m-4 Report

Client Name EUROCHEM Designer H.A.K.
Project Name 22156 Company Birikim Mühendislik End.

Conveyor Name M-4 Filename M-4
Location KOVDORSKIY GOK Date Mart 1, 2023
Description:
System Information
Calculation method DIN / ISO Idler Set Data
Conveyor Length / Height 1192 / -66,0 m Carry Return
Material lift -65,9 m Series name Series 50 Series 30
Ambient temperature range -40 to 35 °C Bearing 6310 6206
Kt factor at minimum temperature 3,01 Number of rolls 3 2
Trough angle (deg) 45 10
Material Properties Type Inline Inline
Type rock Idler spacing (m) 1,50 3,00
Design Tonnage 9000 t/h Number of ıdler sets 794 395
Density 2070 kg/m3 Roll diameter 194 159
Maximum lump size 300 mm Roll rpm 512 625
Surcharge angle 22 deg Total drag (N) --- ---
Roll length 750 1150
Shaft diameter (mm) 50,0 30,0
Belt Properties
Dynamic capacity (kN) 65,0 20,3
Type Steel cord L10 life1 (1000 hrs) 350,0 / 52,0 166,3
Width 1600 mm Shaft deflection (min) 0,62 / 3,18 5,03
Rating 1800 N/mm 1
L10 life above which 95% of idlers exceed
Speed 5,20 m/s
Top / bottom cover thickness 10,0 x 4,0 mm Drive Station
Total thickness 19 mm
Weight (new / worn) 48,7 / 36,8 kg/m Type Variable speed
Modulus 129.600 kN/m Synchronous RPM 1500 RPM
Tape length 2.402 m Motor quantity / rating 2 / 315 kW
Belt cycle time 7,7 min Total ınstalled power 630 kW
Nominal empty / full power (69 / -39%) 436 / -245 kW
Tension Summary Running Momentary Min / max demand power (-85 / 89%) -533 / 562 kW
Maximum tension (kN) 369 502 Frame Size IEC 355L
Minimum safety factor 7,81 5,74 Motor Voltage 400 V
Minimum tension (kN) 182 67,8 Efficiency 94,5 to 97,5%
Maximum belt sag (%) 0,52 1,44 Maximum starting torque 96%
Inertia - Motor 7,0 kg·m²
Cross Sectional Loading Brake quantity / ınertia (1 / 1) 3,64 / 3,64 kg·m2
Material mass (wm) 480,8 kg/m Pulley lagging type Ceramic
Combined mass (wm + wb) 529,4 kg/m Motor wrap angles 181 / 183
Edge distance (required / actual) 105 / 187 mm Lagging friction factor (run / accel) 0,36 / 0,45
Cross sectional area 0,232 m²
Cross sectional loading (utility / total) 73 % / 53 % Take-up Data
Bed depth 277 mm
Type Automatic winch control
Location Tail / Pulley #3
Steady state tension 293 to 293 kN
Momentary tension 206 to 295 kN
Cable reeving ratio (trolley:winch) 1:1
Counterweight mass 59,8 tonnes
Required pulley displacement 5,19 m

Dynamic displacement (incl thermal) 1,23 m
Permanent elongation 1,20 m
Splice length (2 included) 1,76 m
Flooded belt tonnage 16.842 t/h Clearance 1,00 m
Flooded (wm + wb) 948,3 kg/m
Sidewinder - v7.22 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 1 / 47
Description:
1
This is the nominal expected brake torque. The supplied brake
Backstops must operate within the minimum and maximum brake torques.
The brake disk size must also be checked for thermal and other
Backstop type None installed design requirements by the supplier.
Brakes Reducer Information

Name Brake pulley 1 Manufacture N/A
Type High speed - Constant Torque Frame size N/A
Location Head / Pulley #1 Reducer ratio 12,380
Number of Disks 1 Catalog reducer ratio 0,000
Torque rating at high speed shaft1 6.250 N·m RPM (High Speed) 1500 RPM
Torque rating at low speed shaft 77.375 N·m RPM (Low Speed) 121,2 RPM
Reducer Ratio 12,380:1 Configuration Shaft Mount
Pulley diameter 800 mm Number of stages 3
Brake model N/S Service factor 1,4
Number of calipers 1 Power rating 0
Clamping force 29.481 N
Brake disk size 630 x 30 mm Motor Torque
Brake Torque Design Range 100% Motor Torque - High Speed 2.036 N·m
Min Clamping force (at 2,5 mm pad wear) 22.111 N Motor Shaft Torque - Running (FN) -791 N·m
Maximum clamping force 35.377 N Motor Shaft Torque - Starting (FN) -282 N·m
Disk to Pad COF (min/max) 0.35 / 0.45 100% Motor Torque - Low Speed 25.204 N·m
Minimum brake torque 4.102 N·m Low Speed Shaft Torque - Running (FN) -10.366 N·m
Maximum brake torque 8.438 N·m Low Speed Shaft Torque - Running (Max) 21.188 N·m
Low Speed Shaft Torque - Starting (FN) -4.323 N·m
1
This is the nominal expected brake torque. The supplied brake Low Speed Shaft Torque - Starting (Max) 22.676 N·m
must operate within the minimum and maximum brake torques.
The brake disk size must also be checked for thermal and other Starting and Stopping
design requirements by the supplier. Start control Fixed time
Start time 135,0 s
Name Brake pulley 2 Emergency stop control Brake
Type High speed - Constant Torque Emergency stop time 2,1 to 14,7 s
Location Tail / Pulley #6 Material buildup in chute 8,9 m³
Number of Disks 1
Torque rating at high speed shaft1 6.250 N·m
Torque rating at low speed shaft 77.375 N·m
Tension Ratios (Motor Station 1/2)
Reducer Ratio 12,380:1 Allowable (running) 3,12 / 3,15
Pulley diameter 800 mm Running tension ratio 1,27 / 1,18
Brake model N/S Allowable (dynamic) 4,15 / 4,19
Number of calipers 1 Starting tension ratio 1,21 / 1,20
Clamping force 29.481 N Allowable (brake) 4,15 / 4,19
Brake disk size 630 x 30 mm Emergency stop tension ratio 3,71 / 1,82
Brake Torque Design Range Transition Lengths

Min Clamping force (at 2,5 mm pad wear) 22.111 N Transition method CEMA 7
Maximum clamping force 35.377 N Tail transition length (inline) 10,30 m
Disk to Pad COF (min/max) 0.35 / 0.45 Head transition length (inline) 10,30 m
Minimum brake torque 4.102 N·m
Maximum brake torque 8.438 N·m Estimated Splice Data
Splice type 2-Step
Splice step length 405 mm
Transition length (each side) 150 mm
Page 2 / 47
Description:
22 degree bias angle 650 mm Din Factor and Total Equivalent Mass
Total splice length 1760 mm Belt line
Cable diameter 5,3 mm Case Din factor
mass (kg)
Number of cables 108 Empty - NF 0,0300 200.570
Cable pitch / cable gap in splice 14,25 / 4,17 mm Full - NF 0,0300 773.682
Empty - LF 0,0255 172.129
Empty - HF 0,0345 205.182
Take-Up Cable Full - LF 0,0255 745.241
Counterweight mass 59,8 tonnes Full - HF 0,0345 778.294
Take-up cable tension 586,0 kN Maximum Belt Tensions (kN)
Cable diameter 60,0 mm Case Running Dynamic
Cable breaking strength (1800 MPa) 2427,0 kN Empty - NF 298 386
Safety factor 4,1 Full - NF 353 494
Number of clips (crosby clamps) 0 Empty - LF 296 382
Turnback / free end length 0 / 0 mm Empty - HF 299 391
Sheave Root Diam 1050 mm Full - LF 369 486
Full - HF 339 502
Belt Safety Factor

Other Information Case Running Dynamic
Loaded beltline mass (excluding motors) 761.269 kg Empty - NF 9,68 7,45
Total inertia (ref HS shaft) 860 kg·m2 Full - NF 8,16 5,83
Empty - LF 9,75 7,54
Demand Power (kW) Empty - HF 9,62 7,36
Demand % Motor Full - LF 7,81 5,93
Case
power Nameplate Full - HF 8,48 5,74
Empty - NF 436 69,2
Full - NF -245 -38,9 Minimum Belt Tensions (kN)
Empty - LF 276 43,8 Case Running Dynamic
Empty - HF 562 89,3 Empty - NF 239 158
Full - LF -533 -84,6 Full - NF 188 72,0
Full - HF 14 2,2 Empty - LF 254 167
Empty - HF 232 155
Full - LF 182 81,4
Full - HF 201 67,8
Maximum Belt Sag (%)

Case Running Dynamic
Empty - NF 0,08 0,08
Full - NF 0,52 1,35
Empty - LF 0,05 0,06
Empty - HF 0,08 0,09
Full - LF 0,52 1,17
Full - HF 0,49 1,44

Page 3 / 47
Description:
Conveyor Profile
Overall length = 1192 m - Overall height = -66,0 m - True Length = 1194,1 m
Tail Arrangement Head Arrangement
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 - Brk 1 1-MT 181 277 254 531 279 329 607
Pulley 2 4-MT 180 292293 585 292295 587
Take-up Pulley 4-MT 180 293296 589 295298 592
Pulley 4 2-LT 52 296297 258 298299 260
Pulley 5 2-LT 54 298299 272 300301 273
Mtr 2 - Brk 2 3-MT 183 299 349 644 301 476 777
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 / 47
Description:
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Safety Slope at Deflection T1 T2
Pulley # 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 2,93 4,46 0,047 141 347 317 2921 665 183 12,1 133,0
2 2,09 4,87 0,048 110 365 366 2023 733 355 0,3 110,0
3 2,08 4,88 0,048 109 366 370 2023 735 178 1,2 110,3
4 3,29 3,81 0,038 268 370 372 1568 309 60 0,5 46,4
5 2,88 4,34 0,043 172 373 374 1568 353 243 0,5 53,0
6 2,60 4,07 0,040 146 369 436 2837 807 356 27,9 121,1
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,10 on high tension
pulleys, and a multiplier of 1,25 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)
1 Ceramic 800 12,0 824 1800 300 260 2400 3156 23156 3.904
Rubber
2 630 12,0 654 1800 240 180 2200 3140 23140 1.928
Plain
3 Ceramic 800 12,0 824 1800 300 260 2200 3256 23256 3.821
Rubber
4 630 12,0 654 1800 280 220 2200 3248 23248 2.644
Plain
Pulley Shaft Information

Overhun
Hub Bearing
Tensile Yield Fatigue Hub Fillet Overhun g
Locking Shaft Center to Fillet
Type Strength Strength Strength Diameter Radius g Load Moment
Device Material Distance Distance
(MPa) (MPa) (MPa) (mm) (mm) (kN) Arm
(mm) (mm)
(mm)
1 B-LOC 115 SAE 4140 655,0 417,0 327,5 300 1600 165 60 0,0 0
2 B-LOC 106 SAE 4140 655,0 417,0 327,5 240 1600 145 90 0,0 0
3 B-LOC 115 SAE 4140 655,0 417,0 327,5 300 1600 180 60 0,0 0
4 B-LOC 106 SAE 4140 655,0 417,0 327,5 280 1600 165 90 0,0 0

Page 5 / 47
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 = -65,9 m)

Page 6 / 47
Description:
Take-up Displacement Summary

1. Type Automatic Winch Control
2. Location Tail / Pulley #3
3. Belt line tension 293 kN
4. Momentary tension 206 to 295 kN
5. Take-up pulley displacement range
a. Running -1,16 to 0,06 m
b. Momentary -1,16 to 0,07 m
Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) 1,23 m
2. Permanent elongation 1,20 m
3. Splice length (2 included) 1,76 m
4. Clearance 1,00 m
5. Required displacement 5,19 m
Counterweight Displacement Summary (1:1 Cable Reeving Ratio)

1. Dynamic displacement 1,23 m
2. Permanent elongation 1,20 m
3. Splice length (2 included) 1,76 m
4. Clearance 1,00 m
5. Required displacement 5,19 m

Page 7 / 47
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 1,10 on high tension pulleys, and a multiplier of 1,25
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 - Brake 1 1-MT 181 347 317 665 330 362 693
Pulley 2 4-MT 180 365366 733 354357 712
Take-up Pulley 4-MT 180 366370 735 357360 716
Pulley 4 2-LT 52 370372 309 360361 300
Pulley 5 2-LT 54 373374 353 362363 343
Motor 2 - Brake 2 3-MT 183 369 436 807 363 572 936
Required Pulley Diameter (Tension based on a safety factor of 6,67)

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Motor 1 - Brake 1 Head (11) 1 - MT 181 800 630 64 76
Pulley 2 Tail (22) 4 - MT 180 630 630 68 68
Take-up Pulley Tail (24) 4 - MT 180 630 630 69 69
Pulley 4 Tail (26) 2 - LT 52 630 500 69 69
Pulley 5 Tail (28) 2 - LT 54 630 500 69 70
Motor 2 - Brake 2 Tail (30) 3 - MT 183 800 630 81 110
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 2,93 4,46 50,2 2,3 43,8 3,5 50,3 44,2 0,0
2 4 2,09 4,87 51,0 0,1 74,6 0,2 51,0 74,6 0,0
3 4 2,08 4,88 51,2 0,3 74,8 0,6 51,2 74,8 0,0
4 2 3,29 3,81 34,2 0,2 49,2 0,4 34,2 49,2 0,0
5 2 2,88 4,34 39,0 0,2 56,2 0,4 39,0 56,2 0,0
6 3 2,60 4,07 45,7 5,3 58,0 8,1 46,6 59,6 0,0

Page 8 / 47
Description:
Running Drive Tensions by Load Case (kN)

Motor 1 - Brake 1 Motor 2 - Brake 2
Load Case Resultant Resultant
T1 T2 T1 T2
Force Force
Empty - NF 274 239 513 298 261 559
Full - NF 210 239 448 298 326 623
Empty - LF 277 254 531 296 272 567
Empty - HF 277 232 509 299 253 553
Full - LF 200 254 454 296 349 644
Full - HF 225 232 458 299 305 604

Page 9 / 47
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 - Brk 1 274 239 276 237 158 325 158 325
Pulley 2 291 293 292 294 212 211 212 211
Take-up Pulley 293 295 294 296 211 210 211 210
EM-N Empty - NF
Pulley 4 295 296 296 297 210 209 210 209
Pulley 5 297 297 298 299 210 209 210 209
Mtr 2 - Brk 2 298 261 299 259 208 375 208 375
Mtr 1 - Brk 1 210 239 223 237 74,5 262 74,5 262
Pulley 2 291 293 292 294 284 286 284 286
Take-up Pulley 293 295 294 296 285 287 285 287
FL-N Full - NF
Pulley 4 295 296 296 297 287 287 287 287
Pulley 5 297 297 298 299 288 289 288 289
Mtr 2 - Brk 2 298 326 299 313 289 475 289 475
Mtr 1 - Brk 1 277 254 278 252 167 329 167 329
Pulley 2 292 293 292 293 222 220 222 220
Take-up Pulley 293 294 293 294 220 218 220 218
EM-L Empty - LF
Pulley 4 294 294 294 295 218 216 218 216
Pulley 5 295 295 295 296 217 215 217 215
Mtr 2 - Brk 2 296 272 296 269 215 377 215 377
Mtr 1 - Brk 1 277 232 279 231 155 324 155 324
Pulley 2 290 293 292 295 206 207 206 207
Take-up Pulley 293 296 295 298 206 207 206 207
EM-H Empty - HF
Pulley 4 296 297 298 299 206 206 206 206
Pulley 5 298 299 300 301 206 206 206 206
Mtr 2 - Brk 2 299 253 301 252 205 373 205 373
Mtr 1 - Brk 1 200 254 212 252 84,2 269 84,2 269
Pulley 2 292 293 292 293 287 287 287 287
Take-up Pulley 293 294 293 294 287 288 287 288
FL-L Full - LF
Pulley 4 294 294 294 295 288 288 288 288
Pulley 5 295 295 295 296 288 288 288 288
Mtr 2 - Brk 2 296 349 296 335 288 473 288 473
Mtr 1 - Brk 1 225 232 238 231 69,8 259 69,8 259
Pulley 2 290 293 291 294 281 284 281 284
Take-up Pulley 293 296 294 297 283 286 283 286
FL-H Full - HF
Pulley 4 296 297 298 299 286 287 286 287
Pulley 5 298 299 299 301 287 288 287 288
Mtr 2 - Brk 2 299 305 301 292 288 476 288 476

Page 10 / 47
Description:
#1 - Motor 1 - Brake 1 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 210 kN
1. Name (Type-1) Motor 1 - Brake 1 29. Running T2 Tension 239 kN
2. Pulley Diameter 800 mm 30. Design T1 Tension 347 kN
3. Face Width 1800 mm 31. Design T2 Tension 317 kN
32. Wrap angle 181 deg
33. Design Resultant Tension 665 kN
Lagging
34. Resultant Angle 183 deg
4. Lagging Type Ceramic
35. Resultant Moment 133 kN·m
5. Lagging Thickness 12 mm
36. Resultant Torque 12,1 kN·m
6. Diameter with lagging 824 mm
37. Estimated Pulley & Shaft Mass 2.921 kg
38. Estimated Mass with Bearings 3.904 kg
Shaft Specification
7. Shaft Center Diameter 300 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 4,46 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 5,73 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 1,13 mm
42. Shaft deflection at center (%) 0,047
Locking Device 43. Shaft Safety Factor (CEMA) 2,93
11. Hub Center Distance 1600 mm 44. Shaft Safety Factor (AS1403) 2,83
12. Shaft diameter at hub 300 mm 45. Bending Stress 50,2 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 2,3 MPa
14. Locking Device B-LOC 115 47. Von Mises Stress 50,3 MPa
15. Size 300 x 375 48. Fillet Von Mises Stress 44,2 MPa
16. Hub width 120 mm
17. Hub pressure 154,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 248.087 N·m
49. Shell thickness 30 mm
19. Hub outer diameter 587 mm
50. Sitzwohl reqd shell thickness1 29 mm
51. Sitzwohl shell stress 33,7 MPa
Bearing Specifications 52. Shell stress at 180 wa 33,0 MPa
20. Bearing Center Distance 2400 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 260 mm
22. Bearing to Fillet Distance 165 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 60 mm 53. End disk thickness 42 mm
24. Bearing 23156 54. End disk stress 71,6 MPa
25. SNL Plummer Block 3156
26. Dynamic Capacity 2.650 kN
27. Bearing L10 141.345 hours

Page 11 / 47
Description:

#2 - Pulley 2
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-4) Pulley 2 29. Running T1 Tension 291 kN
2. Pulley Diameter 630 mm 30. Running T2 Tension 293 kN
32. Design T2 Tension 366 kN
Lagging
4. Lagging Type Rubber
5. Lagging Pattern Plain
Shaft Specification
17. Hub width 65 mm

Page 12 / 47
Description:

#3 - Take-up Pulley
1. Name (Type-4) Take-up Pulley 29. Running T1 Tension 293 kN
Lagging
Shaft Specification
17. Hub width 65 mm

Page 13 / 47
Description:

#4 - Pulley 4
Lagging
36. Resultant Moment 46,4 kN·m
Shaft Specification
17. Hub width 55 mm

Page 14 / 47
Description:

#5 - Pulley 5
Lagging
Shaft Specification
17. Hub width 55 mm

Page 15 / 47
Description:

#6 - Motor 2 - Brake 2
Lagging
Shaft Specification 38. Estimated Mass with Bearings 3.821 kg
Locking Device 42. Shaft deflection at center (%) 0,040
11. Hub Center Distance 1600 mm 43. Shaft Safety Factor (CEMA) 2,60
12. Shaft diameter at hub 300 mm 44. Shaft Safety Factor (AS1403) 3,06
13. Turndown radius at hub 0 mm 45. Bending Stress 45,7 MPa
14. Locking Device B-LOC 115 46. Torsional Stress 5,3 MPa
15. Size 300 x 375 47. Von Mises Stress 46,6 MPa
16. Hub width 120 mm 48. Fillet Von Mises Stress 59,6 MPa
Bearing Specifications 51. Sitzwohl shell stress 42,0 MPa
20. Bearing Center Distance 2200 mm 52. Shell stress at 180 wa 40,1 MPa
21. Shaft diameter at bearing 260 mm 1
22. Bearing to Fillet Distance 180 mm
23. Turndown radius at bearing 60 mm End Disk Dimension and Stresses
24. Bearing 23256 53. End disk thickness 42 mm
25. SNL Plummer Block 3256 54. End disk stress 65,2 MPa

Page 16 / 47
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 17 / 47
Description:
Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.
Material Trajectory

Page 18 / 47
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) 10,24 10,24
Elevated pulley transition (L2) 6,88 6,88
Pulley elevation (h) 100,174 100,174

Page 19 / 47
Description:
Material Loading Profiles
Material Properties Material 1 on Idler Set 1

Type rock
Design Tonnage 9000 t/h
Density 2070 kg/m3
Maximum lump size 300 mm
Surcharge angle 22 deg
Material 1 on Idler Set 3
Tonnage 9000 t/h

Belt speed 5,20 m/s
Material mass 480,8 kg/m
Edge distance (required / actual) 105 / 187 mm
Cross sectional loading (utility / total) 73 % / 53 %
Bed depth 277 mm
Tonnage 9000 t/h
Belt speed 5,20 m/s
Material mass 480,8 kg/m
Edge distance (required / actual) 105 / 187 mm
Empty Idler Set 2
Cross sectional loading (utility / total) 73 % / 53 %
Bed depth 277 mm

Page 20 / 47
Description:
Idler Specifications
Idler Specifications
Equal Roll Equal Roll
Type VEE
Trough Trough
Number of rolls 3 2 3
Trough angle (deg) 45 10 45
Roll diameter (mm) 194 159 194
Roll length (mm) 750 1150 750
Shaft diameter (mm) 50,0 30,0 50,0
Bearing series 6310 6206 6310
Maximum roll RPM 512 625 512
Min Life (1000 hrs) 350 / 52 160 262 / 49
95% life1 (1000 hrs) 350 / 52 166 262 / 49
Shaft deflection (min) 0,62 / 3,18 5,03 0,73 / 4,45
Mass per Roll (kg) 19,9 21,3 19,9
Rotating mass for set (kg) 59,8 42,5 59,8
Wk2 for set (kg·mm²) 504.541 245.957 504.541
Idler Spacing and Count Summary

General Carry Return Impact
Idler spacing (m) 1,50 3,00 0,30
Number of ıdler sets 794 395 10
Number of rolls 2.382 790 30
Total drag (N)
Nominal friction 13,9 7,9 13,9
High friction 13,9 7,9 13,9
Low friction 0,0 0,0 0,0
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 2,0 1,50 1 350.000 350.000 0,22 0,47
2 2,0 3,0 0,30 3 262.304 48.639 0,73 4,45
3 5,0 4,0 1,50 1 350.000 51.974 0,62 3,18
4-6 9,0 1.054,7 1,50 1 350.000 51.967 0,62 3,18
7-10 1.061,7 76,8 -920 1,50 1 350.000 58.582 0,55 3,00
11 1.138,4 53,6 1,50 1 350.000 55.696 0,57 3,08
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)
13-14 1.192,0 53,6 3,00 2 180.002 4,85
15-18 1.138,4 76,8 -920 3,00 2 350.000 3,17
19-22 1.061,7 1.056,1 3,00 2 160.275 5,03

Page 21 / 47
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 20.490 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 150% 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 20.490 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
Force Force
(min) factor (mm)
Motor 1 - Brake
1 181 4,65 2,93 1,17 62,8 195 260 330 362 693
1
Pulley 2 4 180 4,73 2,09 1,01 185186 373 354357 712
Take-up Pulley 4 180 4,75 2,08 1,02 185186 371 357360 716
Pulley 4 2 52 3,69 3,29 0,79 186185 148 360361 300
Pulley 5 2 54 4,22 2,88 0,91 186185 182 362363 343
Motor 2 - Brake
3 183 4,72 2,52 1,01 185 195 382 363 572 936
2
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 - Brake
181 181 180 3.904 -258 -448 -692 -40,0 -43,3 -46,1
1
Pulley 2 180 356 356 2.644 371 583 709 -48,8 -62,0 -69,8
Take-up Pulley 180 176 176 2.644 -371 -587 -715 -3,02 10,3 18,3
Pulley 4 52 356 125 1.928 79,4 125 153 121 206 255
Pulley 5 54 305 179 1.928 -78,8 -128 -156 -168 -257 -309
Motor 2 - Brake
183 359 356 3.821 379 623 934 -52,8 -63,0 -79,3
2
The idler stringer loading should be based on the flooded belt surge capacity of 16.842 t/h and 948,3 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
Description:
Element Summary Details
Tension Summary
Power Summary

Page 23 / 47
Description:
Vertical Curve Summary

Summary of Vertical Curve on Carry Strand
Running Tension Momentary Tension
Elements Station (m) Type Radius (m) Req'd Radius Req'd Radius
Reason Reason
(m) (m)
7-11 1.062 - 1.138 concave -920 -763 Lift Off -764 Lift Off
Summary of Vertical Curve on Return Strand

Running Tension Momentary Tension
Elements Station (m) Type Radius (m) Req'd Radius Req'd Radius
Reason Reason
(m) (m)
15-19 1.062 - 1.138 concave -920 -708 Lift Off -894 Lift Off

Page 24 / 47
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 2,0 -0,12 -3,54 1,50 1
2 Loading Point 2,0 -0,12 3,0 -0,19 -3,54 0,30 3
3 Skirtboards Only 5,0 -0,31 4,0 -0,25 -3,54 1,50 1
4 9,0 -0,56 351,6 -21,69 -3,54 1,50 1
5 359,9 -22,25 351,6 -21,69 -3,54 1,50 1
6 710,8 -43,94 351,6 -21,69 -3,54 1,50 1
7 1.061,7 -65,63 19,2 -0,98 -2,94 -920 1,50 1
8 1.080,8 -66,61 19,2 -0,58 -1,74 -920 1,50 1
9 1.100,0 -67,20 19,2 -0,18 -0,55 -920 1,50 1
10 1.119,2 -67,38 19,2 0,22 0,65 -920 1,50 1
11 1.138,4 -67,16 53,6 1,16 1,25 1,50 1
12 Motor 1 - Brake 1 1.192,0 -66,00 0,8 -0,82 ---
13 1.192,0 -66,82 1,0 0,00 -0,10 3,00 2
14 1.191,0 -66,83 52,6 -1,09 -1,19 3,00 2
15 1.138,4 -67,91 19,2 -0,22 -0,65 -920 3,00 2
16 1.119,2 -68,13 19,2 0,18 0,55 -920 3,00 2
17 1.100,0 -67,95 19,2 0,58 1,74 -920 3,00 2
18 1.080,8 -67,36 19,2 0,98 2,94 -920 3,00 2
19 1.061,7 -66,38 351,6 21,69 3,54 3,00 2
20 710,8 -44,69 351,6 21,69 3,54 3,00 2
21 359,9 -23,00 348,0 21,22 3,50 3,00 2
22 12,6 -1,78 5,0 0,31 3,54 3,00 2
23 Pulley 2 7,6 -1,47 0,7 -0,65 ---
24 7,5 -2,12 5,0 -0,31 -3,54
25 Take-up Pulley 12,5 -2,43 0,7 -0,65 ---
26 12,5 -3,08 7,0 0,43 3,54
27 Pulley 4 5,5 -2,65 0,3 0,14 ---
28 5,3 -2,51 1,9 1,53 55,11
29 Pulley 5 4,2 -0,98 0,3 0,14 ---
30 3,9 -0,84 4,1 0,07 1,03
31 Motor 2 - Brake 2 -0,1 -0,77 0,8 0,82 ---

Page 25 / 47
Description:
Min/Max Tension Summary per Element

Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 349 253 0,04 476 252 0,04
2 Loading Point 349 253 0,06 476 252 0,07
3 Skirtboards Only 369 274 0,29 502 272 0,30
4 369 275 0,29 501 273 0,30
5 307 274 0,33 361 273 0,34
6 276 244 0,40 276 221 0,44
7 275 184 0,52 275 81,7 1,20
8 275 182 0,52 275 75,1 1,30
9 275 182 0,52 275 70,6 1,38
10 275 183 0,52 276 68,2 1,43
11 276 187 0,51 277 67,8 1,44
12 Motor 1 - Brake 1 277 200 0,00 279 69,8 0,00
13 254 232 0,08 329 231 0,08
14 254 232 0,08 329 231 0,08
15 254 233 0,08 323 231 0,08
16 254 233 0,08 321 232 0,08
17 255 234 0,08 318 232 0,08
18 255 234 0,08 317 233 0,08
19 256 235 0,08 315 234 0,08
20 268 254 0,07 284 253 0,07
21 280 272 0,07 281 240 0,08
22 292 290 0,06 292 206 0,09
23 Pulley 2 292 290 0,00 292 206 0,00
24 293 293 0,00 295 207 0,00
25 Take-up Pulley 293 293 0,00 295 206 0,00
26 296 294 0,00 298 207 0,00
27 Pulley 4 296 294 0,00 298 206 0,00
28 297 294 0,00 299 206 0,00
29 Pulley 5 298 295 0,00 300 206 0,00
30 299 295 0,00 301 206 0,00
31 Motor 2 - Brake 2 299 296 0,00 301 205 0,00

Page 26 / 47
Description:
Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N)
EM-N FL-N EM-L EM-H FL-L FL-H
Total (Beltline) 71.537 -57.129 46.874 90.671 -107.170 -12.618
Total (Power) 83.774 -47.100 53.034 108.133 -102.466 2.637
Lift Force 0 -310.589 0 0 -310.589 -310.589

Frictional Drag 71.537 253.461 46.874 90.671 203.420 297.971
Motor Pulley/Reducer Drag 12.237 10.029 6.160 17.462 4.704 15.255
Rolling Resistance 51.482 219.798 36.673 60.759 179.742 254.323

Material+Belt Flexure 0 0 0 0 0 0
Idler Bearing Drag 0 0 0 0 0 0
Idler Alignment 0 0 0 0 0 0
Pulleys & Accessories 19.441 19.441 9.719 29.166 9.719 29.166
Loading Point 614 14.221 483 746 13.959 14.483
Mechanical Losses 4.789 2.759 2.412 6.293 1.063 4.300

Motor Pulley Drag Components 7.448 7.269 3.748 11.169 3.640 10.954

Page 27 / 47
Description:
Pulley Summary Table - All Cases

Pulley Geometry Details
Type 1 2 3 4
Lagging Type Ceramic Rubber Ceramic Rubber
Diameter (mm) 800 630 800 630
Lagging Thickness (mm) 12,0 12,0 12,0 12,0
Diameter with Lagging (mm) 824 654 824 654
Face Width (mm) 1800 1800 1800 1800
Shaft Center Diameter (mm) 300 240 300 280
Bearing Diameter (mm) 260 180 260 220
Bearing Center Distance (mm) 2400 2200 2200 2200
Plummer Block 3156 3140 3256 3248
Pulley & Shaft Mass (kg) 2.921 1.568 2.837 2.023
Locking Device B-LOC 115 B-LOC 106 B-LOC 115 B-LOC 106
Hub Center Distance (mm) 1600 1600 1600 1600
Hub Diameter (mm) 300 240 300 280
Bearing to Fillet Distance (mm) 165 145 180 165
Fillet Radius (mm) 60 90 60 90
Shaft Material SAE 4140 SAE 4140 SAE 4140 SAE 4140
Yield Strength (MPa) 417,0 417,0 417,0 417,0
Fatigue Strength (MPa) 327,5 327,5 327,5 327,5

Page 28 / 47
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)
1 261.401 -9 48,7 -59 50
2 261.391 13.876 48,7 -89 201 263 13.500
3 275.267 532 48,7 -118 99 351 200
4 275.800 -1.631 48,7 -10.352 8.721
5 274.169 -1.631 48,7 -10.352 8.721
6 272.538 -1.631 48,7 -10.352 8.721
7 270.907 7 48,7 -470 476
8 270.914 198 48,7 -279 477
9 271.111 389 48,7 -88 477
10 271.501 580 48,7 104 477
11 272.081 1.887 48,7 556 1.331
12 - M 273.968 -35.409 48,7 -393 1.690 2.800
13 238.559 18 48,7 -1 19
14 238.577 433 48,7 -520 953
15 239.010 245 48,7 -104 348
16 239.255 436 48,7 88 348
17 239.691 627 48,7 279 348
18 240.318 818 48,7 470 348
19 241.135 16.717 48,7 10.352 6.365
20 257.853 16.717 48,7 10.352 6.365
21 274.570 16.428 48,7 10.128 6.301
22 290.998 238 48,7 147 91
23 - P 291.236 1.840 48,7 -312 2.151
24 293.076 -76 48,7 -147 71
25 - T 293.000 1.852 48,7 -312 2.163
26 294.852 306 48,7 206 100
27 - P 295.158 762 48,7 67 695
28 295.920 744 48,7 729 15
29 - P 296.664 798 48,7 67 731
30 297.462 93 48,7 35 58
31 - M 297.555 -36.154 48,7 393 1.838 1.120

Page 29 / 47
Description:
Element Tension Breakdown - (FL) Fully Loaded - Normal

1 325.928 -9 48,7 -59 50
2 325.919 26.686 9.000 529,4 -963 625 13.523 13.500
3 352.605 279 9.000 529,4 -1.284 665 698 200
4 352.884 -54.268 9.000 529,4 -112.619 58.351
5 298.615 -54.268 9.000 529,4 -112.619 58.351
6 244.347 -54.268 9.000 529,4 -112.619 58.351
7 190.079 -1.923 9.000 529,4 -5.112 3.188
8 188.155 157 9.000 529,4 -3.034 3.191
9 188.313 2.238 9.000 529,4 -954 3.192
10 190.551 4.319 9.000 529,4 1.127 3.192
11 194.870 14.959 9.000 529,4 6.048 8.911
12 - M 209.829 28.730 48,7 -393 1.406 2.800
13 238.559 18 48,7 -1 19
14 238.577 433 48,7 -520 953
15 239.010 245 48,7 -104 348
16 239.255 436 48,7 88 348
17 239.691 627 48,7 279 348
18 240.318 818 48,7 470 348
19 241.135 16.717 48,7 10.352 6.365
20 257.853 16.717 48,7 10.352 6.365
21 274.570 16.428 48,7 10.128 6.301
22 290.998 238 48,7 147 91
23 - P 291.236 1.840 48,7 -312 2.151
24 293.076 -76 48,7 -147 71
25 - T 293.000 1.852 48,7 -312 2.163
26 294.852 306 48,7 206 100
27 - P 295.158 762 48,7 67 695
28 295.920 744 48,7 729 15
29 - P 296.664 798 48,7 67 731
30 297.462 93 48,7 35 58
31 - M 297.555 28.373 48,7 393 1.943 1.120

Page 30 / 47
Description:
Element Tension Breakdown - (EM) Empty - Low

1 271.961 -8 36,8 -45 36
2 271.953 6.977 36,8 -67 162 132 6.750
3 278.930 434 36,8 -89 73 351 100
4 279.364 -1.459 36,8 -7.833 6.374
5 277.905 -1.459 36,8 -7.833 6.374
6 276.445 -1.459 36,8 -7.833 6.374
7 274.986 -7 36,8 -356 348
8 274.979 137 36,8 -211 348
9 275.116 282 36,8 -66 348
10 275.398 427 36,8 78 348
11 275.825 1.393 36,8 421 973
12 - M 277.218 -23.353 36,8 -298 865 1.400
13 253.865 12 36,8 -1 13
14 253.877 261 36,8 -393 655
15 254.138 161 36,8 -78 239
16 254.299 305 36,8 66 239
17 254.604 450 36,8 211 239
18 255.054 594 36,8 356 239
19 255.649 12.205 36,8 7.833 4.372
20 267.854 12.205 36,8 7.833 4.372
21 280.059 11.991 36,8 7.664 4.327
22 292.049 174 36,8 111 62
23 - P 292.223 842 36,8 -236 1.078
24 293.065 -65 36,8 -111 46
25 - T 293.000 845 36,8 -236 1.081
26 293.845 220 36,8 156 64
27 - P 294.065 397 36,8 50 346
28 294.462 562 36,8 552 10
29 - P 295.023 414 36,8 51 364
30 295.438 64 36,8 26 37
31 - M 295.501 -23.540 36,8 297 923 560

Page 31 / 47
Description:
Element Tension Breakdown - (EM) Empty - High

1 253.333 -3 50,6 -61 58
2 253.330 20.786 50,6 -92 233 395 20.250
3 274.116 645 50,6 -123 117 351 300
4 274.761 -503 50,6 -10.760 10.257
5 274.258 -503 50,6 -10.760 10.257
6 273.755 -503 50,6 -10.760 10.257
7 273.252 72 50,6 -488 560
8 273.324 271 50,6 -290 561
9 273.595 470 50,6 -91 561
10 274.064 668 50,6 108 561
11 274.733 2.143 50,6 578 1.565
12 - M 276.876 -44.603 50,6 -409 2.539 4.200
13 232.273 22 50,6 -1 22
14 232.295 590 50,6 -540 1.130
15 232.885 305 50,6 -108 413
16 233.190 504 50,6 91 413
17 233.694 703 50,6 290 413
18 234.396 901 50,6 488 412
19 235.297 18.309 50,6 10.760 7.548
20 253.606 18.309 50,6 10.760 7.548
21 271.914 17.999 50,6 10.527 7.471
22 289.913 260 50,6 153 107
23 - P 290.173 2.894 50,6 -324 3.218
24 293.068 -68 50,6 -153 85
25 - T 293.000 2.924 50,6 -324 3.248
26 295.924 334 50,6 214 120
27 - P 296.258 1.116 50,6 69 1.047
28 297.374 776 50,6 758 18
29 - P 298.150 1.172 50,6 69 1.103
30 299.322 106 50,6 36 69
31 - M 299.428 -46.095 50,6 408 2.750 1.680

Page 32 / 47
Description:
Element Tension Breakdown - (FL) Fully Loaded - Low

1 349.099 -8 36,8 -45 36
2 349.091 19.593 9.000 517,6 -941 523 13.262 6.750
3 368.684 96 9.000 517,6 -1.255 554 698 100
4 368.780 -61.541 9.000 517,6 -110.101 48.559
5 307.239 -61.541 9.000 517,6 -110.101 48.559
6 245.698 -61.541 9.000 517,6 -110.101 48.559
7 184.156 -2.344 9.000 517,6 -4.997 2.653
8 181.812 -310 9.000 517,6 -2.966 2.656
9 181.502 1.724 9.000 517,6 -932 2.657
10 183.226 3.758 9.000 517,6 1.101 2.657
11 186.984 13.329 9.000 517,6 5.913 7.415
12 - M 200.313 53.552 36,8 -298 694 1.400
13 253.865 12 36,8 -1 13
14 253.877 261 36,8 -393 655
15 254.138 161 36,8 -78 239
16 254.299 305 36,8 66 239
17 254.604 450 36,8 211 239
18 255.054 594 36,8 356 239
19 255.649 12.205 36,8 7.833 4.372
20 267.854 12.205 36,8 7.833 4.372
21 280.059 11.991 36,8 7.664 4.327
22 292.049 174 36,8 111 62
23 - P 292.223 842 36,8 -236 1.078
24 293.065 -65 36,8 -111 46
25 - T 293.000 845 36,8 -236 1.081
26 293.845 220 36,8 156 64
27 - P 294.065 397 36,8 50 346
28 294.462 562 36,8 552 10
29 - P 295.023 414 36,8 51 364
30 295.438 64 36,8 26 37
31 - M 295.501 53.598 36,8 297 986 560

Page 33 / 47
Description:
Element Tension Breakdown - (FL) Fully Loaded - High

1 305.211 -3 50,6 -61 58
2 305.208 33.790 9.000 531,4 -966 721 13.785 20.250
3 338.998 477 9.000 531,4 -1.288 768 698 300
4 339.475 -45.696 9.000 531,4 -113.028 67.331
5 293.779 -45.696 9.000 531,4 -113.028 67.331
6 248.082 -45.696 9.000 531,4 -113.028 67.331
7 202.386 -1.451 9.000 531,4 -5.130 3.679
8 200.935 638 9.000 531,4 -3.045 3.682
9 201.573 2.726 9.000 531,4 -957 3.684
10 204.299 4.814 9.000 531,4 1.131 3.684
11 209.113 16.352 9.000 531,4 6.070 10.282
12 - M 225.466 6.808 50,6 -409 2.198 4.200
13 232.273 22 50,6 -1 22
14 232.295 590 50,6 -540 1.130
15 232.885 305 50,6 -108 413
16 233.190 504 50,6 91 413
17 233.694 703 50,6 290 413
18 234.396 901 50,6 488 412
19 235.297 18.309 50,6 10.760 7.548
20 253.606 18.309 50,6 10.760 7.548
21 271.914 17.999 50,6 10.527 7.471
22 289.913 260 50,6 153 107
23 - P 290.173 2.894 50,6 -324 3.218
24 293.068 -68 50,6 -153 85
25 - T 293.000 2.924 50,6 -324 3.248
26 295.924 334 50,6 214 120
27 - P 296.258 1.116 50,6 69 1.047
28 297.374 776 50,6 758 18
29 - P 298.150 1.172 50,6 69 1.103
30 299.322 106 50,6 36 69
31 - M 299.428 5.784 50,6 408 2.877 1.680

Page 34 / 47
Description:
Equipment Tags and Commodity Codes

Table of major items with description, tags, and commodity codes.
Item Description Equipment Tag Commodity Code
Pulley Pulley 1
Motor Motor 1
Reducer Reducer 1
Brake Brake 1
Pulley Pulley 2
Pulley Pulley 3
Pulley Pulley 4
Pulley Pulley 5
Pulley Pulley 6
Motor Motor 2
Reducer Reducer 2
Brake Brake 2
Idlers Carry
Idlers Return
Idlers 6310
Belt -
Take-up -

Page 35 / 47
Description:
Belt Supplier Data Sheet System Information

Type Steel cord Calculation method DIN / ISO
Width 1600 mm Conveyor Length / Height 1192 / -66,0 m
Rating 1800 N/mm Ambient temperature range -40 to 35 °C
Speed 5,20 m/s Kt factor at minimum temperature 3,01
Top / bottom cover thickness 10,0 x 4,0 mm
Total thickness 19 mm Material Properties
Weight (new / worn) 48,7 / 36,8 kg/m Type rock
Modulus 129.600 kN/m Design Tonnage 9000 t/h
Tape length 2.402 m Density 2070 kg/m3
Belt cycle time 7,7 min Maximum lump size 300 mm
Cross Sectional Loading Surcharge angle 22 deg
Material mass (wm) 480,8 kg/m
Combined mass (wm + wb) 529,4 kg/m Drive Station
Edge distance (required / actual) 105 / 187 mm Type Variable speed
Cross sectional area 0,232 m² Synchronous RPM 1500 RPM
Cross sectional loading (utility / total) 73 % / 53 % Motor quantity / rating 2 / 315 kW
Bed depth 277 mm Total ınstalled power 630 kW
Min / max demand power (-85 / 89%) -533 / 562 kW
Maximum starting torque 96%
Pulley lagging type Ceramic
Motor wrap angles 181 / 183
Idler Set Data

Carry Return
Series name Series 50 Series 30
Bearing 6310 6206
Flooded belt tonnage 16.842 t/h Number of rolls 3 2
Flooded (wm + wb) 948,3 kg/m Trough angle (deg) 45 10
Type Inline Inline
Tension Summary Running Momentary Idler spacing (m) 1,50 3,00
Maximum tension (kN) 369 502
Minimum safety factor 7,81 5,74
Pulley Details
Estimated Splice Data Pulley diameter (Type 1) 800 mm
Pulley diameter (Type 2) 630 mm
Splice type 2-Step Pulley diameter (Type 3) 800 mm
Splice step length 405 mm Pulley diameter (Type 4) 630 mm
Transition length (each side) 150 mm
22 degree bias angle 650 mm
Take-up Data
Total splice length 1760 mm
Cable diameter 5,3 mm Type Automatic winch control
Number of cables 108 Location Tail / Pulley #3
Cable pitch / cable gap in splice 14,25 / 4,17 mm Steady state tension 293 to 293 kN
Transition Lengths Required pulley displacement 5,19 m
Transition method CEMA 7
Tail transition length (inline) 10,30 m
Head transition length (inline) 10,30 m

Page 36 / 47
Description:
System Information
Idler Set Data Calculation method DIN / ISO
Carry Return Conveyor Length / Height 1192 / -66,0 m
Series name Series 50 Series 30 Ambient temperature range -40 to 35 °C
Bearing 6310 6206 Kt factor at minimum temperature 3,01
Number of rolls 3 2
Trough angle (deg) 45 10 Material Properties
Type Inline Inline Type rock
Idler spacing (m) 1,50 3,00 Design Tonnage 9000 t/h
Roll diameter 194 159 Density 2070 kg/m3
Roll rpm 512 625 Maximum lump size 300 mm
Total drag (N) --- --- Surcharge angle 22 deg
Shaft diameter (mm) 50,0 30,0 Cross Sectional Loading
Dynamic capacity (kN) 65,0 20,3 Material mass (wm) 480,8 kg/m
L10 life1 (1000 hrs) 350,0 / 52,0 166,3 Combined mass (wm + wb) 529,4 kg/m
Shaft deflection (min) 0,62 / 3,18 5,03 Edge distance (required / actual) 105 / 187 mm
Number of ıdler sets 794 395 Cross sectional loading (utility / total) 73 % / 53 %
Number of rolls 2.382 790 Bed depth 277 mm
Idler Set Data

Impact Transition
Series name Series 50
Bearing 6310
Number of rolls 3 0
Type Inline
Idler spacing (m) 1,50 3,00
Roll diameter 194 0 Flooded belt tonnage 16.842 t/h
Roll rpm 512 0 Flooded (wm + wb) 948,3 kg/m
Total drag (N) --- --- Belt Supplier Data Sheet
Roll length 750 0
Type Steel cord
Width 1600 mm
Rating 1800 N/mm
L10 life1 (1000 hrs) 262,3 / 48,6 0,0 / 0,0
Speed 5,20 m/s
Shaft deflection (min) 0,73 / 4,45 0,00
Top / bottom cover thickness 10,0 x 4,0 mm
Weight (new / worn) 48,7 / 36,8 kg/m
Number of ıdler sets 10 0
Number of rolls 30 0 Tension Summary Running Momentary
Maximum tension (kN) 369 502
1
L10 life above which 95% of idlers exceed Minimum safety factor 7,81 5,74

Page 37 / 47
Description:
System Information
Calculation method DIN / ISO Idler Set Data
Conveyor Length / Height 1192 / -66,0 m Carry Return
Material lift -65,9 m Series name Series 50 Series 30
Ambient temperature range -40 to 35 °C Bearing 6310 6206
Kt factor at minimum temperature 3,01 Number of rolls 3 2
Material Properties Type Inline Inline
Type rock Idler spacing (m) 1,50 3,00
Design Tonnage 9000 t/h Number of ıdler sets 794 395
Density 2070 kg/m3 Roll diameter 194 159
Maximum lump size 300 mm Roll rpm 512 625
Surcharge angle 22 deg Total drag (N) --- ---
Belt Properties
Type Steel cord L10 life1 (1000 hrs) 350,0 / 52,0 166,3
Width 1600 mm Shaft deflection (min) 0,62 / 3,18 5,03
Rating 1800 N/mm 1
L10 life above which 95% of idlers exceed
Speed 5,20 m/s
Top / bottom cover thickness 10,0 x 4,0 mm Drive Station
Total thickness 19 mm
Weight (new / worn) 48,7 / 36,8 kg/m Type Variable speed
Modulus 129.600 kN/m Synchronous RPM 1500 RPM
Tape length 2.402 m Motor quantity / rating 2 / 315 kW
Belt cycle time 7,7 min Total ınstalled power 630 kW
Tension Summary Running Momentary Min / max demand power (-85 / 89%) -533 / 562 kW
Maximum tension (kN) 369 502 Frame Size IEC 355L
Minimum safety factor 7,81 5,74 Motor Voltage 400 V
Minimum tension (kN) 182 67,8 Efficiency 94,5 to 97,5%
Maximum belt sag (%) 0,52 1,44 Maximum starting torque 96%
Cross Sectional Loading Brake quantity / ınertia (1 / 1) 3,64 / 3,64 kg·m2
Material mass (wm) 480,8 kg/m Pulley lagging type Ceramic
Combined mass (wm + wb) 529,4 kg/m Motor wrap angles 181 / 183
Edge distance (required / actual) 105 / 187 mm Lagging friction factor (run / accel) 0,36 / 0,45
Cross sectional loading (utility / total) 73 % / 53 % Take-up Data
Bed depth 277 mm
Type Automatic winch control
Location Tail / Pulley #3
Steady state tension 293 to 293 kN
Counterweight mass 59,8 tonnes
Required pulley displacement 5,19 m

Dynamic displacement (incl thermal) 1,23 m
Permanent elongation 1,20 m
Splice length (2 included) 1,76 m
Flooded belt tonnage 16.842 t/h Clearance 1,00 m
Flooded (wm + wb) 948,3 kg/m

Page 38 / 47
Description:
Conveyor Profile
Overall length = 1192 m - Overall height = -66,0 m - True Length = 1194,1 m
Tail Arrangement Head Arrangement

Page 39 / 47
Description:
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Mtr 1 - Brk 1 1-MT 181 277 254 531 279 329 607
Pulley 2 4-MT 180 292293 585 292295 587
Take-up Pulley 4-MT 180 293296 589 295298 592
Pulley 4 2-LT 52 296297 258 298299 260
Pulley 5 2-LT 54 298299 272 300301 273
Mtr 2 - Brk 2 3-MT 183 299 349 644 301 476 777
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Safety Slope at Deflection T1 T2
Pulley # 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 2,93 4,46 0,047 141 347 317 2921 665 183 12,1 133,0
2 2,09 4,87 0,048 110 365 366 2023 733 355 0,3 110,0
3 2,08 4,88 0,048 109 366 370 2023 735 178 1,2 110,3
4 3,29 3,81 0,038 268 370 372 1568 309 60 0,5 46,4
5 2,88 4,34 0,043 172 373 374 1568 353 243 0,5 53,0
6 2,60 4,07 0,040 146 369 436 2837 807 356 27,9 121,1
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,10 on high tension
pulleys, and a multiplier of 1,25 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)
1 Ceramic 800 12,0 824 1800 300 260 2400 3156 23156 3.904
Rubber
2 630 12,0 654 1800 240 180 2200 3140 23140 1.928
Plain
3 Ceramic 800 12,0 824 1800 300 260 2200 3256 23256 3.821
Rubber
4 630 12,0 654 1800 280 220 2200 3248 23248 2.644
Plain
Pulley Shaft Information

Overhun
Hub Bearing
Tensile Yield Fatigue Hub Fillet Overhun g
Locking Shaft Center to Fillet
Type Strength Strength Strength Diameter Radius g Load Moment
Device Material Distance Distance
(MPa) (MPa) (MPa) (mm) (mm) (kN) Arm
(mm) (mm)
(mm)
1 B-LOC 115 SAE 4140 655,0 417,0 327,5 300 1600 165 60 0,0 0
2 B-LOC 106 SAE 4140 655,0 417,0 327,5 240 1600 145 90 0,0 0
3 B-LOC 115 SAE 4140 655,0 417,0 327,5 300 1600 180 60 0,0 0
4 B-LOC 106 SAE 4140 655,0 417,0 327,5 280 1600 165 90 0,0 0

Page 40 / 47
Description:

Lagging
Shaft Specification

Page 41 / 47
Description:

#2 - Pulley 2
Lagging
Shaft Specification
17. Hub width 65 mm

Page 42 / 47
Description:

#3 - Take-up Pulley
1. Name (Type-4) Take-up Pulley 29. Running T1 Tension 293 kN
Lagging
Shaft Specification
17. Hub width 65 mm

Page 43 / 47
Description:

#4 - Pulley 4
Lagging
Shaft Specification
17. Hub width 55 mm

Page 44 / 47
Description:

#5 - Pulley 5
Lagging
Shaft Specification
17. Hub width 55 mm

Page 45 / 47
Description:

Lagging
Shaft Specification

Page 46 / 47
Description:
Demand Power (kW)

Drive Station Case
Demand % Motor
Type Variable speed power Nameplate
Synchronous RPM 1500 RPM Empty - NF 436 69,2
Motor quantity / rating 2 / 315 kW Full - NF -245 -38,9
Total ınstalled power 630 kW Empty - LF 276 43,8
Nominal empty / full power (69 / -39%) 436 / -245 kW Empty - HF 562 89,3
Min / max demand power (-85 / 89%) -533 / 562 kW Full - LF -533 -84,6
Frame Size IEC 355L Full - HF 14 2,2
Motor Voltage 400 V
Efficiency 94,5 to 97,5%
Maximum starting torque 96%
Brake quantity / ınertia (1 / 1) 3,64 / 3,64 kg·m2
Pulley lagging type Ceramic
Motor wrap angles 181 / 183
Lagging friction factor (run / accel) 0,36 / 0,45
Reducer Information
Manufacture N/A
Frame size N/A
Reducer ratio 12,380
Catalog reducer ratio 0,000
RPM (High Speed) 1500 RPM
RPM (Low Speed) 121,2 RPM
Configuration Shaft Mount
Number of stages 3
Service factor 1,4
Power rating 0
Motor Torque
100% Motor Torque - High Speed 2.036 N·m
Motor Shaft Torque - Running (FN) -791 N·m
Motor Shaft Torque - Starting (FN) -282 N·m
100% Motor Torque - Low Speed 25.204 N·m
Low Speed Shaft Torque - Running (FN) -10.366 N·m
Low Speed Shaft Torque - Running (Max) 21.188 N·m
Low Speed Shaft Torque - Starting (FN) -4.323 N·m
Low Speed Shaft Torque - Starting (Max) 22.676 N·m
Starting and Stopping

Start control Fixed time
Start time 135,0 s
Emergency stop control Brake
Emergency stop time 2,1 to 14,7 s
Material buildup in chute 8,9 m³

Page 47 / 47

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Client Name EUROCHEM Designer H.A.K.

Project Name 22156 Company Birikim Mühendislik End.

Required pulley displacement 5,19 m

Sidewinder - v7.22 - Conveyor Design Software

Brakes Reducer Information

Brake Torque Design Range Transition Lengths

Belt Safety Factor

Maximum Belt Sag (%)

Sidewinder - v7.22 - Conveyor Design Software

Tail Arrangement Head Arrangement

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

Sidewinder - v7.22 - Conveyor Design Software

Conveyor Load Cases

Fully Loaded (Material Lift = -65,9 m)

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Take-up Displacement Summary

Take-up Pulley Displacement Summary

Counterweight Displacement Summary (1:1 Cable Reeving Ratio)

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Pulley Design Tensions (added safety factors as described above)

Required Pulley Diameter (Tension based on a safety factor of 6,67)

Pulley Shaft Stress Analysis (Individual Pulleys)

Sidewinder - v7.22 - Conveyor Design Software

Running Drive Tensions by Load Case (kN)

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Pulley Tension Summary - All Load Cases and Conditions

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#1 - Motor 1 - Brake 1 Design Tensions and Loads

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28. Bearing L10 109.626 hours

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28. Bearing L10 108.588 hours

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28. Bearing L10 267.603 hours

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28. Bearing L10 172.349 hours

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27. Bearing L10 146.131 hours

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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

Material Properties Material 1 on Idler Set 1

Tonnage 9000 t/h

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Idler Spacing and Count Summary

Idler Life and Shaft Deflection Summary-Carry Side

Idler Life and Shaft Deflection Summary-Return Side

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Bearing Reaction Forces (excluding any overhung loads)

Element Summary Details

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Vertical Curve Summary