tail
10 - 15 18 ½” - - - 16
20 - 30 24 ½” - 18 18 20
40 - 50 24 ½” 18 ** 18 18 20
60 - 100 30 1” 20 20 20 24
200 48 1½” 30 30 30 36
** Check for Fit
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Pulleys & Shafts
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Conveyor 101
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Common Idler Styles
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Basic Common Rules
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Idlers - Evolution of Bearing Life
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Idlers
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Idlers
• Basic Rated Life based on number of
operating hours at 500 rpm.
• Based on a statistical model which is
expressed as the total of revolutions 90% of
the bearings are subject to identical operating
conditions.
• In an apparently identical group of bearings
subjected to identical operating conditions.
• They will attain or exceed before a defined
area of material fatigue (flaking, spalling)
occurs on its rings or rolling elements.
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Why Do Rollers Fail?
• Bearing Contamination
o Roller Sealing Systems
• Shell Wear / Abrasion
o Misalignment
• Bearing Load
o Shaft & Tube Deflection
• Rollers Jamming
o Material Spillage
– Roller Construction
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Why Do Rollers Fail?
Impact Zones
Spillage at Transfer Points
Wash‐down Areas
Constant Moisture
Fine Particulate Contaminants
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Idlers
Sealing, Sealing, Sealing
Triple Labyrinth Seal
Rubber Dust Shield 2RS C3 Bearing
ABS Polymer Bearing Housing
Labyrinth Cover
Felt Ring
Shell Painted
Inside
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Idlers
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CEMA Idler Classification
Classification Roll Diameter (in) Belt Width (in)
B4 4 18-48
B5 5 18-48
C4 4 18-60
C5 5 18-60
C6 6 24-60
D5 5 24-72
D6 6 24-72
E6 6 36-96
E7 7 36-96
F6 6 60-96
F7 7 60-96
F8 8 60-96
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Idlers
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Idlers
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Idlers
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Idlers
• Selection Procedure requires calculating:
• Calculated Idler Load; CIL = WB x Si + IML
• Bearing L10 Life Correction based on Effects of:
Load = K2 = CIL / ILR
Belt Speed = K3A = rpm = BS x 12 / Roll Dia X Pi
Diameter = K3B = Figure 5.26
• Potential Idler Life:
Maintenance = K4A = Figure 5.27
Environmental = K4B = Figure 5.28
Operating Conditions = K4C = Figure 5.29
Impact Force = W + (2 x k x WH)1/2
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Idlers
• Idler Height Misalignment is critical for
maintaining L10 Bearing Life.
Si Si
T = Belt Tension
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Idlers
• Manufacturers have different idler’s Height.
• Other K Factors for Idler calculations were
mentioned earlier.
• CEMA only addresses ROLLER Bearing idlers,
there is no mention on the 6th Edition of BALL
Bearings.
• As such, formulas used on L10 Bearing Life
Calculations was developed for roller bearings.
• Load Carrying of Roller Bearings compensated
by installing a larger bearing on the idler.
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Idler Cutaway
RE-GREASABLE 1. EXTERNAL SHIELD
2. FLINGER
3. GREASE HOR.
LABYRINTH
4. GREASE VER.
LABYRINTH
5. CONTACT LIP SEAL
6. REAR SEAL
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Idler Cutaway
SEAL FOR LIFE
End Disc
Seal
Shaft
Bearing
Tube
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Bearing Styles
• Ball Roller
Cage
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Spacing of Idlers
Belt Width Weight of Material Return Idlers
(in) (lbs/cu ft) (ft)
30 50 75 100 150 200 10.0
18 5.5 5.0 5.0 5.0 4.5 4.5 10.0
24 5.0 4.5 4.5 4.0 4.0 4.0 10.0
30 5.0 4.5 4.5 4.0 4.0 4.0 10.0
36 5.0 4.5 4.0 4.0 3.5 3.5 10.0
42 4.5 4.5 4.0 3.5 3.0 3.0 10.0
48 4.5 4.0 4.0 3.5 3.0 3.0 10.0
54 4.5 4.0 3.5 3.5 3.0 3.0 10.0
60 4.0 4.0 3.5 3.0 3.0 3.0 10.0
72 4.0 3.5 3.5 3.0 2.5 2.5 8.0
84 3.5 3.5 3.0 2.5 2.0 2.0 8.0
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Belt Speeds at 500 rpm
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Load Rating: CEMA C
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Load Rating: CEMA D
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Load Rating: CEMA E
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Impact Idler Spacing Factor
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Minimum Energy Ratings for Impact
Idlers
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What makes a belt mistrack?
• Un-level conveyor
• Misaligned
components
• Poor belting
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Conveyor 101
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Conveyor 101
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Belting
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Belting
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Belting Specification
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Design Basics – Rubber Fabric Belt
Top Cover
• Abrasion resistance from material
• Cut and gouge resistance
• Protect carcass
Carcass
• Provide tension to ~2000 PIW
• Impact, Tear Resistance
• Support load over idlers
Pulley Cover
• Protect carcass
• Provide abrasion resistance from idler contact
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4
Rubber Fabric Conveyor Belt
Rubber Top Cover
Rubber Skims
Fabric Ply 1
Fabric Ply 2
Fabric Ply 3
Fabric Ply 4
• Fabric Plies
• Warp - Tensile Strength
• Fill (weft) - Fastener
Holding, Impact
Resistance, Rip & Tear
Resistance
Warp
• Skims
• Rubber Between the
Plies
• Adhesion
• Load Support Fill
(weft)
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Tension Ranges
• Rubber + Fabric
• 220 – 2000 PIW
• PVC + Fabric
• 40 – 1200 PIW
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Compounds
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Place of Manufacturer and QC
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Conveyor Belt Testing
• Tensile • Adhesions
• Durometer • Compression Test
• Elongation • Tension Rating
• Oil Resistance • Ultimate Break
• Ozone Resistance • Covers Compound
• Static Conductivity
• Flame Resistant
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Conveyor 101
• Conclusions:
– Do have a Specification for Conveyor Components;
such as: Pulleys, Shafts, Bearings, Idlers, Belting and
others.
– As a minimum, the Specification needs to address
Warranties as they relate to: Operating Hours & Total
Tons Run before a replacement.
– Have a Standard developed for Conveyor
Components with an aim in reducing replacement
parts inventory.
– When comparing manufacturer’s products have a
perfomance
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Conveyor 101
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END
QUESTIONS??
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Pulleys & Shafts
EXAMPLE OF SHAFT
CALCULATION
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Pulleys & Shafts
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Pulleys & Shafts – Step 1
Example Calculations:
Given: Te = 33,000 x HP/
HP = 100 SPEED
BW = 42”
BRNG CTR. = 60” Te = 33,000 x 100 / 300
WRAP = 210 degree
SPEED = 300 fpm Te = 11,000 #
LAGGED Or from Table I
AUTO TAKE-UP
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Design Forces
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Pulleys & Shafts – Step 2
Snubbed Drive, Automatic GTU and 210 Wrap then:
K =.38 OR Table II
T2 = Te x WRAP FACTOR
T2 = 11,000 lbf. x .38
T2 = 4,180 lbf
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Pulleys & Shafts – Step 2
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Design Forces – Step 3
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Pulleys & Shafts – Step 4
Drive 210
WRAP ANGLE
PULLEY WRAP ANGLE GTU Slack side tension
HEAD – 210 is adjusted by the
SNUB - 20 to 30 amount of weight
on the gravity take
BEND - 90 WEIGHT up pulley.
GTU - 180
TAIL - 180
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Pulleys & Shafts – Step 4
Resultant = T2 x Factor
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Pulleys & Shafts – Step 4
Drive 210
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Pulleys & Shafts – Step 4
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Pulleys & Shafts – Step 4
Drive 210
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Pulleys & Shafts – Step 4
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Pulleys & Shafts – Step 4
Drive 210
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Pulleys & Shafts – Step 5
Drive 210
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Pulleys & Shafts – Step 5
TT = Te + T2 = 11,000 + 4,180
TT = 15,180 lbf
R = 15,180 / 4180
R = 3.63157
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Pulleys & Shafts – Step 5
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Pulleys & Shafts – Step 5
• Drive Pulley Resultant from Table IV and using
Interpolation we get:
Ratio Factor
(TT/T2)
Subtract Subtract
3.60 4.4940
X
.03
.20 .1988
3.63 X
3.80 4.6928
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Pulleys & Shafts – Step 5
By Interpolation:
Factor = 4.5238
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Pulleys & Shafts – Step 5
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Pulleys & Shafts – Step 5
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Pulleys & Shafts – Step 6
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Pulleys & Shafts – Step 7
• Rule of Thumb:
– BW + 12” + 6” or 8” would be a safe bearing center
distanced if none know at the time.
• Bearing Centers = BW + 12 + 6
• B = 42 + 12 + 6
• B =60”
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Pulleys & Shafts – Step 7
• A = B – Pulley Face
• A = 60” – 44”
• A = 16”
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Pulleys & Shafts – Step 7
To determine the shaft diameter Tables VIa & VIb
are provided. One is for CTX & QD Hubs (VIa) &
the other for Taper Lock Hubs (VIb).
• Tables are for Non Drive Pulleys Shafts and are
based on 8,000 psi allowable stress. To convert
to Drive Pulley Shafts of 6,000 psi divide R by
.75 to obtain the correct R value.
• At this stage the selection bearings centers
have to be established.
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Pulleys & Shafts – Step 7
• R = 18,909 / .75
• R = 25,212 lbf
• From Table VIa we determine that:
• A 6” shaft with 60” bearing centers minus face of
16” has a load rating of 27,697 lbf which is the
smallest available without dropping below the
25,212 lbf.
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Pulleys & Shafts – Step 7
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Pulleys & Shafts – Step 7
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Pulleys & Shafts – Step 5
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Pulleys & Shafts – Step 7
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Pulleys & Shafts – Step 5
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Pulleys & Shafts – Step 7
• Using Tables VIa or VIb and previous R value
calculations we determine that:
• Bend Pulleys with an R load of 5,911 lbf & A of
16” - Table VIa indicates the bearing size to be
3 15/16”.
• Snub with an R load of 2,164 lbf & A value of
16” shaft comes to be 2 1/16”.
• Tail & Take Up with an R load of 8,360 lbf shaft
and A of 16” comes out to be 4 7/16”
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Pulleys & Shafts
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Pulleys & Shafts – Step 8
VII
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Pulleys & Shafts – Step 8
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Pulleys & Shafts – Step 8
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Pulleys & Shafts
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Pulleys & Shafts – Suggested Pulley
Diameter per HP
HP Head Lag Snub Bend GTU Tail
10 - 15 18 ½” - - - 16
20 - 30 24 ½” - 18 18 20
40 - 50 24 ½” 18 ** 18 18 20
60 - 100 30 1” 20 20 20 24
200 48 1½” 30 30 30 36
** Check for Fit
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END
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CONVEYOR GLOSSARY
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Conveyor Upgrade Example
1970 Capacity of 2,200 tph per belt, 125 HP, 340 fpm
2013 Capacity of 4,400 tph per belt, 400 HP, 690 fpm
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What If Scenarios
Impact on Conveyor Components
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What If Scenarios
Impact on Conveyor Components
EXAMPLE #1 - Original Design: 800TPH, 400FPM, Screw Take-up
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What If Scenarios
Impact on Conveyor Components
EXAMPLE #1A - 800TPH changed to 1000TPH, 400FPM Gravity Take-up
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What If Scenarios
Impact on Conveyor Components
EXAMPLE #2 - Original Design: 800TPH, 400FPM Gravity Take-up
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What If Scenarios
Impact on Conveyor Components
EXAMPLE #2A - 800TPH Changed to 1000TPH, 400FPM Gravity Take-up
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Conveyor Design Changes
Potential Impact on Components
Think about SAFETY before you change
a Conveyor’s Operating Parameters
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Conveyor Design Changes
Potential Impact on Components
Think about SAFETY if
you see these operating conditions
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Conveyor Design Changes
Potential Impact on Components
Think about SAFETY if
you see these operating conditions
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