Client Name Bülbüloğlu Designer HAK

Project Name 230392 Company Birikim Mühendislik End.

Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

System Information
Calculation method CEMA 6th Idler Set Data
Conveyor Length / Height 17 / 13,0 m Carry Return
Material lift 13,0 m Series name Series 30 Series 25
Ambient temperature -10 °C Bearing 6306 6205
Kt factor at minimum temperature 1,12 Number of rolls 1 2
Trough angle (deg) 0 0
Material Properties Type Inline Inline
Type soda külü Idler spacing (m) 1,00 2,00
Design Tonnage 400 t/h in convex curves 0,35 0,00
Density 950 kg/m3 Number of ıdler sets 22 10
Maximum lump size 1 mm Roll diameter 127 127
Surcharge angle 20 deg Roll rpm 234 234
Total drag (N) 5,0 7,1
Drag range (N) 4,6 - 5,0 8,2 - 8,2
Belt Properties
Roll length 1550 200
Type Fabric (4-Ply) Shaft diameter (mm) 30 25,0
Width 1400 mm Dynamic capacity (kN) 29,6 14,8
Rating 500 N/mm L10 life1 (1000 hrs) 350,0 350,0
Speed 1,56 m/s Shaft deflection (min) 5,26 0,70
Top / bottom cover thickness 5,0 x 2,0 mm 1
L10 life above which 95% of idlers exceed
Total thickness 12 mm
Weight 55,1 kg/m Drive Station
Modulus 5.149 kN/m
Tape length 53,24 m Type Squirrel cage
Belt cycle time 34 s Synchronous RPM 1500 RPM
Motor quantity / rating 1 / 30,0 kW
Tension Summary Running Momentary Total ınstalled power 30,0 kW
Maximum tension (kN) 33,3 38,6 Empty / full power (22 / 72%) 6,5 / 21,6 kW
Minimum safety factor 21,03 18,12 Frame Size IEC 200M
Minimum tension (kN) 14,5 12,7 Motor Voltage 400 V
Maximum belt sag (%) 0,94 0,98 Efficiency 95,5%
Maximum starting torque 150%
Cross Sectional Loading Inertia - Motor 0,3 kg·m²
Material mass (wm) 71,4 kg/m Pulley lagging type Rubber
Combined mass (wm + wb) 126,5 kg/m Motor wrap angles 180
Sidewall width / height 800 x 300 mm Lagging friction factor (run / accel) 0,32 / 0,38
Area (Front / slope) 0,0824 / 0,0480 m²
Area % (Front / slope) 31% / 70% Take-up Data
Bed depth 129 mm
Type Fixed
Location Tail / Pulley #5
Steady state tension 14,6 to 16,8 kN
Momentary tension 13,6 to 16,9 kN

Required pulley displacement 1,18 m

Dynamic displacement (incl thermal) 0,00 m
Permanent elongation 0,35 m
Splice length (1 included) 0,59 m
Clearance 0,25 m
Flooded belt tonnage 568 t/h
Backstops
Flooded (wm + wb) 156,4 kg/m
Location Head on Pulley #2

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

Backstop (quantity x type) 1 x High speed Splice type 3-Step

Pulley diameter 654 mm Splice step length 200 mm
Load Share Factor % 100 22 degree bias angle 570 mm
Service Factor - Material Lift 1,50 Total splice length 1170 mm
Service Factor - Motor Rating 1,50
Material Lift Criteria 119 N·m
Motor Torque Criteria 291 N·m Other Information
Torque rating at high speed shaft 291 N·m Loaded beltline mass (excluding motors) 7.173 kg
Torque rating at low speed shaft 9.493 N·m Total inertia (ref HS shaft) 0,72 kg·m2
Reducer Ratio 32,640:1

Brakes Pocket Belt Conveyor

Brake type None installed Pocket width 800 mm
Sidewall height 300 mm
Reducer Information Sidewall weight 7,0 kg/m
Manufacture Siemens Core belt mass 18,0 kg/m
Frame size B3SH-5 Cleat type T/C
Reducer ratio 32,640 Cleat height 280 mm
Catalog reducer ratio 30,245 Cleat spacing 0,36 m
RPM (High Speed) 1500 RPM Cleat weight 10,4 kg/m
RPM (Low Speed) 46,0 RPM Cleat weight x pocket width 8,3 kg
Configuration Shaft Mount Number of cleats 148
Number of stages 3 Belt mass (core/sidewall/cleat) 55,1 kg/m
Service factor 1,5
Power rating 58,0 Demand Power (kW)
Demand % Motor
Case
Motor Torque power Nameplate
100% Motor Torque - High Speed 194 N·m Empty - NF 6,5 21,7
Motor Shaft Torque - Running (FN) 139 N·m Full - NF 21,6 71,9
Motor Shaft Torque - Starting (FN) 291 N·m
100% Motor Torque - Low Speed 6.329 N·m Din Factor and Total Equivalent Mass
Low Speed Shaft Torque - Running (FN) 4.277 N·m Belt line
Case Din factor
Low Speed Shaft Torque - Running (Max) 4.277 N·m mass (kg)
Low Speed Shaft Torque - Starting (FN) 7.545 N·m Empty - NF 0,0202 8.847
Low Speed Shaft Torque - Starting (Max) 7.545 N·m Full - NF 0,0185 10.616

Maximum Belt Tensions (kN)

Starting and Stopping Case Running Dynamic
Start control Constant torque Empty - NF 26,0 32,8
Start time 0,6 to 1,1 s Full - NF 33,3 38,6
Emergency stop control Drift
Emergency stop time 1,2 to 3,4 s Belt Safety Factor
Material buildup in chute 0,1 m³ Case Running Dynamic
Empty - NF 26,95 21,32
Tension Ratios Full - NF 21,03 18,12
Allowable (running) 2,73
Running tension ratio 1,57 Splice Safety Factor
Allowable (dynamic) 3,30 Case Running Dynamic
Starting tension ratio 2,25 Empty - NF 20,21 15,99
Full - NF 15,77 13,59
Estimated Splice Data

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

Minimum Belt Tensions (kN) Maximum Belt Sag (%)

Case Running Dynamic Case Running Dynamic
Empty - NF 16,7 14,5 Empty - NF 0,58 0,81
Full - NF 14,5 12,7 Full - NF 0,94 0,98

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

Conveyor Profile
Overall length = 17 m - Overall height = 13,0 m - True Length = 25,8 m

Pulleys

Pulleys - Top View

Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Pulley 1 3-LT 72 18,618,9 21,9 19,921,4 24,2
Mtr 1 - Bstp 1 1-MT 180 33,3 23,4 54,5 38,6 24,8 63,4
Pulley 3 3-LT 71 23,523,4 27,3 24,424,2 28,3
Pulley 4 4-LT 73 16,716,7 19,9 17,117,0 20,3
Take-up Pulley 2-LT 178 16,818,2 35,0 16,918,7 35,6
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
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 8,91 4,21 0,039 500 23,3 23,6 784 21,6 137 0,1 2,0
2 4,39 6,70 0,063 500 46,8 24,7 833 72,1 187 6,3 7,9
3 4,73 7,92 0,074 500 29,3 29,3 784 40,6 300 0,0 3,8
4 7,10 7,02 0,063 500 20,9 20,9 517 21,0 133 0,0 1,9
5 5,28 7,14 0,065 500 21,0 22,8 697 44,4 350 0,6 4,3
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. A steady state case at 100% motor power has also been included.

Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
Rubber
1 Herringb 630 10,0 650 1600 130 110 1860 524 23224 930
one
2 None 630 0,0 630 1600 110 90 1825 520 23220 755
3 None 800 0,0 800 1400 100 80 1610 518 22218 828
4 None 505 0,0 505 1600 90 75 1810 517 22217 553

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 XT-60 SAE 4140 655,0 417,0 327,5 130 1420 98 30 0,0 0
2 XT-45 SAE 4140 655,0 417,0 327,5 110 1440 85 30 0,0 0
3 XT-40 SAE 4140 655,0 417,0 327,5 100 1240 75 30 0,0 0
4 XT-40 SAE 4140 655,0 417,0 327,5 90 1455 68 23 0,0 0

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
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 = 13,0 m)

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

Take-up Displacement Summary

1. Type Fixed
2. Location Tail / Pulley #5
3. Steady state tension 14,6 to 16,8 kN
4. Momentary tension 13,6 to 16,9 kN

Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) 0,00 m
2. Permanent elongation 0,35 m
3. Splice length (1 included) 0,59 m
4. Clearance 0,25 m
5. Required displacement 1,18 m

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
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. A steady state case at 100% motor power has also been included.

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
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Pulley 1 3-LT 72 23,323,6 21,6 21,923,6 20,6
Motor 1 - Backstop 1 1-MT 180 46,8 24,7 72,1 45,2 27,5 73,3
Pulley 3 3-LT 71 29,329,3 40,6 26,926,6 37,6
Pulley 4 4-LT 73 20,920,9 21,0 18,818,7 18,4
Take-up Pulley 2-LT 178 21,022,8 44,4 18,620,5 39,8

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

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Pulley 1 Tail (3) 3 - LT 72 800 305 27 31
Motor 1 - Backstop 1 Head (10) 1 - MT 180 630 356 48 55
Pulley 3 Head (13) 3 - LT 71 800 305 34 35
Pulley 4 Tail (15) 4 - LT 73 505 305 24 24
Take-up Pulley Tail (17) 2 - LT 178 630 305 26 27

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 3 8,91 4,21 20,3 0,6 21,0 1,2 20,4 21,1 0,0
2 1 4,39 6,70 36,8 14,7 36,4 24,2 44,7 55,5 0,0
3 3 4,73 7,92 38,3 0,1 39,5 0,2 38,3 39,5 0,0
4 4 7,10 7,02 26,0 0,0 22,9 0,0 26,0 22,9 0,0
5 2 5,28 7,14 32,7 2,2 34,8 3,9 32,9 35,5 0,0

Running Drive Tensions by Load Case (kN)

Motor 1 - Backstop 1
Load Case Resultant
T1 T2
Force
Empty - NF 26,0 23,4 49,4
Full - NF 33,3 21,2 54,5

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
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)
Pulley 1 18,6 18,9 19,9 21,4 18,4 18,4 18,4 18,4
Mtr 1 - Bstp 1 26,0 23,4 32,8 16,6 24,8 24,6 24,8 24,6
EM-N Empty - NF Pulley 3 23,5 23,4 17,8 19,0 24,4 24,2 24,4 24,2
Pulley 4 16,7 16,7 14,5 15,3 17,1 17,0 17,1 17,0
Take-up Pulley 16,8 18,2 16,1 18,7 16,9 18,2 16,9 18,2
Pulley 1 16,7 17,1 17,1 18,2 16,0 15,8 16,0 15,8
Mtr 1 - Bstp 1 33,3 21,2 38,6 17,1 28,2 24,8 28,2 24,8
FL-N Full - NF Pulley 3 21,2 21,2 17,7 18,3 24,3 23,7 24,3 23,7
Pulley 4 14,5 14,5 12,7 13,1 16,0 15,6 16,0 15,6
Take-up Pulley 14,6 16,0 13,6 15,6 15,4 16,3 15,4 16,3

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

#1 - Pulley 1 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 16,7 kN
1. Name (Type-3) Pulley 1 29. Running T2 Tension 17,1 kN
2. Pulley Diameter 800 mm 30. Design T1 Tension 23,3 kN
3. Face Width 1400 mm 31. Design T2 Tension 23,6 kN
32. Wrap angle 72 deg
33. Design Resultant Tension 21,6 kN
Lagging
34. Resultant Angle 137 deg
4. Lagging Type Rubber
35. Resultant Moment 2,00 kN·m
5. Lagging Thickness 0 mm
36. Resultant Torque 0,12 kN·m
6. Diameter with lagging 800 mm
37. Estimated Pulley & Shaft Mass 784 kg
38. Estimated Mass with Bearings 828 kg
Shaft Specification
7. Shaft Center Diameter 100 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 4,21 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 4,98 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 0,63 mm
42. Shaft deflection at center (%) 0,039
Locking Device 43. Shaft Safety Factor (CEMA) 8,91
11. Hub Center Distance 1240 mm 44. Shaft Safety Factor (AS1403) 7,53
12. Shaft diameter at hub 100 mm 45. Bending Stress 20,3 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 0,6 MPa
14. Locking Device XT-40 47. Von Mises Stress 20,4 MPa
15. Size 100 x 191 48. Fillet Von Mises Stress 21,1 MPa
16. Hub width 48 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 18 mm
19. Hub outer diameter 191 mm
50. Sitzwohl reqd shell thickness1 6 mm
51. Sitzwohl shell stress 16,5 MPa
Bearing Specifications 52. Shell stress at 180 wa 5,6 MPa
20. Bearing Center Distance 1610 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 80 mm
22. Bearing to Fillet Distance 75 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 30 mm 53. End disk thickness 27 mm
24. Bearing 22218 54. End disk stress 20,7 MPa
25. SNL Plummer Block 518
26. Dynamic Capacity 325 kN
27. Bearing L10 500.000 hours

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Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

28. Bearing L10 500.000 hours

#2 - Motor 1 - Backstop 1
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-1) Motor 1 - Backstop 1 29. Running T1 Tension 33,3 kN
2. Pulley Diameter 630 mm 30. Running T2 Tension 21,2 kN
3. Face Width 1600 mm 31. Design T1 Tension 46,8 kN
32. Design T2 Tension 24,7 kN
33. Wrap angle 180 deg
Lagging
34. Design Resultant Tension 72,1 kN
4. Lagging Type Rubber
35. Resultant Angle 187 deg
5. Lagging Pattern Herringbone
36. Resultant Moment 7,93 kN·m
6. Lagging Thickness 10 mm
37. Resultant Torque 6,33 kN·m
7. Diameter with lagging 650 mm
38. Estimated Pulley & Shaft Mass 833 kg
39. Estimated Mass with Bearings 930 kg
Shaft Specification
8. Shaft Center Diameter 130 mm
Shaft Stresses & Deflections
9. Shaft Material SAE 4140
40. Shaft slope at hub 6,70 min
10. Yield Strength 417,0 MPa
41. Shaft slope at bearing 7,93 min
11. Fatigue Strength 327,5 MPa
42. Shaft deflection at center 1,17 mm
43. Shaft deflection at center (%) 0,063
Locking Device 44. Shaft Safety Factor (CEMA) 4,39
12. Hub Center Distance 1420 mm 45. Shaft Safety Factor (AS1403) 3,33
13. Shaft diameter at hub 130 mm 46. Bending Stress 36,8 MPa
14. Turndown radius at hub 0 mm 47. Torsional Stress 14,7 MPa
15. Locking Device XT-60 48. Von Mises Stress 44,7 MPa
16. Size 130 x 292 49. Fillet Von Mises Stress 55,5 MPa
17. Hub width 73 mm
18. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
19. Maximum torque 0 N·m
50. Shell thickness 18 mm
20. Hub outer diameter 292 mm
51. Sitzwohl reqd shell thickness1 8 mm
52. Sitzwohl shell stress 8,2 MPa
Bearing Specifications 53. Shell stress at 180 wa 8,2 MPa
21. Bearing Center Distance 1860 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Shaft diameter at bearing 110 mm
23. Bearing to Fillet Distance 98 mm End Disk Dimension and Stresses
24. Turndown radius at bearing 30 mm 54. End disk thickness 27 mm
25. Bearing 23224 55. End disk stress 43,9 MPa
26. SNL Plummer Block 524
27. Dynamic Capacity 695 kN

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Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

#3 - Pulley 3 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 21,2 kN
1. Name (Type-3) Pulley 3 29. Running T2 Tension 21,2 kN
2. Pulley Diameter 800 mm 30. Design T1 Tension 29,3 kN
3. Face Width 1400 mm 31. Design T2 Tension 29,3 kN
32. Wrap angle 71 deg
33. Design Resultant Tension 40,6 kN
Lagging
34. Resultant Angle 300 deg
4. Lagging Type Rubber
35. Resultant Moment 3,76 kN·m
5. Lagging Thickness 0 mm
36. Resultant Torque 0,02 kN·m
6. Diameter with lagging 800 mm
37. Estimated Pulley & Shaft Mass 784 kg
38. Estimated Mass with Bearings 828 kg
Shaft Specification
7. Shaft Center Diameter 100 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 7,92 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 9,38 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 1,19 mm
42. Shaft deflection at center (%) 0,074
Locking Device 43. Shaft Safety Factor (CEMA) 4,73
11. Hub Center Distance 1240 mm 44. Shaft Safety Factor (AS1403) 4,01
12. Shaft diameter at hub 100 mm 45. Bending Stress 38,3 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 0,1 MPa
14. Locking Device XT-40 47. Von Mises Stress 38,3 MPa
15. Size 100 x 191 48. Fillet Von Mises Stress 39,5 MPa
16. Hub width 48 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 18 mm
19. Hub outer diameter 191 mm
50. Sitzwohl reqd shell thickness1 7 mm
51. Sitzwohl shell stress 20,7 MPa
Bearing Specifications 52. Shell stress at 180 wa 7,0 MPa
20. Bearing Center Distance 1610 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 80 mm
22. Bearing to Fillet Distance 75 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 30 mm 53. End disk thickness 27 mm
24. Bearing 22218 54. End disk stress 39,0 MPa
25. SNL Plummer Block 518
26. Dynamic Capacity 325 kN
27. Bearing L10 500.000 hours

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Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

#4 - Pulley 4 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 14,5 kN
1. Name (Type-4) Pulley 4 29. Running T2 Tension 14,5 kN
2. Pulley Diameter 505 mm 30. Design T1 Tension 20,9 kN
3. Face Width 1600 mm 31. Design T2 Tension 20,9 kN
32. Wrap angle 73 deg
33. Design Resultant Tension 21,0 kN
Lagging
34. Resultant Angle 133 deg
4. Lagging Type Rubber
35. Resultant Moment 1,86 kN·m
5. Lagging Thickness 0 mm
36. Resultant Torque 0,00 kN·m
6. Diameter with lagging 505 mm
37. Estimated Pulley & Shaft Mass 517 kg
38. Estimated Mass with Bearings 553 kg
Shaft Specification
7. Shaft Center Diameter 90 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 7,02 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 8,01 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 1,14 mm
42. Shaft deflection at center (%) 0,063
Locking Device 43. Shaft Safety Factor (CEMA) 7,10
11. Hub Center Distance 1455 mm 44. Shaft Safety Factor (AS1403) 5,99
12. Shaft diameter at hub 90 mm 45. Bending Stress 26,0 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 0,0 MPa
14. Locking Device XT-40 47. Von Mises Stress 26,0 MPa
15. Size 90 x 191 48. Fillet Von Mises Stress 22,9 MPa
16. Hub width 48 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 18 mm
19. Hub outer diameter 191 mm
50. Sitzwohl reqd shell thickness1 5 mm
51. Sitzwohl shell stress 10,4 MPa
Bearing Specifications 52. Shell stress at 180 wa 5,0 MPa
20. Bearing Center Distance 1810 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 75 mm
22. Bearing to Fillet Distance 68 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 23 mm 53. End disk thickness 27 mm
24. Bearing 22217 54. End disk stress 19,3 MPa
25. SNL Plummer Block 517
26. Dynamic Capacity 285 kN
27. Bearing L10 500.000 hours

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Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

27. Bearing L10 500.000 hours

#5 - Take-up Pulley
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-2) Take-up Pulley 28. Running T1 Tension 14,6 kN
2. Pulley Diameter 630 mm 29. Running T2 Tension 16,0 kN
3. Face Width 1600 mm 30. Design T1 Tension 21,0 kN
31. Design T2 Tension 22,8 kN
32. Wrap angle 178 deg
Lagging
33. Design Resultant Tension 44,4 kN
4. Lagging Type Rubber
34. Resultant Angle 350 deg
5. Lagging Thickness 0 mm
35. Resultant Moment 4,27 kN·m
6. Diameter with lagging 630 mm
36. Resultant Torque 0,56 kN·m
37. Estimated Pulley & Shaft Mass 697 kg
Shaft Specification 38. Estimated Mass with Bearings 755 kg
7. Shaft Center Diameter 110 mm
8. Shaft Material SAE 4140
Shaft Stresses & Deflections
9. Yield Strength 417,0 MPa
39. Shaft slope at hub 7,14 min
10. Fatigue Strength 327,5 MPa
40. Shaft slope at bearing 8,33 min
41. Shaft deflection at center 1,19 mm
Locking Device 42. Shaft deflection at center (%) 0,065
11. Hub Center Distance 1440 mm 43. Shaft Safety Factor (CEMA) 5,28
12. Shaft diameter at hub 110 mm 44. Shaft Safety Factor (AS1403) 4,60
13. Turndown radius at hub 0 mm 45. Bending Stress 32,7 MPa
14. Locking Device XT-45 46. Torsional Stress 2,2 MPa
15. Size 110 x 203 47. Von Mises Stress 32,9 MPa
16. Hub width 54 mm 48. Fillet Von Mises Stress 35,5 MPa
17. Hub pressure 0,0 N/mm²
18. Maximum torque 0 N·m
Shell Dimension and Stresses
19. Hub outer diameter 203 mm
49. Shell thickness 18 mm
50. Sitzwohl reqd shell thickness1 6 mm
Bearing Specifications 51. Sitzwohl shell stress 5,2 MPa
20. Bearing Center Distance 1825 mm 52. Shell stress at 180 wa 5,0 MPa
21. Shaft diameter at bearing 90 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Bearing to Fillet Distance 85 mm
23. Turndown radius at bearing 30 mm End Disk Dimension and Stresses
24. Bearing 23220 53. End disk thickness 27 mm
25. SNL Plummer Block 520 54. End disk stress 40,8 MPa
26. Dynamic Capacity 475 kN

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
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

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Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.

Material Trajectory

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Belt Transition Length Requirements

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Material 1 on Idler Set 1

Material Loading Profiles

Material Properties
Type soda külü
Design Tonnage 400 t/h
Density 950 kg/m3
Maximum lump size 1 mm
Surcharge angle 20 deg
Material 1 on Idler Set 3

Tonnage 400 t/h

Belt speed 1,56 m/s
Material mass 71,4 kg/m
Edge distance (required / actual) 100 / 0 mm
Cross sectional loading (utility / total) 70 % / 31 %
Bed depth 129 mm

Material 1 on Idler Set 4

Tonnage 400 t/h

Belt speed 1,56 m/s
Material mass 71,4 kg/m
Edge distance (required / actual) 100 / 0 mm
Cross sectional loading (utility / total) 70 % / 31 %
Bed depth 129 mm

Tonnage 400 t/h

Belt speed 1,56 m/s
Material mass 71,4 kg/m
Edge distance (required / actual) 100 / 0 mm
Cross sectional loading (utility / total) 70 % / 31 %
Bed depth 129 mm

Empty Idler Set 2

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Idler Specifications

Idler Specifications
Type Flat Idler VEE Flat Idler Flat Idler
Number of rolls 1 2 1 1
Trough angle (deg) 0 0 0 0
Roll diameter (mm) 127 127 127 127
Roll length (mm) 1550 200 180 1550
Shaft diameter (mm) 30,0 25,0 30,0 40,0
Bearing series 6306 6205 6306 6308
Maximum roll RPM 234 234 234 234
Min Life (1000 hrs) 350 350 350 52
95% life1 (1000 hrs) 350 350 350 52
Shaft deflection (min) 5,26 0,70 0,29 18,50
Mass per Roll (kg) 17,8 2,9 2,7 17,8
Rotating mass for set (kg) 17,8 5,9 2,7 17,8
Wk2 for set (kg·mm²) 66.565 19.709 9.014 66.565

Idler Spacing and Count Summary

General Carry Return Impact Type 4
Idler spacing (m) 1,00 2,00 0,35 0,00
in convex curves < 2 m 0,35
Number of ıdler sets 22 10 4 5
Number of rolls 22 20 4 5
Total drag (N) 5,0 7,1 5,0 6,3

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 1,0 1,00 1 350.000 4,75
2 1,0 1,5 0,35 3 350.000 0,29
3 2,5 2,1 1,00 1 350.000 4,77
5 5,0 12,2 1,00 1 350.000 2,57
6-9 8,8 1,9 2 0,35 4 52.436 18,50
10 10,2 6,6 1,00 1 350.000 5,26

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)
12-13 16,9 7,1 2,00 2 350.000 0,70
15 9,4 13,3 2,00 2 350.000 0,27

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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 581 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 581 t/h under steady state and dynamic conditions + 110% multiplier
Shaft Shaft Shaft Minimum Tensions (kN) Maximum Tensions (kN)
Wrap Hub stress Center
Pulley Type Resultant Resultant
(deg) Slope safety Def. T1 T2 T1 T2
Force Force
(min) factor (mm)
Pulley 1 3 72 4,02 8,74 0,60 14,013,7 11,0 21,923,6 20,6
Motor 1 -
1 180 6,82 4,39 1,19 22,3 15,0 38,3 45,2 27,5 73,3
Backstop 1
Pulley 3 3 71 7,33 4,73 1,10 15,716,1 25,2 26,926,6 37,6
Pulley 4 4 73 6,17 7,10 1,00 10,510,8 9,08 18,818,7 18,4
Take-up Pulley 2 178 6,41 5,28 1,06 11,013,1 25,2 18,620,5 39,8

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
Pulley 1 72 180 72 828 -9,63 -11,3 -14,5 4,91 8,11 14,3
Motor 1 -
180 181 181 930 -37,3 -54,5 -72,8 -9,73 -10,0 -10,3
Backstop 1
Pulley 3 71 0 252 828 10,7 14,6 18,5 -23,3 -28,1 -33,2
Pulley 4 73 72 178 553 -7,46 -9,94 -12,8 4,81 8,72 13,0
Take-up Pulley 178 358 0 755 24,2 30,6 39,2 -7,70 -7,80 -7,90

The idler stringer loading should be based on the flooded belt surge capacity of 568 t/h and 156,4 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

Element Summary Details

Tension Summary

Power Summary

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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)
6-10 9 - 10 convex 2 0 0

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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 1,0 0,00 0,00 1,00 1
2 Loading Point 1,0 0,00 1,5 0,00 0,00 0,35 3
3 2,5 0,00 2,1 0,00 0,00 1,00 1
4 Pulley 1 4,6 0,00 0,5 0,27 ---
5 5,0 0,27 12,2 11,62 71,60 1,00 1
6 8,8 11,89 0,5 0,41 62,33 2 0,35 4
7 9,1 12,30 0,5 0,33 44,87 2 0,35 4
8 9,4 12,63 0,5 0,21 27,31 2 0,35 4
9 9,8 12,84 0,5 0,08 9,72 2 0,35 4
10 10,2 12,92 6,6 0,11 0,93 1,00 1
11 Motor 1 - Backstop 1 16,9 13,02 0,7 -0,65 ---
12 16,9 12,37 1,0 -0,02 -0,95 2,00 2
13 15,9 12,36 6,1 -0,05 -0,43 2,00 2
14 Pulley 3 9,7 12,31 0,5 -0,27 ---
15 9,4 12,04 13,3 -12,63 -71,67 2,00 2
16 Pulley 4 5,2 -0,59 0,3 -0,17 ---
17 4,9 -0,76 5,0 0,13 1,52
18 Take-up Pulley 0,0 -0,63 0,6 0,63 ---

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Min/Max Tension Summary per Element

Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 18,2 16,0 0,42 18,7 15,6 0,43
2 Loading Point 18,2 16,0 0,34 18,9 15,7 0,35
3 18,5 16,6 0,94 19,4 16,3 0,95
4 Pulley 1 18,6 16,7 0,00 19,9 16,0 0,00
5 18,9 17,1 0,91 21,4 15,8 0,98
6 31,7 25,2 0,17 35,2 24,4 0,19
7 32,2 25,5 0,17 35,9 24,6 0,19
8 32,6 25,7 0,17 36,4 24,8 0,19
9 32,9 25,8 0,16 36,8 24,9 0,19
10 33,1 25,9 0,47 37,1 24,9 0,53
Motor 1 -
11 33,3 26,0 0,00 38,6 24,8 0,00
Backstop 1
12 23,4 21,2 0,64 24,8 16,6 0,81
13 23,4 21,2 0,64 24,7 16,8 0,80
14 Pulley 3 23,5 21,2 0,00 24,4 17,7 0,00
15 23,4 21,2 0,64 24,2 18,3 0,74
16 Pulley 4 16,7 14,5 0,00 17,1 12,7 0,00
17 16,7 14,5 0,00 17,0 13,1 0,00
18 Take-up Pulley 16,8 14,6 0,00 16,9 13,6 0,00

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 Client Name Bülbüloğlu Designer HAK
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Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N)
EM-N FL-N
Total (Beltline) 2.182 11.717
Total (Power) 4.149 13.852

Lift Force 0 9.116

Frictional Drag 2.182 2.601
Motor Pulley/Reducer Drag 1.968 2.135

Rolling Resistance 81 146

Material+Belt Flexure 0 12
Idler Bearing Drag 273 283
Idler Alignment 116 195
Pulleys & Accessories 1.580 1.580
Loading Point 131 384

Mechanical Losses 622 772

Motor Pulley Drag Components 1.346 1.363

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Pulley Summary Table - All Cases

Pulley Geometry Details
Type 1 2 3 4
Lagging Type Rubber None None None
Diameter (mm) 630 630 800 505
Lagging Thickness (mm) 10,0 0,0 0,0 0,0
Diameter with Lagging (mm) 650 630 800 505
Face Width (mm) 1600 1600 1400 1600
Shaft Center Diameter (mm) 130 110 100 90
Bearing Diameter (mm) 110 90 80 75
Bearing Center Distance (mm) 1860 1825 1610 1810
Plummer Block 524 520 518 517
Pulley & Shaft Mass (kg) 833 697 784 517
Locking Device XT-60 XT-45 XT-40 XT-40
Hub Center Distance (mm) 1420 1440 1240 1455
Hub Diameter (mm) 130 110 100 90
Bearing to Fillet Distance (mm) 98 85 75 68
Fillet Radius (mm) 30 30 30 23
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

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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 18.220 9 55,1 1 7
2 18.229 306 55,1 1 23 131 150
3 18.534 68 55,1 3 15 50
4-P 18.602 248 55,1 148 100
5 18.850 6.381 55,1 6.276 17 88
6 25.231 240 55,1 221 0 18
7 25.471 195 55,1 176 0 18
8 25.666 133 55,1 115 0 18
9 25.799 61 55,1 42 0 18
10 25.860 115 55,1 58 9 48
11 - M 25.975 -2.533 55,1 -351 121 1.225
12 23.442 0 55,1 -9 2 7
13 23.442 30 55,1 -25 14 41
14 - P 23.472 -48 55,1 -148 100
15 23.424 -6.702 55,1 -6.821 31 88
16 - P 16.723 7 55,1 -93 100
17 16.729 71 55,1 71
18 - T 16.800 1.420 55,1 340 100 980

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Element Tension Breakdown - (FL) Fully Loaded - 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 15.997 9 55,1 1 7
2 16.006 570 400 126,5 7 28 384 150
3 16.576 83 400 126,5 10 23 50
4-P 16.658 439 400 126,5 339 100
5 17.098 14.595 400 126,5 14.407 56 133
6 31.693 530 400 126,5 508 2 20
7 32.223 427 400 126,5 405 2 20
8 32.649 285 400 126,5 263 2 20
9 32.934 119 400 126,5 97 2 20
10 33.053 234 400 126,5 133 29 72
11 - M 33.288 -12.068 55,1 -351 138 1.225
12 21.220 0 55,1 -9 2 7
13 21.220 30 55,1 -25 14 41
14 - P 21.250 -48 55,1 -148 100
15 21.202 -6.702 55,1 -6.821 31 88
16 - P 14.500 7 55,1 -93 100
17 14.506 71 55,1 71
18 - T 14.577 1.420 55,1 340 100 980

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 Client Name Bülbüloğlu Designer HAK
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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
Pulley Pulley 2
Motor Motor 1
Reducer Reducer 1
Backstop Backstop 1
Pulley Pulley 3
Pulley Pulley 4
Pulley Pulley 5

Idlers Carry
Idlers Return
Idlers 6306
Idlers 6308

Belt -

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Belt Supplier Data Sheet System Information

Type Fabric (4-Ply) Calculation method CEMA 6th
Width 1400 mm Conveyor Length / Height 17 / 13,0 m
Rating 500 N/mm Ambient temperature -10 °C
Speed 1,56 m/s Kt factor at minimum temperature 1,12
Top / bottom cover thickness 5,0 x 2,0 mm
Total thickness 12 mm Material Properties
Weight 55,1 kg/m Type soda külü
Modulus 5.149 kN/m Design Tonnage 400 t/h
Tape length 53,24 m Density 950 kg/m3
Belt cycle time 34 s Maximum lump size 1 mm
Cross Sectional Loading Surcharge angle 20 deg
Material mass (wm) 71,4 kg/m
Combined mass (wm + wb) 126,5 kg/m Drive Station
Sidewall width / height 800 x 300 mm Type Squirrel cage
Area (Front / slope) 0,0824 / 0,0480 m² Synchronous RPM 1500 RPM
Area % (Front / slope) 31% / 70% Motor quantity / rating 1 / 30,0 kW
Bed depth 129 mm Total ınstalled power 30,0 kW
Empty / full power (22 / 72%) 6,5 / 21,6 kW
Maximum starting torque 150%
Pulley lagging type Rubber
Motor wrap angles 180

Idler Set Data

Carry Return
Series name Series 30 Series 25
Bearing 6306 6205
Number of rolls 1 2
Flooded belt tonnage 568 t/h Trough angle (deg) 0 0
Flooded (wm + wb) 156,4 kg/m Type Inline Inline
Idler spacing (m) 1,00 2,00
Tension Summary Running Momentary in convex curves 0,35 0,00
Maximum tension (kN) 33,3 38,6
Minimum safety factor 21,03 18,12
Pulley Details
Estimated Splice Data Pulley diameter (Type 1) 630 mm
Pulley diameter (Type 2) 630 mm
Splice type 3-Step Pulley diameter (Type 3) 800 mm
Splice step length 200 mm Pulley diameter (Type 4) 505 mm
22 degree bias angle 570 mm
Total splice length 1170 mm
Take-up Data
Type Fixed
Location Tail / Pulley #5
Steady state tension 14,6 to 16,8 kN
Momentary tension 13,6 to 16,9 kN
Required pulley displacement 1,18 m

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System Information
Idler Set Data Calculation method CEMA 6th
Carry Return Conveyor Length / Height 17 / 13,0 m
Series name Series 30 Series 25 Ambient temperature -10 °C
Bearing 6306 6205 Kt factor at minimum temperature 1,12
Number of rolls 1 2
Trough angle (deg) 0 0 Material Properties
Type Inline Inline Type soda külü
Idler spacing (m) 1,00 2,00 Design Tonnage 400 t/h
in convex curves 0,35 0,00 Density 950 kg/m3
Roll diameter 127 127 Maximum lump size 1 mm
Roll rpm 234 234 Surcharge angle 20 deg
Total drag (N) 5,0 7,1
Drag range (N) 4,6 - 5,0 8,2 - 8,2 Cross Sectional Loading
Roll length 1550 200 Material mass (wm) 71,4 kg/m
Shaft diameter (mm) 30 25,0 Combined mass (wm + wb) 126,5 kg/m
Dynamic capacity (kN) 29,6 14,8 Sidewall width / height 800 x 300 mm
L10 life1 (1000 hrs) 350,0 350,0 Area (Front / slope) 0,0824 / 0,0480 m²
Shaft deflection (min) 5,26 0,70 Area % (Front / slope) 31% / 70%
Bed depth 129 mm
Number of ıdler sets 22 10
Number of rolls 22 20

Idler Set Data

Impact Transition
Series name Series 30 Series 40
Bearing 6306 6308
Number of rolls 1 1
Trough angle (deg) 0 0
Type Inline Inline Flooded belt tonnage 568 t/h
Idler spacing (m) 1,00 2,00 Flooded (wm + wb) 156,4 kg/m
in convex curves 0,35 0,00 Belt Supplier Data Sheet
Roll diameter 127 127
Type Fabric (4-Ply)
Roll rpm 234 234
Width 1400 mm
Total drag (N) 5,0 6,3
Rating 500 N/mm
Drag range (N) 4,4 - 4,6 12,9 - 13,2
Speed 1,56 m/s
Roll length 180 1550
Top / bottom cover thickness 5,0 x 2,0 mm
Shaft diameter (mm) 30 40,0
Weight 55,1 kg/m
Dynamic capacity (kN) 29,6 42,3
L10 life1 (1000 hrs) 350,0 52,4 Tension Summary Running Momentary
Shaft deflection (min) 0,29 18,50 Maximum tension (kN) 33,3 38,6
Minimum safety factor 21,03 18,12
Number of ıdler sets 4 5
Number of rolls 4 5
1
L10 life above which 95% of idlers exceed

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Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

System Information Flooded (wm + wb) 156,4 kg/m

Calculation method CEMA 6th
Conveyor Length / Height 17 / 13,0 m Idler Set Data
Material lift 13,0 m Carry Return
Ambient temperature -10 °C Series name Series 30 Series 25
Kt factor at minimum temperature 1,12 Bearing 6306 6205
Number of rolls 1 2
Material Properties Trough angle (deg) 0 0
Type soda külü Type Inline Inline
Design Tonnage 400 t/h Idler spacing (m) 1,00 2,00
Density 950 kg/m3 in convex curves 0,35 0,00
Maximum lump size 1 mm Number of ıdler sets 22 10
Surcharge angle 20 deg Roll diameter 127 127
Roll rpm 234 234
Total drag (N) 5,0 7,1
Belt Properties
Drag range (N) 4,6 - 5,0 8,2 - 8,2
Type Fabric (4-Ply) Roll length 1550 200
Width 1400 mm Shaft diameter (mm) 30 25,0
Rating 500 N/mm Dynamic capacity (kN) 29,6 14,8
Speed 1,56 m/s L10 life1 (1000 hrs) 350,0 350,0
Top / bottom cover thickness 5,0 x 2,0 mm Shaft deflection (min) 5,26 0,70
Total thickness 12 mm 1
L10 life above which 95% of idlers exceed
Weight 55,1 kg/m
Modulus 5.149 kN/m Drive Station
Tape length 53,24 m
Belt cycle time 34 s Type Squirrel cage
Synchronous RPM 1500 RPM
Tension Summary Running Momentary Motor quantity / rating 1 / 30,0 kW
Maximum tension (kN) 33,3 38,6 Total ınstalled power 30,0 kW
Minimum safety factor 21,03 18,12 Empty / full power (22 / 72%) 6,5 / 21,6 kW
Minimum tension (kN) 14,5 12,7 Frame Size IEC 200M
Maximum belt sag (%) 0,94 0,98 Motor Voltage 400 V
Efficiency 95,5%
Cross Sectional Loading Maximum starting torque 150%
Material mass (wm) 71,4 kg/m Inertia - Motor 0,3 kg·m²
Combined mass (wm + wb) 126,5 kg/m Pulley lagging type Rubber
Sidewall width / height 800 x 300 mm Motor wrap angles 180
Area (Front / slope) 0,0824 / 0,0480 m² Lagging friction factor (run / accel) 0,32 / 0,38
Area % (Front / slope) 31% / 70%
Bed depth 129 mm Take-up Data
Type Fixed
Location Tail / Pulley #5
Steady state tension 14,6 to 16,8 kN
Momentary tension 13,6 to 16,9 kN

Required pulley displacement 1,18 m

Dynamic displacement (incl thermal) 0,00 m
Permanent elongation 0,35 m
Splice length (1 included) 0,59 m
Clearance 0,25 m
Flooded belt tonnage 568 t/h

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

Conveyor Profile
Overall length = 17 m - Overall height = 13,0 m - True Length = 25,8 m

Pulleys

Pulleys - Top View

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

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
Pulley 1 3-LT 72 18,618,9 21,9 19,921,4 24,2
Mtr 1 - Bstp 1 1-MT 180 33,3 23,4 54,5 38,6 24,8 63,4
Pulley 3 3-LT 71 23,523,4 27,3 24,424,2 28,3
Pulley 4 4-LT 73 16,716,7 19,9 17,117,0 20,3
Take-up Pulley 2-LT 178 16,818,2 35,0 16,918,7 35,6
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 8,91 4,21 0,039 500 23,3 23,6 784 21,6 137 0,1 2,0
2 4,39 6,70 0,063 500 46,8 24,7 833 72,1 187 6,3 7,9
3 4,73 7,92 0,074 500 29,3 29,3 784 40,6 300 0,0 3,8
4 7,10 7,02 0,063 500 20,9 20,9 517 21,0 133 0,0 1,9
5 5,28 7,14 0,065 500 21,0 22,8 697 44,4 350 0,6 4,3
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. A steady state case at 100% motor power has also been included.

Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
Rubber
1 Herringb 630 10,0 650 1600 130 110 1860 524 23224 930
one
2 None 630 0,0 630 1600 110 90 1825 520 23220 755
3 None 800 0,0 800 1400 100 80 1610 518 22218 828
4 None 505 0,0 505 1600 90 75 1810 517 22217 553

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 XT-60 SAE 4140 655,0 417,0 327,5 130 1420 98 30 0,0 0
2 XT-45 SAE 4140 655,0 417,0 327,5 110 1440 85 30 0,0 0
3 XT-40 SAE 4140 655,0 417,0 327,5 100 1240 75 30 0,0 0
4 XT-40 SAE 4140 655,0 417,0 327,5 90 1455 68 23 0,0 0

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

#1 - Pulley 1 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 16,7 kN
1. Name (Type-3) Pulley 1 29. Running T2 Tension 17,1 kN
2. Pulley Diameter 800 mm 30. Design T1 Tension 23,3 kN
3. Face Width 1400 mm 31. Design T2 Tension 23,6 kN
32. Wrap angle 72 deg
33. Design Resultant Tension 21,6 kN
Lagging
34. Resultant Angle 137 deg
4. Lagging Type Rubber
35. Resultant Moment 2,00 kN·m
5. Lagging Thickness 0 mm
36. Resultant Torque 0,12 kN·m
6. Diameter with lagging 800 mm
37. Estimated Pulley & Shaft Mass 784 kg
38. Estimated Mass with Bearings 828 kg
Shaft Specification
7. Shaft Center Diameter 100 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 4,21 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 4,98 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 0,63 mm
42. Shaft deflection at center (%) 0,039
Locking Device 43. Shaft Safety Factor (CEMA) 8,91
11. Hub Center Distance 1240 mm 44. Shaft Safety Factor (AS1403) 7,53
12. Shaft diameter at hub 100 mm 45. Bending Stress 20,3 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 0,6 MPa
14. Locking Device XT-40 47. Von Mises Stress 20,4 MPa
15. Size 100 x 191 48. Fillet Von Mises Stress 21,1 MPa
16. Hub width 48 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 18 mm
19. Hub outer diameter 191 mm
50. Sitzwohl reqd shell thickness1 6 mm
51. Sitzwohl shell stress 16,5 MPa
Bearing Specifications 52. Shell stress at 180 wa 5,6 MPa
20. Bearing Center Distance 1610 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 80 mm
22. Bearing to Fillet Distance 75 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 30 mm 53. End disk thickness 27 mm
24. Bearing 22218 54. End disk stress 20,7 MPa
25. SNL Plummer Block 518
26. Dynamic Capacity 325 kN
27. Bearing L10 500.000 hours

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

28. Bearing L10 500.000 hours

#2 - Motor 1 - Backstop 1
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-1) Motor 1 - Backstop 1 29. Running T1 Tension 33,3 kN
2. Pulley Diameter 630 mm 30. Running T2 Tension 21,2 kN
3. Face Width 1600 mm 31. Design T1 Tension 46,8 kN
32. Design T2 Tension 24,7 kN
33. Wrap angle 180 deg
Lagging
34. Design Resultant Tension 72,1 kN
4. Lagging Type Rubber
35. Resultant Angle 187 deg
5. Lagging Pattern Herringbone
36. Resultant Moment 7,93 kN·m
6. Lagging Thickness 10 mm
37. Resultant Torque 6,33 kN·m
7. Diameter with lagging 650 mm
38. Estimated Pulley & Shaft Mass 833 kg
39. Estimated Mass with Bearings 930 kg
Shaft Specification
8. Shaft Center Diameter 130 mm
Shaft Stresses & Deflections
9. Shaft Material SAE 4140
40. Shaft slope at hub 6,70 min
10. Yield Strength 417,0 MPa
41. Shaft slope at bearing 7,93 min
11. Fatigue Strength 327,5 MPa
42. Shaft deflection at center 1,17 mm
43. Shaft deflection at center (%) 0,063
Locking Device 44. Shaft Safety Factor (CEMA) 4,39
12. Hub Center Distance 1420 mm 45. Shaft Safety Factor (AS1403) 3,33
13. Shaft diameter at hub 130 mm 46. Bending Stress 36,8 MPa
14. Turndown radius at hub 0 mm 47. Torsional Stress 14,7 MPa
15. Locking Device XT-60 48. Von Mises Stress 44,7 MPa
16. Size 130 x 292 49. Fillet Von Mises Stress 55,5 MPa
17. Hub width 73 mm
18. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
19. Maximum torque 0 N·m
50. Shell thickness 18 mm
20. Hub outer diameter 292 mm
51. Sitzwohl reqd shell thickness1 8 mm
52. Sitzwohl shell stress 8,2 MPa
Bearing Specifications 53. Shell stress at 180 wa 8,2 MPa
21. Bearing Center Distance 1860 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Shaft diameter at bearing 110 mm
23. Bearing to Fillet Distance 98 mm End Disk Dimension and Stresses
24. Turndown radius at bearing 30 mm 54. End disk thickness 27 mm
25. Bearing 23224 55. End disk stress 43,9 MPa
26. SNL Plummer Block 524
27. Dynamic Capacity 695 kN

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

#3 - Pulley 3 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 21,2 kN
1. Name (Type-3) Pulley 3 29. Running T2 Tension 21,2 kN
2. Pulley Diameter 800 mm 30. Design T1 Tension 29,3 kN
3. Face Width 1400 mm 31. Design T2 Tension 29,3 kN
32. Wrap angle 71 deg
33. Design Resultant Tension 40,6 kN
Lagging
34. Resultant Angle 300 deg
4. Lagging Type Rubber
35. Resultant Moment 3,76 kN·m
5. Lagging Thickness 0 mm
36. Resultant Torque 0,02 kN·m
6. Diameter with lagging 800 mm
37. Estimated Pulley & Shaft Mass 784 kg
38. Estimated Mass with Bearings 828 kg
Shaft Specification
7. Shaft Center Diameter 100 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 7,92 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 9,38 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 1,19 mm
42. Shaft deflection at center (%) 0,074
Locking Device 43. Shaft Safety Factor (CEMA) 4,73
11. Hub Center Distance 1240 mm 44. Shaft Safety Factor (AS1403) 4,01
12. Shaft diameter at hub 100 mm 45. Bending Stress 38,3 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 0,1 MPa
14. Locking Device XT-40 47. Von Mises Stress 38,3 MPa
15. Size 100 x 191 48. Fillet Von Mises Stress 39,5 MPa
16. Hub width 48 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 18 mm
19. Hub outer diameter 191 mm
50. Sitzwohl reqd shell thickness1 7 mm
51. Sitzwohl shell stress 20,7 MPa
Bearing Specifications 52. Shell stress at 180 wa 7,0 MPa
20. Bearing Center Distance 1610 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 80 mm
22. Bearing to Fillet Distance 75 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 30 mm 53. End disk thickness 27 mm
24. Bearing 22218 54. End disk stress 39,0 MPa
25. SNL Plummer Block 518
26. Dynamic Capacity 325 kN
27. Bearing L10 500.000 hours

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

#4 - Pulley 4 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 14,5 kN
1. Name (Type-4) Pulley 4 29. Running T2 Tension 14,5 kN
2. Pulley Diameter 505 mm 30. Design T1 Tension 20,9 kN
3. Face Width 1600 mm 31. Design T2 Tension 20,9 kN
32. Wrap angle 73 deg
33. Design Resultant Tension 21,0 kN
Lagging
34. Resultant Angle 133 deg
4. Lagging Type Rubber
35. Resultant Moment 1,86 kN·m
5. Lagging Thickness 0 mm
36. Resultant Torque 0,00 kN·m
6. Diameter with lagging 505 mm
37. Estimated Pulley & Shaft Mass 517 kg
38. Estimated Mass with Bearings 553 kg
Shaft Specification
7. Shaft Center Diameter 90 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 7,02 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 8,01 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 1,14 mm
42. Shaft deflection at center (%) 0,063
Locking Device 43. Shaft Safety Factor (CEMA) 7,10
11. Hub Center Distance 1455 mm 44. Shaft Safety Factor (AS1403) 5,99
12. Shaft diameter at hub 90 mm 45. Bending Stress 26,0 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 0,0 MPa
14. Locking Device XT-40 47. Von Mises Stress 26,0 MPa
15. Size 90 x 191 48. Fillet Von Mises Stress 22,9 MPa
16. Hub width 48 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 18 mm
19. Hub outer diameter 191 mm
50. Sitzwohl reqd shell thickness1 5 mm
51. Sitzwohl shell stress 10,4 MPa
Bearing Specifications 52. Shell stress at 180 wa 5,0 MPa
20. Bearing Center Distance 1810 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 75 mm
22. Bearing to Fillet Distance 68 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 23 mm 53. End disk thickness 27 mm
24. Bearing 22217 54. End disk stress 19,3 MPa
25. SNL Plummer Block 517
26. Dynamic Capacity 285 kN
27. Bearing L10 500.000 hours

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

#5 - Take-up Pulley Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 14,6 kN
1. Name (Type-2) Take-up Pulley 29. Running T2 Tension 16,0 kN
2. Pulley Diameter 630 mm 30. Design T1 Tension 21,0 kN
3. Face Width 1600 mm 31. Design T2 Tension 22,8 kN
32. Wrap angle 178 deg
33. Design Resultant Tension 44,4 kN
Lagging
34. Resultant Angle 350 deg
4. Lagging Type Rubber
35. Resultant Moment 4,27 kN·m
5. Lagging Thickness 0 mm
36. Resultant Torque 0,56 kN·m
6. Diameter with lagging 630 mm
37. Estimated Pulley & Shaft Mass 697 kg
38. Estimated Mass with Bearings 755 kg
Shaft Specification
7. Shaft Center Diameter 110 mm
Shaft Stresses & Deflections
8. Shaft Material SAE 4140
39. Shaft slope at hub 7,14 min
9. Yield Strength 417,0 MPa
40. Shaft slope at bearing 8,33 min
10. Fatigue Strength 327,5 MPa
41. Shaft deflection at center 1,19 mm
42. Shaft deflection at center (%) 0,065
Locking Device 43. Shaft Safety Factor (CEMA) 5,28
11. Hub Center Distance 1440 mm 44. Shaft Safety Factor (AS1403) 4,60
12. Shaft diameter at hub 110 mm 45. Bending Stress 32,7 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 2,2 MPa
14. Locking Device XT-45 47. Von Mises Stress 32,9 MPa
15. Size 110 x 203 48. Fillet Von Mises Stress 35,5 MPa
16. Hub width 54 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 18 mm
19. Hub outer diameter 203 mm
50. Sitzwohl reqd shell thickness1 6 mm
51. Sitzwohl shell stress 5,2 MPa
Bearing Specifications 52. Shell stress at 180 wa 5,0 MPa
20. Bearing Center Distance 1825 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 90 mm
22. Bearing to Fillet Distance 85 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 30 mm 53. End disk thickness 27 mm
24. Bearing 23220 54. End disk stress 40,8 MPa
25. SNL Plummer Block 520
26. Dynamic Capacity 475 kN
27. Bearing L10 500.000 hours

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 Client Name Bülbüloğlu Designer HAK
Project Name 230392 Company Birikim Mühendislik End.
Conveyor Name z bant Filename z bant
Location Date Nisan 6, 2023
Description:

Demand Power (kW)

Drive Station Case
Demand % Motor
Type Squirrel cage power Nameplate
Synchronous RPM 1500 RPM Empty - NF 6,5 21,7
Motor quantity / rating 1 / 30,0 kW Full - NF 21,6 71,9
Total ınstalled power 30,0 kW
Empty / full power (22 / 72%) 6,5 / 21,6 kW
Frame Size IEC 200M
Motor Voltage 400 V
Efficiency 95,5%
Maximum starting torque 150%
Inertia - Motor 0,3 kg·m²
Pulley lagging type Rubber
Motor wrap angles 180
Lagging friction factor (run / accel) 0,32 / 0,38

Reducer Information
Manufacture Siemens
Frame size B3SH-5
Reducer ratio 32,640
Catalog reducer ratio 30,245
RPM (High Speed) 1500 RPM
RPM (Low Speed) 46,0 RPM
Configuration Shaft Mount
Number of stages 3
Service factor 1,5
Power rating 58,0

Motor Torque
100% Motor Torque - High Speed 194 N·m
Motor Shaft Torque - Running (FN) 139 N·m
Motor Shaft Torque - Starting (FN) 291 N·m
100% Motor Torque - Low Speed 6.329 N·m
Low Speed Shaft Torque - Running (FN) 4.277 N·m
Low Speed Shaft Torque - Running (Max) 4.277 N·m
Low Speed Shaft Torque - Starting (FN) 7.545 N·m
Low Speed Shaft Torque - Starting (Max) 7.545 N·m

Starting and Stopping

Start control Constant torque
Start time 0,6 to 1,1 s
Emergency stop control Drift
Emergency stop time 1,2 to 3,4 s
Material buildup in chute 0,1 m³

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