30 Sep 2020 14:04 Conveyor Design Summary Page 1/23

Helix Technologies Pty Ltd

Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Conveyed Material
Material Description COAL BITUMINOUS SIZED Surcharge Angle 20 deg
Low Bulk Density 850 kg/m3 Angle of Repose 35 deg
High Bulk Density 850 kg/m3 Material Lump size 50 mm
Conveyor Data
Conveying Distance 103.57 m Design Capacity 120 tonnes/hr
Nett Lift / Lower (-) 20.78 m Belt Speed 1 m/s
Belt Details
Belt Width 800 mm Calculated Belt % Full 53.0 %
Belt Class & Run Safety Factor PN100/3 11.38 Top Cover Thickness 6 mm
Belt Rated Tension 31.5 kN/m Bottom Cover Thickness 3 mm
Belt Total Length 234.4 m Belt Mass 11.06 kg/m
Belt Tensions and Power Calculations CEMA
Effective Tens. Fully Loaded 11.07 kN Belt Power - Empty Belt 3.17 kW
Maximum Tension Tmax 21.08 kN Belt Power - Inclines Loaded 11.04 kW
Minimum Tension Tmin 8.95 kN Belt Power - Declines Loaded 3.36 kW
Sag Tension 1.5 % 4.35 kN Belt Power - Fully Loaded 11.07 kW
Takeup Type Vertical Gravity Drive Efficiency 95.0 %
Takeup Mass 2000 kg Absorbed Power Fully Loaded 11.65 kW
Takeup Pulley Belt Tension 9.81 kN Installed Motor Power 15 kW
Carry and Return Idlers
Carry Idler Trough Angle 45 º Return Idler Trough Angle 0 º
Carry Idler Spacing 1.2 m Return Idler Spacing 3 m
Carry Idler No Rolls x Dia 3 x 102 mm Return Idler No Rolls x Dia 1 x 114 mm
Dynamics and Miscellaneous Data
Startup Factor - Fully Loaded 150 % CEMA Temperature Factor Kt 1.00
Startup Factor - Empty 150 % Total Braking Torque LSS 0.00 kNm
Starting Time - Fully Loaded 1.06 sec Stop Time - Loaded, Braking 0.99 sec
Starting Time - Empty 0.41 sec Stop Time - Loaded, Coasting 0.99 sec

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Helix Technologies Pty Ltd
Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Sectio
Section Section Cap- Ten Idler Skirt Friction
Length Lift X co- Y co- Z co- acity Adj. Spacing Length No. of Factor
Station Description m m ord m ord m ord m tph kN m m Scrapers Input

1 Tail 5.98 0.48 0.00 0.00 0.00 0 1.20 2 0.0000

2 Hopper 6.00 0.00 5.96 0.00 0.68 120 0.50 4.00 0.0000

3 Hopper 6.03 0.00 11.96 0.00 0.68 120 0.50 4.00 0.0000

4 Int. Pt 40.86 11.26 17.99 0.00 0.68 120 1.00 0.0000

5 Int. Pt 36.06 9.94 57.27 0.00 11.94 120 1.20 0.0000

6 Int. Pt 14.62 -0.43 91.94 0.00 21.88 120 1.20 0.0000

7 Drive 8.01 -0.91 106.55 0.00 21.20 0 3.00 2 0.0000

8 Bend 7.55 -7.49 98.59 0.00 19.85 0 3.00 0.0000

9 Takeup 7.56 7.50 97.24 0.00 12.35 0 3.00 1 0.0000

10 Bend 3.95 0.47 95.89 0.00 19.85 0 3.00 0.0000

11 Int. Pt 35.93 -9.91 91.97 0.00 20.53 0 3.00 0.0000

12 Int. Pt 40.99 -11.30 57.43 0.00 10.62 0 3.00 0.0000

13 Int. Pt 18.03 0.48 18.03 0.00 -0.68 0 3.00 0.0000

Totals: 231.59 0.10 0.00 8.00 5

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Drive Torque Start-up Factor Loaded 150 % Takeup Pulley Belt Tension 9.81 kN
Drive Torque Start-up Factor Empty 150 % Takeup Mass 2000 kg
Running Starting Braking

Drive Fully Empty Fully Empty Fully Empty

Number Loaded Belt Loaded Belt Loaded Belt
Drive No. 1 Drive
Pulley No. 7 Lagging Type Ceramic Ceramic Ceramic
Wrap Angle º 180 180 180 180 180 180
Co-efficient of Friction 0.25 0.25 0.35 0.35 0.35 0.35
Drive Factor Cw 0.838 0.838 0.499 0.499 0.499 0.499
Calculated Belt Tension T1 kN 20.99 13.1 27.72 22.07 13.77 11.54
Calculated Belt Tension T2 kN 10 10 9.66 9.11 10.53 10.22
Minimum Required T2 kN 9.21 2.6 9.01 6.47 1.62 0.66
Surplus T2 Tension (T1-T2) kN 0.79 7.4 0.65 2.64 8.91 9.56

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Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Drive Torque Start-up Factor Loaded 150 %

Drive Torque Start-up Factor Empty 150 % Takeup Mass 2000 kg

Running Starting Braking Coasting

Fully Inclines Declines Fully Fully Fully
Loaded Empty Loaded Loaded Loaded Empty Loaded Empty Loaded Empty
Station Tension Tension Tension Tension Tension Tension Tension Tension Tension Tension
No kN kN kN kN kN kN kN kN kN kN
1 Tail 9.03 9.03 9.03 9.03 10.67 13.25 7.28 8.30 7.28 8.30

2 Hopper 9.84 9.84 9.84 9.84 11.70 14.64 7.83 9.00 7.83 9.00

3 Hopper 10.15 9.97 10.11 10.11 12.34 15.13 7.80 9.07 7.80 9.07

4 Int. Pt 10.43 10.10 10.36 10.36 12.95 15.62 7.73 9.15 7.73 9.15

5 Int. Pt 16.09 11.71 16.01 11.96 20.48 18.75 11.38 10.48 11.38 10.48

6 Int. Pt 21.08 13.13 21.01 13.38 27.13 21.52 14.60 11.67 14.60 11.67

7 Drive 20.99 13.10 20.98 13.29 27.72 22.07 13.77 11.54 13.77 11.54

8 Bend 10.54 10.54 10.54 10.54 10.31 9.95 10.96 10.72 10.96 10.72

9 Takeup 9.81 9.81 9.81 9.81 9.81 9.81 9.81 9.81 9.81 9.81

10 Bend 11.00 11.00 11.00 11.00 11.24 11.61 10.75 10.90 10.75 10.90

11 Int. Pt 11.12 11.12 11.12 11.12 11.54 12.20 10.68 10.94 10.68 10.94

12 Int. Pt 10.11 10.11 10.11 10.11 10.99 12.37 9.17 9.72 9.17 9.72

13 Int. Pt 8.95 8.95 8.95 8.95 10.36 12.57 7.44 8.32 7.44 8.32

Minimum Ten 8.95 8.95 8.95 8.95 9.81 9.81 7.28 8.30 7.28 8.30
Maximum Ten 21.08 13.13 21.01 13.38 27.72 22.07 14.60 11.67 14.60 11.67
Effective Ten 11.07 3.17 11.04 3.36

Ave. Belt Ten 12.56 10.70 12.53 10.80 14.94 14.99 10.01 9.95 10.01 9.95
Belt Elong. m 0.324 0.123 0.321 0.133 0.583 0.588 0.048 0.041 0.048 0.041
T/up Travel m 0.162 0.062 0.16 0.066 0.292 0.294 0.024 0.02 0.024 0.02

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 30 Sep 2020 14:04 Belt Details Report Page 5/23
Helix Technologies Pty Ltd
Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Low BD = 850kg/m3 High BD = 850kg/m3

Conveyed Material Belt Speed & Capacity
Material Description COAL BITUMINOUS SIZED Belt Speed 1 m/s
Low Bulk Density 850 kg/m3 Belt Design Capacity Input 120 tonnes/hr
High Bulk Density 850 kg/m3 Section Loading Max Capacity 120 tonnes/hr
Surcharge Angle 20 deg Carry Idler Trough Angle 45 º
Angle of Repose 35 deg Belt Dimensions
Material Lump size 50 mm Top Cover Thickness 6 mm
Belt Make & Class Bottom Cover Thickness 3 mm
Belt Category Apex PN Fabric - obsolete Belt Carcass Thickness 3.6 mm
Belt Description APEX PN Belt Total Thickness 12.6 mm
Belt Class / Plies PN100/3 3 Belt Total Belt Length (L) 234.4 m
Belt Reinforcement Fibre Fabric Time for 1 Revolution 234.4 sec
Belt Width 800 mm Belt Load Area and Capacity at 850kg/m3
Belt Modulus 2700 kN/m Minimum Rec. Edge Distance 67 mm
Actual Edge Distance Low BD 146 mm
Load Burden Depth 0 mm
Load Burden Width 0 mm
Belt Tensions Belt Load Area at Minimum
Recommended Edge Distance 0.0739 m2
Belt Rated Tension / m width 31.5 kN/m
Calculated Tension / m width 26.4 kN/m Belt Load Area Utilised at Low
Belt Rated Tension for width 25.2 kN Bulk Density 0.0392 m2
Calculated Max Run Tension 21.08 kN Belt Actual % Full at Low BD 53.0 %
Minimum Tension Tmin 8.95 kN Belt Load Area and Capacity at 850kg/m3
Allowable Tension Rise, Starting 150 % Minimum Rec. Edge Distance 67 mm
Allowable Belt Tension, Starting 37.8 kN Actual Edge Distance High BD 146 mm
Actual Belt Tension, Starting 27.72 kN Belt Load Area Utilised at High
Bulk Density 0.0392 m2
Belt and Material Mass Belt Actual % Full at High BD 53 %
Belt Top Cover Mass 5.4 kg/m Flooded Belt Capacity at 850kg/m3
Belt Bottom Cover Mass 2.7 kg/m Flooded Belt Load Area at Zero
Edge Distance 0.1094 m2
Belt Carcass Mass 2.9 kg/m
Belt Mass Wb (per linear m) 11.1 kg/m Flooded Belt Capacity 335 tonnes/hr
Material Mass Wm 33.3 kg/m Flooded Belt Material Mass 93 kg/m
Total Mass (Wb + Wm) 44.4 kg/m
Total Belt Mass (Wb x L) 2592 kg
Designers Comments

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Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Allowable Belt Sag % Running 1.5 %

Allowable Belt Sag % Start / Stop 5 % Takeup Mass 2000 kg

Running Starting Braking Coasting

Fully Inclines Declines Fully Fully Fully
Loaded Empty Loaded Loaded Loaded Empty Loaded Empty Loaded Empty
Station Tension Tension Tension Tension Tension Tension Tension Tension Tension Tension
No kN kN kN kN kN kN kN kN kN kN
1 Tail 9.03 9.03 9.03 9.03 10.67 13.25 7.28 8.30 7.28 8.30
Idler Spacing m 1.20
Belt Sag % 0.18 0.18 0.18 0.18 0.15 0.12 0.22 0.2 0.22 0.2
2 Hopper 9.84 9.84 9.84 9.84 11.70 14.64 7.83 9.00 7.83 9.00
Idler Spacing m 0.50
Belt Sag % 0.28 0.07 0.28 0.28 0.23 0.05 0.35 0.08 0.35 0.08
3 Hopper 10.15 9.97 10.11 10.11 12.34 15.13 7.80 9.07 7.80 9.07
Idler Spacing m 0.50
Belt Sag % 0.27 0.07 0.27 0.27 0.22 0.04 0.35 0.07 0.35 0.07
4 Int. Pt 10.43 10.10 10.36 10.36 12.95 15.62 7.73 9.15 7.73 9.15
Idler Spacing m 1.00
Belt Sag % 0.78 0.2 0.79 0.2 0.63 0.13 1.06 0.22 1.06 0.22
5 Int. Pt 16.09 11.71 16.01 11.96 20.48 18.75 11.38 10.48 11.38 10.48
Idler Spacing m 1.20
Belt Sag % 0.51 0.17 0.51 0.17 0.4 0.11 0.72 0.19 0.72 0.19
6 Int. Pt 21.08 13.13 21.01 13.38 27.13 21.52 14.60 11.67 14.60 11.67
Idler Spacing m 1.20
Belt Sag % 0.31 0.12 0.08 0.49 0.24 0.08 0.45 0.14 0.45 0.14
7 Drive 20.99 13.10 20.98 13.29 27.72 22.07 13.77 11.54 13.77 11.54
Idler Spacing m 3.00
Belt Sag % 0.19 0.31 0.19 0.31 0.15 0.18 0.3 0.35 0.3 0.35
8 Bend 10.54 10.54 10.54 10.54 10.31 9.95 10.96 10.72 10.96 10.72
Idler Spacing m 3.00
Belt Sag % 0.39 0.39 0.39 0.39 0.39 0.41 0.37 0.38 0.37 0.38
9 Takeup 9.81 9.81 9.81 9.81 9.81 9.81 9.81 9.81 9.81 9.81
Idler Spacing m 3.00
Belt Sag % 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41 0.41
10 Bend 11.00 11.00 11.00 11.00 11.24 11.61 10.75 10.90 10.75 10.90
Idler Spacing m 3.00
Belt Sag % 0.37 0.37 0.37 0.37 0.36 0.35 0.38 0.37 0.38 0.37

E:\BAMA\Project\PT JGC\koordinat\BC01.xml Helix

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Running Starting Braking Coasting

Fully Inclines Declines Fully Fully Fully
Loaded Empty Loaded Loaded Loaded Empty Loaded Empty Loaded Empty
Station Tension Tension Tension Tension Tension Tension Tension Tension Tension Tension
No kN kN kN kN kN kN kN kN kN kN
11 Int. Pt 11.12 11.12 11.12 11.12 11.54 12.20 10.68 10.94 10.68 10.94
Idler Spacing m 3.00
Belt Sag % 0.37 0.37 0.37 0.37 0.35 0.33 0.38 0.37 0.38 0.37
12 Int. Pt 10.11 10.11 10.11 10.11 10.99 12.37 9.17 9.72 9.17 9.72
Idler Spacing m 3.00
Belt Sag % 0.4 0.4 0.4 0.4 0.37 0.33 0.44 0.42 0.44 0.42
13 Int. Pt 8.95 8.95 8.95 8.95 10.36 12.57 7.44 8.32 7.44 8.32
Idler Spacing m 3.00
Belt Sag % 0.45 0.45 0.45 0.45 0.39 0.32 0.55 0.49 0.55 0.49

Minimum Ten 8.95 8.95 8.95 8.95 9.81 9.81 7.28 8.30 7.28 8.30
Maximum Sag 0.78 0.45 0.79 0.49 0.63 0.41 1.06 0.49 1.06 0.49

E:\BAMA\Project\PT JGC\koordinat\BC01.xml Helix

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Takeup Mass 2000 kg

Tensions
Section Section Ten Material Skirt Scraper Section CEMA
Station / Pulley
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 5.98 0.48 9.03 9.09 0.06 0.63 0.12 0.0191

2 Hopper 6.00 0.00 9.84 9.84 0.03 0.11 0.17 0.0172

3 Hopper 6.03 0.00 10.15 10.15 0.11 0.17 0.0172

4 Int. Pt 40.86 11.26 10.43 10.43 5.66 0.0253

5 Int. Pt 36.06 9.94 16.09 16.09 4.99 0.0253

6 Int. Pt 14.62 -0.43 21.08 21.08 -0.09 0.0135*

7 Drive 8.01 -0.91 20.99 10.00 0.08 10.99 0.63 -0.09 0.015

8 Bend 7.55 -7.49 10.54 10.61 0.06 -0.80 0.015

9 Takeup 7.56 7.50 9.81 9.87 0.06 0.31 0.83 0.015

10 Bend 3.95 0.47 11.00 11.07 0.06 0.06 0.015

11 Int. Pt 35.93 -9.91 11.12 11.12 -1.02 0.015

12 Int. Pt 40.99 -11.30 10.11 10.11 -1.16 0.015

13 Int. Pt 18.03 0.48 8.95 8.95 0.08 0.015

Totals: 0.32 11.0 0.00 0.03 0.22 1.57 8.92

Maximum Tension 21.08 kN Total Effective Tension 11.07 kN
Minimum Tension 8.95 kN Total Belt Power (Te x V) 11.07 kW
Average Tension Fully Loaded 12.56 kN Belt Modulus 2700 kN/m
Average Tension Belt Stationary 9.57 kN Total Belt Length 234.40 m
Average Tension Difference 2.99 kN Belt Elastic Elongation 0.324 m
* Reduced Friction factor x 0.66 used for CEMA calculation Takeup Movement 0.162 m

E:\BAMA\Project\PT JGC\koordinat\BC01.xml Helix

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Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Pulley Tensions

Section Section Ten Material Skirt Scraper Section CEMA
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 5.98 0.48 9.03 9.09 0.06 0.63 0.12 0.0191

2 Hopper 6.00 0.00 9.84 9.84 0.13 0.0172

3 Hopper 6.03 0.00 9.97 9.97 0.13 0.0172

4 Int. Pt 40.86 11.26 10.10 10.10 1.61 0.0253

5 Int. Pt 36.06 9.94 11.71 11.71 1.42 0.0253

6 Int. Pt 14.62 -0.43 13.13 13.13 -0.02 0.0135*

7 Drive 8.01 -0.91 13.10 10.00 0.07 3.10 0.63 -0.09 0.015

8 Bend 7.55 -7.49 10.54 10.61 0.06 -0.80 0.015

9 Takeup 7.56 7.50 9.81 9.87 0.06 0.31 0.83 0.015

10 Bend 3.95 0.47 11.00 11.07 0.06 0.06 0.015

11 Int. Pt 35.93 -9.91 11.12 11.12 -1.02 0.015

12 Int. Pt 40.99 -11.30 10.11 10.11 -1.16 0.015

13 Int. Pt 18.03 0.48 8.95 8.95 0.08 0.015

Totals: 0.31 3.10 0.00 1.57 1.29

Maximum Tension 13.13 kN Total Effective Tension 3.17 kN
Minimum Tension 8.95 kN Total Belt Power (Te x V) 3.17 kW
Average Tension Fully Loaded 10.70 kN Belt Modulus 2700 kN/m
Average Tension Belt Stationary 9.57 kN Total Belt Length 234.40 m
Average Tension Difference 1.13 kN Belt Elastic Elongation 0.123 m
* Reduced Friction factor x 0.66 used for CEMA calculation Takeup Movement 0.062 m

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Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Pulley Tensions

Section Section Ten Material Skirt Scraper Section CEMA
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 5.98 0.48 9.03 9.09 0.06 0.63 0.12 0.0191

2 Hopper 6.00 0.00 9.84 9.84 0.03 0.11 0.13 0.016

3 Hopper 6.03 0.00 10.11 10.11 0.11 0.13 0.016

4 Int. Pt 40.86 11.26 10.36 10.36 5.66 0.0253

5 Int. Pt 36.06 9.94 16.01 16.01 4.99 0.0253

6 Int. Pt 14.62 -0.43 21.01 21.01 -0.02 0.0191

7 Drive 8.01 -0.91 20.98 10.00 0.05 10.98 0.63 -0.09 0.015

8 Bend 7.55 -7.49 10.54 10.61 0.06 -0.80 0.015

9 Takeup 7.56 7.50 9.81 9.87 0.06 0.31 0.83 0.015

10 Bend 3.95 0.47 11.00 11.07 0.06 0.06 0.015

11 Int. Pt 35.93 -9.91 11.12 11.12 -1.02 0.015

12 Int. Pt 40.99 -11.30 10.11 10.11 -1.16 0.015

13 Int. Pt 18.03 0.48 8.95 8.95 0.08 0.015

Totals: 0.32 10.99 0.00 0.03 0.22 1.57 8.92

Maximum Tension 21.01 kN Total Effective Tension 11.04 kN
Minimum Tension 8.95 kN Total Belt Power (Te x V) 11.04 kW
Average Tension Inclines Loaded 12.53 kN Belt Modulus 2700 kN/m
Average Tension Belt Stationary 9.57 kN Total Belt Length 234.40 m
Average Tension Difference 2.96 kN Belt Elastic Elongation 0.321 m
Takeup Movement 0.16 m

E:\BAMA\Project\PT JGC\koordinat\BC01.xml Helix

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Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Pulley Tensions

Section Section Ten Material Skirt Scraper Section CEMA
Length Lift T1 Run T2 Run Tp Drive Adj. Accel. Friction Friction Effective Friction
Station m m kN kN Pulley Te kN kN kN kN kN Tension Factor

1 Tail 5.98 0.48 9.03 9.09 0.06 0.63 0.12 0.0191

2 Hopper 6.00 0.00 9.84 9.84 0.03 0.11 0.13 0.0172

3 Hopper 6.03 0.00 10.11 10.11 0.11 0.13 0.0172

4 Int. Pt 40.86 11.26 10.36 10.36 1.61 0.0253

5 Int. Pt 36.06 9.94 11.96 11.96 1.42 0.0253

6 Int. Pt 14.62 -0.43 13.38 13.38 -0.09 0.0135*

7 Drive 8.01 -0.91 13.29 10.00 0.07 3.30 0.63 -0.09 0.015

8 Bend 7.55 -7.49 10.54 10.61 0.06 -0.80 0.015

9 Takeup 7.56 7.50 9.81 9.87 0.06 0.31 0.83 0.015

10 Bend 3.95 0.47 11.00 11.07 0.06 0.06 0.015

11 Int. Pt 35.93 -9.91 11.12 11.12 -1.02 0.015

12 Int. Pt 40.99 -11.30 10.11 10.11 -1.16 0.015

13 Int. Pt 18.03 0.48 8.95 8.95 0.08 0.015

Totals: 0.32 11.0 0.00 0.03 0.22 1.57 8.92

Maximum Tension 13.38 kN Total Effective Tension 3.36 kN
Minimum Tension 8.95 kN Total Belt Power (Te x V) 3.36 kW
Average Tension Declines Loaded 10.80 kN Belt Modulus 2700 kN/m
Average Tension Belt Stationary 9.57 kN Total Belt Length 234.40 m
Average Tension Difference 1.23 kN Belt Elastic Elongation 0.133 m
* Reduced Friction factor x 0.66 used for CEMA calculation Takeup Movement 0.066 m

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Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

System Masses Input Data

Mass of Belt 2,593 kg Belt Speed 1 m/s
Mass of Material 3,452 kg Belt Rated Tension 31.5 kN/m
Carry Idler Equivalent Mass 607 kg Allow. Belt Start Tension Rise 150 %
Return Idler Equivalent Mass 323 kg Drive Inertia 0.14 kg-m2
Pulley Equivalent Mass 743 kg Total Braking Torque 0 kNm
Drive Equivalent Mass 3,250 kg Start-up Factor - Loaded 150 %
Total System Equivalent Mass 10,968 kg Start-up Factor - Empty 150 %
Installed Power 15 kW
Tensions and Accelerating Forces
Drive Efficiency (Average) 95 %
Effective Tens. Fully Loaded 11.07 kN
Effective Tension Empty 3.17 kN Stopping Times & Deceleration Rates
Total Braking Force 0.00 kN Stopping Time Loaded Braking 0.99 sec
Stopping Time Loaded Coasting 0.99 sec
Tension Available to Accelerate Conveyor
Stopping Time Empty Braking 2.37 sec
Accelerating Tension - Loaded 10.31 kN
Stopping Time Empty Coasting 2.37 sec
Accelerating Tension - Empty 18.21 kN
Deceleration - Loaded Braking -1.01 m/s2
Starting Times & Acceleration Rates
Deceleration - Loaded Coasting -1.01 m/s2
Starting Time - Fully Loaded 1.06 sec
Deceleration - Empty Braking -0.42 m/s2
Starting Time - Empty 0.41 sec
Deceleration - Empty Coasting -0.42 m/s2
Acceleration Rate - Loaded 0.94 m/s2
Accelerating Rate - Empty 2.42 m/s2 Stopping Distances & Discharge Volumes
Stopping Distance Loaded Braking 0.5 m
Belt Tension Rise Starting / Braking
Stopping Distance Loaded Coasting 0.5 m
Max Belt Tension, Start/Brake 27.72 kN
Stopping Distance Empty Braking 1.19 m
Belt Width 800 mm
Stopping Distance Empty Coasting 1.19 m
Maximum Belt Tension / width 34.65 kN/m
Belt Rated Tension / width 31.5 kN/m Discharge Mass, Braking 17 kg
Actual Max Tension, Start/Brake 110 % Discharge Mass, Coasting 17 kg
Discharge Volume, Braking 0.02 m3
Discharge Volume, Coasting 0.02 m3

E:\BAMA\Project\PT JGC\koordinat\BC01.xml Helix

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Carry Side Idlers Return Side Idlers

Idler Category Sandvik Carry Sandvik Flat Return
Idler Description Series 10 3 Roll Carry 102 Plain Series 05 1 Roll Flat Carry
Offset 114 Dia
Idler Design Belt Width 800 mm 800 mm
Idler Series 10 5
Drawing Number
Nominal Idler Spacing 1.2 m 3 m
Total Number of Idlers 92 42
Idler Price 0 0
Troughing Angle 45.0 deg 0.0 deg
Idler Shaft Diameter 20.0 mm 27.0 mm
Idler Bearing Diameter 20.0 mm 25.0 mm
Number of Idler Rolls 3 1
Idler Roll Diameter 102 mm 114 mm
Idler Rotation Speed 187 rpm 168 rpm
Roll Face Width 291 mm 895 mm
Roll Bearing Centres 236.8 mm 840.8 mm
Shaft Support Centres 317 mm 921 mm
Idler Support Fixing Width 1050 mm 1050 mm
Idlerset Rotating Mass 6.6 kg 7.7 kg
Idlerset Total Mass 20 kg 15 kg
Idler Vertical Misalignment Allowance 3.0 mm 5.0 mm
Dynamic Load Factor 1.01 1.40
Belt Deviation Load 500 N 500 N
Total Load on Centre Roll 882 N 1,097 N
Type of Bearing Ball Ball
Bearing Designation 6204 6205
Bearing Dynamic Load Rating C 12,700 N 14,000 N
Bearing L10h Life 2,127,404 hrs 1,656,383 hrs
Allowable Shaft Deflection at Bearing 8.00 min 10.00 min
Actual Shaft Deflection at Bearing 4.36 min 5.80 min

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Carry Roll Diameter 102 mm Belt Speed 1 m/s

Return Roll Diameter 114 mm Takeup Mass 2000 kg
Belt Resonance +/- Tolerance 2 %
Station / Sectio Running Fully Loaded Belt Resonance
Critical Critical Idler
Start End Belt Transverse Idler Roll Section Idler Idler Spacing
Belt Belt Wave Frequency Excitation Idler Spacing Spacing within

Mode
Station Description
Tension Tension Range Frequency Spacing Start End +/- 10%
kN kN Hz to Hz Hz m m m m

1 Tail 9.09 10.15 11.93 12.61 3.12 1.2 4.59 4.85 OK

2 Hopper 9.84 10.43 14.82 15.26 3.12 0.5 2.37 2.45 OK

3 Hopper 10.15 16.09 15.06 18.99 3.12 0.5 2.41 3.04 OK

4 Int. Pt 10.43 21.08 7.63 10.87 3.12 1 2.45 3.48 OK

5 Int. Pt 16.09 20.99 7.91 9.04 3.12 1.2 3.04 3.48 OK

6 Int. Pt 21.08 10.54 9.06 6.39 3.12 1.2 3.48 2.46 OK

7 Drive 10.0 9.81 5.01 4.96 2.79 3 5.38 5.33 OK

8 Bend 10.61 11 5.16 5.25 2.79 3 5.54 5.64 OK

9 Takeup 9.87 11.12 4.97 5.28 2.79 3 5.34 5.67 OK

10 Bend 11.07 10.11 5.27 5.03 2.79 3 5.66 5.41 OK

11 Int. Pt 11.12 8.95 5.28 4.74 2.79 3 5.67 5.09 OK

12 Int. Pt 10.11 9.03 5.03 4.76 2.79 3 5.41 5.11 OK

13 Int. Pt 8.95 9.03 4.74 4.76 2.79 3 5.09 5.11 OK

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Takeup Travel
Takeup Type Vertical Gravity
Auto Calc Takeup Mass
Takeup Mass step increment 200 kg
Max no. of Calc Increments 100
Takeup Mass kg (Manual 1649.9 kg
Input)
Takeup Mass Calculated 2000 kg
Takeup Travel Estimate
Safety Margin Top + 0.5 m
Belt Splice Allowance + 1 m
Dynamic Travel Up + 0.5 m
Dynamic Travel Down + 0.5 m
Safety Margin Bottom + 0.5 m
Thermal Expansion Distance
Minimum Site Temperature 0 deg
Maximum Site Temperature 45 deg
Belt Expansion co-efficient
1.17E-05
m/m per degree C
Total Belt Length 234.40 m
Thermal Expansion Distance + 0 m
Permanent Belt Stretch
Permanent Stretch co-
0.15 %
efficient % of Belt Length
Permanent Belt Stretch 0 m
Distance +
Total Takeup Travel Distance 0 m

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Drive No. 1 Drive Pulley No. 7

Drive Description Head Pulley Condition Moist
Load Share on Drive Pulley 100 % Pulley Lagging Type Ceramic
Starting Torque Factor, Fully Loaded 150 % Belt Wrap Angle 180 º
Starting Torque Factor, Empty 150 % Coefficient of Friction, Running 0.25
Number of Motors on Drive Pulley 1 Drive Factor Cw, Running 0.84
Motor Description Electric Motor Coefficient of Friction, Starting 0.35
Motor Power Rating 15 kW Drive Factor Cw, Starting 0.5
Motor Voltage 415 Volts Pulley and Shaft Dimensions
Gearbox Description Flender Helical Bevel Gear Pulley Shell Diameter 500 mm
Drive Efficiency 95 % Pulley Lagging Thickness 12 mm
Fluid Coupling Pulley Outside Diameter 524 mm
Fluid Coupling VOITH TVV Pulley Shaft Diameter at Hub 120 mm
Fluid Coupling Size 366 Pulley Shaft Diameter at Brg 110 mm
High Speed Coupling Pulley and Belt Speed
Motor Full Load Speed 1455 rpm
Required Gearbox Ratio 38.723 :1
Low Speed Coupling Selected Gearbox Ratio 40 :1
LS Coupling Make David Brown Required Pulley Speed 37.57 rpm
LS Coupling Model MC135 Calculated Pulley Speed for Reducer 35.28 rpm
Brake Required Belt Speed 1 m/s
Brake Location High Speed Calculated Belt Speed 0.97 m/s
Low Speed Brake Torque Input 0 kNm Drive Inertia
Equiv HS Brake Torque 0 Nm Motor Inertia 0.14 kg-m2
Holdback High Speed Coupling Inertia 0 kg-m2
Static Analysis Runback Force Fv 6790 N High Speed Brake Disc Inertia 0 kg-m2
Static Analysis Horizontal Force Fh 4280 N Flywheel Inertia 0 kg-m2
Calculated Holdback Torque 1218 Nm Gearbox Inertia (HSS) 0 kg-m2
Holdback Required (Yes / No) Yes Fv>Fh/2 Total Drive Inertia 0.14 kg-m2
Holdback Torque 3 x Motor FLT 11791 Nm Total Drive Equivalent Mass 3250 kg
Holdback Make No Selection
Holdback Model

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Drive No. 1 Drive Pulley No. 7

Drive Description Head Total Motor Power on Drive 15 kW
Number of Motors on Drive Pulley 1 Absorbed Power at Pulley 11.07 kW
Motor Category Metric Motor Drive Efficiency 95 %
Motor Description Electric Motor Absorbed Power at Motor 11.65 kW
Motor Power Rating 15 kW Motor Full Load Speed 1455 rpm
Motor Voltage 415 Volts Motor Full Load Torque 98 Nm
Number of poles 4 Motor Full Load Current 28.6 Amps
Motor Frame Size F160L04 Motor Efficiency @ Duty Point 87.2 %
Motor Shaft Diameter 42 mm Motor Power Factor @ Duty Pt 0.79
Motor Shaft Height 160 mm Mass of Motor 140 kg
Motor Inertia 0.14 kg-m2

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Drive No. 1 Drive Pulley No. 7

Drive Description Head Motor Power Rating 15 kW
Number of Motors on Drive Pulley 1 Motor Full Load Speed 1455 rpm
Selection Mode Auto Motor Torque @ FL Speed 98 Nm
Gearbox Category Flender Motor Torque at Pulley Speed 3813 Nm
Gearbox Description Flender Helical Bevel Gear Gearbox Rated Torque 6400 Nm
Type Helical Bevel Gear Service Factor Required 1.5
Size 4 Service Factor Calculated 1.68
Code B3SH4
Plus Speed Selection Tolerance 5 %
Ratio 40
Minus Speed Selection Tolerance 5 %
Number of Stages 3
Fluid Coupling Slip 3 %
Design Efficiency (Input) 95 % Required Gearbox Ratio 38.723 :1
Gearbox Actual Efficiency 93 % Selected Gearbox Ratio 40 :1
Maximum Input Shaft Speed 1500 rpm Required Pulley Speed 37.57 rpm
Minimum Input Shaft Speed 700 rpm Calculated Pulley Speed for Reducer 35.28 rpm
Input Shaft Diameter 30 mm Required Belt Speed 1 m/s
Output Shaft Diameter 80 mm Calculated Belt Speed 0.97 m/s
Gearbox Inertia kg-m2 Mass of Gearbox 210 kg

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Drive No. 1 Drive Pulley No. 7

Drive Description Head Motor Power Rating 15 kW
Load Share on Drive Pulley 100 % Motor Full Load Speed 1455 rpm
Starting Torque Factor, Fully Loaded 150 % Motor Torque @ FL Speed 98 Nm
Starting Torque Factor, Empty 150 % Motor Torque at Pulley Speed 3813 Nm
Number of Motors on Drive Pulley 1 Pulley Shaft Diameter at Brg 110 mm
Drive Efficiency 95 %

High Speed Coupling Low Speed Coupling

HS Coupling Category Falk SteelFlex Grid LS Coupling Category David Brown Cone-Ring
HS Coupling Make Falk LS Coupling Make David Brown
HS Coupling Model 1050T LS Coupling Model MC135
Coupling Type Grid Coupling Type Pin & Buffer
Coupling Torque Rating 435 Nm Coupling Torque Rating 12000 Nm
Service Factor Required 1.5 Service Factor Required 1.5
Service Factor Calculated 4.42 Service Factor Calculated 3.05
Maximum Shaft Bore 50 mm Maximum Shaft Bore 135 mm
Minimum Shaft Bore 0 mm Minimum Shaft Bore 67 mm
Maximum Rotation Speed 4500 rpm Maximum Rotation Speed 1660 rpm
High Speed Coupling Inertia 0.0073 kg-m2 Low Speed Coupling Inertia 0 kg-m2
Drawing Number Drawing Number
High Speed Coupling Mass 5.44 kg Low Speed Coupling Mass 163 kg
High Speed Coupling Price 0 Low Speed Coupling Price 0
Fluid Coupling
Direct Drive
Fluid Coupling VOITH TVV
Fluid Coupling Size 366

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Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Sectio Resul- Calculated Selected

T1 T2 tant T1
Shaft Wrap Run Run Start Defl. Dt. Shaft Brg Brg Shaft
Length Angle Force Dia Dia Dia Dia Ctrs Mass
Station Description mm deg kN kN kN kN mm mm mm mm mm kg
1 Tail 1690 180.0 9.0 9.1 18.1 10.7 91.0 86.2 100 90 1370 104

7 Drive 1740 180.0 21.0 10.0 30.9 27.7 104.1 108.6 120 110 1370 154

8 Bend BBK 1650 90.0 10.5 10.6 14.9 10.3 86.8 80.8 90 80 1370 82

9 Takeup 1690 180.0 9.8 9.9 19.6 9.8 92.9 88.6 100 90 1370 104

10 Bend BBK 1650 90.0 11.0 11.1 15.6 11.2 87.7 82.0 90 80 1370 82

Designers Comments * Denotes manual pulley shaft dimensions entered

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Sectio
Face Shaft Brg Shaft Brg Wrap Pulley Pulley & Mom of
Shell Lagging Width Length Ctrs Dia Dia Angle Speed Shaft Inertia
Station Description Dia mm mm mm mm mm mm mm deg rpm Mass kg kgm2
1 Tail 400 12 950 1690 1370 100 90 180.0 45.0 291 6.2

7 Drive 500 12 950 1740 1370 120 110 180.0 36.4 426 13.4

8 Bend 400 12 950 1650 1370 90 80 90.0 45.0 270 6.1

9 Takeup 400 12 950 1690 1370 100 90 180.0 45.0 291 6.2

10 Bend 400 12 950 1650 1370 90 80 90.0 45.0 270 6.1

Designers Comments * Denotes manual pulley dimensions entered

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Sectio
Calc Face Shaft Shaft Brg Pulley & Mom of
Shell Shell t Shell t Lagging OD Width Length Dia Dia Shaft Inertia
Station Description Dia mm mm mm mm mm mm mm mm mm Mass kg kgm2
1 Tail 400 12 5.0 12 424 950 1690 100 90 291 6.2

7 Drive 500 12 6.6 12 524 950 1740 120 110 426 13.4

8 Bend 400 12 5.4 12 424 950 1650 90 80 270 6.1

9 Takeup 400 12 5.2 12 424 950 1690 100 90 291 6.2

10 Bend 400 12 5.6 12 424 950 1650 90 80 270 6.1

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Project Project Client ABC Engineering
Project No. Prepared By PCB
Conveyor No. BC 01 Design Date

Station / Sectio
Face Brg Drive Wrap Pulley T1 T2 T1 T2
Shell Lagging Width Ctrs Power Angle Speed Run Run Start Start
Station Description Dia mm mm mm mm kW deg rpm kN kN kN kN
1 Tail 400 12 950 1370 180.0 45.0 9.03 9.09 13.25 13.64
Running Full Starting Empty

7 Drive 500 12 950 1370 15 180.0 36.4 20.99 10.0 27.72 9.66
Running Full Starting Full

8 Bend 400 12 950 1370 90.0 45.0 10.54 10.61 10.96 10.88
Running Full Braking Full

9 Takeup 400 12 950 1370 180.0 45.0 9.81 9.87 9.81 10.2
Running Full Starting Empty

10 Bend 400 12 950 1370 90.0 45.0 11.0 11.07 11.61 12.01
Running Full Starting Empty

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