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Module 3: DESIGN OF BELT CONVEYOR SYSTEM

1. Introduction
Belt Conveyors are traction type conveyors and a powerful material handling tool. Using conveyor systems
is a good way to reduce the risks of musculoskeletal damage in tasks or processes that involve manual
handling, as they reduce the need for cyclic lifting and carrying. They offer the opportunity to improve
productivity, reduce product handling and damage, and minimize labor content in a manufacturing or
distribution facility. Belt conveyor can be more economical than railways and automotive transport over
a distance of 25km and even 100km when the tonnage to be hauled amounts to 25 millions tons per
year.[1]
Conveyors are generally classified as either Unit Load Conveyors that are designed to handle specific
uniform units such as cartons or pallets, or Process Conveyors that are designed to handle loose product
such as sand, gravel, coffee, cookies, etc. which are fed to machinery for further operations or mixing. It
is quite common for manufacturing plants to combine both Process and Unit Load conveyors in its
operations. Roller conveyor is not subjected to complex state of loading even though we found that it is
designed with higher factor of safety. If we redesigned critical parts e.g. Roller (Idler), Bearing & Frame
etc then it is possible to minimize the overall weight of the assembly.
Idler is the supporting device for belt and cargo of a belt conveyor. Idlers move as the belt moves so as
to reduce the running resistance of the conveyor. Idlers’ qualities depend on the usage of the belt
conveyor, particularly the life span of the belt. However, the maintenance costs of idlers have become the
major part of the conveyor’s operating costs. Hence, idlers need to have reasonable structure, durability
in use, small ratio of steering resistance, reliability, and dust or coal dust cannot get in bearing, due to
which the conveyor has a small running resistance, saves energy and prolongs the service life.
Major Components of Conveyor
• Driving traction element i.e. Long Continuous belt
• Idlers or rollers held by frame
• Drive pulleys and take up unit at ends
• Pulleys coupled to gears and motors
• Peripheral Devices to drop on belt, direct around corner, clean, discharge etc. (Loading and
unloading devices, snub pulley, belt cleaners etc.)
Conveyor Belting Parts
• Carcass - woven fabric or material for tensile strength
• Skims - rubber layers between carcass plys
• Braker - fabric coat above carcass to break impact of load
• Top Cover - A rubber that resists cutting abrasion and sometimes chemical action

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2. List of conveyor categories and sub categories

1. Gravity Conveyor – gravity, non-powered conveyor, is typically used in truck off loading, package
sorting, and assembly or kitting areas. Gravity is the cheapest form of conveyor but lacks in
product control.
2. Belt Conveyor – is typically used in package handling, raw material handling, and small part
handling. It is effectively used for elevation change or incline/decline applications. A more
common application of belt conveyor you might not notice is in the check-out line at your local
grocery store.
3. Powered Roller Conveyor
 Live Roller Conveyor – is typically used in general transport when product accumulation is not
required. It is also used in package handling applications and is ideal for light- to medium-product
loads.
 Minimum Pressure Conveyor – is used in short sections of accumulation, general transport of
product, and is ideal for medium to light loads such as package handling applications.
 Zero Pressure Conveyor – is commonly found in distribution centers where there is a wide variety
of product width and weight. Applications include buffering of product prior to sortation,
packaging, kitting, or shipping areas. It is also ideal for picking areas and palletizing areas. This
conveyor is used in high throughput systems.
4. Pallet Conveyor
 Drag Chain – is typically used for handling extremely heavy loads, special pallet configurations,
and extremely low- to high-temperature areas.
 Roller – Roller pallet conveyor is typically used for handling extremely heavy loads and is ideal for
accumulation zones in pack out areas.
5. Overhead Conveyor – is typically used in paint and finishing lines, trash removal, food packing,
and assembly lines. These are some of the oldest conveyors still used in the industry today
because they are very reliable and require little maintenance.
 Table Top Chain – is used in accumulation, package handling, filling, labeling, and wash-down
applications.
 Magnetic Slide Conveyor – is used in metal stamping, chip removal, and small part transport
application.
Conveyor Belting Types

 Multi-Ply - multi-ply carcass separated by skims - traditional - trade-off between stiffness and
strength.
 Reduced Ply - complex interwoven carcass not dependent on separate plys thinner less stiff for
same strength.
 Steel - carcass lengthwise steel belts - high tensile strength - heavy ores long runs.
 Solid Woven - Carcass impregnated with elastomer.

3. Requirements of Conveyer Belt

i. It should have adequate strength
ii. Good longitudinal and lateral flexibility
iii. High wear resistance

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iv. Freedom from ply separation due to repeated bending

v. Low elastic and permanent elongation
vi. Low water absorption
vii. Effect of moisture on strength and life of belt should be negligible
4. Typical Belt Conveyor Paths
Conveyor transportation are available in various layout as per requirement. Some layouts are shown
in figure 1.

Figure 1: Typical Belt Conveyor Paths

5. Advantages of Conveyer Belt

i. Noiseless operation.
ii. Large length of conveying path.
iii. Lower power consumption.
iv. Long life.
v. Adaptability to different types of goods.
vi. Ability to carry almost any bulk material.
vii. High reliability of operation.
viii. Can transport material in any direction.
ix. Reduction in numbers of personnel.
x. Reduction in energy consumption.
xi. Long periods between maintenance.
xii. Independence of the system to its surrounds.
xiii. Reduced business costs.

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6. Disadvantages of Conveyer Belt

i. Accumulation is difficult.
ii. Complicated marshalling.
iii. The loss of light weight bulk material carried away as dust or spilled from the belt along its
path is another objectionable features.
iv. Continuous or periodic monitoring of belt is necessary.
v. Heat affects the material of belt.
vi. The normal design of a belt conveyor is opened. If your product needs to be contained,
covers and or drip pans can become expensive and cumbersome.
vii. If the material is sticky, belt cleaning can be difficult and generally not very successful.
viii. There is almost always material carry over from the belt discharge and this becomes a house
keeping problem.
ix. If the material being conveyed is sticky it will ultimately get transferred to the return side of
the belt and then to the rolls, idlers and pulleys, then belt tracking can be an ongoing issue.

7. Applications of Conveyer Belt

i. Moving loads and bulk material in foundry, mining, cement industry,
ii. In line production,
iii. Coal handling plant,
iv. Automotive sector,
v. Agricultural,
vi. Food processing,
vii. Pharmaceutical,
viii. Chemical, bottling and canning,
ix. Print finishing and packaging.

8. Belt speed
Speed of conveyer depends on following factors.
1. Size of the lump and nature of the material to be conveyed.
Fine material transported at low speed to avoid spillage due to fanning effect ( Fanning Effect is loss of
material from the conveyor due to flowing of air). Heavy lump transported at low speed to avoid the
damage of the belt while passing over the idlers and pulleys. Coke and coal are transported at low
speed to avoid degradation through reduction in size.
2. Belt Width : wider belt width can be operated at higher speed allowing to better distribution of the
material and aligning of the belt in travel.
Very high speeds have meant a large increase in the volumes conveyed. Compared with the load in
total there is a reduction in the weight of conveyed material per linear meter of conveyor and therefore
there is a reduction in the costs of the structure in the troughing set frames and in the belt itself. The
physical characteristics of the conveyed material are the determining factor in calculating the belt
speed. With the increase of material lump size, or its abrasiveness, or that of its specific weight, it is
necessary to reduce the conveyor belt speed. Considering the factors that limit the maximum

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conveyor speed we may conclude. When one considers the inclination of the belt leaving the load
point; the greater the inclination, the increase in the amount of turbulence as the material rotates on
the belt. This phenomenon is a limiting factor in calculating the maximum belt speed in that its effect
is to prematurely wear out the belt surface. The repeated action of abrasion on the belt material, given
by numerous loadings onto a particular section of the belt under the load hopper, is directly
proportional to the belt speed and inversely proportional to its length.

9. Basic components of a typical belt conveyor

Figure 2. Components of Belt Conveyor Assembly

 Drive
May be of traditional design or with motorised drum unit:
1. Traditional:
Comprises a drive group consisting of a drive drum of a diameter appropriately sized to the load on the
belt, and an idler drum at the opposing end. The power is supplied by a direct coupled motor gearbox or
by a direct or parallel shaft drive driving the drive drum through a suitably sized couple.
2. Motorised Drum
In this arrangement the motor, gearbox and bearings form a complete designed unit inside and protected
by the drum shell which directly powers the belt. This eliminates all the external complication of external
drive, couples etc. as described above in the traditional design. Today motorised drums are produced in
diameters up to 800mm with power in the order of 130 KW and with a drive efficiency which may reach
97 %.

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 Drive pulley
The shell face of the conventional drive pulley or the motorised drum may be left as normal finish or clad
in rubber of a thickness calculated knowing the power to be transmitted.
The cladding may be grooved as herringbone design; or horizontal grooves to the direction of travel; or
diamond grooves; all designed to increase the coefficient of friction and to facilitate the release of water
from the drum surface.
 Return pulleys
The shell face does not necessarily need to be clad except in certain cases, and the diameter is normally
less than that designed for the drive pulley.
 Snub pulleys
These are used to increase the angle of wrap of the belt and overall for all the necessary changes in belt
direction in the areas of counterweight tensioner, mobile unloader etc.
The choice of the optimum conveyor system and its project design and rationalisation depends on full
knowledge of the construction characteristics and the forces involved that apply themselves to all the
system components.
 Rollers
Support the belt and are guaranteed to rotate freely and easily under load. They are the most important
components of the conveyor and represent a considerable value of the whole cost. The correct sizing of
the roller is fundamental to the guarantee of the plant efficiency and economy in use.
Upper carrying troughing and return sets: The carrying rollers are in general positioned in brackets welded
to a cross member or frame. The angle of the side roller varies from 20º to 45º. It is also possible to arrive
at angles of up to 60º using the “garland” suspension design.
The return roller set may be designed incorporating one single width roller or two rollers operating in a
“V” formation at angles of 10º
Depending on various types of material being conveyed the upper carrying sets may be designed
symmetrically or not, to suit.

 Tension units
The force necessary to maintain the belt contact to the drive pulley is provided by a tension unit which
may be a screw type unit, a counterweight or a motorised winch unit.
The counterweight provides a constant tensional force to the belt independent of the conditions. Its
weight designed according to the minimum limits necessary to guarantee the belt pull and to avoid
unnecessary belt stretch.
The designed movement of the counterweight tension unit is derived from the elasticity of the belt during
its various phases of operation as a conveyor. The minimum movement of a tension unit must not be less
than 2% of the distance between the centres of the conveyor using textile woven belts, or 0.5% of the
conveyor using steel corded belts.

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 Hopper
The hopper is designed to allow easy loading and sliding of the material in a way to absorb the shocks of
the load and avoids blockage and damage to the belt. It caters for instantaneous charging of load and its
eventual accumulation.
The hopper slide should relate to the way the material falls and its trajectory and is designed according to
the speed of the conveyor. Lump size and the specific gravity of the charge and its physical properties
such as humidity, corrosiveness etc. are all very relevant to the design.
 Cleaning devices
The system of cleaning the belt today must be considered with particular attention to reduce the need
for frequent maintenance especially when the belt is conveying wet or sticky materials. Efficient cleaning
allows the conveyor to obtain maximum productivity.
There are many types and designs of belt cleaners. The most straight forward simple design is that of a
straight scraper blade mounted on rubber supports.
 Conveyor covers
Covers over the conveyor are of fundamental importance when it is necessary to protect the conveyed
material from the atmosphere and to guarantee efficient plant function.
 Conveyed material
The correct project design of the belt conveyor must begin with an evaluation of the characteristics of the
conveyed material and in particular the angle of repose and the angle of surcharge.
The angle of repose of a material, also known as the “angle of natural friction” is the angle at which the
material, when heaped freely onto a horizontal surface takes up to the horizontal plane.

10. Belt Width Selection:

The width of belt is predominantly governed by two factors, the lump size of the material conveyed and
the capacity requirements of the conveyor. For individual loads , free margins between 50 and 100mm
wide must be provided on either side of the belt. The width of the belt conveyor moving bulk material
cannot be less than a certain minimum width decided by the size of parts. For example Minimum width
B = 2 x amax + 200 mm for ungraded material and B = 3.3 x amax + 200 mm for graded material.
The capacity of a belt conveyor is determined primarily by the following three factors:
a) Cross section of load on the belt:
The crosssectional load on the belt will vary with the width of belt, the type of carrying idlers used which
determines the amount of toughing given to the belt and the nature of the material being handled,
which determines the quantity of material that can be safely loaded on to a given cross-section
b) Speed of belt
c) Slope factor
The standard width of belts in millimetres as specified in
IS 1891 (Part I) are as follows: 300, 400, 500, 600, 650, 800, 1000, 1200, 1400, 1600, 1800 and 2000.

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11. Belt Construction

A conveyor belt consists of two elements, the carcase and the cover. The fabric ply- constructed belting is
the most widely used kind. Its carcase is made up of number of layers or plies of cotton fabric.
The carcase is the reinforcing member and may be of either textile reinforements steel cords and suppli
es the tensile strength and the body to the belt to hold the shape. Carcase absorbs longitudinal tensile
stresses and elastic protective filler protect carcase against moisture, mechanical damage and abrasion
due to conveying material.
In case of textile reinforcement, the carcass is normally built up of plies of textile fabric. The strength of
fabric and the number of plies in the carcass of the belt may be varied together to suit the strength
requirements. However, the strength of carcass has a practical limit. If the belt is too tough, toughing and
training the belt will be very difficult. Therefore, the belt with lesser number of plies with stronger fabric
is generally preferred because it is more flexible both in toughing and going round the terminal pulleys.
The steel cord belting is used to meet the condition of small elongation and good troughbility in
conjunction with higher operating tensile forces. PVC belting is generally selected for underground mining
applications where fire hazard exists.

Figure 3 . Belt construction

12) BELT PROTECTIVE COVER THICKNESS

The properties needed for the cover of belt include resistance to cutting, gauging, tearing, abrasion, aging,
moisture absorption and in some conditions to oils, chemical and heat. The grade and thickness of top
cover of belt depend upon a number of conditions, the most important of which are:
a) Abrasive qualities of the material being handled.
b) Loading cycle, that is, the frequency with which the belt receives the load.
c) Lump size of the material.
d) Loading and unloading conditions.
e) Temperature of the material to be handled.
f) Chemical activity of the material.
g) Contamination of the material with oils.

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h) Fire resistant cover needed or not.

The back cover thickness of a belt is generally 1.0 to 3. 0 mm for textile rubber belts and 0.8 to 1.2 mm
for PVC belts. In case of steel cord belts, back cover thickness is minimum 4.0 mm and range up to full
thickness of face cover.
Care shall be taken for the determination of back cover thickness for belts on tandem drives and other
special applications, where there is considerable wear and tear in the back side of the belt. In such cases
the back cover thickness may be increased to 3 mm and above as may be necessary.
The cover grade is determined by characteristics of the material handled. Belt protective cover thickness
ratio is the ratio of upper cover thickness to the thickness of lower cover thickness. For different cases the
ratio is as below.

- Low abrasive bulk material 3:1

- Moderately abrasive fine lump material 4.5:1
- Medium size lump material ( 4.5-8 ) : 2
- Strongly abrasive , medium and large size lump material (4.5 – 10) : (2-3)
- For unit loads (2-3) : (1-2)
13) END JOINING
Various methods are used for the joining of the ends of conveying belt which includes, Hot or cold
cementing using special adhesive between pressure plates (Vulcanization), Metallic staples, Hinges, Rivets
in lapped joints, leather straps etc.
The two options available for end joining are explained as below.
1. Vulcanization or welding (the process of joining belt ends using heat and/or chemicals)
2. Mechanical splicing (the process of joining belt ends using metal or plastic hinges or plates)
 Vulcanization or welding:
Heat welding the two ends of a polyurethane belt can be done in the factory, in a specialized belt shop,
or in the field. The belt ends are typically joined using either a finger splice or a butt splice.

 Mechanical Fastening:

 Wire Hooks
Wire hooks date back to the days of flat, fabric belts. The hooks were designed to penetrate and grab onto
the fabric plies of the belt carcass.
Wire hooks offer a low profile fastening system that is relatively simple to install. The tooling is
inexpensive. Hooks are available in a wide variety of wire diameters, materials, leg and point lengths, and
strip lengths. There are various methods of installation, including a rolling device and a hydraulic device.
Hooks and connecting pins are available in stainless steel for food processing operations where sanitation
is a prime concern. The key benefit to this fastening system is ease of installation and the ability to take
the belt on and off. The risk of the hooks breaking and contaminating the food stream is a factor to
consider before employing this fastening method. Metal Staples

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Metal staples are well suited for light and medium duty fastener applications on synthetic carcass belts.
The staples can be pre inserted into a one-piece fastener strip which is placed over the ends of the belt
and installed using a lightweight tool. The staples are then driven into place with a hammer.
Metal staples are available in stainless steel alloys for food grade applications. They can be used to repair
a belt for temporary use, or as a permanent splice.
 Metal Lacing
Metal lacing gives the appearance of a piano hinge. The laces are provided in a continuous strip to match
the width of the belt. They are placed over the ends of the belt and the teeth are embedded into the belt
carcass with a hammer.
Metal lacing creates a low profile splice that is economical to install. It can operate over pulleys as small
as 1” in diameter. Both fasteners and hinge pins are available in stainless steel for food grade applications.
The hinge pins are removable so the belt can be separated for cleaning.

Figure 4. Wire hook fastener and Metal staples

 Plastic Rivets
Plastic rivets are a non-metallic fastener that can pass through metal detectors. This non-scratching, non-
magnetic fastening system has rivets with bevelled front edges that are moulded into the carcass to
present a flat surface. They travel over conveyor components more easily and quietly than metal systems.
Plastic rivet fasteners have hinge pins that can be removed for belt disassembly and cleaning. This
fastening system requires a special tool for assembly, and offers a low-cost alternative to vulcanization.
Plastic rivet fasteners have mechanical fastener ratings up to 65 PIW, and a minimum pulley size of 1 ½”.

Figure 5 . Plastic rivets and Pin Splice

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 Hybrid Joining System: Pin Splice

Pin splice joining system combines vulcanization with mechanical fastening. Designed for light to medium
weight loads, the fastening system has no metal parts to set off metal detectors.
The pin splice is designed for fibre-reinforced food grade urethane belts. The vulcanization process takes
place at the factory, where urethane is welded to the belt in the pin area. An end cap is welded to the belt
ends to seal off the tensile cords and maintain the integrity of the reinforcement. This process also
prevents exposing the cords to bacteria.
A plastic pin is inserted through the splice to join the belt ends in the field. No special tooling or equipment
is needed. The splice is easy to clean and sanitize.

14) BELT SUPPORTS

The rollers are the supporting members of the belt. There are 2 types of rollers upper and lower sets.
The upper rollers carry the load of the belt. They are straight for straight belt and sometimes trough for
2-3 m wide belt conveying bulk loads. The spacing between the rollers is less, for standard conveyors it is
1.5 m.
The lower rollers are mostly straight, single roller cylindrical, some are trough with angle of roller inclined
at 10° for better centering of moving belts if width is more than 1 m. The spacing is more for return idlers
about 3 m.

Figure 6 : Straight Lower roller Figure 7 :Trough Upper roller

15) BELT DRIVE

Types of Belt Drive:
1. Single, un-snubbed:
The simplest drive arrangement consists of one steel pulley connected to the source of power, having
belt wrapped around it on an arc of 180° to 240o. It is suitable for low capacity, short centre conveyors
handling non-abrasive material. The pulley may be lagged to increase the coefficient of friction and avoid
pulley wear for abrasive materials. This is simple design with high reliability, smaller dimension.

2. Bare/lagged pulley drive

The ratio of maximum belt tension to effective belt tension for the drive is decreased by snubbing the belt
at head pulley which may be bare or lagged. The arc of contact is increased from 180 ° to 210° and can

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further be increased to 260° by providing snub/drive pulley. In majority of normal medium to large
capacity belt conveyors, handling mil d abrasive to fairly abrasive materials, 210° snub pulley drive with
head pulley lagged with hard rubber is adopted.
3. Tandem drive
Where the belt tensile forces are very high and it is necessary to increase the angle of arc of contact,
tandem drives are used. The tandem pulleys are both driven and share the load resulting in a lower
effective tension for a given power transmitted. The tandem drive with arc of contact from 300° to 440°
or more can function with one or two motors. The location of such drive is usually determined by the
physical requirements of the plant and its accessibility. These have greater dimension and more intricate
design, lower reliability of operation , higher cost. Because of multiple bending belt life is shorter.

16) BELT TAKE UP ARRANGEMENT

Main functions of take up are:
1. Ensuring adequate tension of the belt leavingthe drive pulley so as to avoid any slipping of the b
elt.
2. Permanently ensuring adequate belt tension at the loading point and at any other point of the
conveyor to keep the troughed belt in shape and limit belt sag between carrying idler
3. compensating for operating belt length variation due to physical factors (instantaneous
tensions, permanent elongation, outside temperature, temperature of conveyed material,
dampness, etc.)
4. Making available, if needed, an adequate extra length of belt to enable re-joining without having
to add an extra piece of belt.
Two types of belt take up devices are generally used:
1. Fixed take-up device s that are adjusted periodically
2. Automatic take-up devices (constant load type)
 Fixed take up devices:
In this type of take-up devices, the take-up pulley remains fixed between successive periodic adjustments.
Take-ups of this type generally used are:
1. Screw take-up — in this system the adjustment is manually effected by means of two screws
acting upon the pulley bearings and which are tightened simultaneously or successively. The
screw is normally of non-extendable type and sliding surfaces are suitably protected against
ingress of dirt. In this system, the applied tension is not fully determinable. This generally leads to
excessive tension of belt (when tension is insufficient, belt slips and quickly deteriorates). This
excessive tension is unavoidable and shall be taken into account when determining the size of the
belt, designing the mechanical components and calculating the adjustments. For this reason,
these devices are used only in case of short conveyors of up to 60 m length s and under light duty
cycle condition.

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2. Winch take-up — in this system, the tension is adjusted by means of a mechanical motorized
device which does not automatically compensate for belt length variations. A tension indicator
may be included between winch and pulley. This system also requires careful checking of tension
and leads to excessive belt tension in order to avoid too frequent take-ups. However, it may be
used for long conveyors and under heavy duty conditions provided that these conveyors are
equipped with belts having very low elongation coefficient under the effect of load and over a
long period, for example, steel cord belt s which are use d almost exclusively.

 Automatic take up devices:

In this system, take-up pulley is mounted on slides or on a trolley and travels freely while a constant
tension is automatically maintained to ensure normal conveyor operation in all cases. The most frequently
used type is gravity weight operated take-up device. Hydraulic, pneumatic or electrical take-up devices of
various types are also used. All types of automatic take up devices shall include a system for adjusting belt
tension. Automatic take-up has following features:
1. It is self-adjusting and automatic.
2. Greater take-up movement is possible.
3. It is suitable for horizontal or vertical installation.
4. It is preferred for long centre conveyors.
5. It can be located at drive end (preferred for low tensions).
6. In case of underground mines, provision of loop at drive end may be made to cater for take-up
and small extension of belt conveyor lengths.
Winch take up (automatic):
Winch take-up device can also be used as automatic take-up arrangement when automatic tension
regulation (ATR, by employing load cells, electronic sensing devices etc.) is provided to signal for the winch
motor to run in one direction or reverse for specific number of turns or to stop as governed by
predetermined values of belt tensions for any particular installation . This is highly recommended for long
centres high capacity belt conveyors since it fetches less space (horizontal/vertical) and also do not
unnecessarily put the belt always in heavy tension a s imparted by the constant counter weights necessary
for operation a t maximum design load in a gravity take-up. The heavy tension is gravity type-up
arrangements continues to exist in the belt even when it is not running.

Figure 8. Screw take up Figure 9. Gravity take-up Figure 10 . Gear take up

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17) CLEANING DEVICES

 Requirements:
It is necessary to clean the belt when snub pulleys or tandem drive pulleys make contact with the dirty
side of the belt on the return run. This is especially the case when handling materials which are likely to
pack on the belt, such as sticky and wet materials, or those that are likely to have damp, greasy or oily
patches which eventually rot the belt.
 Types:
There are three main types of external automatic belt cleaners:

1. A rotary brush
2. The counterweighted wiper
3. The spring-loaded wiper.

Figure 11. Belt Cleaners type Figure 12. Wiper and Rotary Brush

In addition, internal belt cleaners of V-type shall be used near tail pulley to prevent material from getting
between the pulley and belt as it wraps round the tail pulley. These V-type plough cleaners shall be
adjusted to float on the return belt without exerting undue load on belt surface. These can also be made
of adjustable counterweighted type. Their use is recommended even on short conveyor lengths and
where full length decking is provided from the feed to the discharge end as a safety measure.
The rotary brush is fitted with a drive pulley and is rotated in opposite direction from it by a short centre
roller chain drive. A cantilevered weighted arm is attached to the brush for facing it to the belt, whilst at
the same time, preventing jamming and unnecessary wear on the bristles. The speed of the tip of the
bristles for brushes 200 to 300 mm in diameter shall generally be:
Dry materials: 2.0 to 3.0 m/s
Damp materials: 5.0 to 7.5 m/s
Wet and sticky materials: 6.0 to 7.5 m/s
The brush shall be mounted so that it can be adjusted toward the belt to compensate for wear on the tips
of bristles and in such a way that the drive to the brush is not affected.
Because of high speed, brushes are short-lived. The most effective as well as most economic type of belt
cleaning apparatus is the spring-loaded type belt wiper. Dry or very wet materials are easiest to remove.
When particularly gummy materials with tendency to cling to the belt and solidify, are encountered, it is
recommended to use water spray directed against the return belt about 500 mm ahead of the cleaner. It
is also beneficial to have a very fine spray directed against the belt just before it passes under the loading
point, as this will tend to keep the material from adhering. Usually a small amount of water will suffice.
As the cleaner is especially effective in removing water, there is little danger of objectionable dribble.

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Where cleaning is of primary importance, two cleaners may be provided so that one can be removed at
any time for servicing. In any case, arrange pulleys at the discharge end to allow ample room for cleaning
equipment including dribble chute of flume. The blades of the spring type cleaner shall engage the belt
only where it is straight, never on a pulley. One cleaner shall generally have at least 300 mm of straight
belt, two cleaners not less than 750 mm.
It is sometimes necessary to use steel scrappers on the rims of snub pulleys. Tripper pulleys and deflector
pulleys that engage the carrying side of belt, in order to prevent accumulation of material, may hurt the
surface of the belt or cause it to run out of line. The blade shall be located so that the scrapings can be
disposed of.
18) CAUSES OF BELT FAILURE
Conveyor belts are subject to three primary failure mechanisms: Yield, Fatigue and Wear.
Yield Failure occurs when an object has been loaded to the point where it no longer has the ability to
return to its original shape. If a conveyor belt is deformed to the point where it no longer fulfils the
function for which it was designed, it has failed. While a belt usually breaks shortly after the start of yield,
it does not, however, have to break to be considered ‘failed’.
Fatigue Failure occurs when an object is subject to a time varying load, called cyclic loading, which includes
some component of tension
Wear Failure is an erosion of material which occurs whenever there is a relative motion between two
contacting surfaces.
19) BELT SAG
Belt sag is the vertical sag of the belt between adjacent idlers. Often belt sag doesn’t allow for effective
sealing of the belt, which increases dust and spillage. Belt sag encourages material spillage which increases
the risk of trips, slips, falls and entanglement. Fugitive materials like spillage and dust increase
maintenance costs and reduce efficiency, plant safety, and product quality. Fugitive material may bury
idlers, conveyor components, or structural supports, requiring costly clean-up labour and replacement
parts. Belt sag can be eliminated by correctly supporting the belt. The spacing between the rolling
components has a dramatic effect on the idler’s support. Idlers should be placed close enough to support
a belt preventing the belt from sagging excessively between the rollers. If the belt is allowed too much
sag, the load shifts as it is carried up and over each idler and down into the valley between. This shifting
of the load increases wear in the belt and power consumption. The sag also encourages material spillage.

Figure 13 : Belt sag

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20) Types of Belt Conveyor

 Horizontal Belt Conveyor:

This type of belt conveyor consists of a centre drive, gear motor, and take-up. Based on the drive of the
conveyor, it can come with one or two pulleys at the end. The belt of the conveyor is flexible and the
entire system has floor supports along its length.

 Incline and Decline Conveyor

This type of conveyor is similar to a horizontal belt conveyor, but has an additional component. It comes
with a single or double nose over and sometimes it also has a feeder portion. Typically, this type of
conveyor has a rough surface on the belt during incline or decline rather than making use of a smooth-
surfaced belt. This offers more traction to the items placed on the conveyor and prevents them from
rolling backwards or forwards.

Figure 14. Horizontal Belt Conveyor system Figure 15. Inclined Belt Conveyor

Combination of inclined and horizontal conveyor is shown in figure 17.

Figure 16. Combination of inclined and horizontal conveyor

21) Drive pulley Considerations

 Pulley should be large enough to avoid hard bend at point of tension application
 Pulley should have grab - risk of slippage is function of grab and tension - more grab - less tension -
could mean a cheaper belt
 Place Drive in practical location to minimize the highest tension in the belt - a head pulley location
often good on a belt up a slope

 Idlers
The efficiency of belt conveyor is mainly dependent on idlers. For higher efficiency of conveying systems,
the idlers must be accurately made and provide a rigid framework. This will maintain a permanent, well
balanced smooth running alignment.

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There are, in general, three kinds of belt carrying idlers used in handling of bulk materials. The type of
idlers affects the cross-sectional load on the belt.

1. Flat belt idlers: are used for granular materials having an angle of repose of not less than 35°. Flat
belt idlers are preferred for low capacity requirements.

2. Toughing idlers with 20° through: are used for conveying all kinds of bulk materials.

3. Troughing idlers with 35° and 45° through: are used for transportation of small particles and
lightweight materials like grain, cotton seed etc.

There are two basic type of belt conveyor idlers :

a) Carrying idlers which support the loaded run of the conveyor belt; and
b) Return idlers which support empty return run of the conveyor belt.
 Carrying idlers
1. Usually troughed with 3 equal size rollers on a frame in mining applications

2. Some suspended catenary systems have 5 rollers

3. Toughing angles are usually 20, 35, 45 degrees

4. Deeper trough more volume

5. Requires thinner belt to lay in trough which limits strength.

Figure 17. Types of Idlers

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 Returning Idlers
1. Usually Flat and one piece

2. Sometimes two-piece V for belt training

3. Spiral roll to self and belt clean

Rollers
A wide range of rollers, from standard belt-conveyor rollers to shaft-free, rubber-disk return, rubber
impact, and aluminium rollers.
22) Conveyor Loading and Unloading
For a successful belt conveyor installation, it is absolutely necessary that the conveyor belt be loaded properly
and discharged properly. The requirements of loading and discharge are so important that they need very
careful consideration while planning the layout and detailing of the loading/unloading facilities.

 Loading the conveyor

Figure 18. Feeding Hopper of Belt conveyor Figure 19. Belt Unloading Arrangement
This can be done at any point along the path, yet the preferred location of the loading station is at the foot
pulley. Conveyors handling unit loads can be loaded by means of a gravity or manually. Those intended to
move bulk material are provided with a chute. To feed the material on the belt along its centre line in a
uniform way, the outlet from the chute has to be of a width B= 0.6 or 0.7 B. The size of chute must be inclined
at an angle exceeding the angle of internal friction of the material by 10 to 15 degrees or this will tend to
accumulate in the chute. Perforated chutes offer a means of reducing belt wear due to the impact from heavy
lumps at loading station.

 Unloading the Conveyor

The simplest and convenient way of doing this to dump the material over drive pulley. Yet process
requirement may call for removing materials from conveyor at more than one stations along the path as this
may be the case in the foundry where a number of moulding machines are supplied with sand by a conveyor
running down the shop. There are various kind of unloading devices. The simplest among which is the plough
– a blade extending across the belt for one side discharge or a V-shaped blade for two side discharge.

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23) Power Requirement of Belt Conveyors:

The power Requirement of Belt conveyor consist of two parts. One for lifting the load to given height and
second for moving the load horizontally. The required power in KW is given by
N = Nlifting + NHorizontal = Q.H/367 + Co.Q.L/367
Where, Q - Capacity in TPH, H – Height in meter, L – Belt Length, Co – specific friction factor ( ie. The Frictional
resistance to be overcome in moving 1ton through 1m).
Frictional resistance is of two different kind. 1) Distributed frictional resistance over the length of the path
and 2) concentrated at given point e.g. Pulley, loading, unloading and cleaning devices points. Distributed
frictional resistance calculation is explain as below.
a) Distributed Frictional Resistance of the Belt Conveyor
1. Frictional resistance of the idlers supporting horizontal belt section.
Let’s Idlers are spaced a distance ‘t’ apart and each sustain load ‘K’. In carrying run K = qo.t and in
return run K =(q +qo).t. where q – load per unit length due to weight of material and qo – load per
unit length due to belt weight.
The resistance moment set up at the idler as made up of resistance moment at the bearing and that
due to rolling over the rubber belt can be determined from
𝑑
𝑀𝑟 = M1 + M2 = (𝐾 + 𝐺𝑖 ) 𝑓 + 𝜇𝐾
2
Where,
K = Load sustained, Gi = Dead weight of idler
𝑑= diameter of idler pin journal in cm,
𝑓= Coefficient of friction for idler bearing
𝜇= Rolling friction coefficient
The resistance moment set up by number of idlers within a section of conveyor will be given by -
𝑑
𝑀′𝑟 = (Σ𝐾 + Σ𝐺𝑖 ) 𝑓 + Σ𝜇𝐾
2
Since the values of 𝑓 and 𝜇 are influenced by numerous factors and can be assessed with difficulty hence
frictional factor c is taken into account, covering all components of the frictional resistance to motion
within every section of the conveyor. Then the resisting force exerted by a group of idlers within a
horizontal section of the carrying run can be expressed as-
Σ𝐺𝑖 Σ𝐺𝑖
𝐹𝑐.𝑟. = ( 𝑞 + 𝑞𝑜 + 𝑙
) 𝑙𝑐 and of the return run as 𝐹𝑟.𝑟. = ( 𝑞𝑜 + 𝑙
) 𝑙𝑐
Σ𝐺𝑖
where, = 𝑞𝑖 is the distributed load due to dead weight of group of idlers.
𝑙

2. Frictional resistance of the idlers supporting an inclined belt section

The loading sustained by an idler in this case is quite different from the previous one. An inclined conveyor
with a belt of length 𝑙𝑜 raising material through a vertical height h carries a load , Σ𝐾 = (𝑞 + 𝑞𝑜 )𝑙𝑜

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Some conveying installations consisting of number of horizontal sections make use of idler- supported
convex or concave transition curves as shown below.
The total resisting force coming into play in convex transition curve is

F = [T1 − (qo + q + qi )R](eβc − 1)

Where, T1- Belt tension, qo = Gg = weight of conveyed material per meter length, q = Gb = weight of
belt per meter length, 𝑞𝑖 is the distributed load, R – Radius of curve , β –angle between the roller as
shown in figure, c- frictional factor.

Figure 21. Frictional Resistance of Idlers at transition curves

o ensure that the belt will not lift off the idlers supporting a curved section, the minimum allowable radius
T T
of curvature is given by R 𝑚𝑖𝑛1 = q1 for empty belt and R 𝑚𝑖𝑛2 = q+ 1q for the loaded belt.
𝑜 𝑜

Practically the transition curves are designed as a part of circle with radius R which is determined from
T T
the relationship q+ 1q < 𝑅 < q1 .
𝑜 𝑜

24) Nomenclature
𝜌 = density, 𝛿 = angle of inclination, amax = maximum lump size, C = factor for type of idler,
V = belt speed , B = belt width, 𝑤𝑜 =resistance of belt on top run, 𝑤𝑢 = resistance of belt on bottom run,
𝐺𝑔 =weight of conveyed material per meter length, 𝐺𝑏 =weight of belt per meter length,
𝐺𝑟𝑜 = Weight of straight idlers on bottom run, f = fraction factor between idler and belt
L = conveyor length, 𝑇1 = tension in tight side, 𝑇2 =tension in slack side,
𝜃 = angle of contact between pulley and belt, i = No. of ply, 𝐿𝑏 = Bearing span,
ds = shaft diameter , dh = hub diameter, 𝐹𝑎 =axial load, 𝐹𝑟 = radial load

25) Design procedure for Belt Conveyor System

The design of a belt conveyor system takes into account the followings:
i. Dimension, capacity and speed
ii. Maximum loading capacity
iii. Roller diameter
iv. Belt power and tension

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v. Idler spacing
vi. Pulley diameter
vii. Motor
viii. Type of drive unit
ix. Location and arrangement of pulley

DESIGN STEPS

1. Selection of Belt Width and Velocity

The selection of belt width and velocity is probably the most frustrating of problems facing the designer.
There are a variety of factors being used, factors such as the belt width must be three times the maximum
lump size, the belt width must be such that the system can cater for 66% excess capacity, and if a tripper
is used the factors must be increased by a further 30% etc.
Belt width is calculated using general formula B = (X. amax + 200) , where X = 2 factor for graded and X
= 3.3 for ungraded material, amax is maximum lump size. Then velocity of belt is assumed from material
and the minimum width is to be calculated using formula Bmin = 1.11[{Q/(ρ. c. v)}1/2 + 0.05] from PSG
9.18, Then for higher value, standard belt width is to be selected and from this width the actual velocity
is to be found out.

2. Design of Drive Unit

The standardization of drives is the key to most successful conveyor systems. The problem is however
that some drives have to be drastically oversized to obtain some degree of conformity.
The Resistance to the belt on the top run and returning motion is need to calculate as.

Wo = C. f. l [(Gg + Gb )cosδ + Gro ] ± H(Gg + Gb )

Wo :The resistance to the top run which is depends on many factor like, C = secondary resistance factor
corresponding to length of conveyor,
L in metre 10 20 32 40 50 80 90 100 140 200 300 500 2000
C 4.5 3.0 2.6 2.4 2.2 1.92 1.86 1.78 1.63 1.45 1.27 1.20 1
f : Coefficient of friction between idler and belt depend on types of conveyors, L: length of conveyor , Gg :
weight of conveyed material per meter length, Gb ∶ Weight of belt per meter length, δ:Angle of inclination,
Gro ∶ Weight of troughing idler on the top run per meter length, H : Height of the conveyor system and
the material conveying direction. (Note: + for material conveying upward and – for material conveying
downward direction)
The resistance for the bottom run is given by , Wu = C. f. l[(Gb cosδ + Gru )] ∓ H. Gb
Gru : Weight of straight idler on the bottom run per meter length, (Note: – for material conveying upward
and + for material conveying downward direction)
Then the effective load on the belt is calculated by adding both the resistances. From this data and velocity
, Motor power required for the whole system is to be calculated and standard motor is to be selected.

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3. Force analysis
Tension on tight side and slack side are to be calculate from power and belt tension equations.

4. Traction element calculation –

𝑇1
No. of plies required are to be calculated in this step by using equation, No. of ply: i = 𝐵∗𝑓

Where, 𝑇1 is maximum tension in the belt, B is Width of the belt and f is working tension for the belt
depend on joint type , take up arrangement and std. types of belt to be selected from PSG: 9.21 .
Now by assuming thickness of each ply, top cover thickness and bottom cover thickness, total thickness
for a belt are to be calculated.

5. Idler Design –
The choice of type and spacing for Idlers should be on a more scientific basis. The types of Idler to be used
on conveyors are; transition, troughing, impact and return idlers. Design of troughing idler and returning
idler are need to carry out and checked for failure in this step.

6. Pulley, Shaft and Bearing design –

Pulley and shaft diameters should be kept to a minimum of two per conveyor, with as much
standardization as possible being employed on the whole conveyor system. In this step dimensions of the
pulleys are decided, shaft diameter based on equivalent torque and bearing design is to be done. Also
snub pulley dimensions are to be decided.

7. Checking for a need of an arresting mechanism-

In this step, Resistance of the belt on the top run Wo is calculated for reverse motion and the need for
an arresting mechanism is checked.

8. Design of tension take up unit.

The weight required to be attached to belt is to be calculated in this step.

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NUMERICALS
1. DESIGN OF BELT CONVEYOR SYSTEM FOR SPECIFICATION;
Troughing angle = 20degrees
Material to be conveyed – Coal
Capacity = 200TPH
Lump Size = 125mm
Inclination = 15degrees
Centre to Centre Distance = 90m
Solution:
Assumption: It is assumed that loading is taking place at tail pulley and unloading at head pulley.

Given Data: material = Coal, Q= 200TPH, amax = 125𝑚𝑚, δ = 15degree, L = 90m, troughing angle =
20,
Design Capacity and Material Properties
Assuming 10% Extra, Design capacity =1.1 ∗ Q = 1.1 ∗ 200 = 220 TPH
Material properties:
For Coal,
Density = 0.65 ~ 0.78 = 0.7 Ton/m3 ………………. (PSG 9.23)
Step I. Belt width:
Using empirical relation with lump size, Assuming graded material hence x= 3.3
Belt Width, B = (x. amax + 200) = 3.3*125 + 200 = 612.5 mm

Also, Bmin = 1.11[{Q/(ρ. c. v)}1/2 + 0.05] …………………. (PSG 9.18)

Where, C= Factor for type of idler (460 for troughing angle 20)
V= Belt speed= 2m/s ………………... (Assumption)

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1
220
Bmin = 1.11 [{0.7∗460∗2}2 + 0.05] = 0.704𝑚

Selecting standard width for belt as B= 800mm

Substituting B= 800mm in above formula

800 = 1.11[{220/(0.7 ∗ 460 ∗ v)}1/2 + 0.05]

𝐯𝐚𝐜𝐭𝐮𝐚𝐥 = 1.52 m/s
Step II. DRIVE UNIT:
Providing driving traction required for moving the belt and load. A drive unit consist of motor, gear
reduction unit, a drive pulley and couplings. The drive should be capable of moving the belt at constant
or variable speed according to the requirement.
Resistance of the belt on the top run wo for conveying up is given by,

wo = C. f. l [(Gg + Gb )cosδ + Gro ] + H(Gg + Gb ) ………….. (PSG 9.18)

Where, C = secondary resistance factor = 1.8 for L= 90m from graph,

f = friction between idler and belt =0.02 for std. conveyors, l = 90m
Gg = weight of conveyed material per meter length
220 220
Gg = 3.6∗v = = 40.21kgf/m
3.6∗1.52

Gb = Weight of belt per meter length =12kgf ……… (Table 1:PSG 9.19)
Gro = Weight of troughing idler on the top run per meter length
Gru = Weight of straight idler on the bottom run per meter length
Tube diameter = 140mm and bearing diameter = 25 mm (Assumption) ……..… (PSG 9.19/T4)
Maximum spacing for troughing idler = 1.5m and Maximum spacing for straight idler = 3 m
27.4 18.8
Gro = 1.5
= 18.26 kgf/m , Gru = 3
= 6.26 kgf/m

Height through which material is to be lifted, H

H= Lsinδ = 90sin (15) = 23.29m

Resistance of the belt on the top run, wo = Cfl [(Gg + Gb ) cosδ + Gro ] + H(Gg + Gb )

wo = 1.8*0.02*90 [(40.21 + 12) cos15 + 18.26] + 23.29 (40.21 + 12) = 1438.53kgf

Resistance of the belt on the bottom run wu is given by,
wu = C. f. l[(Gb cosδ + Gru )] − H. Gb ………………. (PSG9.18)
wu = 1.8*0.02*90[40.21 cos15 + 6.26] - (23.29*12)
wu = -221.64kgf

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Effective load on belt,

P = wo + wu = 1438.53 – 221.64 = 1216.89kgf
Motor Power = P*V = 1216.89*1.52*10 = 18496 W
Selecting a standard motor Power = 18.5KW
Step III. Force Analysis:
T1
T2
= eμθ , Assume coefficient of friction between belt and pulley, µ=0.25 and θ = 200 degree

T1 π
= e(0.25∗200∗180)
T2
T1 =2.39T2 ……. (1)
Also, P = (T1 − T2 ) V

(T1 − T2 ) =1217.11kgf ………. (2)

From (1) & (2), T2 =875.6kgf, T1 =2092.7 kgf

T3 =T1 + Wu=2092.7 – 221.64 =1871.11kgf

Step IV. Traction Element

1𝑇
No. of ply: i = 𝐵∗𝑓

For density 0.7 Ton/m3 and belt width 800mm,

Working tension f =0.62 for 32 OZ vulcanised joint and
gravity take up………(PSG 9.21/T5)
2092.7 Figure. Traction Element
i = 0.62∗800 = 4.21= 5

Also, corresponding to density of the material and belt width, Maximum no. of ply = 7 and Minimum no.
of ply = 4 …………. (PSG 9.21/T4)
i =5,
Let thickness of each ply = 2mm for fabric strength of 400N/mm2
t i = Total thickness of ply= 6*2=12mm,
Top thickness = t t = 2mm
Bottom thickness = t b = 1mm,
Total thickness of belt, T = t i + t t + t b = 𝟏𝟓𝐦𝐦

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Step V. Idler Design

To prevent the belt from sagging due to gravity and under the load, a number of idler rolls between the
terminal pulleys. The most common configuration for idler rollers is 3 rollers of equal length.
 Troughing Idler:

Let the material for idler be C-25, with [σb] = 60Mpa,

Shape is tubular and provision for bearing block

Belt Width = B = L + (2L − 100), 800 = 3L − 100

Length of troughing idler, L= 300mm,
Figure: Troughing idler assembly
Troughing Idler Size: φ140 * 300mm
Total no. of troughing idler systems = L / spacing = 90/1.5 = 60
Total no. of troughing idlers = 3 * 60 = 180
Total weight acting on troughing idler,

W ′ =(Gg + Gb + Gro ) ∗ spacing = (40.21+12+18.25) *1.5 = 105.7 kgf

Middle idlers generally take 70% of total load, W= 0.7*105.7 = 74 kgf =740N
Wo = (40.21+12+18.25) = 70.46 kgf/m = 0.7046 N/mm
L1 =300mm , L2 = 200mm ( Assuming margin for bearing block)

Figure: Idler cross section

Calculation for maximum bending moment at the centre,

𝐿1 2 𝑊 𝐿2 3002 740 200 Figure: Force and BMD for idler
𝐵𝑀𝑚𝑎𝑥 = 𝑊𝑜 𝑥 8
−
2
𝑥
2
= 0.7046 𝑥
8
−
2
𝑥
2

𝐵𝑀𝑚𝑎𝑥 = 𝑚𝑜𝑑(−29073.25) = 29073.25𝑁. 𝑚𝑚

Assuming thickness of idler as 2.5mm, do =140mm, di=135mm, ds = Axle diameter = 30mm, db = bearing
outer diameter = 47 mm (from bearing design)
M 29073.25∗32 29073.25 ∗32
(σb ) = Z = 𝑑 4 − 𝑑𝑖 4
= 1404 − 1354
= 0.797 N/mm2,
π∗( 𝑜 ) π∗(
140
)
𝑑𝑜

(σb ) < [σb ], Hence, design is safe.

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

 Returning Idler:
(For returning idler, material load is not present hence assumed as safe under different failure, the
bearing and the bearing selected for troughing idler can be used for returning idler also.)

Length of returning idler, L2 = B + Margin = 800 +100 = 900mm

Returning idler φ140 * 900 mm
Total no. of returning idlers = L / spacing = 90/3 = 30

 Design of Bearing for idler:

Bearing inner diameter = 25mm (Assumed)
Forces acting on bearing are,
W 740
Fr = 2
= = 370N, Fa =0
2

Assuming working at room temp, nature of load as medium shock and life in hours as 15000Hrs,
Equivalent load, Peq = (X. V. Fr + Y. Fa ) S

Where, X =1, V = 1.2, S = 1.2,

Peq = (1.2 *370 *1.2) = 532.8 N
𝑣 ∗ 60 1.52 ∗ 60
𝑁= = = 207.35 𝑟𝑝𝑚
𝜋 𝑑𝑜 𝜋 ∗ 0.140
Lhr ∗N∗60 15000∗207.35∗60
Lmr = = = 186.62mr, also k=3 for Ball bearing
106 106
1
Dynamic load carrying capacity, C = Peq (Lmr )k = 532.8 * (186.62) (1/3)

C = 3044.74N, C =304.47Kgf
Selecting DGBB, No. 6005 with d= 25mm, D= 47mm,
width =12mm and C =780Kgf
 Design of Axle for idler:
Let the material for axle be C-25, with
[σb ]=60 N/mm2, [σcr ]=90 N/mm2
Axle diameter, d= 30mm, d1 =bearing inner diameter = 25mm,
d2 = 20mm (assumed)
Figure: Idler shaft, force and BMD
L1 = 200mm (from idler design)
L2 = Rigid support span = Idler length + margin+ frame width
L2 = 300 +12+14 = 326mm ( Assuming frame thickness =14mm)
Load acting W/2 = 370N

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𝑊
𝐵𝑀 𝑚𝑎𝑥 ( )∗(𝐿2−𝐿1)/2 370∗63 𝑁
Checking for bending failure, (σb ) = Z
= 2
π∗d^3 = 2650.7
= 8.79 𝑚𝑚2 < [σb ] hence, safe
32

𝑊/2 370 𝑁
Checking for crushing failure, (σcr ) = d2∗Frame thickness = 20∗14
= 1.32 𝑚𝑚2 < [σcr ] hence, safe

Step VI. PULLEY DESIGN

Pulleys are necessary in conveyors to change the direction
of belt in vertical planes and to form endless loop for continuous motion.
D1 = k1 ∗ k 2 ∗ i
Where, k1 = factor for pulley material = 1.4 (for high tensile Anide)
k 2 = factor depends upon angle of contact and belt tension
k 2 = 100 (for 𝜃>180)
D1 = 1.4 * 100 * 5 = 700 mm , 𝑡𝑟 = 6~8 = 7mm, 𝑡𝑤 = 10mm
Width of the pulley, B1 = B + margin = 800 + 100 = 900mm
π∗D∗N π∗0.7∗N
V= 60
, 1.52= 60
, N= 34.56 rpm

 Shaft diameter
Let shaft material be C-25, Due to shock loads taking more FOS,
[𝜏]=25 N/mm2, [σb ]=60 N/mm2 B1
P∗60 18500∗60
T = 2∗π∗N =2∗𝜋∗34.56 = 5111.75 N-m Figure : Section of a Pulley

Bearing span can be take larger for easy maintenance but to control lateral deflection,
Assuming bearing span = 1.25*𝐵1 = 1.25*900 =1125 mm, W = T1 +T2
WL (2092.7+875.6)∗10∗1125
BMmax = 4
= = 8348.34 N-m
4∗1000

Equivalent torque = Teq =√T 2 + M 2 = √(5111.75)2 + (8348.34)2 = 9789 N-m

Teq ∗16 9789 ∗1000∗16
[𝜎𝑠 ] = , 25 =
π∗(ds)3 π∗ds3

Therefore, ds= 125.87 ≈ 126 mm, Let ds1= 1.1ds = 138.6 ≈140mm,
Lh1 = dh1 = 1.5ds1 = 1.5*140 = 210mm
 Bearing Selection for pulley
A bearing is a machine element that constrains relative motion to only the desired motion, and reduces
friction between moving parts. Bearing in the conveyor belt system is used between pulley and shaft.
W T1 +T2 (2092.7+875.6)∗10
Fr = 2
= 2
= = 14841.5N, Fa =0
2

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Peq = (x. v. Fr + y. Fa ) S.F. = (1.2 *14841.5) *1.2 = 21371.76 N

Assuming Lhr = 10000 hrs

Lhr ∗N∗60 10000∗34.56∗60
Lmr = = = 20.72mr
106 106
1
C = Peq (Lmr )k = 21371.76 * (20.72) (1/3), C = 5869.98 kgf

For d= 140 & C > 5869.98kgf, Selecting bearing no. SKF6028 [ d=140mm, C=8600kgf ]
Step VII. Snub Pulley
Snub rollers are used to:
•Increase the angle of contact between the belt and the driving pulley and improve the
torque transmitted.
•Decrease the distance between the belt carrying side and return side.
•Improve belt tracking with adjustable snub rollers.
It is located at the slack side of the head pulley. The construction features and material is same as head
pulley.
Diameter of Snub pulley = 0.6* head pulley diameter = 420mm

Step VIII. Check for arresting mechanism

Resistance of the belt on the top run 𝐰𝐨 for conveying down, is given by
wo = Cfl [(Gg + Gb )cosδ + Gro ] − H(Gg + Gb )

wo = 1.8*0.02*90[(40.21+12) cos15 +18.26] – 23.29(40.21+12) = -993.412 kgf

Since 𝑤𝑜 is negative, if motor stops working, the belt will move in opposite direction. Hence there is a
need of arresting mechanism.

Step IX. Tension take up Unit

The tension take-up unit is required to maintain the tension in belt. The simplest form of it is gravity
loaded tension take-up unit. To determine the tensioning weight required ( TR ) with 180 degree arc of
contact, using the relation,
TR = 2T2-TTR
Where, T2 – Slack side tension, TTR – Weight of tension roller
TR = 2 x 875.6 - 50 ( Assuming weight of tension roller as 50Kgf)
The tensioning weight required ( TR ) = 1701Kgf

Fig: Tension take up system

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

Numerical 2. DESIGN OF BELT CONVEYER SYSTEM FOR FOLLOWING SPECIFICATION

Material to be conveyed = stone (lime)
Capacity = 300TPH
Troughing angle= 250
Lump size= 80mm
Inclination (δ) = 120
CTC distance= 50m
The requirements are as follows:
i) Selection of belt
ii) Design of tension, take up unit, Idler pulley.
iii) Power requirement

Solution:
Assumption: It is assumed that loading is taking place at tail pulley and unloading at head pulley.

Given Data: material = Stone, Q = 300TPH, amax = 80𝑚𝑚, δ = 12 degree, L = 50m,

troughing angle = 25 degree
Drive selection: AC motor, head pulley is driven, belt supports, over run troughing idler assembly and
Under run idler assembly is single straight idler assembly.
300
Design capacity= [Q] = = 333.33= 334 TPH
0.9

Material properties for Stone (lime) ……… (PSG 9.22)

Density (p) = 1.2 to 1.5 , let 1.4 Tonne/m3
Max inclination = 200 and Angle of repose= 450

 Belt width (B) & speed (V)

Let speed of the belt is (v) = 1.75 m/s …….. (PSG 9.20 table 3)

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Using relation , B = X.amax + 200

Where , X= 3.3 for ungraded material and X= 2.5 for graded material
B =3.3 x 80+ 200 = 464 mm
𝑄
Also based on capacity, the minimum width of pulley is given by Bmin = 1.11 [(𝑝𝑐𝑣)1/2+ 0.05]

Where density ρ = 1.4 T/m3, Q = 334 TPH and factor for types of idler C= 510 for troughing angle of 250
334
Bmin= 1.11[(1.4𝑥 510 𝑥1.75)1/2+ 0.05] = 0.659m = 629.38 mm

Selecting next standard width of belt B = 650mm

Calculating Actual velocity, Vact = 1.63 m/s, Acceptable

 Drive unit:
f = friction between idler and belt …………………..(PSG 9.18)
let f = 0.02 for standard conveyer
Length L= 50m , C =2.2 from graph
Now,
1) Weight of conveyed material per meter length
𝑊𝑡.𝑜𝑓 𝑐𝑜𝑛𝑣𝑒𝑦𝑒𝑟 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑄
Gg = 𝑚𝑒𝑡𝑟𝑒 𝑙𝑒𝑛𝑔ℎ𝑡
= 3.6 𝑉

334
Gg = 3.6 𝑥 1.63
= 56.92kgf/m
Fig: Graph for length (L) vs Secondary resistance
factor(C)
2) Weight of Belt per meter length,
𝑊𝑇.𝑂𝐹 𝐵𝐸𝐿𝑇
Gb = 𝑚𝑒𝑡𝑅𝐸 𝐿𝐸𝑁𝐺𝑇𝐻
= 9 kgf/m …….…… (PSG 9.19)

3) Weight of troughing idler on the top run per meter length

𝑊𝑡.𝑜𝑓 troughing idler on the top run

Gro = 𝑚𝑒𝑡𝑟𝑒 𝑙𝑒𝑛𝑔𝑡ℎ

Let tube diameter be 140 mm and Bearing diameter= 25mm

Weight of troughing idler pulley = 24.6 kgf/idler assembly
Maximum spacing for idler
For density = 1.2~ 2 Tonne/m3 and Belt Width B= 650mm ………(PSG 9.19 table 2)
Max spacing = 1.5 m, Spacing for return idler = 3 m,

Gro = 24.6/1.5 = 16.4 Kgf/ m – for troughing idler,

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Gru= 15.9 /3= 5.3 Kgf/ m – for returning idler,

Now, Height through which material is conveyed H is given by

H= L*sin δ = 50 x sin12 = 10.396 m

 Resistance of the belt on the top run and bottom run ……… (PSG 9.18)

Wo= C . f . L [(Gg+ Gb) cos δ + Gro] + H (Gg + Gb)

Wo= 2.2 x 0.02 x 50 [(56.92 + 9) cos 12 + 16.4] + 10.4 (56.92 + 9) = 863.5kgf
And, Wu= C.f.L [Gb × cos δ + Gru] - H× Gb
Wu= 2.2 x 0.02 x 50 [ 9 cos 12 + 5.3] - 10.4 x 9 = -62.57 kgf

 Effective tension P = Wo+ Wu ………(PSG 9.18)

P = 863.5 – 62.57 = 800.9 kgf
Motor power = P x V = 800.9 x 1.63 = 1305.5 kgf.m/s = 13.06 kW
Selecting 15 kW standard motor ………. (PSG 5.124)

 Force analysis and calculation of no. of plies

Power P = (T1- T2) V
No. of plies i= T1/ B.f …… PSG 9.18
T1
= eμθ , Assume coefficient of friction between belt
T2
and pulley, µ=0.25 and θ = 200 degree
T1 π
= e(0.25∗200∗180)
T2
T1 =2.39T2 ……. (1)

Also, P = (T1 − T2 ) V

(T1 − T2 ) x 1.63 = 1500 kgf m/s

(T1 − T2 ) = 920.25 ………. (2)

From (1) & (2), T2 = 662.05 kgf, T1 = 1582.3 kgf

T3 =T1 + Wu = 1582.3 – 62.57 = 1519.73 kgf and T4=T3

Now No. of plies i= T1/ B.f
where f is working tension in conveyor belts, from PSG 9.21, corresponding to density assuming 32OZ
designation of belt fabric and assuming mechanical joint and gravity take up,

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f = 0.57 ………..Table 5, PSG 9.21

i = 1582.3 / 650 x 0.57 = 4.27
For Belt width 650 mm, and 32oz designation,
Maximum and Minimum No. of plies are 5 and 6 ………..Table 4, PSG 9.21
Selecting no. of plies as i = 5

 Traction element
Proportions:
Thickness of ply = i x thickness of ply = 5x 2 = 10mm
Assuming, thickness of ply = 2mm,
Top cover thickness (tt ) = 2mm and
Bottom cover thickness (tb ) = 1mm
Total thickness= tt + tb + ti = 13mm
Fig: Belt cross section

 Troughing idler
The troughing idler angle for the current problem as a troughing angle of 250

and the material to be transported is stone i:e a bulk material

Let the material for idler be C-25, with [σb] = 60Mpa,

Shape is tubular and provision for bearing block

Belt Width = B = L + (2L − 100), 650 = 3L − 100

Length of troughing idler, L= 250mm,
Troughing Idler Size: φ140 * 250mm
Total no. of troughing idler systems = L / spacing = 50/1.5 = 33.33 =34
Total no. of troughing idlers = 3 * 34 = 102
Total weight acting on troughing idler,

W ′ =(Gg + Gb + Gro ) ∗ spacing

W ′ = (56.92 + 9 + 16.4) *1.5 = 123.48 kgf

Middle idlers generally take 70% of total load,
W= 0.7* 23.48 = 86.44 kgf = 864 N
Fig: Idler cross section
UDL, Wo = (56.92 + 9 + 16.4) = 82.32 kgf/m = 0.8232 N/mm

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L1 = 250mm , L2 = 150mm ( Assuming margin for bearing block)

Calculation for maximum bending moment at the centre,
𝐿1 2 𝑊 𝐿2 2502 864 150
𝐵𝑀𝑚𝑎𝑥 = 𝑊𝑜 𝑥 8
− 𝑥 = 0.8232 𝑥 − 𝑥
2 2 8 2 2

𝐵𝑀𝑚𝑎𝑥 = 𝑚𝑜𝑑(−25968.75) = 25968.75 𝑁. 𝑚𝑚

Assuming thickness of idler as 2.5mm, do =140mm, di=135mm,
ds = Axle diameter = 30mm,
db = bearing outer diameter = 47 mm (from bearing design)
M 25968.75∗32 29073.25 ∗32 Figure: Force and BMD for idler
(σb ) = = 𝑑 4− 𝑑 4 = 1404 − 1354
= 0.712 N/mm2 ,
Z
π∗( 𝑜 𝑖 ) π∗(
140
)
𝑑𝑜

(σb ) < [σb ], Hence, design is safe.

 Returning Idler:
(For returning idler, material load is not present hence assumed as safe under different failure, the
bearing and the bearing selected for troughing idler can be used for returning idler also.)

Length of returning idler, L2 = B + Margin = 650 +100 = 750mm

Returning idler φ140 * 750 mm
Total no. of returning idlers = L / spacing = 50/3 = 17

 Design of Bearing for idler:

Bearing inner diameter = 25mm (Assumed)
Forces acting on bearing are,
W 864
Fr = 2
= 2
= 432N, Fa =0

Assuming working at room temp, nature of load as medium shock and life in hours as 15000Hrs,
Equivalent load, Peq = (X. V. Fr + Y. Fa ) S

Where, X =1, V = 1.2, S = 1.2,

Peq = (1.2 *432 *1.2) = 622 N
𝑣 ∗ 60 1.63 ∗ 60
𝑁= = = 222.36 𝑟𝑝𝑚
𝜋 𝑑𝑜 𝜋 ∗ 0.140
Lhr ∗N∗60 15000 ∗ 222.36 ∗ 60
Assuming life of bearing as 15000 Hrs, Lmr = 106
= 106
= 200.13mr,
1
also k=3 for Ball bearing, Dynamic load carrying capacity, C = Peq (Lmr )k = 622 * (200.13) (1/3)

C = 3638.24 N, C =363.8Kgf,
Selecting DGBB, No. 6005 with d= 25mm, D= 47mm, width =12mm and C =780Kgf

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 Design of Axle for idler:

Let the material for axle be C-25, with
[σb ]=60 N/mm2, [σcr ]=90 N/mm2
Axle diameter, d= 30mm, d1 =bearing inner diameter = 25mm,
d2 = 20mm (assumed)
L1 = 150mm (from idler design)
L2 = Rigid support span = Idler length + margin+ frame width
L2 = 250 +10+10 = 270mm ( Assuming frame thickness =10mm)
Figure: Idler shaft, force and BMD
Load acting W/2 = 432N
𝑊 𝐿2−𝐿1
𝐵𝑀 𝑚𝑎𝑥 ( )∗ 432 ∗60 𝑁
2 2
Checking for bending failure, (σb ) = Z
= π∗d3
= = 9.778 𝑚𝑚2
2650.7
32

(σb ) < [σb ] hence, safe

𝑊/2 432 𝑁
Checking for crushing failure, (σcr ) = d2∗Frame thickness = 20∗10
= 2.16 𝑚𝑚2 < [σcr ] hence, safe

 Head pulley
Head/Drive Pulley is located at the discharge terminus of the conveyor. It provides the driving force for
the conveyor. In order to increase pulley life and traction, it has often larger diameter than other pulleys.

 Drive Pulley Considerations

 Pulley should be large enough to avoid bending at point of tension application
 Pulley should have grab, risk of slippage is function of grab and tension, more grab - less tension
- could mean a cheaper belt
 Place Drive in practical location to minimize the highest tension in the belt - a head pulley location
often good on a belt up a slope.

Pulley Dimension:
Diameter of Pulley is given by D= K1. K2. i
…... for fabric ply construction
K1 = factor for ply material (1.25 to 2.5) = 1.4
K2 = 100 ……..Factor depends on angle of contact Ɵ >180 ,
D = 1.4 x 100 x 5
D= 700mm
Now, V = πDN/60, N= (1.63 x 60)/( πx 0.7) = 44.47 rpm B1

Figure : Section of a Pulley

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Assume tw=10mm, tr = 6 to 8 mm
B1= B + margin = 650 +100= 750mm
Let’s design Shaft for pulley ,
Let material for shaft be C-25/C30, Permissible stress [τ]= 25 N/ mm2
𝑃𝑥60 15 𝑥 1000 𝑥 60
Torque T = 2𝜋𝑁
= 2𝜋 𝑥 44.47 = 3.22 x 106 N.mm

Let bearing span , Lb1= 1.25 x B1= 1.25 x 750 = 937.5 mm

Total load F = T1+T2 = 15823 + 6620.5 = 22443.5N, i.e. Total load acting F = 22.44 KN
Bending Moment M = F.Lb1/4 = (22443 x 937.5) / 4

M = 5.26 x106 N.mm ,

Teq = √𝑀2 + 𝑇2 = √(5.26𝑥10^6)2 + (3.22𝑥10^6)2

Teq = 6.167 x106 N.mm
[τ]= Teq/ (π/16.ds3), 25 = (6.167 x106 x 16) / ( π ds3)
Solving ds= 107.9 mm
To account for key effect, ds =1.1x 107.9 = 118.69 mm, Selecting ds = 120mm

 Bearing Design
Load acting on the bearing are,
Radial Load, Fr=W/2=( T1+T2)2= 22.44/2= 11.22 KN
Axial Load, Fa =0 N
Equivalent Load, Peq= (X.V.Fr + Y.Fa) x.1.2
…Assuming service factor as 1.2, X=1, V=1
Peq = 13.464 kN = 1346.4 kgf ,
Figure: Cross section of bearing
Now, N = 44.47 rpm
Assuming life of bearing as Lhr = 5000 hrs.
Life in millions of revolution, Lmr = (Lhrx60xN)/ 106 = (5000 x 60 x 44.47)/106 = 13.34 mr
Dynamic Load carrying capacity C = (Lmr)1/k. Peq , k=3 for ball bearing,
C = (13.34)1/3 x 1346.4 = 3193.3 kgf
Selecting standard bearing as SKF 6024
d= 120mm and C = 6700Kgf,

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 Snub pulley

Pulley, which is provided to increase/decrease, warp/contact angle of belt on nearby pulley ,is called Snub
pulley. Mounted close to the drive pulley on the return side of the belt, the snub pulley's primary job is to
increase the angle of wrap around the drive pulley, thereby increasing traction. Its secondary purpose is
reducing belt tension, which is important in maximizing conveyor component life. May be lagged for
longer wear life.
Location : slack side of Head pulley
Size of snub pulley = 0.6 x Diameter of head pulley = 0.6x 700 = 420 mm

 Check for arresting mechanism

Resistance to belt on the top run for conveying down is given by

Wo = C.f.L [(Gg +Gb) cosδ+ Gro]- H(Gg+ Gb)
Wo= 2.2 x 0.02 x 50 [(56.92 + 9) cos 12 + 16.4] - 10.4 (56.92 + 9)
Wo = -507.63 Negative sign shows that under power failure the material flow reverses, so there is a
need of arresting mechanism.

 Tension take up Unit

The tension take-up unit is required to maintain the tension in belt. The simplest form of it is gravity
loaded tension take-up unit. To determine the tensioning weight required ( TR ) with 180 degree arc of
contact, using the relation,
TR = 2T2-TTR
Where, T2 – Slack side tension, TTR – Weight of tension roller
TR = 2 x 662.5 - 50 ( Assuming weight of tension roller as 50Kgf)
The tensioning weight required ( TR ) = 1275Kgf

Fig: Tension take up system

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

Numerical 3. Design a belt conveyer system for the following specifications,

Material to be conveyed: Coal

Troughing angle: 20º
Capacity: 100 TPH
Lump size: 150mm
Inclination: 15º
Centre to centre distance: 150m

Solution:
Units: 1) Drive Unit
2) Transmission Unit
3) Belt Conveyer
𝑄 100
Design Capacity, [Q] = 0.9 = = 112 TPH
0.9

Material Properties: For Coal

Density (ρ) = 0.65 – 0.78 tonne/m3, Let ρ = 0.7 tonne/ m3
Max. Inclination, δ = 18º
Angle of Repose = 50º ……………………PSG 9.22
 Belt Width and Speed
B = X . amax + 200 ….empirical relation
Let X= 2, for ungraded material
B = (150 x 2) + 200 = 500 mm
𝑄
Bmin = 1.11 [{ρCV}0.5 + 0.05] …………………..PSG 9.18

Let, C = 460 for 20 degree troughing idler ,

Assuming, V = 2m/s
112
Bmin = 1.11 [{0.7 x 460 x 2 }0.5 + 0.05]

B min = 0.518m = 518 mm

Selecting standard belt width, B = 650mm …………………..PSG 9.20
Actual velocity,
112
0.65 = 1.11 [{0.7 x 460 x V}0.5 + 0.05] , Vact = 1.21m/s

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

 Drive Unit:
Resistance of belt on top run
Wo = CfL [(Gg + Gb)cosδ + Gro] + H(Gg + Gb) …………………..PSG 9.18
for L = 150, C = 1.6 from graph
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐶𝑜𝑛𝑣𝑒𝑦𝑒𝑑 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 112
Gg = 𝑀𝑒𝑡𝑒𝑟 𝑙𝑒𝑛𝑔𝑡ℎ
= 3.6 𝑥 1.21 = 25.71 kgf/m

Gb = Weight of belt per meter length = 9 kgf/m

Gro = Weight of straight idlers due to bottom run / meter length
Let, Tube diameter = 140mm, Bearing diameter = 25mm
Weight of troughing idler assembly = 24.6 kgf/idler
Max spacing for idler = 1.6m…(For B= 650mm & ρ = 0.7 tonne/m3)
24.6
Gro = 1.6
= 15.375 m …………………..PSG 9.19

Let spacing for returning idler = 3m

15.9
Gru = 3
= 5.3 kgf/m

Now, H = L sinδ = 150 sin15º = 38.82m

Wo = CfL [(Gg + Gb)cosδ + Gro] + H(Gg + Gb)
Where, C = 1.6, f = 0.02 for std. conveyers, L = 150m
Substituting, Wo = 1.6 x 0.02 x 150 [(25.71 + 9)cos 15 + 15.375] + 38.82 (25.71 + 9)
Wo = 1582.17 kgf
Resistance of belt on bottom run, Wu = C.f.L [(Gb cosδ + Gru] - H(Gb)
Wu = 1.6 x 0.02 x 150 ( 9 cos 15 + 5.3) - 38.82 x 9
Wu = -282.21 kgf
Effective tensions,
P = Wo + Wu = 1582.17 – 282.21 = 1300 kgf ………..PSG 9.18
Motor power = P x V = 1300 x 1.21 = 15730 W
Selecting Std. motor of 18.5 KW …………………..PSG 5.124

 Force Analysis
Using relations,
T1
T2
= 𝑒 μ𝜃 Let µ = 0.25, θ= 200º

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T1 = 2.39 T2 …………………………..(1)
Also, P = (T1 − T2 ) V

(T1 − T2 ) x 1.63 = 1850 kgf. m/s

T1 - T2 = 1134.9 ……………..(2)
Solving, T1 = 1951.42 kgf = 19514.2 N, and T2 = 816.52kgf = 8165.2 N
𝑇1
No of plies, i = 𝐵𝑓 …………………..PSG 9.18

Material Designation: For density ρ = 0.7 tonne/ m3 and belt width 650mm Selecting 32 OZ
( Table 4, PSG 9.21, i max = 6, i min = 4 )
For 32 OZ Belt and Vulcanized & joint gravity take up,
Working tension, Kgf/mm width per ply , f = 0.62 ………….. table 5, PSG 9.21
𝑇1 1951.42
No of plies, i = 𝐵𝑓 , i = 650 𝑥 0.62 = 4.84 ≈ 5 i=5

 Traction Element
Proportions of traction element is as shown in figure.
Thickness of ply = i x thickness of 1 ply = 5 x 2 = 10mm
Assuming , Top thickness, tt = 4mm
Bottom thickness, tb = 2mm
Figure: Traction Element
Total thickness, T = 10 + 4 + 2 = 16mm

 Idler Design:
Assuming 50 mm margin on both sides,
∴ B = 3L – 100 ∴650 = 3L – 100 ∴L = 250 mm
Diameter of roller = φ140 x 250 mm
𝐿 150
Total no. of troughing idlers = = = 94
𝑆𝑝𝑎𝑐𝑖𝑛𝑔 1.6

Total idlers = 100 x 3 = 300

For returning idlers, Figure: Troughing Idler
L = B + margin = 650 + 100 = 750mm
Dimensions of returning idlers = φ140 x 750 mm
150
Total no. of returning idlers = 3
= 50

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

Total weight acting on troughing idler = (Gg + Gb + Gro) x spacing

W’ = (25.71 + 9 + 15.375) x 1.6 = 80.136 kgf
Middle idlers generally take 70% of total load,
W= 0.7* 80.136 = 56.09kgf = 561 N
UDL, Wo = (25.71 + 9 + 15.375) = 50.085 kgf/m = 0.5 N/mm
L1 = 250mm , L2 = 150mm ( Assuming margin for bearing block)
Fig: Idler cross section
Calculation for maximum bending moment at the centre,
𝐿1 2 𝑊 𝐿2 2502 561 150
𝐵𝑀𝑚𝑎𝑥 = 𝑊𝑜 𝑥 − 𝑥 = 0.5 𝑥 − 𝑥
8 2 2 8 2 2

𝐵𝑀𝑚𝑎𝑥 = 𝑚𝑜𝑑(−17131.25) = 17131.25 𝑁. 𝑚𝑚

Assuming thickness of idler as 2 mm, do =140mm, di=136mm,
Let, ds = Axle diameter = 25mm,
M 𝑀 ∗32 17131.25 ∗32
(σb ) = Z
= 𝑑 4 − 𝑑𝑖 4
= 1404 − 1364
= 0.5808 N/mm2,
π∗( 𝑜 ) π∗(
140
)
𝑑𝑜

(σb ) < [σb ], Hence, design is safe.

Figure: Force and BMD for idler

 Design of Bearing for idler:
Bearing inner diameter = 25mm (Assumed)
Forces acting on bearing are,
W 561
Fr = 2
=
2
= 280 N, Fa =0

Assuming working at room temp, nature of load as medium shock and life in hours as 15000Hrs,
Equivalent load, Peq = (X. V. Fr + Y. Fa ) S

Where, X =1, V = 1.2, S = 1.2,

Peq = (1.2 *280 *1.2) = 403.2 N
𝑣 ∗ 60 1.21 ∗ 60
𝑁= = = 165.07 𝑟𝑝𝑚
𝜋 𝑑𝑜 𝜋 ∗ 0.140
Lhr ∗N∗60 15000 ∗ 165.07 ∗ 60
Assuming life of bearing as 15000 Hrs, Lmr = 106
= 106
= 148.56 mr,
1
also k=3 for Ball bearing, Dynamic load carrying capacity, C = Peq (Lmr )k = 403.2* (148.56) (1/3)

C = 2135.44 N, C = 213.5 Kgf,

Selecting DGBB, No. 6005 with d= 25mm, D= 47mm, width =12mm and C =780Kgf

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

 Design of Axle for idler:

Let the material for axle be C-25, with
[σb ]=60 N/mm2, [σcr ]=90 N/mm2
Axle diameter, d= 25mm, d1 =bearing inner diameter = 25mm,
d2 = 20mm (assumed)
L1 = 150mm (from idler design)
L2 = Rigid support span = Idler length + margin+ frame width
L2 = 250 +10+10 = 270mm ( Assuming frame thickness =10mm)
Figure: Idler shaft, force and BMD
Load acting W/2 = 280 N
𝑊 𝐿2−𝐿1
𝐵𝑀 𝑚𝑎𝑥 ( )∗ 280 ∗60 𝑁
2 2
Checking for bending failure, (σb ) = Z
= π∗d3
= = 6.338 𝑚𝑚2
2650.7
32

(σb ) < [σb ] hence, safe

𝑊/2 280 𝑁
Checking for crushing failure, (σcr ) = d2∗Frame thickness = 20∗10
= 1.4 𝑚𝑚2 < [σcr ] hence, safe

 Head Pulley
D1 = k1.k2.i
Let k1 = 1.4 (factor for ply material), k2 = 100, θ >180, i =5
Diameter of pulley = 1.4 x 100 x 5 = 700 mm
𝜋𝐷𝑁 60 𝑥 𝑉 60 𝑥 1.21
V= ∴N= = = 33 rpm
60 𝜋𝐷 𝜋 𝑥 0.7

Assuming , tw=10mm, tr = 6 to 8 mm
B1= B + margin = 650 +100= 750mm
Let’s design Shaft for pulley ,
Let material for shaft be C-25/C30, Permissible stress [τ]= 30 N/ mm2
B1
𝑃 𝑥 60 18.5 𝑥 1000 𝑥 60
Torque T = = = 5.354 x 106 N.mm
2𝜋𝑁 2𝜋 𝑥 33 Figure : Section of a Pulley
Let bearing span , Lb1= 1.25 x B1= 1.25 x 750 = 937.5 ≈ 938𝑚𝑚
Total load F = T1 + T2 = 19514.2+ 8165.2 = 27679.4 N, i.e. Total load acting F = 27.68 KN
Bending Moment M = F.Lb1/4 = (27679.4 x 938) / 4,

M = 6.5 x106 N.mm , Teq = √𝑀2 + 𝑇2 = √(6.5 𝑥10^6)2 + (5.356𝑥10^6)2

Teq = 8.422 x106 N.mm

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[τ]= Teq / (π/16.ds3) , 30 = (8.422 x106 x 16) / ( π ds3)

Solving ds= 112.65 mm, To account for key effect, ds =1.1x 112.65 = 123.9mm, Selecting ds = 130mm
Diameter of hub = Length of hub = 1.5 ds = 195 𝑚𝑚

 Bearing Design:
Loads acting on the bearing are, Radial load Fr
Fr = W/2 = (T1 + T2)/2 = (27679.4)/2 = 13839.7N and Axial Load, Fa = 0
Equivalent Load is given by , Peq = (XVFr + YFa) x S …………..PSG 4.4
Assuming Race rotation factor V = 1 (inner race rotates) ,
Radial Load factor X =1.2 and Service factor S = 1.2
Peq = 1 x 1.2 x 13.84 x 1.2 = 19.93 kN
Assuming life of bearing as Lhr = 8000 hrs
𝐿ℎ 𝑥 𝑁 𝑥 60 8000 𝑥 33 𝑥 60
Lmr = 106
= = 14.4 millions of revolutions,
106

Dynamic Load Capacity required , C = (Lmr)1/k x Peq = (14.4)1/3 x 19.93 = 48.487 kN = 4848.7 kgf
Selecting suitable bearings as SKF 6026, d = 130 mm, D=200mm, B =33mm, C= 8300 kgf

 Snub pulley:
Need: To improve lap angle
Location: Slack side of head pulley
Size of snub pulley = 0.6 x Diameter of head pulley = 0.6 x 700 = 420 mm

 Checking for Arresting Mechanism

Resistance to belt on the top run for conveying down is given by
Wo = CPL [(Gg + Gb) cosδ + Gro] - H(Gg + Gb)
Wo = 1.6 x 0.02 x 150 [(25.71 + 9) cos 15 + 15.375] – 38.82[25.71 + 9] = -1112.71 kgf
The value obtained is negative, an arresting mechanism will be required for the setup.

 Tension take up Unit

The tension take-up unit is required to maintain the tension in belt. The simplest form of it is gravity
loaded tension take-up unit. To determine the tensioning weight required ( TR ) with 180 degree arc of
contact, using the relation,

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TR = 2T2-TTR
Where, T2 – Slack side tension, TTR – Weight of tension roller
TR = 2 x 816.52 - 50 ( Assuming weight of tension roller as 60Kgf)
The tensioning weight required ( TR ) = 1583Kgf

Fig: Tension take up system

SUMMARY
Belt
Belt width: 650 mm, Vact = 1.21m/s, No of plies: 5
Total thickness of traction element: 16 mm, Motor Power: 18.5 KW
For carrying idler:
Length of roller: 250 mm, Diameter of roller: 140 mm, Total no. idlers: 300
do = 140mm, di = 136mm
For returning idler:
Length of roller: 750 mm, Diameter of roller: 140 mm, Total no. idlers: 50,
Bearing for idlers: DGBB, No. 6005
Axle for idlers: d = 25mm
Shaft and head pulley: Diameter = 700 mm, Width = 750mm, Hub length = Hub diameter = 195,
Shaft diameter = 130mm
Bearing for pulley: SKF 6026, d = 130 mm, D=200mm, B =33mm, C= 8300 kgf
Snub pulley : D = 420mm

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

Numerical 4. DESIGN OF BELT CONVEYOR SYSTEM WITH THE FOLLOWING SPECIFICATION

Material to be carried – dry sand

Capacity Q = 100 TPH
Lump size = 150 mm
Inclination angle = 150
Centre To Centre distance = 100 m
Solution:
The belt conveyor system (BCS) consists of:
1. Drive unit
2. Pulleys
3. Belts
4. Idlers
5. Arresting mechanism and take up arrangement

Fig: Belt Conveyor System

 Belt width selection and speed calculation
𝑄 100
Design capacity , [Q] = 0.9 = = 111.11 TPH ≈ 110 TPH
0.9

Material properties
Density of dry sand = ῥ = 1.4 – 1.65 tonnes/m3 …………..PSG 9.22 ,Table 6
Let density of dry sand = 1.5 tonnes/m3
Maximum Inclination angle 𝜕 max = 180 ……………PSG 9.22 Table 6
Angle of repose = 450 ……..PSG 9.22 Table 6
𝜕 = 15 < 𝜕 max hence Acceptable
Using relation, B = X * amax + 200
Where, B= belt width , amax= lump size, X = 2 for ungraded material and X = 3.3 for graded material
Considering ungraded material,
B = 2 * 150 + 200 = 500 mm
1⁄
𝑄 2
Also, B min = 1.11 {ῥ c v} +0.05 ……PSG 9.18

Where v = belt speed in m/s

c = factor for type of idler
Let v = 1.5 m/s …….. PSG 9.20, Table 3

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Assuming trough angle 250, therefore c = 510 ……….PSG 9.18

1
110 2
Bmin = 1.11 {(1,5 𝑥 1.5 𝑥 510) + 0.05 }

Bmin = 399.17 mm
Selecting standard belt width, B = 500, Vmax = 3 m/s
Substituting B= 500 mm in above formula,
𝑄 110
Vact = 2 = 2
𝐵𝑚𝑖𝑛 0.5
(( )−0.05) ∗𝑣∗𝑐) (( )−0.05) ∗1.5∗510)
1.11 1.11

Vact = 0.8966 m/s < Vmax = 3 m/s

 Drive unit
W0 = c f L [( Gg + Gb ) cos 𝜕 + Gro ] + H (Gg + Gb) ……..PSG 9.18
Wu = c f l [ (Gg cos 𝜕 ) + Gru ] – H.Gb ……..PSG 9.18
Where,
𝑤𝑜 =resistance of belt on top run, kgf
𝑤𝑢 = resistance of belt on bottom run, kgf
𝐺𝑔 =weight of conveyed material per meter length, kgf/m
𝐺𝑏 =weight of belt per meter length, kgf/m
𝐺𝑟𝑜 = Weight of straight idlers on bottom run, kgf/m
Gru = Weight of troughing idler on top run, kgf/m
L= conveyor length, m
F= friction between idler and belt
C= secondary resistance factor = 1.78 for L = 100 m;
f = 0.02 for standard conveyor
C = 1.4 …………. PSG 9.18 graph
𝑄 110
𝐺𝑔 = 3.6 𝑥 ʋ = 360 𝑥 1.5 = 20.37 kgf / m …………. PSG 9.23

𝐺𝑏 = Weight of belt per meter length = 6.5 kgf …………..PSG 9.19

Considering tube diameter = 125mm and bearing diameter =25 …………..PSG 9.19, table3
Gru = 10.7 kgf / idler assembly, Gro = 20 kgf / idler assembly
Maximum spacing of idler is 1.5 m for top run and 3 m for return idler.

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20 10.7
Gro = = 13. 33 kgf / m , Gru = = 3.56 kgf / m
1.5 3

Height through which material is to be lifted, H

H= 𝐿𝑠𝑖𝑛𝛿
Taking L = 100 m
H = 100 sin 15 = 25.881 m

W0 = 1.78 ∗ 0.02 ∗ 100 [((20.37 + 6.5) cos 15 + 13.33) + 25.881 (25.37)] Figure: Belt Inclination

W0 = 835.25 kgf

Wu = 1.78 ∗ 0.02 ∗ 100((20.37) cos 15 + 3.56) − 25.881(6.5)

Wu = - 85.5kgf
P = Wo + Wu = 750 kgf
Motor Power = P x V= 7500 * 0.8966 = 6.724 kW
Selecting Standard motor = 7.5 kW ……….. PSG 5.124

 Force Analysis
(T1 – T2) V = Power
T1= max. tension in belt, kgf
T2= tension in slack side, kgf
V=velocity of belt, m/s
𝑇1
= 𝑒 𝜇𝜃
𝑇2
Assume coefficient of friction between belt and pulley, µ=0.25 and angle of lap 200 degree,
𝜋
𝑇1
𝑇2
= 𝑒 (0.25∗200∗180) , 𝑇1 =2.393𝑇2 ….(1)

(𝑇1 − 𝑇2 ) = 836.5 kgf ….(2)

From (1) & (2), 𝑇2 = 600.5 kgf and 𝑇1 =1437 kgf Tt
Ti
Tb
 Traction element
i = no. of plies, B
𝑇
i = 𝐵 1𝑓

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

Selecting Belt for density 1.5 tones/m3 and belt width of 500mm as 32 OZ fabric belt,
(imin = 4 and imax =5)
Now working tension in conveyor belt for 32 OZ fabric belt and vulcanised joint and gravity take-up
arrangement is f = 0.62 ……..Table 4, 5, PSG 9.21
𝑇1 1437
Substituting values of T1, B and f , No. of plies, i = = = 4.635, selecting i= 5
𝐵 𝑓 500∗0.62

Let thickness of each ply= 3 mm for fabric strength of 400𝑁/𝑚𝑚2

𝑡𝑖 = Total thickness of ply = 5*3 = 15mm
Top thickness = 𝑡𝑡 = 2 mm
Bottom thickness = 𝑡𝑏 = 1mm
𝑻𝒐𝒕𝒂𝒍 𝒕𝒉𝒊𝒄𝒌𝒏𝒆𝒔𝒔 (𝒕) = 𝑡𝑖 + 𝑡𝑡 + 𝑡𝑏 = 𝟏𝟖 𝒎𝒎

 Idler Design

 Troughing idler
The troughing idler angle is assumed as 250 and the material to be transported is stone i:e a bulk material

Let the material for idler be C-20, with [σb] = 60Mpa,

Shape is tubular and provision for bearing block

Belt Width = B = L + (2L − 100), 500 = 3L − 100

Length of troughing idler, L= 200mm,
Troughing Idler Size: φ125 * 250mm
Total no. of troughing idler systems = L / spacing = 100/1.5 =66.66 = 67
Total no. of troughing idlers = 3 * 67 = 201
Total weight acting on troughing idler,

W ′ =(Gg + Gb + Gro ) ∗ spacing

W ′ = (20.37 + 6.5 + 13.33) *1.5 = 60.3 kgf

Middle idlers generally take 70% of total load,
W= 0.7* 23.48 = 42.21 kgf = 422 N
UDL, Wo = (20.37 + 6.5 + 13.33) = 40.2 kgf/m = 0.402 N/mm
L1 = 200mm , L2 = 140mm ( Assuming margin for bearing block)
Fig: Idler cross section
Calculation for maximum bending moment at the centre,

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𝐿1 2 𝑊 𝐿2 2002 422 140

𝐵𝑀𝑚𝑎𝑥 = 𝑊𝑜 𝑥 8
− 2
𝑥 2
= 0.402 𝑥 8
− 2
𝑥 2

𝐵𝑀𝑚𝑎𝑥 = 𝑚𝑜𝑑(−12760) = 12760𝑁. 𝑚𝑚

Assuming thickness of idler as 1.5 mm, do =125mm, di=122mm,
ds = Axle diameter = 25mm,
db = bearing outer diameter = 47 mm (from bearing design)
M 𝑀∗32 12760 ∗32
(σb ) = Z
= 𝑑 4 − 𝑑𝑖 4
= 1254 − 1224
= 0.718 N/mm2 ,
π∗( 𝑜 ) π∗(
125
)
𝑑𝑜

(σb ) < [σb ], Hence, design is safe. Figure: Force and BMD for idler

(Note: As the induced stresses are very low, the material like thermoplastic PVC can be used for idlers.)
 Returning Idler:
(For returning idler, material load is not present hence assumed as safe under different failure, the
bearing and the bearing selected for troughing idler can be used for returning idler also.)

Length of returning idler, L2 = B + Margin = 500 + 50 = 550mm

Returning idler φ140 * 550 mm
Total no. of returning idlers = L / spacing = 100/3 = 33.33 = 34

 Design of Bearing for idler:

Bearing inner diameter = 25mm (Assumed)
Forces acting on bearing are,
W 422
Fr = 2
= 2
= 211N, Fa =0

Assuming working at room temp, nature of load as medium shock and life in hours as 15000Hrs,
Equivalent load, Peq = (X. V. Fr + Y. Fa ) S

Where, X =1, V = 1.2, S = 1.2,

Peq = (1.2 *211 *1.2) = 303.84 N
𝑣 ∗ 60 0.8966 ∗ 60
𝑁= = = 136.99 𝑟𝑝𝑚
𝜋 𝑑𝑜 𝜋 ∗ 0.125
Lhr ∗N∗60 20000 ∗ 136.99 ∗ 60
Assuming life of bearing as 20,000 Hrs, Lmr = 106
= 106
= 164.39mr,

k = 3 for Ball bearing, Dynamic load carrying capacity,

1
C = Peq (Lmr )k = 303.84 * (164.39) (1/3)

C = 1664.44 N, C = 166.4Kgf,
Selecting DGBB, No. 6005 with d= 25mm, D= 47mm, width =12mm and C =780Kgf

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Design of Mechanical System / MEC801 / Semester VIII / Mechanical Engineering / Mumbai University.

 Design of Axle for idler:

Let the material for axle be C-20, with
[σb ]=60 N/mm2, [σcr ]=90 N/mm2
Axle diameter, d= 25mm, d1 =bearing inner diameter = 25mm,
d2 = 20mm (assumed)
L1 = 140mm (from idler design)
L2 = Rigid support span = Idler length + margin+ frame width
L2 = 200 +10+10 = 220mm ( Assuming frame thickness =10mm) Figure: Idler shaft, force and BMD
Load acting W/2 = 211N
𝑊 𝐿2−𝐿1
𝐵𝑀 𝑚𝑎𝑥 ( )∗ 211 ∗60 𝑁
2 2
Checking for bending failure, (σb ) = Z
= π∗d3
= = 4.776 𝑚𝑚2,
2650.7
32

(σb ) < [σb ] hence, safe

𝑊/2 211 𝑁
Checking for crushing failure, (σcr ) = d2∗Frame thickness = 20∗10
= 1.055 𝑚𝑚2 < [σcr ] hence, safe

 Head Pulley
Diameter of head pulley is given by, D1 = k1.k2.i
Let k1 = 1.4 (factor for ply material), k2 = 100 for θ >180 o, i =5
Diameter of pulley = 1.4 x 100 x 5 = 700 mm
𝜋𝐷𝑁 60 𝑥 𝑉 60 𝑥 0.8966
V= ∴N= = = 24.46 rpm
60 𝜋𝐷 𝜋 𝑥 0.7

Assuming , tw=10mm, tr = 6 to 8 mm
B1= B + margin = 500 + 50= 550mm
Let’s design Shaft for pulley ,
Let material for shaft be C-25/C30, Permissible stress [τ]= 25 N/ mm2
B1
𝑃 𝑥 60 7.5 𝑥 1000 𝑥 60
Torque T = = = 2.93 x 106 N.mm
2𝜋𝑁 2𝜋 𝑥 24.46
Figure : Section of a Pulley
Let bearing span , Lb1= 1.25 x B1= 1.25 x 550 = 687.5 ≈ 688𝑚𝑚
Total load F = T1 + T2 = 14370+ 6005 = 20375N, i.e. Total load acting F = 20.38 KN
Bending Moment, M = F.Lb1/4 = (20375 x 688) / 4, M = 3.5 x106 N.mm ,

Teq = √𝑀2 + 𝑇2 = √(3.5 𝑥10^6)2 + (2.93𝑥10^6)2

Teq = 4.565 x 106 N.mm

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[τ]= Teq / (π/16.ds3) , 25 = (4.565x106 x 16) / ( π ds3)

Solving ds= 97.6mm, To account for key effect, ds =1.1 x 97.6 = 107.36mm, Selecting ds = 110mm
Diameter of hub = Length of hub = 1.5 ds = 165 𝑚𝑚
 Bearing Design:
Loads acting on the bearing are, Radial load Fr
Fr = W/2 = (T1 + T2)/2 = (20375)/2 = 10187.5N and Axial Load, Fa = 0
Equivalent Load is given by , Peq = (XVFr + YFa) x S …………..PSG 4.4
Assuming Race rotation factor V = 1 (inner race rotates) ,
Radial Load factor X =1.2 and Service factor S = 1.2
Peq = 1 x 1.2 x 10.19 x 1.2 = 14.6736 kN
Assuming life of bearing as Lhr = 10000 hrs
𝐿ℎ 𝑥 𝑁 𝑥 60 10000 𝑥 24.46 𝑥 60
Lmr = 106
= 106
= 14.676 millions of revolutions,

Dynamic Load Capacity required , C = (Lmr)1/k x Peq = (14.676)1/3 x 14.6736 = 35.93 kN = 3593 kgf
Selecting suitable bearings as SKF 6022, d = 110 mm, D=170mm, B =28mm, C= 6400 kgf

 Snub pulley:
Need: To improve lap angle
Location: Slack side of head pulley
Size of snub pulley = 0.6 x Diameter of head pulley = 0.6 x 700 = 420 mm
Fig: Snub Pulley

 Checking for Arresting Mechanism

Resistance to belt on the top run for conveying down is given by
Wo = CPL [(Gg + Gb) cosδ + Gro] - H(Gg + Gb)

W0 = 1.78 ∗ 0.02 ∗ 100 [((20.37 + 6.5) cos 15 + 13.33) − 25.881 (25.37)]

W0 = -516.75 kgf
The value obtained is negative, an arresting mechanism will be required for the setup.

 Tension take up Unit

The tension take-up unit is required to maintain the tension in belt. The simplest form of it is gravity
loaded tension take-up unit. To determine the tensioning weight required ( TR ) with 180 degree arc of
contact, using the relation,

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TR = 2T2-TTR
Where, T2 – Slack side tension, TTR – Weight of tension roller
TR = 2 x 600.5 - 50 ( Assuming weight of tension roller as 50Kgf)
The tensioning weight required ( TR ) = 1151Kgf
DESIGN SUMMARY: Fig: Tension take up system

Sr. No Component Parameter Dimension

1 Design Specification Design capacity 220 TPH

2 Material Coal

3 Material Density 0.7

4 Inclination 15

5 Centre to Centre distance 100 m

6 Belt Width 500 mm

7 Speed 0.8966 m/s

8 Thickness 18mm

9 Number of ply 5

10 Motor Rated power 7.5 KW

12 Head and Tail Pulley Diameter 700 mm

13 Snub Pulley Diameter 420 mm

14 Shaft Diameter 110 mm

15 Bearing Bearing number SKF 6022

16 Dynamic Load carrying capacity 6400 kgf

17 Troughing Idler Diameter 125 mm

18 Spacing 1.5 m

19 Number of idlers 201

20 Length 200 mm

21 Returning idler Diameter 125 mm

22 Spacing 3m

23 Number of idlers 34

24 Length 550 mm

25 Tension Take-up unit Load 1151 kg

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References
1. Material Handling Equipment by M.P.Alexandrov, MIR publisher, Moscow.
2. Material Handling Equipment, Michael G. Kay, North Carolina State University, January 12, 2012
3. RULMECA, Technical information for project and design criteria for belt conveyers
4. ‘Design and Selecting the Proper Conveyer belt’, Konakalla Naga Sri Ananth, Vaitla Rakesh, E-
ISSN 0976-3945
5. Selection and Design of Belt Conveyers- Code of Practice’, IIS 11592 (2000)
6. Design Data book , P.S.G College of Technology, Coimbatore
7. https://en.wikipedia.org/wiki/Conveyor_belt
8. http://www.conveyorkit.com/papers/Belt%20Conveyors/paper2.html
9. http://precisionconveyor.org/beltconveyor.htm

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