Kartal Konveyör

Client Name Designer HAK
Project Name Company

Conveyor Name cv01 Filename
Location Date Nisan 5, 2021
Description
System Information Idler Set Data

Calculation method .......................................... CEMA 6th Carry Return
Conveyor Length / Height .................................. 8 / 2,6 m Series name Series 20 Series 20
Material lift .............................................................. 2,4 m Bearing 6204 6204
Ambient temperature range ........................... -15 to 35 °C Number of rolls 3 1
Kt factor at minimum temperature............................. 1,21 Trough angle (deg) 30 0
Type Inline Inline
Material Properties Idler spacing (m) 1,00 3,00
Type ..................................................................copper ore Number of ıdler sets 12 3
Design Tonnage ....................................................... 30 t/h Roll diameter 89 89
Density ............................................................ 2000 kg/m3 Roll rpm 303 303
Maximum lump size .............................................. 15 mm Total drag (N) 11,5 3,8
Surcharge angle ...................................................... 22 deg Drag range (N) 8,5 - 26,0 2,9 - 8,8
Roll length 213 640
Shaft diameter (mm) 20,0 20,0
Belt Properties
Dynamic capacity (kN) 13,5 13,5
Type ............................................................ Fabric (3-Ply) L10 life1 (1000 hrs) 350,0 / 350,0 0,0
Width ................................................................... 550 mm Shaft deflection (min) 0,10 / 0,32 2,19
Rating............................................................... 400 N/mm 1 L10 life above which 95% of idlers exceed
Speed ................................................................... 1,41 m/s
Top / bottom cover thickness ....................... 4,0 x 2,0 mm Drive Station
Total thickness ....................................................... 10 mm
Type ............................................................. Squirrel cage
Weight (new / worn) ................................... 6,0 / 4,2 kg/m
Synchronous RPM ...........................................1500 RPM
Modulus ......................................................... 4.447 kN/m
Motor quantity / rating ................................... 1 / 5,50 kW
Tape length .......................................................... 17,36 m
Total ınstalled power ........................................... 5,50 kW
Belt cycle time ............................................................ 12 s
Nominal empty / full power .... (55 / 59%) 3,01 / 3,23 kW
Tension Summary Running Momentary Min / max demand power........ (32 / 86%) 1,74 / 4,71 kW
Maximum tension (kN) 4,05 4,73 Frame Size......................................................... IEC 132S
Minimum safety factor 54,35 46,49 Motor Voltage ............................................. Not Specified
Minimum tension (kN) 2,34 2,09 Efficiency .................................................... 94,5 to 97,5%
Maximum belt sag (%) 0,99 1,14 Maximum starting torque .........................................180%
Inertia - Motor ................................................... 0,1 kg·m²
Cross Sectional Loading Pulley lagging type ................................................ Rubber
Material mass (wm) ............................................. 5,9 kg/m Motor wrap angles....................................................... 180
Combined mass (wm + wb) ................................ 11,9 kg/m Lagging friction factor (run / accel) ................. 0,32 / 0,38
Edge distance (required / actual)................... 53 / 172 mm
Cross sectional area ............................................ 0,003 m² Take-up Data
Cross sectional loading (utility / total) ............. 10 % / 6 %
Bed depth ............................................................... 21 mm Type ......................................................................... Fixed
Location ................................................... Tail / Pulley #2
Steady state tension .................................. 2,34 to 2,59 kN
Momentary tension................................... 2,25 to 2,67 kN
Required pulley displacement ................................ 0,68 m

Dynamic displacement (incl thermal) .............. 0,00 m
Permanent elongation ...................................... 0,11 m
Splice length (1 included) ................................ 0,31 m
Clearance ......................................................... 0,25 m
Backstops
Flooded belt tonnage.............................................. 468 t/h
Flooded (wm + wb) ............................................ 98,2 kg/m Location ...............................................Head on Pulley #1
Backstop (quantity x type) .........................1 x Low speed
Sidewinder - v7.22 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 1 / 26
Description
Pulley diameter .................................................... 274 mm Estimated Splice Data

Load Share Factor % .................................................. 100 Splice type ...............................................................2-Step
Service Factor - Material Lift .................................... 1,50 Splice step length ................................................. 200 mm
Service Factor - Motor Rating ................................... 1,50 22 degree bias angle ............................................. 225 mm
Material Lift Criteria.......................................... 0,00 N·m Total splice length ................................................ 625 mm
Motor Torque Criteria......................................... 807 N·m
Torque rating at low speed shaft ......................... 807 N·m
Other Information
Brakes Loaded beltline mass (excluding motors)............... 345 kg
Brake type .................................................. None installed Total inertia (ref HS shaft) .............................. 0,03 kg·m2
Reducer Information Demand Power (kW)

Manufacture ................................................................N/A Demand % Motor
Case
Frame size ...................................................................N/A power Nameplate
Reducer ratio.......................................................... 15,140 Empty - NF 3,0 54,8
Catalog reducer ratio................................................ 0,000 Full - NF 3,2 58,8
RPM (High Speed) .......................................... 1500 RPM Full - LF 1,7 31,6
RPM (Low Speed) ............................................ 99,1 RPM Full - HF 4,7 85,6
Configuration ................................................ Shaft Mount
Number of stages ............................................................ 3 Din Factor and Total Equivalent Mass
Service factor ............................................................... 1,4 Belt line
Case Din factor
Power rating............................................................... 0,00 mass (kg)
Empty - NF 0,1481 911
Full - NF 0,1195 957
Motor Torque
Full - LF 0,0730 926
100% Motor Torque - High Speed........................ 36 N·m Full - HF 0,1732 968
Motor Shaft Torque - Running (FN) ..................... 21 N·m
Motor Shaft Torque - Starting (FN) ...................... 64 N·m Maximum Belt Tensions (kN)
100% Motor Torque - Low Speed ...................... 538 N·m Case Running Dynamic
Low Speed Shaft Torque - Running (FN)........... 294 N·m Empty - NF 3,57 4,22
Low Speed Shaft Torque - Running (Max) ........ 432 N·m Full - NF 3,73 4,53
Low Speed Shaft Torque - Starting (FN) ............ 506 N·m Full - LF 3,32 4,16
Low Speed Shaft Torque - Starting (Max).......... 600 N·m Full - HF 4,05 4,73
Starting and Stopping Belt Safety Factor

Start control ............................................. Constant torque Case Running Dynamic
Start time.......................................................... 0,2 to 0,4 s Empty - NF 61,57 52,14
Emergency stop control ............................................. Drift Full - NF 59,00 48,59
Emergency stop time ....................................... 0,4 to 1,1 s Full - LF 66,30 52,86
Material buildup in chute ........................................ 0,0 m³ Full - HF 54,35 46,49
Splice Safety Factor

Tension Ratios
Case Running Dynamic
Allowable (running)................................................... 2,73 Empty - NF 41,05 34,76
Running tension ratio ................................................. 1,64 Full - NF 39,33 32,40
Allowable (dynamic) ................................................. 3,30 Full - LF 44,20 35,24
Starting tension ratio .................................................. 2,22 Full - HF 36,24 30,99
Transition Lengths
Transition method ............................................... CEMA 7
Tail transition length (inline) ................................. 1,00 m
Head transition length (inline) ............................... 1,00 m

Page 2 / 26
Description
Minimum Belt Tensions (kN)

Empty - NF 2,50 2,13
Full - NF 2,50 2,14
Full - LF 2,59 2,09
Full - HF 2,34 2,13
Maximum Belt Sag (%)

Empty - NF 0,84 1,03
Full - NF 0,84 1,02
Full - LF 0,57 0,74
Full - HF 0,99 1,14

Page 3 / 26
Description
Conveyor Profile
Overall length = 8 m - Overall height = 2,6 m - True Length = 8,4 m
Pulleys
Pulleys - Top View
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Mtr 1 - Bstp 1 1-LT 180 4,05 2,69 6,52 4,73 2,90 7,59
Take-up Pulley 2-LT 180 2,59 5,50 2,67 5,71
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

Page 4 / 26
Description
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Pulley Safety Slope at Deflection T1 T2
L10 Life Shaft Force Angle Torque Moment
# Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)
1 7,83 3,67 0,038 500 4,45 2,72 100 7,53 205 0,2 0,5
2 9,61 3,04 0,032 500 2,75 3,30 100 5,82 9 0,1 0,4
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,25 on high tension
pulleys, and a multiplier of 1,10 on all other pulleys.
Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
Rubber
1 Herringb 250 10,0 270 650 60 60 820 513 22213 121
one
Rubber
2 250 10,0 270 650 60 60 840 513 22213 121
Plain
Pulley Shaft Information

Hub Bearing Overhung
Tensile Yield Fatigue Hub Fillet Overhung
Locking Shaft Center to Fillet Moment
Type Strength Strength Strength Diameter Radius Load
Device Material Distance Distance Arm
(MPa) (MPa) (MPa) (mm) (mm) (kN)
(mm) (mm) (mm)
1 XT-25 C45 630,0 360,0 315,0 60 550 60 0 0,0 0
2 XT-25 C45 630,0 360,0 315,0 60 550 60 0 0,0 0

Page 5 / 26
Description
Conveyor Load Cases

During the course of operation, the conveyor experiences different operating conditions at various frequencies. Normal
operating conditions, such as steady state running, loading and unloading, and other common load cases are designated as
Design Level 1. Unusual operating conditions, such as when all incline or decline section are simultaneously loaded, are
defined as Design Level 2. These design levels allow easy summarization of the various possible loading conditions.
For this conveyor, there are two Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
In the load case figures, the red line is the conveyor profile and the blue line indicates positions that are loaded.
Empty
Fully Loaded (Material Lift = 2,4 m)

Page 6 / 26
Description
Take-up Displacement Summary

1. Type ......................................................................................................................................................Fixed
2. Location ................................................................................................................................ Tail / Pulley #2
3. Steady state tension .............................................................................................................. 2,34 to 2,59 kN
4. Momentary tension ............................................................................................................... 2,25 to 2,67 kN
Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) .................................................................................................0,00 m
2. Permanent elongation .........................................................................................................................0,11 m
3. Splice length (1 included) ...................................................................................................................0,31 m
4. Clearance ............................................................................................................................................0,25 m
5. Required displacement .......................................................................................................................0,68 m

Page 7 / 26
Description
Pulley Details
The following table lists recommended pulley design tensions. The first column lists belt tensions for bearing L10
life and pulley fatigue stress calculations. Belt tensions for the fatigue design criterion are based on all design
level 1 cases. Running tensions have an added multiplier of 1,25 on high tension pulleys, and a multiplier of 1,10
on all other pulleys.
Pulleys are also to be design for the structural design tensions. For structural design tensions, the pulley
manufacturer is to ensure that the pulleys will be adequate to meet these worst case conditions.
Pulley Design Tensions (added safety factors as described above)

Fatigue Design Tensions (kN) Structural Design Tension (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 - Backstop 1 1-LT 180 4,45 2,72 7,53 6,39 3,49 10,2
Take-up Pulley 2-LT 180 2,75 5,82 3,11 6,62
Required Pulley Diameter (Tension based on a safety factor of 10)

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Motor 1 - Backstop 1 Head (4) 1 - LT 180 250 250 18 22
Take-up Pulley Tail (7) 2 - LT 180 250 250 14 15
Pulley Shaft Stress Analysis (Individual Pulleys)

Hub Hub Fillet Fillet Fillet Von Hub Von Overhung
Shaft Slope
Pulley Safety Bending Torsion Bending Torsion Mises Mises Von Mises
Type at Hub
# Factor Stress Stress Stress Stress Stress Stress Stress
(min)
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
1 1 7,83 3,67 24,0 5,6 10,7 5,6 25,9 14,4 0,0
2 2 9,61 3,04 19,9 1,8 8,2 1,8 20,1 8,8 0,0
Running Drive Tensions by Load Case (kN)

Motor 1 - Backstop 1
Load Case Resultant
T1 T2
Force
Empty - NF 3,57 2,63 6,20
Full - NF 3,73 2,63 6,36
Full - LF 3,32 2,69 6,00
Full - HF 4,05 2,47 6,52

Page 8 / 26
Description
Pulley Tension Summary - All Load Cases and Conditions

Load Case Running Starting O-Stop E-Stop
Pulley T1 T2 T1 T2 T1 T2 T1 T2
ID Description
(kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN)
Mtr 1 - Bstp 1 3,57 2,63 4,22 2,13 3,27 2,88 3,27 2,88
EM-N Empty - NF
Take-up Pulley 2,50 3,00 2,32 3,11 2,61 2,99 2,61 2,99
Mtr 1 - Bstp 1 3,73 2,63 4,53 2,14 3,33 2,90 3,33 2,90
FL-N Full - NF
Take-up Pulley 2,50 3,00 2,32 3,08 2,64 3,01 2,64 3,01
Mtr 1 - Bstp 1 3,32 2,69 4,16 2,09 3,12 2,83 3,12 2,83
FL-L Full - LF
Take-up Pulley 2,59 2,84 2,28 2,86 2,67 2,86 2,67 2,86
Mtr 1 - Bstp 1 4,05 2,47 4,73 2,13 3,42 2,86 3,42 2,86
FL-H Full - HF
Take-up Pulley 2,34 3,08 2,25 3,19 2,50 3,07 2,50 3,07

Page 9 / 26
Description
28. Bearing L10.....................................500.000 hours

#1 - Motor 1 - Backstop 1
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-1)....................... Motor 1 - Backstop 1 29. Running T1 Tension ................................. 3,73 kN
2. Pulley Diameter ..........................................250 mm 30. Running T2 Tension ................................. 2,63 kN
3. Face Width..................................................650 mm 31. Design T1 Tension ................................... 4,45 kN
32. Design T2 Tension ................................... 2,72 kN
33. Wrap angle ................................................180 deg
Lagging
34. Design Resultant Tension......................... 7,53 kN
4. Lagging Type ............................................... Rubber
35. Resultant Angle .........................................205 deg
5. Lagging Pattern....................................Herringbone
36. Resultant Moment ................................ 0,51 kN·m
6. Lagging Thickness ........................................10 mm
37. Resultant Torque .................................. 0,24 kN·m
7. Diameter with lagging ................................270 mm
38. Estimated Pulley & Shaft Mass .................. 100 kg
39. Estimated Mass with Bearings ................... 121 kg
Shaft Specification
8. Shaft Center Diameter ..................................60 mm
Shaft Stresses & Deflections
9. Shaft Material ................................................... C45
40. Shaft slope at hub .................................... 3,67 min
10. Yield Strength ...................................... 360,0 MPa
41. Shaft slope at bearing .............................. 4,57 min
11. Fatigue Strength ................................... 315,0 MPa
42. Shaft deflection at center ......................... 0,31 mm
43. Shaft deflection at center (%) ....................... 0,038
Locking Device 44. Shaft Safety Factor (CEMA) .......................... 7,83
12. Hub Center Distance .................................550 mm 45. Shaft Safety Factor (AS1403) ........................ 6,28
13. Shaft diameter at hub ..................................60 mm 46. Bending Stress ........................................ 24,0 MPa
14. Turndown radius at hub ............................... 0 mm 47. Torsional Stress ........................................ 5,6 MPa
15. Locking Device ........................................... XT-25 48. Von Mises Stress .................................... 25,9 MPa
16. Size .......................................................... 60 x 114 49. Fillet Von Mises Stress .......................... 14,4 MPa
17. Hub width ...................................................32 mm
18. Hub pressure ........................................ 0,0 N/mm²
Shell Dimension and Stresses
19. Maximum torque ........................................ 0 N·m
50. Shell thickness ............................................ 14 mm
20. Hub outer diameter ...................................114 mm
51. Sitzwohl reqd shell thickness1 ...................... 2 mm
52. Sitzwohl shell stress ................................. 2,0 MPa
Bearing Specifications 53. Shell stress at 180 wa ............................... 2,0 MPa
21. Bearing Center Distance ...........................820 mm 1 Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Shaft diameter at bearing ............................60 mm
23. Bearing to Fillet Distance ...........................60 mm End Disk Dimension and Stresses
24. Turndown radius at bearing ......................... 0 mm 54. End disk thickness ...................................... 32 mm
25. Bearing......................................................... 22213 55. End disk stress .......................................... 5,7 MPa
26. SNL Plummer Block........................................ 513
27. Dynamic Capacity ..................................... 193 kN

Page 10 / 26
Description
28. Bearing L10.....................................500.000 hours

#2 - Take-up Pulley
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-2)................................ Take-up Pulley 29. Running T1 Tension ................................. 2,50 kN
2. Pulley Diameter ..........................................250 mm 30. Running T2 Tension ................................. 3,00 kN
3. Face Width..................................................650 mm 31. Design T1 Tension ................................... 2,75 kN
32. Design T2 Tension ................................... 3,30 kN
33. Wrap angle ................................................180 deg
Lagging
34. Design Resultant Tension......................... 5,82 kN
4. Lagging Type ............................................... Rubber
35. Resultant Angle .............................................9 deg
5. Lagging Pattern............................................... Plain
36. Resultant Moment ................................ 0,42 kN·m
6. Lagging Thickness ........................................10 mm
37. Resultant Torque .................................. 0,08 kN·m
7. Diameter with lagging ................................270 mm
38. Estimated Pulley & Shaft Mass .................. 100 kg
39. Estimated Mass with Bearings ................... 121 kg
Shaft Specification
8. Shaft Center Diameter ..................................60 mm
Shaft Stresses & Deflections
9. Shaft Material ................................................... C45
40. Shaft slope at hub .................................... 3,04 min
10. Yield Strength ...................................... 360,0 MPa
41. Shaft slope at bearing .............................. 3,85 min
11. Fatigue Strength ................................... 315,0 MPa
42. Shaft deflection at center ......................... 0,27 mm
43. Shaft deflection at center (%) ....................... 0,032
Locking Device 44. Shaft Safety Factor (CEMA) .......................... 9,61
12. Hub Center Distance .................................550 mm 45. Shaft Safety Factor (AS1403) ........................ 8,06
13. Shaft diameter at hub ..................................60 mm 46. Bending Stress ........................................ 19,9 MPa
14. Turndown radius at hub ............................... 0 mm 47. Torsional Stress ........................................ 1,8 MPa
15. Locking Device ........................................... XT-25 48. Von Mises Stress .................................... 20,1 MPa
16. Size .......................................................... 60 x 114 49. Fillet Von Mises Stress ............................ 8,8 MPa
17. Hub width ...................................................32 mm
18. Hub pressure ........................................ 0,0 N/mm²
Shell Dimension and Stresses
19. Maximum torque ........................................ 0 N·m
50. Shell thickness ............................................ 14 mm
20. Hub outer diameter ...................................114 mm
51. Sitzwohl reqd shell thickness1 ...................... 2 mm
52. Sitzwohl shell stress ................................. 1,7 MPa
Bearing Specifications 53. Shell stress at 180 wa ............................... 1,7 MPa
21. Bearing Center Distance ...........................840 mm 1 Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Shaft diameter at bearing ............................60 mm
23. Bearing to Fillet Distance ...........................60 mm End Disk Dimension and Stresses
24. Turndown radius at bearing ......................... 0 mm 54. End disk thickness ...................................... 32 mm
25. Bearing......................................................... 22213 55. End disk stress .......................................... 4,7 MPa
26. SNL Plummer Block........................................ 513
27. Dynamic Capacity ..................................... 193 kN

Page 11 / 26
Description
Belt Flap Summary

Belt flap may occur when the natural frequency of the belt matches the rotational frequency of the idlers. If belt flap is
severe, it can destroy the idlers and increase the demand power of the conveyor. Belt flap should be avoided.
The belt flap ratio is defined as the rotational frequency of the idler divided by the natural frequency of the belt. If this ratio
is equal to an integer (i.e. 1, 2, 3) then the idler may induce transverse vibrations at the natural frequency mode and result in
resonance.
The chart below shows the flap ratio along the length of the conveyor. The solid green line shows flap mode of the empty
belt under the normal friction case. The shaded pink areas should be avoided.
*
Belt flap resonance occurs at flap ratios 1, 2, 3, and 4

Page 12 / 26
Description
Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.
Material Trajectory

Page 13 / 26
Description
Belt Transition Length Requirements

The table below lists the required transition length at head and tail pulleys. Transition lengths are based on the CEMA 7th
Method. The figure below shows the geometry of the inline transition and elevated pulley transition.
Geometry of inline and elevated pulley transition
Required transition lengths

Head pulley transition
Tail pulley transition (m)
(m)
Inline transition (L1) 0,99 0,99
Elevated pulley transition (L2) 0,66 0,66
Pulley elevation (h) 28,125 28,125

Page 14 / 26
Description
Material Loading Profiles
Material Properties
Type ..................................................................copper ore
Design Tonnage ....................................................... 30 t/h
Density ............................................................ 2000 kg/m3
Maximum lump size .............................................. 15 mm
Surcharge angle ...................................................... 22 deg
Tonnage ................................................................... 30 t/h

Belt speed ............................................................ 1,41 m/s
Material mass ...................................................... 5,9 kg/m
Edge distance (required / actual)................... 53 / 172 mm
Cross sectional loading (utility / total) ............. 10 % / 6 %
Bed depth ............................................................... 21 mm

Page 15 / 26
Description
Idler Specifications
Idler Specifications
Equal Roll
Type Flat Idler
Trough
Number of rolls 3 1
Trough angle (deg) 30 0
Roll diameter (mm) 89 89
Roll length (mm) 213 640
Shaft diameter (mm) 20,0 20,0
Bearing series 6204 6204
Maximum roll RPM 303 303
Min Life (1000 hrs) 350 / 350 350
95% life1 (1000 hrs) 350 / 350
Shaft deflection (min) 0,10 / 0,32 2,19
Mass per Roll (kg) 1,7 4,4
Rotating mass for set (kg) 5,0 4,4
Wk2 for set (kg·mm²) 8.403 7.851
Idler Spacing and Count Summary

General Carry Return
Idler spacing (m) 1,00 3,00
Number of ıdler sets 12 3
Number of rolls 36 3
Total drag (N)
Nominal friction 11,5 3,8
High friction 26,0 8,8
Low friction 8,5 2,9
Idler Life and Shaft Deflection Summary-Carry Side

Center
Idler Wing L10 Center L10 Wing Shaft
Vertical Idler Shaft
# Station (m) Length (m) Spacing Life Life Deflection
Radius (m) Type Deflection
(m) (hours) (hours) (min)
(min)
1 0,0 0,7 1,00 1 350.000 350.000 0,13
2 0,7 1,6 0,30 1 350.000 350.000 0,32
3-4 2,2 6,1 1,00 1 350.000 350.000 0,29

Page 16 / 26
Description
Idler Life and Shaft Deflection Summary-Return Side

Center
Idler Wing L10 Center L10 Wing Shaft
Vertical Idler Shaft
# Station (m) Length (m) Spacing Life Life Deflection
Radius (m) Type Deflection
(m) (hours) (hours) (min)
(min)
6-7 8,1 8,4 3,00 2 350.000 2,19

Page 17 / 26
Description
Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures). Additionally they must include any other external loads
(wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the required live
load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes for the project.
The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and other
details. These forces must then be multiplied by the required dead load structural design safety factor requirements (typically
1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together to obtain the
total structural design forces.
The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for the
high friction case with 173 t/h have also been included. This specific load case results in 100% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 180% for this case. The maximum tension values have been
multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum tensions have
been reduced by 10%. The resultant force values include the vertical weight of the pulley.
Structural Live Loads - Includes case with 173 t/h under steady state and dynamic conditions + 110% multiplier
Shaft Shaft Shaft Minimum Tensions (kN) Maximum Tensions (kN)
Wrap Hub stress Center
(deg) Slope safety Def. T1 T2 T1 T2
(min) factor (mm) Force Force
Motor 1 -
1 180 4,98 7,53 0,43 2,81 1,88 5,08 6,39 3,49 10,2
Backstop 1
Take-up Pulley 2 180 3,46 9,60 0,31 1,99 4,35 3,11 6,62
Bearing Reaction Forces (excluding any overhung loads)

Entry Exiting Pulley, Bearing Horizontal Direction (kN) Bearing Vertical Direction (kN)
Wrap Vector Vector Shaft & Structural Structural Structural Structural
Pulley FL-N FL-N
(deg) Angle Angle Bearings Min Max Min Max
Case Case
(deg) (deg) Mass (kg) Tension Tension Tension Tension
Motor 1 -
180 198 198 121 -4,46 -6,05 -9,40 -2,64 -3,16 -4,25
Backstop 1
Take-up Pulley 180 18 18 121 4,32 5,23 6,52 0,22 0,51 0,93
The idler stringer loading should be based on the flooded belt surge capacity of 468 t/h and 98,2 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.

Page 18 / 26
Description

Page 19 / 26
Description
Element Summary Details
Tension Summary
Power Summary

Page 20 / 26
Description
Element Summary Details

Summary of Conveyor Elements
Vertical Idler
Station Elevation Length Height Slope Idler
# Name Radius Spacing
(m) (m) (m) (m) (deg) Type
(m) (m)
1 0,0 0,00 0,7 0,23 18,00 1,00 1
2 Loading Point 0,7 0,23 1,6 0,49 18,00 0,30 1
3 2,2 0,71 0,8 0,26 18,00 1,00 1
4 3,0 0,97 5,3 1,62 18,00 1,00 1
5 Motor 1 - Backstop 1 8,0 2,60 0,3 -0,26 ---
6 8,1 2,34 1,0 -0,31 -18,00 3,00 2
7 7,1 2,03 7,4 -2,29 -18,00 3,00 2
8 Take-up Pulley 0,1 -0,26 0,3 0,26 ---

Page 21 / 26
Description
Min/Max Tension Summary per Element

Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 3,08 2,84 0,26 3,19 2,84 0,26
2 Loading Point 3,12 2,86 0,15 3,26 2,86 0,15
3 3,65 3,07 0,43 3,94 2,99 0,46
4 3,70 3,11 0,42 4,05 3,01 0,46
Motor 1 -
5 4,05 3,32 0,00 4,73 3,12 0,00
Backstop 1
6 2,69 2,47 0,98 2,90 2,09 1,14
7 2,67 2,46 0,99 2,87 2,11 1,13
8 Take-up Pulley 2,59 2,34 0,00 2,67 2,25 0,00

Page 22 / 26
Description
Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N)
EM-N FL-N FL-L FL-H
Total (Beltline) 929 1.084 622 1.559
Total (Power) 2.138 2.295 1.227 3.353
Lift Force 0 138 137 138

Frictional Drag 929 947 485 1.420
Motor Pulley/Reducer Drag 1.209 1.211 605 1.795
Rolling Resistance 3 4 2 7
Material+Belt Flexure 0 0 0 0
Idler Bearing Drag 219 219 111 339
Idler Alignment 10 14 11 15
Pulleys & Accessories 560 560 280 840
Loading Point 138 150 81 219
Mechanical Losses 146 149 74 201

Motor Pulley Drag Components 1.063 1.063 531 1.594

Page 23 / 26
Description
Pulley Summary Table - All Cases

Pulley Geometry Details
Type 1 2
Lagging Type Rubber Rubber
Diameter (mm) 250 250
Lagging Thickness (mm) 10,0 10,0
Diameter with Lagging (mm) 270 270
Face Width (mm) 650 650
Shaft Center Diameter (mm) 60 60
Bearing Diameter (mm) 60 60
Bearing Center Distance (mm) 820 840
Plummer Block 513 513
Pulley & Shaft Mass (kg) 100 100
Locking Device XT-25 XT-25
Hub Center Distance (mm) 550 550
Hub Diameter (mm) 60 60
Bearing to Fillet Distance (mm) 60 60
Fillet Radius (mm) 0 0
Shaft Material C45 C45
Yield Strength (MPa) 360,0 360,0
Fatigue Strength (MPa) 315,0 315,0

Page 24 / 26
Description
Element Tension Details per Case
Element Tension Breakdown - (EM) Empty - Normal

Individual drag components per element
Running Running Element Pulley Feeder Extra
Wm+Wb Lift Belt Idler
# Tension Ten Diff Tonnage Drag Pt. Force Accessory
(kg/m) Force (N) Force (N) Force (N)
(N) (N) (t/h) Force (N) (N) Force (N)
1 3.000 26 6,0 13 0 13
2 3.026 331 6,0 28 0 89 138 75
3 3.357 30 6,0 15 0 15
4 3.387 187 6,0 95 1 91
5-M 3.573 -944 6,0 -15 100 963
6 2.629 -15 6,0 -18 0 2
7 2.614 -114 6,0 -134 1 18
8-T 2.500 500 6,0 15 100 385
Element Tension Breakdown - (FL) Fully Loaded - Normal

1 3.000 26 6,0 13 0 13
2 3.026 372 30 11,9 57 0 90 150 75
3 3.398 46 30 11,9 30 0 15
4 3.443 285 30 11,9 189 2 94
5-M 3.729 -1.099 6,0 -15 100 963
6 2.630 -15 6,0 -18 0 2
7 2.614 -114 6,0 -134 1 18
8-T 2.500 500 6,0 15 100 385
Element Tension Breakdown - (FL) Fully Loaded - Low

1 2.845 16 4,2 9 0 7
2 2.861 213 30 10,1 48 0 46 81 38
3 3.073 34 30 10,1 26 0 8
4 3.107 211 30 10,1 160 1 50
5-M 3.318 -632 4,2 -11 50 481
6 2.686 -11 4,2 -13 0 1
7 2.675 -83 4,2 -94 1 10
8-T 2.592 253 4,2 11 50 193

Page 25 / 26
Description
Element Tension Breakdown - (FL) Fully Loaded - High

1 3.080 35 6,6 15 0 20
2 3.115 530 30 12,6 60 1 138 219 113
3 3.645 55 30 12,6 32 1 23
4 3.701 347 30 12,6 200 3 143
5-M 4.047 -1.575 6,6 -17 150 1.444
6 2.472 -16 6,6 -20 0 4
7 2.456 -120 6,6 -149 2 26
8-T 2.336 744 6,6 17 150 578

Page 26 / 26

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Client Name Designer HAK

Project Name Company

System Information Idler Set Data

Required pulley displacement ................................ 0,68 m

Sidewinder - v7.22 - Conveyor Design Software

Pulley diameter .................................................... 274 mm Estimated Splice Data

Reducer Information Demand Power (kW)

Starting and Stopping Belt Safety Factor

Splice Safety Factor

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Minimum Belt Tensions (kN)

Maximum Belt Sag (%)

Sidewinder - v7.22 - Conveyor Design Software

Pulleys - Top View

Maximum Pulley Tensions (without any additional safety factors)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Shaft Results

Pulley Geometry Details (Pulley Types)

Pulley Shaft Information

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Conveyor Load Cases

Fully Loaded (Material Lift = 2,4 m)

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Take-up Displacement Summary

Take-up Pulley Displacement Summary

Sidewinder - v7.22 - Conveyor Design Software

Pulley Design Tensions (added safety factors as described above)

Required Pulley Diameter (Tension based on a safety factor of 10)

Pulley Shaft Stress Analysis (Individual Pulleys)

Running Drive Tensions by Load Case (kN)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Tension Summary - All Load Cases and Conditions

Sidewinder - v7.22 - Conveyor Design Software

28. Bearing L10.....................................500.000 hours

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28. Bearing L10.....................................500.000 hours

Sidewinder - v7.22 - Conveyor Design Software

Belt Flap Summary

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Belt Transition Length Requirements

Geometry of inline and elevated pulley transition

Required transition lengths

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Material Loading Profiles

Tonnage ................................................................... 30 t/h

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Idler Spacing and Count Summary

Idler Life and Shaft Deflection Summary-Carry Side

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Idler Life and Shaft Deflection Summary-Return Side

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Bearing Reaction Forces (excluding any overhung loads)

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Element Summary Details

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