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Inclined (ii)
(v)
Horizontal, Inclined &
Horizontal
(iii)
Horizontal +
Inclined
(iv)
Inclined +
Horizontal
(vi)
Inclined, Horizontal & Inclined
The program calculates all the dimensional details, after receiving the values of certain
input parameters, with respect to the selected profile.
(i)
(ii)
Input parameters to be provided for profile no.: c/c Horizontal length (m)
c/c Horizontal length (m)
Inclination (Deg) / Lift (m)
(vi)
2.
Following material characteristics are entered:Volumetric & power densities - These values are taken from CEMA for
respective materials. Sometimes for a material, two values are given, then lower
value is considered as volumetric density and the higher one as power density.
Volumetric bulk density is used to check capacity & power density to determine the
final power requirements.
Angles of surcharge & repose are also entered / taken from database as per
CEMA. Five options for angle of surcharge are 00, 100, 150, 200, 300.
Values of volume & power densities, angles of surcharge & repose can be
changed if required.
3.
This comes into picture only for conveyors having inclination & values are provided in
the program as per graph in IS-11592.
Capacity
Belt Speed
Belt width range consists of following belt widths in mm :400, 500, 650, 750, 800, 900, 1000, 1200, 1400, 1600.
4.
Belting Selection :Belt selection i.e. rating, duty will be as per DUNLOP catalogue
only.Min.belt widths for adequate troughing of empty belts for 35 0 troughing
2
For determining
Grade
M24
HR
SHR
UHR
FR
Factor
1.1
1.21
1.265
1.375
1.32
If material density exceeds 2.5 T/m3, same values of belt widths for 2.5T/m 3 are
assigned.
It also calculates top cover thickness of the belt -
1.5 mm
Abrasive
2 mm
Very abrasive
2.5 mm
We can also enter top/bottom cover thicknesses as per requirement.
After selecting min. belt rating, now we can calculate belt weight -
6.
400
500
600
650
750
800
900
1000
1200
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
3
3
3
3
3
3
3
3
3
1400
1600
1.0
1.0
0.75
0.75
3
3
76.1
88.9
114.3
127
139.7
152.4
4
4
5
5
6
6
Ai
A, B , C
2.3
A, B , C ,D
1.8
C, D
1.5
165.1
7
E
2.4
168.3
7
Now with respect to belt width and troughing angle duty type is decided i.e. whether
idler rating is A, B, C, D or E. These values tabulated below are interpolated from
CEMA for belt widths available in India.
A type - Belt Width (mm)
400
500
600
650
750
800
900
B type - Belt Width (mm)
400
500
600
650
750
800
900
1000
1200
C type - Belt Width (mm)
400
20
300
300
300
300
300
294
278
Troughing
30
300
300
300
295
282
275
259
Angle
35
300
300
300
295
282
275
259
20
410
410
410
410
410
410
410
399
382
Troughing
30
410
410
410
410
410
410
410
384
355
Angle
35
410
410
410
410
410
410
410
384
355
20
900
Troughing Angle
30
35
900
900
5
45
297
297
290
284
270
265
251
45
410
410
410
410
410
407
398
371
344
45
900
Return Idler
150
143
127
119
102
94
78
Return Idler
220
212
192
184
167
163
156
147
132
Return Idler
475
500
600
650
750
800
900
1000
1200
1400
900
900
900
900
900
900
872
807
741
900
900
900
900
885
843
812
750
690
900
900
900
900
885
843
812
750
690
20
1200
1200
1200
1200
1200
1200
1191
1125
1060
Troughing Angle
30
35
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1108
1108
1032
1032
986
986
20
1800
1800
1800
1800
1800
1800
1800
Troughing Angle
30
35
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1730
1730
900
900
900
900
878
819
785
726
667
45
1200
1200
1200
1200
1200
1200
1056
1013
954
45
1800
1800
1800
1800
1800
1800
1699
433
330
306
256
238
205
172
129
Return Idler
600
600
600
600
544
435
358
249
167
Return Idler
1000
1000
1000
912
813
715
616
Now, we get Ai value, once we fix the combination of [Duty type - Roller dia]
A, B, C, D, E
7.
4, 5, 6, 7 inches
(i)
Conveyor length
(ii) Wb + Wm
(iii)
Percent Slope
With respect to this data, decide primary value of Ky. But this is for certain
specific spacing. These idler spacings are in ft (3,3.5,4,4.5,5). Converting it to
metres, gives the values, which are nearly equal to generally recommended idler
spacings.
Then corrected Ky values are decided from next table in CEMA on pg 80.
Here correct idler spacing is used for a range of (Wb + Wm).
All the basic parameters required for calculating effective tension are now available
at this stage.
Default roller diameter for carrying, return & impact idlers are also put in the
program with respect to belt width, which are as follows :(This information is picked up from one of the enquiries of Grasim cements where the
consultants were Holtec ltd.)
Impact idler
Roller dia/Rubber ring OD
76.1/114.3
76.1/114.3
76.1/114.3
76.1/114.3
76.1/114.3
88.9/165
88.9/165
88.9/165
88.9/165
1400
1600
8.
152.4
152.4
139.7
139.7
114.3/190
114.3/190
developed = ___ ft
length (ft)
Screw
VGT
HGT
8
Head Pulley
Tail Pulley
Snub Pulley
Bend Pulley
Take up Pulley
Type of Pulley
Head/Drive
Tail/Take up
Snub/Bend
1
1
1
1
1
1
2
1
1
1
1
4
1
HGT
1000
1300
Force needed to accelerate the material as it is fed onto the belt Tam = Capacity (TPH) x 2204 x Belt speed (fpm) = _______ lbs
3600 x 32.2 x 60
Resistance due to belt cleaners = Resistance due to + Resistance due to
(Tbc)
external scrapper
internal scrapper
This factor is a constant as per CEMA = 5 x Belt Width (mm) x [2 +
25.4
2]
Effective tension, Te=Ty + Tyb (Tyc + Tyr) + Tym + Tm + Tp + (Tbc + Tsb) + Tam = ___ lbs
Now calculate T1 as follows :T1 = (1 + Wrap factor) x Te = __________ lbs
Following database is introduced - CEMA
Wrap angle over head pulley
VGT / HGT
Bare
lagged
pulley
pulley
9
Screw take up
Bare
Lagged
pulley
pulley
1800
2000
2100
2200
2400
0.84
0.72
0.66
0.62
0.54
0.5
0.42
0.38
0.35
0.54
1.2
1
1
0.9
0.8
0.8
0.7
0.7
0.6
0.6
60 - 80 %
Head
(H)
2.8 - 3.5
3.6 - 4.4
4.5 - 5.5
5.6 - 7.0
7.1 - 8.8
8.9 - 11.1
323
400
500
630
800
1000
Tail/
Bend
(T)
273
323
400
500
630
800
0 - 60 %
Snub
(S)
219
273
323
400
500
630
323
400
500
630
800
273
323
400
500
630
219
273
323
400
500
10
If wrap angles over head pulley & other pulleys also are not specified, then the
program will select the following tabulated valves -
Profile No
(v)
S V
H
(vi)
S V
H
<--------------------------------------------------------------------------------------------------------------------------->
<
--------------------------------------------------------------------------------------------------------------------------->
<----------------------------------------------------------30 0
by
-------------------------------------------------->
900 90
900+
900+
90 90
90 90
0
0
0
0
0
Angle
Angle
of
of
inclinati
inclinati
on
on
180 0
S
Head Pulley
a. without
snub
b. with
snub
Snub
Pulley
Bend
Pulley
(i)
V
(ii)
V
(iii)
V
(iv)
V
H
210 0
default
900+
Angle
of
inclinati
on
Motor KW required = Y x Motor service factor (1.15 Default value. Option open
to change)
Adapt a motor of next higher rating (KW )
10. Gear Box Selection :To consider Peripheral speed of the belt, while selecting gear box Pulley dia = Base pulley dia (mm) +
2[lagging thk mm) +(top+bottom cover thk(mm)) + carcass thk (mm)]
11
If gear box type is changed, accordingly efficiency will change & absorbed as
well as rated KW of motor will also change.
Once we specify the type of gear box, to arrive at proper size, the program follows the
following path Gear Box
Helical
Worm
Solid Shaft
Hollow Shaft
Bevel Helical
Solid Shaft
Hollow Shaft
NU
SBN/SCN
FSM It will go
Foot
Shaft KBN/KCN Foot
Shaft
downward while
mounted mounted
mounted mounted
selecting the correct
gear box size
SBH/SCH SBA/SCA
KBH/KCH KBA/KCA
The program will go from B to C i.e. from double to triple
reduction to select correct gear box size & ratio.
A separate gear box screen is introduced, which on getting the correct data selects
suitable gear box size Absorbed Power
Gear box selection based on
Rated Power
Default Option
Type of gear box
Worm
Helical
Bevel Helical
Shafting
Solid
Foot mounting
Hollow
Shaft mounting
Service factor
12
1.
Worm
Min. hp required for gear box = Absorbed/Rated motor x Gear box
hp
hp
service factor
= ___________ hp
Now the gear box ratio calculated, will not be always equal to or tally with the
standard ratios available.
Hence the program always selects the previous /lower gear box ratio.
Now with respect to this gear box ratio, & min. hp requirement, the program
selects the correct gear box size.
Due to reduction in gear box ratio, belt speed of conveyor will rise. Hence the
conveying capacity will increase for same belt width. There will also be a change in
motor power requirement, which increases from its original value.
Change in speed
Change in hp / New hp
Capacity increased/decreased
Hence, the program will always display the lower gear box ratio selected.
But if needed, we can select higher ratio & check whether capacity gets satisfied
or not. As we change ratio, corresponding charges will also be observed on the
screen. Only those ratios available in that particular series will get displayed.
2.
HELICAL/BEVEL HELICAL
Min. KW required for gear box = Absorbed/Rated motor KW x Gear box
service factor
Now with this KW and selected gear box ratio, program selects suitable size.
Selected ore
Drpurpm changed
=
=
Speed changed
1440
Drpurpm
___________ (Let it be X)
1440
X
x Dr.Dia x Drpurpm changed/60
13
Capacity increased = Area x increased speed x 3600 x material bulk density x Kf.
11.
Coupling selection :Input coupling is selected, once motor & gear box are finalised selection
procedure for three types of couplings is introduced in the program. (Fluid, bin
& bush & geared).
If,
1.
Fluid Coupling
Check, whether the coupling is with or without delay chamber. See motor KW
selected. Select the coupling with rating equal to or greater than the above
motor KW at 1450 rpm.
2.
Pin & bush / Geared Coupling
Input coupling torque = 716 x Rated motor x cplg service factor x 9.81(NM)
1440
Select the greater value among motor shaft dia & gear box input shaft dia with respect
to this greater value, decide the keyway portion in hub, as per the following database Shaft dia (mm) [From - upto & including)
45 - 50
51 - 58
59 - 65
66 - 75
76 - 85
86 - 95
96 - 110
111 - 130
131 - 150
151 - 170
171 - 200
201 - 230
23 - 30
31 - 38
3.8
4.3
4.4
4.9
5.9
5.4
6.4
7.4
8.4
9.4
10.4
11.4
3.3
3.3
14
39 - 44
3.3
Following two conditions are checked Shaft dia of motor as well as I/p gear box should be min.bore of coupling
max.bore of coupling
= Head Pulley dia (m) Force needed to lift the load (m)
2
- (Idler friction (Tx) + Resistance
of belt flexure over idlers (Tyb)
+ Resistance of material flexure
over belt (Tym)/2)
= ___________ lbs/ft
= __________ x 0.4536 x 0.3048 = ____________ Kg.m
Screw take-up
15
2.
Should consider
bare pulley dia (m)
VGT
Belt length = 2 x developed length (m) + 1 m +
[ Head Pulley dia + Tail Pulley dia + Take up dia ]
2
2
+ 0.025 x developed length (m) x 2 = __________ m
3. HGT
Belt length = 2 x developed length (m) + 1 m +
[ Head Pulley dia + Tail Pulley dia + Take up dia ]
2
2
+ 0.025 x developed length (m) x 2 = __________ m
Equivalent mass of rotating = (i) + (ii) + (iii) + (iv) + (v)
parts of a conveyor
= ___________ lbs 2.204 = ______________ kgs
(a)
Now,
i. Belt weight = Total belt length (ft) x Wb (lbs/ft) = __________ lbs
ii. Weight of rotating parts = Weight of rotating parts of unit idler (lbs)
of carrying idler
x Total developed length (ft)
Carrying idler spacing (ft)
iii. Weight of rotating parts = Weight of rotating parts of unit idler
of return idler
x Total developed length (ft)
Return idler spacing (ft)
iv. Material weight = Developed length (ft) x Wm = ____________ lbs
v. Equivalent weight of = 2/3 Tail pulley wt + Snub pulley wt (lbs) +
non-driving pulleys
+ Take-up pulley wt (lbs) + No of bends pulleys
x bend pulley wt (lbs)
G92 value of conveyor, reterred =
a
to motor shaft
x motor rpm (1440) 2
belt speed (m/sec) x 60
= _____________ kg.m2 Total G92 of conveyor
without motor at motor
shaft
16
= (x + y)
Mass of rotating parts of conveyor without drive m1 = a
9.81
= _________ kg/m/sec2
= ________ x 2.204
3.28
= __________ lbs.sec2
G92 value of drive unit = G92 of motor
+ Gear Box
+ Input Coupling
+ Output Coupling
Mass of Drive unit reterred
to belt line
= b
x x motor rpm (1440)
9.81 belt speed (m/sec) x 60
= ___________ Kg/m/sec2 = ________ x 2.204
3.28
2
= ___________ lbs.sec /ft
219
273
323
400
500
630
800
1000
Let G- starting force produced, by drive unit considering average starting torque 160 %
of motor rated torque.
G = 1.6 x motor hp x Gear box x 75
Belt Speed (m/sec)
17
= _____________ Kg.f
= ________ x 2.204
= _______________ lbs
Acceleration = G - Te =
lbs
m
lbs.sec2/ft
= _________ ft/sec2
Effective force during starting,
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
For calculating tensions of various points in the profile, it is assumed that snub
pulley is always present in the conveyor. Take up travel is considered 3% of
developed length in case of screw take-up & 2.5% in the case of VGT & HGT.
Separate calculations with respect to profile & type of take-up are introduced in
the program.
Profile No. 5 - (v) (Horizontal, inclined & horizontal), HGT (Elecon type)
32.2
= T2st + 100 + x mass of snub pulley x 2.204 + 5 x 2 x Belt width (mm)
32.2
25.4
= __________ lbs
T4st = T3st [0.015 x L4 (H) + 0.015 x L4(ft) x Wb (lbs/ft)] + x L4(ft) [Wb(lbs/ft) +
32.2
Wt. of rotating parts of unit return idler (lbs)]
= ___________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H5 (ft) x Wb(lbs/ft)
= ________ lbs
T6st = T5st + 100 + x mass of bend pulley x 2.204 = _________ lbs
32.2
T7st = T7st + 100 + x mass of take-up pulley x 2.204 = _________ lbs
32.2
T9st = T8st + 100 + x mass of bend pulley x 2.204 = __________ lbs
32.2
Considering four fall, wire rope arrangement, at take-up tower,
Min. counter weight = (T6st + T7st) x 2
= _____________ lbs/2.204 = ___________ Kgs.
(Make it a round figure, to ensure no slip)
From this calculated counter weight, fixed normal running full load belt tensions are
worked out as follows :T6 = Counter weight (lbs)/4 = ________ lbs = T7
T5 = T6 - 100
T4 = T5 - 100 + H5(ft) x Wb(lbs/ft) = ____________ lbs
T3 = T4 - [0.015 x L4(g) + 0.015 x L4 x Wb] = ________________ lbs
T2 = T3 - 100 = ______________ lbs
T1 = T2 + Te + 5 x 2 x Belt Width (mm) - H7 x Wb +
25.4
(0.015 x L10 + 0.015 x L10 x Wb(lbs/ft) = ______________ lbs
T11 = T10 + 100 = _______________ lbs
Profile No. 5 (v) VGT
Horizontal, Inclined & Horizontal
T1st = e . T2st
=
=
=
=
=
=
T1st = e . T2st
2.204
Normal running full load belt tensions :T6 = Counter weight = ___________ lbs = T5
2
T4 = T5-100 + H5 x Wb = ____________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100 = _________ lbs
T1 = T2 + Te + 5 x 2 x Belt Width (mm)/25.4 = ________ lbs
T7 = T6 + (H5 x Wb) = ________ lbs + 100
T8 = T7 + 5 x 2 x Belt width (mm) - H7 x Wb + (0.015 x l10 + 0.015 x Wb)= _____ lbs
25.4
T9 = T8 + 100 = ___________ lbs
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
= T2st.eo - T2st
= T2st (e0 - 1)
T2st = Test/(e0 - 1)
T1st = Test + T2st
T3st = T2st + 100 + x mass of snub pulley x 2.204 + Texternal scraper
32.2
= T2st + 100 + x mass of snub pulley x 2.204 + 5 x 2 x Belt width (mm)
32.2
25.4
= __________ lbs
T4st = T3st +[0.015 x l4 + 0.015 x l4 x Wb] + x l4 x [Wb + wt. of rotating parts of
32.2
unit return idler wt]
= -H5 x Wb = _____________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H6 x Wb = _________ lbs
32.2
T6st = T5st + 100 + x mass of bend pulley x 2.204 = ________ lbs
32.2
T7st = T6st + 160 + x mass of bend pulley x 2.204 = ________ lbs
32.2
T7 = T6 + 100 + H7 x Wb = ______________ lbs
T8 = T7 + 5 x 2 x Belt Width (mm) - H8 x Wb + [0.015 x l10 + 0.015 x l10 x Wb]
25.4
T9 = T8 + 100 = ___________ lbs
Profile No. (i) Horizontal - Screw take up
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
24
32.2
= T2st + 100 + x mass of snub pulley x 2.204 + 5 x 2 x Belt width (mm)
32.2
25.4
= __________ lbs
Assuming tension at the at tail pulley is at least equal to min. tension T0, for % seq Options - 2%
T4 = 6.25 Si (ft) [Wb + Wm] = _________ lbs
T5 = T4 + 100
T3 = T4 -[0.015 x l4+0.015 x l4 x Wb] = __________ lbs
T2 = T3 - 100
T1 = Te + T2 + 5 x 2 x Belt Width (mm) = _________ lbs
25.4
Profile (i)
Horizontal VGT
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
25
Screw Take up
26
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
=
=
=
=
Profile (ii)
VGT
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
27
T1st = e . T2st
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
28
T2st
T1st = e . T2st
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
Profile (i)
Horizontal VGT
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
T1st = e . T2st
31
Normal running full load belt tensions :T6 = Counter weight = ___________ lbs = T5
2
T4 = T5 - 100 + (H5 x Wb) = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100
T1 = Te + T2 + 5 x x Belt width (mm) = _________ lbs
25.4
T7 = T6 + 100 + (H5 x Wb) = ___________ lbs
T8 = T7 + 5 x 2 x Belt Width (mm) + (0.015 x l8 + 2.015 x l8 x Wb(lbs/ft)= _____ lbs
25.4
T9 = T8 + 100 = _________ lbs
HGT :
After calculating tensions at various points, with respect to profile, proceed with the
follwing :Rated belt tensions = ________________ (KN/m) width
= ________________ KN/belt width (m) (eg. 50 KN/m)
ex.
= 50 x 103
9.81
= _________ kgs x 2.204 = ___________ lbs (RBT)
Considering starting tensions is limited to 160 % of the rated belt tension :Then, allowable extra belt tension :32
Let addition of
these be X.
X = ___________ lbs
(X+A)
Test
:- with VGT/SCREW/HGT,
SCREW
Test = G x m1
= _________ lbs
34
T1st = e . T2st
Profile (i)
Horizontal VGT
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
35
T1st = e . T2st
Normal running full load belt tensions :T6 = Counter weight = ___________ lbs = T5
2
T4 = T5 - 100 + (H5 x Wb) = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100
T1 = Te + T2 + 5 x x Belt width (mm) = _________ lbs
25.4
T7 = T6 + 100 + (H5 x Wb) = ___________ lbs
T8 = T7 + 5 x 2 x Belt Width (mm) + (0.015 x l8 + 2.015 x l8 x Wb(lbs/ft)= _____ lbs
25.4
T9 = T8 + 100 = _________ lbs
36
HGT :
Considering starting tensions is limited to 160 % of the rated belt tension :Then, allowable extra belt tension :Fa1 = 1.6 x (RBT) - T1
= _______________ lbs
Time for acceleration = M1 [Belt speed (fpm)]
60
Fa1
t
= ________________ secs
Max. permissible belt tension = 1.6 x RBT = ____________ lbs
Not to exceed, the max. permisible belt tensions, the time used for acceleration
should not be less than t.
- Known value calculated previously.
37
Let addition of
these be X.
X = ___________ lbs
(X+A)
T10st = T9st + (Kyreturn side + Kyreturn side x Wb)l1 - H7 x Wb + Tbc + l1 (Wb + Wm)
2
9
= T9st + (0.015 + 0.015 x Wb) x l1 only upto point C
- H7 x Wb + 5 x
i.e. the first
2
(ft)
horizontal portion
x Belt width (mm) x l1 (Wb + Wm)
25.4
32.2
= ____________ lbs
T11st
Test
= __________________ Kgs
39
Always
To consider key effect, increase shaft dia as follows :Greater value among the two shaft dia (let it be O) + O = __________ cm x 10
2
= ______________ mm
Adopted shaft dia at brg = (Next available brg in our database) = ________ mcm
at hub = This value + 10 = ________ mcm
Now, checking for deflection due to bending & torsion as well, as per following
procedure :Checking for bending deflection :Deflection at centre, c = M
[ 3lbr2 - 4a2]
24EI
40
Permissible twist = 0.08 x 3.28 x lbr (m) (Take care, while putting into program,
lbr is in metres).
< permissible twist, - Dispaly message
Checking for bearing life :Brg type :- Display No. (brg + adapter sleeve)
[After displaying type of brg (always double row spherical roller brg)]
Basic dynamic capacity = C = ___________ Kgs
Bearing load = P = 1.2 x Radial load
= 1.2 x R = _________ Kgs
2
Bearing life in millions of revolutions = Lf = (C) 10/3
P
= _____________ mill. revolutions
Bearing life in hours = Lf x 106
60 x Pulley rpm
For Profile Nos. (I), (iv) & (v) - head pulley shaft - calculations
T1
T1 = __________
Kgs
T2
T2 = __________
W
R=
Next, each & every step remains the same as explained above for the remaining
profiles.
41
Snub pulley shaft dia calculations :For profile Nos (ii), (iii) & (vi)
R=
[T3cos -T2cos(-180-)]2+[T3sin+T2sin(-180-)+snub pulley wt(kgs)]2
= ______________ Kgs
32 x M x 1.5/ x fb
= ______________ cm x 10 = ______________ mm
R2 =
32 x M x 1.5/ x fb
= _________ cm x 10 = ____________ mm
42
Check for bending due to deflection only and calculate bearing life, as explained and
calculated earlier.
For profile nos (I), (iv) & (v)
(-180) R =
T2
W
VGT - There are two bend pulleys. In case of horizontal conveyors with Vgt, wrap
angle over both pulleys is same. But in case of inclined conveyors, wrap angle over
bend pulley nearer to snub pulley is less than, that over bend pulley nearer to tail
side. Hence in such cases, shaft dia is calculated, taking into consideration the
greater wrap angle and same is applicable to other bend pulley. Also in case of profile
nos (iii) and (iv) is assumed that, Vgt will always be placed in the inclined portion only,
near the head pulley.
For profiles (ii), (iii) & (iv)
T7
T6
Bend pulley shaft diameter if type of take up is HGT
For profiles (ii), (iii) & (vii)
Please note :- This angle is for profile nos (ii) & (iii) but it is
2 (i.e. inclination 2) for profile (vi) because, it
T9
contains two inclined portions.
W T8
R = (T9cos )2 + [T9sin + W(bend pulley wt kgs) + T8]2 ----> For profiles (ii) & (iii)
For profile (iv) replace by 2 (inclination of 2nd portion)
43
T8
Rest is same.
Take up pulley shaft dia calculations :For VGT - and all profiles
T6
T5
R=
(-T5 - T6)2 + [Take up pulley weight (kgs)]2 = _________ Kgs
T4 = T8 & T5 T9
T4 = T10 & T5
T11
T5 R =
T4
W
Use the following tensions in case of,
VGT
HGT
T4
T4
T8, T5
T10, T5
T9
T11
45
= ____________ kgs