INTRODUCTION TO MATERIAL HANDLING

The industrial development has led to the growth of the factory or plant sizes. The groh of
the factory or plant sizes has created huge demand for the material handling systems.
Although the material handling does not add any value to a product. it adds a significant
element of cost. In general, the material handling cost ranges from 10% to 35% of the cost
of the product.
• As the material handling cost constitutes a large portion of the product cost, the material
handling engineer’s primary function is to minimize the material handling. It is said that.
“The best handling is the least handling r
SYSTEM CONCEPTS FOR MATERIAL HANDLING
Any solution to the material handling problem must satisfy the following conditions:
1. The solution to material handling problem should not transfer the problems into other
areas of the product cycle.
2. The solution should not only resolve the immediate problems, but also take care of
problems for a reasonably long period of time. It should be able to account for future
expansion or modification without unreasonable cost.
3. The solution should be as simple as possible and easy to adopt.
4. The solution should be such that. Or initial cost as well as operational costs should be
minimum.
5. The rate of return on investment should justify the solution.
Types of load handled by material handling systems
The load handled by material handling system can be classified into two types.
1. Bulk load
2. Unit load
1.Bulk Loads:
The bulk load consists of a large number of homogeneous particles or lumps of any
material.
The examples of bulk load are : coal. mineral we. sand. stone, clay, cement, etc.
2. Unit Loads:
The unit load is a rigid single mass which is handled and transported as one piece
The examples of unit load are : machines. boxes. Containers. etc.
Containerization:
➢ In a factory or a plant, it is inconvient b handle the bulk loads. In adtion. it is highly
inconvenient and uneconomical to treat small size components or products as a unit
load. in material handling.
➢ The containers of different sizes and shapes used for handling the bulk loads as well
as the products of small size.
➢ The containers act like a special type of unit loads and they can be handled as a unit
load.
➢ In material handling, depending upon the gze of the containers, one container may
be treated as a unit load or a number of containers stacked together may be treated
as a unit.
➢ The process of convening d bulk loads or small units into a unit load by using the
containers is known as containerization.
Considerations In containerization:
Some of the considerations in developing the containers are as follows:
➢ Limit the number of container sizes and shapes.
➢ Design the container size and shape based on the load to be handled.
➢ Size the containers taking in to account the space available in material handling
equipment.
➢ Design the containers for stacking arrangements.
➢ Design the containers for flexibility and maximum utilization.
➢ Keep the containers painted.
➢ Color-code the containers by functions.
➢ Wire-mesh and solid steel containers are preferred over wood or plastic containers
for the sake of cleanliness. Fire protection and long life.
➢ In many applications, wire-mesh containers are preferred over solid steel
containers due to following reasons:
(a) Wire-mesh containers are cleaning.
(b) When parts are dropped into the container, die wire-mesh containers produce less
noise as compared to the solid steel containers.
(c) Wire-mesh containers are used for washing parts without removing them from the
container.
(d) Parts will dry and cool faster in wire-mesh containers than in solid steel containers.
INTRODUCTION TO MATERIA HANDLING EQUIPMENT
Material handling equipments are used for moving loads in factories or plants. Construction
sites, mines, ports. Storage centers. etc; in horizontal, vertical or inclined directions over
comparatively short distances of tens or hundreds of meters and occasionally thousands of
meters.
Material handling equipment ensures a constant load transfer between two or several
point connected by the common activities.
It is important to note that, the transfer of the load is not confined only to shifting of load
from place to place but also include loading and unloading operations.

Classification of material handling equipments

The material handling equipments are classified into three groups
➢ Hoisting equipments
➢ Conveying equipments
➢ Surface and overhead equipments
 Fig: Classification of material handling equipments
Hoisting Equipment:
Hoisting equipment are group of devices with lifting gear used for:
(a) Moving the loads in vertical direction, or
(b) Moving the loads in vertical direction as well as transferring them from one point to
another in horizontal direction. Within the coverage area of the equipment.
The hoisting equipment are mainly used for unit loads and they move the loads in batches
Types of hoisting equipments
• Hoisting machines
• Cranes
• Elevators

Hoisting machines:
These are the group of periodic action devices with lifting gears used for:
a) Lifting the load in vertical direction
b) Lifting the load in vertical direction and moving them in horizontal
direction along fixed predetermined direction.
 Fig: Travelling power operated hoist
The examples of hoisting machines are : jacks, chain pulleys. rope pulleys, portable hand
hoist. Portable power operated hoists, travelling power operated hoists. etc.
Cranes:
Cranes are group of devices, with lifting gear, used for lifting the loads in vertical direction
and moving them in multiple horizontal directions (linear or angular) so as to obtain the
controlled reach within the coverage area of the equipment.
The examples of cranes are wall Jib cranes, stationary jib cranes with rotary pillar,
stationary cranes with turntable, telescopic tower cranes, travelling cantilever wall cranes.
Electrically-operated overhead travelling cranes, gantry cranes, and tractor mounted cranes,
etc.

Jib cranes
Elevators
It is a group of devices used for raising loads in guide ways.

Fig: Elevators
The examples of elevators are cage elevators, vertical skip elevators etc.
Conveying Equipment:

Conveying equipment are group of device. With no lifting gears , used for moving loads
in horizontal or inclined direction in a continuous flow.
The conveying equipments are mainly used for bulk load.
• Head pulley or drive pulley
• Tail pulley
• \snub pulley
• Belt carrying idlers or rollers
• Return idlers or rollers
• Bend pulleys
• Take up pulley
• Counter weight
• Belt cleaner conveyor belt
• Feeder
• Hooper
• Bulk material
 Fig: Belt conveyor
The different types of conveyors are: flat belt conveyors, troughed belt conveyors, blanket
belt conveyors, chain conveyors, apron conveyors, screw conveyors, bucket conveyors,
Surface and Overhead Equipment:
Surface and overhead equipment are group of devices used for:
moving the loads on the ground, or moving the loads in horizontal direction on the
overhead tracks.

Surface and overhead equipment are normally not provided with lifting gear. The
examples of surface and overhead equipment are: trackless trucks, narrow-gauge cars,
overhead track age systems, etc.

OBJECTIVES OF MATERIAL HANDLING SYSTEM

An ideal material handling system should fulfill the following objectives:
1. Accuracy in Transporting Loads to Destination
2. Precision in Pick-up of Loads
3. Transporting Loads in Scheduled Time
4. Transporting Loads of Required Quantity
5. Transporting Loads without Damage
6. Automation with Minimum Manpower
7. Low Initial and Operational costs
8. Simplicity and Easy Maintenance
9. 0perational Safety
1. Accuracy in Transporting Loads to Dest nation;
The material handling system should transport the loads to the destination with fair degree
of positional accuracy.
2. Precision in Pick-up of Loads:
The material handling system should pick-cup the loads from their position within the
shortest time with minimum human intervention.
3. Transporting Loads in Scheduled Time:
The material handling system should move the loads to their destination in the scheduled
time.
4. Transporting Loads of Required Quantity:
• The material handling system should deliver the loads to the department, or place in the
required quantity.
• The rate of supply of material, by the material handling system, is very important
parameter affecting the performance of the plant, especially in continuous flow of bulk
loads.
5. Transporting Loads without Damage:
The material handling system should not damage the load, being transported, at the time
of loading, unloading or transportation.
6. Automation with Minimum Manpower:
The material handling system should be mechanized to the fullest possible extent so as to
minimize the man power requirement for operation and control.
7. Low Initial and Operational Costs:
The material handling system should have low initial as well as running costs.
8. Simplicity and Easy Maintenance:
• The material handling system should have simple arrangement.
The hoisting and conveying equipment are now-adays assembled from standard units. The
different standard mechanical and structural components or units are assembled to form the
material handling system.
• The standardization improves the performance of the system and reduces. its cost.
• The standard units not only simplify the arrangegement but also are convenient in
servicing. The unit needing repair can be easily replaced and repairs can be carried out at
specialized workshops, thus minimizing the requirement of onsite maintenance facilities. .
9. Operational Safety:
The material handling system should be safe in operation. It should have sufficient number
of inbuilt safety devices, so as to ensure the safe working environment.
GUIDELINES IN SELECTIIIG MATERIAL HANDLING EQUIPMENT
Material handling equipments are manufactured in large variety of designs. The different
types of material handling equipment can be used for the same operations. In order to
optimize the performance of the system, it is necessary to select the proper material
handling equipment for the given operation.
The following factors are considered while selecting the material handling equipment for
the given operation

1. Direction of Load Travel

2. Length of Load Travel
3. Type and Properties of Loads to be Handled
4. Required Load Moving Capacity of Unit
5. Characteristics of Production Processes
6. Methods of Stacking Loads at Initial and Final Points
7. Local Conditions
8. Initial and Operational Costs
CONVEYORS
➢ Conveyors are used for moving the loads in horizontal or inclined direction along a
fixed path in a continuous flow.
➢ The conveyors are mainly used for handling of bulk loads. In addition, conveyors
are also used as processing lines in production units. For example, conveyors are
used as assembly lines in automobile industry.
Advantages of Conveyors:
Conveyors, as a bulk material handling system, offer the following advantages:
1. Due to continuous flow, conveyors ensure steady and sufficient supply of material at
processing units or sites.
2. Conveyors can transfer the material at extremely high rates. Hence, the capacity of
conveyors is much higher than the other material handling systems.
3. By changing the speed of the conveyor, the rate of material flow can be changed so as to
suit the requirements at processing units or sites.
4. The conveyors can be started or stopped within shortest time. Hence, with conveyors the
material flow can be started or stopped within the shortest time.
5. Conveyors carry material along fairly direct routes, and hence require minimum time for
transferring the material.
6. Conveyors can be placed at floor level, at work station level or at higher level as per
requirement. Therefore, conveyors need not occupy valuable floor space and they can
utilize the airspace of the plant.
7. In places like assembly units, the conveyors can serve the dual purpose. They are used
as production or processing lines as well as material handling systems.
In conveyor type production or processing lines, the conveyor speed ensures the rate of
production.
The conveyors can take the material to the locations where manual loading is not possible
due to extreme operating conditions. For example, furnace, automatic paint units, high
pressure cleaning units, etc.
10. Un1ike.other material handling equipment, conveyors do not necessarily have to have
an operator. They can run without operator.
1 1. Conveyors are most suitable material handling systems for automation of plants.
12. When properly designed and installed, conveyors are very reliable in operation and
require minimum maintenance.
Limitations of Conveyors:
Conveyors, as the material handling system have the following limitations:
1. Conveyors can handle the materials only along the fixed routes.
2. Conveyors are unsuitable for heavy unit loads.
3. Once installed, conveyors are fairly inflexible regarding alterations in : location,
capacity, shape, or type of materials to be handled.
4. Due to inflexibility, conveyors are suitable for plants with operations that are permanent
for a considerable length of time.
Applications of Conveyors:
1. The conveyors are used for continuous flow of bulk loads in mines, ports, thermal power
plants, etc.
2. The conveyors are also used for material handling in different industries like:
Manufacturing industry, food processing industry, dairy industry, pharmaceutical industry,
etc.
3. The conveyors are used as assembly lines in automobile industry.
7.8.4 Types of Materials Handled by Conveyors:
Conveyors can be used to handle different types of materials which can be broadly
classified into four groups :
1. Bulk Materials
2. Hazardous Materials
3. Loose Materials
4. Packages
1. Bulk Materials :
. The bulk materials are in the form of granules or cakes of different sizes and shapes.
The different bulk materials handled by conveyors are : mineral ores, coal, sand, stone,
clay, cement, powdered materials such as flours, slurries, etc.
2. Hazardous Materials:
The explosive substances or mixtures which can not be handled by hoists or elevators due
to potential risk of explosion under impact, can be handled by conveyors.
3. Loose Materials: .
The in process small parts like nuts, bolts, castings, forgings, plastic parts, etc. are
transferred by conveyors.
4.Packages:
The packages like cogitated cartons, plastic boxes, wooden boxes, drums, etc. can be
transferred by conveyors.
TYPES OF CONVEYORS
The following types of conveyors are used for material handling purpose:
1. Flat Belt Conveyors
2. Troughed Belt Conveyors
3. Blanket Belt Conveyors
4. Woven Wire Belt Conveyors
5. Chain Conveyors
6. Apron Conveyors
7. Screw Conveyors
Flat Belt Conveyors
I : Head Pulley or Drive Pulley
2 : Tail Pulley
3 : Snub Pulleys
4: Belt-Carrying Idlers or Rollers
5: Return Idlers or Rollers
6: Bend Pulleys
7 : Take-up Pulley
8 : Counter-Weight
9 : Belt Cleaner (Scraper)
10 : Internal Belt Cleaner (Scraper)
I I : Conveyor Belt
12 : Feeder
13:Hooper
14 : Bulk Material

Layout of Flat Belt Conveyors .

The flat belt conveyor, shown in Fig. 7.7, consists of endless belt (11) running over the
head or drive pulley (1) and tail pulley (2).
The belt conveyor rear end is known as tail end, where as its front. End is known as, head-
end.
The drive pulley, which is coupled to the drive unit, drives the belt conveyor and is located
at the head-end of the conveyor.
The material is fed onto belt conveyor near the tail end. The material so fed onto belt
conveyor travels with the belt. On reaching the head end, the material drops down
automatically due to gravity and belt speed.
The point where material is loaded onto belt conveyor is known as feed-point. Some
conveyors have more than one feed point. The location of rear most feed point is close to
the tail-end.
The point where material is discharged from belt conveyor is known as discharge-point.
Normally the discharge point is the head end of the conveyor.
The load carrying upper run of the belt is supported on the belt-carrying rollers (4), while
the lower run of the belt is supported on the return rollers (5).
Take up pulley (7) and counter weight (8) are used as belt tensioning device.
The whole assembly is supported on a suitable frame.

Fig: Cross section of flat belt drive

Advantages of Flat Belt Conveyors:
• Flat belt conveyors are light in weight and have simple construction.
• Flat belt conveyors require minimum maintenance.
• belt conveyors offer the following advantages:
• Conveyors can be operated over the long distances.
• Conveyors have high material handling capacity.
• Conveyors can easily adapt to natural contours of the ground.
• of low frictional characteristics, flat belt conveyors require low power for operation.
• It requires less maintenance.
Methods of Feeding or Loading to Flat Belt Conveyor:
• The flat belt conveyors receive the feed by any of the following methods:
• 1. By Hooper
• 2. By Preceding Conveyor
• 3. By Process Equipment
• 4. By Travelling Machine
 Fig: Feed by Hooper

The feeder extracts the material from hooper at controlled rate and feeds it into the
conveyors as shown.
2. By preceding conveyor

Fig: By Preceding Conveyor

The discharge ofg preceding conveyor is taken as the feed for the next conveyor, as
shown.
3. By Process Equipment

Fig: By Process Equipment

The discharge from process equipment like : crusher, mixer, screen, etc. is taken as the feed
for the conveyor, as shown in Fig. 7.9(c).
4. By. Travelling Machine:
The travelling machines, like travelling Hooper, feed the material to the conveyor. The
feeding point on the conveyor will shift according to the position of travelling machine.

Methods of Discharge from Flat Belt Conveyor:

The material is discharged from the flat belt conveyor by one of the following methods:
1. Head Pulley Discharge
2. Both End Discharge
3. Tripper Discharge
4. Plow Discharge
Head Pulley Discharge:
In this method, the material flows from feeder point to head pulley along with the belt and
is discharged from belt at head pulley, as shown in Fig. This is most widely used and natural
method for material discharge from the belt.
 Fig: Head Pulley Discharge

Both end discharge :

Fig: Both end discharge

The reversible conveyors are used for discharges at both the ends i.e. at head end while
running in forward direction and alternatively at tail while running in reverse direction
Tripper Discharge:
• The tripper arrangement is made by forming the belt loop in upper run of the belt
By means of tripper pulley, as shown in Fig.
• This method is used for dividing the discharge. The intermediate discharge of
Required quantity can be obtained from tripper pulley.
• The tripper discharge can be on one or both sides of the conveyor belt.
• The tripper discharge arrangement is of two types:
(i) Fixed tripper discharge
(ii) Travelling tripper discharge
Fixed tripper discharge

Fig: Fixed tripper discharge

Travelling tripper discharge

Fig: Travelling tripper discharge

In travelling tripper discharge arrangement, shown in Fig. the tripper arrangement
reciprocates along the belt length between two limits. The tripper arrangement is a separate
unit with wheels running on rails installed along the conveyor length.
While moving to and fro along the path, the tripper pulley discharges the material on one
or both sides of conveyor belt.
 Plow Discharge

Fig: Plow Discharge

• The discharge plow is used for intermediate discharge of small quantity in case of slow
speed flat belt conveyors, as shown In fig.
• The plow diverts the material to tall (rum he side of the hell, The plow can be positioned
as per the requirements of discharge point.
• The biggest disadvantage of the plow discharge it leads to faster wear of the belt
TROUGHED BELT CONVEYORS
• The width of the flat belt conveyor the volume carrying capacity of the flat belt conveyors.
• By giving the trough’ shape to the belt by means of idlers, the volume carrying capacity
of the conveyors can be increased. Such conveyors air known troughed belt conveyors The
troughed belt conveyors air generally three idler type ur flse4dler type.
• With increase in number of idlers, the depth of the trough increases. However, higher the
depth, higher is the required flexibility of the belt
• The nylon and polyester belts. Which are more flexible than cotton belts. used kit troughed
belt conveyors.
 Fig: Cross section of flat and troughed belt conveyors

Capacity of Belt Conveyors (Q):

The rate at which the material is carried by the conveyor is known as capacity of the
Conveyor.
The capacity can be either volume flow rate (m3/s) or mass flow rate (kg/s). Width of the
belt, m
B= width of the material storage on belt, m
b= (O.9B—O.05),m
v= belt speed, rn/s
Q= capacity of conveyor
M= capacity of conveyor
p = mass density of bulk material, kg/rn3
Capacity of Horizontal Belt Conveyors:

Where, c = surcharge factor

 Table: Surcharge Factor ‘C’

Table: Flow ability Factor ‘k’

Conveyor Belt Speeds (v):

• The speed of belt conveyors moving bulk material depends upon:
• the lump size and the nature of material; and
• the belt width
• The light weight and fine materials should be transported at low conveyor belt
speeds so as to prevent their spillage due to fanning effect.
 • The materials that can degrade through reduction in size (e.g. coke) due to high
speed should be transported at low conveyor belt speeds.
• Wider belts can be operated at higher speeds due to better distribution of materials.
• The recommended conveyor belt speeds for various materials are given in Table .

Recommended conveyor belt speed v m/s

4. Standard Belt Widths (B):
The standard belt widths used for conveyor belts are : 400, 450, 500, 600, 650, 750, 800,
900, 1000, 1200, 1400, 1600, 1800, 2000, 2200, 2400 mm.
BLANKET BELT CONVEYORS
• The flat belt and troughed belt conveyors cannot be used for inclination more than 350
• If the belt inclination is more, the material will slide down. In such cases, blanket belt
conveyors are used.
 BLANKET BELT CONVEYORS
The blanket belt conveyor, shown in Fig., consists of a main belt conveyor and an auxiliary
belt conveyor.
The material on main belt is prevented from sliding down by a blanket belt which is
actuated by an auxiliary belt conveyor.
The blanket belt, which is made of rubber impregnated construction or welded chain
sections, offers high flexibility both longitudinally and transversely.
In case of blanket belt conveyors, the belt slope varies between 45° and 600.
WOVEN WIRE BELT CONVEYORS
Woven wire belt conveyors consist of wire mesh belt woven from stainless steel or mild
steel wires.
As air or liquid can readily pass through the mesh, the woven wire belt conveyors are used
for carrying materials through woven, quenching baths, washing plants, drying plants, etc.
 Fig: Woven Wire Belt
Chain conveyors
Chain conveyor [Fig. consists of endless chain running over the drive or head sprocket and
tail sprocket. The drive sprocket is coupled to the drive unit.
The load carrying strand of the chain is supported on the load carrying tracks, while the
return strand of the chain is supported on the return tracks.

Fig: Chain conveyors

Advantages of chain conveyors:
1. The chain conveyors display low stretch ability under load.
2. The chain conveyors can take impact loads which are unsuitable to belt conveyors.
3. The chain conveyors can transport large loads.
4. The chain conveyors can be used at elevated temperatures.
5. There is no possibility of slip in chain conveyors.
Limitations of chain conveyors:
1. Operation of chain conveyors require careful attention and regular lubrication.
2. At high operating speeds, chain wear is significant. Hence, chain conveyors are run at a
maximum speed of 0.6 to 1.0 rn/s.
APRON CONVEYORS
The apron conveyor consists of a pair of parallel endless roller chains running on tracks
supported by the frame. The overlapping metal plates are attached to the chains to form a
continuous moving bed.
The apron conveyors are rugged, relatively heavy and runs at slow speed of about 0.35 to
0.4 rn/s.
The apron conveyors can transport large loads.
SCREW CONVEYORS
The screw conveyor, shown in Fig. 7.15, consists of a screw or worm, in the form of
Helix, rotating in a trough or tube.
The material is moved along the axis due to the action of the screw. The full-bladed screws
are used for maximum conveying capacity.
The screw conveyors can handle hot as well as wet materials. They can transport the
materials from fine powder to animal feeds, coal to slurries, etc.

Fig: Screw Conveyor

CONVEYOR BELTS
Belt is an important component of a conveyor system due to the following reasons:
(i) Belt is actually responsible for conveying material.
(ii) Belt is in contact with material and is taking all the punishment from material, such as
impact, abrasion, etc.
(iii) It is the costliest item.
Requirements of good belt:
The good belt must satisfy following requirements:
1. Adequate strength;
2. Good longitudinal and lateral flexibility;
3. High wear resistance;
4. Freedom from ply separation due to repeated bending; .
5. Low elastic and permanent elongation;
6. Low water absorption;
7. Least affected by moisture.
• Components of conveyor belts:
The conveyor belt primarily consists of two parts Fig.
1. Carcase
2. Rubber Covers

Conveyor belt
1. Carcase:
Carcase is the body of belt, which provides basic strength to take care of all forces. acting
on belt during conveyor operation.
Two types of carcase are used in conveyor belt. One is textile fabric carcase and other is
steel cord carcase.
2. Rubber Covers:
The carcase is encased all around by rubber. This is done by incorporating rubber layer on
top side of carcase as well as on bottom side of carcase.
1 Types of Conveyor Belts:
The conveyor belts are of two types:
I - Fabric Ply Belts:
 Fig.: Fabric Ply Belt
• .Fabric-ply belt Fig. consists of a load supporting carcase made up of number of
layers of plies of cotton, polyester, rayon or polyamide fabric. The plies of fabric
are impregnated with rubber.
The carcase is covered at the top and bottom by rubber covers providing protection
against damage.
• The thickness of rubber cover at top is between 5 mm to 10 mm, while at the bottom
it is between 2 mm to 5 mm. The number of plies vary between 3 to 12.
• The polyester, rayon or polyamide fabric belts are having higher strength than the
cotton fabric belts. Therefore, polyester, rayon or polyamide fabric belts consist of
lesser number of plies and are therefore more flexible. They can be operated by
small pulleys.
2. Steel Cord Belts:

Steel Cord Belts

• The thickness of rubber cover at top is between 5 mm to 10 mm, while at the bottom
it is 2 mm to 5 mm.
• The steel cord belt consists of a load carrying carcase made up of steel cords running
parallel along the length of belt as shown in Fig. 7.17(b).
• The steel cords are reinforced by transverse textile strings at top and bottom and are
impregnated with rubber.
• The carcase is covered at the top and bottom by rubber covers providing protection
against damage.
Advantages of steel cord belts:
(i) The steel cord belts have higher breaking strength then the fabric-ply belts. The steel
cord belts have ultimate tensile strengths up to 8000 N/mm compared to up to 2000 N/mm
for fabric- ply belts.
(ii) The steel cord belts have low elongation or stretch ability as compared to fabricp1y
belts. Hence, steel cord belts require less movement of take-up pulley to absorb belt stretch
during operation.
(iii) The steel cord belts are more flexible and hence can run on smaller diameter pulleys
as compared to fabric ply belts.
(iv) The steel cord belts are flexible in transverse direction as well. Therefore, they do not
create bending resistance to toughing and are suitable for troughed belt conveyors.
(v) In fabric-ply belts, the rubber from top face to bottom face is divided into number of
layers due to fabric plies. This weakens rubber mass. In steel cord belts, the rubber acts as
a single mass without discontinuity. This makes belt more homogenous.
18 CONVEYOR PULLEYS
The different pulleys used in conveyors are as follows:
1. Drive (orHead)Pulley
2. Tail Pulley
3. Snub Pulleys
4. Idlers
5. Take-up Pulleys
Drive (Head) and Tail Pulleys
The ply separation due to the repetitive bending over the pulleys is the most common cause
of the belt failure. The larger the pulley, the less the belt is strained and larger is its life.
The tension in the belt is maximum at the drive and tail pulleys. Hence, diameters of drive
pulley and tail pulley are larger than the rest of pulleys.The minimum diameters of drive
pulley and tail pulley are given by,

………………… (A)
Where, Dmin = minimum diameter of drive pulley and tail pulley, mm
Zp = number of plies
K1 = material factor for plies
K2 = belt tension and arc of contact factor
 Table : Material Factor for Plies ‘K1’

Table : Belt Tension and Arc of Contact Factor ‘K2’

Note: ∑ 𝐹 is the vector sum of belt tensions on tight side and slack side
➢ The pulleys are standardized on the basis of belt width.
➢ For a required belt width (Refer Section 7.11.1), the standard pulley diameter is
selected such that it is greater than the minimum pulley diameter given by Equation
(A).
➢ The length of pulley is given by,
lP =B+2s
where, lp= length of ul1ey, mm
B = width of pulley, mm
s = side margin
= 6Oto75mm
Types of drive and tail pulleys
Two types of pulleys are commonly used as drive and tail pulleys:
(I) crown-face type pulley
(ii) wing-type pulley
 Fig: Crown-Face Type Pulley

Fig: Wing-Type Pulley

➢ Above figures show the crown face type and wing-type pulleys respectively. In
wing-type pulleys, the belt contacts the cross members only. This arrangement
reduces the sticking of material to the pulley face and reduces the belt wear.
➢ The coefficient of friction of the pulley can be increased by providing the
lagging (rubber, PVC or polyamide). The PVC or polyamide lagging increases
the coefficient of friction (upto 0.5 to 0.6) as well as prolongs the belt life.
Snub Pulleys:
In belt conveyors, it is necessary to change the direction of belt for various reasons like:
1. Increasing the angle of lap on drive and tail pulleys;
2. Changing the path of carrying run of the belt;
3. Changing the path of return run of the belt; and
4. Facilitating the loading and unloading operations.
The change in direction of belt is achieved by the pulleys, known as snub pulleys.
Idlers:
Purpose of using idlers:
The idlers are used in belt conveyors for following purposes:
(i) To support the conveyor belt along with the load on upper run, with minimum resistance
to belt-motion.
(ii) To support the conveyor belt on lower run, with minimum resistance to belt motion.
(iii) To provide support to belt at loading point with minimum wear and tear to belt.
(iv) To align the belt on the pulleys. The idlers should automatically try to bring the belt
center line close to conveyor center line.
(v) To give the trough profile to the belt in case of troughed belt conveyor.
(vi) In case of troughed belt conveyor, the belt has trough profile on the upper run while
flat profile on the lower run. The transition idlers gradually change the shape of belt profile
from flat to trough and trough to flat with minimum strain to belt.
Types of idlers:
The different types of idlers used in conveyor belts are as follows:
(i) Roller type idlers with ball bearings
(ii) Roller type idlers with roller bearings
(iii) Rubber covered idlers
(iv) Impact idlers
(v) Disc-type idlers
(vi) Spring idlers
(i) Roller type idlers with ball bearings

Fig: Roller Type Idlers with Ball Bearings

The roller type idlers with ball bearings are used in light-duty applications.
(ii) Roller type idlers with roller bearings:
The roller type idlers with roller bearings are used in heavy duty applications.

Fig: Roller type idlers with roller bearings

(iii) Rubber covered idlers

➢ In rubber covered idlers, a thin rubber sleeve is put on the rollers. A thin rubber
sleeve gives the protection to roller against abrasive wear which is heavy in the
return run idlers due to dirty side of the belt.
➢ The rubber covered idlers are used in conveyors where abrasive loads are
transported.
(iv) Impact idlers

Fig: Impact idlers

➢ In impact-idlers, a thick rubber disc is fitted on the smooth roller.
➢ The impact idlers are fitted at loading points to cushion the impact of heavy lumps
and to give the protection to the belt and bearings.
 (v) Disc-type idlers
Disc-type idlers are used to avoid the build up of material on smooth rollers and clean

the belt.

Fig: Disc-type idlers

(vi) Spring idlers

Fig: Spring idlers

The spring idlers are used with steel band conveyors. The spring idlers provide trough to
the belt and increase the load carrying capacity to 1.5 to 2.0 times that of flat band.
Idler size and spacing:
➢ The idlers are available in standard diameters of 89, 108, 133, 159 and 194 mm.
The larger size idlers are used for high belt speeds and large lump size.
➢ At loading point, the spacing between the idlers is 0.5 m to 0.75 m. On the carrying
run (upper run) side, the idler spacing is between 1 m to 1.5 m. On the return run
(lower run) side, the idler spacing is between 2 m to 3 m.
BELT TAKE-UP DEVICES
Belt take-up device is used in belt conveyors to maintain adequate tension in belt so as to:
(i) transmit the mechanical power from drive pulley to belt without slip under operating
conditions; and
(ii) limit the belt sag.
The standard take-up travel of horizontal conveyors is commonly (1/100)th of the belt
length or 400 mm, whichever is greater; and that of inclined installations is (3/200) th of
the belt length.
Types of Belt Take-Up Devices:
There are four types of belt take-up devices:
1. Screw Type Take-Up
2. Vertical Gravity Type Take-Up
3. Horizontal Gravity Type Take-Up Winch Operated Take-Up
4. Winch Operated Take-Up
1. Screw Type Take-Up:
➢ Fig. shows a screw type take-up. The take up device is installed with tail pulley,
which also acts as a take-up pulley.
➢ The screw type take-up consists of two bearing housings supporting the shaft and
capable of sliding in fixed guides (2 nos).
➢ The bearing housings are connected to screws (2 nos).
➢ By rotating the screws the bearing housings can be made to slide in fixed guides,
thereby adjusting the belt tensions.
➢ Due to belt tensions, screws, are always under compression.
➢ The screw type take-ups are compact in arrangement. However, such take-ups
require careful attention while carrying out adjustment so as to avoid excessive
tension in belt. Hence, screw type take-ups are used only in short length conveyors
operating under practically stable ambient temperature.
Fig: Screw Type Take-Up
2. Vertical Gravity Type Take-Up:
➢ The vertical gravity type take-up device, shown in Fig. 7.22, consists of: two bend
pulleys, a take up pulley and the dead weights.
➢ The device is located in a place where the belt tension is minimum i.e. on lower run
of a belt near the tail pulley.
➢ The belt tensions can be adjusted by applying the dead weight on take-up pulley.
The vertical gravity type take-ups are highly reliable and maintenance free. The
exact required belt tensions can be created by putting the appropriate dead weights.
However, the arrangements of gravity type take-up are relatively bulky.

Fig: Vertical Gravity Type Take-Up

3.Horizontal Gravity Type Take-Up :

Fig: Horizontal Gravity Type Take-Up

➢ The horizontal gravity type take up device, shown in Fig. 7.23, consists of tail pulley
mounted on pulley trolley having four flanged wheels.
➢ The pulley trolley, which is loaded by dead weight, through rope moves along the
guide- frame.
➢ As the take up device moves in horizontal direction, it is known as horizontal
gravity type take-up.
➢ The horizontal gravity type take-ups are used where conveyor set up does not have
necessary head room to install vertical gravity type take-up between ground and
conveyor. They are also used in long conveyors with fabric belt.
3. Winch Operated Take-Up:

Fig: Winch Operated Take-Up

➢ The winch operated take-up device, shown in Fig. 7.24, consists of tail pulley
mounted on pulley trolley having four flanged wheels.
➢ The pulley trolley, which is loaded by motorized winch, moves along the horizontal
guide frame.
➢ The winch motor is automatically operated by the sensor unit which takes input
from the tension in wire rope of winch.
➢ When the belt tension and hence the tension in wire rope of winch reduces below
particular limit, the sensor unit switches on the winch motor, thereby increasing the
belt tension. Once the tension in belt reaches the desired value, the sensor unit
switches off the winch motor.
POWER REQUIREMENT OF BELT CONVEYORS
Power requirement of belt conveyor consists of two parts:
1. Power required for lifting load through height ‘h’ (P1)
2. Power required for overcoming frictional resistance at various points while moving
the load(Pf) -
Fig. shows an inclined belt conveyor.
Let, Q = Capacity of conveyor, m3/s
𝜌 = mass density of material, kg/rn3
h = height through which, material is to be lifted, m
L = belt length, m
CO = specific friction factor (It is the frictional resistance at idlers, pulleys, loading section
and unloading section per Newton load per meter belt length

Fig : Power Requirement of Belt Conveyors

1. Power required for lifting load through height ‘h’ (Pl):
The power required for lifting load through height ‘h’ is given by,

2. Power required for overcoming frictional resistance at various points while

moving the load (Pf):
The power required for overcoming the frictional resistance at various points while
moving the load is given by,

3. Total power requirement (P):

The total power required at drive pulley is given by,

-------------- (a)
However, as the specific friction factor ‘C0’ is unknown for most of the conveyors, it is
difficult to use Equation (a) for determining the power required at drive pulley.
ANALYSIS OF POWER REQUIREMENT OFBELT CONVEYORS
The detail analysis of power requirement at drive pulley is given in subsequent section.
Different Resisting Forces on Conveyor Belt:
The different resisting forces on conveyor belt are. as follows --
1. Load Resistance Due to Lifting of Material ( Fm)
2. Frictional Resistance Due to Idlers (Fr)
3. Frictional Resistance at Pulley (Fe)
4. Resistance at Loading Staff on (FL)
5. Frictional Resistance at Unloading Station (Fe)
6. Frictional Resistance at Cleaning Station (FCL)
1. Load Resistance Due to Lifting of Material (Fm):

Fig: Load Resistance Due to Lifting of Material (Fm)

Let, M = capacity of conveyor or mass of material carried by conveyor, kg/s
mm = material carried by conveyor per unit belt length, kg/rn
v = belt speed, rn/s
l = length of load carrying run of belt, rn
lr= length of return run of belt, m
h = height through which the material is lifted, m
𝛼 = angle of inclination of belt..

From Figure
Total material load acting on the load carrying run of the belt is,

The total material load ‘Wm’ can be resolved into two components
2. Frictional Resistance Due to Idlers (Fr)

➢ When the belt is moving over the carrying run and return run idlers, the idlers
offer the frictional resistance to the motion of belt.
➢ Hence, the total frictional resistance due to idlers consists of

(i) Frictional resistance due ‘to carrying run idlers (Fcr)

(ii) Frictional resistance due to return run idlers (Fir)

Let, mm = mass of material carried by conveyor per unit belt length, kg/rn

mb = mass of belt per unit length, kg/rn

mi = mass of each idler, kg

tc = pitch of carrying run idlers, m

tr = pitch of return run idlers, m

ZC= number of carrying run idlers

Zr = number of return run idlers
dr= diameter of idler or roller, m
dp= diameter of idler pin, m
𝛍𝐫 = coefficient of friction between idler and belt
𝛍𝐩 = coefficient of friction between idler and idler pin

(a) Carrying Run Idlers

 (b) Return Run Idlers
Fig: Frictional Resistance Due to Idlers
Frictional resistance due, to carrying run idlers (Fcr):
➢ Vertical load on each carrying run idler is,

➢ Normal reaction between each carrying run idler and belt is,

➢ Frictional force between each carrying run idler and belt is,

➢ Total frictional force between all carrying run idlers and belt is

➢ Reaction between each carrying run idler and idler pin is,

➢ Frictional force between each carrying run idler and idler pin is,

➢ Total frictional force between all carrying run idlers and idler pins is,

➢ The frictional force between carrying run idlers and idler pins is at a distance dp/2
(i.e. radius of pin) from the centre of pin.
➢ Equivalent frictional force along the belt due to frictional force between the idlers
and idler pins is,

➢ Frictional resistance due to carrying run idlers is given by,

➢ where, f = friction factor (Refer Table).

(ii) Frictional resistance due to return run idlers (F)
➢ The mass of material carried by return run is zero (i.e. mm =0)
Hence, from Equation (a), the frictional resistance due to return run idlers is given by,

3. FrIctional Resistance at Pulley (Fe):

The frictional resistance at pulley is due to pulley bearings and belt stiffness. It is
determined as follows:

Fig: Frictional Resistance at Pulle

Let,
F1 = effective tension in tight side of pulley belt, N
F2 = effective tension in slack side of pulley belt, N
m = mass of pulley, kg
db = diameter of pulley bearings, m
DP = diameter of pulley, m
WR = resultant load acting on pulley bearings, N

= coefficient of friction at pulley bearings.

➢ The resultant load acting on the pulley bearings ‘WR’ is the vector sum of belt
tensions (F1 and F2) and pulley weight ‘mP g’.
 ➢ Frictional resistance at the pulley bearings =
➢ Equivalent frictional resistance at pulley is,

➢ The frictional resistance due to belt stiffness is difficult to estimate accurately. The
total frictional resistance at pulley due to pulley bearings and belt stiffness is given
by following empirical relation.

4.Resistance at Loading Station (FL)

➢ The belt has to apply a force on the material at loading point so as to accelerate it
from initial speed v to belt speed v.
Let,
M capacity of conveyor or mass of material carried by conveyor, kg/s
v = belt speed, rn/s
vi= component of incoming material velocity along the belt line, rn/s

Fig: Resistance at Loading Station

➢ The incoming material applies inertia or resisting force on the belt, where as the
belt applies equal’and opposite accelerating force on the incoming material. From
above Fig, the resistance of incoming material on the belt at loading station is given
by,
5. Frictionai Resistance at Unloading Station (Fe) :
The unloading by plough offers frictional resistance to the belt and is given by,

where, mm = material carried by conveyor per unit belt length, kg/rn

B = belt width,m
6.Frictional Resistaice at Cleaning Station (FCL)
The frictional resistance due to cleaning device is given by,

Belt Tensions at Various Points Along Conveyor Path

The different resisting forces acting on conveyor belts are summarized in following Table.
 Fig: Typical Layout of Belt Conveyor
➢ Above Fig. shows a typical layout of belt conveyor. The total resisting force acting
on the conveyor belt and the belt tensions at various points along the conveyor path
can be determined by subdividing the conveyor belt in to a number of sections.
➢ The belt tension at every succeeding point is equal to the belt tension at the
preceding point plus the resisting force within the section between the two points.
➢ The analysis begins from the point where the belt leaves the drive pulley, known as
initial point; while the analysis ends at the point where the belt approaches the drive
pulley, known as fmal point.
Let, Fslack = effective tension in slack side of drive pulley, N
Ftight = effective tension in tight side of drive pulley, N

Where, FCL = frictional resistance due to belt cleaner

B = belt width, m
KC = (2to6)Vb
Vb = circumferential speed of brush, rn/s
Power Requirement of Belt Conveyors:
1. Effective Tension in Tight and Slack Sides of Drive Pulley
 2. Power Required on Drive Pulley (PO):
The power required on drive pulley is given by,

3. Input Power ( Pi):

The input power to conveyor belt is given by,

SELECTION OF NUMBER OF PLIES FOR CONVEYOR BELTS

The maximum tension in conveyor belt is given by,

where, Fc = centrifugal tension in conveyor belt, N

mb = mass of belt per unit length, kg/rn
 Table: Ultimate Tensile Strengths for Belts Sut

DRIVE UNIT FOR BELT CONVEYORS

Fig shows a typical drive unit layout for belt conveyor. It consists of an electric
motor driving the drive pulley through a spur or worm gear reduction unit. Inclined belt
conveyors are fitted with belt hold back devices and brakes so as to prevent possible
backward movement of the conveyor in case of stoppage of electric motor. The horizontal
belt conveyors also require brakes for emergency stoppage.
CONVEYOR BELT SAG

The belt sag among the idlers increases the angle ‘𝜃’ at which the belt enters an idler.
This outcome in to:
(i) Spilling of material from belt,
(ii) Accumulation of material on belt,
(iii) Impact of substance load on belt at the idlers.
Therefore, it is needed to remain the best sag within the permissible limit. The maximum
permissible belt sag is given by,
The maximum permissible belt sag is shown by,

The belt sag on carrying run is given by

The belt sag on return run is as follow

In order to maintain the belt sag inside the permissible limit, the minimum belt tensions in
carrying run and return run are given by,
Problem 1. A triple pay belt conveyor is required to transport 2 ton of iron ore per hour
through a distance of 1000 m and a height of 300 m. The permissible belt speed is 90
rn/mm. if the mass density of iron ore is 2.5 ton per cubic meter, determine:
(i) the belt width;
(ii) the diameter of drive pulley;
(iii) the reduction ratio of gear reducer, if electric motor speed is 1440 r.p.m.
Use following data:
Flow ability factor ‘k’:

a. Standard belt widths : 400, 450, 500, 600, 650, 750, 800, 900, 1000, 1200, 1400,
1600,
1800,2000mm
b. Material factor for plies for Capron belt: K1 = 2.0.
c. Belt tension and arc of contact factor: K2 = 80.
Solution :
Problem 2. An inclined belt conveyor is used for loading the mineral oral in a ship. The
belt inclination is 20o for which the flow ability factor ‘k’ is 2.5×10-4. The belt width is
1000mm while belt sped is 2.0m/s. If the specific weight of the mineral ore is 16000N/m3.
Determine the capacity of the conveyor.

Solution :
Problem 3The following data refers to a horizontal belt conveyor for carrying bulk
material

• Capacity of conveyor = 250 Metric Tons/hr

• Belt speed = 1.5 rn/s.
• Width of the belt = 1200 mm
• Belt mass per unit length = 18.6 kg/rn
• Mass of each carrying run idler = 30.0 kg
• Mass of each return run idler = 25.0 kg
• Pitch of carrying run idler = 1.0 m
• Pitch of return run idler = 2.0 m.
• Friction factor for idlers = 0.02
• Snub factor for snub pulley = 0.03
• Snub factor for drive and tail pulley = 0.06
• Drive and tail pulley diameters = 500 mm
• Frictional resistance due to belt cleaner, = (100 B) N
where B = belt width, m
• Angle of lap on drive pulley = 2000
• Coefficient of friction between belt and drive pulley = 0.4
• Drive efficiency =90 %
• Motor speed, = 1440
Assuming that the bulk material is carried over a length of 300 meters and neglecting
resistance at the loading station, determine:
(I) the reduction ratio of gear box
(ii)’ the power required to drive the belt.
Solution:
.