Boru Bant Versiyon 3

Client Name Designer HAK
Project Name 230384 Company Birikim Mühendislik End.

Conveyor Name botu bant Filename boru bant3
Location Aydın /çine Date Nisan 6, 2023
Description:
System Information
Calculation method DIN / ISO Idler Set Data
Conveyor Length / Height 1078 / 11,0 m Carry Return
Material lift 11,0 m Series name Series 20 Series 20
Ambient temperature range -10 to 40 °C Bearing 6204 6204
Kt factor at minimum temperature 1,12 Number of rolls 6 6
Trough angle (deg) 0 0
Material Properties Type Offset Offset
Type Masse Idler spacing (m) 2,00 2,00
Design Tonnage 250 t/h Number of ıdler sets 550 540
Density 1700 kg/m3 Roll diameter 108 108
Maximum lump size 0 mm Roll rpm 287 287
Surcharge angle 10 deg Total drag (N) --- ---
Roll length 250 222
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 / 350,0
Width 1000 mm Shaft deflection (min) 3,99 / 2,16 2,53
Rating 1000 N/mm 1
L10 life above which 95% of idlers exceed
Speed 1,62 m/s
Top / bottom cover thickness 6,0 x 3,0 mm Drive Station
Total thickness 15 mm
Weight (new / worn) 16,8 / 12,2 kg/m Type Fluid coupling
Modulus 8.657 kN/m Synchronous RPM 1500 RPM
Tape length 2.160 m Motor quantity / rating 1 / 90,0 kW
Belt cycle time 22,2 min Total ınstalled power 90,0 kW
Nominal empty / full power (37 / 71%) 33,6 / 63,6 kW
Tension Summary Running Momentary Min / max demand power (37 / 88%) 33,6 / 79,0 kW
Maximum tension (kN) 85,7 110 Frame Size IEC 280M
Minimum safety factor 11,67 9,12 Motor Voltage 400 V
Minimum tension (kN) 46,4 27,1 Efficiency 91,5 to 94,5%
Maximum belt sag (%) 0,27 0,29 Maximum starting torque 152%
Inertia - Motor 2,0 kg·m²
Cross Sectional Loading Inertia - Fluid Coupling 0,1 kg·m²
Pipe diameter (inside / outside) 250 / 280 mm Pulley lagging type Rubber
Belt overlap distance 167 mm Motor wrap angles 180
Material mass (wm) 42,8 kg/m Lagging friction factor (run / accel) 0,32 / 0,38
Combined mass (wm + wb) 59,6 kg/m
Cross sectional area 0,025 m² Take-up Data
Cross sectional loading (utility / total) 73 % / 55 %
Bed depth 131 mm Type Gravity
Location Tail / Pulley #2
Required belt line tension 52,6 kN
Cable reeving ratio (trolley:counterweight) 1:1
Counterweight mass 10,7 tonnes
Required pulley displacement 17,35 m

Dynamic displacement (incl thermal) 1,21 m
Permanent elongation 14,04 m
Splice length (2 included) 1,11 m
Clearance 1,00 m
Flooded belt tonnage 459 t/h
Backstops
Flooded (wm + wb) 95,3 kg/m
Sidewinder - v7.22 - Conveyor Design Software
Advanced Conveyor Technologies, Inc.
Page 1 / 38
Description:
Backstop type None installed
Brakes Take-Up Cable

Brake type None installed Counterweight mass 10,7 tonnes
Reducer Information Take-up cable tension 105,2 kN
Manufacture N/A Cable diameter 26,0 mm
Frame size N/A Cable breaking strength (1800 MPa) 449,0 kN
Reducer ratio 30,750 Safety factor 4,3
Catalog reducer ratio 0,000 Number of clips (crosby clamps) 5
RPM (High Speed) 1500 RPM Turnback / free end length 1120 / 130 mm
RPM (Low Speed) 48,8 RPM Sheave Root Diam 455 mm
Configuration Shaft Mount
Number of stages 3
Service factor 1,4 Other Information
Power rating 0,0 Loaded beltline mass (excluding motors) 97.527 kg
Total inertia (ref HS shaft) 11,1 kg·m2
Motor Torque
100% Motor Torque - High Speed 582 N·m Demand Power (kW)
Motor Shaft Torque - Running (FN) 418 N·m Demand % Motor
Case
Motor Shaft Torque - Starting (FN) 820 N·m power Nameplate
100% Motor Torque - Low Speed 17.887 N·m Empty - NF 33,6 37,4
Low Speed Shaft Torque - Running (FN) 11.675 N·m Full - NF 63,6 70,7
Low Speed Shaft Torque - Running (Max) 14.667 N·m Full - LF 47,2 52,4
Low Speed Shaft Torque - Starting (FN) 23.551 N·m Full - HF 79,0 87,8
Low Speed Shaft Torque - Starting (Max) 25.304 N·m
Din Factor and Total Equivalent Mass
Belt line
Starting and Stopping Case Din factor
mass (kg)
Start control Constant torque Empty - NF 0,0280 69.032
Start time 2,0 to 4,9 s Full - NF 0,0280 115.125
Emergency stop control Drift Full - LF 0,0238 104.894
Emergency stop time 4,0 to 6,1 s Full - HF 0,0322 118.085
Material buildup in chute 0,1 m³
Maximum Belt Tensions (kN)
Tension Ratios Case Running Dynamic
Allowable (running) 2,73 Empty - NF 62,8 84,3
Running tension ratio 1,85 Full - NF 80,5 107
Allowable (dynamic) 3,30 Full - LF 74,7 106
Starting tension ratio 3,11 Full - HF 85,7 110
Transition Lengths Belt Safety Factor

Case Running Dynamic
Transition method Pipe Empty - NF 15,94 11,86
Head transition length (elevated 140 mm) 8,40 m Full - NF 12,42 9,31
Tail transition length (elevated 140 mm) 8,40 m Full - LF 13,39 9,47
Full - HF 11,67 9,12
Estimated Splice Data
Splice type 2-Step
Splice step length 350 mm
22 degree bias angle 405 mm
Total splice length 1105 mm
Page 2 / 38
Description:
Splice Safety Factor Minimum Belt Tensions (kN)

Case Running Dynamic Case Running Dynamic
Empty - NF 10,62 7,91 Empty - NF 47,7 27,1
Full - NF 8,28 6,21 Full - NF 47,7 38,5
Full - LF 8,92 6,31 Full - LF 49,3 40,2
Full - HF 7,78 6,08 Full - HF 46,4 38,0
Maximum Belt Sag (%)

Case Running Dynamic
Empty - NF 0,09 0,15
Full - NF 0,27 0,28
Full - LF 0,25 0,26
Full - HF 0,27 0,29

Page 3 / 38
Description:
Conveyor Profile
Overall length = 1078 m - Overall height = 11,0 m - True Length = 1079,2 m
Horizontal Profile 1:1 Scale

Page 4 / 38
Description:
Tail Arrangement Head Arrangement
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
Motor 1 1-HT 180 85,7 49,3 132 110 56,7 166
Take-up Pulley 2-MT 180 52,654,7 107 52,654,8 107
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Safety Slope at Deflection T1 T2
Pulley # L10 Life Shaft Force Angle Torque Moment
Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)
1 2,01 7,74 0,080 500 104 51,0 761 156 183 17,9 17,5
2 2,52 8,01 0,080 500 65,8 68,7 646 135 357 1,0 13,5
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,10 on high tension
pulleys, and a multiplier of 1,25 on all other pulleys. A steady state case at 100% motor power has also been included.
Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
Rubber
1 Herringb 630 10,0 650 1150 140 115 1450 526 23226 870
one
2 Rubber 630 10,0 650 1150 130 110 1400 524 23224 743

Page 5 / 38
Description:
Pulley Shaft Information

Overhun
Hub Bearing
Tensile Yield Fatigue Hub Fillet Overhun g
Locking Shaft Center to Fillet
Type Strength Strength Strength Diameter Radius g Load Moment
Device Material Distance Distance
(MPa) (MPa) (MPa) (mm) (mm) (kN) Arm
(mm) (mm)
(mm)
1 XT-60 C45 630,0 360,0 315,0 140 1000 100 38 0,0 0
2 XT-60 C45 630,0 360,0 315,0 130 1000 98 30 0,0 0

Page 6 / 38
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 = 11,0 m)

Page 7 / 38
Description:
Take-up Displacement Summary

1. Type Gravity
2. Location Tail / Pulley #2
3. Belt line tension 52,6 kN
4. Take-up pulley displacement range
a. Running -0,68 to 0,00 m
b. Momentary -1,16 to 0,04 m
Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) 1,21 m
2. Permanent elongation 14,04 m
3. Splice length (2 included) 1,11 m
4. Clearance 1,00 m
5. Required displacement 17,35 m
Counterweight Displacement Summary (1:1 Cable Reeving Ratio)

1. Dynamic displacement 1,21 m
2. Permanent elongation 14,04 m
3. Splice length (2 included) 1,11 m
4. Clearance 1,00 m
5. Required displacement 17,35 m

Page 8 / 38
Description:
Pulley Details
The following table lists recommended pulley design tensions. The first column lists belt tensions for bearing L10
life and pulley fatigue stress calculations. Belt tensions for the fatigue design criterion are based on all design
level 1 cases. Running tensions have an added multiplier of 1,10 on high tension pulleys, and a multiplier of 1,25
on all other pulleys. A steady state case at 100% motor power has also been included.
Pulleys are also to be design for the structural design tensions. For structural design tensions, the pulley
manufacturer is to ensure that the pulleys will be adequate to meet these worst case conditions.
Pulley Design Tensions (added safety factors as described above)

Fatigue Design Tensions (kN) Structural Design Tension (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-HT 180 104 51,0 156 132 62,4 195
Take-up Pulley 2-MT 180 65,868,7 135 57,960,5 119
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 Head (15) 1 - HT 180 630 630 86 110
Take-up Pulley Tail (33) 2 - MT 180 630 500 55 55
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 2,01 7,74 65,0 33,2 69,1 59,9 86,8 124,6 0,0
2 2 2,52 8,01 62,4 2,2 67,9 3,7 62,5 68,2 0,0
Running Drive Tensions by Load Case (kN)

Motor 1
Load Case Resultant
T1 T2
Force
Empty - NF 62,8 47,7 110
Full - NF 80,5 47,7 128
Full - LF 74,7 49,3 124
Full - HF 85,7 46,4 132

Page 9 / 38
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)
Motor 1 62,8 47,7 84,3 27,1 55,2 54,7 55,2 54,7
EM-N Empty - NF
Take-up Pulley 52,6 53,6 52,6 53,8 52,6 53,5 52,6 53,5
Motor 1 80,5 47,7 107 38,5 56,5 55,7 56,5 55,7
FL-N Full - NF
Take-up Pulley 52,6 53,8 52,6 53,9 52,6 53,7 52,6 53,7
Motor 1 74,7 49,3 106 40,2 56,7 54,6 56,7 54,6
FL-L Full - LF
Take-up Pulley 52,6 53,1 52,6 53,2 52,6 53,0 52,6 53,0
Motor 1 85,7 46,4 110 38,0 55,8 56,7 55,8 56,7
FL-H Full - HF
Take-up Pulley 52,6 54,7 52,6 54,8 52,6 54,6 52,6 54,6

Page 10 / 38
Description:
28. Bearing L10 500.000 hours

#1 - Motor 1
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-1) Motor 1 29. Running T1 Tension 80,5 kN
2. Pulley Diameter 630 mm 30. Running T2 Tension 47,7 kN
3. Face Width 1150 mm 31. Design T1 Tension 104 kN
32. Design T2 Tension 51,0 kN
33. Wrap angle 180 deg
Lagging
34. Design Resultant Tension 156 kN
4. Lagging Type Rubber
35. Resultant Angle 183 deg
5. Lagging Pattern Herringbone
36. Resultant Moment 17,5 kN·m
6. Lagging Thickness 10 mm
37. Resultant Torque 17,9 kN·m
7. Diameter with lagging 650 mm
38. Estimated Pulley & Shaft Mass 761 kg
39. Estimated Mass with Bearings 870 kg
Shaft Specification
8. Shaft Center Diameter 140 mm
Shaft Stresses & Deflections
9. Shaft Material C45
40. Shaft slope at hub 7,74 min
10. Yield Strength 360,0 MPa
41. Shaft slope at bearing 9,90 min
11. Fatigue Strength 315,0 MPa
42. Shaft deflection at center 1,15 mm
43. Shaft deflection at center (%) 0,080
Locking Device 44. Shaft Safety Factor (CEMA) 2,01
12. Hub Center Distance 1000 mm 45. Shaft Safety Factor (AS1403) 1,64
13. Shaft diameter at hub 140 mm 46. Bending Stress 65,0 MPa
14. Turndown radius at hub 0 mm 47. Torsional Stress 33,2 MPa
15. Locking Device XT-60 48. Von Mises Stress 86,8 MPa
16. Size 140 x 292 49. Fillet Von Mises Stress 124,6 MPa
17. Hub width 73 mm
18. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
19. Maximum torque 0 N·m
50. Shell thickness 22 mm
20. Hub outer diameter 292 mm
51. Sitzwohl reqd shell thickness1 14 mm
52. Sitzwohl shell stress 15,8 MPa
Bearing Specifications 53. Shell stress at 180 wa 15,8 MPa
21. Bearing Center Distance 1450 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Shaft diameter at bearing 115 mm
23. Bearing to Fillet Distance 100 mm End Disk Dimension and Stresses
24. Turndown radius at bearing 38 mm 54. End disk thickness 33 mm
25. Bearing 23226 55. End disk stress 64,0 MPa
26. SNL Plummer Block 526
27. Dynamic Capacity 780 kN

Page 11 / 38
Description:

#2 - Take-up Pulley
1. Name (Type-2) Take-up Pulley 28. Running T1 Tension 52,6 kN
3. Face Width 1150 mm 30. Design T1 Tension 65,8 kN
Lagging
Shaft Specification 38. Estimated Mass with Bearings 743 kg
Locking Device 42. Shaft deflection at center (%) 0,080
11. Hub Center Distance 1000 mm 43. Shaft Safety Factor (CEMA) 2,52
12. Shaft diameter at hub 130 mm 44. Shaft Safety Factor (AS1403) 2,29
13. Turndown radius at hub 0 mm 45. Bending Stress 62,4 MPa
14. Locking Device XT-60 46. Torsional Stress 2,2 MPa
15. Size 130 x 292 47. Von Mises Stress 62,5 MPa
16. Hub width 73 mm 48. Fillet Von Mises Stress 68,2 MPa
Bearing Specifications 51. Sitzwohl shell stress 18,8 MPa
20. Bearing Center Distance 1400 mm 52. Shell stress at 180 wa 18,8 MPa
21. Shaft diameter at bearing 110 mm 1
22. Bearing to Fillet Distance 98 mm
23. Turndown radius at bearing 30 mm End Disk Dimension and Stresses
24. Bearing 23224 53. End disk thickness 27 mm
25. SNL Plummer Block 524 54. End disk stress 71,0 MPa

Page 12 / 38
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 13 / 38
Description:
Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.
Material Trajectory

Page 14 / 38
Description:
Material Loading Profiles
Material Properties
Type Masse
Design Tonnage 250 t/h
Density 1700 kg/m3
Maximum lump size 0 mm
Surcharge angle 10 deg
Tonnage 250 t/h

Belt speed 1,62 m/s
Material mass 42,8 kg/m
Edge distance (required / actual) 75 / 308 mm
Cross sectional loading (utility / total) 73 % / 55 %
Bed depth 131 mm

Page 15 / 38
Description:
Idler Specifications
Idler Specifications for Idler Type 1: 6 Roll Trough Idler

Center Middle Wing Outer Wing
Roll angle (deg) 120 60 0
Non-Symmetric Roll Angle (deg) 180 240 300
Roll diameter (mm) 108 108 108
Roll length (mm) 250 250 250
Shaft diameter (mm) 20,0 20,0 20,0
Bearing series 6204 6204 6204
Maximum roll RPM 287 287 287
Min life (1000 hrs) 350 75 160
95% life1 (1000 hrs) 350 350 350
Shaft deflection (min) 2,16 3,99 6,25
Total ıdler mass (kg) 20,5
Rotating mass (kg) 15,5
Wk2 for set (kg·mm²) 38.915
Idler Specifications for Idler Type 2: 6 Roll Trough Idler

Center Middle Wing Outer Wing
Roll angle (deg) 120 60 0
Non-Symmetric Roll Angle (deg) 180 240 300
Roll diameter (mm) 108 108 108
Roll length (mm) 222 222 222
Shaft diameter (mm) 20,0 20,0 20,0
Bearing series 6204 6204 6204
Maximum roll RPM 287 287 287
Min life (1000 hrs) 350 217 350
95% life1 (1000 hrs) 350 350 350
Shaft deflection (min) 1,36 2,19 2,53
Total ıdler mass (kg) 18,7
Rotating mass (kg) 14,1
Wk2 for set (kg·mm²) 34.969
Idler Spacing and Count Summary

Type 1: 6 Roll Type 2: 6 Roll
General
Trough Idler Trough Idler
Idler spacing (m) 2,00 2,00
Number of ıdler sets 550 540
Number of rolls 3.300 3.240
Total drag (N)
Nominal friction 18,9 18,9
High friction 18,9 18,9
Low friction 0,0 0,0

Page 16 / 38
Description:
Idler Life and Shaft Deflection Summary-Carry Side

Vertical Idler Wing L10 Center L10 Wing Shaft Center
Station Length Horizontal Idler Shaft
# Radius Radius (m) Spacing Life Life Deflection
(m) (m) Type (min)
Deflection
(m) (m) (hours) (hours) (min)
1 0,0 2,0 2,00 1 350.000 350.000 0,56 0,17
2 2,0 3,0 0,25 1 350.000 350.000 1,07 0,50
3-4 5,0 674,6 2,00 1 350.000 350.000 2,68 0,18
5-8 679,6 12,7 -70 2,00 1 350.000 350.000 2,69 2,49
9 692,3 50,1 2,00 1 350.000 350.000 2,65 0,19
10-11 741,5 9,1 50 2,00 1 74.632 350.000 6,25 0,20
12 750,5 30,5 2,00 1 350.000 350.000 2,70 0,20
13-14 781,1 159,1 -110 2,00 1 350.000 350.000 2,70 0,99
15 940,2 138,1 2,00 1 350.000 350.000 2,71 0,21
Idler Life and Shaft Deflection Summary-Return Side

Vertical Idler Wing L10 Center L10 Wing Shaft Center
Station Length Horizontal Idler Shaft
# Radius Radius (m) Spacing Life Life Deflection
(m) (m) Type (min)
Deflection
(m) (m) (hours) (hours) (min)
17-18 1.078,3 138,1 2,00 2 350.000 350.000 0,47 0,13
19-20 940,2 159,1 -110 2,00 2 350.000 350.000 0,88 0,58
21 781,1 30,5 2,00 2 350.000 350.000 0,48 0,14
22-23 750,5 9,1 50 2,00 2 217.205 350.000 2,53 0,14
24 741,5 50,1 2,00 2 350.000 350.000 0,47 0,14
25-28 692,3 12,7 -70 2,00 2 350.000 350.000 1,36 1,57
29-33 679,6 679,6 2,00 2 350.000 350.000 0,48 0,14

Page 17 / 38
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 361 t/h have also been included. This specific load case results in 97% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 160% 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 361 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
Force Force
(min) factor (mm)
Motor 1 1 180 9,70 2,01 1,44 49,7 24,4 74,4 132 62,4 195
Take-up Pulley 2 180 7,05 2,52 0,98 47,347,7 95,3 57,960,5 119
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 1 180 180 180 870 -74,1 -128 -195 -8,54 -8,54 -8,54
Take-up Pulley 180 0 0 743 95,1 106 118 -7,29 -7,29 -7,29
The idler stringer loading should be based on the flooded belt surge capacity of 459 t/h and 95,3 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
Description:
Element Summary Details
Tension Summary
Power Summary

Page 19 / 38
Description:
Vertical Curve Summary

Summary of Vertical Curve on Carry Strand
Running Tension Momentary Tension
Elements Station (m) Type Radius (m) Req'd Radius Req'd Radius
Reason Reason
(m) (m)
5-9 680 - 692 concave -70 -32 Max Stress -32 Max Stress
10-12 742 - 751 convex 50 39 Max Stress 39 Max Stress
13-15 781 - 940 convex 0 -44 Max Stress -44 Max Stress
Summary of Vertical Curve on Return Strand

Running Tension Momentary Tension
Elements Station (m) Type Radius (m) Req'd Radius Req'd Radius
Reason Reason
(m) (m)
25-29 680 - 692 concave -70 -29 Min Stress -29 Min Stress
22-24 742 - 751 convex 50 28 Min Stress 28 Min Stress
19-21 781 - 940 convex 0 -29 Min Stress -29 Min Stress
Horizontal Curves
Summary of Horizontal Curve on Carry Strand
Spacing Spacing
Section Horizontal Vertical Idler Banking
Inside Outside
Station (m) Length Radius Radius Idler Type Spacing Angle
Guide Roll Guide Roll
(m) (m) (m) (m) (deg)
(m) (m)
781 - 940 159 -110 0 1 2,00 0,00 0,00 0,00
Summary of Horizontal Curve on Return Strand

Spacing Spacing
Section Horizontal Vertical Idler Banking
Inside Outside
Station (m) Length Radius Radius Idler Type Spacing Angle
Guide Roll Guide Roll
(m) (m) (m) (m) (deg)
(m) (m)
781 - 940 159 -110 0 2 2,00 0,00 0,00 0,00
The following tables summarize the displacement range in the horizontal curves. These table only list
the displacement for the running condition (i.e. starting and stopping displacements are not listed).
Column 'All Load Cases' lists the displacements assuming the belt is loaded per the load case.
However column 'All Load Cases - Assume Empty Belt' calculates the displacement assuming the belt
is locally empty in the horizontal curve.
Displacement Summary of Horizontal Curves on Carry Strand - Running Tensions Only

Horizon All Load Cases -
Vertical Empty - Normal Full - Normal
tal All Load Cases Assume Empty
Station (m) Radius Friction Friction
Radius Belt
(m)
(m) min max min max min max min max
781 - 940 -110 0 0 0 0 0 0 0 0 0

Page 20 / 38
Description:
Displacement Summary of Horizontal Curves on Return Strand - Running Tensions Only

Horizon All Load Cases -
Vertical Empty - Normal Full - Normal
tal All Load Cases Assume Empty
Station (m) Radius Friction Friction
Radius Belt
(m)
(m) min max min max min max min max
781 - 940 -110 0 0 0 0 0 0 0 0 0

Page 21 / 38
Description:
Element Summary Details

Summary of Conveyor Elements
Vertical Horizontal Idler
Station Elevation Length Height Slope Idler
# Name Radius Radius Spacing
(m) (m) (m) (m) (deg) (m) Type
(m) (m)
1 0,0 0,00 2,0 0,00 0,00 0 2,00 1
2 Loading Point 2,0 0,00 3,0 0,00 0,00 0 0,25 1
3 5,0 0,00 337,3 0,00 0,00 0 2,00 1
4 342,3 0,00 337,3 0,00 0,00 0 2,00 1
5 679,6 0,00 3,2 0,07 1,30 -70 0 2,00 1
6 682,8 0,07 3,2 0,22 3,90 -70 0 2,00 1
7 686,0 0,29 3,2 0,36 6,49 -70 0 2,00 1
8 689,1 0,65 3,2 0,50 9,09 -70 0 2,00 1
9 692,3 1,15 50,1 9,03 10,39 0 2,00 1
10 741,5 10,18 4,5 0,61 7,79 50 0 2,00 1
11 746,0 10,79 4,5 0,21 2,60 50 0 2,00 1
12 750,5 11,00 30,5 0,00 0,00 0 2,00 1
13 781,1 11,00 1,0 0,00 0,00 -110 2,00 1
14 782,1 11,00 158,1 0,00 0,00 -110 2,00 1
15 940,2 11,00 138,1 0,00 0,00 0 2,00 1
16 Motor 1 1.078,3 11,00 0,6 -0,65 --- 0
17 1.078,3 10,35 1,0 0,00 0,00 0 2,00 2
18 1.077,3 10,35 137,1 -0,05 -0,02 0 2,00 2
19 940,2 10,30 158,1 -0,05 -0,02 -110 2,00 2
20 782,1 10,25 1,0 0,00 0,00 -110 2,00 2
21 781,1 10,25 30,5 0,00 0,00 0 2,00 2
22 750,5 10,25 4,5 -0,21 -2,60 50 0 2,00 2
23 746,0 10,04 4,5 -0,61 -7,79 50 0 2,00 2
24 741,5 9,43 50,1 -9,03 -10,39 0 2,00 2
25 692,3 0,40 3,2 -0,50 -9,09 -70 0 2,00 2
26 689,1 -0,10 3,2 -0,36 -6,49 -70 0 2,00 2
27 686,0 -0,46 3,2 -0,22 -3,90 -70 0 2,00 2
28 682,8 -0,68 3,2 -0,07 -1,30 -70 0 2,00 2
29 679,6 -0,75 337,3 0,00 0,00 0 2,00 2
30 342,3 -0,75 337,3 0,00 0,00 0 2,00 2
31 5,0 -0,75 3,0 0,00 0,00 0 2,00 2
32 2,0 -0,75 1,0 0,12 6,96 0 2,00 2
33 1,0 -0,63 1,0 0,00 0,00 0 2,00 2
34 Take-up Pulley 0,0 -0,63 0,6 0,63 --- 0

Page 22 / 38
Description:
Min/Max Tension Summary per Element

Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 54,7 53,1 0,08 54,8 53,0 0,08
2 Loading Point 54,7 53,1 0,03 54,8 53,0 0,03
3 56,1 53,5 0,27 56,4 53,1 0,27
4 63,4 56,2 0,24 71,0 52,4 0,28
5 70,6 58,4 0,22 85,7 51,4 0,29
6 70,7 58,4 0,22 85,9 51,5 0,29
7 70,9 58,5 0,22 86,1 51,6 0,29
8 71,2 58,5 0,22 86,5 51,8 0,29
9 71,5 58,6 0,22 86,9 52,0 0,29
10 78,0 60,5 0,20 94,5 55,2 0,26
11 78,5 60,6 0,20 95,0 55,3 0,26
12 78,7 60,6 0,20 95,4 55,3 0,26
13 79,3 60,8 0,19 96,7 55,3 0,26
14 79,4 60,8 0,19 96,7 55,3 0,26
15 82,7 61,9 0,19 104 55,2 0,26
16 Motor 1 85,7 62,8 0,00 110 55,2 0,00
17 49,3 46,4 0,09 56,7 27,1 0,15
18 49,3 46,4 0,09 56,7 27,1 0,15
19 49,9 47,4 0,09 56,4 30,6 0,13
20 50,6 48,6 0,09 56,1 34,6 0,12
21 50,6 48,6 0,09 56,1 34,6 0,12
22 50,7 48,8 0,09 56,0 35,4 0,12
23 50,7 48,8 0,09 56,0 35,4 0,12
24 50,7 48,8 0,09 55,9 35,5 0,12
25 49,8 47,5 0,09 54,2 35,2 0,12
26 49,7 47,5 0,09 54,1 35,2 0,12
27 49,7 47,4 0,09 54,0 35,3 0,12
28 49,7 47,4 0,09 53,9 35,3 0,12
29 49,7 47,4 0,09 53,9 35,4 0,12
30 51,1 50,0 0,09 53,3 43,9 0,09
31 52,6 52,5 0,08 52,6 52,5 0,08
32 52,6 52,6 0,08 52,6 52,5 0,08
33 52,6 52,6 0,08 52,6 52,6 0,08
34 Take-up Pulley 52,6 52,6 0,00 52,6 52,6 0,00

Page 23 / 38
Description:
Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N)
EM-N FL-N FL-L FL-H
Total (Beltline) 14.980 32.761 25.293 39.201
Total (Power) 20.407 39.188 28.831 49.061
Lift Force 0 4.616 4.577 4.653

Frictional Drag 14.980 28.146 20.716 34.548
Motor Pulley/Reducer Drag 5.427 6.427 3.538 9.860
Rolling Resistance 13.716 26.361 20.023 31.249

Material+Belt Flexure 0 0 0 0
Idler Bearing Drag 0 0 0 0
Idler Alignment 0 0 0 0
Pulleys & Accessories 888 1.061 419 2.014
Loading Point 376 723 275 1.285
Mechanical Losses 3.112 3.593 2.457 4.343

Motor Pulley Drag Components 2.314 2.834 1.081 5.517

Page 24 / 38
Description:
Pulley Summary Table - All Cases

Pulley Geometry Details
Type 1 2
Lagging Type Rubber Rubber
Diameter (mm) 630 630
Lagging Thickness (mm) 10,0 10,0
Diameter with Lagging (mm) 650 650
Face Width (mm) 1150 1150
Shaft Center Diameter (mm) 140 130
Bearing Diameter (mm) 115 110
Bearing Center Distance (mm) 1450 1400
Plummer Block 526 524
Pulley & Shaft Mass (kg) 761 646
Locking Device XT-60 XT-60
Hub Center Distance (mm) 1000 1000
Hub Diameter (mm) 140 130
Bearing to Fillet Distance (mm) 100 98
Fillet Radius (mm) 38 30
Shaft Material C45 C45
Yield Strength (MPa) 360,0 360,0
Fatigue Strength (MPa) 315,0 315,0

Page 25 / 38
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 53.591 13 16,8 13
2 53.604 434 16,8 58 376
3 54.038 2.170 16,8 2.170
4 56.208 2.170 16,8 2.170
5 58.378 32 16,8 12 20
6 58.410 56 16,8 35 20
7 58.466 79 16,8 59 20
8 58.546 103 16,8 82 20
9 58.648 1.803 16,8 1.484 318
10 60.451 130 16,8 101 29
11 60.581 63 16,8 34 29
12 60.644 196 16,8 196
13 60.840 7 16,8 7
14 60.847 1.017 16,8 1.017
15 61.864 888 16,8 888
16 - M 62.752 -15.087 16,8 -107 564 1.750
17 47.666 6 16,8 6
18 47.672 849 16,8 -8 857
19 48.521 979 16,8 -9 988
20 49.500 6 16,8 6
21 49.506 191 16,8 191
22 49.697 -5 16,8 -34 28
23 49.691 -73 16,8 -101 28
24 49.619 -1.175 16,8 -1.484 309
25 48.443 -63 16,8 -82 20
26 48.381 -39 16,8 -59 20
27 48.341 -16 16,8 -35 20
28 48.326 8 16,8 -12 20
29 48.334 2.107 16,8 2.107
30 50.441 2.107 16,8 2.107
31 52.549 19 16,8 19
32 52.567 26 16,8 20 6
33 52.594 6 16,8 6
34 - T 52.600 991 16,8 103 188 700

Page 26 / 38
Description:
Element Tension Breakdown - (FL) Fully Loaded - Normal

1 53.765 13 16,8 13
2 53.778 816 250 59,5 93 723
3 54.593 6.133 250 59,5 6.133
4 60.727 6.133 250 59,5 6.133
5 66.860 100 250 59,5 42 58
6 66.960 183 250 59,5 126 58
7 67.143 267 250 59,5 210 57
8 67.410 350 250 59,5 293 57
9 67.760 6.172 250 59,5 5.275 897
10 73.932 440 250 59,5 359 82
11 74.372 202 250 59,5 120 82
12 74.574 555 250 59,5 555
13 75.129 19 250 59,5 19
14 75.148 2.875 250 59,5 2.875
15 78.023 2.511 250 59,5 2.511
16 - M 80.534 -32.868 16,8 -107 1.084 1.750
17 47.666 6 16,8 6
18 47.672 849 16,8 -8 857
19 48.521 979 16,8 -9 988
20 49.500 6 16,8 6
21 49.506 191 16,8 191
22 49.697 -5 16,8 -34 28
23 49.691 -73 16,8 -101 28
24 49.619 -1.175 16,8 -1.484 309
25 48.443 -63 16,8 -82 20
26 48.381 -39 16,8 -59 20
27 48.341 -16 16,8 -35 20
28 48.326 8 16,8 -12 20
29 48.334 2.107 16,8 2.107
30 50.441 2.107 16,8 2.107
31 52.549 19 16,8 19
32 52.567 26 16,8 20 6
33 52.594 6 16,8 6
34 - T 52.600 1.165 16,8 103 361 700

Page 27 / 38
Description:
Element Tension Breakdown - (FL) Fully Loaded - Low

1 53.094 9 12,2 9
2 53.103 350 250 54,6 76 275
3 53.453 4.826 250 54,6 4.826
4 58.279 4.826 250 54,6 4.826
5 63.105 84 250 54,6 39 45
6 63.189 161 250 54,6 115 45
7 63.350 237 250 54,6 192 45
8 63.587 313 250 54,6 269 45
9 63.901 5.545 250 54,6 4.839 706
10 69.446 393 250 54,6 329 64
11 69.840 175 250 54,6 110 65
12 70.014 437 250 54,6 437
13 70.451 15 250 54,6 15
14 70.466 2.262 250 54,6 2.262
15 72.728 1.976 250 54,6 1.976
16 - M 74.704 -25.371 12,2 -78 206 875
17 49.333 4 12,2 4
18 49.337 577 12,2 -6 582
19 49.914 665 12,2 -6 671
20 50.579 4 12,2 4
21 50.583 130 12,2 130
22 50.713 -5 12,2 -25 19
23 50.707 -54 12,2 -73 19
24 50.653 -870 12,2 -1.080 210
25 49.783 -47 12,2 -60 13
26 49.736 -30 12,2 -43 13
27 49.707 -12 12,2 -26 13
28 49.695 5 12,2 -9 13
29 49.700 1.432 12,2 1.432
30 51.132 1.432 12,2 1.432
31 52.564 13 12,2 13
32 52.577 19 12,2 15 4
33 52.596 4 12,2 4
34 - T 52.600 494 12,2 75 69 350

Page 28 / 38
Description:
Element Tension Breakdown - (FL) Fully Loaded - High

1 54.725 16 18,0 16
2 54.740 1.394 250 61,1 108 1.285
3 56.134 7.217 250 61,1 7.217
4 63.351 7.217 250 61,1 7.217
5 70.569 111 250 61,1 43 68
6 70.680 197 250 61,1 129 68
7 70.877 282 250 61,1 215 68
8 71.159 367 250 61,1 300 67
9 71.527 6.467 250 61,1 5.411 1.056
10 77.994 464 250 61,1 368 96
11 78.458 220 250 61,1 123 97
12 78.678 653 250 61,1 653
13 79.331 22 250 61,1 22
14 79.353 3.383 250 61,1 3.383
15 82.736 2.955 250 61,1 2.955
16 - M 85.691 -39.315 18,0 -114 2.892 2.625
17 46.375 8 18,0 8
18 46.383 1.029 18,0 -8 1.037
19 47.412 1.186 18,0 -9 1.196
20 48.598 8 18,0 8
21 48.606 231 18,0 231
22 48.837 -2 18,0 -36 34
23 48.835 -74 18,0 -108 34
24 48.761 -1.216 18,0 -1.591 374
25 47.544 -64 18,0 -88 24
26 47.480 -39 18,0 -63 24
27 47.441 -14 18,0 -38 24
28 47.427 11 18,0 -13 24
29 47.438 2.551 18,0 2.551
30 49.989 2.551 18,0 2.551
31 52.541 23 18,0 23
32 52.563 29 18,0 21 8
33 52.592 8 18,0 8
34 - T 52.600 2.125 18,0 111 964 1.050

Page 29 / 38
Description:
Equipment Tags and Commodity Codes

Table of major items with description, tags, and commodity codes.
Item Description Equipment Tag Commodity Code
Pulley Pulley 1
Motor Motor 1
Reducer Reducer 1
Pulley Pulley 2
Idlers Carry
Idlers Return
Belt -

Page 30 / 38
Description:
Belt Supplier Data Sheet System Information

Type Fabric (3-Ply) Calculation method DIN / ISO
Width 1000 mm Conveyor Length / Height 1078 / 11,0 m
Rating 1000 N/mm Ambient temperature range -10 to 40 °C
Speed 1,62 m/s Kt factor at minimum temperature 1,12
Top / bottom cover thickness 6,0 x 3,0 mm
Total thickness 15 mm Material Properties
Weight (new / worn) 16,8 / 12,2 kg/m Type Masse
Modulus 8.657 kN/m Design Tonnage 250 t/h
Tape length 2.160 m Density 1700 kg/m3
Belt cycle time 22,2 min Maximum lump size 0 mm
Cross Sectional Loading Surcharge angle 10 deg
Pipe diameter (inside / outside) 250 / 280 mm
Belt overlap distance 167 mm Drive Station
Material mass (wm) 42,8 kg/m Type Fluid coupling
Combined mass (wm + wb) 59,6 kg/m Synchronous RPM 1500 RPM
Cross sectional area 0,025 m² Motor quantity / rating 1 / 90,0 kW
Cross sectional loading (utility / total) 73 % / 55 % Total ınstalled power 90,0 kW
Bed depth 131 mm Nominal empty / full power (37 / 71%) 33,6 / 63,6 kW
Min / max demand power (37 / 88%) 33,6 / 79,0 kW
Maximum starting torque 152%
Pulley lagging type Rubber
Motor wrap angles 180
Idler Set Data

Carry Return
Series name Series 20 Series 20
Bearing 6204 6204
Number of rolls 6 6
Flooded belt tonnage 459 t/h Trough angle (deg) 0 0
Flooded (wm + wb) 95,3 kg/m Type Offset Offset
Tension Summary Running Momentary
Maximum tension (kN) 85,7 110
Minimum safety factor 11,67 9,12 Pulley Details
Pulley diameter (Type 1) 630 mm
Estimated Splice Data Pulley diameter (Type 2) 630 mm
Splice type 2-Step
Take-up Data
Splice step length 350 mm
22 degree bias angle 405 mm Type Gravity
Total splice length 1105 mm Location Tail / Pulley #2
Transition Lengths Required pulley displacement 17,35 m
Transition method Pipe
Head transition length (elevated 140 mm) 8,40 m
Tail transition length (elevated 140 mm) 8,40 m

Page 31 / 38
Description:
System Information
Idler Set Data Calculation method DIN / ISO
Carry Return Conveyor Length / Height 1078 / 11,0 m
Series name Series 20 Series 20 Ambient temperature range -10 to 40 °C
Bearing 6204 6204 Kt factor at minimum temperature 1,12
Number of rolls 6 6
Trough angle (deg) 0 0 Material Properties
Type Offset Offset Type Masse
Idler spacing (m) 2,00 2,00 Design Tonnage 250 t/h
Roll diameter 108 108 Density 1700 kg/m3
Roll rpm 287 287 Maximum lump size 0 mm
Total drag (N) --- --- Surcharge angle 10 deg
Roll length 250 222
Shaft diameter (mm) 20,0 20,0 Cross Sectional Loading
Dynamic capacity (kN) 13,5 13,5 Pipe diameter (inside / outside) 250 / 280 mm
L10 life1 (1000 hrs) 350,0 / 350,0 350,0 / 350,0 Belt overlap distance 167 mm
Shaft deflection (min) 3,99 / 2,16 2,53 Material mass (wm) 42,8 kg/m
Combined mass (wm + wb) 59,6 kg/m
Number of ıdler sets 550 540 Cross sectional area 0,025 m²
Number of rolls 3.300 3.240 Cross sectional loading (utility / total) 73 % / 55 %
Bed depth 131 mm
Idler Set Data

Impact Transition
Series name
Bearing
Number of rolls 0 0
Trough angle (deg) 0 0
Type
Roll diameter 0 0
Roll rpm 0 0 Flooded belt tonnage 459 t/h
Total drag (N) --- --- Flooded (wm + wb) 95,3 kg/m
Roll length 0 0 Belt Supplier Data Sheet
Type Fabric (3-Ply)
Dynamic capacity (kN) 0,0 0,0
Width 1000 mm
L10 life1 (1000 hrs) 0,0 / 0,0 0,0 / 0,0
Rating 1000 N/mm
Shaft deflection (min) 0,00 0,00
Speed 1,62 m/s
Number of ıdler sets 0 0
Weight (new / worn) 16,8 / 12,2 kg/m
Number of rolls 0 0
Tension Summary Running Momentary
1
L10 life above which 95% of idlers exceed Maximum tension (kN) 85,7 110
Minimum safety factor 11,67 9,12

Page 32 / 38
Description:
System Information Flooded (wm + wb) 95,3 kg/m

Calculation method DIN / ISO
Conveyor Length / Height 1078 / 11,0 m Idler Set Data
Material lift 11,0 m Carry Return
Ambient temperature range -10 to 40 °C Series name Series 20 Series 20
Kt factor at minimum temperature 1,12 Bearing 6204 6204
Number of rolls 6 6
Material Properties Trough angle (deg) 0 0
Type Masse Type Offset Offset
Design Tonnage 250 t/h Idler spacing (m) 2,00 2,00
Density 1700 kg/m3 Number of ıdler sets 550 540
Maximum lump size 0 mm Roll diameter 108 108
Surcharge angle 10 deg Roll rpm 287 287
Total drag (N) --- ---
Roll length 250 222
Belt Properties
Type Fabric (3-Ply) Dynamic capacity (kN) 13,5 13,5
Width 1000 mm L10 life1 (1000 hrs) 350,0 / 350,0 350,0 / 350,0
Rating 1000 N/mm Shaft deflection (min) 3,99 / 2,16 2,53
Speed 1,62 m/s 1
L10 life above which 95% of idlers exceed
Total thickness 15 mm Drive Station
Weight (new / worn) 16,8 / 12,2 kg/m
Modulus 8.657 kN/m Type Fluid coupling
Tape length 2.160 m Synchronous RPM 1500 RPM
Belt cycle time 22,2 min Motor quantity / rating 1 / 90,0 kW
Total ınstalled power 90,0 kW
Tension Summary Running Momentary Nominal empty / full power (37 / 71%) 33,6 / 63,6 kW
Maximum tension (kN) 85,7 110 Min / max demand power (37 / 88%) 33,6 / 79,0 kW
Minimum safety factor 11,67 9,12 Frame Size IEC 280M
Minimum tension (kN) 46,4 27,1 Motor Voltage 400 V
Maximum belt sag (%) 0,27 0,29 Efficiency 91,5 to 94,5%
Cross Sectional Loading Inertia - Motor 2,0 kg·m²
Pipe diameter (inside / outside) 250 / 280 mm Inertia - Fluid Coupling 0,1 kg·m²
Belt overlap distance 167 mm Pulley lagging type Rubber
Material mass (wm) 42,8 kg/m Motor wrap angles 180
Combined mass (wm + wb) 59,6 kg/m Lagging friction factor (run / accel) 0,32 / 0,38
Cross sectional area 0,025 m²
Cross sectional loading (utility / total) 73 % / 55 % Take-up Data
Bed depth 131 mm
Type Gravity
Location Tail / Pulley #2
Counterweight mass 10,7 tonnes
Required pulley displacement 17,35 m

Dynamic displacement (incl thermal) 1,21 m
Permanent elongation 14,04 m
Splice length (2 included) 1,11 m
Clearance 1,00 m
Flooded belt tonnage 459 t/h

Page 33 / 38
Description:
Conveyor Profile
Overall length = 1078 m - Overall height = 11,0 m - True Length = 1079,2 m
Horizontal Profile 1:1 Scale
Tail Arrangement Head Arrangement

Page 34 / 38
Description:
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-HT 180 85,7 49,3 132 110 56,7 166
Take-up Pulley 2-MT 180 52,654,7 107 52,654,8 107
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Safety Slope at Deflection T1 T2
Pulley # L10 Life Shaft Force Angle Torque Moment
Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)
1 2,01 7,74 0,080 500 104 51,0 761 156 183 17,9 17,5
2 2,52 8,01 0,080 500 65,8 68,7 646 135 357 1,0 13,5
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,10 on high tension
pulleys, and a multiplier of 1,25 on all other pulleys. A steady state case at 100% motor power has also been included.
Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
Rubber
1 Herringb 630 10,0 650 1150 140 115 1450 526 23226 870
one
2 Rubber 630 10,0 650 1150 130 110 1400 524 23224 743
Pulley Shaft Information

Overhun
Hub Bearing
Tensile Yield Fatigue Hub Fillet Overhun g
Locking Shaft Center to Fillet
Type Strength Strength Strength Diameter Radius g Load Moment
Device Material Distance Distance
(MPa) (MPa) (MPa) (mm) (mm) (kN) Arm
(mm) (mm)
(mm)
1 XT-60 C45 630,0 360,0 315,0 140 1000 100 38 0,0 0
2 XT-60 C45 630,0 360,0 315,0 130 1000 98 30 0,0 0

Page 35 / 38
Description:

#1 - Motor 1
1. Name (Type-1) Motor 1 29. Running T1 Tension 80,5 kN
3. Face Width 1150 mm 31. Design T1 Tension 104 kN
Lagging
5. Lagging Pattern Herringbone
Shaft Specification
17. Hub width 73 mm

Page 36 / 38
Description:
#2 - Take-up Pulley Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 52,6 kN
1. Name (Type-2) Take-up Pulley 29. Running T2 Tension 53,8 kN
2. Pulley Diameter 630 mm 30. Design T1 Tension 65,8 kN
3. Face Width 1150 mm 31. Design T2 Tension 68,7 kN
Lagging
Shaft Specification
16. Hub width 73 mm

Page 37 / 38
Description:
Demand Power (kW)

Drive Station Case
Demand % Motor
Type Fluid coupling power Nameplate
Synchronous RPM 1500 RPM Empty - NF 33,6 37,4
Motor quantity / rating 1 / 90,0 kW Full - NF 63,6 70,7
Total ınstalled power 90,0 kW Full - LF 47,2 52,4
Nominal empty / full power (37 / 71%) 33,6 / 63,6 kW Full - HF 79,0 87,8
Min / max demand power (37 / 88%) 33,6 / 79,0 kW
Frame Size IEC 280M
Motor Voltage 400 V
Efficiency 91,5 to 94,5%
Inertia - Motor 2,0 kg·m²
Inertia - Fluid Coupling 0,1 kg·m²
Pulley lagging type Rubber
Motor wrap angles 180
Lagging friction factor (run / accel) 0,32 / 0,38
Reducer Information
Manufacture N/A
Frame size N/A
Reducer ratio 30,750
Catalog reducer ratio 0,000
RPM (High Speed) 1500 RPM
RPM (Low Speed) 48,8 RPM
Configuration Shaft Mount
Number of stages 3
Service factor 1,4
Power rating 0,0
Motor Torque
100% Motor Torque - High Speed 582 N·m
Motor Shaft Torque - Running (FN) 418 N·m
Motor Shaft Torque - Starting (FN) 820 N·m
100% Motor Torque - Low Speed 17.887 N·m
Low Speed Shaft Torque - Running (FN) 11.675 N·m
Low Speed Shaft Torque - Running (Max) 14.667 N·m
Low Speed Shaft Torque - Starting (FN) 23.551 N·m
Low Speed Shaft Torque - Starting (Max) 25.304 N·m
Starting and Stopping

Start control Constant torque
Start time 2,0 to 4,9 s
Emergency stop control Drift
Emergency stop time 4,0 to 6,1 s
Material buildup in chute 0,1 m³

Page 38 / 38

Boru Bant Versiyon 3

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Client Name Designer HAK

Project Name 230384 Company Birikim Mühendislik End.

Required pulley displacement 17,35 m

Backstop type None installed

Brakes Take-Up Cable

Transition Lengths Belt Safety Factor

Splice Safety Factor Minimum Belt Tensions (kN)

Maximum Belt Sag (%)

Sidewinder - v7.22 - Conveyor Design Software

Horizontal Profile 1:1 Scale

Sidewinder - v7.22 - Conveyor Design Software

Tail Arrangement Head Arrangement

Maximum Pulley Tensions (without any additional safety factors)

Pulley Shaft Results

Pulley Geometry Details (Pulley Types)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Shaft Information

Sidewinder - v7.22 - Conveyor Design Software

Conveyor Load Cases

Fully Loaded (Material Lift = 11,0 m)

Sidewinder - v7.22 - Conveyor Design Software

Take-up Displacement Summary

Take-up Pulley Displacement Summary

Counterweight Displacement Summary (1:1 Cable Reeving Ratio)

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

27. Bearing L10 500.000 hours

Sidewinder - v7.22 - Conveyor Design Software

Belt Flap Summary

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Material Loading Profiles

Tonnage 250 t/h

Sidewinder - v7.22 - Conveyor Design Software

Idler Specifications for Idler Type 1: 6 Roll Trough Idler

Idler Specifications for Idler Type 2: 6 Roll Trough Idler

Idler Spacing and Count Summary

Sidewinder - v7.22 - Conveyor Design Software

Idler Life and Shaft Deflection Summary-Carry Side

Idler Life and Shaft Deflection Summary-Return Side

Sidewinder - v7.22 - Conveyor Design Software

Bearing Reaction Forces (excluding any overhung loads)

Element Summary Details

Sidewinder - v7.22 - Conveyor Design Software

Vertical Curve Summary

Summary of Vertical Curve on Return Strand

Summary of Horizontal Curve on Return Strand

Displacement Summary of Horizontal Curves on Carry Strand - Running Tensions Only

Sidewinder - v7.22 - Conveyor Design Software

Displacement Summary of Horizontal Curves on Return Strand - Running Tensions Only