CALCULATION:

Vermicompost Properties
Vermicompost Equivalent Value
Bulk Density 683.3 kg/m3
Moisture Content 44.4%
Angle of Repose 43.3°
Surcharge angle, 𝜷:
From the study of Rulmeca(2009), the equivalent surcharge angle was based on the angle
of repose of material. Using the angle of repose 43.3°,its surcharge angle was 30°.(Refer to the
figure below in determining surcharge angle).

Source:(Rulmeca, 2009)
Conveyor Production Capacity:
In this study the target conveyor production capacity of vermicompost was 5 tonnes/hr.
Troughing Angle, λ:
In the past study, inclination of the side rollers of a troughing set has been 20° . Due to
sudden modification and innovation to improve the structure and materials in the manufacture of
conveyor belts, a troughing angle of 30° or 35° was used. In this study a troughing of angle of 30°
was used.
Angle of Inclination:
In this study, smooth belt conveyor was used to transport the vermicompost. For smooth
carrying surface, the limit angle was 18° -20°. In the design, the angle of inclination used was
20°.
Belt Speed, v
Based on the table of recommended velocity for the design of belt conveyor, by considering
the vermicompost under the category of unit loads, assembly, the recommended velocity was
≤1.68m/s. Considering the range of recommended velocity, the design used 1 m/s for the belt
speed.
 Source: Conveyor Belt Technique:Design and Calculation
Material Lump Size: K
The material lump size determines whether it is sized or unsized. Consider the bulk load
definition of Vermicompost is lumps, the equivalent K for lumps is 10 mm to 200 mm. Assume
K= 80 mm for vermicompost.
Belt Width Selection
Based on the standard minimum belt width of conveyor , the equivalent belt width for lump
size 80 mm is 500 mm. Use B = 500 mm

Source: Conveyor Belt Technique:Design and Calculation

Belt Material
Considering the application of the belt conveyor which is handling of vermicompost, the
selected material was Dunloflex. Dunloflex belt type is designed for use with all types of bulk
material transporation under light to medium-heavy service conditions.
 The Dunloflex carcass construction consists of two synthetic polyester-polyamide(EP)
plies with an extra thick rubber layer between the plies to give excellent impact and tear
resistance. Polyester-polyamide (EP) are suitable to handle material with high moisture content.
Refer to table below for the application of EP ply material.

Source: Conveyor Belt Technique:Design and Calculation

From the catalog, Dunlop Dunloflex belts are custom made to order. They can be supplied
in all Dunlop cover grades and in tensile strengths ranging from 200 N/mm up to 800 N/mm in
widths from 400mm up to 2200mm.
Dunloflex Belt Type Catalog

The selected belt type for the design was D200. It has a maximum tensile strength of 200
N/mm. Since the availability of this material is custom to made, the selected belt was 500 mm.
Conveying Length
The desired conveying length for the transporting vermicompost is 3.5 meters.

Maximum Capacity of Belt

For Standard Troughing Type, 3 Equal Roller
Qm = Qv × ρ
Qv = A × v × φ
Assuming Normal Working Condition:
φ=1
For Area, A
A = A1 + A2
A1 = 0.25(tan β)[l + (b − l)𝑐𝑜𝑠λ]2
A2 = l1 (sinλ)[l + l1 (cosλ)]
b = usable belt width
l = length of idler rollers
l1 = loading width of the outer roller
For the usable belt width:
b = 0.9B − 50mm ; for belts, B ≤ 2000mm
b = 0.9(500𝑚𝑚) − 50mm
b = 400mm
For Length of idler rollers:
Using the selected belt width, for 3 roll troughing type, the standard equivalent length of
roller is 200 mm. (refer to table from Conveyor Belt Technique Handbook). Use l = 200mm.
For the loading width of outer roller:
l1 = 0.5(b − l) ; for 3 roll idler sets
l1 = 0.5(400mm − 200mm)
l1 = 100 mm
Solving for A1 and A2:
A1 = 0.25(tan 30)[200mm + (400mm − 200mm)𝑐𝑜𝑠30]2
A1 = 20103.62971 mm2
A2 = 100mm(sinλ)[200mm + 100mm(cos30)]
A2 = 14330.12702 𝑚𝑚2
Thus,
1m
A = (20103.62971 mm2 + 14330.12702 mm2 ) ×
10002 mm2
A = 0.03443375673 m2
Solving for the capacity:
Qv = 0.03443375673 m2 × 1m2 /s × 1
m3
Qv = 0.03443375673
s
m3 𝑘𝑔 1 𝑡𝑜𝑛𝑛𝑒 3600 𝑠
Qm = 0.03443375673 × 683.3 3 × ×
s 𝑚 1000𝑘𝑔 1 ℎ𝑟
𝐐𝐦 = 𝟖𝟒. 𝟕𝟎𝟐𝟗𝟎𝟗𝟓 𝐭𝐨𝐧𝐧𝐞/𝐡𝐫
For V Trough, 2 roller
For Standard Troughing Type, 3 Equal Roller
Qm = Qv × ρ
Qv = A × v × φ
Assuming Normal Working Condition:
φ=1
For Area, A
A = A1 + A2
A1 = 0.25(tan β)[bcosλ]2
A2 = l1 (sinλ)[l1 (cosλ)]
b = usable belt width
l = length of idler rollers
l1 = loading width of the outer roller
λ = troughing angle, 20°, for V trough
Used same belt width. B = 500mm. For 2 roll troughing type, the standard equivalent length of
roller is 315 mm. (refer to table from Conveyor Belt Technique Handbook). Use l = 315mm.
For the usable belt width:
b = 0.9B − 50mm ; for belts, B ≤ 2000mm
b = 0.9(500𝑚𝑚) − 50mm
b = 400mm
For the loading width of outer roller:
l1 = 0.5b ; for 2 roll idler sets
l1 = 0.5(400mm)
l1 = 200 mm
Solving for A1 and A2:
A1 = 0.25(tan 30)[(400mm)𝑐𝑜𝑠20]2
A1 = 20392.52469 mm2
A2 = 200mm(sin20)[200mm(cos20)]
A2 = 12855.75219mm2
Thus,
2 2)
1m2
A = (20392.52469 mm + 12855.75219mm ×
10002 mm2
A = 0.03324827689 m2
Solving for the capacity:
Qv = 0.03324827689 m2 × 1m2 /s × 1
m3
Qv = 0.03324827689
s
m3 𝑘𝑔 1 𝑡𝑜𝑛𝑛𝑒 3600 𝑠
Qm = 0.03324827689 × 683.3 3 × ×
s 𝑚 1000𝑘𝑔 1 ℎ𝑟
𝐐𝐦 = 𝟖𝟏. 𝟕𝟖𝟔𝟕𝟕𝟏𝟑𝟓 𝐭𝐨𝐧𝐧𝐞/𝐡𝐫
For Deep Trough, 3 rollers, 45˚ troughing angle
Qm = Qv × ρ
Qv = A × v × φ
Assuming Normal Working Condition:
φ=1
For Area, A
A = A1 + A2
A1 = 0.25(tan β)[l + (b − l)𝑐𝑜𝑠λ]2
A2 = l1 (sinλ)[l + l1 (cosλ)]
b = usable belt width
l = length of idler rollers
l1 = loading width of the outer roller
Based on the standard minimum belt width of conveyor , the equivalent belt width for lump size
80 mm is 500 mm. Use B = 500 mm
For the usable belt width:
b = 0.9B − 50mm ; for belts, B ≤ 2000mm
b = 0.9(500𝑚𝑚) − 50mm
b = 400mm
For Length of idler rollers:
Using the selected belt width, for 3 roll troughing type, the standard equivalent length of roller is
200 mm. (refer to table from Conveyor Belt Technique Handbook). Use l = 200mm.
For the loading width of outer roller:
l1 = 0.5(b − l) ; for 3 roll idler sets
l1 = 0.5(400mm − 200mm)
l1 = 100 mm
Solving for A1 and A2:
A1 = 0.25(tan 30)[200mm + (400mm − 200mm)𝑐𝑜𝑠45]2
A1 = 16825.21985 mm2
A2 = 100mm(sin45)[200mm + 100mm(cos45)]
A2 = 19142.13562 𝑚𝑚2
Thus,
1m
A = (16825.21985 mm2 + 19142.13562 mm2 ) ×
10002 mm2
A = 0.03596735547 m2
Solving for the capacity:
Qv = 0.03596735547 m2 × 1m2 /s × 1
m3
Qv = 0.03596735547
s
m3 𝑘𝑔 1 𝑡𝑜𝑛𝑛𝑒 3600 𝑠
Qm = 0.03596735547 × 683.3 3 × ×
s 𝑚 1000𝑘𝑔 1 ℎ𝑟
𝐐𝐦 = 𝟖𝟖. 𝟒𝟕𝟓𝟑𝟕𝟖𝟑𝟖 𝐭𝐨𝐧𝐧𝐞/𝐡𝐫
Idler Roller Specification:
• Idler Roller Diameter, DR
v
nR =
DR π
v
DR =
nR π
According to conveyor belt technique handbook, idler roller rotation should not be greater
than approximately 650rpm. Used nR = 650rpm.
1 m/s
DR =
rev 1 min
(650 min × 60 s ) π
1000mm
DR = 0.02938245103 m ×
1m
DR = 29.38245108 mm
From the standard values of idler diameter, the next highest value for diameter if idler roller
was 63.5 mm. Refer to table below to determine the standard idler roller diameter.
 Source: Idlers and Conveyor Belt Rollers, Kuppers Standard (2016)
Thus, DR = 63.5 mm.
For idler roller rotational speed:
1 m/s 60 s
nR = ×
1m
(51 mm × 1000mm) π 1 min
nR = 300.7652468 rpm
Thus, idler rotational speed is approximately 301 rpm.
• Idler Length, l
For Standard 3 roll troughing type
l = 200 mm
For V trough, 2 roll troughing type
l = 315 mm
For Deep Trough, 3 roll troughing type
l = 200 mm
• Idler Roller Spacing
For Standard troughing type, 3 equal roller
For Carrying Side:
8 × T × hrel
Io =
(m′L + m′G )g
Where: hrel = 0.005 to 0.015 for carrying side
used hrel = 0.01
 g = 9. 81 m/s2
m’L = mass of load per meter
m’G = mass of the belt per meter
T = tension in the conveyor belt
Qm
m′L =
v
Mass of load per meter:
84.7029095 tonne/hr 1 ℎ𝑟 1000𝑘𝑔
m′L = × ×
1 m/s 3600 𝑠 1 𝑡𝑜𝑛𝑛𝑒
′
mL = 23.52858597 kg/m
Mass of belt per meter:
m′G = m′′G×B
′′
mG = 𝑏𝑒𝑙𝑡 𝑤𝑒𝑖𝑔ℎ𝑡 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 𝑠𝑞𝑢𝑎𝑟𝑒
B = belt width
For m′′
G , considering the material of the belt is necessary. In this design, a dunfloflex
2 ply belt was used. D200 was the reference for the weight of belt per meter square.
Consider the belt cover thickness for carrying and pulley side is 2mm.

Source: Conveyor Belt Technique:Design and Calculation

Based on the table of conveyor belt thicknesses and weights, using D200 and the
sum of the cover thickness for carrying side and pulley side, m′′ 2
G is equal to 7.7 kg /m .

Source: Conveyor Belt Technique:Design and Calculation

1𝑚
m′G = 7.7kg/m2 × 500mm ×
1000𝑚𝑚
 𝑘𝑔
m′G = 3.85
𝑚
For the Tension:
From the head drum pulley:
T1 fθ
=e
T2
Where: T1 = tension at tight side
T2 = tension at slack side
f =friction coefficient
𝜃 = wrap angle
𝑇1 = 𝑇2 𝑒 𝑓𝜃
For friction of coefficient f, considering the table for values of friction of coefficient;

Source: Conveyor Belt Technique:Design and Calculation

Since the pulley surface is smooth and vermicompost can be consider under the
operating condition of wet(dirty mud, clay), the friction coefficient is in the range of 0.05
to 0.1.
Use f = 0.075
For wrap angle, 𝜃 = 230° (based on the maximum angle for a single drive pulley)
𝜋
𝑇1 = 𝑇2 𝑒 0.075(230°×180°)
𝑇1 = 𝑇2 (1.351302978)
But, Torque T,
DTR
T=(T1 -T2 )
2
𝐷𝑇𝑅
T=Fμ ( )
2
Diameter of head drum pulley,𝐷𝑇𝑅
DTR = CTR × d
CTR = value of wrap material of carcase
d = thickness of carcase
For Dunloplex, 2 ply belt
 Source: Conveyor belt Technique HandBook
CTR =80
d = 4 mm
DTR = 80 × 4 𝑚𝑚
DTR = 320 mm
From catalog, standard diameter of drive drum pulley,

Source: Pulleys For Belt Conveyors Bulk Handling General Catalog (Rulmeca)
Used DTR =320 mm
For the peripheral force, Fμ
Fμ =c∙f∙L∙g∙(m' R +2(m' G +m' L )(cosδ)+H∙g(m' L )+Fs
where: C = length factor
f = friction factor
L = conveyor length
g = 9.81 m/s2
m’R = mass of rotary carrying and return idlers, kg/m
m’G = mass of belt, kg/m
m’L = mass of load
δ = angle of inclination
H = conveying height
Fs = special resistance

Conveyor Length, L:
In this study, the target length of conveyor is 3.5 meters. L =3.5 meters
Length Factor, C:
For L=3.5 meters, the equivalent length factor is 8.3. C = 8.3. (refer to table below for
length factor).

Source: Conveyor belt Technique HandBook

For friction factor f:
f = f5m/s × c
For f5m/s, refer to table below from Conveyor Belt Technique Handbook:
 Considering normal installation, normal material, f5m/s = 0.020
For factor c, refer to table below from Conveyor Belt Technique Handbook:

Since, v = 1 m/s, by interpolation

c = 0.705
f = 0.020 × 0.705
f = 0.0141
Mass of rotary carrying and return idlers m’R
′
m′o m′u
mR = +
Io Iu
Where: Io = idler spacing at carrying side
Iu = idler spacing at return side
m′o = mass of one set of carrying idler roller
m′u = mass of one set of return idler roller
Since idler spacing is not yet given, assume the values of spacing based on the
recommended values. For normal installation,
Io = 1.2 m
Iu = 2Io =2(1.2m)
Iu = 2.4 m
For m’O and m’U, refer to table below from Design of Conveyor Belt Technique
Handbook:
 For 3 roll, troughing type :
m’O = 3.2 kg m’U = 2.2 kg
3.2 kg 2.2 kg
m′R = +
1.2 m 2.4 m
m′R =3.583333333 kg/m
For mass of belt
𝑘𝑔
m′G = 3.85
𝑚
For mass of load
m′L = 23.52858597 kg/m
Angle of Inclination, 𝛿=20˚
Conveying Height, H
H = (sinδ) × 3
H = (sin20°) × 3
H = 1.02606043 m
Assume Fs to be negligible.
Fμ =c∙f∙L∙g∙[m′ R + 2(m′ G + m′ L )(cosδ)]+H∙g(m' L )
𝑚 kg kg
𝐹𝑢 = 8.3(0.0141)(3.5 𝑚) (9.81 𝑠2 ) [3.583333333 m + 2 (3.85 m + 23.52858597 kg/
m kg
m) (sin 20)] + 1.02606043 m(9.81 s2 )(23.52858597 m )
Fu = 326.4827604 𝑁
Using Fu, Solve for torque,
320 mm
T=326.4827604 N ( )
2
T=52237.24166 N ∙ mm
DTR
T=(T1 -T2 )
2
2𝑇
(T1 -T2 )=
𝐷𝑇𝑅
 Since,
𝑇1 = 𝑇2 (1.351302978)
Thus
2(52237.2416 N ∙ mm)
(T2 (1.351302978)-T2 )=
320 mm
T2 (0.351302978) =326.4827604 N
T2 = 929.3481145 N
T1 = 929.3481145 N(1.351302978)
T1 = 1255.830875 N
Solving for Idler Spacing:
8 × T × hrel 8(1255.830875 N)(0.01)
Io = =
(m′L + m′G )g kg 𝑘𝑔 9,81𝑚
(23.52858597 m + 3.85 𝑚 )( 2 )
𝑠
𝐈𝐨 = 𝟎. 𝟑𝟕𝟒𝟎𝟓𝟗𝟖𝟕𝟐𝟕 ≈ 𝟑𝟕𝟓 𝐦𝐦
For Return Side
IU = 2𝐼𝑂 = 2(375 𝑚𝑚)
𝐈𝐔 = 𝟕𝟓𝟎 𝐦𝐦
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑙𝑒𝑛𝑔𝑡ℎ 3500𝑚𝑚
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒓𝒐𝒍𝒍𝒆𝒓 = = ≈ 𝟗(𝒄𝒂𝒓𝒓𝒚𝒊𝒏𝒈 𝒔𝒊𝒅𝒆)
𝐼𝑜 375𝑚𝑚
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑙𝑒𝑛𝑔𝑡ℎ 3500𝑚𝑚
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒓𝒐𝒍𝒍𝒆𝒓 = = ≈ 𝟓(𝒄𝒂𝒓𝒓𝒚𝒊𝒏𝒈 𝒔𝒊𝒅𝒆)
𝐼𝑢 750𝑚𝑚
For V trough ,2 roller:
For Carrying Side:
8 × T × hrel
Io =
(m′L + m′G )g
Qm
m′L =
v
Mass of load per meter:
81.78677135 tonne/hr 1 ℎ𝑟 1000𝑘𝑔
m′L = × ×
1 m/s 3600 𝑠 1 𝑡𝑜𝑛𝑛𝑒
′
mL = 22.7185476 kg/m
Mass of belt per meter:
𝑘𝑔
m′G = 3.85
𝑚
For tension:
𝜋
𝑇1 = 𝑇2 𝑒 0.075(230°×180°)
𝑇1 = 𝑇2 (1.351302978)
But, Torque T,
DTR
T=(T1 -T2 )
2
 𝐷𝑇𝑅
T=Fμ ( )
2
For the peripheral force
Fμ =c∙f∙L∙g[∙ (m′ R + 2(m′ G + m′ L )(cosδ) +]H∙g(m' L )
Some parameters is the same of the 3 roll troughing type
Mass of rotary carrying and return idlers m’R
m′o m′u
m′R = +
Io Iu
Since idler spacing is not yet given, assume the values of spacing based on the
recommended values. For normal installation,
Io = 1.2 m
Iu = 2Io =2(1.2m)
Iu = 2.4 m
For m’O and m’U, refer to table below from Design of Conveyor Belt Technique
Handbook:

For 2 roll, V troughing type :

m’O = 2.8 kg m’U = 2.2 kg
2.8 kg 2.2 kg
m′R = +
1.2 m 2.4 m
m′R =3.25 kg/m
Solving for the peripheral force, Fu
𝑚 kg kg
𝐹𝑢 = 8.3(0.0141)(3.5) (9.81 𝑠2 ) [3.25 m + 2 (3.85 m + 22.7185476 kgm)] (sin 20) +
m
1.02606043m(9.81 s2 )(22.7185476 kg/m)
𝐹𝑢 = 314.763293 𝑁
Using Fu, Solve for torque, DTR = 320 mm
320mm
T=314.763293 𝑁 ( )
2
T=50363.12688 N ∙ mm
 DTR
T=(T1 -T2 )
2
2𝑇
(T1 -T2 )=
𝐷𝑇𝑅
Since,
𝑇1 = 𝑇2 (1.351302978)
Thus
2(50363.12688 N ∙ mm)
(T2 (1.351302978)-T2 )=
320 mm
T2 (0.351302978) =314.763293 𝑁
T2 = 895.9881146 N
T1 = 895.9881146 N(1.351302978)
T1 = 1210.751408 N
Solving for Idler Spacing:
8 × T × hrel 8(1210.751408 N)(0.01)
Io = =
(m′L + m′G )g 𝑘𝑔 9,81𝑚
(22.7185476 kg/m + 3.85 𝑚 )( 2 )
𝑠
𝐈𝐨 = 𝟎. 𝟑𝟕𝟏𝟔𝟐𝟕𝟕𝟔𝟎𝟔 ≈ 𝟑𝟕𝟐 𝐦𝐦
For Return Side
IU = 2𝐼𝑂 = 2(372 𝑚𝑚)
𝐈𝐔 = 𝟕𝟒𝟒 𝐦𝐦
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑙𝑒𝑛𝑔𝑡ℎ 3500𝑚𝑚
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒓𝒐𝒍𝒍𝒆𝒓 = = ≈ 𝟗(𝒄𝒂𝒓𝒓𝒚𝒊𝒏𝒈 𝒔𝒊𝒅𝒆)
𝐼𝑜 372𝑚𝑚
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑙𝑒𝑛𝑔𝑡ℎ 3500𝑚𝑚
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒓𝒐𝒍𝒍𝒆𝒓 = = ≈ 𝟓(𝒄𝒂𝒓𝒓𝒚𝒊𝒏𝒈 𝒔𝒊𝒅𝒆)
𝐼𝑢 744𝑚𝑚
For Deep trough, 3 roller:
For Carrying Side:
8 × T × hrel
Io =
(m′L + m′G )g
Qm
m′L =
v
Mass of load per meter:
88.47537838 tonne/hr 1 ℎ𝑟 1000𝑘𝑔
m′L = × ×
1 m/s 3600 𝑠 1 𝑡𝑜𝑛𝑛𝑒
′
mL = 24.57649399 kg/m
Mass of belt per meter:
𝑘𝑔
m′G = 3.85
𝑚
For the Tension:
From the head drum pulley:
T1
=efθ use f = 0.075 and 𝜃 = 230˚
T2
 𝜋
𝑇1 = 𝑇2 𝑒 0.075(230°×180°)
𝑇1 = 𝑇2 (1.351302978)
But, Torque T,
DTR
T=(T1 -T2 )
2
𝐷𝑇𝑅
T=Fμ ( )
2
Diameter of head drum pulley,𝐷𝑇𝑅
DTR = 320𝑚𝑚
For the peripheral force:
Fμ =c∙f∙L∙g∙(m' R +2(m' G +m' L )(cosδ)+H∙g(m' L )
Use the same values of other parameters in the 3 roll type trougher except for m’L.
m kg
Fμ = 8.3(0.0141)(3.5 m) (9.81 2 ) [3.583333333
s m
kg
+ 2 (3.85 + 24.57649399 kg/m)] (sin20)
m
9.81m kg
+ 1.02606043m( 2 )(24.57649399 )
s m
Fμ = 339.1909478 N
For torque:
320 𝑚𝑚
T=339.1909478 N ( )
2
T=54385.75165 𝑁/𝑚𝑚
DTR
T=(T1 -T2 )
2
2𝑇
(T1 -T2 )=
𝐷𝑇𝑅
Since,
𝑇1 = 𝑇2 (1.351302978)
Thus
2(54385.75165 𝑁 𝑚𝑚)
(T2 (1.351302978)-T2 )=
320mm
T2 (0.351302978) =339.1909478 N
T2 = 967.5720645 N
T1 = 967.5720645 N(1.351302978)
T1 = 1307.483012 N
Solving for Idler Spacing:
8 × T × hrel 8(1307.483012 N)(0.01)
Io = =
(m′L + m′G )g 𝑘𝑔 9,81𝑚
(24.57649399 kg/m + 3.85 𝑚 )( 2 )
𝑠
𝐈𝐨 = 𝟎. 𝟑𝟕𝟓𝟎𝟖𝟖𝟒𝟖𝟖𝟒 𝐦 ≈ 𝟑𝟕𝟓 𝐦𝐦
 For Return Side
IU = 2𝐼𝑂 = 2(375 𝑚𝑚)
𝐈𝐔 = 𝟕𝟓𝟎 𝐦𝐦
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑙𝑒𝑛𝑔𝑡ℎ 3500𝑚𝑚
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒓𝒐𝒍𝒍𝒆𝒓 = = ≈ 𝟗(𝒄𝒂𝒓𝒓𝒚𝒊𝒏𝒈 𝒔𝒊𝒅𝒆)
𝐼𝑜 375𝑚𝑚
𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑙𝑒𝑛𝑔𝑡ℎ 3500𝑚𝑚
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒓𝒐𝒍𝒍𝒆𝒓 = = ≈ 𝟓(𝒄𝒂𝒓𝒓𝒚𝒊𝒏𝒈 𝒔𝒊𝒅𝒆)
𝐼𝑢 750𝑚𝑚
Head Drum and Tail Drum Pulley Size
Drive Dum Pulley Diameter, DTR:
From the previous calculation,
DDP = 315𝑚𝑚
Tail Drum Pulley Diameter:
Using the largest diameter DTR, the tail drum diameter can be determine using the table
below:

From section B which is the tail pulleys the equivalent diameter of 315 mm is 250mm.
DTP = 250 mm
Using catalog, the tail pulley diameter for standard sizes was 220 mm.
Return Pulley(F220 - F320)
 Source: Source: Pulleys For Belt Conveyors Bulk Handling General Catalog (Rulmeca)

Shaft Size

16
D3 = √(K s T)2 + (K m M)2
πSsmax

Consider the maximum torque:

T=54385.75165 𝑁/𝑚𝑚
Maximum Force:
Fμ = 339.1909478 N
Weight of drive drum Pulley from previous catalog: mass = 88 kg
𝑚
𝑊 = 𝑚𝑔 = 88𝑘𝑔 (9.81 𝑠 )
W = 863.28 N
For the other forces:
𝑅𝐴 (720 𝑚𝑚) = 𝐹𝑢 (60𝑚𝑚) + 𝐹𝑢 (660𝑚𝑚) + 𝑊𝑝𝑢𝑙𝑙𝑒𝑦 (360𝑚𝑚)
𝑅𝐴 (720 𝑚𝑚) = 339.1909478 N(60) + 339.1909478 N(660) + 863.28 N(360𝑚𝑚)
𝑅𝐴 = 770.8309478 𝑁
𝑅𝐵 (720 𝑚𝑚) = 𝐹𝑢 (60𝑚𝑚) + 𝐹𝑢 (660𝑚𝑚) + 𝑊𝑝𝑢𝑙𝑙𝑒𝑦 (360𝑚𝑚)
𝑅𝐵 (720 𝑚𝑚) = 339.1909478 N(60) + 339.1909478 N(660) + 863.28 N(360𝑚𝑚)
𝑅𝐵 = 770.8309478 𝑁
For maximum Bending Moment:
MA = 0
MB = 0
M1 = R A (60mm) = 770.8309478 N(60 mm)
M1 = 46249.85687 N ∙ mm
M3 = R B (60mm) = 770.8309478 N(60mm)
M3 = 46249.85687 N ∙ mm
M2 = R A (350mm) − Fu (300mm)
M2 = 770.8309478 N(360mm) − 339.1909478 N(300mm)
M2 = 175741.8569 N ∙ mm
MMAX = 175741.8569 N ∙ mm
Material Specification:
AISI C1045, as rolled
From Table AT7
𝑺𝒚 = 𝟓𝟗𝒌𝒔𝒊
From Table 1.1
Based on yield strength:
N= 4 (repeated reversed)
Sys
Ssmax =
N
101.325kPa
Sys = 0.6Sy = 0.6 (59000psi × ) = 244007.1429kPa
14.7psi
N 1 m2
Sys = 244007142.9Pa = 244007142.9 2 ×
m (1000 mm)2
N
Sys = 244.0071429
mm2
N
244.0071429
Ssmax = mm2
4
N
Ssmax = 61.00178571
mm2
Allowance for keyway: Consider strength reduction factor 0.75
From table 9.1
Suddenly applied minor shocks
 𝑲𝒎 =1.75
𝑲𝒔 =1.25
Allowance for keyway:
16
D3 = √(K s T)2 + (K m M)2
πSsmax (0.75)
D3
16
= √(1.25(54385.75165))2 + (1.75(175741.8569 N ∙ mm))2
N
π(61.00178571 )(0.75)
mm2
𝐷 = 32.73001366mm
For standard sizes: To consider the safety of shaft larger diameter was selected:
From the catalog below, the suggested size of shaft is 34 mm.
Thus,
D = 34 mm

Source: Industrial Tube Steel Corporation

Power Requirement, PT
PT = 2𝜋𝑇𝑁
Where : 𝑣 = 𝜋𝐷𝑁
DFμ
T=
2
DFμ 𝑣
PT = 2𝜋 ( )( )
2 𝜋𝐷
 PT = Fμ × 𝑣
For 3 Roller Troughing Type
Fu = 326.4827604 𝑁
1𝑚
PT = 326.4827604 𝑁 ×
𝑠
PT = 326.4827604 𝑊
𝐏𝐓 = 𝟎. 𝟑𝟐𝟔𝟒𝟖𝟐𝟕𝟔𝟎𝟒 𝐤𝑾
T=52237.24166 N ∙ mm
𝑣 1 𝑚/𝑠
𝑁= =
𝜋𝐷 0.320𝑚(𝜋)
𝑁 = 59.68310366 𝑟𝑝𝑚
For V trough, 2 roller
𝐹𝑢 = 314.763293 𝑁
1𝑚
PT = 314.763293 𝑁 ×
𝑠
PT = 314.763293 𝑊
𝐏𝐓 = 𝟎. 𝟑𝟏𝟒𝟕𝟔𝟑𝟐𝟗𝟑 𝒌𝑾
T=50363.12688 N ∙ mm
𝑣 1 𝑚/𝑠
𝑁= =
𝜋𝐷 0.320𝑚(𝜋)
𝑁 = 59.68310366 𝑟𝑝𝑚
For Deep Trough
Fμ = 339.1909478 N
1𝑚
PT = 339.19094783 N ×
𝑠
PT = 339.1909478 𝑊
𝐏𝐓 = 𝟎. 𝟑𝟑𝟗𝟏𝟗𝟎𝟗𝟒𝟕𝟖 𝐤𝑾
T=54385.75165 𝑁/𝑚𝑚
𝑣 1 𝑚/𝑠
𝑁= =
𝜋𝐷 0.320𝑚(𝜋)
𝑁 = 59.68310366 𝑟𝑝𝑚
Breaking Strength of the Conveyor belt, k:
CR PT
k= ×
CV v
For Friction value factor CR, using the table below
Considering the drive pulley surface bare, dry, lagged wet, use CR = 34
For the breaking strength loss at joint factor Cv, using table below;

For Dunloflex, 2 ply overlap, Cv =1

For standard trough, 3 roller
PT = 0.3264827604 k𝑊

CR PT 37(0.3264827604 )
k= × =
CV v 1(1)
𝐤 = 𝟏𝟐. 𝟎𝟕𝟗𝟖𝟔𝟐𝟏𝟑 𝑵/mm
For V trough, 2 roller
PT = 0.314763293 𝑘𝑊
CR PT 37(0.314763293 )
k= × =
CV v 1(1)
𝐤 = 𝟏𝟏. 𝟔𝟒𝟐𝟒𝟏𝟖𝟒 𝑵/𝒎𝒎
For Deep trough, 3 roller
PT = 0.3391909478 k𝑊
CR PT 37(0.3391909478 )
k= × =
CV v 1(1)
 𝐤 = 𝟏𝟐. 𝟓𝟓𝟎𝟎𝟔𝟓𝟎𝟕 𝑵/𝒎𝒎
Drive Motor At Pulley: PM
PT
PM = 𝑤ℎ𝑒𝑟𝑒 𝑛 = 0.96 𝑓𝑜𝑟 𝑝𝑢𝑙𝑙𝑒𝑦 𝑚𝑜𝑡𝑜𝑟
𝑛
For 3 Roller Troughing Type
0.3264827604 k𝑊 1 ℎ𝑝
PM = ×
0.96 0.746 𝑘𝑊
𝐏𝐌 = 𝟎. 𝟒𝟓𝟓𝟖𝟕𝟗𝟔𝟑𝟔𝟒 𝐡𝐩
For V trough, 2 roller
0.314763293 𝑘𝑊 1 ℎ𝑝
PM = ×
0.96 0.746 𝑘𝑊
𝐏𝐌 = 𝟎. 𝟒𝟑𝟗𝟓𝟏𝟓𝟑𝟐𝟐 𝐡𝐩
For Deep Trough
0.3391909478 𝑘𝑊 1 ℎ𝑝
PM = ×
0.96 0.746 𝑘𝑊
𝐏𝐌 = 𝟎. 𝟒𝟕𝟑𝟔𝟐𝟒𝟓𝟑𝟔𝟏 𝐡𝐩

Use 1 hp motor.

Belt and pulley Calculation

Power Requirement, PT
Standard Trough

PT = 0.3264827604 k𝑊

T=52237.24166 N ∙ mm

𝑁 = 59.68310366 𝑟𝑝𝑚
For V trough, 2 roller

PT = 0.314763293 𝑘𝑊
T=50363.12688 N ∙ mm

𝑁 = 59.68310366 𝑟𝑝𝑚
For Deep Trough

PT = 0.3391909478 k𝑊

T=54385.75165 𝑁/𝑚𝑚

𝑁 = 59.68310366 𝑟𝑝𝑚
Motor Specification

P=1 hp

N1 =180 rpm

N2 =59.68310366 rpm

C= D2

Service Factor=1.2

Design Hp=(Nsf )(Transmitted Hp) ; Nsf =1.2 (From Table 17.7, Service Fac𝑡𝑜𝑟𝑠)

Nsf =1.2-0.2, since it operates below 16 hr/day

Design Hp=(1)(1 hp)

Design Hp=1 hp
𝟐𝟏 𝟏𝟑
Section B; 𝒃 = 𝟑𝟐 𝒊𝒏 and 𝒕 = 𝟑𝟐 𝒊𝒏

𝑫 = 𝟓. 𝟒 𝒊𝒏
For D2,

N1 D1 =N2 D2
N1 D1
D2 =
N2
(180 rpm)(5.4 in)
D2 =
59.68310366 rpm

D2 = 16.28601632

D2 = 16 in
Belt Speed,
1 ft
Vm =π (5.4 in x ) (180 rpm)
12 in
ft
Vm =81π or 254.4690049
min
For Center Distance,

C= D2

C= 16 in
For Length,

π (D2 -D1 )2
L= (D1 +D2 )+ 2C+
2 4C
π (16-5.4)2 in2
L= (5.4 +16) in+ 2(16 in)+
2 4(16 in)

L= 67.37066639 in

L= 67 in
Use B68 V-belt ; L= 69.8
For rated hp per belt,
D2 16 in
=
D1 5.4 in
D2
= 2.962962963
D1
Based on Table 17.4, Kd =1.14, (2,949 and over)

rated hp 103 0.09 C Vm Vm

= [a ( ) - -e 6 ]
belt Vm Kd D1 10 103

Belt constants (From Table 17.3)

a=4.737

c=13.962

e=0.0234

103 0.09 103

a( ) =4.737 ( )0.09 =5.357920243
Vm ft
81π min

C 13.962
= =2.268031189
Kd D1 (1.14)(5.4 in)
ft
Vm 81π min
e 6 =0.0234 ( ) =5.954574716 x 10-6
10 106

rated hp 81π
=[5.307354175-2.268031189-5.954574716 x 10-6 ] ( 3 )
belt 10
rated hp
=0.7862794776 hp
belt
For adjusted hp,

adjusted hp= K∅ KL (rated hp)

D2 - D1 16 in-5.4 in
= =0.5888888889
C 18 in

D2 - D1 K∅ , VV
c
0.5 0.93
0.5888888889 x
0.6 0.91
x=0.9122222222
Based on Table 17.5

K∅ =0.9122222222

Based on Table 17.6

KL =0.97

adjusted rated hp= K∅ KL (rated hp)

adjusted rated hp=(0.9122222222)(0.97)(0.7862794776 hp)

adjusted rated hp=0.695743764 hp

For no. of belts,
design hp
no.of belts=
adjusted rated hp
1 hp
no.of belts=
0.695743764 hp

no.of belts= 1.437310763 belts

no.of belts= 2 belts

Other Components
Bearings
A pillow block bearing or plummer block bearing was used to support the rotating drive
drum of the conveyor belt. This bearing is commonly used in conveyor belt applications. The
sizes of bearing was depend on the shaft diameter of pulley. Using the catalog below:

The selected pillowblock was SN508 for the supporting mechanism for roating
mechanism.
Supporting members
Idler Roller Support
For the idler roller support, the material used was carbon steel Q235. Density of
this steel is 7.85 g/cm3, tensile strength is 370-500 MPa; yield strength is 235 MPa. This
material was used to support the load on its roller.
Q235 Carbon Steel Angle bar

Source:LiaoCheng Huajian Steel Co. LTD

Frame
A channel bar was used for the structural support of the main components of the
conveyor belt. A36 hot rolled steel bar channels was used. Its common application is for
structural support. It has an ultimate tensile strength ranging 400-500 Mpa and high yield
strength of 250 MPa. This material will be able to withstand the load of the conveyor belt.

Source: Montanstahl Special Profile in Steel