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Dunlop Conveyor Belt Design Manual - HTML
Dunlop Conveyor Belt Design Manual - HTML
Introduction
Dunlop Conveyor Belting Range
Belting Characteristics
Additional Features
SABS Specifications
Conveyor Belt Design
Step By Step Example of Belt Tension Calculation
Table 1: Table of Symbols
Table 2: Material Characteristics
Table 2(a): Typical Flowability
Determination of Conveyor Capacities
Table 3: Capacities of Troughed Belt Conveyors
Table 4: Recommended Maximum Belt Speed for Normal Use
Table 5: Recommended Idler Spacing
Table 6: Friction Factors
Table 7: Sag Factor
Table 7(a): Recommended Percentage Sag
Table 8: Estimated Belt Mass
Table 9: Typical Mass of Rotating Parts of Idlers
Table 10: Mass of Moving Parts
Table 11: Drive Factor
Conveyor Belt Selection
Table 12: Maximum Recommended Operating Tensions
Table 13: Recommended Minimum Pulley Diameters
Table 14: Load Support
Table 15: Maximum Number of Plies Recommended for Correct Empty Belt Troughing
Table 16: Carcass Thickness
Table 17: Mass of Belt Carcass
Table 18: Mass of Covers per mm of Thickness
Rate of Wear Graph
Table 19: Minimum Belt Top Cover Gauge Guide
Table 20: Belt Modulus
Tabulator Calculations
Sheet 1: Empty Belt
Sheet 2: Fully Loaded Belt
Sheet 3: Non-Declines Loaded
Sheet 4: Declines Loaded
Tension Tabulator
Vertical Curves
Maximum Incline Angle
Graph for Estimating Belt Length/Rolled Belt Diameter
Useful Data Conversion Factors
Conveyor Belting Design Manual
INTRODUCTION
Dunlop Africa Industrial Products is the leading designer and manufacturer of industrial rubber products in
South Africa. In fact our belting systems can be seen on some highly productive plants all around the globe.
What more can you expect, when you consider that our belts have been designed and fabricated by some of
the best engineers in the industry and from only the finest raw materials.
Using the most current technology, many components have taken years of refinement to attain such
technological precision. And every belt is guaranteed to provide maximum performance and maximum life.
And with some 750 000 various specifications available, you can expect to find the right belt for your
requirements no matter how specialised.
This manual contains all the elements, formulae and tables you need to specify the exact belt. It has been
compiled for your benefit, as a quick reference book for easy selection. If however you have an application not
covered in the following pages, please contact Dunlop Africa Industrial Products. A team of experienced and
helpful engineers will be pleased to assist you.
Our range of excellent products, competitive pricing and impeccable service, has earned Dunlop Africa
Industrial Products the reputation of being the market's first choice.
Dunlop Africa Industrial Products manufactures the most comprehensive range of conveyor belting in South
Africa.
Steelcord belting
Flinger belts
BELTING CHARACTERISTICS
XT Rubber Conveyor Belting (conforms to SABS 1173-1977)
• From the early days of cotton duck plies, progress has been made in the manufacture of all-synthetic
plies offering many advantages.
• The range of strengths has been greatly increased, with improvements in the flexible structure. The
modern multi-ply belt is manufactured with a synthetic fibre carcass in a wide slab, then slit to width as
required for individual orders.
• A wide range of belt specifications is available with current belt constructions having versatile
applications.
• The standard XT belting (Grade N) incorporates covers suitable for the handling of most abrasive
materials, having a blend of natural and synthetic rubber.
• Grade M Belts have covers with high natural rubber content recommended for belts operating under
extremely arduous conditions where cutting and gouging of covers occurs.
• Phoenix Heat Resistant belting covers are styrene butadiene based and are recommended for belts
handling materials with temperatures up to 1200C.
• Super Phoenix Heat Resistant belts have chlorobutyl covers and are recommended for belts handling
materials with temperatures of up to 1700C.
• Delta Hete heat resistant belting with EPDM synthetic rubber covers in a formulation developed to allow
conveying materials of temperatures up to 2000C.
• Fire Resistant XT belting is manufactured with covers containing neoprene and multi-ply carcass
constructions to meet the stringent standards for safety in all underground mining industries and is
therefore particularly suited to shaft applications.
Woodmaster
• This belt has been especially developed for the Timber Industry. The rubber has been compounded to
provide resistance to oil and resin, and is non-staining.
Rufftop Belting
• This is a range of rough top package belting, of two or three ply all-synthetic carcass belts with deep
impression rubber covers. The range is ideal for the packaging and warehousing industries and baggage
handling installations such as airports and railway stations etc.
• Riffled conveyor belting has raised edges, is 1 500 mm wide and available in endless form. These belts
are uniquely applied at gold mine concentrators.
• Food quality belting is ideal where foodstuffs come into direct contact with the belt surface. This range
of belting is manufactured from non-toxic materials and is resistant to oils, fats and staining, and meets
the strict hygiene requirements laid down by the food processing industry. The two types available are
Grey food belting and Salmon pink belting
Endless Belting
• The complete XT range can be made available as factory spliced endless belts. These belts are
recommended for short conveyor installations. (Suitable for lengths up to 50 in.)
Flinger Belts
• Flinger Belts are fitted to flinger conveyors, the primary function of which is to disperse the discharging
material over a wide area, thus minimising heap build-up below the main conveyor. The flinging effect
is achieved by running the flinger belt at a high speed in a U configuration. Flinger belts are built and
cured on a drum to eliminate a spliced join.
• Commonly known as 'Vinyplast' solid woven PVC. The construction has inherently high fastener holding
qualities. The belting is constructed of polyester and nylon with a cotton armouring, is impregnated with
PVC and has PVC covers. These belts have been specially developed to resist impact, tear, rot and
abrasion and to meet the most stringent flame-resistant standards.
• The nitrile cover on solid woven PVC belts is specially designed to meet the SABS specifications for use
in mines, where a fire hazard exists. In general the nitrile cover has good flame-retardant properties
and oil, abrasion and heat resistance.
• Steelcord conveyor belting is designed for very long hauls where textile reinforcement would either not
achieve the requisite strength or would have too high an elongation at reference load. Resistance to
severe shock and exceptional tensile loading is achieved by the wire reinforcement encased between
thick top and bottom covers of the highest quality rubber. These belts are designed to conform to or
exceed the requirements of stringent standards and offer a long belt life.
Fire Resistant Steelcord Belting (Conforms to SABS 1366. 1982 type F).
• Steelcord belting of fire-resistant quality is made with specially compounded rubbers which render it
self extinguishing. Fire-resistant steelcord belting offers great advantages in maintenance-free
operation and long belt life for conveyors situated in fiery mines.
• Oil resistant belting provides easily cleanable covers of either nitrile or neoprene on all-synthetic fabric
plies. Choice of covers gives maximum resistance to mineral and vegetable oils thus permitting the user
to convey a wide variety of materials containing mineral and vegetable oils.
ADDITIONAL FEATURES
1. Rip Protector
As an additional feature rip protection can be incorporated into the belt by means of arranging strong
nylon fibres transversely or by inclusion of electronic loops. The textile rip protection can be built into the
belt in 2-metre lengths at regular intervals or over the full length of the belt.
For applications where the lump size of the material carried is large and where adverse loading
conditions exist, an open weave breaker ply can be incorporated below the top cover as an extra
protection for the carcass.
This incorporates steel tyre cord in a 'V shape, as a rip protection, at intervals over the belt length.
Particularly recommended for XT belting where arduous conditions are experienced i.e. slag
transportation.
4. Belt Edges
Many conveyor belts track off at some stage of their lives, causing edge damage to a greater or lesser
extent. Belts can be supplied with either slit or moulded edges.
Slit edges:
All-synthetic constructed carcasses have good resistance to edge chafing, due to modern fibre
construction In addition there is minimal penetration of moisture to the carcass and therefore no problem
with carrying out hot vulcanised splices or repairs.
Moulded edges:
A moulded rubber edge can be provided to protect the carcass from acids, chemicals and oils. In most
applications a moulded edge is unnecessary as synthetic fibres will not rot or be degraded by mildew.
SABS SPECIFICATIONS
Dunlop Africa Industrial Products conveyor belting complies with the stringent standards as laid down by the
SABS.
The above specifications cover the requirements of the various conveyor belts and are classified according to
the minimum full thickness breaking strength of the finished belting in kilonewtons per metre width.
Introduction
1. Reinforcement or a carcass which provides the tensile strength of the belt, imparts rigidity for load
support and provides a means of joining the belt.
2. An elastometric cover which protects the carcass against damage from the material being conveyed
and provides a satisfactory surface for transmitting the drive power to the carcass.
In selecting the most suitable belt for a particular application, several factors have to be considered:
1. The tensile strength of the belt carcass must be adequate to transmit the power required in
conveying the material over the distance involved.
2. The belt carcass selected must have the characteristics necessary to:
a. provide load support for the duty.
b. conform to the contour of the troughing idlers when empty, and
c. flex satisfactorily around the pulleys used on the conveyor installation.
3. The quality and gauge of cover material must be suitable to withstand the physical and chemical
effects of the material conveyed.
Belt Tensions
In order to calculate the maximum belt tension and hence the strength of belt that is required, it is first
necessary to calculate the effective tension. This is the force required to move the conveyor and the load it is
conveying at constant speed. Since the calculation of effective tension is based on a constant speed conveyor,
the forces required to move the conveyor and material are only those to overcome frictional resistance and
gravitational force.
For the sake of simplicity the conveyor is considered to be made up of interconnected unit length components
all of equal mass. The mass of each of these units is called the mass of the moving parts and is calculated by
adding the total mass of the belting, the rotating mass of all the carrying and return idlers and the rotating
mass of all pulleys. This total is divided by the horizontal length of the conveyor to get the mean mass of all the
components. At the outset the belt idlers and pulleys have not been selected and hence no mass for these
components can be determined. Therefore the mass of the moving parts is selected from the tabulated values
to be found in Table 10.
As is the case with the components the load that is conveyed is considered to be evenly distributed along the
length of the conveyor. Given the peak capacity in ton per hour the mass of the load per unit length is given
by:
τ τ
Q = 0,278 or Q=
S 3,600S
Te = Tx + Ty + Tz +Tu
Tx = 9,8G x fx x Lc
Tz = 9,8Q x H
Various conveyor accessories that add resistance to belt movement are standard on most conveyors. The most
common are skirtboards at the loading point and belt scrapers. Other accessories include movable trippers and
belt plows.
9,8fs x Q x Ls
Tus =
Sxb
Tuc = A x ρ x fc
In the case of a belt plow the additional tension required to overcome the resistance of each plow is
Tup = 1,5W
Moving trippers require additional pulleys in the system and therefore add tension. If the mass of the additional
pulleys has been included in the mass of moving parts then no additional tension is added. However, if a
separate calculation of the tension to overcome the resistance of the additional pulleys is required this can be
determined for each additional pulley as follows
do x T1
Tut = 0,01
Dt
Corrected length Lc
Short conveyors require relatively more force to overcome frictional resistance than longer conveyors and
therefore an adjustment is made to the length of the conveyor used in determining the effective tension. The
adjusted length is always greater than the actual horizontal length.
LC = L + 70
Lc
C=
L
All conveyors require an additional tension in the belt to enable the drive pulley to transmit the effective
tension into the belt without slipping. This tension, termed the slack side tension T 2, is induced by the take-up
system. In the case of a simple horizontal conveyor the maximum belt tension T 1 is the sum of the effective
tension Te and the slack side tension T2
ie: T1 = Te + T2
For a more complex conveyor profile that is inclined, additional tensions are induced due to the mass of the
belt on the slope. This tension is termed the slope tension 'h and increases the total tension.
Thus T1 = Te + T2 + Th
The slack side tension is determined by consideration of two conditions that must be met in any conveyor. The
first condition is that there must be sufficient tension on the slack side to prevent belt slip on the drive. The
second condition is that there must be sufficient tension to prevent excessive sag between the carrying idlers.
Minimum tension to prevent slip Tm
T1
= eθ
T2
Since T1 = Te + T2
1
T2 = Te
eθ - 1
1
The expression :
eθ - 1
is called the drive factor k. and the value of T 2 that will just prevent slip is referred to as the minimum to
prevent slip Tm and therefore
Tm = k x T e
The tension required to limit sag is dependent on the combined mass of belt and load, the spacing of the carry
idlers and the amount of sag that is permissable.
Ts = 9,8Sf x (B + Q) x ld
The value of the slack side tension must ensure that both conditions are met and therefore T2 must be the
larger of Tm or Ts.
Slope tension Th
The slope tension is the product of the belt weight and the vertical lift and has its maximum value at the
highest point of the conveyor.
Th = 9,8B x H
Unit tension T
The maximum belt tension T1 has as its reference width the full width of the belt. Usually this is converted to
the tension per unit of belt width as this is the reference dimension for belt strengths.
T1
T=
W
Absorbed power
The amount of power required by the conveyor is by definition of power equal to the product of the force
applied and the speed at which the conveyor belt travels. The force applied is the effective tension and hence
the power required at the shaft of the drive pulley/s is
P = Te x S
STEP BY STEP EXAMPLE OF BELT TENSION CALCULATION
As an example of the application of the formulae the belt tensions for the following conveyor will be
determined:
τ
Q= 0,278
S
0,278 x 400
=
1,4
= 79,4 kg/m
2. Look up the value of the mass of moving parts in Table 10. From the idler roll diameter and the nature of the
material conveyed the application is considered as medium duty. For a 900 mm wide belt the mass of moving parts
from Table 10 is 55 kg/m
3. Calculate the corrected length and the length correction factor.
LC = L + 70
= 250 + 70
= 320 m
LC
C=
L
320
=
250
= 1,28
4. Tension to move the empty belt.
TX = 9,8G x fX x LC
= 9,8 x 55 x 0,022 x 320
= 3794 N
5. Tension to move the load horizontally.
TX = 9,8Q x fY x LC
= 9,8 x 79,4 x 0,027 x 320
= 6723 N
6. Tension to lift the load.
TZ = 9,8Q x H
= 9,8 x 79,4 x 20
= 15562 N
7. No accessories are present and therefore the tension to overcome the resistance of accessories is zero.
8. Effective tension.
Te = TX + TY + TZ + TU
= 3794 + 6723 + 15562 + 0
= 26079 N
9. The absorbed power
P = Te x S
= 26079 x 1,4
= 36511W
10. The slack side tension.
Slack side tension to prevent slip.
The drive factor for 210 degree wrap and lagged pulley with a gravity take-up, as given in Table 11, is 0,38.
Tm = k x Te
= 0,38 x 36079
= 9910 N
Slack side tension to limit sag to 2%. The sag factor for 2% sag is 6,3 and the estimated belt mass for a medium
load and 900 mm belt width, as given in Table 8, is 11,1kg/m.
TS = 9,8Sf (B + Q) x ld
= 9,8 x 6,3 x (11,1 + 79,4) x 1,2
= 6705 N
Th = 9,8B x H
= 9,8 x 11,1 x 20
= 2176 N
12. The maximum belt tension
T1 = Te + T2 + Th
= 26079 + 9910 + 2176
= 38165 N
Effective tension.
T1
T=
W
38165
=
900
= 42,4 N/mm
= 42,4 kN/m
TABLE 1 TABLE OF SYMBOLS
Characteristics
Cover Grade
Angle of Angle of
Material Characteristics
Surcharge α Repose
5° 0° - 19° Uniform Size
10° 20° - 29° Rounded, dry ,medium weight
20° 30° - 34° Granular lumpy (Coal, Clay)
25° 35° - 39° Coal, stone, ores
30° 40° - 45° Irregular (wood chips)
Determination of Conveyor Capacities
1. The cross sectional area of the load which can be carried without spillage.
2. The belt speed.
3. The material density.
The cross sectional area is influenced by many factors including the flowability of the material, the angle of
surcharge and the incline angle at the load point of the conveyor. To achieve optimum load area the loading
chutes must be designed to ensure the most advantageous initial load shape and this can only be achieved if:
To ensure that the optimum load shape is maintained along the entire belt length:
Where
M = 0,3145W - 3,2 - Bc
Where
Belt Width Grain or Other Run of Mine Hard Ores and Stone -
(mm) Free Flowing Material Coal and Earth + Primary Crushed ++
300 2,5 1,5 1,5
400 2,5 2,0 1,8
500 3,0 2,0 1,8
600 3,0 2,5 2,3
750 3,6 3,0 2,8
900 4,0 3,3 3,0
1050 4,0 3,6 3,0
1200 4,6 3,6 3,3
1350 5,0 3,6 3,3
1500 5,0 3,6 3,3
1800 4,0 3,8
2000 and over 4,0 3,8
* These speeds are intended as guides to general practice and are not absolute.
+ Moderately abrasive materials.
++ Very abrasive materials.
Note: In the case of belts loaded on inclines of 100 or more it may be necessary to reduce the above speeds in
order to achieve maximum capacity.
Operating Conditions
Belt Width
(mm) Light Duty Medium Duty Heavy Duty
(kg/m) (kg/m) (kg/m)
500 4,1 6,2 10,3
600 5,0 7,4 12,3
750 6,2 9,3 15,5
900 7,4 11,1 18,5
1050 8,6 13,0 21,6
1200 9,8 14,8 24,7
1350 11,0 16,7 27,8
1500 12,3 18,6 30,9
1650 13,5 20,5 33,9
1800 14,7 22,3 37,0
2100 17,2 26,0 43,3
2200 18,0 27,3 45,3
Note:
The values given in the table are estimated values for use in the calculation of maximum belt operating tension
necessary to make the correct belt selection. When the belt specification has been determined, the mass should
be checked more accurately from Table 17. If the actual mass of the specification differs considerably from the
approximate value obtained from the table the tension calculation should be rechecked using the more accurate
belt mass.
Notes:
1. When calculating the driving tension required for dual drive units, the drive factor selected must correspond to
the total angle of driving wrap.
2. The drive factors quoted for gravity or automatic take-up systems are minimum values based on the relationship
between angle of wrap and coefficient of friction between belt and drum at the point of slip. In the case of screw
take-up units, an adjustment has been made to the drive factor to allow for the extra tension which may be
induced in the belt either:
a. to compensate for the effect of belt elongation when the material is loaded.
b. due to the difficulty in measuring the amount of tension applied.
3. In those cases where an electrically or hydraulically loaded winch type take-up is used, where the induced
tension can be preset and controlled, the drive factor should be selected to correspond with a gravity take-up
system.
Tensile strength
The belt class required is that which has an operating tension greater than or equal to the calculated maximum unit
tension T. (Table 12).
Load support
Choose the lowest class which meets the tensile strength requirement. Looking at Table 14, determine which load category
best describes the load being conveyed i.e. A, B, C, D or E category load. The value obtained at the intersection of the belt
specification row and the load category column gives the maximum width at which that belt specification can be used.
Additional Information
Belt modulus
Refer to Table 20 for belt modulus.
Belt mass
The mass of a particular belt construction can be determined by adding the carcass mass found in Table 17 to the
combined mass of covers found in Table 18. This will give the mass per unit area. To calculate the mass per unit length
multiply by the belt width in metres.
Belt thickness
The belt thickness can be obtained from the information given in Table 16.
Recommended maximum belt width (mm) for correct load support. Multi-ply textile reinforced rubber belting.
A B C D E
Light Duty Light to Medium Duty Medium Duty Heavy Duty Extra Heavy Duty
Belt Spec
Up to 800 kg/m3 Up to 1200 kg/m3 Up to 1600 kg/m3 Up to 2400 kg/m3 Up to 3000 kg/m3
- 25mm Lumps - 50mm Lumps - 100mm Lumps - 250mm Lumps + 250mm Lumps
160/2 750 600 500 400 Not Recommended
200/2 750 600 600 4500 Not Recommended
250/2 900 750 750 600 500
250/3 1050 900 750 600 600
315/2 900 900 750 600 500
315/3 1200 1050 1050 750 600
400/2 1200 1050 1050 900 750
400/3 1200 1050 1050 900 750
400/4 1500 1500 1350 900 750
500/2 1200 1200 1200 1050 900
500/3 1350 1200 1200 1050 900
500/4 1650 1500 1350 1200 900
500/5 1800 1800 1800 1500 1350
630/2 1200 1200 1200 1050 900
630/3 1650 1350 1200 1050 1050
630/4 1650 1500 1350 1200 1050
630/5 2100 2100 1800 1650 1350
800/2 1650 1500 1500 1350 1200
800/3 1800 1650 1500 1350 1200
800/4 2100 1800 1650 1500 1350
800/5 2400 2400 2100 1800 1500
1000/2 1800 1650 1500 1350 1200
1000/3 2100 1650 1500 1350 1200
1000/4 2400 1800 1800 1500 1350
1000/5 2400 2400 2200 1800 1500
1250/3 2100 1800 1800 1350 1200
1250/4 2400 2200 2200 1650 1500
1250/5 2400 2400 2400 1800 1800
1600/3 2400 2400 1800 1650 1650
1600/4 2400 2400 2200 1800 1800
1600/5 2400 2400 2400 2200 1800
2000/4 2400 2400 2400 1800 1800
2000/5 2400 2400 2400 2200 2100
TABLE 15 MAXIMUM NUMBER OF PLIES RECOMMENDED FOR CORRECT EMPTY BELT TROUGHING
Add the thickness of the covers to get the total belt thickness
TABLE 17 MASS OF BELT CARCASS (kg/m2)
To obtain total belt mass add the mass of the combined covers from Table 18.
The mass per unit length is determined by multiplying the total mass by the belt width in metres.
The rate at which a belt cover wears is related to the thickness of the cover and to the impact energy imparted by material
lumps.
Impact energy can be calculated for any material of known lump mass and vertical velocity.
γ - ω x νv J
Material Class D
Material Class A Material Class B Material Class C
Steelcord
Multi-ply Textile Solid Woven
Belt Class Reinforced
Reinforced Belting PVC Belting
Rubber Belting
160 1060
200 1330
250 1660
315 2070 1750
400 2950 2220
500 3330 2800 29000
630 4200 3500 37700
800 5330 4440 47900
1000 6660 5550 59800
1250 8330 6900 74800
1600 10660 8890 95800
2000 13330 11110 119700
2500 149700
3150 188600
4000 240000
5000 300000
6300 377200
TABULATOR CALCULATIONS
The tabulation method described below is a convenient means of calculating the tensions at any point on the conveyor.
Blank copies of the "Conveyor Tabulation Sheets" are available from Dunlop Africa Industrial Products.
The following method is used to determine the tension at any point along the conveyor:
It may be found that the value of T2 obtained when the maximum effective tension has been calculated is different to that
used in the calculations. If this is the case the new T2 value is used to calculate tensions at each point.
Steps 7, 8 and 9 should be repeated for four load cases viz empty, fully loaded, non-declined sections loaded and declined
sections loaded.
EXAMPLE
Step 1
L + 70
C=
L
570
=
500
= 1,14
Step 2
From Table 10 the mass of the moving parts for a 1200 mm wide conveyor of medium duty is 71 kg/m.
Step 3
τ
Q= 0,278
s
0,278 x 4500
=
3,5
= 357,4 kg/m
Step 4
Calculate the maximum effective tension when the non-declined sections of the conveyor are all carrying load and the
declined sections have no load. The total horizontal length of non-declined sections is 20 + 330 = 350 m.
The overall change in elevation on the non-declined sections is 70 in. Note that the actual length of the conveyor is used to
calculate Tx and only the loaded length to calculate Ty. The length correction factor is a constant and is used to convert the
actual length to a corrected length. The friction factors are determined by the total conveyor length in all cases.
Tx = 9,8G x fx C x L
= 9,8 x 71 x 0,020 x 1,14 x 500
= 7932N
Ty = 9,8Q x fy C x L
= 9,8 x 357,4 x 0,020 x 1,14 x 350
= 30745N
Tz = 9,8Q x H
= 9,8 x 357,4 x 70
= 245176N
Effective tension to overcome skirtboard friction The inter-skirtboard width is assumed to be 2/3 of the belt width i.e. 0,8
m.
9,8fs x Q x Ls
Tus =
S x b2
9,8 x 357,4 x 0,020 x 1,14 x 350
=
3,5 x 0,64
= 3050N
Te = Tx + Ty + Tz + Tus
= 7932 + 30745 + 245176 + 3050
= 286903N
Step 5
Tm = k x Te
k = 0,38 from Table 11 and hence
Tm = 0,38 x 286903
= 109023
The minimum slack side tension to prevent excessive belt sag is:
Ts = 9,8Sf x (B + Q) x Id
= 9,8 x 6,3 x (14,8 + 357,4) x 1,2
= 27576N
Since
Tm > Ts
T2 = Tm
i.e. T2 = 109023N
Step 6
Step 7
Calculations of the effective tension for each segment (or run) is shown on Sheet 1 for the empty belt, Sheet 2 for the fully
loaded belt, Sheet 3 for the case where only non-decline sections are loaded and Sheet 4 where only the decline sections
are loaded.
Step 8
The accumulated effective tension column is the sum of the effective tensions of the current segment and all preceeding
segments.
Step 9
The total effective tension for each load case is the value in the last row of the column titled 'Accumulated Effective
Tension'.
The reason for the difference between the effective tension determine step 4 and that on Sheet 3 is the more accurate
figures used for mass of the moving parts on the tabulation sheets.
The tension at any point along the conveyor can now be determined, all load cases, by adding the effective tension at the
point to the slope tension at the point and then adding the worst case T2 value.
The highest Te value occurs when all non-declines are loaded. i.e. Te = 283609N
Tm = k x Te
= 0,38 x 283609N
= 107771N
T2 = Tm
i.e. T2 = 107771N
Thus, for example, the effective tension at run L - M takes the following values:
From these it is determined that the tension at point M under the four cases, given by
Te + T2 + Th is
Empty belt
4302 + 107771 + 0
= 112073N
-24577 + 107771 + 0
= 83194N
Non-declines loaded
6059 + 107771 + 0
= 113830N
Declines loaded
-26334 + 107771 + 0
= 81437N
CLIENT NAME CONVEYOR EQUIPMENT NO.
Belt width W 1200 mm
Conveyor length L 500 m
Lift H 45 m
Max capacity τ 4500 t/hr
Belt speed S 3,5 m/s
Skirt length Ls 3m
Idler Data Carry Return Impact
Material conveyed Iron Ore
Trough Angle 35 0 35 degree
Lump size 100 mm
Roll Diameter 127 127 159 mm
Bulk densiy 2,4 t/m3
Spacing 1,2 3,6 0,45 m
Corrected length Lc 570 m
Rotating Parts Mass M 19,9 17,1 22,9 kg/set
Correction factor C 1,14
Friction Factors
Rotating Parts fx 0,020 Pulleys Diameter Location
Load Friction fy 0,022 Head 630 mm O
Skirt Friction fs 0,65 Drive Head mm O
Scraper Friction fc 0,60 HT Bend - mm -
Drive & Take-up Tail 500 mm I
Angle of Wrap 210° Take-up 500 mm E
Take-up Bend 500 mm D,F
Drive Surface Lagged Bare
LT Bend 450 mm B
Take-up Type Gravity Screw Tripper - mm -
Drive Factor k 0,38
Friction Factors
Rotating Parts fx 0,020 Pulleys Diameter Location
Load Friction fy 0,022 Head 630 mm O
Skirt Friction fs 0,65 Drive Head mm O
Scraper Friction fc 0,60 HT Bend - mm -
Drive & Take-up Tail 500 mm I
Angle of Wrap 210° Take-up 500 mm E
Take-up Bend 500 mm D,F
Drive Surface Lagged Bare
LT Bend 450 mm B
Take-up Type Gravity Screw Tripper - mm -
Drive Factor k 0,38
Friction Factors
Rotating Parts fx 0,020 Pulleys Diameter Location
Load Friction fy 0,022 Head 630 mm O
Skirt Friction fs 0,65 Drive Head mm O
Scraper Friction fc 0,60 HT Bend - mm -
Drive & Take-up Tail 500 mm I
Angle of Wrap 210° Take-up 500 mm E
Take-up Bend 500 mm D,F
Drive Surface Lagged Bare
LT Bend 450 mm B
Take-up Type Gravity Screw Tripper - mm -
Drive Factor k 0,38
Friction Factors
Rotating Parts fx 0,020 Pulleys Diameter Location
Load Friction fy 0,022 Head 630 mm O
Skirt Friction fs 0,65 Drive Head mm O
Scraper Friction fc 0,60 HT Bend - mm -
Drive & Take-up Tail 500 mm I
Angle of Wrap 210° Take-up 500 mm E
Take-up Bend 500 mm D,F
Drive Surface Lagged Bare
LT Bend 450 mm B
Take-up Type Gravity Screw Tripper - mm -
Drive Factor k 0,38
Friction Factors
Rotating Parts fx _______ Pulleys Diameter Location
Load Friction fy _______ Head _______ mm _______
Skirt Friction fs _______ Drive _______ mm _______
Scraper Friction fc _______ HT Bend _______ mm _______
Drive & Take-up Tail _______ mm _______
Angle of Wrap _______ Take-up _______ mm _______
Take-up Bend _______ mm _______
Drive Surface Lagged Bare
LT Bend _______ mm _______
Take-up Type Gravity Screw Tripper _______ mm _______
Drive Factor k _______
VERTICAL CURVES
It is necessary to calculate the tension at the point under consideration following the method described in Tabulator
Calculations.
Concave curves
The worst condition exists when the belt is loaded to the start of the curve and under these conditions the minimum radius
of curvature to prevent the belt lifting off the idlers is
113 Tp
R=
B
Where
R = radius of curvature (m)
Tp = Belt tension at the point under consideration (kN)
B = Belt mass per unit length (kg/m)
Sinβ x W x E
R=
4494 (tr - tc)
Sinβ x W x E
R=
8988 (tr - 5,2)
3. Maximum allowable change of incline per idler to prevent overstress of belt edges
The curve must be designed with a radius at least large enough to satisfy conditions 1 and 2 and the idler spacing must
ensure that conditions 3 and 4 are satisfied.
Belt length:
π(D + d)N
L=
2
or
Assuming the length of belt is large and the
Where d 0,3m for general stock belting and up
thickness not abnormally small, then the core
to 0,5m for heavy rolls of belting, such as
diameter can be neglected in approximate
steelcord belting or very wide belts.
calculations.