Çan Koveyör

Client Name UET Designer HAK
Project Name Çan kireç taşı öğütme tessi Company SVS mühensidlik
Conveyor Name bc01 Filename default
Location çan Date Kasım 23, 2020
Description
System Information Idler Set Data

Calculation method .......................................... CEMA 6th Carry Return
Conveyor Length / Height .............................. 48 / 13,7 m Series name Series 20 Series 20
Material lift ............................................................ 13,1 m Bearing 6204 6204
Ambient temperature range ........................... -15 to 35 °C Number of rolls 3 1
Kt factor at minimum temperature............................. 1,21 Trough angle (deg) 30 0
Type Inline Inline
Material Properties Idler spacing (m) 1,00 3,00
Type .................................................. Limestone, Crushed Number of ıdler sets 62 17
Design Tonnage ....................................................... 40 t/h Roll diameter 108 108
Density ............................................................ 1150 kg/m3 Roll rpm 30 30
Maximum lump size .............................................. 40 mm Total drag (N) 9,4 3,1
Surcharge angle ...................................................... 20 deg Drag range (N) 3,7 - 11,3 1,2 - 3,9
Roll length 298 891
Shaft diameter (mm) 20,0 20,0
Belt Properties
Dynamic capacity (kN) 13,5 13,5
Type ............................................................ Fabric (3-Ply) L10 life1 (1000 hrs) 350,0 / 350,0 350,0
Width ................................................................... 800 mm Shaft deflection (min) 1,01 / 2,53 6,33
Rating............................................................... 800 N/mm 1 L10 life above which 95% of idlers exceed
Speed ................................................................... 0,17 m/s
Top / bottom cover thickness ....................... 5,0 x 2,0 mm Drive Station
Total thickness ....................................................... 12 mm
Type ............................................................. Squirrel cage
Weight (new / worn) ................................. 10,9 / 7,7 kg/m
Synchronous RPM ...........................................1500 RPM
Modulus ......................................................... 7.254 kN/m
Motor quantity / rating ................................... 1 / 7,50 kW
Tape length .......................................................... 100,2 m
Total ınstalled power ........................................... 7,50 kW
Belt cycle time ...................................................... 9,8 min
Nominal empty / full power .... (12 / 62%) 0,88 / 4,67 kW
Tension Summary Running Momentary Min / max demand power........ (12 / 72%) 0,88 / 5,41 kW
Maximum tension (kN) 56,8 67,2 Frame Size........................................................ IEC 132M
Minimum safety factor 11,26 9,53 Motor Voltage ............................................. Not Specified
Minimum tension (kN) 28,2 20,4 Efficiency .................................................... 94,5 to 97,5%
Maximum belt sag (%) 0,21 0,22 Maximum starting torque .........................................180%
Inertia - Motor ................................................... 0,1 kg·m²
Cross Sectional Loading Pulley lagging type ................................................ Rubber
Material mass (wm) ........................................... 65,4 kg/m Motor wrap angles....................................................... 180
Combined mass (wm + wb) ................................ 76,2 kg/m Lagging friction factor (run / accel) ................. 0,32 / 0,38
Edge distance (required / actual).................................N/A
Cross sectional area ....................................................N/A Take-up Data
Cross sectional loading (utility / total) ........................N/A
Bed depth ....................................................................N/A Type ......................................................................... Fixed
Location ................................................... Tail / Pulley #2
Steady state tension .................................. 28,2 to 37,6 kN
Momentary tension................................... 20,4 to 37,7 kN
Required pulley displacement ................................ 1,36 m

Dynamic displacement (incl thermal) .............. 0,00 m
Permanent elongation ...................................... 0,65 m
Splice length (1 included) ................................ 0,46 m
Clearance ......................................................... 0,25 m
Backstops
Flooded belt tonnage................................................ 40 t/h
Flooded (wm + wb) ............................................ 75,9 kg/m Location ...............................................Head on Pulley #1
Backstop (quantity x type) .........................1 x Low speed
Sidewinder - v7.22 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 1 / 30
Description
Pulley diameter .................................................... 528 mm Estimated Splice Data

Load Share Factor % .................................................. 100 Splice type ...............................................................2-Step
Service Factor - Material Lift .................................... 1,50 Splice step length ................................................. 300 mm
Service Factor - Motor Rating ................................... 1,50 22 degree bias angle ............................................. 325 mm
Material Lift Criteria........................................... 858 N·m Total splice length ................................................ 925 mm
Motor Torque Criteria.................................... 17.471 N·m
Torque rating at low speed shaft .................... 17.471 N·m
Other Information
Brakes Loaded beltline mass (excluding motors)............ 8.033 kg
Brake type .................................................. None installed Total inertia (ref HS shaft) .............................. 0,01 kg·m2
Reducer Information Demand Power (kW)

Manufacture ................................................................N/A Demand % Motor
Case
Frame size ...................................................................N/A power Nameplate
Reducer ratio........................................................ 240,280 Empty - NF 0,9 11,7
Catalog reducer ratio................................................ 0,000 Full - NF 4,7 62,3
RPM (High Speed) .......................................... 1500 RPM Full - LF 3,9 51,7
RPM (Low Speed) .............................................. 6,2 RPM Full - HF 5,4 72,1
Configuration ................................................ Shaft Mount
Number of stages ............................................................ 3 Din Factor and Total Equivalent Mass
Service factor ............................................................... 1,4 Belt line
Case Din factor
Power rating............................................................... 0,00 mass (kg)
Empty - NF 0,0364 61.505
Full - NF 0,0221 64.621
Motor Torque
Full - LF 0,0156 64.308
100% Motor Torque - High Speed........................ 48 N·m Full - HF 0,0289 64.717
Motor Shaft Torque - Running (FN) ..................... 30 N·m
Motor Shaft Torque - Starting (FN) ...................... 87 N·m Maximum Belt Tensions (kN)
100% Motor Torque - Low Speed ................. 11.647 N·m Case Running Dynamic
Low Speed Shaft Torque - Running (FN)........ 6.769 N·m Empty - NF 41,2 42,4
Low Speed Shaft Torque - Running (Max) ..... 7.801 N·m Full - NF 55,0 65,6
Low Speed Shaft Torque - Starting (FN) ....... 11.769 N·m Full - LF 53,1 63,9
Low Speed Shaft Torque - Starting (Max)..... 12.717 N·m Full - HF 56,8 67,2
Starting and Stopping Belt Safety Factor

Start control ............................................. Constant torque Case Running Dynamic
Start time.......................................................... 0,1 to 0,4 s Empty - NF 15,54 15,10
Emergency stop control .............................................Drift Full - NF 11,64 9,76
Emergency stop time ....................................... 0,5 to 2,2 s Full - LF 12,06 10,02
Material buildup in chute ........................................ 0,0 m³ Full - HF 11,26 9,53
Splice Safety Factor

Tension Ratios
Case Running Dynamic
Allowable (running)................................................... 2,73 Empty - NF 10,36 10,07
Running tension ratio ................................................. 1,92 Full - NF 7,76 6,50
Allowable (dynamic) ................................................. 3,30 Full - LF 8,04 6,68
Starting tension ratio .................................................. 3,13 Full - HF 7,51 6,35
Transition Lengths
Transition method ............................................... CEMA 7
Tail transition length (inline) ................................. 1,50 m
Head transition length (elevated 42 mm) ............... 1,20 m

Page 2 / 30
Description
Minimum Belt Tensions (kN)

Empty - NF 37,6 37,4
Full - NF 29,6 21,7
Full - LF 31,1 23,2
Full - HF 28,2 20,4
Maximum Belt Sag (%)

Empty - NF 0,10 0,11
Full - NF 0,21 0,22
Full - LF 0,20 0,22
Full - HF 0,20 0,22

Page 3 / 30
Description
Conveyor Profile
Overall length = 48 m - Overall height = 13,7 m - True Length = 49,6 m
Pulleys
Pulleys - Top View
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Mtr 1 - Bstp 1 1-HT 180 56,8 38,9 86,5 67,2 39,1 101
Take-up Pulley 2-MT 180 37,6 76,0 37,7 76,2
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Pulley Safety Slope at Deflection T1 T2
L10 Life Shaft Force Angle Torque Moment
# Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)
1 1,51 6,99 0,072 500 65,4 34,1 401 101 198 8,3 9,6
2 1,67 7,76 0,079 476 41,4 42,2 287 82,9 14 0,2 7,5
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,15 on high tension
pulleys, and a multiplier of 1,10 on all other pulleys.

Page 4 / 30
Description
Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
Rubber
1 500 12,0 524 950 120 75 1220 517 22217 437
Diamond
2 None 400 0,0 400 950 110 65 1200 515 22215 313
Pulley Shaft Information

Hub Bearing Overhung
Tensile Yield Fatigue Hub Fillet Overhung
Locking Shaft Center to Fillet Moment
Type Strength Strength Strength Diameter Radius Load
Device Material Distance Distance Arm
(MPa) (MPa) (MPa) (mm) (mm) (kN)
(mm) (mm) (mm)
1 XT-45 SAE 4140 655,0 417,0 327,5 110 840 68 53 0,0 0
2 XT-40 SAE 4140 655,0 417,0 327,5 100 840 63 53 0,0 0

Page 5 / 30
Description
Conveyor Load Cases

During the course of operation, the conveyor experiences different operating conditions at various frequencies. Normal
operating conditions, such as steady state running, loading and unloading, and other common load cases are designated as
Design Level 1. Unusual operating conditions, such as when all incline or decline section are simultaneously loaded, are
defined as Design Level 2. These design levels allow easy summarization of the various possible loading conditions.
For this conveyor, there are two Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
In the load case figures, the red line is the conveyor profile and the blue line indicates positions that are loaded.
Empty
Fully Loaded (Material Lift = 13,1 m)

Page 6 / 30
Description
Take-up Displacement Summary

1. Type ......................................................................................................................................................Fixed
2. Location ................................................................................................................................ Tail / Pulley #2
3. Steady state tension .............................................................................................................. 28,2 to 37,6 kN
4. Momentary tension ............................................................................................................... 20,4 to 37,7 kN
Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) .................................................................................................0,00 m
2. Permanent elongation .........................................................................................................................0,65 m
3. Splice length (1 included) ...................................................................................................................0,46 m
4. Clearance ............................................................................................................................................0,25 m
5. Required displacement .......................................................................................................................1,36 m

Page 7 / 30
Description
Pulley Details
The following table lists recommended pulley design tensions. The first column lists belt tensions for bearing L10
life and pulley fatigue stress calculations. Belt tensions for the fatigue design criterion are based on all design
level 1 cases. Running tensions have an added multiplier of 1,15 on high tension pulleys, and a multiplier of 1,10
on all other pulleys.
Pulleys are also to be design for the structural design tensions. For structural design tensions, the pulley
manufacturer is to ensure that the pulleys will be adequate to meet these worst case conditions.
Pulley Design Tensions (added safety factors as described above)

Fatigue Design Tensions (kN) Structural Design Tension (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 - Backstop 1 1-HT 180 65,4 34,1 101 86,4 43,0 131
Take-up Pulley 2-MT 180 41,4 82,9 41,5 83,1
Required Pulley Diameter (Tension based on a safety factor of 10)

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Motor 1 - Backstop 1 Head (5) 1 - HT 180 500 630 89 105
Take-up Pulley Tail (8) 2 - MT 180 400 500 60 60
Pulley Shaft Stress Analysis (Individual Pulleys)

Hub Hub Fillet Fillet Fillet Von Hub Von Overhung
Shaft Slope
Pulley Safety Bending Torsion Bending Torsion Mises Mises Von Mises
Type at Hub
# Factor Stress Stress Stress Stress Stress Stress Stress
(min)
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
1 1 1,51 6,99 73,1 31,6 98,5 99,7 91,4 198,8 0,0
2 2 1,67 7,76 76,0 0,9 113,2 3,3 76,0 113,4 0,0
Running Drive Tensions by Load Case (kN)

Motor 1 - Backstop 1
Load Case Resultant
T1 T2
Force
Empty - NF 41,2 38,9 80,1
Full - NF 55,0 30,9 85,9
Full - LF 53,1 32,1 85,2
Full - HF 56,8 29,6 86,5

Page 8 / 30
Description
Pulley Tension Summary - All Load Cases and Conditions

Load Case Running Starting O-Stop E-Stop
Pulley T1 T2 T1 T2 T1 T2 T1 T2
ID Description
(kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN)
Mtr 1 - Bstp 1 41,2 38,9 42,4 37,9 40,9 39,1 40,9 39,1
EM-N Empty - NF
Take-up Pulley 37,6 38,4 37,4 38,4 37,7 38,5 37,7 38,5
Mtr 1 - Bstp 1 55,0 30,9 65,6 22,7 50,3 34,6 50,3 34,6
FL-N Full - NF
Take-up Pulley 29,6 30,3 21,7 22,6 33,0 33,7 33,0 33,7
Mtr 1 - Bstp 1 53,1 32,1 63,9 23,9 49,2 35,1 49,2 35,1
FL-L Full - LF
Take-up Pulley 31,1 31,5 23,2 23,7 34,0 34,3 34,0 34,3
Mtr 1 - Bstp 1 56,8 29,6 67,2 21,5 51,3 33,8 51,3 33,8
FL-H Full - HF
Take-up Pulley 28,2 29,3 20,4 21,6 32,1 33,2 32,1 33,2

Page 9 / 30
Description
28. Bearing L10.....................................500.000 hours

#1 - Motor 1 - Backstop 1
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-1)....................... Motor 1 - Backstop 1 29. Running T1 Tension ................................. 55,0 kN
2. Pulley Diameter ..........................................500 mm 30. Running T2 Tension ................................. 30,9 kN
3. Face Width..................................................950 mm 31. Design T1 Tension ................................... 65,4 kN
32. Design T2 Tension ................................... 34,1 kN
33. Wrap angle ................................................180 deg
Lagging
34. Design Resultant Tension.......................... 101 kN
4. Lagging Type ............................................... Rubber
35. Resultant Angle .........................................198 deg
5. Lagging Pattern......................................... Diamond
36. Resultant Moment ................................ 9,56 kN·m
6. Lagging Thickness ........................................12 mm
37. Resultant Torque .................................. 8,26 kN·m
7. Diameter with lagging ................................524 mm
38. Estimated Pulley & Shaft Mass .................. 401 kg
39. Estimated Mass with Bearings ................... 437 kg
Shaft Specification
8. Shaft Center Diameter ................................120 mm
Shaft Stresses & Deflections
9. Shaft Material ......................................... SAE 4140
40. Shaft slope at hub .................................... 6,99 min
10. Yield Strength ...................................... 417,0 MPa
41. Shaft slope at bearing ............................ 10,07 min
11. Fatigue Strength ................................... 327,5 MPa
42. Shaft deflection at center ......................... 0,88 mm
43. Shaft deflection at center (%) ....................... 0,072
Locking Device 44. Shaft Safety Factor (CEMA) .......................... 1,51
12. Hub Center Distance .................................840 mm 45. Shaft Safety Factor (AS1403) ........................ 1,66
13. Shaft diameter at hub ................................110 mm 46. Bending Stress ........................................ 73,1 MPa
14. Turndown radius at hub ..............................15 mm 47. Torsional Stress ...................................... 31,6 MPa
15. Locking Device ........................................... XT-45 48. Von Mises Stress .................................... 91,4 MPa
16. Size ........................................................ 110 x 203 49. Fillet Von Mises Stress ........................ 198,8 MPa
17. Hub width ...................................................54 mm
18. Hub pressure ........................................ 0,0 N/mm²
Shell Dimension and Stresses
19. Maximum torque ........................................ 0 N·m
50. Shell thickness ............................................ 18 mm
20. Hub outer diameter ...................................203 mm
51. Sitzwohl reqd shell thickness1 .................... 11 mm
52. Sitzwohl shell stress ............................... 15,2 MPa
Bearing Specifications 53. Shell stress at 180 wa ............................. 15,2 MPa
21. Bearing Center Distance .........................1220 mm 1 Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Shaft diameter at bearing ............................75 mm
23. Bearing to Fillet Distance ...........................68 mm End Disk Dimension and Stresses
24. Turndown radius at bearing ........................53 mm 54. End disk thickness ...................................... 27 mm
25. Bearing......................................................... 22217 55. End disk stress ........................................ 81,0 MPa
26. SNL Plummer Block........................................ 517
27. Dynamic Capacity ..................................... 285 kN

Page 10 / 30
Description
#2 - Take-up Pulley Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension ................................. 29,6 kN
1. Name (Type-2)................................ Take-up Pulley 29. Running T2 Tension ................................. 30,3 kN
2. Pulley Diameter ..........................................400 mm 30. Design T1 Tension ................................... 41,4 kN
3. Face Width..................................................950 mm 31. Design T2 Tension ................................... 42,2 kN
32. Wrap angle ................................................180 deg
33. Design Resultant Tension......................... 82,9 kN
Lagging
34. Resultant Angle ...........................................14 deg
4. Lagging Type ............................................... Rubber
35. Resultant Moment ................................ 7,46 kN·m
5. Lagging Thickness ......................................... 0 mm
36. Resultant Torque .................................. 0,18 kN·m
6. Diameter with lagging ................................400 mm
37. Estimated Pulley & Shaft Mass .................. 287 kg
38. Estimated Mass with Bearings ................... 313 kg
Shaft Specification
7. Shaft Center Diameter ................................110 mm
Shaft Stresses & Deflections
8. Shaft Material ......................................... SAE 4140
39. Shaft slope at hub .................................... 7,76 min
9. Yield Strength ........................................ 417,0 MPa
40. Shaft slope at bearing ............................ 11,30 min
10. Fatigue Strength ................................... 327,5 MPa
41. Shaft deflection at center ......................... 0,95 mm
42. Shaft deflection at center (%) ....................... 0,079
Locking Device 43. Shaft Safety Factor (CEMA) .......................... 1,67
11. Hub Center Distance .................................840 mm 44. Shaft Safety Factor (AS1403) ........................ 2,02
12. Shaft diameter at hub ................................100 mm 45. Bending Stress ........................................ 76,0 MPa
13. Turndown radius at hub ..............................15 mm 46. Torsional Stress ........................................ 0,9 MPa
14. Locking Device ........................................... XT-40 47. Von Mises Stress .................................... 76,0 MPa
15. Size ........................................................ 100 x 191 48. Fillet Von Mises Stress ........................ 113,4 MPa
16. Hub width ...................................................48 mm
17. Hub pressure ........................................ 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque ........................................ 0 N·m
49. Shell thickness ............................................ 18 mm
19. Hub outer diameter ...................................191 mm
50. Sitzwohl reqd shell thickness1 ...................... 9 mm
51. Sitzwohl shell stress ............................... 12,8 MPa
Bearing Specifications 52. Shell stress at 180 wa ............................. 12,7 MPa
20. Bearing Center Distance .........................1200 mm 1 Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing ............................65 mm
22. Bearing to Fillet Distance ...........................63 mm End Disk Dimension and Stresses
23. Turndown radius at bearing ........................53 mm 53. End disk thickness ...................................... 27 mm
24. Bearing......................................................... 22215 54. End disk stress ........................................ 64,3 MPa
25. SNL Plummer Block........................................ 515
26. Dynamic Capacity ..................................... 212 kN
27. Bearing L10 .................................... 475.960 hours

Page 11 / 30
Description
Belt Flap Summary

Belt flap may occur when the natural frequency of the belt matches the rotational frequency of the idlers. If belt flap is
severe, it can destroy the idlers and increase the demand power of the conveyor. Belt flap should be avoided.
The belt flap ratio is defined as the rotational frequency of the idler divided by the natural frequency of the belt. If this ratio
is equal to an integer (i.e. 1, 2, 3) then the idler may induce transverse vibrations at the natural frequency mode and result in
resonance.
The chart below shows the flap ratio along the length of the conveyor. The solid green line shows flap mode of the empty
belt under the normal friction case. The shaded pink areas should be avoided.
*
Belt flap resonance occurs at flap ratios 1, 2, 3, and 4

Page 12 / 30
Description
Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.
Material Trajectory

Page 13 / 30
Description
Belt Transition Length Requirements

The table below lists the required transition length at head and tail pulleys. Transition lengths are based on the CEMA 7th
Method. The figure below shows the geometry of the inline transition and elevated pulley transition.
Geometry of inline and elevated pulley transition
Required transition lengths

Head pulley transition
Tail pulley transition (m)
(m)
Inline transition (L1) 1,44 1,92
Elevated pulley transition (L2) 0,96 1,12
Pulley elevation (h) 41,833 41,833

Page 14 / 30
Description
Material Loading Profiles
Material Properties
Type .................................................. Limestone, Crushed
Design Tonnage ....................................................... 40 t/h
Density ............................................................ 1150 kg/m3
Maximum lump size .............................................. 40 mm
Surcharge angle ...................................................... 20 deg
Tonnage ................................................................... 40 t/h

Belt speed ............................................................ 0,17 m/s
Material mass .................................................... 65,0 kg/m

Page 15 / 30
Description
Idler Specifications
Idler Specifications
Equal Roll
Type Flat Idler
Trough
Number of rolls 3 1
Trough angle (deg) 30 0
Roll diameter (mm) 108 108
Roll length (mm) 298 891
Shaft diameter (mm) 20,0 20,0
Bearing series 6204 6204
Maximum roll RPM 30 30
Min Life (1000 hrs) 350 / 350 350
95% life1 (1000 hrs) 350 / 350 350
Shaft deflection (min) 1,01 / 2,53 6,33
Mass per Roll (kg) 3,0 8,0
Rotating mass for set (kg) 9,0 8,0
Wk2 for set (kg·mm²) 22.798 21.345
Idler Spacing and Count Summary

General Carry Return
Idler spacing (m) 0,80 3,00
Number of ıdler sets 62 17
Number of rolls 186 17
Total drag (N)
Nominal friction 9,4 3,1
High friction 11,3 3,9
Low friction 3,7 1,2
Idler Life and Shaft Deflection Summary-Carry Side

Center
Idler Wing L10 Center L10 Wing Shaft
Vertical Idler Shaft
# Station (m) Length (m) Spacing Life Life Deflection
Radius (m) Type Deflection
(m) (hours) (hours) (min)
(min)
1 0,0 0,7 1,00 1 350.000 350.000 0,42 0,55
2 0,7 1,2 1,00 1 350.000 350.000 0,42 0,55
3 1,9 4,3 0,25 1 350.000 350.000 0,91 1,77
4 6,0 1,8 1,00 1 350.000 350.000 1,00 2,52
5 7,7 41,6 1,00 1 350.000 350.000 1,01 2,53

Page 16 / 30
Description
Idler Life and Shaft Deflection Summary-Return Side

Center
Idler Wing L10 Center L10 Wing Shaft
Vertical Idler Shaft
# Station (m) Length (m) Spacing Life Life Deflection
Radius (m) Type Deflection
(m) (hours) (hours) (min)
(min)
7-8 47,9 49,6 3,00 2 350.000 6,33

Page 17 / 30
Description
Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures). Additionally they must include any other external loads
(wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the required live
load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes for the project.
The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and other
details. These forces must then be multiplied by the required dead load structural design safety factor requirements (typically
1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together to obtain the
total structural design forces.
The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for the
high friction case with 102 t/h have also been included. This specific load case results in 100% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 180% for this case. The maximum tension values have been
multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum tensions have
been reduced by 10%. The resultant force values include the vertical weight of the pulley.
Structural Live Loads - Includes case with 102 t/h under steady state and dynamic conditions + 110% multiplier
Shaft Shaft Shaft Minimum Tensions (kN) Maximum Tensions (kN)
Wrap Hub stress Center
(deg) Slope safety Def. T1 T2 T1 T2
(min) factor (mm) Force Force
Motor 1 -
1 180 9,08 1,30 1,06 36,8 16,3 54,4 86,4 43,0 131
Backstop 1
Take-up Pulley 2 180 7,78 1,67 0,88 15,2 30,7 41,5 83,1
Bearing Reaction Forces (excluding any overhung loads)

Entry Exiting Pulley, Bearing Horizontal Direction (kN) Bearing Vertical Direction (kN)
Wrap Vector Vector Shaft & Structural Structural Structural Structural
Pulley FL-N FL-N
(deg) Angle Angle Bearings Min Max Min Max
Case Case
(deg) (deg) Mass (kg) Tension Tension Tension Tension
Motor 1 -
180 196 196 437 -51,1 -82,6 -124 -18,9 -28,0 -40,0
Backstop 1
Take-up Pulley 180 16 16 313 30,2 57,6 80,6 5,55 13,4 19,9
The idler stringer loading should be based on the flooded belt surge capacity of 40 t/h and 75,9 kg/m plus the idler and frame
masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.

Page 18 / 30
Description

Page 19 / 30
Description
Other Forces
Load Case # 2 - Loading Point # 1 17. Drag Forces - Slot .................................... 4.511 N
Calculation Method ......................................... CEMA 18. Drag Forces - External .................................. 16 N
19. Sliderbed Drag Forces ..................................... 0 N
20. Material Acceleration ...................................... 2 N
Pullout Forces
21. Surcharge Factor (qf) ..................................... 0,89
22. Vertical Load.......................................... 13.828 N
23. Material Shear Force ................................ 8.889 N
Startup Forces
24. Surcharge Factor (qi)...................................... 2,50
25. qi/qf ................................................................ 2,81
26. Vertical Load.......................................... 38.886 N
27. Material Shear Force .............................. 24.996 N
Calculation Data
Total Drag 28. Shear Coefficient (u) .................................... 0,643
1. Steady State .............................................. 13.418 N 29. hc .............................................................. 0,00 m
2. Starting...................................................... 29.525 N 30. Qc/Ac ............................................................ 0 Pa
31. Beta ............................................................0,0 deg
Dimensions 32. X - Factor .................................................0,00 deg
3. Slot Length ...................................................4,10 m 33. Y - Factor .................................................0,00 deg
4. Slot Width at Front .......................................0,58 m
5. Slot Width at Rear ........................................0,58 m
6. Exit Length ...................................................0,17 m
7. Material Depth on Skirtboards ....................... 0 mm
Hopper
8. Hopper Width ...............................................1,16 m
9. Hopper Length .............................................. 4,10 m
10. Hopper Half Angle................................... 20,0 deg
11. Hopper Wall Friction Angle .................... 30,0 deg
12. Hopper Shape Factor ........................................ 0,0
Bin - Area Above Hopper

13. Material Height in Bin ................................0,00 m
14. Bin Shape Factor............................................... 0,0
15. Material Surcharge Height in Bin ...............0,00 m
16. Surcharge Shape Factor .................................... 0,0

Page 20 / 30
Description
Other Forces
Calculation Method ......................................... CEMA 18. Drag Forces - External .................................... 8 N
Pullout Forces
22. Vertical Load.......................................... 13.828 N
Startup Forces
25. qi/qf ................................................................ 2,81
26. Vertical Load.......................................... 38.886 N
Calculation Data
31. Beta ............................................................0,0 deg
6. Exit Length ...................................................0,17 m
Hopper
8. Hopper Width ...............................................1,16 m
9. Hopper Length .............................................. 4,10 m

14. Bin Shape Factor............................................... 0,0

Page 21 / 30
Description
Other Forces
Calculation Method ......................................... CEMA 18. Drag Forces - External .................................. 24 N
Pullout Forces
22. Vertical Load.......................................... 13.828 N
Startup Forces
25. qi/qf ................................................................ 2,81
26. Vertical Load.......................................... 38.886 N
Calculation Data
31. Beta ............................................................0,0 deg
6. Exit Length ...................................................0,17 m
Hopper
8. Hopper Width ...............................................1,16 m
9. Hopper Length .............................................. 4,10 m

14. Bin Shape Factor............................................... 0,0

Page 22 / 30
Description
Element Summary Details
Tension Summary

Page 23 / 30
Description
Power Summary

Page 24 / 30
Description
Element Summary Details

Summary of Conveyor Elements
Vertical Idler
Station Elevation Length Height Slope Idler
# Name Radius Spacing
(m) (m) (m) (m) (deg) Type
(m) (m)
1 0,0 0,00 0,7 0,20 16,00 1,00 1
2 Skirtboards Only 0,7 0,20 1,2 0,34 16,00 1,00 1
3 Loading Point 1,9 0,54 4,3 1,18 16,00 0,25 1
4 Skirtboards Only 6,0 1,72 1,8 0,49 16,00 1,00 1
5 7,7 2,21 41,6 11,47 16,00 1,00 1
6 Motor 1 - Backstop 1 47,7 13,68 0,5 -0,50 ---
7 47,9 13,18 1,0 -0,28 -16,00 3,00 2
8 46,9 12,90 48,6 -13,29 -15,85 3,00 2
9 Take-up Pulley 0,1 -0,38 0,4 0,38 ---

Page 25 / 30
Description
Min/Max Tension Summary per Element

Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 38,4 29,3 0,05 38,5 21,6 0,07
2 Skirtboards Only 38,4 29,3 0,05 38,5 21,6 0,07
3 Loading Point 38,5 29,4 0,08 38,6 21,7 0,11
4 Skirtboards Only 46,6 39,4 0,21 55,2 39,3 0,22
5 47,2 39,6 0,20 55,9 39,4 0,22
Motor 1 -
6 56,8 41,2 0,00 67,2 40,9 0,00
Backstop 1
7 38,9 29,6 0,15 39,1 21,5 0,20
8 38,9 29,6 0,15 39,1 21,4 0,20
9 Take-up Pulley 37,6 28,2 0,00 37,7 20,4 0,00

Page 26 / 30
Description
Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N)
EM-N FL-N FL-L FL-H
Total (Beltline) 2.172 24.037 20.929 27.138
Total (Power) 5.090 27.334 22.635 31.694
Lift Force 0 8.420 8.420 8.420

Frictional Drag 2.172 15.616 12.508 18.718
Motor Pulley/Reducer Drag 2.919 3.297 1.706 4.556
Rolling Resistance 25 145 82 210

Material+Belt Flexure 0 52 51 51
Idler Bearing Drag 485 503 251 768
Idler Alignment 78 305 282 312
Pulleys & Accessories 1.055 1.020 513 1.521
Loading Point 528 13.592 11.328 15.856
Mechanical Losses 1.349 1.694 907 2.146

Motor Pulley Drag Components 1.569 1.603 799 2.410

Page 27 / 30
Description
Pulley Summary Table - All Cases

Pulley Geometry Details
Type 1 2
Lagging Type Rubber None
Diameter (mm) 500 400
Lagging Thickness (mm) 12,0 0,0
Diameter with Lagging (mm) 524 400
Face Width (mm) 950 950
Shaft Center Diameter (mm) 120 110
Bearing Diameter (mm) 75 65
Bearing Center Distance (mm) 1220 1200
Plummer Block 517 515
Pulley & Shaft Mass (kg) 401 287
Locking Device XT-45 XT-40
Hub Center Distance (mm) 840 840
Hub Diameter (mm) 110 100
Bearing to Fillet Distance (mm) 68 63
Fillet Radius (mm) 53 53
Shaft Material SAE 4140 SAE 4140
Yield Strength (MPa) 417,0 417,0
Fatigue Strength (MPa) 327,5 327,5

Page 28 / 30
Description
Element Tension Details per Case
Element Tension Breakdown - (EM) Empty - Normal

Individual drag components per element
Running Running Element Pulley Feeder Extra
Wm+Wb Lift Belt Idler
# Tension Ten Diff Tonnage Drag Pt. Force Accessory
(kg/m) Force (N) Force (N) Force (N)
(N) (N) (t/h) Force (N) (N) Force (N)
1 38.396 27 10,9 21 0 6
2 38.423 47 10,9 37 0 10
3 38.470 923 10,9 125 1 124 373 300
4 39.393 221 10,9 52 0 14 155
5 39.614 1.560 10,9 1.222 9 329
6-M 41.174 -2.225 10,9 -54 169 1.400
7 38.949 -27 10,9 -29 0 2
8 38.921 -1.321 10,9 -1.415 15 79
9-T 37.600 796 10,9 41 195 560
Element Tension Breakdown - (FL) Fully Loaded - Normal

1 30.325 27 10,9 21 0 6
2 30.352 47 10,9 37 0 10
3 30.399 14.750 40 76,2 879 8 146 13.418 300
4 45.149 569 40 76,2 364 7 23 174
5 45.718 9.285 40 76,2 8.577 167 542
6-M 55.003 -24.090 10,9 -54 203 1.400
7 30.913 -27 10,9 -29 0 2
8 30.886 -1.321 10,9 -1.415 15 79
9-T 29.564 761 10,9 41 160 560

Page 29 / 30
Description
Element Tension Breakdown - (FL) Fully Loaded - Low

1 31.525 18 7,7 15 0 3
2 31.544 31 7,7 26 0 5
3 31.575 12.235 40 73,1 843 4 84 11.154 150
4 43.810 545 40 73,1 349 5 16 174
5 44.355 8.719 40 73,1 8.226 116 377
6-M 53.074 -20.967 7,7 -38 99 700
7 32.107 -20 7,7 -21 0 1
8 32.087 -954 7,7 -1.009 7 48
9-T 31.133 392 7,7 29 83 280
Element Tension Breakdown - (FL) Fully Loaded - High

1 29.316 32 11,8 23 0 9
2 29.348 55 11,8 40 0 15
3 29.403 17.244 40 77,2 890 11 211 15.682 450
4 46.647 583 40 77,2 369 9 30 174
5 47.230 9.612 40 77,2 8.685 219 708
6-M 56.841 -27.196 11,8 -58 310 2.100
7 29.645 -29 11,8 -32 0 2
8 29.616 -1.416 11,8 -1.541 20 105
9-T 28.200 1.116 11,8 45 231 840

Page 30 / 30

Çan Koveyör

Uploaded by

Copyright:

Available Formats

Çan Koveyör

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Çan Koveyör

Uploaded by

Copyright:

Available Formats

Client Name UET Designer HAK

System Information Idler Set Data

Required pulley displacement ................................ 1,36 m

Sidewinder - v7.22 - Conveyor Design Software

Pulley diameter .................................................... 528 mm Estimated Splice Data

Reducer Information Demand Power (kW)

Starting and Stopping Belt Safety Factor

Splice Safety Factor

Sidewinder - v7.22 - Conveyor Design Software

Minimum Belt Tensions (kN)

Maximum Belt Sag (%)

Sidewinder - v7.22 - Conveyor Design Software

Pulleys - Top View

Maximum Pulley Tensions (without any additional safety factors)

Pulley Shaft Results

Sidewinder - v7.22 - Conveyor Design Software

Pulley Geometry Details (Pulley Types)

Pulley Shaft Information

Sidewinder - v7.22 - Conveyor Design Software

Conveyor Load Cases

Fully Loaded (Material Lift = 13,1 m)

Sidewinder - v7.22 - Conveyor Design Software

Take-up Displacement Summary

Take-up Pulley Displacement Summary

Sidewinder - v7.22 - Conveyor Design Software

Pulley Design Tensions (added safety factors as described above)

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

Pulley Shaft Stress Analysis (Individual Pulleys)

Running Drive Tensions by Load Case (kN)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Tension Summary - All Load Cases and Conditions

Sidewinder - v7.22 - Conveyor Design Software

28. Bearing L10.....................................500.000 hours

Sidewinder - v7.22 - Conveyor Design Software

#2 - Take-up Pulley Design Tensions and Loads

Sidewinder - v7.22 - Conveyor Design Software

Belt Flap Summary

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Belt Transition Length Requirements

Geometry of inline and elevated pulley transition

Required transition lengths

Sidewinder - v7.22 - Conveyor Design Software

Material Loading Profiles

Tonnage ................................................................... 40 t/h

Sidewinder - v7.22 - Conveyor Design Software

Idler Spacing and Count Summary

Idler Life and Shaft Deflection Summary-Carry Side

Sidewinder - v7.22 - Conveyor Design Software

Idler Life and Shaft Deflection Summary-Return Side

Sidewinder - v7.22 - Conveyor Design Software

Bearing Reaction Forces (excluding any overhung loads)

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Bin - Area Above Hopper

Sidewinder - v7.22 - Conveyor Design Software

Bin - Area Above Hopper

Sidewinder - v7.22 - Conveyor Design Software