6

7
8
9
2

5
1
3 4
 Flight
Length Cumulative No. of Pulley Pulley Pulley
Flight Description (ft) Length (ft) Lift (ft) Pulley Dia.(in) Shaft Dia. Weight(lbf)
2 Loading 0.0 0 9.84 1 13 2.95276 716.5015
3 Carrying 59.39 59.39 -10.95 1 13 2.95276 716.5015
4 Carrying 127.94 187.34 0.00
5 Carrying 127.94 315.28 0.00 1 16 3.74016 881.848
6 Carrying 67.27 382.54 12.47
7 Carrying 0.00 382.54 0.00 1 16 3.74016 881.848
8 Carrying 1.97 384.51 0.00
9 Carrying 7.87 392.39 -1.52 1 13 2.95276 716.5015
1 Carrying 0 384.51 -9.84 1 13 2.95276 716.5015

Initial
Initial step iteration Update
Flight / Initial dT tension final dT tension belt to
Station Description (lbf) (lbf) (lbf) (lbf) 1200 PIW
1 Loading
2 Carrying
3 Carrying
4 Carrying
5 Carrying
6 Carrying
7 Carrying
8 Carrying
9 Drive/Active head pulley
10 Return
11 Return
12 Return
13 Return
14 Return
15 Return
16 Return
17 Return
18 Bend Pulley
19 Gravity takeup pulley
20 Bend pulley
21 Tail Pulley

Pulley Diameter, D 24 inch

Idler diameter, d 6 inch
Belt Thickness, t 1 inch
 Loaded
Percent Belt Conveyor Conveyor conveyor
Loaded skirt seal Cleaners V-Plow length(ft) length(M) length(ft)
9.84 3.0 0.00
60.39 18.4 0.00
1 127.94 39.0 0.00
100 127.94 39.0 127.94
100 3 68.41 20.9 68.41
0.00 0.0 0.00
1 1.97 0.6 0.00
8.02 2.4 0.00
9.84 3.0 0.00
Total 414.36 126.3 Total 196.35

Update
Update to to drive
1.5% sag Tmin
limit (lbf)
 Loaded
conveyor
length(M)
0.0
0.0
0.0
39.0
20.9
0.0
0.0
0.0
0.0
59.8
 Energy Main
Skirtboard Belt on
Material seal Idler Belt Idler
Acceleration( friction(lbf Idler seal bearing Deformation alignment
Flight No. Lift(lbf) lbf) ) drag(lbf) losses(lbf) (lbf) friction(lbf)

2 49.212 0.0 0.0 0.0 0.0 0.0 0.0

3 -54.741 0.0 0.0 20.1 0.2 1.2 1.6
4 0.000 0.0 0.0 43.3 0.4 2.5 3.4
5 0.000 0.0 0.0 108.2 1.3 8.9 10.9
6 201.962 10.2 177.2 56.9 0.7 4.7 5.7
7 0.000 0.0 0.0 0.0 0.0 0.0 0.0
8 0.000 0.0 0.0 0.7 0.0 0.0 0.1
9 -7.595 0.0 0.0 0.0 0.0 0.2 0.0
1 -49.212 0.0 0.0 0.0 0.0 0.0 0.0
 Point
Tension
Pulleys as provided by Cumulative
Material Belt Belt Passive drive Total
Skirtboard trampling Cleaners Discharge Point Total Pulley(T e
) Tension(lbf
Friction(lbf) loss(lbf) (lbf) Plows(lbf) Losses (lbf) Tension (lbf) (lbf) )
Take up weight 460.0
0 0.0 0.0 0.0 12.1 61.3 521.3
0.0 0.00 0.0 0.0 10.0 -21.8 499.5
0.0 0.00 130.0 0.0 0.0 179.6 679.1
0.0 17.99 0.0 0.0 10.1 157.3 836.4
1.5 6.09 0.0 0.0 0.0 464.9 1301.3
0.0 0.00 0.0 0.0 14.1 14.1 -939.6 375.8
0.0 0.00 130.0 0.0 0.0 130.8 506.5
0.0 0.00 0.0 0.0 10.1 2.7 509.2
0.0 0.00 0.0 0.0 0.0 -49.2 460.00

Te 4.18 KN

67.1623
16.7987
Cumulative Cumulative
Total Belt Total
Tension(lbf) Error Sag(%) Belt Sag Rmz Tension(KN) Cw
2.046
521.3 0.00000 0.00 0.000 34.4 2.3
499.5 0.00000 1.23 0.012 34.0 2.2
679.1 0.00000 0.91 0.009 34.1 3.0
836.4 0.00000 0.95 0.010 34.1 3.7
1301.3 0.00000 0.61 0.006 34.1 5.8
375.8 0.00000 0.00 0.000 34.4 1.7 0.400
506.5 0.00000 1.21 0.012 34.0 2.3
509.2 -0.00020 1.21 0.012 34.0 2.3
460.00 -0.00020 0.00 0.000 34.4 2.0
Torque(Lbf) Power(HP) Power(KW)

616.54669692 5.604970 4.2037275

 Energy Main

Skirtboard Belt on
Material seal Idler Belt Idler
Acceleration( friction(lbf Idler seal bearing Deformation alignment
Flight No. Lift(lbf) lbf) ) drag(lbf) losses(lbf) (lbf) friction(lbf)

2 49.212 0.0 0.0 0.0 0.0 0.0 0.0

3 -54.741 0.0 0.0 20.1 0.2 1.2 1.6
4 0.000 0.0 0.0 43.3 0.4 2.5 3.4
5 0.000 0.0 0.0 108.2 0.4 2.5 3.4
6 62.336 0.0 177.2 56.9 0.2 1.3 1.8
7 0.000 0.0 0.0 0.0 0.0 0.0 0.0
8 0.000 0.0 0.0 0.7 0.0 0.0 0.1
9 -7.595 0.0 0.0 0.0 0.0 0.2 0.2
1 -49.212 0.0 0.0 0.0 0.0 0.0 0.0
 Point

Pulleys as Tension Cumulative

Material Belt Belt Passive provided by Total
Skirtboard trampling Cleaners Discharge Point Total drive Pulley(Te) Tension(lbf
Friction(lbf) loss(lbf) (lbf) Plows(lbf) Losses (lbf) Tension (lbf) (lbf) )
Take up weight 460
0 0.0 0.0 0.0 12.1 61.3 521.3
0 0.0 0.0 0.0 10.0 -21.8 499.5
0 0.0 130.0 0.0 0.0 179.6 679.1
0 0.0 0.0 0.0 10.1 124.5 803.6
0 0.0 0.0 0.0 0.0 299.7 1103.3
0 0.0 0.0 0.0 12.8 12.8 -740.5 375.6
0 0.0 130.0 0.0 0.0 130.8 506.3
0 0.0 0.0 0.0 10.1 2.9 509.2
0 0.0 0.0 0.0 0.0 -49.2 460.0

Te 3.29 KN
Take up 2.05 KN
67.1623
16.7987
Cumulative Cumulative
Total Belt Total
Tension(lbf) Error Sag(%) Belt Sag Rmz Tension(KN) Cw

521.3 0.00000 0.00 0.000 34.4 2.3

499.5 0.00000 1.23 0.012 34.0 2.2
679.1 0.00000 0.91 0.009 34.1 3.0
803.6 0.00000 0.99 0.010 34.1 3.6
1103.3 0.00000 0.72 0.007 34.1 4.9
375.6 0.00000 0.00 0.000 34.4 1.7 0.5072
506.3 0.00000 1.21 0.012 34.0 2.3
509.2 0.00066 1.21 0.012 34.0 2.3
460.0 0.00066 0.00 0.000 34.4 2.0
Torque(Lbf) Power(HP) Power(KW)

485.890923 4.417190 3.3128927

 Types of losses
Energy Main Point

Belt on Pulleys as Tension

Skirtboard Idler Passive provided Cumulative
Material seal Idler Belt alignment Material Belt Belt Point Total by drive Cumulative Cumulative Total
Acceleration friction(lbf Idler seal bearing Deformation friction(lbf Skirtboard trampling Cleaners Discharge Losses Tension Pulley(Te) Total Total Belt Belt Tension(K Torqu Power Power
Flight No. Lift(lbf) (lbf) ) drag(lbf) losses(lbf) (lbf) ) Friction(lbf) loss(lbf) (lbf) Plows(lbf) (lbf) (lbf) (lbf) Tension(lbf) Tension(lbf) Error Sag(%) Sag Rmz N) Cw e(Lbf) (HP) (KW)
460.0 2.046
2 49.212 0.0 0.0 0.0 0.0 0.0 0.0 0 0.0 0.0 0.0 12.1 61.3 521.3 521.3 0.00000 0.00 0.000 34.4 2.3
3 -54.741 0.0 0.0 20.1 0.2 1.2 1.6 0.0 0.00 0.0 0.0 10.0 -21.8 499.5 499.5 0.00000 1.23 0.012 34.0 2.2
4 0.000 0.0 0.0 43.3 0.4 2.5 3.4 0.0 0.00 130.0 0.0 0.0 179.6 679.1 679.1 0.00000 0.91 0.009 34.1 3.0
5 0.000 0.0 0.0 108.2 1.3 8.9 10.9 0.0 17.99 0.0 0.0 10.1 157.3 836.4 836.4 0.00000 0.95 0.010 34.1 3.7
6 201.962 10.2 177.2 56.9 0.7 4.7 5.7 1.5 6.09 0.0 0.0 0.0 464.9 1301.3 1301.3 0.00000 0.61 0.006 34.1 5.8
7 0.000 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.00 0.0 0.0 14.1 14.1 -939.6 375.8 375.8 0.00000 0.00 0.000 34.4 1.7 0.400 616.5 5.60 4.204
8 0.000 0.0 0.0 0.7 0.0 0.0 0.1 0.0 0.00 130.0 0.0 0.0 130.8 506.5 506.5 0.00000 1.21 0.012 34.0 2.3
9 -7.595 0.0 0.0 0.0 0.0 0.2 0.0 0.0 0.00 0.0 0.0 10.1 2.7 509.2 509.2 0.00000 1.21 0.012 34.0 2.3
1 -49.212 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.00 0.0 0.0 0.0 -49.2 460.0 460.00 0.00000 0.00 0.000 34.4 2.0

Te 4.18 KN
Take up 2.05 KN
67.1623
16.7987
Passive Stopping Drift
Total Material weight 2071.81814 (lbf)
Total belt weight 2199.08096 (lbf)

Moving Mass Wet 34728.12 (lbm)

28768.13 (lbm) 82.83814 %
Motor GD 2
0.108 Kg-m 2

2.6 lb-ft2
Motor Speed 1900 rpm
Gear Box Ratio 39.79

Met 1078.51 slug 893.4202 slug

Acceleration, a 0.871 ft/sec2
Time, t 3.77 sec
Drift distance,Ld 6.18 (ft)

Material accumulation at the time of belt stopping 3.05 (ft3)

Startup

Maximum belt tension should not be 150% of rated belt tension

Starting time should be less than 10s for motor over heating problem

Belt allowable tension 6969.1 (lbf)

Max. belt tension at acceleration 10453.61 (lbf)
Tension of drive pulley at tight side 1301.3 (lbf)
Tension for belt acceleration 9152.3 (lbf)
Startup time 0.320 sec
Time should not be less than that time to avoid high belt tension

Motor power 10 (hp)

Torque provided at the tme of starting 1.8 times
Tension provided by motor 3957 (lbf)
Acceleration 4.43 (ft/s2)
Time required 0.740725 (sec)
This time should be less than motor starting time for motor over heating

Stopping
 Input Parameters

Parameter Values Unit

1 Q (tph), Capacity 60 (tph)
2 BW, Belt Width 26 (in)
Total Belt Length(ft) 0 (ft)
3 1.01.00 Wm (lb/ft) = Distributed gravity load of bulk material along length of belt. 11.2 (lb/ft)
4 1.01.00 Wb (lb/ft) = Distributed gravity load of belt along length of belt. 5.0 (lb/ft)
6 1.02.00 Hd(ft) = hight between two belts 5.0 (ft)
7 1.02.00 θi (deg.)Material Flow Angle 0.0 (deg.)
8 1.02.00 Vo = 0 (default value) 1077 (ft/min)
9 1.02.00 V = Belt speed, ft/min 196.8 (ft/min)
10 2.01.01 Css = number of rolls per idler set 6 (lbf/ft)
11 2.01.02 nr = number of rolls per idler set 3 (nos)
12 2.01.02 TF (°F) = Operating ambient temperature 166.68 (°F)
13 2.01.02 Sin (ft) = Idler spacing in flight ‘n’ Carrying Side 3.937 (ft)
13 2.01.02 Sin (ft) = Idler spacing in flight ‘n’ Return side 9.8425 (ft)
14 2.02.02 E0 (psi) = Rubber stiffness property, Table 6.28 1644 (psi)
15 2.02.02 Dr (in) = Roll diameter 6 (in)
16 2.02.02 hb (in) = Belt cover thickness 0.125 (in)
17 2.02.02 wi = Load distribution factor, Table 6.26 1.36
18 2.02.04 Cs (lbf/ft/in2) = Consolidated skirt friction and material property, Table 6.40 0.12 (lbf/ft/in2)
19 2.02.04 L(ft) = length of Skirt 9.8425 (ft)
20 2.02.04 ϕs = Material surcharge angle. (degrees when used with a trig function and in
radians when used alone.) 20 (deg.) 0.35 (rad)
20 2.02.04 β (deg) = Idler trough angle. 35 (in) 0.61 (rad)
21 2.02.04 Bc (in) = Idler center roll length. Figure 6.39 15 (in)
22 2.02.04 Ws (in) = Skirtboard spacing. Figure 6.39 17 (in)
23 2.02.04 dms (in) = Depth of material sliding on the skirtboard,as per Figure 6.39,chapter 4 0.7 (in)
page63
24 2.03.01 dm (in) = Maximum material depth at center of belt, Reference Chapter 4,page 62 4.8 (in) 120.7 (mm)
26 2.03.01 γm (lbf/ft3) = Density of bulk material, Reference Chapter 3 22.65 (lbf/ft3)
27 2.03.01 Cmz = Net material friction loss factor per Table 6.45 3.3
28 2.03.01 Rmz = Correction between actual sag and catenary sag per Equation. 6.44 2.5755
29 2.03.02 Vc (ft/min) = The critical maximum belt speed without causing material liftoff (ft/min)
30 2.03.02 Tmn (lbf ) = Minimum tension in flight ‘n’ equation. 6.65 797.22 (lbf )
31 2.03.02 Eb (lbf/in) = Longitudinal Belt Modulus(Table 7.33) 62,000 (lbf/in )
32 3.01.00 tb (in) = Conveyor belt thickness 0.394 (in)
33 3.01.00 Dpn (in) = Pulley ‘n’ diameter 15.7 (in)
37 3.02.00 m = Number of belt cleaners in flight n 2 (nos)
38 3.02.00 Cbcm (lbf/in) = Frictional resistance from belt movement under cleaner pressure 5 (lbf/in )
39 3.02.00 µbcm = Sliding friction factor between belt and the cleaner blade = 1.0 for default use 1
40 3.02.00 Fbcm (lbf/in) = Effective normal force between belt and cleaner 5 (lbf/in )
The historical CEMA value of Cbc = 5.0 lbf/in of belt width may be
considered as a nominal value
41 3.02.00 Dn (in) = Pulley diameter 15.7 (in)
Mp (lbf) = Pulley Weight 881.8 Lbf
42 A θn (radians) = Belt wrap on pulley n per Figure 6.60 3.67 (rad.)
43 A f = Coefficient of friction between pulley surface and belt surface 0.25
Design f values for rubber covered belts are as follows
0.25 rubber surfaced belt driving bare steel pulley
0.35 rubber surfaced belt driving rubber lagged pulley surface
0.50 for dimpled ceramic or equivalent hard material
Belt Tension calculation

ΔTn = ΣΔTenergy n + ΣΔTmain n + ΣΔTpoint n

ΔTenergy = ΣΔTHn + ΣΔTamn

ΔTMain n = ΣΔTssn + ΣΔTisn + ΣΔTiWn + ΣΔTbin + ΣΔTmn + ΣΔTsbn + ΣΔTsn + ΣΔTmzn

ΔTpoint n = ΣΔTpxn + ΣΔTprn + ΣΔTbcn

∆Tn (lbf ) = Total change in belt tension to cause steady belt speed
∆THn (lbf ) = Change in belt tension to lift or lower the material and belt
∆Tamn (lbf ) = Tension added in loading to continuously accelerate material to belt speed
∆Tssn (lbf ) = Tension change due to the belt sliding on skirtboard seal
∆Tisn (lbf ) = Change in tension from idler seal friction
∆TiWn (lbf ) = Change in tension from idler load friction
∆Tbin (lbf ) = Tension increase from visco-elastic deformation of belt
∆Tmn (lbf ) = Tension loss from idler misalignment
∆Tsbn (lbf ) = Drag due to Slider Beds
∆Tsn (lbf ) = Tension change due to bulk materials sliding on skirtboards
∆Tmn (lbf ) = Tension change due to bulk materials moving between the idlers
∆Tpxn (lbf ) = Tension change due to belt bending on the pulley
∆Tprn (lbf ) = Tension change due to pulley bearings
∆Tbcn (lbf ) = Tension added due to belt cleaners and plows
∆Tdpn (lbf ) = Tension added due to discharge plow

1.00.00 Change in energy

1.01.00 Material lift

THn = Hn x (Wb + Wm)

Hn = tan(θin) x Ln

Wb = Belt weight
Wm = material Weight
Ln = length of flight

1.02.00 Chute Loading(material acceleration)

Tamn = (Q/(gx108)) x (V-Vo sin(θi))

Vo = ( 2gHd) 0.5
 Hd = hight between two belts
Vo = 0 (default value)

2.00.00 Main Resistances

2.01.00 Load indendent Friction

2.01.01 Skirtboard seal friction

Tssn = Css x Ln
Css = 2 x μss x Fss

Css = Frictional resistance to the belt movement.

Typical value of μss =1.0 & Fss= 3 lbf/ft

2.01.02 Idler seal drag

Tisn=[(3.82 x V)/Dr - 500) x Kiv + Kis ] x 1/(Dr/2) x Kit x (nr/Sin) x Ln

Tisn/Ln = 0.85 (Carrying)
0.34 (Return)
nr = number of rolls per idler set 3
Dr = idler roll diameter 6
Kis as per table 6.19 4
Kiv as per table 6.19 0.004

Kiv (in x
table:-6.19 Idler Series Kis (in x lbf ) lbf / rpm)
B 3.00 0.004
C 3.25 0.004
D 4.00 0.004
E 7.25 0.003

Tf = ambient operating temperature 166.68 (°F)

Kit = temperature correction factor
Kit=1.114 x 10-8x Tf4-3.763 x 10-6 Tf3+4.458 x 10-4 Tf2-2.136x 10-2 Tf + 1.333 1.330902

Sin (ft) = Idler spacing in flight ‘n’ 3.936996 (Carrying)

9.84249 (Return)
2.02.00 Load depended friction

2.02.01 Idler bearing losses

Tiwn = Ciw x (Wb + Wm)/(Dr/2) x Ln

Tisn/Ln = 0.0099897
Tisn/Ln = 0.0030833 (empty conveyor)
 Ciw as per table 6.21

Deep
groove
ball
Table:- 6.21 Idler series Taper roller bearing
B 0.00155 0.00125
C 0.0017 0.00145
D 0.0017 0.00185
E 0.0029 0.00255
Idler Classification
Classification Roll Diameter (in) Belt Width (in)
B4 4 18 through 48
B5 5 18 through 48
C4 4 18 through 60
C5 5 18 through 60
C6 6 24 through 60
D5 5 24 through 72
D6 6 24 through 72
E6 6 36 through 96
E7 7 36 through 96
F6 6 60 through 96
F7 7 60 through 96
F8 8 60 through 96

2.02.02 Belt Deformation

Tbin = Kbir x Pjn x (Wb + Wm) x Wi x Ln

Tbin/Ln 0.06948
0.01967
Pjn=[{(Wb+Wm)x Sin x hb} / {EO(Dr/2)2 x BW}]1/3 0.0274675 (carrying)
0.0251935 (empty Conveyor)
Kbir = b0+b1x[1+tanh{b2+b3x(log(V)+aTexp)}] 1.15E-01

aTexp=a0+a1xTf+a2xTf2+a3xTf3+a4xTf4+a5xTf5 -2.56E-02
Tf 0.00 (shoul be taken as 166.68 deg.F etc. same as input data f
V = Belt speed, ft/min
Fabric Belts Steel cable Belts
Table:- 6.28 n an bn an bn
0 -0.025600 0.0720 -0.025600 0.1400
Constants for 1 -0.057400 0.0290 -0.057400 0.0290
equation 6.27, 2 0.000106 -1.7500 0.000106 -1.7500
KbiR with 3 -2.61E-06 1.0000 -2.61E-06 1.0000
E0 = 1,644 psi 4 3.20E-08 3.20E-08
5 -1.03E-10 -1.03E-10
 E0 = Rubber stiffness property
E0 = 1644 psi

∆Tbin (lbf ) = Tension increase from viscoelastic deformation of the belt cover
TF (°F) = Operating ambient temperature
KbiR = Viscoelastic characteristic of belt cover rubber -Equation 6.29
Pjn = Cover indentation parameter (dimensionless)
E0 (psi) = Rubber stiffness property, Table 6.28
Dr (in) = Roll diameter
hb (in) = Belt cover thickness
wi = Load distribution factor, Table 6.26

Load distribution factor Wi table

Belt and material

Table:26 Troughing Angle 20 deg. 35 deg 45 deg. Flat

Wi 1.28 1.36 1.39 1.14
Belt Only

Troughing Angle 20 deg. 35 deg 45 deg. Flat

Wi 1.265 1.406 1.465 1

2.02.03 Belt on Idler alignment friction

ΔTimn = Cim x Ln x (Wb + Wm)

ΔTimn/Ln 0.085260624303938
0.026315789473684
Cim = Cbi x eim Cbi = 0.5 sliding friction factor for steel roll on rubber belt cover
Cbi = 0.75 sliding friction factor for rubber roll on rubber belt cover
Cim 0.005263157894737
eim = ΔAe/As
eim 0.010526315789474
ΔAe = ΔAei + ΔAem + ΔAet
ΔAe 0.6

ΔAe = Effective Total deviation from perpendicular to belt travel in inch

ΔAei = Expected average installation misalignment in inch
= 0.375 for permanent rigid structure with deliberate angular alignment procedures
= 0.5 when installed without alignment measurement
= 0.75 in. when mounted on independent, imprecise footings
 ΔAem = Effective misalignment due to manufacturing variation in inch
0.1 in for variation from parallel of wing rolls to the center roll on a common idler set
See idler discussion later in this chapter.

ΔAet = Effective misalignment due to Intensional inclination of idler frame δ it in inch

As = Distance between idler support points in the belt width direction in inch
As =2 x( bwmc x BW) cos(Φs)+2 x 2.33 x 2 + bc x BW 26.67952 57
δit (in/in) = Intentional inclination of idler frame or wing roll to aid in belt tracking
δit = 0 (tangent of inclination angle in degrees) (inch/inch)

ΔAet =2 x Awc/Asc x δit x tan (β) x As

ΔAet 2 x (1/6) x 0 x tan (β) x As 0
Awc/Asc = 1/6 for equal roll idler

2.02.04 Skirtboard Friction

ΔTsn = Cs x dms 2 x Ln 0.508

Cs (lbf/ft/in2) = Consolidated skirt friction and material property, Table 6.40

dms (in) = Contact depth of material on skirting, Figure 6.41

Table: 6.40 Material Cs Factor

Alumina, pulverized, dry 0.121
Ashes, coal, dry 0.057
Bauxite, ground 0.188
Beans, navy, dry 0.08
Borax 0.073
Bran, granular 0.024
Cement, Portland, dry 0.212
Cement clinker 0.123
Clay, ceramic, dry fines 0.092
Coal, anthracite, sized 0.054
Coal, bituminous, mined 0.075
Coke, ground fine 0.045
Coke, lumps and fines 0.019
Copra, lumpy 0.02
Cullet 0.084
Flour, wheat 0.027
Grains, wheat, corn or rye 0.043
Gravel, bank run 0.115
Gypsum, 1/2" screenings 0.09
Iron ore, 200 lbs/cu ft 0.276
Lime, burned, 1/8" 0.117
Lime, hydrated 0.049
Limestone, pulverized, dry 0.128
Magnesium chloride, dry 0.028
Oats 0.022
 Phosphate rock, dry, broken 0.018
Salt, common, dry, fine 0.081
Sand, dry, bank 0.137
Sawdust, dry 0.008
Soda ash, heavy 0.07
Starch, small lumps 0.062
Sugar, granulated dry 0.034
Wood chips, hogged fuel 0.009

Ws

φs

Am dms

Bc

Fig. 6.41

dms = Am x 144 -0.25(Ws2-Bc2) x tan(β)-0.25Ws2[φs/sin(φs)2-cot(φs)]

Am is the material cross section area in ft2.

Am = Q x 2000 / V x γm x 60

γm (lbf/ft3) = Density of the bulk material.

ϕs = Material surcharge angle. (degrees when used with a trig function and in radians when
used alone.)
β (deg) = Idler trough angle.
Bc (in) = Idler center roll length. Figure 6.39
Ws (in) = Skirtboard spacing. Figure 6.39
dms (in) = Depth of material sliding on the skirtboard. skirtboard per Figure 6.39

2.03.00 Load and tension dependent friction

2.03.01 Material trampling loss

ΔTmzn = Wmzn x Ln / Sin2
ΔTmzn/TnLn 0.133816346374349
0.041292605799296 (empty conveyor)
Wmzn = 1/124 x dm3 x γm x Cmz x BW [ exp[(Wb + Wm) x Sin/Tn]-1] x exp[-1/2 x (Wb + Wm) x Sin/Tn] x Rmz
2.07414500581817
 0.640032809267049 (empty conveyor)

∆Tmzn (lbf ) = Tension loss in flight n from internal movements in the bulk material
Wmzn (ft-lbf ) = Belt work required to cause material movement from one idler to the next
dm (in) = Maximum material depth at center of belt, Reference Chapter 4
Tn (lbf ) = Belt tension in flight n
γm (lbf/ft3) = Density of bulk material, Reference Chapter 3
Cmz = Net material friction loss factor per Table 6.45
Rmz = Correction between actual sag and catenary sag per Equation. 6.44

For troughed fabric carcass belt

Rmz = 1/12 x exp[4.181-1.572(BW/(Sin x 12))1.5-1.0827Δysn0.5] 2.575472 ### check

For all flat belt conveying

Rmz = 1/12 0.083

∆ysn (%) = Average catenary belt sag for flight n as a percentage of the idler spacing:

∆ysn = Sin x (Wb + Wm) / 8Tn x 100

Δysn 1.00 0.01
Angle of
Repose
Table: 6.45 Flowability (Ref. Table 3.3) (deg) Cmz
Material friction loss factor CVery Free Flowing 0 to 19 1.5
Average Flowing 20 to 25 2.1
Average Flowing 26 to 29 2.5
Average Flowing 30 to 34 3.3
Average Flowing 35 to 39 4.2
Sluggish 40 to 45 5.7

2.03.02 Lift off loss

Vcn = [5 / (-2 x C1n+C1n x Sin x 12 x C3n)] x [C1n(-2+Sin x 12 x C3n)]0.5

Vcn 39 ft/min

Vc (ft/min) = The critical maximum belt speed without causing material liftoff
C1n, C1in, and C3n = Functions in Equation 6.49
g = 32.2 ft/sec2

C1in = (Wm + Wb) / ( 8 x Tm x 0.371 x 12 ) 0.0001761

C1n = 1 / (233.67 + 0.255/C1in + 64.3745/(BW/(Sin x 12))2) 0.0005279

 C3n = 1.8123-0.004476(Eb)0.5- 558.3/(Eb)1.5 0.6977488

dm (in) = Maximum material depth at center of belt

Tmn (lbf ) = Minimum tension in flight ‘n’
Eb (lbf/in) = Longitudinal Belt Modulus

3.00.00 POINT SOURCES OF TENSION

3.01.00 Pulleys as Passive Point Losses

ΔTpn = ΔTpxn + ΔTPRN

ΔTpfn = 9 x BW(0.8+ 0.01 x Tn/BW) x tb/Dpn

For fabric carcass belt

ΔTPRN = 0.01 x (dsn / Dpn) x Rpn

∆Tpn (lbf ) =Tension added by pulley n

∆Tpxn (lbf ) = Tension added to belt from belt to flex over pulley n
x = Subscript in ∆Tpxn;
‘f’ for Fabric Carcass belt
‘s’ for Steel Cable belt construction
∆TPRN (lbf ) = Resistance of pulley ’n’ bearings, lubricant, and seals
tb (in) = Conveyor belt thickness
Dpn (in) = Pulley ‘n’ diameter
dsn (in) = Pulley n shaft diameter
Rpn (lbf ) = Resultant radial load (vector sum of belt tensions and pulley weight) of pulley ‘n’
Tn (lbf ) = Belt tension at the pulley ‘n’
Rrp = Pulley drag, can vary up to Rrp = 0.67

3.02.00 Belt Cleaners

ΔTbcn = BW x Σ Cbcm 130 lbf

Cbcm = μbcm x Fbcm

∆Tbcn (lbf ) = Tension change due to the ‘m’ belt cleaners sliding on flight n
m = Number of belt cleaners in flight n
Cbcm (lbf/in) = Frictional resistance from belt movement under cleaner pressure
µbcm = Sliding friction factor between belt and the cleaner blade = 1.0 for default use
Fbcm (lbf/in) = Effective normal force between belt and cleaner
The historical CEMA value of Cbc = 5.0 lbf/in of belt width may be
considered as a nominal value
3.03.00 Belt Discharge Plows

ΔTdpn = 0.8 x BW 20.8 lbf

3.04.00 Active tension contribution

ΔTen = Tqn x 12 / (Dn/2)

Tqn (ft-lbf ) = The active torque provided to the pulley
Dn (in) = Pulley diameter

A Belt minimum Tension

ΔTemn = Tmn x (efθa -1)

∆Temn (lbf ) = Maximum belt tension change possible at pulley n

Tmn (lbf ) = Minimum tension at pulley n
e = Base of naperian logarithms = 2.718
θn (radians) = Belt wrap on pulley n per Figure 6.60
f = Coefficient of friction between pulley surface and belt surface
Design f values for rubber covered belts are as follows
0.25 rubber surfaced belt driving bare steel pulley
0.35 rubber surfaced belt driving rubber lagged pulley surface
0.50 for dimpled ceramic or equivalent hard material

Cw = 1/ (efθ - 1.0) = T2 / Tθ
0.38361418929184 0.399925890091592
θ wrap
Table: 6.62 Type of drive Pulley deg. Automatic take up Manual take up
Bared Lagged Bared
Pulley Pulley Pulley
Table of common Single, no Snub 180 0.84 0.5 1.2
wrap factors, Single with Snub 200 0.72 0.42 1.0
Cw (rubber belt 210 0.66 0.38 1.0
covers) 220 0.62 0.35 0.9

1. For wet belts and smooth lagging use bare pulley factors.
2. For wet belts and grooved lagging use lagged pulley factors.
3. If wrap is unknown assume the following: Single no Snub = 180°, Single with Snub = 210°.

B Belt Sag Between Idlers

ΔYs =W x Si / 8 x Tmn
ΔYsn =(Wb + Wm) x Sin / 8 x Tn
Δysn =((Wb + Wm) x Sin / 8 x Tn ) x 100
 ∆Ys (ft) = Vertical drop between idlers for flight n
∆ys (%) = Vertical drop between idlers for flight n as a % of the idler spacing
Wb (lbf/ft) = Belt weight per foot of length
Wm (lbf/ft) = Material weight per foot of length
Tmn (lbf ) = Minimum Belt tension in flight n
Sin (ft) = Idler spacing in flight ‘n’

Tmn = 12.5 x Sin( Wb + Wm) / Δys 797.218 lbf

Tmn (lbf ) = Minimum tension to meet sag percentage rule

Table:6.66 Idler Trough Angle (deg)

Material Lump Size 20 35 45
All Fines 3.00% 3.00% 3.00% Recommended belt
50% of Maximum per Fig 4.1 3.00% 3.00% 2.00% sag percentage for
100% of Maximum per Fig 4.1 3.00% 3.00% 1.50% various full load
conditions
C High acceleration and deceleration force

Moving Mass

Wet = Wbt + Wmt + Σ (Wr x Ki2 x ( 2 x π x Ni / V )2)

Met = Wet / g
ΔTa = Met x a
a = ΔTa / Met
ΔV = a x t x 60
Vt =V - ΔV

Ta (lbf ) = Accelerating or decelerating (-) force provided to the moving conveyor

Met (slugs) = Equivalent mass of moving parts of the conveyor and load
Wet (lbf ) = Total equivalent weight of moving parts of the conveyor and load
Wr x Ki2(2π Ni/V)2 (lbf ) = equivalent translating weight of rotating part i
Wbt (lbf ) = Total weight of the belt=Wb*Lb
Wmt (lbf ) = Total weight of the bulk material on the belt=Wm*Lm
Wi (lbf ) = Weight of rotating component i, lbs
Ki (ft) = Polar Moment of Inertia or effective radius of rotating component i, ft
Ni (rpm) = Rotational speed of component i, rpm
Lb (ft) = Total length of the belt, usually twice the conveyor length, or 2*L
Lm (ft) = Total loaded length of the belt, varies between 0 and total conveyor
length L
i = Index for each individual rotating component including drive components
(n for pulleys)
g (ft/sec2) = Acceleration of gravity = 32.2
a (ft/sec2) = Acceleration
 V (fpm) = Nominal belt velocity or velocity before time t
∆V (fpm) = Change in belt velocity during time interval t
Vt (fpm) = Transient belt velocity after time t.
t (sec) = Time interval being analyzed

D Passive Speed Change

a = ΣΔTen / ΣMe

t = ΔV / a

Ld = ΔV / 2 x t/60

Σ∆Ten (lbf ) = Total tension added before stopping initiated

ΣMe (slugs) = Total effective moving mass, reference Equation 6.67
t (sec) = Stopping time
∆V (ft/min) = Change in belt speed
Ld (ft) = Drift distance

Implications of passive stopping or drift include;

1. Emergency stopping time should be considered for its safety implications.
2. Short drift time can be an indicator of the potential for high dynamic tensions to develop. This is
discussed as a Transient Tension effect.
3. The amount of material discharged may flood a receiving conveyor.

E Material Discharge during stopping

Md = Ld x Wm / 2000

Md (tons) = Material discharged during stopping

Wm (lbf/ft) = Weight of the bulk material on the belt

F Active Speed Change - Acceleration/Deceleration

ΔTa = ΔTet -( ΔTef -ΔTei )

∆Ta (lbf ) = Tension available to cause speed change

∆Tet (lbf ) = Temporary or transient active tension provided by the drive
∆Tef (lbf ) = ∆Tef required at the new speed
∆Tei (lbf ) = Initial ∆Te before the speed change

G Speed of Tension Change

Vw = (Eb/(Wb / (BW x g)))0.5 x 60

 Vw (ft/min)= Wave front velocity
Eb (lbf/in) = Longitudinal Belt Modulus
Wb (lbf/ft) = Weight of belt per unit length
BW (in) = Belt Width
g (ft/sec2) = 32.2

H Torque & Power

Tqn=ΔTem x ( Dn / 2) x 1/12

Tqn (ft-lb) = The active torque provided to the pulley

Dn (in) = Pulley diameter
ΔTem = Effective tension at drive pulley
V(ft/min) = Velocity
P(hp) = Power
P = ΔTem x V / 33000
etc. same as input data for other)
10 deg.
V return
NA

10 deg.
V return
1.45
Manual take up
Lagged
Pulley
0.8
0.7
0.7
0.6
Table: 5.19 Troughing Idler Spacing (Si) *
Belt Width Weight of material Handled, lbf/ft3
Suggested normal (inch) 30 50 75 100 150 200 Return Idler
spacing of belt 18 5.5 5 5 5 4.5 4.5 10
idlers (Si ) 24 5 4.5 4.5 4 4 4 10
30 5 4.5 4.5 4 4 4 10
36 5 4.5 4 4 3.5 3.5 10
42 4.5 4.5 4 3.5 3 3 10
48 4.5 4 4 3.5 3 3 10
54 4.5 4 3.5 3.5 3 3 10
60 4 4 3.5 3 3 3 10
72 4 3.5 3.5 3 2.5 2.5 8
84 3.5 3.5 3 2.5 2.5 2 8
96 3.5 3.5 3 2.5 2 2 8

* Spacing indicated in feet. Spacing may be limited by load rating of idler. See idler load ratings in Tables 5.30 – 5.36.

1.00.00 IDLER SELECTION

1.01.00 TYPE OF MATERIAL HANDLED

The weight of the material governs the idler load and spacing, and lump size modifies the effect of weight by
introducing an impact factor. Table 5.23 combines the unit weight and the lump size into a group of
empirical factors referred to as K1.

1.02.00 LUMP SIZE

For a 20 degree surcharge, with 10 percent lumps and 90 percent fines, the recommended maximum lump
is 1/3 the belt width (BW/3). With all lumps, the recommended maximum lump is 1/5 belt width (BW/5).
For a 30 degree surcharge, with 10 percent lumps and 90 percent fines, the recommended maximum
lump is 1/6 the belt width (BW/6). With all lumps, maximum lump is 1/10 the belt width (BW/10).

1.03.00 IDLER LOAD (Step No. 1) for troughing idlers and (Step No. 2) for return idlers.

TROUGHED IDLER
To select the proper CEMA class (series) of idler, it is necessary to calculate the idler load.
Select idler class by comparing calculated idler load with idler load ratings (CIL and CILR) from Tables
5.30 through 5.36. CEMA idler manufacturers have standard designs meeting these load ratings and
dimensional standards shown in tables listed in this publication.

Calculated Idler Load (lbf ) = CIL = ((Wb + (Wm x K1)) x Si) + IML
Where:
Wb = Belt weight (lbf/ft) use actual or estimate from Table 5.22

1.03.01 Table 5.22 Belt Width Material Carried, lbf/ft3

(in (BW)) 30-74 75-129 130-200
Wb = Estimated 18 3.5 4 4.5
Average Belt Weight, 24 4.5 5.5 6.5
Multiple and 30 6 7 8
Reduced Ply Belts 36 9 10 12
(lbf/ft) 42 11 12 14
48 14 15 17
 54 16 17 19
60 18 20 22
72 21 24 26
84 25 30 33
96 30 35 38
For steel cable belts increase the above values by 50%.

Q = Quantity of material conveyed (tons per hour)

V = Design belt speed (fpm)
Si = Spacing of idlers (ft)
K1 = Lump adjustment Factor (see Table 5.23)

Material
Lump
1.03.02 Table 5.23 Size (in) Material Weight, lbf/ft3
50 75 100 125 150 175 200
K1 = Lump 4 1 1 1 1 1.1 1.1 1.1
Adjustment Factor 6 1 1 1 1.1 1.1 1.1 1.1
8 1 1 1.1 1.1 1.2 1.2 1.2
10 1 1.1 1.1 1.1 1.2 1.2 1.2
12 1 1.1 1.1 1.2 1.2 1.2 1.3
14 1.1 1.1 1.1 1.2 1.2 1.3 1.3
16 1.1 1.1 1.2 1.2 1.3 1.3 1.4
18 1.1 1.1 1.2 1.2 1.3 1.3 1.4

NOTE: The actual weight of the lump should be compared with the Wm value. In certain situations it
may be necessary to use actual lump weight as Wm. Contact your CEMA idler manufacture if you have
doubts as to which value to use.
IML is the idler misalignment load (lbf ) due to idler height deviation and belt tension
IML = (D x T) / (6 X Si ) where: D
D = Misalignment (in) T
T = Belt Tension (lbf )
Si = Idler spacing (ft) Si Si
IML

RETURN IDLER
Calculated Idler Load (lbf ) = CILR= (Wb x Si) + IML

1.03.03 Table 5.30 Belt Width Trough Angle Single Roll

(in) 20° 35° 45° Return
load ratings 18 410 410 410 220
for CEMA B idlers, 24 410 410 410 190
lbf (rigid frame) 30 410 410 410 165
36 410 410 396 155
42 390 363 351 140
48 380 353 342 130
 Two Roll
"Vee"
Belt Width Trough Angle Single Roll Return
1.03.04 Table 5.31 (in) 20° 35° 45° Return
18 900 900 900 475
Load ratings for 24 900 900 900 325 500
CEMA C idlers, lbf 30 900 900 900 250 500
(rigid frame) 36 900 791 765 200 500
42 850 744 720 150 500
48 800 698 675 125 500
54 750 650 630 * 500
60 * 500
66 500

* Use CEMA D return idler.

Two Roll
"Vee"
Belt Width Trough Angle Single Roll Return
1.03.05 Table 5.32 (in) 20° 35° 45° Return
24 1200 1200 1200 600
Load ratings for 30 1200 1200 1200 600
CEMA D idlers, lbf 36 1200 1200 1200 600 850
(rigid frame) 42 1200 1200 1200 500 850
48 1200 1200 1200 425 850
54 1200 1116 1080 375 850
60 1150 1070 1035 280 850
72 1050 977 945 155 850
78 850

Two Roll
"Vee"
Belt Width Trough Angle Single Roll Return
1.03.06 Table 5.33 (in) 20° 35° 45° Return 1300
36 1800 1800 1800 1000 1300
Load ratings for 42 1800 1800 1800 1000 1300
CEMA E idlers, lbf, 48 1800 1800 1800 1000 1300
(rigid frame and 54 1800 1800 1800 925 1300
garland where 60 1800 1800 1800 850 1300
applicable) 72 1800 1800 1800 700 1300
84 1800 1674 1620 550 1300
96 1750 1628 1575 400 1300
102 1300

Notes:
1. Troughing idler load ratings (Tables 5.30 – 5.36) are for three equal length rolls.
2. Load ratings also apply to impact rolls.
3. Troughing idler load ratings are based on a load distribution of 70% on center roll and 15% on each
end roll for all trough angles.
4. Unequal length or picking idlers are not covered by this standard.
 Two Roll
"Vee"
Belt Width Trough Angle Single Roll Return
1.03.07 Table 5.34 (in) 20° 35° 45° Return **
60 3000 3000 3000 1500 **
Load ratings 72 3000 3000 3000 1200 **
for CEMA F idlers, 84 3000 3000 3000 900 **
lbf (rigid frame) 96 2800 2800 2800 600 **

** For "Vee" returns consider using CEMA E series.

1.04.00 IMPACT FORCES (Step 3)

When large lumps, greater than 2 inches, are present, the impact idler energy rating, WH, may become
a factor. Table 5.40 shows the minimum energy rating and the maximum lump size for each CEMA series
impact idler. Q

F
F = W + ( 2 x k x W x H) 1/2

If the conveyed material does not contain lumps, but instead is a homogeneous stream of material

F = 0.1389 x Q x H0.5

W = Weight of lump (lbf )

H = Height of fall (ft)
k = Spring constant for specific idler type (lbf/ft)
(Consult idler manufacturer for k)

Unit Impact Force(lbf) = Fu = F x f

Use this unit impact force, Fu, and select the proper series of impact idler from Tables 5.39 through 5.40.
Fu should be equal to or less than the idler rating.

Impact Idler Spacing, Impact Idler Spacing

1.04.01 Table 5.39 Si -impact(ft) Factor, f
Impact idler 1 0.5
spacing factor 1.5 0.7
2 0.9
> 2.0 1

1.04.02 Table 5.40 CEMA Series WH (lbf-ft) Maximum Lump Size (in)
B 40 4
Minimum energy C 160 6
ratings for impact D 240 8
idlers E 460 12
F 870 18

1.05.00 EFFECT OF LOAD ON PREDICTED BEARING L10 LIFE (Step 4)

When calculated idler load (CIL) is less than CEMA load rating of series idler selected, the bearing L10
life will increase. Figure 5.24 (Step No. 3) shows this relationship for either a tapered roller bearing or
 a ball bearing idler design. This chart can be used in conjunction with the type of service or life
expectancy of the conveyor system. If the specified design life of the conveyor system exceeds the
CEMA L10 life rating at rated load, it may still meet specification based on percent of rated idler load vs.
calculated idler load (CIL).

CEMA B load rating based on minimum L10 of 30,000 hours at 500 rpm
CEMA C load rating based on minimum L10 of 30,000 hours at 500 rpm
CEMA D load rating based on minimum L10 of 60,000 hours at 500 rpm
CEMA E load rating based on minimum L10 of 60,000 hours at 500 rpm
CEMA F load rating based on minimum L10 of 60,000 hours at 500 rpm

Find
K2 = CIL / Idler Load Rating(CILR)

From above list find B,C,D etc. idler life and multiply this bearing life with K2 to get actual bearing life
Find bearing life for both troughed and return idler

1.06.00 BELT SPEED (Step 5)

Roll Speed(rpm) = Belt speed(fpm) x 12 / Roll Diameter(in) x π

Select minimum roll diameter for < 500 rpm at belt speed at fpm from From Table 5.20

Roll Belt
Diameter Speed
1.06.01 Table 5.20 (in) (fpm)
4 534
Belt speeds at 5 654
500 rpm 6 785
7 916
8 1047

1.06.02 Find K3A (from Figure 5.25)

Actual Bearing Life will be = Bearing life after Load correction( K2 correction factor) x K3A
For both troughed and return idler

1.07.00 ROLL DIAMETER (Step 6)

For a given belt speed, using larger diameter rolls will increase idler bearing L10. Figure 5.26
shows this relationship.

If 5 inch bearing roll is selected after all previous calculations, now we awnt to make it 6 inch, then

Compare bearing L10 life increase for 6 inch diameter roll.

From Fig.5.26

(6 inch dia. Roll = 1.5) / (5 inch dia. Roll=1.25) = 1.2

So, 20 % increase in bearing L10 life

Example:
Troughing idler = (60,000 x 1.2) = 72,000 hours (60,000 L10 life coming after all calculations)
Return idler = (69,000 x 1.2) = 82,800 hours (60,000 L10 life coming after all calculations)
Idler CIL/(Idler
Misalignment( Load
in) IML(lbf) CIL(lbf) CILR(lbf) F(lbf) F(lbf) lump rating) L10 (Hours)
2 67.49799 87.18297 410 13.17721 9.944272 0.2126414 30000
 Actual
bearing
Life(hours) Roll dia.(in) Roll K3A (from K3B(from Density Idler(D1) Idler(D2)
K2 (fig.5.24) (Table:5.20) Speed(rpm) Fig.5.25) Fig.5.26) (lb/ft3) (in) (in)
10 300000 4 188 2.5 487 5.54331 5.11811
487 5.54331 5.11811
 WK2 or
Length GD2
(in) W(lbf) K(ft) (lbf/ft2) Ni(RPM) We(lbf)
29.688 29.78935 0.4445788654 5.887876 141.0527 119.3469
30.66 30.76467 0.4445788654 6.080648 141.0527 123.2544
 WK2 or
Density Pulley Pulley Length GD2
(lb/ft3) Dia(in) Dia(in) (in) W(lbf) K(ft) (lbf/ft2) Ni(RPM) We(lbf)
487 13 12 30.66 716.5015 1.043436 780.0973 60.05829 2866.715
487 16 16 30.66 881.848 1.317031 1529.628 47.57981 3527.939
Table 5.22 Belt Width Material Carried, lbf/ft3
(in (BW)) 30-74 75-129 130-200
Wb = Estimated 18 3.5 4 4.5
Average Belt Weight, 24 4.5 5.5 6.5
Multiple and 30 6 7 8
Reduced Ply Belts 36 9 10 12
(lbf/ft) 42 11 12 14
48 14 15 17
54 16 17 19
60 18 20 22
72 21 24 26
84 25 30 33
96 30 35 38

For steel cable belts increase the above values by 50%.

Belt weight 5

Belt edge distance:

the material load on the troughed belt does not extend to the belt edges. The distance from the edges of the
material load to the edges of the belt is set at "standard edge distance," which is defined as
0.055BW + 0.9 inch, where BW is the width of the belt in inches.

Table: 4.3

Belt Width (in) 18 24 26 30 36 42 48 54

Standard
Edge
distance(in) 1.89 2.22 2.33 2.55 2.88 3.21 3.54 3.87
e edges of the

60 72 84 96 108 120

4.2 4.86 5.52 6.18 6.84 7.5

 β
Φs Φ r

bwe
bwmc bw

bc

Si(ft) = Idler spacing (chapter 5)

Ys = ΔYs/Si dimensionless ratio for belt sag between idlers
g (ft/s2) = Acceleration due to gravity 32.2 ft/s2
β(deg.) Troughing Angle
Φs(deg.) Surcharge Angle

bwmc (in) = 0.2595 x BW - 1.025 Length of belt on wing roller in contact with material
bc (in) = 0.371 x BW + .25 length of belt on centre roll in contact with the material

bwmc 5.722 (in)

bc 9.896 (in)
 bc x BW

β
dm x BW Asc

bwexBW
bwmcxBW bw x BW

Φs Φs
rsch x BW rsch x BW

Fig. 4.9 Area of standard surcharge load cross section, Asc

Belt Size 26 (in)

Belt Speed 196.8 (ft/min)

Area of the tropezoid

Ab = [0.371 x BW + 0.25 + (0.2595 x BW + 1.025) x cosβ] x [ 0.2595 x BW -1.025) x sinβ]

Ab 53.37343 in2
Area of circular segment

As = [{0.1855 x BW +.125 + (0.2595 x BW -1.025) x cosβ}/sinΦs]2 x ( Л x (Φs/180) - sin(2Φs)/2)

As 26.87803 in2

Total area Asc (ft2) = (Ab + As)/144 0.55730184 ft2 80 % loading

length of the flat surface of the center roll averages 0.371 BW +.25, where BW is the belt width in
inches.

A(ft2) = Total material cross sectional area based on design criteria = (Q x 2000) / (V x γ x 60)
A 0.448494 ft2 Wm 11.19952 (lbf/ft)
Ass(ft2) = Total cross sectional area skirted profile.
Asc(ft2) = Cross sectional area based on the surcharge angle with circular top surface and a known edge distance
bc = Ratio of upper surface of belt above centre roll = (0.371 x BW + 0.25)/BW
bw = Ratio of upper surface of belt above wing roll = bwe + bwmc = (1-bc)/2
bwe = Ratio of upper surface surface belt edge above wing roll (0.055x BW +0.9)/BW
bwmc = Ratio of surface belt with material contact on it above wing roll
dm(in) = Maximum depth of material profile
β(rad) = Troughing angle(degrees when used with trig function otherwise radians)
Φs(rad) = Surcharge Angle(degrees when used with trig function otherwise radians)
Φr(rad) = Angle of repose(degrees when used with trig function otherwise radians)
Q(tph) = Design capacityin tons per hour
Q100(ft3/hr) = Equivalent capacity at 100fpm
V(fpm) = Belt speed
γ(lbf/ft3) = Bulk density of material
rsch = Ratio of effective radius of the top surface of the material based on surcharge angle compared to BW, belt width.
= (bc/2)/sin(Φs) + cos(β) bwmc/sin(Φs)

SF = Capacity design factor for reducing the capacity for design purpose
 rr = Ratio of effective radius of the top surface of the material based on angle of repose compared to BW, belt width
= (bc/2)/sin(Φr) +(cos(β) bwmc) /sin(Φr)

1.01.00 Calculation of total cross section area

Asc = 2 x BW2/144 x [rsch2 x (Φs/2 - sin(Φs) x cos(Φs)/2] + (bc/2 x (bwmc) x sin(β)] + bwmc2 x sin(β) x cos(β)/2]

1.02.00 CALCULATION OF EDGE DISTANCE WITH A MAXIMUM MATERIAL DEPTH ON BELT

bc 0.380615 (ratio)
bwe 0.089615 (ratio) 2.33 (in)
bwe = bw - bwmc

bwmc =( -b + (b2-4ac)0.5) / 2a 0.248107 (ratio) A is considered as Asc

bwmc =( -b + (b2-4ac)0.5) / 2a 0.207861 (ratio) A is considered as A

a = cos(β)2/sin(Φs)2 [Φs- sinΦs x cosΦs] + cosβ x sinβ 0.628579

b = bc x sinβ + bc x cosβ/sin(Φs)2 x [Φs- sinΦs x cosΦs] 0.289295
c =- 144 x A/BW2 + 1/4 bc2/sinΦs2 x [Φs- sinΦs x cosΦs] -0.11047 A is considered as Asc
c =- 144 x A/BW2 + 1/4 bc2/sinΦs2 x [Φs- sinΦs x cosΦs] -0.087292 A is considered as A (i.e. Actual
value of material cross section)
1.03.00 MAXIMUM MATERIAL DEPTH ON BELT

Maximum depth of belt , dm

dm = bd x BW
bd = bwmc sinβ +[( bc/2 )/ sin(Φs) + (cosβ bwmc/sin(Φs))] x (1-cosΦs)
bd 0.211701
0.182804
dm 5.50423 (in) 139.8074 mm
4.752897 (in) 120.7236 mm

1.04.00 MATERIAL CROSS SECTION AREA BETWEEN SKIRTBOARDS

The CEMA recommended skirtboard width to belt width ratio is 0.67 BW.

Belt
Table 4.10 Width(in) 18 24 30 36 42 48 54 60 72 84 96 108 120
Standard Standard
skirtboard skirt
widths width(in) 12 16 20 24 28 32 36 40 48 56 64 72 80

Ws

β
dms x BW Ass

bc x BW

Fig. 4.11 Skirt board cross sectional area Ass

Bs = Ws/BW
Check that skirt board width Ws is greater than central roll width, bc x BW

if bs>bc recalculate Asc as Ass using bwmc = bs - bc/2 x cosβ

Rectangular area is
As = A - Asc
dms = As x 144/Ws As in ft2

As = dms x Ws/144
The total area for a particular depth can be calculated from A = As + Ass

Ws 17.3 (in)
As 0.2 (ft2)
dms 1.6 (in)

dms = (Am x 144 - 0.25(Ws2 -Bc2) x tan(β) - 0.25 Ws2[Φs/sin(Φs)2 -cot(Φs)]) / Ws

0.6556463 (in)