Chapter4

Belt Conveyor
-

41 INTRODUCTION
A belt conveyor system consists essentially of an endless belt of resilient material
connected between two flat pulleys and moved by rotating one of the pulleys
by
electric motor. Normally, material is fed on the belt near the other end pulley. The
moving belt carrying the material towards the driver pulley is likely to sag between
the two end pulleys due to its self weight and pay load. That is why the belt is
supported both on the carrying side and the return side by a number of rollers,
called the idlers. As the belt is always under tension, it is prone to
elongation
resulting in slackness over the pulleys and loss of tension and power. That is why
some kind of device for tensioning the belt is incorporated in the system. This
tensioning device is known as take-up arrangement. The system is inherently very
simple.
Belt conveyors have attained dominant position in transporting bu!k mate
a
rials due to a number of inherent advantages like the economy and safety of
operaticn, reliability, versatility and practically unlimited range of capacities. In
addition, they are suitable for performing numerous processing function while
supporting a continuous flow of material between operations. Low labour and loww
energy requirements are fundamental with belt conveyors as compared with other
means of transportation. The reliability of belt conveyors has been proved over
decades and in every industry. Belt conveyors are operated at the touch of a
button, at any time of the day or week and they can and often do operate
continuously, shift after shift. Belt conveyors are environmentally more acceptable
than other means of transport. They neither pollute the air nor deafen the ears.
Conveying of a wide variety of materials is possible with belt conveyor, and belt
Conveyors are capable of transporting at a hourly rate much in excess of any
pracical requirement. Belt conveyors can deliver materials at a great distance from
the loading point
covering all odd terrain.
42. ESSENTIAL COMPONENTS OF A BELT cONVEYOR
gure 4.1. shows the general arrangement of a belt conveyor system.
The essential features of a belt conveyor system can be described with reference to
Fg4.1. It consists of a driving pulley (1) at the head end, and a take-up pulley
67
 70
Mechanical Handling of Material
- LOADING HOPPER

DRIVE
-HORIZONTAL PATH

-INCLINED UPWARD PATH

INCLINED HORIZONTAL PATH

1ORIZONTAL-INCLINED PATH

HORIZONTAL-INCLINED
HORIZONTAL PATH

PINCLINED-HORIZONTAL
ORVE INCLINED PATH
OHORIZONTAL-INCLINED PATH

Fig. 4.3 Conveyor travel paths

4.6. DETALS OF COMPONENT PARTS

(A) Conveyor Belts
It is quite obvious that the belt should be of resilient material. The desirable
properties of an ideal belt material are: high strength, low self weight, small specific
elongation, high flexibility, high resistivity to ply separation, low hygroscopicity
and long service life. It is found from experience that reinforced rubber belts meet
these requirements better than any other materials.
In general, a conveyor belt consists of three elements: top cover, carcass, and
bottom cover. Fig. 4.4. shows the cross section of a typical belt.
rTOP COVER CARCASs (FABRIC) STEEL CORD

8 8 8 88

BOTTOM COVER
Fig. 44 Cross section of a typical belt.
The carcass is the reinforcing element and takes up the tensile forces neces
sary in starting and moving the loaded belt, absorbs the impact energy of material
during loading. The carcass may be of either textile reinforcement or steel cords
In case of textile reinforcement the carcass is normally built up of a number of plies
of textile fabric. These plies may be made from rough woven cotton fabric and a
connected by vulcanisation with natural or synthetic rubber. Sometimes the plies
are made of extra-strong synthetic fabrics like capron, pernol, nylon, etc. 1
strength of fabric and the number of plies in the carcass of the belt may be varne
together to suit the strength requirement. However, if the belt is too tough, troughing
of the belt and bending it round the terminal pulleys will be very difficult. There
fore, the belt with lesser number of pli>s with stronger fabric is generally preferred
because it is more flexible. Steel cord belting is used when good troughability, sma
Belt Conveyor

71
ecific elongation and higher operating tensile forces are
t e elongation

specific
erally elected
selected:for underground required. PVC
mining applications where fire hazardbeltingg is exists.
Belt cover grades

The
primary
rimary purpose of
of the covers is to
protect the
belt carcass
The any
poecial deteriorating factors that may be present in the against environ-
special deterio damage
and
.hher or rubber - like compounds are used for the operating
and bottom covers
Various chemicals are mixed with these top
ment.
men belting.
of
or conveyor

ced physical properties necessary for service conditions. compounds to achieve

The rties
prope
ded for the cover of belt include resistance to cutting, gauging, tearing, abrassion.
ne
acing, moisture absorptions and in some cases resistance to oil, chemical and heat.
Different qualities of cover material are designated by different grades. The cover
erade is determined by the characteristics of the material to be handled. The
recommended values of cover grade selection are given in IS: 1891 (part 1) (Rubber
conveyor and elevator belting: Part I, general purpose belting).
Indian All-Synthetic conveyor belting is available in the following cover grades:
Grade M24: Natural rubber compound offering superior resistance to cutting,
gauging and abrasion wear.
Grade N17:Compounded rubberwith improved flex life for moderatly abrasive
material, high abrasion resistance. Resistance to cutting and guaging is inferior to
that of M24.
Grade HR: Suitable for handling alumina, ash, chemical, etc. at temperatures
over 65 C, upto 120° C.
Grade Betaplus': Recommended for handling materials like foundry sand,
coke
cement clinker, sinter ore at temperature range 65*C to 180* C for coarse
wharf,
and fine materials.
and materials
Grade FR: Suitable for underground mining and for equipment
requiring fire resistant and antistatic charge properties.
to mineral, vegetable and
Grade OR Suitable for best possible resistance
animal oil.
"All-Synthetic conveyor
For details one should consult technical catalogue
on

belting" of M/s. Dunlop India Ltd.

Designation of Belts meter width
tensile strength per
US designated to denote the full thicknesstextile. Examples: 500/3 belt indi-
are
and the number of reinforcing plies
of reinforcing plies of syninet
synthetic e tensile strength of S00 kkN
number thickness tensile strength of 500
a minimum guaranteed full fabric reinforced

m,
naving For all synthetic
incorporating 3 plies of textilei
Conveyor
reinforcement.

is applied to obtain the

maximum

factor of safety of 10
W or belting usually a
orKing tension with vulcanised splicing by the minimum
"ST" followed
is designated by the prefix minimum tensile
ST-1800 belt has
a
fullthickness tensile
Dll thickneeDeting
in kN/m. Example: Grade M-

strength of 1R strength
1800 KN/m. are
available with
cover

ngth of Dunlop steel cord belts the maximum working

24
and and Gra R . A factor of safety of 7
is applied
to obtain
 72 Mechanical
Handling of
lateriat
tension of the belt. For details one should, consult Dunlop's technical catale.
and technical persons. catalogue,
Belt Splicing
The two ends of a belt are joined directly on the conveyor either by vulcanising.
hinged metal belt fasteners of different designs. Vulcanisation is the most re
method of splicing. Vulcanisation technique is a specialised job and expensive,k
liable
but
yields the best result. Mechanical fasteners are often used for connecting flat belting

(B) Idlers:
Conveyor belts are usually supported on idler rollers. In some cases they an
supported by solid wood or runway of steel sheet or a combination suppor
comprising of the two types of supports placed alternately.
There are two basic types of idlers: () Carrying idlers; and (in) return idlers
The most commonly used type of carrying idlers used for handling bulk lou
consist of three in line idler rolls of equal length as shown in Fig. 4.5. The thre
equal length roll troughing idlers form the belt into the best troughed shape to
cary a maximum load cross section.
For handling unit load or for handling nominal bulk load, or for supporting belt
in return side, straight idlers are used, as shown in
Fig. 4.5, positioned between
brackets attached directly to the conveyor frame. Another type of carrying idlers are
used at the loading points where the lump size and the
weight of the material may
seriously damage the belt if the belt were rigidly supported. Such idlers are called
impact idlers. The most frequently used type of impact idlers consist of a three rol
assembly, each roll being made of spaced resilient discs. These idlers are also known
as cushion idlers.

BELT wIDTH

(a) CARRYING ILDERS-TROUGHED

BELT WIDTH
-
LENGTH OF ROLLER
(b) RETURN ILDER-STRAIGHT

(C) IMPACT ILDER

Fig. 4.5
Different types of idlers
Belt Conveyor 73

Return idlers: The return idlers which carry the weight of the empty belt in the
return side or the lower side of the conveyor are mostly single roller straight idler
shown in Fig. 4.5. (b).
as
The main dimension of the idler is the diameter and length. The diameters, in
millimetres, of carrying and return idlers shall be selected from the following:
63.5, 76.1, 88.9, 101.6, 108, 114.3, 127, 133, 139.7, 152.4, 168.3, 193.7
The following tables may be used in selecting the idlers

2000

B
SLOTTED HOLES FOR
STIFFNER PLATE- F BOLTS
(NOT FOR ALL SIZES)

Table 4.1. Life Sealed ldlers with ball Bearings

Troughing Idler
series
4000, 5000, 6000, 7000, 8000, 9000

(Roll Dia) D¢ MM 168.3 10/20/25/30/35°/45°

159
101.6 1143 127 139.7 152.4|

E MM
FO
Belt A B C Do (ROLL DIA)
Size 159 68.3 MM
MM MM MM MMO1.6 114.3 |127 39.7|/52.4 M12
225
400 690325 160 200 225 | 275 275 275 290 M12
S00 790 325 200200 225 |225 M12
225 225 275 275 275 | 290
650 940 30 250 200 275 275 290 M12
225 275
800 1090 30 315 200 | 225 275 275
275 | 290 M12
225 225
1000 1290| 30 380 200
275 275 275 290 M16
1200 1490 35 465 215 240 240 | 275 290 M16
240 275 275
1400 1690 215 240 M16
30 530 275 275 290
240 275
1600 1900 25 600 240 275 275 290 M20
275
1800 2100 25 670 275 275 290 M20
2000 2300 25 750
 74 Mechanical Handling of Mate,
teria
8LOTTED HOLES FOR BOLTS

40
125

Table 4.2. Straight roller idler.

Return lder
4000, 5000, 6000, 7000, 8000, 9000 Series
(ROLL DIA) D 9 mm
101.6 114.3 127 139.7 152.4 159 168.J
E 160 160 160 160 200 200 2200

Belt Size A BO C
Mm m n m

400 690 M 12 S00

500 790 M 12 600

650 940 M 12 750

800 1090 M 12 950
1000 1290 M 12 1150
1200 1490 M 16 1400
1400 1690 M 16 1600
1600 1900 M 16 1800
1800 2100 M 20 2000
2000 2300 M 20 2200

Idler spacing
The spacing of idlers on the loaded run of the conveyor, teris

carryingthebulk
depends on the belt width, the specific weight of the bulk material, typemao
It is given in table 4.3.
Belt Conveyor
75

Table 4.3. Recommended idler spacing

Troughed belt idler for
Belt width matls. of bulk density Flat belt Return idler
in mm in hn idler
0.4 to 1.2 Y =1.2 to 2.8
300
400
500 1500 1000 1000 3000
650
800
1000 1000 1000 3000
1200
1400
1600 1000 750 750 3000
1800
2000

The spacing of idlers in the loading zone of the belt is about half the normal
spacing of idlers in the carrying side.
A set of self-aligning-idler or training-idler should be provided at the carrying
side and return side at an interval of 15m on the carrying run and 30 m at the return
run. Fig. 4.6 shows the design of a training-idler. It consist of an ordinary troughed
three roller idler 1, mounted on swivel frame 2, which is free to swivel within a limit
about a vetical pivot 3. When the belt shifts off the centre, the edge contacts on
actuating roller 4 with a slight pressure, and this makes the idier take a skewed
position when a force acts which tends to steer the belt back to its central position.
As the belt returns to its central position, it automatically returns the idler to its
initial position.

VIEW-AA
DIRECTION of BELT TRAVEL

T
idler
Fig 46 Troughed belt training
IS:8598-(Specifications for
of idlers, the reader is referred to
idlers details
and a1dler sets technical catalogue on idlers published
by Td for belt conveyor), and
by Tata Robins Fraser Ltd.
 Mechanical Handling of Mater
76

and return side offer rolling resistan.

The idlers along the carrying
account by an artificial coefficient ne
motion of the belt. It is taken into
of rolling resistance of the
idlers along the ca on
dimensionless, comprising
return sides of belt and the belt advancernent resistance. This coefficient.off
belt conveyors and the sam
basic value of 0.02 for normal' aligned
has a

basic value of 0.012 for down

hill conveyor requiring a brake motor. 8h2s
The basic value of 0.02 of the coefficient of friction is only appliçahia .
installations used at 70% to 110% of their nominal capacity, equipped withth
roll carrying idlers for the upperside of the belt, a 30° side troughing angle
of about 20" C, and 108 to 1
speed of about 5 m/s, surrounding temperature
mm diameter carrying idlers with ball bearing and labyrinth grease seals, togeth
with idler spacing of 1.0 to 1.5 m for the carrying side and 3.0 m for the retum
side of the belt.
Under favourable conditions, such as properly aligned installations with pop

erly lubricated ball the value of the coefficient of friction may be as low
bearings,
as 0.016. For unfavourable conditions, such as poorly aligned belt conveyers with
old bearings, f ' may be as high 0.03.

(C) Drive Arrangement

In belt conveyors the driving power is transmitted to the belt by the driving pulley
transmission od
which is rotated by an electric motor. The basic mechanism of
power from the pulley to the belt is
based on the theory of friction drive. The
fundamental equation for a belt conveyor drive is given by: (the Euler's equation)
T ST2a 4.)
at the
Where, T and T2 are the tight side and slack side tensions of the belt
driving pulley;
a = wrap angle of the belt in radian
than
e = Naperian base; friction factor; The ratio of the T,/T2 can beiessu
this value, but it cannot be more than this.
n the
The peripheral effective pull Tp from a driving pulley, neglecting losses
driving pulley due to belt stiffness, is determined from the following rela
T. T-T2
42)
T2min Emax (eM-1)
Ocus

Where, Temax is the maximum effeutive peripheral pull in

in N, which often e rc o n

when starting up or when braking the completely loaded conveyor. in 2 0

ditions T, is the average effective pull. Maximum effective pull is usua

motor staster

50% more then the average effective pull, depending on the type of me

and coupling. 44
Table
The values of coefficient of friction u can can be obtained
n e dfroml3
from
Bell Conveyor
7

4.4.
Coefflicient of friction between driving pulley and rubber belting
Table
Type of Pulley Lag

Smooth Rubber lagging| Polyurethane Ceramic PVC

bare with herring agging with| lagging8 belt
Operating steel bone grooves Herring-bone with
condition pulley grooves. Herring
bone grooves.|
0.35 to 0.4 to 0.45 0.35 to 0.4 0.4 to 0.45 0.25 to
Dry 04 035

Clean wet 0.1 035 035 0.35 to 0.4 0.15 to

03
(water)
0.25 to 0.3 02 035 less
Wet and0.05 to
0.1 than
dirty 025
(clay or

loam)
The value of oa depends on the particular drive system selected and may range
from 180 to maximum 440.
Minimum Belt Tension
The minimum belt tension is estimated considering two factors; viz., (1) the T2min
tension required to derive the belt without slippage oa pulley and given by
equation (4.2); (2) by To»the tension required to limit the belt sag at the point of
minimum tension. The minimum tension is calculated both ways and the larger
value used. The minimum belt tension on the carrying side usually occurs at the
than
tail (feed) end. Experience has shown that when a conveyor belt sags more
3% of the span between conscentive idlers, load spillage often results. The basic
as a relation of belt tension T, idler spacing Pc
and
sag formula expressed
can be
the following form:
weight of belt and pay load per unit length, in

Vertical drop (sag) between idlers P (W,8T+W

For 3% sag, the formula can be written as:

PE (W, +W,)3P
8T 100
or
T 4.2 P (W, + W) 4.3)
Where, P.= idler spacing on the carrying side, W, Wm are the weights of belt
p a y load per meter length of belt respectively
ypes and Selection of Drives
O r v e arrangements for belt conveyors are shown in Fig. 4.7.

ungle Unsnubbed Bare/Lagged Pulley Drive

Reference Fig. 4.7.
4 (a). This is the simplest drive arrangement consisting of a steel
Pulley
pulley con
ccted to motor and the belt wrapped round
a
it of 180. This
on an arc can
 78 Mechanical Handling of
Malerig
asive mata.
be used for low capacity short centre conveyors handling non-abrasive material. T,
the coefficient of friction.
pulley may be lagged to increase

SNUB-PULLEY
DRVE PULLEY
DRIVE PULLEY (a) (b)
SINGLE PULLEY

DRIVE
PULLEYS DRIVE PULLEYS
TWIN PULLEY
(C)

()
SPECIAL DRIVE
WITH SNUB PULLEYS

SPECIAL DRIVE
WITH PRESSURE BELT

Fig. 4.7 Typical drive arrangemnents for belt conveyors

Drive
Snubbed Bare/Lagged Pulley
where the angle of wrap is increased from
Fig. 4.7.(b) shows the arrangement a snub pulley to the driving pulley.
to 210, or even upto 2309, by providing
belt conveyors, handling mild abrasive
majority of medium to large capacity witn
fair!yabrasive materials, pulley drive with load pulley lagged
210" snub
rubber is adopted.
Tondem Drive
Where belt ten
and (d) show two pulley drives (or tandem drive).
Fig. (c)
4.7.
of wrap is increased by adopting tandem
estimated to be high, the angle of contact irou t
are driven. The tandem drive, with arc
Both of tandem pulleys
can operate with one or two motors.
The location of sud
to 480 or more,
determined by the physical requirements of
the plant and su
is usually
constraints.

Special Drives
and (t) show special drives with snub pulleys
and pressure b
Fig. 4.7. (e)
and long conveyors.
in heavy
12
Driving Pulley mendks
of standard pulleys are: 200, 250, 315, 400, 500. 630, 800, 100
The diameters diameter should be done as recom
and 1600 mm. Selection of pulley
1400
 Bell Conveyor

79
K of IS: 1891 (part D), or
in Appendix
technical catalogues pub.
by consulting
lished by belt manufacturers. A typical

pulley is shown in Fig. 4.8. Pulley may

faced or crowned. The crown D
be straight
the belt centred. The
serves to keep
height of crown, is usually 0.5% of the
pulley width, but not less than 4 mm. Fig. 4.8 Driving Pulley.
The pulley diameter Dp depends on
the number of plies of belt and may also be determined from the formula:
Dpk imm.
Where K a factor, depending on the number of plies, the value ranges from
125 to 150. K =125 for number of plies 2 to 6 and K =150 for number of plies 8
to 12. i = no. of plies. The computed value should be rounded off to the nearest
standard size. While selecting the pulley diameter it should be ascertained that the
diameter selected is larger than the minimum diameter of pulley for the particular
belt selected. The minimum diameter is given by the manufacturers' catalogue or
IS:1891, 1961.
The drive pulley may be lagged by rubber coating whenever necessary, to
increase the coefficient of friction. The lagging thickness shall vary between 6 to
12 mm. The hardness of rubber lagging of the pulley shall be less than that of the
cover rubber of the running belt.
The pulley may be made from cast iron grade FG 200 of IS:210-1976, mild steel
to IS:1239.
Conforming to IS:226-1975 or mild steel tubes conforming
Pulley Types shown in
is the standard stel pulley a
The most commonly used conveyor pulley of a continuous
4.9. They manufactured in a wide range of sizes, consisting
ig. are
the conveyor pulleys intermediate
and two end discs fitted with hubs. In most of
m self cleaning wing
discs welded inside the rim. Other pulleys are
SEiffening are
snub pulley where material
tends to
which used as the tail, takeup or
pEs are
of pulleys are used to
remove tramp

up on the pulley face. Magnetic type

d through 4.9 (d) show
the more
4.9 (a)
rom the material being conveyed. Fig
Common types of conveyor pulley.

Curve Crown Pulley

a Typical Welded Steel Pulley b) Spun-end
80
Mechanical Handling of Maieriais

(c) Welded Steel Pulley

with Grooved Lagging (d) Welded Steel Pulley
with Grooved Lagging
Fig. 4.9. Pulley Types
Power Caleulation for the Drive Unit
The horse power required at the drive of a belt conveyor, is derived from the
following formula:
h.p. ev
75
Where, T, is the effective tension in the belt in N; v =the velocity of the belt
in meter per second. So, to calculate the horse power of the motor required to drive
the pulley we have to evaluate the effective tension T, and the belt velocity.

The required effective tension T. on the driving pulley of a belt conveyor is

obtained by adding up all the resistances.
The formula for calculating the effective tension may be taken from the book
Belt conveyors for bulk materials', published by conveyor equipment manufactur-
ers association of the USA
The effective tension may also be calculated from the formula given in equa-
tion (6) of IS:11592-1985.

Power Caleulation Per IS: 11592

Driving Force and as

of belt conveyor is
The required perpheral force T, on the driving pulley(s) a

obtained by adding up all the resistances to belt motion.

T R+ R, + Rspl t Rsp2 + Rs

where, T =
driving force on the driving pulley
in N
R main resistances in N comprising of:
rotational resistances at the carrying and return idler due to friction in
idler bearings.
(ii) resistance to the belt due recurring flexing over idlers.
Rs Secondary resistances in N, comprising of
() inertial resistance due to acceleration of the material at the loading area
() resistances due to friction on side skirt board at the loading area.
(i) resistances due to wrapping over pulleys.
Rgpspecial main resistances in N, if applicable due to forward tilting of theidie
RsP2 special secondary resistance in N comprising of:
 81
B e l tC o n v e y o r

resistances due to belt cleaning

due to dischange ploughs and trippers.
resistances
i)
due to slope of the inclined
RsL = resistances conveyor.
force be
Te may written as
However, the peripheral
T = fLg m, +m,+ (2mg +mg) cos )]+m, H.g + Rg + RsP1++RsP2
artificial coefficient of friction
where, f
0.020 for normal conveyor,
0.012 for downhill conveyor requiring brake.
For a detail discussion of Rg,RsPIRsP2 the reader is referred to clause 7.5 of
S11592
Speed Reduction Mechanism
Soeed reduction mechanism is an essential part of the drive arrangement. Fig. 4.10
few typical speed reduction mechanism usually used with belt conveyor
drive arrangements.

BELT
ON DRIVER BELT ON PULLEY
PULLEY

V-BELTING3
SPEED REDUCER
MOTOR - MOTOR

(a) (6)
BELT ON
BELT ON PULLEY
/ PULLEY

coUPLING
MOTOR
SPEED
REDUCER
SPEED
REDUCER H
-wOTOR
C) (d)

() (9

4.10 Typical speed reduction mechanism

g
Shaft.Fig. 4.10. (a) shows a gear-motor directly connected by flexiblecoupling drive
It is gear-motor the speed
Teduct8arssimple,
ion gears
ple, reliable
reliabe and economical
In a
arrangem-nt.
condition.
are cou
coupled with the motor in the built-in
82 Mechanical Handling »f Mut.

shows parallel-shaft speed

reducer directly coupled totthe molor
reduction(b)of speed takes place through
4.10.
FinalFig. v-belting. It is reliable.,
heavier and easy to maintain. generaly
Fig. 4.10. (c) shows parallel shaft speed reducer coupled to motor anand COn
nected to the drive shaft directly.
Fit. 4.10. (d) shows spiral-bevel helical speed reducer or worm-gear
ar
to motor and to the drive
shaft. sped
reducer, directly coupled
Fig.4.10. (e) shows an arrangement of primary through V-belta
reduction
box mounted on the drive shaft.
final reduction through the gear
drive system when power requirements o
Fig. 4.10. (f) shows a dual pulley
very large and use ofheavy drive equipment may be economical in order to rediae

belt tension by increasing angle of wrap.

Drive efficiencies for various speed reduction arrangements are given inthe
table below:
reduction mechanism.
Table 4.5 Mechanical efficiencies of speed
reduction Approxinate mechanical eff.
Type of speed
094
V-belt and sheave
093
Roller chain-sprocket
Single stage
0.95
helical/herringbone gear
Worm gear speed reducer
ratio 20:1 to 60:1 0.70
Worm gear speed reducer
ratio 60:1 to 100:1 0.50
Generated spur gear
single stage 094

(D) Take-up Arrangement

require the use ofsome form of take up device for the follow
All belt conveyors
reasons:

(a) to ensure adequate tension of the belt leaving the drive pulley so as to a
any slippage of the belt.
to ensure proper belt tension at the loading and other points along
(b)
conveyor.
C)to compensate for changes in belt length due to elongation.
Usual
(d) to provide extra length of belt when necessary for splicing purpose.
there are two types of take up arrangements. These are:
fixed take up device that may be adjusted periodically by manualop
(in automatic take up devices (constant load type).
vhichissho
The most commonly used manual take up is the screw take up whiCh
in Fig. 4.11.
 B r l t C n r o r
83

TAKE-UP PULLEY

-ADJUSTMENT|

OPERATING sCREW
Fig. 411 Screw take-up

Tn a take-up system the take-up pulley rotates in two bearing blocks

SCrew
with the help of two screws. The tension
slide on stationary guideways
hich may slid
with
two screws which are tightened and periodically adjusted
ated by the
to use screws with trapezoidal thread to decrease the
spanner.
It iis preferable
a
to tighten the belt.
effort required
main problem with the
use of mannual take-up is that it requires a vigilant
The is required. Perfect ten-
to observe when takeup adjustment
and careful operator For this reason these devices
with this system is also not possible.
sion adjustment of up 60 m length and light duty.
used only in case of short conveyors
are
is mounted on slides or on
automatic takeup arrangement the takeup pulley
In and deflecting pulleys.
backwards by means of a steel rope
atrolley which is.pulled axis of the
mounted parallel to the langitudinal
travels on guideways inclined
The carriage horizontal conveyors and at
an incline in
in
conveyor, i.e., horizontally automatic take-up arrangement.
Hydraulic,
4.12. shows a gravity type
comveyors. Fig.
devices are also used.
pneumatic and elctrical take-up

cOUNTER
WEIGHT

TAKE UP PULLEY

ADJUSTMENT

take-up.
Fig. 4.12 Gravity

Aulomatic take-up has the following features

9t is self adjusting and automatic.
Greater take-up movement is possible.
Problem
A horizontal belt conveyor has the following specifications

Capacity: 600 tons of crushed bauxite/hour.

= 75 m.
ength of conveyor (centre to centre)
Angle of surchary of the material = 10.
with return idler straight.

Throughed aler set of 25*

should be used
84
Mechanical Handling of Malei
kg.
idler 15
Mass of rotating parts of carrying
return idler 10 kg. =

Mass of rotating parts of

210°
Angle of wrap at the driving pulley
Tentatively)
Belt weight 4.0 kg/meter (Assumed
=

1m
Idlerspacing carrying side
=

Idler spacing of returm side 3m

0.022 G)
fficient of friction at the idlers
=

Coe
Coefficient of friction between belt and pulley = 0.25 G)
Coefficient of friction at the bearing of the driving pulley = 0.03 6)

Bulk density of material = 1300 kg/m

Step 1
Belt Velocity: If belt width is not given, belt velocity should be first determined
Assume lump size factor = 3

Consult IS: 11592, C1.6.3

Abrasiveness factor=3
abrasiveness factor 6 Consulting Table5 =
Speed factor Lump size factor+
=

and assuming tentatively the belt width 1000 mm, we get the belt velocity
=

Maximum recommended belt speed (m/s)

600 to 750 to 950 to 1200 to
BeltBelt width upto
500 mm 650 mm 800 mm 1050 mm 2000mm
Speed
Factor 3.0 350 4.00 450
250
230 2.75 3.20 365 4.12
2
238 2.75 3.15 3.55
2.00
1.65 2.00 235 2.65 3.00
5-6
262
7-8 145 1.75 205 235
From table, v = 2.65 m/s.
However, if belt width is given or known, velocity of belt is ascertainedfod
the volume of material handled per unit time.

Step 2
Load Area: Weight of material conveyed/hr = 3600 A.v.p.
where, V Velocity of belt in m/s
p density of material in kg/m*
A =Cross sectional area of bulk material on the beltinm
600 x 1000=3600 A. 2.65 x 1300
A 600x 1000
A 0.0484 m2.
3600x 2.65x1300
 Be Coanper
85

Now consult Table 7 of IS:ll1592 and search out a load area very near to the
uated value against surcharge angle of 10 and troughing angle 25°. The figure
is 0.0771 m, which is higher but satisfies all the requirements.
The width of belt is 1000 mm with a load area of 0.0771 m.
Let us check the conveyer capacity. The mass of material discharged per hour
in given by

W:
Load area x belt velocity (ms) x 3600 x Buck density
1000 ton

0.0771x 2.65x3600x 1300

= 956 ton/hour
1000
This is greater than the design capacity of the conveyor which is 600 ton/
hour.
So finally the belt width is takes as 1000 mm and belt velocity of 2.65 m/sec.
If belt width is not known and cannot be assumed, it may be found from the
following formula:
W
B
160vp[3.6C, tan (,)+1
Where W kg of materialconveyed/hour
surcharge angle.
C Inclination factor. (C = 1.0 for belt inclination up to 15)
Step 3.
Point by Point Method Calculation: In this method the entire
is divided into a few conveyor periphery
important points and marked 1,2,3,4, starting from the point
where the belt is leaving the
driving pulley. Let the tension at point 1 be denoted
s
S. Hence, the tension at point 2, denoted as S may be written as
TAL END =PONT 3 DLER POINT4
PULLEY CARRYING sDE
DRIVER
PULLEY
ANGLE OF
LAP 210

POINT 2 IDLER
RETURN
PoINT 1
SIDE SNUB
PULLEY

+frictional resistance to motion of the belt between point 1 and 2.

S S+Lf, (W,+W)
Where, L =
Length of
conveyor 75 m =

coeff. of friction at the bearing of the idlers 0.022

weight of belt per unit length = 4.0 kg/m
W,weight of rotating parts of the return idlers/m of idler spacing = 10/3
ubstituting the appropriate values we get,
S = S+75 x 0.022 (4 + 10/3) =S +12.099 (1)
 Mechanical llunl1ng u Mae.
86

may be written
denoted as S, as:
Again the tension at point 3,
to 1.07
S, =
k.S where, k varies from 1.05
1.07 x S
12.94
-
1.07 (S, +12.099) 1.07 S, +

The tension at point 4, denoted as may be written as:

S,
resistance to motion ofthe belt
between point 3and,
S =
S,+friction
- S+ Lf (W+Wi + W)
Where w, = weight of payload per unit length
weight of rotating parts of idler at the carrying side.
W
= 15/1 = 15 kg/m

w= A.p
= 0.0771 x 1300 100.23 kg/m
where, A = load area on belting [See Step 2]
S = 1.07 S, + 12.94 +75 x 0.022 (4.0+ 100.23+ 15)
1.07 S +210.0
Again, we know that S and S4 are related by Euler's equation.

5210 = e 25
S = 2.5 S
Substituting this in equation (3), we get,
S = 147 kgf S, = 170 kgf
S = 159 kgf S= 367.5 kgf

Step 4.
Belt Selection : Assume a factor of safety 10 for the belt. Design tension of t
bell 3675 Newton. Consulting Dunlop's catalogue for synthetic conveyor beltin
we chose a general duty belt of rating 400/3 with a cover grade M24.
The weight belt 3.7 kg/m", three ply; maximum tension 40 kN/m width.
HP. of the Motor
Net pull in belt =
(S,- S1) +5(S, +
S
where, = Coefficient of friction at the bearing of the driving pule

(367.5-147) +0.03(367.5+ 147)

236 kgf.

Net pullx velocity of belt

H.P. of motor Efficiency
=

of power transmission x 75
Efficiençy, n = (95" x 0.9. Assuming a three stage speed reduction gear
having 95% efficiency per stage, and 90 % efficiency of the coupling.
n 0.77

H.P.=36x 2.65 =
10.83
0.77 x 75
 Belt Conveyor
87

Choose a 15 h.p. motor.

Solution of the Belt Conveyor problem using 1S:11592-1985
The data is the same as in previous problem.
The required peripheral force T, on the driving pulley(s) of a belt conveyor is
obtained by adding up all the resistances. See clause 7.5 of IS: 11592-1985.
T R+Rs+ RsPI + R sP2 + RsL
f. L.g (m, +
m, +
(2m, + m) cos 8) + Rs+Rsp2 + mg. H.g
where,
f Artificial friction coefficient 0.020 (See art 4.6 (B))
=

L Conveyor length (distance between centres) = 75 m

g Acceleration due to gravity 9.81 m/sec2
m = Mass of revolving idler at the carrying side = 15 kg

m Mass of revolving idler at the return side = 10 kg

m- Mass of belt per metre 4.0 kg/m

m Mass of payload on belt per metre = 600x1000

2.65x 3600
= 62.9 kg/m
V Belt velocity in m/sec 2.65 m/sec
= Angle of inclination of the conveyor 0 (since it is horizontal)
H Height of lift of conveyor in metre = 0 (since horizontal)]
RsPI Special main resistances
Rsp2Special secondary resistances
R Primary resistances
RSL Slope resistance in N = mg H.g = 0 here (horizontal)
Rs Secondary resistances in N, comprises of:
9 the inertial and frictional resistances due to acceleration of the material at
the loading area,
i) resistance due to friction on the side walls of the skirt board at the loading
area,
m)pulley bearing resistance applicable for other than the driving pulley,
V) resistance due to the wrapping of the belt on pulleys.

CALCULATIONS FOR PRIMARY RESISTANCE

RfL-gIme + m, + (2m,+ m)cos ]
0.02 x 75 x 9.81[15 +10+(2.4.0+62.9) cos 0)
x 1411.17N
CALCULATIONS FOR SECONDARY RESISTANCE

R R+RgK, +
R +
R
88 Mechanical Handling of Maleri.

Where,
R. = inertial and frictional resistance at the loading point and in the aco
eration area between the material and the belt in N ace

Q.p. (v-vo)
= 0.128 x 1300 x (2.65-2.50)
= 24.96 N
Q = volume of material conveyed per sec = load area on belt x belt velor
= 0.128 m'/sec
V = Velocity of belt = 2.65 m/s
o material conveying speed component in the direction of belt mot
at the loading point
2.50 m/s (assumed)

H0pg
(+ b
2
acceleration length at loading area in m

2g-1
belt
hcoefficient of friction between material and
= 0.5 to 0.7, take = 0.5

b, = interskirt plate width = 0.85 m (assumed)

in N
Rwrab resistance between belt and pulley,
The wrap resistance can be taken from the table below which gives a guië
value.
Location of pulley Degree ofwrap of belt | Warp resistance in N

Tight side 150 to 240 230

Slack side 150 to 240 175

All other pulleys 140

R= 175 N for tail pulley and 230 N for drive pulley

Total R= 405 N

4
-6(2.65)2 -(2.5)
2.9.81.0.5
7.002-6.2
9.81
0.078 m

0.5x (0.128) 1300x9.81x 0.078

RRSka H2:02 p 8 .
x

(2.65+2.5) (0.85)2
2 2
1.70 N
R = Pulley bearing resistance (for tail pulley only)
 89
B e l t C o n v e y o r

O.005R
where
diameter inside bearing in m
d shaft
= 0.05 m (assumed)
in 500 (assumed)
Pulley diameter mm
m =
D
R. Vectorial sum ofthe two belt tensions acting on the pulley and of the
to m a s s of revolving part
of the pulley
forces due
We have calculated primary resistance = 1411.17 N
Tentatively we take T1- T2 =Primary resistance =1411.17
We also known that,

= e4 = e0.35 x 210 p/180) = 3.607

Where = angle of wrap on the pulley = 210

coeficient offriction between driving pul!ey & belt
= 0.35 (taken from Table 15 of IS: 11592)
T = 3.6 T2
3.6 T2-T, = 1411.17
2.6 T2 = 1411.17

T 542.75 N
T 3.6 x 542.7 =
1953.9 N
value
The total belt tension at the tail pulley is approximately taken twice the
1500 N (assumed). Hence vectorial sum of belt
The weight of tail pulley =

tension and weight

R,V2x542.7)2 +(1500)2 =18300 N
Tail pulley bearing resistance R, is given by
R 0.005 R=0.05 0.5
1830 =0.914
Total secondary resistance
, 24.96+ 1.70 + 405+0.914 = 432.5 N
Special Resistances
The special resis
resistances include (i) resistance due to idler tilting;
resistance due to friction between material and skirt plate;
ufrictional resistance due to belt cleaners;
iv) resistance due to
friction at the discharge plough. to idler tilting
and
resistance due
isi are usually small. Here the plough the resistance due
resistances
kiPecia

skirt resistance
rt resista discharge
to

plough is igno8nored.
ignored. There being no
 90 Mechanical Handling of
lerial
Here we are taking only the resistance due to belt cleaner. For guidancea
between 360 and 530 N/m length of each scraper may be used.
ance a value
We take the resistance due to belt cleaner as 400 N.
Hence the total driving force on the driving pulley is given by
T = 1411.17 (Primary resistance) + 432.5 (Total secondary resistance 4
400.0 (special resistance)
2244.07N
Hence operating power requirement at the driving pulcy is given by,

Ty
Tkw 2244x
PpP 1000
2.65
= 5.947 kw
1000
Absorbed power

T w* w: after taking driving pulley losses into account

1000 1000

5.947 4 (230+44)2.0
1000
=6.66 kw
where R =
wrap resistance at the driving pulley
= 230 N (from guiding value)
R =Drive pulley bearing resistance = wt of pulley x coefficient offriction
at the pulley bearing.
150 x 0.03 = 4.5 kgf = 44 N
The motor output power (shaft)

Absorbed power
PTra
Transmission efficiency
Transmission efficiency may consist of 94% efficiency per stage of a thre
stage gear reduction unit ad 90% efficiency of a coupling. This gives the final
transmission efficiency h = (0.94) x 0.90 =0.747 0.75%.
Hence the motor output power is given by
Pm 6.66/0.75 8.88 kw
= =

We can choose a 10-kw motor.

Belt Selection
Maximum tension T has been calculated as 1953 N. This may be taken as maximum
design tension of the belt. Assume a factor of safety of 10 for the belt. Consulting
belt manufacturer's catalogue for synthetic conveyer belting we choose a
genete
duty belt of rating 400/3 with a cover grade M24. The belt has a maximum tentro
taking capacity of 40 kN/meter width. The extra strong belt is chosen to take ca
of the maximum belt tension arising during starting.
The weight of belt = 3.7 kg.m', three ply, with a maximum tension 40 kN/m widt
 91
onveyor

y Selection

a Table VIll of IS: L891-1961

ulating Table
we find that the minimum pulley size for the
elected is:
= 305 mm
Oriving Pulley
= 254 mm
ail Pulley = 203 mm
Snub Pulley of diameter 400 mm, tail pulley of diameter 315 mm and
ve select a drive pulley
250 mm. These standard diameters are chosen consulting
pulley diameter of
31-1986.
such that belts shall have minimum edge clear
ulleys shall be manufactured650 75 mm for belt widths of 800 and 1000 mm;
width of mm;
50 mm upto belt
1000 mm. The edge clearances are applicable
00 mm for belt widths exceeding
than 3m/sec. For belt speeds greater
than 3 m/
belt speed not greater
nveyor the purchaser and the
shall be as agreed to between
clearances
the edge
facturer. Beltwidth +2x Edge clearance
Pulley face width (L)
=

1000+ 2x 75

1150 mm
rences and Bibliography Manufacturers
Materials", Conveyor Equipment
"Belt conveyors for Bulk
Association, U.S.A. Publishers
Peace
"Conveyors and related Equipment,"
Spiva kovsky, A.O,
Moscow. Elsevier
Bulk Solids,
Colijn, H., Mechanical conveyors for
for selection and design of belt conveyors.
S: 11592-1985 Code of practice