GRADE

THE DESIGN OF BELT DRIVEN CONVEYOR AND GEAR DRIVEN GEARBOX

MOTOR FOR BULK MATERIAL COAL HANDLING WITH A CAPACITY OF 1000
TPH

A Study/Design Report
Presented to

DR. JAMES JAIME P. HONRA

Professor of the School of Mechanical and Manufacturing Engineering
MAPÚA UNIVERSITY
Muralla St., Intramuros, Manila

Submitted in Partial Fulfillment of the Requirements for the Subject

ME151P-2/E01 – Machine Design 2 in the Degree
Bachelor of Science in Mechanical Engineering

by

DAYADANTE, Jan Claryze R. - 2018109752

LABANIEGO II, Gregorio “Lot Lot” S. - 2018103321
ONG, Ralph John S. - 2018103188
RECTO, Rishon Raef B. - 2016141963
SOLIMAN, Francis David R. - 2018100873
July 2021

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 TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION .............................................................................................................. 3

1.1 OVERVIEW AND BACKGROUND ........................................................................................ 3
1.2 STATEMENT OF THE PROBLEM .............................................................................................. 4
1.3 OBJECTIVES OF THE STUDY ..................................................................................................... 5
1.4 SIGNIFICANCE OF THE STUDY................................................................................................. 5
1.5 SCOPES AND LIMITATIONS ....................................................................................................... 6
CHAPTER 2: REVIEW OF RELATED LITERATURE ....................................................................... 7
Belt drives ................................................................................................................................................ 7
Gear drives .............................................................................................................................................. 8
Definition and application of conveyors................................................................................................ 9
Coal Components and Physical Parameters ....................................................................................... 11
Existing studies ...................................................................................................................................... 13
CHAPTER 3: DESIGN CALCULATION ............................................................................................. 15
A. Belt Conveyor Design Capacity and Equipment Calculations.................................................. 15
B. Belt Conveyor Components.......................................................................................................... 36
C. Gearbox Design and Equipment Calculations ........................................................................... 38
D. Gearbox Components ................................................................................................................... 49
CHAPTER 4: DESCRIPTION OF THE MACHINE AND DESIGN CONSIDERATION .............. 51
Description of the Machine .................................................................................................................. 51
Description of Machine Utility ............................................................................................................. 51
DESIGN CONSIDERATIONS ............................................................................................................ 52
Health, Safety and Welfare .................................................................................................................. 52
Social Factors ........................................................................................................................................ 52
Global &cultural sensitivity awareness............................................................................................... 53
CHAPTER 5: RESULTS & DISCUSSION ............................................................................................ 54
RESULTS & DISCUSSION................................................................................................................. 54
CONSLUSION ...................................................................................................................................... 55
RECOMMENDATION ........................................................................................................................ 55
REFERENCES .......................................................................................................................................... 57

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 CHAPTER 1: INTRODUCTION

1.1 OVERVIEW AND BACKGROUND

The belt conveyor is a frequently used continuous transportation equipment with high

efficiency and large transmission capacity, easier construction and low maintenance. Different

materials can be transported on different distances. In thermal power plant and other projects, it is

widely used in coal mining systems. The belt conveyor system comprises of driving units (electric

motor, multistage coupling, gearbox), pulleys (drive pulley and others), idlers, and belts with their

joints (Jayashwal, Gurjarl, & Yadav, 2012). A bulk material handling facility consists of multiple

equipment that works together to reach the ultimate functional requirements. In such plants, belt

conveying systems are required to maintain material flow through a range of installation

equipment, such as car tips, crushers, packing / reclamation devices, vibration screens, trippers etc.

In addition, solids are grouped in two basic groups: load unit and bulk. In order to build a conveyor

belts for handling bulk materials, the features of the material to be conveyed are accurately

assessed. The behavior of bulk materials depends very much on the material's moisture content

and dispersion in particle sizes. Large differences in material behavior, bulk density and particle

size may result in unforeseen tonnage or capability problems, in the accumulation of excessive

spill or materials and in a malfunctioning or failing equipment or system (Shah, 2018). The figure

below illustrates the coal handling layout, the study will focus on the unloading process before the

preparation (crusher), from coal supplied by the truck into conveying the coal to the crusher for

preparation (Saif, 2020).

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 Figure 1. Coal Handling Layout

The study will use an open belt type of a belt conveyor, for the literature will be focusing on

the material handling for bulk materials as it aims to improve the existing designs by enhancing

the belt drives of the belt conveyor and gear drives of the gearbox motor.

1.2 STATEMENT OF THE PROBLEM

The most crucial component of a belt conveyor system is the conveyor belt. The belt is

frequently the most expensive component of a conveyor. As a result, the conveyor belt must be

chosen with considerable care. It should be able to do the following functions: transport the load,

absorb the impact energy at the loading point, withstand temperature and the effects of chemicals,

and to meet with safety requirements. The design of the transportation system is heavily influenced

by the total capacity of the power plant, the fuel type, and the modes of transportation. The belt

conveyors are used practically to reduce effort of transporting the coal from one place to another,

specifically from unloading to the crusher house. Damages can occur in the form of belt slippage

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or damaged parts. Belt slippage can be caused by too little or too much tension. There are also gear

drives that can be damaged due to heavy load being transmitted using the conveyor. So, it is

important that each part should be carefully designed to withstand heavy workloads and heavy

usage time.

1.3 OBJECTIVES OF THE STUDY

To solve the specified problems of the design, the following objectives of the design of a

belt conveyor and gear driven gearbox for bulk material coal handling are as follows:

1. To understand and conceptualize the process of transportation from unloading the coal to

the crusher house.

2. To understand and apply the concepts of methodologies in the design.

3. To understand and design a belt conveyor for coal handling system.

4. To understand and design a gear driven gearbox motor for coal handling belt conveyor.

5. To ensure that the coal transportation will maintain high productivity.

1.4 SIGNIFICANCE OF THE STUDY

The most important aspect of material handling is that it improves productivity and,

as a result, boosts the profitability of an industry. A well-designed material handling system aims

to accomplish the following: improve the effectiveness of a production system by ensuring that the

proper amount of materials is delivered at the right place at the right time in the most cost-effective

manner, reduce damage of materials during storage and movement, increase area utilization by

properly storing products, lowering storage and handling costs, minimize accident during materials

handling, and by improving material handling to reduce overall costs. The design of a belt

conveyor for coal handling would ensure that:

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 a. The design can be beneficial to the coal handling system since it aims to provide a

material handling component for transportation of the materials.

b. The design can be beneficial to the customers by establishing material handling which

can improve customer service by minimizing the time spent transporting the materials.

c. The design can be beneficial to the power station, particularly the thermal power plant,

by preserving its high productivity.

d. The design can be beneficial to the power station, particularly the thermal power plant,

because it would ensure the reliability of the preparation and storage process.

1.5 SCOPES AND LIMITATIONS

The scope and limitation of this design are all related to the engineering topics and research

regarding the coal handling system, transportation of the coal. These include the following:

• Research for the concept and importance of material handling in the industry.

• Research for the procedures and processes involved in the design of a belt conveyor using

the belt drive.

• Application of the proper methodologies in the design.

• Calculation in the design of the belt conveyor.

• Calculation in the design of the gearbox motor.

• Construction of the layout or drawing of the belt conveyor and the gearbox motor for the

coal handling system.

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 CHAPTER 2: REVIEW OF RELATED LITERATURE

Belt drives

According to (Childs, 2019), belt drives are capable of transmitting mechanical power

between two spinning shafts. Belt drives are generally less expensive than similar gears and are

helpful for transferring power between widely separated shafts or nonparallel drives. Belt drives,

technology, and wedge and flat belt selection and specification are all available in a variety of

configurations. Belt drives represent an innovation opportunity area, particularly for new

applications, extended life and improved reliability, as well as miniaturization, and the technology

is constantly evolving with new materials and surface treatments, improvements in understanding

of kinematics and wear, and associated modeling procedures.

Belt drives compared to other drives such as chain drive are known to have the following

advantages such as having a shock and vibration damping characteristics as well as it produces

low noise during the operation. Additional advantages includes both simple and cost effective.

Belt drives are typically associated to low maintenance and high energy efficiency which is up to

98% wherein this type of drive makes it as one of the attractive choices. Belt drives are commonly

associated in material handling equipment that is use for transporting a material from one location

to another location with least human interference. An example of material handling would be a

belt conveyor system which is able to handle high load capacity for up to 30000t/h with a huge

amount of length for the conveying path which may reach up to 3 or 4 km.

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Gear drives

A gear is a toothed wheel that contacts another toothed mechanism to adjust transmission

speed or direction. In general, gears are utilized in one of four reasons. Increase or reduce rotational

speed, modify the amount of force or torque, move rotational motion to a new axis (parallel, right

angles, rotating, linear, etc.) and reverse the direction of rotation are some of the causes. Gears are

positive-engagement, compact power transmission components that can change the amount of

force or torque applied. The American Gear Manufacturers Association (AGMA) and the

American National Standards Institute have set standards for selecting and manufacturing gears

(ANSI).

THE LAW OF GEARING

The fundamental law of gearing specifies that throughout the gear mesh, the angular

velocity ratio of all gears must remain constant. When the common normal at the point of contact

between the teeth crosses through a fixed point on the line of centers, known as the pitch point,

this condition is satisfied.

Figure 2. Schematic of Diesel Locomotive

The transfer of energy from its source to a location where it can be used to do productive

work is known as power transmission. Belts, ropes, chains, gears, couplings, and friction clutches

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are commonly used for power transmission. Gears are the most resilient and durable of all

mechanical devices because they are capable of delivering force or motion without slipping. A

gear transmits rotating force from the prime mover (diesel engine) to another driven shaft in the

diagram below (locomotive wheels). Gears' most important attribute is that they generate a

mechanical advantage, which is a measure of force amplification (Bhatia).

Definition and application of conveyors

Conveyor Systems are mechanical devices or assemblies that are designed to carry material

with the least amount of effort possible. However, while there are many distinct types of conveyor

systems, they all have the same basic design. They consist of a frame that supports either rollers

or wheels or a belt, which transports things from one location to another. A motor, gravity, or

human effort can all be used to propel them forward. This type of material handling system is

available in a wide range of configurations to accommodate the various products or commodities

that need to be transferred.

Conveyors, according to the American Society of Mechanical Engineers, are "horizontal,

inclined, or vertical devices for moving or carrying bulk items, parcels, objects, or passengers in a

course indicated by their design." One of the most important aspects of this description, and what

distinguishes conveyors from other types of material handling equipment, is the fact that they carry

product in a straight line "device is predetermined by the way it is constructed.” As a bonus, this

is the one characteristic that all conveyor types have, regardless of their application, industry, or

sector. Many types of conveyors, particularly those found in sorting systems, have the ability to

divert goods in a variety of routes; however, all of these directions are planned courses.

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 When it comes to conveyor systems, there are three essential components: the belt support,

the pulley, and the drive unit. Each component is critical to the functionality of the conveyor unit

and must be carefully selected. Despite the fact that all conveyor systems involve these

components, designs differ in terms of the materials used in construction and the location of each

component.

Belt support is a component that guarantees that the belt moves smoothly as it moves

through the machine. Workers can cause the belt to sag when they place a large object on it if the

support unit is not strong enough, and the sagging causes the belt to not move as smoothly or

quickly as it should. The installation of a robust support unit ensures that the belt remains taut and

runs efficiently throughout.

The pulley system is an external component that is used to regulate the movement of the

belt. Each unit is equipped with at least two pulleys, one of which is powered and the other which

is not. More complicated conveyor systems may include a number of rotors distributed throughout

its structure.

The drive unit is responsible for the movement of the system. The unit is equipped with a

counter bearing, which ensures that the pieces move as effectively as possible. The belt can also

be moved in reverse with the help of this unit, which also manages the repeated direction changes

required by some systems. Some conveyor systems are run by hand, while others are computer

controlled. These systems still make use of a drive unit, but it is not powered in any way.

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Coal Components and Physical Parameters

Coal is a combustible sedimentary rock that is black or brownish black in color and

contains a high concentration of carbon and hydrocarbons. Coal is regarded as a nonrenewable

energy source since it takes millions of years to develop and is therefore considered a fossil fuel.

Coal is made up of the energy stored by plants that lived hundreds of millions of years ago in

marshy forests and have been buried underground. Over millions of years, layers of earth and rock

accumulated on top of the plants. The pressure and heat that resulted from this transformed the

plants into the substance we know as coal.

Figure 3. Coal Components

In addition to mineral matter, volatile matter is composed of aliphatic carbon atoms

(connected in open chains) or aromatic hydrocarbons (one or more six-carbon rings characteristic

of the benzene series) and halogen atoms (linked in closed chains).

A specific set of physical properties characterizes each form of coal, with the majority of

them being governed by moisture, volatile content (aliphatic or aromatic hydrocarbons), and

carbon content. Aliphatic is a term used to describe a class of organic chemical compounds (carbon

compounds) in which the carbon atoms are connected together in a chain-like

structure. Hydrocarbons is a class of organic chemicals that include substances such as benzene

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and methane but solely include carbon and hydrogen. Aromatic is having one or more six-carbon

rings characteristic of the benzene series as one or more constituents.

Figure 4. Anthracite Coal

Anthracite coal is a compact, hard rock with a jet-black color and a metallic shine that is

used in the production of steel. Its carbon content ranges between 86 and 98 percent by weight,

and it burns slowly, producing a faint blue flame and very little smoke as it does so. Anthracite is

also known as "hard coal," anthracite is a type of bituminous coal that occurs when tremendous

pressures build up in folded rock strata during the formation of mountain ranges, causing the coal

to harden. This occurs exclusively in a few geographical places, primarily in Pennsylvania's

Appalachian region, and is a rare occurrence. Coke is made from anthracite, which has the highest

energy content of all coals and is used in steel foundry ovens because it has the highest energy

content of all coals.

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Existing studies

According to (Ananth, Rakesh, & Visweswarao, 2013), belt conveyors is the means of

transportation of material from one place to another. It has high load carrying capacity and long

length of conveying path making it a reliable form of transportation. Also, from the paper of

Ananth, Rakesh, & Visweswarao, 2013, Prior to the process of designing and selecting the

conveyor belt for a certain application, it is important the volume of load that it will carry so that

the design can account for it and can also be designed for a certain percent of overloading. It is

important that the characteristics of material to be loaded on the conveyor belt is identified such

as the angle of repose and angle of natural friction. These characteristics are the ones that determine

the surface it covers in the belt when it is loaded freely.

According to the study of Zhang and Xia, the energy efficiency of conveyor belt systems

can be improved at equipment or operational levels. Their study proposes switching control and

variable speed control to improve belt conveyors' energy efficiency. The existing implementations

focus mostly on lower-level control loops or an individual conveyor at the system level without

operational considerations. Increasing operating performance also saves energy by synchronizing

the belt speeds and feed rate, and hence energy costs. The optimum control plan based on VSD

includes the power model of belt conveyors, the TOU tariff and belt velocity ramps. With this

method, ideal controlled operational instructions about working time, belt speeds and feed rates

will increase the operating performance of belt conveyors. The coordination of two or more

physical sub-systems, the time when the energy is utilized or the human capacity which is utilized

by the system, can indeed indicate operational efficiency. The two optimal control systems can be

used as an open loop or a closed loop. Operators are guided by the open-loop implementation to

get the belt conveyor system optimally operated without interfering with the control system.

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However, with their optimal operating instructions the closed loop implementation directly drives

the belt carrier. In its best operational efficiency, it controls the conveyor systems automatically,

while also relieving the operators. As general optimal control issues, the two optimal control

strategies for belt conveyor systems are formulated so that they can readily be adapted to other

conveyor systems or the related industry applications (Xhang & Xia, 2010).

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 CHAPTER 3: DESIGN CALCULATION

A. Belt Conveyor Design Capacity and Equipment Calculations

INPUT DATA

Service use = To transport coal from unloading directly to the crusher house.

From CEMA material characteristics and weight per cubic foot (Kulinowski & Kasza),

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Material name = Coal, Anthracite, Sized (C26)

𝐴𝑛𝑔𝑙𝑒 𝑜𝑓 𝑟𝑒𝑝𝑜𝑠𝑒 = 27°

𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑖𝑛𝑐𝑙𝑖𝑛𝑎𝑡𝑖𝑜𝑛 = 16°

𝑙𝑏𝑠
𝐵𝑢𝑙𝑘 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 60
𝑓𝑡 3
𝑡𝑜𝑛
𝐷𝑒𝑠𝑖𝑔𝑛 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 1000
ℎ𝑟
𝐿𝑒𝑛𝑔𝑡ℎ = 420 𝑓𝑡

𝐵𝑒𝑙𝑡 𝑠𝑝𝑒𝑒𝑑 = 800 𝑓𝑝𝑚

𝐵𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ = 42 𝑖𝑛𝑐ℎ𝑒𝑠

𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝐶𝑜𝑛𝑣𝑒𝑦𝑜𝑟 (𝐻) = 30𝑓𝑡

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Belt Conveyor Capacity Table

1. Determine the surcharge angle of the material.

𝑆𝑢𝑟𝑐ℎ𝑎𝑟𝑔𝑒 𝐴𝑛𝑔𝑙𝑒 = 27° − 13° = 𝟏𝟒°
*Surcharge angle is typically less than 5degress to 15degress to the angle of repose

2. Determine the density of the material per cubic foot (lb/ft3).

𝒍𝒃𝒔
𝐵𝑢𝑙𝑘 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 𝟔𝟎
𝒇𝒕𝟑
3. Choose idler shape.
4. Select suitable conveyor belt speed.
5. Convert the desired tonnage per hour (tph) to be conveyed to the equivalent in cubic feet
per hour (ft3/hr)
𝑡𝑜𝑛
1000 𝑥2000 𝒇𝒕𝟑
ℎ𝑟 = 𝟑𝟑𝟑𝟑𝟑. 𝟑𝟑𝟑𝟑
𝑙𝑏𝑠 𝒉𝒓
60 3
𝑓𝑡

6. Convert the desired capacity in cubic feet per hour to the equivalent capacity at a belt speed
of 100 fpm.

𝑓𝑡
3
100 ⁄𝑚 𝟔𝟔𝟔𝟕𝒇𝒕𝟑
33333.3333𝑓𝑡 /ℎ𝑟 ( ) = 𝟒𝟏𝟔𝟔.
𝑓𝑡 𝒉𝒓
800 ⁄𝑚

7. Find the appropriate belt width

8. Selected belt speed may require revision

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Cross Section of Load and Capacity at 100 FPM

10° − 14° 1.148𝑓𝑡 2 − 𝐴𝑡 6891 − 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦

= =
10° − 15° 1.148𝑓𝑡 2 − 1.254𝑓𝑡 2 6891 − 7524

𝐴𝑡 = 1.233𝑓𝑡 2

𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 𝟕𝟑𝟗𝟕𝒇𝒕𝟑 /𝒉𝒓

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Idler Spacing

Now we have:

𝐵𝑒𝑙𝑡 𝑠𝑝𝑒𝑒𝑑 = 800 𝑟𝑝𝑚

𝐵𝑒𝑙𝑡 𝑤𝑖𝑑𝑡ℎ = 42 𝑖𝑛𝑐ℎ𝑒𝑠

𝑇ℎ𝑟𝑜𝑢𝑔ℎ 𝐴𝑛𝑔𝑙𝑒 = 35°

4166.6667𝑓𝑡 3 /ℎ𝑟
= 56.33%
7397𝑓𝑡 3 /ℎ𝑟

𝐼𝑑𝑙𝑒𝑟 𝑆𝑝𝑎𝑐𝑖𝑛𝑔 = 𝟒. 𝟓𝒇𝒕

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*There is no need for interpolation as the values are the same.

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Calculated Idler Load

𝐶𝐼𝐿 = {[𝑊𝐵 + (𝑊𝑀 × 𝐾1)] × 𝑆𝐼} + 𝐼𝑀𝐿

Where:

𝑊𝐵 = 𝑏𝑒𝑙𝑡 𝑤𝑒𝑖𝑔ℎ𝑡

𝑄 × 2000
𝑊𝑀 = 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 =
60 × 𝑉𝑒𝑒
𝑄 = 𝑞𝑢𝑎𝑛𝑡𝑖𝑡𝑦 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑣𝑒𝑦𝑒𝑑

𝑉𝑒𝑒 = 𝑑𝑒𝑠𝑖𝑔𝑛 𝑏𝑒𝑙𝑡 𝑠𝑝𝑒𝑒𝑑

𝑆𝐼 = 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 𝑜𝑓 𝑖𝑑𝑙𝑒𝑟𝑠

𝐾1 = 𝐿𝑢𝑚𝑝 𝑎𝑑𝑗𝑢𝑠𝑡𝑚𝑒𝑛𝑡 𝑓𝑎𝑐𝑡𝑜𝑟

𝐼𝑀𝐿 = 𝑖𝑑𝑙𝑒𝑟 𝑚𝑖𝑠𝑎𝑙𝑖𝑔𝑛𝑚𝑒𝑛𝑡 𝑙𝑜𝑎𝑑 𝑑𝑢𝑒 𝑡𝑜 𝑖𝑑𝑙𝑒𝑟 ℎ𝑒𝑖𝑔ℎ𝑡 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝑏𝑒𝑙𝑡 𝑡𝑒𝑛𝑠𝑖𝑜𝑛

*IML is assumed to be zero in this computation

1000 𝑇𝑜𝑛𝑠⁄ℎ𝑟 × 2000

𝑊𝑀 = = 𝟒𝟏. 𝟔𝟔𝟔𝟕 𝒍𝒃⁄𝒇𝒕
60 × 800𝑓𝑝𝑚

𝐶𝐼𝐿 = {[11 𝑙𝑏⁄𝑓𝑡 + (41.6667 𝑙𝑏⁄𝑓𝑡 × 1)] × 4.5𝑓𝑡} + 0 = 𝟏𝟗𝟖. 𝟓𝟎𝟏𝟓𝒍𝒃𝒔

Calculated Idler Return Load

𝐶𝐼𝐿𝑅 = 11 𝑙𝑏⁄𝑓𝑡 × 10𝑓𝑡 = 𝟏𝟏𝟎 𝒍𝒃𝒔

21
Effect of Load on Predicted Bearing L10 Life

𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝐼𝑑𝑙𝑒𝑟 𝐿𝑜𝑎𝑑 198.5015

= = 𝟎. 𝟓𝟓
𝐼𝑑𝑙𝑒𝑟 𝐿𝑜𝑎𝑑 𝑅𝑎𝑡𝑖𝑛𝑔 363

K2 Factor = 7.5

*The bearing to be used is roller bearing

𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝐿10 = 30000 × 7.5 = 𝟐𝟐𝟓𝟎𝟎𝟎𝒉𝒓

Effect of Belt Speed on Predicted L10 life

𝐵𝑒𝑙𝑡 𝑆𝑝𝑒𝑒𝑑 × 12 800 × 12

𝑟𝑝𝑚 = = = 𝟓𝟎𝟗. 𝟑𝟎
𝑅𝑜𝑙𝑙 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 × 𝜋 6𝜋
*The designers chose the 6 inches as the roll diameter

22
K3A Factor = 0.9

Effect of roll diameter on predicted bearing L10 Life

𝐼𝑓 𝑟𝑜𝑙𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑖𝑠 6 𝑖𝑛𝑐ℎ𝑒𝑠 𝑡ℎ𝑒𝑛 𝐾3𝐵 𝑖𝑠 1.50

𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝐿10 = 225000ℎ𝑟 × 0.9 × 1.50 = 270000ℎ𝑟

Effect of Environmental, maintenance, and other special condition

Effect of maintenance on potential idler life

*The designers assumed that the maintenance will be fair.

23
K4A = 0.5

Effect of environmental conditions on potential idler life

K4B = 0.6

Effect of operating temperature on potential idler life

*At a depth of 1.8ft, the temperate in a coal mine is 32.6oC

9
(32.6℃) + 32 = 90.68℉
5

24
K4C = 1

𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝐿10 = 270000ℎ𝑟 × 0.5 × 0.6 × 1.0 = 81000ℎ𝑟

Basic Power Requirements

𝑇𝑒 × 𝑉
ℎ𝑝 =
33000
Te is the final summarization of the belt tensions produced by forces such as:

• The gravitational load to lift or lower the material being transported.

• The frictional resistance of the conveyor components, drive, and all accessories while
operating at design capacity.
• The frictional resistance of the material as it is being conveyed.
• The force required to accelerate the material continuously as it is fed onto the conveyor
by a chute or a feeder.

Effective Tension

𝑇𝑒 = 𝐿𝐾𝑡 (𝐾𝑥 + 𝐾𝑦 𝑊𝑏 + 0.015𝑊𝑏 ) + 𝑊𝑚 (𝐿𝐾𝑦 ± 𝐻) + 𝑇𝑝 + 𝑇𝑎𝑚 + 𝑇𝑎𝑐

Where:

𝐿 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟, 𝑓𝑡

𝐾𝑡 = 𝑎𝑚𝑏𝑖𝑒𝑛𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟

𝐾𝑥 = 𝑓𝑎𝑐𝑡𝑜𝑟 𝑢𝑠𝑒𝑑 𝑡𝑜 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒 𝑡ℎ𝑒 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑖𝑑𝑙𝑒𝑟𝑠 𝑎𝑛𝑑 𝑡ℎ𝑒 𝑠𝑙𝑖𝑑𝑖𝑛𝑔

25
 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑡ℎ𝑒 𝑏𝑒𝑙𝑡 𝑎𝑛𝑑 𝑖𝑑𝑙𝑒𝑟 𝑟𝑜𝑙𝑙𝑠, 𝑙𝑏𝑠 𝑝𝑒𝑟 𝑓𝑡

𝐾𝑦 = 𝑐𝑎𝑟𝑟𝑦𝑖𝑛𝑔 𝑟𝑢𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 𝑢𝑠𝑒𝑑 𝑡𝑜 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒 𝑡ℎ𝑒 𝑐𝑜𝑚𝑏𝑖𝑛𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒

𝑜𝑓 𝑡ℎ𝑒 𝑏𝑒𝑙𝑡 𝑎𝑛𝑑 𝑡ℎ𝑒 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑜𝑎𝑑 𝑡𝑜 𝑓𝑙𝑒𝑥𝑢𝑟𝑒 𝑎𝑠 𝑡ℎ𝑒 𝑏𝑒𝑙𝑡 𝑎𝑛𝑑 𝑙𝑜𝑎𝑑 𝑚𝑜𝑣𝑒 𝑜𝑣𝑒𝑟 𝑡ℎ𝑒 𝑖𝑑𝑙𝑒𝑟𝑠.

𝐹𝑜𝑟 𝑟𝑒𝑡𝑢𝑟𝑛 𝑟𝑢𝑛 𝑢𝑠𝑒 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 0.015.

𝑊𝑏 = 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑏𝑒𝑙𝑡 𝑖𝑛 𝑝𝑜𝑢𝑛𝑑𝑠 𝑝𝑒𝑟 𝑓𝑜𝑜𝑡 𝑜𝑓 𝑏𝑒𝑙𝑡 𝑙𝑒𝑛𝑔𝑡ℎ.

𝑊𝑚 = 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙, 𝑙𝑏𝑠 𝑝𝑒𝑟 𝑓𝑜𝑜𝑡 𝑜𝑓 𝑏𝑒𝑙𝑡 𝑙𝑒𝑛𝑔𝑡ℎ

𝐻 = 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑡ℎ𝑎𝑡 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑖𝑠 𝑙𝑖𝑓𝑡𝑒𝑑 𝑜𝑟 𝑙𝑜𝑤𝑒𝑟𝑒𝑑, 𝑓𝑡

𝑇𝑝 = 𝑡𝑒𝑛𝑠𝑖𝑜𝑛 𝑟𝑒𝑠𝑢𝑙𝑡𝑖𝑛𝑔 𝑓𝑟𝑜𝑚 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑏𝑒𝑙𝑡 𝑡𝑜 𝑓𝑙𝑒𝑥𝑢𝑟𝑒 𝑎𝑟𝑜𝑢𝑛𝑑 𝑝𝑢𝑙𝑙𝑒𝑦𝑠 𝑎𝑛𝑑 𝑡ℎ𝑒

𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑜𝑓 𝑝𝑢𝑙𝑙𝑒𝑦𝑠 𝑡𝑜 𝑟𝑜𝑡𝑎𝑡𝑖𝑜𝑛 𝑜𝑛 𝑡ℎ𝑒𝑖𝑟 𝑏𝑒𝑎𝑟𝑖𝑛𝑔𝑠, 𝑡𝑜𝑡𝑎𝑙 𝑓𝑜𝑟 𝑎𝑙𝑙 𝑝𝑢𝑙𝑙𝑒𝑦𝑠, 𝑙𝑏𝑠

𝑇𝑎𝑚 = 𝑡𝑒𝑛𝑠𝑖𝑜𝑛 𝑟𝑒𝑠𝑢𝑙𝑡𝑖𝑛𝑔 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑓𝑜𝑟𝑐𝑒 𝑡𝑜 𝑎𝑐𝑐𝑒𝑙𝑒𝑟𝑎𝑡𝑒 𝑡ℎ𝑒 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑐𝑜𝑛𝑡𝑖𝑛𝑢𝑜𝑢𝑠𝑙𝑦 𝑎𝑠

𝑖𝑡 𝑖𝑠 f𝑒𝑑 𝑜𝑛𝑡𝑜 𝑡ℎ𝑒 𝑏𝑒𝑙𝑡𝑠, 𝑙𝑏𝑠

𝑇𝑎𝑐 = 𝑡𝑜𝑡𝑎𝑙 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑒𝑛𝑠𝑖𝑜𝑛𝑠 𝑓𝑟𝑜𝑚 𝑐𝑜𝑛𝑣𝑒𝑦𝑜𝑟 𝑎𝑐𝑐𝑒𝑠𝑠𝑜𝑟𝑖𝑒𝑠, 𝑙𝑏𝑠

Ambient Temperature Correction Factor

The temperature used for the computation is 32.6oC which is converted into 90.68oF

26
*Since the curve of Kt is at the value of 1 at 40oF and it will form a straight line to the right, then
it is safe to assume that the value of Kt at 90.68oF will be 1.

𝐾𝑡 = 1

Idler Friction Factor

𝐴𝑖
𝐾𝑥 = 0.00068(𝑊𝑏 + 𝑊𝑚 ) +
𝑆𝑖

For the value of Ai, the data was taken from CEMA tables:

1.5
𝐾𝑥 = 0.00068 (11 𝑙𝑏⁄𝑓𝑡 + 41.6667 𝑙𝑏⁄𝑓𝑡) + = 𝟎. 𝟑𝟕
4.5

Factor for calculating the Force of Belt and Load Flexure over the Idlers

𝑊𝑏 + 𝑊𝑚 = 𝟓𝟐. 𝟔𝟔𝟔𝟕 𝒍𝒃⁄𝒇𝒕

𝑆𝑖 = 𝟒. 𝟓𝒇𝒕

𝐿𝑒𝑛𝑔𝑡ℎ = 𝟒𝟐𝟎𝒇𝒕

𝑆𝑙𝑜𝑝𝑒 = 𝟐𝟎°

27
 𝐾𝑦 = 0.033

Corrected factor

Interpolation:

0.032 − 0.033 0.0335 − 𝐾𝑦

=
0.032 − 0.034 0.0335 − 0.035
𝑲𝒚 = 𝟎. 𝟎𝟑𝟒𝟑

28
Total of the belt tensions required to rotate each of the pulleys on the conveyor

2 × 200 = 400𝑙𝑏𝑠

3 × 250 = 450𝑙𝑏𝑠

𝑇𝑝 = 950𝑙𝑏𝑠

29
Force to accelerate the material continuously as it is fed onto the belt

𝑄 × 2000 𝑉 − 𝑉0
𝑇𝑎𝑚 = ×
3600 × 32.2 60
Where:

𝑄 = 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑙𝑜𝑎𝑑𝑖𝑛𝑔, 𝑡𝑜𝑛𝑠 𝑝𝑒𝑟 ℎ𝑜𝑢𝑟

𝑔 = 32.2𝑓𝑡/𝑠𝑒𝑐 2

𝑉 = 𝑑𝑒𝑠𝑖𝑔𝑛 𝑏𝑒𝑙𝑡 𝑠𝑝𝑒𝑒𝑑, 𝑓𝑝𝑚

𝑉0 = 𝑖𝑛𝑖𝑡𝑖𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑎𝑠 𝑖𝑡 𝑖𝑠 𝑓𝑒𝑑 𝑜𝑛𝑡𝑜 𝑏𝑒𝑙𝑡

1000 × 2000 800 − 0

𝑇𝑎𝑚 = ×
3600 × 32.2 60
𝑻𝒂𝒎 = 𝟐𝟑𝟎. 𝟎𝟒𝟑𝟕

30
Resistance generated by conveyor accessories

*Resistance from trippers, stackers, and belt-cleaning devices are assumed to be zero

𝑇𝑠𝑏 = 𝐿𝑏 (𝐶𝑠 ℎ𝑠 + 6)

𝐿𝑏 = 𝑠𝑘𝑖𝑟𝑡𝑏𝑜𝑎𝑟𝑑 𝑙𝑒𝑛𝑔𝑡ℎ, 𝑓𝑡 = 15𝑓𝑡

ℎ𝑠 = 𝑑𝑒𝑝𝑡ℎ 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑡𝑜𝑢𝑐ℎ𝑖𝑛𝑔 𝑡ℎ𝑒 𝑠𝑘𝑖𝑟𝑏𝑜𝑎𝑟𝑑, 𝑖𝑛 = 15𝑖𝑛

𝑇𝑠𝑏 = 15𝑓𝑡(0.0538 × 15𝑖𝑛 + 6) = 𝟐𝟕𝟏. 𝟓𝟕𝟓

Resistance Calculations, Te

Idler Friction

𝑇𝑥 = 𝐿 × 𝐾𝑥 × 𝐾𝑡

𝑇𝑥 = 420 × 0.37 × 1 = 𝟏𝟓𝟓. 𝟒

Belt flexure, carrying idlers

𝑇𝑦𝑐 = 𝐿 × 𝐾𝑦 × 𝑊𝑏 × 𝐾𝑡

𝑇𝑦𝑐 = 420 × 0.0343 × 11 × 1 = 𝟏𝟓𝟖. 𝟒𝟔𝟔

Belt flexure, return idlers

31
 𝑇𝑦𝑐 = 𝐿 × 0.015 × 𝑊𝑏 × 𝐾𝑡

𝑇𝑦𝑐 = 420 × 0.015 × 11 × 1 = 69.3

𝑆𝑢𝑏𝑡𝑜𝑡𝑎𝑙(𝑎): 𝐿𝐾𝑡 (𝐾𝑥 + 𝐾𝑦 𝑊𝑏 + 0.015𝑊𝑏 ) = 155.4 + 158.466 + 69.3 = 𝟑𝟖𝟑. 𝟏𝟔𝟔

Material flexure

𝑇𝑦𝑚 = 𝐿 × 𝐾𝑦 × 𝑊𝑚

𝑇𝑦𝑚 = 420 × 0.0343 × 41.6667 = 𝟔𝟎𝟎. 𝟐𝟓

Lift or lower

𝑇𝑚 = 𝐻 × 𝑊𝑚

𝑇𝑚 = 30 × 41.6667 = 1250

𝑆𝑢𝑏𝑡𝑜𝑡𝑎𝑙(𝑏): 𝑊𝑚 (𝐿𝐾𝑦 ± 𝐻) = 600.25 + 1250 = 𝟏𝟖𝟓𝟎. 𝟐𝟓

Pulley resistance

𝑇𝑝 = 950

Accelerated Material

𝑇𝑎𝑚 = 230.0437

Accessories

𝑇𝑎𝑐 = 271.575

𝑆𝑢𝑏𝑡𝑜𝑡𝑎𝑙(𝑐): 𝑇𝑝 + 𝑇𝑎𝑚 + 𝑇𝑎𝑐 = 950 + 230.0437 + 271.575 = 1451.6187

Total:

𝑇𝑒 = 𝑆𝑢𝑏𝑡𝑜𝑡𝑎𝑙(𝑎) + 𝑆𝑢𝑏𝑡𝑜𝑡𝑎𝑙(𝑏) + 𝑆𝑢𝑏𝑡𝑜𝑡𝑎𝑙(𝑐) = 383.166 + 1850.25 + 1451.6187

𝑇𝑒 = 𝟑𝟔𝟖𝟓. 𝟎𝟑𝟒𝟕𝒍𝒃𝒔

Horsepower

𝑇𝑒 × 𝑉
ℎ𝑝 =
33000
3685.0347 × 800
ℎ𝑝 = = 𝟗𝟖. 𝟐𝟕𝒉𝒑
33000

32
*Assuming drive efficiency is at 94% at motor shaft, then:

98.27ℎ𝑝
0.94
𝐴𝑐𝑡𝑢𝑎𝑙 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 = 𝟏𝟎𝟒. 𝟓𝟒

Wrap Factor

𝑐𝑤 = 0.08

33
 𝑇2 1
= 𝑓𝜃
𝑇𝑒 𝑒 − 1

Where:

Te = T1- T2 = effective belt tension, lbs

T1 = tight-side tension at pulley, lbs

T2 = slack-side tension at pulley, lbs

e = base of naperian logarithms = 2.718

f = coefficient of friction between pulley surface and belt surface (0.25 rubber surfaced belt
driving bare steel or cast-iron pulley; 0.35 rubber surfaced belt driving rubber lagged pulley
surface). Values apply to normal running calculations

θ = wrap of belt around the pulley, radians (one degree = 0.0174 radians)

Tension Relationships and Belt Sag Between Idlers

𝑊𝑆𝑖2
𝑆𝑎𝑔 =
8𝑇
However,

34
 𝑇0 = 6.25(4.5)(52.6667) = 𝟏𝟒𝟖𝟏. 𝟐𝟓𝒍𝒃𝒔

Maximum and Minimum Belt Tensions

Tension Tb is the weight of the carrying and/or return run belt for a sloped conveyor is carried on
the pulley at the top of the slope

𝑇𝑏 = 𝐻 × 𝑊𝑏

𝑇𝑏 = 30 × 11 = 𝟑𝟑𝟎

Return Belt Friction Tension, Tyr is the return belt friction is the belt tension resulting from the
empty belt moving over the return run idlers

𝑇𝑦𝑟 = 0.015 × 𝐿 × 𝑊𝑏 × 𝐾𝑡

𝑇𝑦𝑟 = 0.015 × 420 × 11 × 1 = 𝟔𝟗. 𝟑

Solving for T2

𝑇2 = 𝑇𝑒 𝑐𝑤

𝑇2 = (3685.0347𝑙𝑏𝑠)(0.08) = 𝟐𝟗𝟒. 𝟖𝟎𝒍𝒃𝒔

However,

𝑇2 = 𝑇0 ± 𝑇𝑏 ± 𝑇𝑦𝑟

𝑇2 = 1481.25 + 330 − 69.3 = 𝟏𝟕𝟒𝟏. 𝟗𝟓𝒍𝒃𝒔

Use the larger value

𝑇𝑡 = 𝑇2 −𝑇𝑏 + 𝑇𝑦𝑟

𝑇𝑡 = 𝑇0 = 𝑇𝑚𝑖𝑛
35
 𝑇𝑚𝑎𝑥 = 𝑇1 = 𝑇2 + 𝑇𝑒

𝑇𝑚𝑖𝑛 = 294.80 − 330 + 69.3

𝑇𝑚𝑖𝑛 = 34.1𝑙𝑏𝑠

𝑇𝑚𝑎𝑥 = 1741.95𝑙𝑏𝑠 + 3685.0347

𝑇𝑚𝑎𝑥 = 𝟓𝟒𝟐𝟔. 𝟗𝟖𝒍𝒃𝒔

Belt Selection

𝑇1
𝐵𝑒𝑙𝑡 𝑆𝑡𝑟𝑒𝑠𝑠 =
𝐵𝑒𝑙𝑡 𝑊𝑖𝑑𝑡ℎ
5426.98𝑙𝑏𝑠 𝒍𝒃𝒔
𝐵𝑒𝑙𝑡 𝑆𝑡𝑟𝑒𝑠𝑠 = = 𝟏𝟐𝟗. 𝟐𝟏
42 𝒊𝒏𝒄𝒉

36
B. Belt Conveyor Components

36
37
 C. Gearbox Design and Equipment Calculations

SINGLE STAGE GEARBOX (SPEED REDUCER)

a) Horsepower

𝑇𝑒 × 𝑉
ℎ𝑝 =
33000
3685.0347 × 800
ℎ𝑝 = = 𝟗𝟖. 𝟐𝟕𝒉𝒑
33000

• Assuming drive efficiency is at 94% at motor shaft, then:

98.27ℎ𝑝
0.94
𝐴𝑐𝑡𝑢𝑎𝑙 𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 = 𝟏𝟎𝟒. 𝟓𝟒

b) Motor Selection

• Based on the Standard Motor Catalogue, the chosen output HP is 115 HP or

equivalent to 86 kW

38
 115 HP /885 rpm (AESV2E/AESU2E)
c) Other Parameters

𝑁 𝐷
• Velocity Ratio or V.R. = 𝑁𝐴 = 𝐷𝐵 (where A is the driver)
𝐵 𝐴

𝑁𝐴 𝑜𝑟 𝑝𝑖𝑛𝑖𝑜𝑛 = 𝟖𝟖𝟓 𝒓𝒑𝒎

𝐵𝑒𝑙𝑡 𝑆𝑝𝑒𝑒𝑑 × 12 800 × 12

𝑟𝑝𝑚 = = = 509.30
𝑅𝑜𝑙𝑙 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 × 𝜋 6𝜋
𝑁𝐵 𝑜𝑟 𝑔𝑒𝑎𝑟 = 𝟓𝟎𝟗. 𝟑𝟎 𝒓𝒑𝒎

𝑁𝐴 885 𝑟𝑝𝑚
V. R. = = = 𝟏. 𝟕𝟒
𝑁𝐵 509.30 𝑟𝑝𝑚
9.5488 𝑥 𝑃𝑜𝑤𝑒𝑟 (𝑘𝑊)
• Full Torque Load = 𝑥 𝐺𝑒𝑎𝑟 𝑏𝑜𝑥 𝑅𝑎𝑡𝑖𝑜
𝑆𝑝𝑒𝑒𝑑 (𝑅𝑃𝑀)

9.5488 𝑥 86 𝑘𝑊
= 𝑥 1.74 = 1.61 kN-m
885 𝑅𝑃𝑀

• Using 20 degrees Stub involute system because it has a strong tooth to take heavy loads

39
• The Static Stress for cast iron, ordinary is 56 MPa

• Assuming that the Service Factor would be 1.00

40
 • Modulus of Elasticity (Cast Iron) – 100 GPa

The Parameters in Statement Form:

A gear drive is required to transmit a maximum power of 86 kW. The velocity ratio is 1.74
and rpm of the pinion is 885.The approximate centre distance between the shafts may be taken as
300 mm. The gears are well-cut commercial gears having teeth of 20 degrees Stub involute
profiles. The static stress for the gear material (which is cast iron) may be taken as 56 MPa and
face width as 10 times the module. Assuming that the drive operated 8 to 10 hours per day under
steady conditions, find the module, face width and number of teeth on each gear. Check the design
for dynamic, static tooth load, and wear loads. The modulus of elasticity for cast iron may be taken
as 100 GPa.

Given:

P= 86 kW or 86000 Watts

V.R.=1.74

𝑁𝑝 = 885 𝑟𝑝𝑚

L =300 mm

∅ = 20° (𝑆𝑡𝑢𝑏 𝑖𝑛𝑣𝑜𝑙𝑢𝑡𝑒, 𝑤𝑒𝑙𝑙 − 𝑐𝑢𝑡 𝑐𝑜𝑚𝑚𝑒𝑟𝑐𝑖𝑎𝑙 𝑡𝑒𝑒𝑡ℎ)

𝑁
𝑆𝑜𝑝 = 𝑆𝑜𝑔 = 56 ; 𝑏 = 10(𝑚)
𝑚𝑚2
Service: 8-10 hrs. a day, with steady conditions;

𝐸𝑝 = 𝐸𝑔 = 100 𝐺𝑃𝑎 = 100000 𝑁/𝑚𝑚2

Solution:

𝐷𝑝 + 𝐷𝑔
𝐿=
2
2(300) = 𝐷𝑝 + 𝐷𝑔

𝐷𝑔
𝑉𝑅 = 1.74 =
𝐷𝑝

𝐷𝑔 = 1.74𝐷𝑝

600 = 𝐷𝑝 + 1.74𝐷𝑝

𝐷𝑝 = 218.98 𝑚𝑚

41
 𝐷𝑔 = 1.74(218.98) = 381.0252𝑚𝑚

• Both the gears are of the same materials, thus, design is based on pinion

218.98
𝜋𝐷𝑝 𝑁𝑝 𝜋 ( 1000 ) (885 ) 𝑚
𝑣= = = 10.1472
60 60 𝑠
4.5
𝑐𝑣 = 4.5+𝑣 For carefully cut gears at velocities up to 12.5 m/s

4.5
𝑐𝑣 = = 0.3072
4.5 + 10.1472

• Tooth form or Lewis’factor,

0.841
𝑦 = 0.175 − 𝑓𝑜𝑟 20° 𝑠𝑡𝑢𝑏 𝑠𝑦𝑠𝑡𝑒𝑚
𝑇
𝐷𝑝
𝑇𝑝 =
𝑚
0.841 0.841𝑚
𝑦𝑝 = 0.175 − = 0.175 − = 0.175 − 0.00384𝑚
𝑇𝑝 218.98

𝑃
𝑊𝑇 = 𝐶 ; 𝐹𝑜𝑟 8 − 10 ℎ𝑟𝑠, 𝑠𝑡𝑒𝑎𝑑𝑦, 𝐶𝑠 = 1.00
𝑣 𝑠
86000𝑊
𝑊𝑇 = (1.00) = 8475.24 𝑁
10.1472𝑚/𝑠

𝑊𝑇 = 𝑆𝑤𝑝 𝑏𝜋𝑚𝑦𝑝 = (𝑆𝑜𝑝 𝑐𝑣 ) 𝑏𝜋𝑚𝑦𝑝

8475.24 = (56)(0.3072)(10𝑚)𝜋𝑚(0.175 − 0.00384𝑚)

𝑚 =10.84387≈ 10 mm

42
• Nearest standard module, m= 10 mm
• b=10(10) =100mm

218.98
𝑇𝑝 = = 21.898 ≈ 𝟐𝟐
10
381.0252
𝑇𝑔 = = 𝟑𝟖
10
d) Pinion and Gear Dimension Calculations (Standard Proportions of gear systems/
20° 𝑠𝑡𝑢𝑏 𝑖𝑛𝑣𝑜𝑙𝑢𝑡𝑒 𝑠𝑦𝑠𝑡𝑒𝑚)

• Addendum = 0.8 m = 0.8 x 10 = 8 mm

• Dedendum = 1 m = 1 x 10 = 10 mm
• Working depth = 1.60 m = 1.60 x 10 = 16 mm
• Minimum total depth = 1.80m = 1.80 x 10 = 18 mm
• Tooth thickness = 1.5708 m = 1.5708 x 10 = 15.708 mm
• Minimum clearance = 0.2 m = 0.2 x 10 = 2 mm
• Fillet radius at root= 0.4 m = 0.4 x 10= 4 mm

e) Check the design for dynamic, static tooth load, and wear loads

• Calculating for the dynamic load by Buckingham equation,

43
 21𝑣(𝑏𝐶 + 𝑊𝑇 )
𝑊𝐷 = 𝑊𝑇 +
21𝑣 + √𝑏𝐶 + 𝑊𝑇

• In calculating the dynamic load 𝑊𝐷 , the value of tangential load 𝑊𝑇 maybe calculated
neglecting service factor Cs, that is,

𝑃 86000
𝑊𝑇 = = = 𝟖𝟒𝟕𝟓. 𝟐𝟒 𝑵
𝑣 10.1472

• Computing for C,

𝑘𝑒𝐸𝑝 𝐸𝑔
𝐶=
𝐸𝑝 + 𝐸𝑔

Where: k = 0.115, for 20 Degrees stub teeth

𝑁
𝐸𝑝 = 𝐸𝑔 = 100 𝐺𝑃𝑎 = 100000 𝑚𝑚2

• From the table. For well-cut gears and v= 10.1472 m/s

10 − 101472 0.0375 − 𝑋
𝐼𝑛𝑡𝑒𝑟𝑝𝑜𝑙𝑎𝑡𝑖𝑜𝑛: =
10 − 11.25 0.0375 − 0.0325
e= tooth error in action = 0.0369 mm

𝑁 2
𝑘𝑒𝐸𝑝 𝐸𝑔 0.115(0.0369𝑚𝑚) (100000 𝑚𝑚2 ) 𝑁
𝐶= = = 212.175
𝐸𝑝 + 𝐸𝑔 𝑁 𝑚𝑚
2(100000 )
𝑚𝑚2

44
 21(10.1472)((100)(212.175)+8475.24))
𝑊𝐷 = 8475.24 + =24892.33N
21(10.1472)+√(100)(212.175)+8475.24

• Calculating the static tooth load (beam strength or the endurance strength of the tooth):

𝑊𝑆 = 𝑆𝑒 𝑏𝜋𝑚𝑦𝑝

𝑦𝑝 = 0.175 − 0.00384𝑚 = 0.175 − 0.00384(10) = 0.1366

𝑁
• From the Table, for cast iron, the flexural endurance limit 𝑆𝑒 = 84 𝑚𝑚2

𝑊𝑠 =84(100) 𝜋(10)(0.1366 ) = 𝟑𝟔𝟎𝟒𝟕. 𝟖𝟗𝑵

• Calculating for the wear tooth load by:

𝑊𝑤 = 𝐷𝑝 𝑏𝑄𝐾

2𝑉𝑅 2𝑇𝑔
𝑄 = 𝑅𝑎𝑡𝑖𝑜 𝐹𝑎𝑐𝑡𝑜𝑟 = = , 𝑓𝑜𝑟 𝑒𝑥𝑡𝑒𝑟𝑛𝑎𝑙 𝑔𝑒𝑎𝑟𝑠
𝑉𝑅 + 1 𝑇𝑔 + 𝑇𝑃

2(1.74)
𝑄= = 1.27
1.74 + 1
(𝑆𝑒𝑠 )2 𝑠𝑖𝑛∅ 1 1 𝑁
𝐾= ( + ) : 𝐸𝑝 = 𝐸𝑔 = 100000
1.4 𝐸𝑝 𝐸𝑔 𝑚𝑚2

45
 • From the table, for cast iron, 𝑆𝑒𝑠 = 630 𝑁/𝑚𝑚2

(𝑆𝑒𝑠 )2 𝑠𝑖𝑛∅ 2 (630)2 𝑠𝑖𝑛20° 2

𝐾= ( )= ( ) = 1.939
1.4 𝐸𝑝 1.4 100000

𝑊𝑤 = 𝐷𝑝 𝑏𝑄𝐾 = 218.98(100)(1.27)(1.939) = 𝟓𝟑𝟗𝟐𝟒. 𝟒𝟖 𝑵

• Conclusion

𝑺𝒊𝒏𝒄𝒆 𝒕𝒉𝒆 𝑾𝒔 𝒂𝒏𝒅 𝑾𝒘 𝒂𝒓𝒆 𝒃𝒐𝒕𝒉 𝒈𝒓𝒆𝒂𝒕𝒆𝒓 𝒕𝒉𝒂𝒏 𝑾𝑫 , 𝒕𝒉𝒆𝒓𝒆𝒇𝒐𝒓𝒆 𝒕𝒉𝒆 𝒅𝒆𝒔𝒊𝒈𝒏 𝒊𝒔 𝒔𝒂𝒇𝒆.

f) Design for the pinion shaft

• We know that the normal load acting between the tooth surfaces,

𝑊𝑇 8475.24
𝑊𝑁 = = = 9019.16 𝑁
𝑐𝑜𝑠∅ 𝑐𝑜𝑠20

• And weight of the pinion,

𝑊𝑃 = 0.00118 𝑥 𝑇𝑝 𝑥 𝑏 𝑥 𝑚2 = 0.00118𝑥22𝑥100𝑥102 = 259.6 𝑁

• Therefore, The Resultant load acting on the pinion,

2
𝑊𝑅 = √(𝑊𝑁 )2 + (𝑊𝑝 ) + 2𝑊𝑁 𝑥𝑊𝑝 𝑥𝑐𝑜𝑠∅

= √(9019.16 )2 + (259.6 )2 + 2𝑥9019.16𝑥259.6 𝑥𝑐𝑜𝑠20 = 9263.53 𝑁

46
 • Assuming that the pinion is overhung on the shaft and taking overhang as 100 mm,
therefore Bending moment on the shaft due to the resultant load,

𝑀 = 𝑊𝑅 𝑥100 = 9263.53𝑥100 = 926353 𝑁 − 𝑚𝑚

Since the weight of the pinion 𝑊𝑃 is very small as compared to the normal load 𝑊𝑁 ,
therefore it may be neglected. Thus the resultant load acting on the pinion 𝑊𝑅 may be taken
equal to 𝑊𝑁 .

• The twisting moment on the shaft,

𝐷𝑝 218.98
𝑇 = 𝑊𝑇 𝑥 = 8475.24𝑥 = 927954 𝑁 − 𝑚𝑚
2 2
Therefore, the equivalent twisting moment,

𝑇𝑒 = √𝑀2 + 𝑇 2 = √(926353)2 + (927954)2 = 1311193 𝑁 − 𝑚𝑚

• Let 𝑑𝑝 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑖𝑛𝑖𝑜𝑛 𝑠ℎ𝑎𝑓𝑡

We know that equivalent twisting moment (𝑇𝑒 ), Assuming a safe stress of 40 MPa may
be taken from the shaft on which the gear is mounted and for the key.
𝜋 3 𝜋 3 3
1311193 = 𝑥 𝜏(𝑑𝑝 ) = 𝑥40(𝑑𝑝 ) = 7.855(𝑑𝑝 )
16 16
3 1311193
(𝑑𝑝 ) =
7.855
𝒅𝒑 = 𝟓𝟓 𝒎𝒎

• We know that the diameter of the pinion hub

=1.8 𝑑𝑝 = 1.8 𝑥 55 = 99𝑚𝑚

And length of the hub will be equal to the face width which is 100 mm

g) Design for the gear shaft

• We have calculated above that the normal load acting between the tooth surfaces,

𝑊𝑁 = 9019.16 𝑁

• We know that weight of the gear,

𝑊𝐺 = 0.00118 𝑥 𝑇𝑔 𝑥 𝑏 𝑥 𝑚2 = 0.00118𝑥38𝑥100𝑥102 = 448.4 𝑁

47
• Therefore, the resulting load acting on the gear,

𝑊𝑅 = √(𝑊𝑁 )2 + (𝑊𝐺 )2 + 2𝑊𝑁 𝑥𝑊𝐺 𝑥𝑐𝑜𝑠∅

= √(9019.16 )2 + (448.4 )2 + 2𝑥9019.16𝑥448.4𝑥𝑐𝑜𝑠20 = 9441.76 𝑁

• Assuming that the gear is overhung on the shaft and taking overhang as 100 mm,
therefore Bending moment on the shaft due to the resultant load,

𝑀 = 𝑊𝑅 𝑥100 = 9441.76 𝑥100 = 944176 𝑁 − 𝑚𝑚

• The twisting moment on the shaft,

𝐷𝐺 381.0252
𝑇 = 𝑊𝑇 𝑥 = 8475.24𝑥 = 1614640 𝑁 − 𝑚𝑚
2 2
Therefore, the equivalent twisting moment,

𝑇𝑒 = √𝑀2 + 𝑇 2 = √(944176)2 + (1614640)2 = 1870435 𝑁 − 𝑚𝑚

• Let 𝑑𝐺 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑔𝑒𝑎𝑟 𝑠ℎ𝑎𝑓𝑡

We know that equivalent twisting moment (𝑇𝑒 ),

𝜋 𝜋
1870435 = 𝑥 𝜏(𝑑𝐺 )3 = 𝑥40(𝑑𝐺 )3 = 7.855(𝑑𝐺 )3
16 16
1870435
(𝑑𝐺 )3 =
7.855
𝒅𝑮 = 𝟔𝟐 𝒎𝒎

• We know that the diameter of the pinion hub

=1.8 𝑑𝐺 = 1.8 𝑥 62 = 111.6 𝑚𝑚

And length of the hub will be equal to the face width which is 100 mm

48
D. Gearbox Components

49
50
 CHAPTER 4: DESCRIPTION OF THE MACHINE AND DESIGN CONSIDERATION

Description of the Machine

The coal belt conveyors can be used to transport products in a straight line or via variations

in height or direction, depending on the application. A troughed belt conveyor is used for moving

bulk materials such as grains, ore, coal, sand, and other similar materials along moderate slopes or

gentle curves. Because it is a closed system, it can be used both outside and inside, depending on

the application. Nevertheless, the impact force of the discharge will have an impact on the product

quality of fragile materials. As a result, when selecting speeds, it is necessary to consider the

fragility of the materials. Coal, for example, is a free-flowing bulk material that is well suited for

transportation.

Description of Machine Utility

The coal conveyor transmits power with minimal effort with the use of a belt support,

pulley, and the drive unit. It is used to transport or move materials from one place to another. It is

designed to carry the amount that is too heavy or too bulky for human to carry. The coal conveyor

is composed of components that are researched and observed from different designs. First, the belt

is the carrying medium of the conveyor system. It transfers power between widely separated shafts

or non-parallel drives. It is also advantageous to use belt because of its characteristics such as the

shock and vibration dampening. Next is the gear box. The gearbox is used for changing the speed

that comes out of the motor. In the case of the coal conveyor, the gearbox is used as a speed

reducer. It is connected to the motor that transmits power; the power then is transferred to the

gearbox where the speed is reduced before going to the pulleys of the conveyor system.

51
DESIGN CONSIDERATIONS

Health, Safety and Welfare

• Conveyor feed apertures for excavators and other mechanical equipment should be

constructed in such a way that the rotating and movement components of the conveyor are

entirely contained.

• The conveyor is not overloaded, and it is not used for anything other than coal

transportation in the design.

• All belt and gear driven housings are equipped with the warning signs listed below, which

are in the locations indicated. Signage should never be removed from their housings or

painted over with any type of paint.

• When operating conveyors, be sure that the housing completely includes the moving

components and that all required electrical power precautions are in place before starting

the machine.

Social Factors

• Being cost effective is a desirable feature.

• The machine is fabricated locally to support local companies and provide earning

opportunities for the workers.

• Durability was a sought-after feature since the device will be used to transport big amounts

of coal.

52
Global &cultural sensitivity awareness

• All sizes of materials were complied, properly sized and in conformance to the most

common international standard such as CEMA.

• The machine could extend its usage for transport of materials other than coal.

• The machine is made to transport anthracite coals which is environmentally friendly

compared to other fossil fuels as it produces virtually no smoke.

• Design is based on existing designs so that other people will be familiar as to how to operate

it.

53
 CHAPTER 5: RESULTS & DISCUSSION

RESULTS & DISCUSSION

The computations for the design of the belt conveyor system were based on the desired

capacity of 1000 tons per hour. The material that will be transferred using the conveyor is the

anthracite coal which has a bulk density of 60 lbs./ft3. The angle of repose of the anthracite coal

is 27 degrees with a maximum inclination of 16 degrees. The angle of repose is an important

parameter in designing the belt for the conveyor. The belt width that will be used for the conveyor

is 42 inches, and it was an important parameter in choosing other components for the computation

for the belt sizing. The belt width was chosen from CEMA standards as well as other computations

that used the standard and recommended values. The idler spacing was computed to be 4.5 ft. with

a return load of 110 lbs. The computed horsepower needed for the conveyor is 98.27 hp, but with

an assumed 94% efficiency, the actual horsepower needed is 104.54 hp. Lastly, for the belt

computations, considering maximum load tension on the belt, the computed belt stress is 129.21

lbs./ inch. The values used for computations for the belt such as the belt speed and the power

needed were also used in the computations for the important parameters for the gears. The full

torque load for the gear is 1.61 kN-m. The material used for the gear is cast iron that will be used

for 8 to 10 hours a day, giving a service factor of 1. The modulus of elasticity based on the material

is 100 GPa. The computed value for dynamic load is 24,892.33 N, 36,047.89N for the static load,

and 53,424.48 N for the wear tooth load. The static and wear tooth load was computed and shown

to be greater than the computed dynamic load. Therefore, the computations for the gears were

correct and the design is safe.

54
CONSLUSION

The following objectives of the design have been accomplished such as to understand and

conceptualize the process of transportation from unloading the coal to the crusher house, to

understand and apply the concepts of methodologies in the design, to understand and design a belt

conveyor for coal handling system, to understand and design a gear driven gearbox motor for coal

handling belt conveyor and to ensure that the coal transportation will maintain high productivity.

The group was able to determine the belt conveyor design capacity and equipment calculations,

belt conveyor components and gearbox design and equipment calculations. The group also uses

table due to the standards like CEMA material characteristics and weight, standard table for Cross

Section of Load and Capacity at 100 FPM, Idler Spacing, Effect of Load on Predicted Bearing L10

Life and etc. as it can be seen in the design calculation. The group also learned about the workflow

in a manufacturing equipment and improved the efficiency of the production of coal. In this study

the researchers developed a design of belt driven conveyor and gear driven gearbox motor for bulk

material coal handling with the capacity of a 1000 TPH. As we all know that the design of the

transportation system is heavily influenced by the total capacity of the power plant, the fuel type,

and the modes of transportation and also gear drives that can be damaged due to heavy load being

transmitted using the conveyor and it is applied in this paper specially the standards.

RECOMMENDATION

It is recommended that before installing agricultural equipment, the group plan the design

and follow the proper design methodology that was provided and is available in brochures.

Furthermore, when constructing a belt driven conveyor and gear driven gearbox motor for coal

55
handling, the group must be aware of the factors required for calculating the size and length of the

belt conveyor in order to reduce the mistake given during the construction phase. Finally, thorough

planning yields a favorable result when constructing a belt conveyor and its gearbox motor.

56
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Vogel B (2015) Riemen energetisch enger schnallen. Bundesamt für Energie BFE

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