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D E S I G N A N D C A L C U L AT I O N
Index
1
1.1
1.2
1.3
Introduction
Foreword
Development chronology, development aims
Dunlop-Enerka test rig
2
2.1
Belt Conveyors
Basic sketch, concept, description
3.
3.1
3.2
Drive Systems
Pulley arrangement, conveying systems
Single pulley head drive, Dual pulley head drive, Head and tail drive,
general criteria
Drive components
Pulley motor, Geared motor, Motor-gears-Couplings
3.3
4
4.1
4.2
4.3
Couplings
Coupling types, fixed coupling, flexible coupling, fluid coupling,
hydro dynamic coupling
Start-up procedure
Run back prevention (holdback)
5.
5.1
5.2
Drive Pulley
Force transmission, Eytelwein limitations, slip, creep
Friction factor , angle of wrap
6.
6.1
7
7.1
Detection Devices
Belt tension detection, off-track detection, belt slip detection,
longitudinal slitting safety device
8
8.1
8.2
Cleaning Devices
General, ground rules
Cable scraper, transverse scraper, fan scraper staggered scraper,
rotary scraper (vertical)
Rotary scraper (horizontal) rapping roller, belt turnover, high pressure water cleaning
8.3
9
9.1
9.2
10
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
Load
General, bulk loads, piece loads, bulk density, angle of repose/surcharge, lump size, classification
Temperature, moisture, chemical characteristics, pH value, angle of
inclination
Conveyor Belt
General, belt construction
Carcase, ply material
Covers, cover qualities (DIN/ISO)
Special qualities, cover thickness ratio
Angle of inclination values, cover thickness values
DUNLOP cover qualities, specifications
Basic Materials
Belt specification, DUNLOP belt types
Index
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8
11.9
11.10
11.11
11.12
11.13
11.14
11.15
11.16
11.17
12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
12.12
12.13
12.14
12.15
12.16
12.17
12.18
12.19
12.20
12.21
12.22
12.23
12.24
12.25
12.26
12.27
12.28
12.29
12.30
12.31
Design
Main data, belt speed, standard values, recommended values
Belt widths, standard widths, minimum belt width, idler arrangement, idler spacing
Idler spacing (recommended values) idler rotation, idler roll diameter, standard idler roll lengths L
Photograph
Cross sectional area of load, comparison various cross sections
Conveyor capacity, load stream volume, load stream mass, degree
of filling, reduction factor
Power requirement, electric motor type list
Adjustment factors
Belt types
Pulley diameters, standard diameters
Pulley rotation, pulley loading
Average surface pressure, transmission capability, start-up torque
Troughing transition, pulley lift
Convex vertical curve values
Concave vertical curve, curve co-ordinates
Belt turnover, turnover length, values
Horizontal curve, values
Basis of Calculation
Resistance to motion, main resistance, secondary resistance, slope
resistance, special resistances
Peripheral force FU (working), summation
Factor C (allowance for secondary resistance)
Fictitious friction factor f
Mass of rotating idler parts. Mass of belt
Mass of material load. Peripheral force FA (start-up) friction cut-off
material/belt
Start-up factor KA, acceleration aA, take-off time, acceleration
distance
Peripheral force FB (braking), delay, over-run distance, braking torque of motor MM, drive power at pulley PT, motor power PM
Degree of efficiency , nominal motor power (DIN) drive system
Distribution of drive power with head and tail drive, distribution of
drive power with dual pulley head drive
Factor x for various drive conditions
Distribution of drive power with dual pulley head and tail drive
Belt tensions T1 and T2. Belt tension correction, fixed take-up
Correction of belt tensions moveable take-up
Correction of belt tensions for minimum belt tensions
Sequential calculation to ascertain belt tensions T1 to T4, force
distribution, individual resistances
Sequential calculation for single pulley head drive
Sequential calculation for tail drive and tail drive braking
Sequential calculation for head and tail drive and dual pulley head
drive
Section loadings
Nominal belt strength, safety factor
Selection of belt type (criteria)
Selection of belt type (criteria continuation)
Selection of belt type (criteria continuation)
Belt reference to ascertain a belt type
Determination of fall energy at the loading point
Influence of stresses on belt selection
Photograph
Determination of troughing capabilities
Determination of cover thicknesses
Determination of take-up travel, values
II
Index
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
Calculation Example
Duty data, short calculation
Peripheral force FU and motor performance PM
Individual resistances, sequential calculation
Sequential calculation for various take-up systems
Belt safety, pre-tension, take-up travel
Pulley diameter, troughing transition
Convex and concave vertical curve
Control of additional stresses
Computer calculations
Photograph
14
14.1
14.2
14.3
14.4
14.5
14.6
14.7
15
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10
15.11
15.12
15.13
III
Index
A
A.1
A.2
A.3
A.4
A.5
A.6
B
B.1
B.2
C
C.1
C.2
C.3
C.4
D
D.1
D.2
E
E.1
E.2
Secondary Resistances
Inertial and frictional resistance at the loading point
Frictional resistance from skirt plates (loading point)
Frictional resistance from belt cleaners
Belt bending (flexing) resistance, pulley bearing resistance
Special Resistances
Resistance due to idler tilt
Frictional resistance from skirt plates beyond the loading point
Resistance due to sideways load discharge
Resistance from trippers
Resistance to belt sealing strip beyond the loading point
Resistance from motion of bunker drag-out belts
F
F.1
G
G.1
G.2
Safety Factor S
Belt safety (definition) time/strength behaviour, reductions
Safety factors S for steady and non-steady state working and for
temporary localised peak stresses
H
H.1
H.2
Stress-Strain Curve
Elongation characteristics (hysteresis curve)
Stress-strain curve (diagram)
I
I.1
I.2
I.3
I.4
I.5
I.6
I.7
I.8
Additional Stresses
Belt safety, elastic modulus
Values for Smin, elongation value kD
Troughing transition: safety and elongation
Troughing transition with raised pulley
Concave vertical curves
Convex vertical curves
Horizontal curve
Belt turnover
J
J.1
Roll Diameter
Standard rolls, coiled roll, double coiled roll, `S form coiled roll, roll
on oval core
Diameter of standard rolls (table)
J.2
IV
Index
K
K.1
K.2
K.3
Pulley Diameters
Pulley diameters for DUNLOP-ENERKA belt types
Pulley diameters for DUNLOPLAST PVG and PVC belts
Pulley diameters for steel cord belts SILVERCORD
L
L.1
Crowned Pulleys
Dimensions, taper
M
M.1
N
N.1
N.2
N.3
Chemical Resistance
Resistance of the carcase
Resistance of the covers
Resistance of the covers (continued)
O
O.1
O.2
P
P.1
P.2
Endless Splicing
Methods, hot vulcanising
Warm vulcanization, cold vulcanisation, mechanical fasteners
Q
Q.1
Q.2
Q.3
Q.4
Q.5
Q.6
Material Characteristics
Material characteristics
Material characteristics (continued)
Material characteristics (continued)
Material characteristics (continued)
Material characteristics (continued)
Material characteristics (continued)
Dunlop-Enerka Belting
P.O. Box 86
Centurion Way
Farington, Leyland
Preston, Lancashire PR5 2EY
United Kingdom
Tel. +44 (0) 1772 433 751
Fax +44 (0) 1772 623 967
Telex 627080
Dunlop-CCT s.a.
Boulevard des Combattants 64
7500 Tournai
Belgium
Tel. +32 (0) 69 254 811
Fax +32 (0) 69 226 270
Telex 57187
Dunlop-Enerka b.v.
Visokovoltnij Proezd, 1
127577, Moskow
Russia
Tel. +7 095 901 8857
Fax +7 095 901 2921
Dunlop-Enerka b.v.
Postbus 14
9200 AA Drachten
The Netherlands
Tel. +31 (0) 512 585 555
Fax +31 (0) 512 585 490
Telex 46116
Dunlop-CCT s.a.
Ovnatanyana str. 4
340017, Donjetsk
The Ukraine
Tel. +38 0622 955 038
Fax +38 0622 323 977
Dunlop-Enerka GmbH
Friedrich-Bergius-Strasse 10
41516 Grevenbroich
Germany
Tel. +49 (0) 2181 2701 00
Fax +49 (0) 2181 2701 30
Dunlop-Enerka S.L.
Pol. Ind. Les Comes
C/Italia, Parc, 70 Nave 3
08700 Igualada
Barcelona
Spain
Tel. +34 (9)3 80 55 446
Fax +34 (9)3 80 54 269
All information contained in this manual has been assembled with great care. It represents up-to-date knowledge and techniques and is based on our long experience of the
industry. We would however advise you that modifications may be necessary to cater for new technical developments. All information, guide values, comments etc. are given
for guidance purposes only and the ultimate responsibility for the use of this information in conveyor design and any subsequent liability rests with the end user, particularly
where the suitability of our products for certain applications is concerned. The data and values given are based on average values.
Introduction
Foreword
Conveyor belts have been used for decades to transport bulk and unit loads.
They have proved their worth everywhere because belt conveyor installations
can be adapted to meet nearly all local conditions. They are work-safe and
economical.
The demand for ever increasing capacities and ever longer conveying lengths
has accelerated the development of the belt conveyor technique, new materials are being developed, new conveying systems are being planned and
tested especially those having regard to the environmental.
The conveyor belt plays the major part in the whole system and has to overcome the many and varied stresses. In addition to this every conveying
problem is different and needs careful planning and selection of the right elements in order to achieve the optimum conveying capacity in an economical
way.
There are a number of practical rules, values and experiences which can be
useful during the planning stage. This manual aims to be of assistance to
operators, engineers and project people and provides a substantial amount of
elementary data. In addition there are a number of instructions and hints
offered to enable accurate calculations or checks on installation components
that impinge on the running of the belt.
In future there will be more and more use of the computer for calculations
and dimensioning of belt conveyors. With this often the correlation of the
valuation criteria will no longer be recognizable. This manual should also help
to understand the background to a calculation, the selection criteria for an
optimum belt type and to recognize a special operating case.
All new standards DIN, EN, or ISO, have been taken into consideration as
well as the results of individual research studies. The developments continue
and we are grateful for all hints and practical experiences.
July 1994
1.1
Introduction
Chronological
Development
Until the mid 1970s conveyor belt development and technology was concentrated on the search for appropriate materials for the belt and the solving of
drive problems. In the first instance transmission of traction played a part. As
the demand grew for conveyors of larger capacity and longer length, additional requirements effecting the belt had to be considered and researched such
as greater work load, elongation, slit resistance and endless splice jointing.
from 1870
up to 1914
1921
1923/1924
1926
from 1928
from 1933
from 1939
1941/1942
1942
from 1945
1954/1955
from 1955
from 1970
from 1980
This brief history illustrates the more important stages in conveyor belt development. The search for new materials became necessary because of the
ever increasing demands to optimise installation construction such as pulley
diameters, vertical and horizontal curves etc. and the demands of new
conveying systems.
Development Goals
1.2
Introduction
DUNLOP-ENERKA
Belt Testing Rig
To assist in future development of new belt types and splice joining techniques, Dunlop-Enerka have developed and installed a new type of belt testing
rig. The principal intention of the testing methods is to simulate actual operating conditions encountered by a belt in service.
1.3
Belt Conveyor
Construction
An installation consists of a drive system, a take-up system, additional components and the principal item, the conveyor belt. In addition to the conventional conveyor there are other conveyor system developments in which the
belt is the conveying element.
Basic Sketch
25
24
17
16
33
34
Components
Explanation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Motor
Motor Coupling
Brake
Drive Transmission
Anti Runback
Drive Coupling
Pulley Bearings
Drive Pulley
Tail Pulley
Deflection or Snub Pulley
Impact Idler Garland
Carrying Side Idler
Return Side Idler
Guide Roller
Counter Weight Take-up
Screw Take-up
Take-up Weight
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
2.1
Drive Systems
Drive Systems
A drive system consists of all components that provide for driving, start-up
and braking forces. The transmission of traction power from the drive pulley
is dependent upon the following factors:
Angle of wrap the belt makes on the drive pulley
Friction coefficient between belt and drive pulley
Pre Tension Tv.
Pulley Arrangement
and Belt Path
Eintrommel-Antrieb
mit direct
direktem
Abwurf
Single
pulley drive with
discharge
Eintrommel-Antrieb
mit swivel
Schwenkarm
Single
pulley drive with
arm andund
Abwurfausleger
discharge
jib
Eintrommel-Antrieb
mit discharge
Abwurfausleger
Single
pulley drive with
jib
Zweitrommel-Kopfantrieb
direktem
Abwurf
Dual
pulley head drive withmit
direct
discharge
Single
pulley head drive with single pulley
Eintrommel-Kopfantrieb
tail
mitdrive
Eintrommel-Umkehrantrieb
Zweitrommel-Kopfantrieb
Dual
pulley head drive with single pulley
mitdrive
Eintrommel-Umkehrantrieb
tail
Conveyor Systems
The above sketches of drive systems and belt paths are of the classical and
most frequently used types. Additionally there are a number of new proven
developments or those which are still undergoing trials, for instance, tube
conveyors, piggy-back conveyors, clamp conveyors, aerobelt conveyors, loop
belt conveyors and others.
Here are some examples:
Conveyor belt
Material
Drive motors
Hangers
Conveying
Through
Drive Rollers
Loop Belt with Clamp Edges Air Film
Material Load
Airinlet
Loop Belt Conveyor
(FMW System)
Aerobelt Conveyor
System
3.1
Drive Systems
The single pulley head drive is the most common and preferred drive. For
light duty applications the Motorized Conveyor Pulley or V-rope Drive is
often used.
Under normal circumstances the drive unit comprises motor, coupling and
gear box located at the side of the drive pulley and connected by means of a
flexible coupling, flanged coupling or extension gear box. With higher duty
applications the drive units can be located on both sides of the drive pulley.
For the higher duty applications the dual pulley drive is used which enables an
increase in angle of wrap and traction transmission. 2 to 4 drives are possible
which as a rule for reasons of standardization, would be of the same size.
By distributing the drive power in the ratio of 1:1 or 1/3 : 2/3, the transmission
capability of the first pulley would not be fully utilized. All motors take approximately the same work load. Almost the same size work load can be achieved
by selecting a fluid coupling whose slip characteristic can be modified by
adjusting the volume of fluid in the working circuit. If slip ring motors are
used this can be achieved by adjusting the slip resistance.
Head and Tail Drive
P1
General Criteria
P2
The head and tail drive may be used for relatively long installations, reversible
drives or where high return side resistance can occur. Start-up and braking is
made easier on long installations. The tail drive overcomes the resistances to
motion on the return side run, the pre-tension at the head drive can be
increased.
The choice of drive system depends on the total working duty, the belt characteristics and general operating conditions. With the higher duties the drive
pulley is driven on both sides. The pulley shaft is then symmetrically used and
able to take a higher loading.
With multi-pulley drives the belt should be so reeved that the pulley side is
leading over the drive pulley. In situations of high belt stress additional
deflection of the belt should be avoided thereby preventing unnecessary
bending stresses.
One should be particularly aware of dirt build-up. Prompt cleaning can avoid
down time and repair costs.
3.2
Drive Systems
Drive Components
In principle there are three possibilities for conveyor belt driving systems.
Pulley Motor
Geared Motor
Drive units comprising these three components are used the most. Typical
are work loads up to 600 kW with maximums up to approximately 1500 kW.
The advantage of this arrangement is the good accessibility and interchangeability of components and favourable spares inventory etc.
Motor
Coupling
Gearbox
In most cases, especially on large installations, coupling and brake are built
into the drive unit.
Drive Motor
As a rule a belt conveyor has to operate under variable load conditions. The
drive capability has to take account of these changes, also must run at constant revolutions and even speed.
This type of motor is simple to build, is robust and economical. The high torque when starting can be minimised and adjusted by means of flexible couplings, fluid couplings and slip couplings. Small installations up to approximately 10-12 kW can run without intermediate coupling. The high stresses
imposed upon the system during loaded start-up can be limited by step by
step increases in resistance or by the Star Delta reduced voltage system.
With this type of motor the starting torque can be reduced by the increase of
resistances within the electrical circuit.
The slip ring motor is used on large installations if a quasi stationary gentle
start-up is required.
3.3
Couplings
Coupling Types
When starting up a belt conveyor, for a short time forces result which are higher than those which occur during normal running conditions e.g. start-up and
acceleration forces. The motor in contrast creates by far the greater start-up
torque. The difference between the load torque and the start-up torque of the
motor, is the acceleration torque.
Depending on the size and type of motor, a gentle start-up is provided when
a flexible or hydraulic coupling is used.
Rigid Coupling
Rigid couplings are used only on small
installations up to a maximum of 30 kW
and at slow speeds.
Flexible Couplings
Centrifugal Couplings
Centrifugal and magnetic type couplings with controlled torque are hardly
ever used because of their high cost and are no longer a significantly used
item for belt start-up.
Hydraulic Coupling
Fluid couplings or hydraulic couplings are often used for larger drives in
combination with squirrel cage motors. They permit a load free acceleration
of the motor and consequently with increasing oil fill, provide a gentle quasi
steady state start-up of the belt conveyor. The maximum torque occurring
during the start-up process is restricted to lowest possible level. The conveyor belt and splice joints are relieved and conserved.
The principle of
a Turbo coupling
Empty at Rest
Full at Start-up
Full Working
4.1
Couplings
Start-up Procedure
The electric motor produces a variable torque with speed of rotation which is
illustrated below by line M. The belt conveyor as a working unit opposes torque MM at the same rotational speed set against torque ML.
At the moment of switch on, the electric motor delivers the start-up torque
MA. When this happens, the belt conveyor demands the break away torque
MLB. As rotation increases the motor torque declines to saddle torque MS
and then increases to the brink torque MK. Thereafter the torque at the nominal speed of rotation reduces to the nominal torque of the motor MN. The
load increases steadily.
Torque M
The difference between the motor torque MM and the load torque ML is the
acceleration torque MB up to the torque intersection of both lines.
MK
MA
MS
MB
MN
MLb
ML
MA
MS
MK
MN
MLb
ML
MB
Revolutions n
The start-up of the electric motor occurs practically load free compared with
the coupling torque MK up to the cut-off point 1 of the graph line MK and the
load graph line ML.
The motor remains at point 2 and accelerates the belt conveyor up to synchronous speed. Thereafter the motor, the coupling and the belt conveyor
reach the drive speed of rotation at point 3. This type of coupling is only
effective on a high speed shaft.
Torque M
MM
2
3
1
ML
MK
MM
ML
MK
Motor Torque
Load Torque
Coupling Torque
Revolutions n
4.2
Couplings
A holdback device is necessary if the force due to the loaded incline of a conveyor FSt exceeds that of the peripheral force FH stemming from conveying
the load over the horizontal distance. This is the case with all steeply inclined
conveyors and with those having a decline of approximately 6 to 10.
Holdback
stands fast
free
locked
FSt > FH
(N)
FSt = H * g * mL
(N)
FH = f * L * g ( mL + mR )
(N)
FSt
FH
mL
mR
L
H
f
g
(N)
(N)
(Kg/m)
(Kg/m)
(m)
(m)
(-)
(m/s2)
Incline Force
Force due to Horizontal Conveying
Mass of Load Stream on Belt
Mass of Rotating Carrying Idler Rollers
Conveyor Length
Height Difference
Artificial Friction Factor
Acceleration due to gravity
During installation a check should be made as to whether the direction of pulley rotation corresponds with the free wheeling direction of rotation and that
reverse travel of the belt is no longer possible.
4.3
Drive Pulley
Force Transmission
T1
T2
Because of the friction coefficient between belt and pulley, T1 is greater than
T2. The difference between both forces is peripheral force FU.
FU = T1 - T2
or
T1 = FU + T2
Eytelwein Limitations
T1
T1 T2 * e
Sp
log
ira
le
gl
T1
eo
An
T2
or
fw
rap
T1
A
of r ngle
epo
se
T1max
e
T2
1
T1 = FU * ( 1 +
e - 1
) = FU * c1
1
T2 = FU * (
e - 1
) = F U * c2
Creep
During the reduction of tension from T1 to T2 along the service arc, a decrease in the belt stretch occurs. It is not proportional to the time it occurs at a
slower rate. Creep remains on the pulley circumference and often creates a
whistling sound.
Entry side speed
= pulley peripheral speed.
Leaving side speed < entry side speed.
5.1
Drive Pulley
Friction Coefficient
The factors determining the transmission of peripheral force Fu are the friction coefficient, the angle of wrap and the pretension T2 e.g. Tv.
The number of drive pulleys, the pretension force as well as various other
installation components are dependent upon the friction coefficient . In
order to assess the friction coefficient, full knowledge of the operation is
desirable. In practice the friction coefficient varies within limits which are
dependent upon:
Surface condition of the pulley
Lubricating material such as water
or load slime between belt and pulley
Temperature
Surface pressure
Slip and creep speed
The friction coefficient declines with increasing surface pressure and increases with increasing speed of creep for instance at start-up.
Pulley Surface
Operating
Condition
Polyurethane
lagging
(grooved)
Rubber lagging
(grooved)
Ceramic lagging
(porous)
Dry
0.35 to 0.4
0.35 to 0.4
0.4 to 0.45
0.4 to 0.45
Wet
(Clean)
0.1
0.35
0.35
0.35 to 0.4
Wet (dirty
mud, clay)
0.05 to 0.1
0.2
0.25 - 0.3
0.35
180
230
1 + 2 ca. 450
c1 c2
Drive Factors
Facteurs
de commande
Angle of Wrap
Plain Steel
(smooth)
c1
c2
Angle
wrap
arc de of
contact
coefficient
de coefficient
frottement
Friction
5.2
Take-up Systems
General
Belt conveyors are equipped with take-up (tension) devices. These are
necessary to make it possible for the transmission of force on the drive pulley
or to accommodate changes in the length of the belt as the load changes and
to provide a smooth start-up of the installation. The choice of take-up system
depends on the general conditions of the installation, the elongation characteristics of the belt, the start up behaviour, climate and perhaps the
conveying distance and the inclination of the installation.
Depending on the application one differentiates between:
Fixed take-up
Moveable take-up with a constant pre-tension provided by a gravity weight
or with a pre-tension regulated by motor
This simple take-up device is used for relatively short conveyor lengths or
with belts having a low elongation such as steelcord. After tensioning the
belt, the length stays constant but the belt pull force changes according to
the change in load through permanent or elastic stretch.
The level of pre-tension force can be determined practically by tensioning the
belt until the forces react at all parts of the installation. The belt is permanently tensioned sufficiently high as is necessary for full load conditions. It is
possible to ascertain and actually adjust the tension by means of a sensor.
Gravity Weight
6.1
Detection Devices
This device detects the belt tension changes during different working conditions such as starting, braking and load variations.
A tensiometer measures the changing belt tensions. As soon as the defined
limits of the upper and lower belts tensions are exceeded a signal is transmitted to the take-up unit.
Chute detection
With the help of this device the overloading of a transfer point is registered.
A contact probe is suspended in the chute and adjusted to the required material flow. With an overload, contact is made with the probe and the installation is switched off.
This device detects the force transmission between belt and drive pulley.
Too great or too long a duration of slip leads to overheating of the pulley surface which can lead to fire. Slip can occur more often at start up as well as
overload conditions or when the pre-tension is too low.
Longitudinal Slitting
Safety Device
7.1
Cleaning Devices
General
loss of load
soiling of the installation
damage to the belt
off tracking of the belt
damage to idlers
The material from which the scraper is made has to be in accord with the
type of belt and the material to be scraped off.
The following need to be observed:
the hardness of the belt and scraper;
In general the material from which the scraper is made should not be harder than the belt surface. The scraper should be designed in such a way
that it makes contact with the biggest possible area of the belt, perhaps a
double or staggered scraper.
the contact pressure of the scraper;
An excessive contact pressure increases energy consumption and wear
and tear of the belt. A small gap between the scraper and belt surface provides a sufficient cleaning effect with most bulk loads, causing minimum
wear and tear. Sliding friction becomes rolling friction.
In nearly every case the most effective and economic solution has to be established, possibly by trial and error. Several well proven systems are listed as
follows.
8.1
Cleaning Devices
Transverse Scraper
Fan Scraper
Plough Scraper
Staggered Scraper
Rotary Scraper
8.2
Cleaning Devices
Rotary Scraper
Rapping Roller
Situated on the belt running side located in the region of the discharge hopper. For belts with a profiled carrying
side and steep inclined belts.
Belt turnover
Pulley side
Turnover Length
Good cleaning method where good water supply and drainage are available.
8.3
Load
General
Bulk Loads
Dusty, granular or lumps. Loads for instance, stone, earth, sand, grain,
cement. They are defined by their physical characteristics such as density,
granulometry, moisture, oil and fat content, pH value, abrasiveness, angle of
surcharge etc.
Unit Loads
Piece loads comprise such as boxes sacks, blocks etc., and are defined by
shape, measurement and weight.
Bulk Density
m
=
( t/m3 )
V
Angle of repose
Surcharge
If a load is loosely poured a static angle of slope st will form. If the under
layer is moved as when being transported on a conveyor belt, the angle of
surcharge dyn is formed. The particles of the bulk load interact and the
lower the internal friction of the material the lower the surcharge angle dyn.
Approximately:
dyn = (0.5 - 0.9) * st
The surcharge angle is only to a degree related to material size. It depends
on the friction between material and belt, how the material is loaded and the
geometry of the conveyor installation. The tabulated values in the Appendix
are approximate values. If exact values are necessary they have to be determined by practical trials.
Granulometry k
kk
Unsized load
Granulometry
Measurement
Bulk Load Definition
Dust
Granular
Lumps
Large Lumps
Granulometry (mm)
0.5
0.5 - 10
10 - 200
> 200
9.1
Load
Temperature
Moisture
Chemical Characteristics
alkalis
neutral
acid
Angle of Inclination
ca. 8
pH > 7
pH = 7
pH < 7
ca. 90
pH Value
Elevators
ca.
40
5
ca. 3
ca. 22
9.2
Conveyor Belt
General
The conveyor belt is the most important element of a belt conveyor installation. It has to be capable of doing numerous tasks:
Carrying
Side Covers
Full Rubber Edge
Breaker Ply or
Longitudinal Slit
Preventor
Carcase of
textile plies
Pulley Side
Cover
10.1
Conveyor Belt
Carcase
The carcase can be made from various materials and in different constructions. The most frequently used are textile ply carcases and Steel Cord.
DUNLOFLEX
2 Ply
TRIOFLEX
3 Ply
SUPERFORT
Multi Ply
DUNLOPLAST
Carcase of the Steel
weave type
FERROFLEX
Carcase with Steel
Cords. ST-belts
Cover
Steelcord
Core Rubber
SILVERCORD
Material
For textile, solid woven or steel reinforced types the principal materials used
are as follows:
Symbol
Ply Materials
B
P
E
EP
D
F
ST
Cotton
Polyamide
Polyester
Polyester-Polyamide
Aramid
Steel Weave
Steel Cord
(Natural fibre)
(Synthetic fibre)
(Synthetic fibre)
(Synthetic fibre)
(Synthetic fibre)
(Ferroflex)
(ST belt)
10.2
Conveyor Belt
Of the textile ply types the wholly synthetic plies have proved to be the
best over the years e.g. polyester (E) in the warp (longitudinal direction)
and polyamide (P) in the weft (transverse direction). The abbreviation of
this ply construction is called EP.
Carcases from Aramid (D) are in development and are high tensile and low
elongation carcases.
Steel Cord belts have very low elongation and are used predominantly on
long haul installations.
Evaluation of various Material Properties
Key and evaluation of the plies
Characteristics
Tensile Strength
Adhesion
Elongation
Moisture Resistance
Impact Resistance
= bad
Covers
EP
ST
++
++
+
+
++
++
++
++
+
++
++
++
++
+
+++
++
+++
++
+
++
++
+++
+
++
+++
+++
+++
++
+++
= medium
+ = good
++ = very good
+++ = excellent
The carcase is protected against outside influences by the covers which are
normally made out of either rubber or PVC. The carrying side cover should
not be more than 3 times thicker than the running side cover.
Carrying side : Running Side 3:1
Belt Edges
With wholly synthetic and rot resistant plies it is not necessary to have full
rubber edge protection, it is sufficient to have heat sealed cut edges.
Exceptions are belts requiring special qualities such as oil and fat resistance.
Grades
The basic grades and principal properties are in accordance with ISO and DIN.
DIN 22102 (April 1991)
Cover grade
Tensile strength
Breaking elongation
Abrasion loss
N/mm2 min.
%
mm3 max.
18
400
90
25
450
120
20
400
150
15
350
250
N/mm2 min.
%
mm3
24
450
120
28
400
100
15
350
200
Various other special grades exclude laid down mechanical or other values.
10.3
Conveyor Belt
Special Qualities
Cover Surface
Characteristics
Type
Flame Resistant
Anti Static
Flame Resistant, Anti Static
Heat Resistant
Low Temperature Resistant
Oil and Fat Resistant
Food Stuff
Chemical Products
F
E
S or K
T
R
G
A
C
The carrying side surface depends on the load, the inclination of the installation or depending on the use of the belt, smooth, profiled, cleated and with
corrugated edges.
Herringbone Profile
Multiprof Profile
Rufftop Profile
HIGH-CHEVRON Profile
10.4
Conveyor Belt
Gradient values
Cover Surface
Belt Type
Max. Gradient
Application
Smooth
Normal
18 - 20
Unit and
bulk loads
all types
Profiled
Fishbone
Rufftop
up to 35
Piece and
bulk loads
Steep conveyor
profile
Steep conveyor
CHEVRON
HIGH-CHEVRON
Multiprof
up to 40
Bulk loads
(non-sticky)
Piece loads
(sacks)
T-cleats
with or without
corrugated edges
Belts with
corrugated side
walls, with or
without T-Cleats
With Steel
or rubber
buckets attached
Elevator
belts
Load
Wooden crates
Bricks
Paper Sacks
Jute Sacks
Plastic Boxes-dry
Plastic Boxes-wet
Carrying side
Cover thickness
up to 90
80 - 90
Piece and
bulk loads
Bulk loads
all types
Herringbone profile
40
40
35
35
40
25
30
30
30
35
30
25
The thickness of the carrying side cover depends upon the nature of the load
and loading conditions (type of load, gradient, height of fall etc.).
Cover Thickness (mm)
Conveyor Load/Duty
Light package Conveying
Gravel, Earth, Potash etc.
Ore, Ballast, Coal
Slag
Coarse ballast, coarse Ore
large lump Coal
Carrying Side
Pulley Side
2
2-4
4-8
4-8
8 - 12
8 - 12
2
2-3
2-3
2-3
3-5
3-5
10.5
Conveyor belt
Dunlop-Enerka
Cover Qualities
DunlopEnerka
Quality
Quality
DIN
Temperature (C)
ISO.
Basic
Characteristics
base
Application
Y (N)
RE
X (M)
RS
-30
80
100
SBR
-40
80
90
NR
-30
80
90
BETAHETE
-20
150
170
SBR
STAR-
-20
180
220
IIR
-20
200
400
EPDM
ROS
-20
80
120
NBR
ROM
-30
80
90
HETE
DELTAHETE
MORS
-20
80
90
BV
S/K
-30
80
90
BVO
S/G
-20
80
90
Basic materials
Code
Rubber type
NR
SBR
NBR
IIR
EPDM
CR
Natural Rubber
Styrene-Butadiene Rubber
Nitrile Rubber
Butyl Rubber
Ethylene-Propylene-Diene Rubber
Chloroprene Rubber
10.6
Conveyor belt
Basic Materials
Natural Rubber NR
Natural rubber, because of its special properties is a good basic material for
belt cover rubbers.
Technical Characteristics
Very good tensile strength and elongation
High heat resistance and elasticity
High tearing and shear strength
Good abrasion resistance characteristics
Temperature Stability
Generally stable within the temperature range of -30 to + 80C. With special
rubber compounding a widening of this range may be achieved from -40C to
+ 100C.
Chemical Stability
Resistant to water, alcohol, acetone, dilute acids and alkalis - limited resistance to concentrated acids and alkalis where compounding and service temperatures are major consideration.
Special characteristics
With special compounding natural rubber based mixes can be made antistatic
and flame resistant.
By adding antiozonants a substantial protection against harsh temperature
effects, sunlight and ambient weather conditions can be achieved.
Scope
Everywhere where high physical properties are called for and the chemical
and temperature demands are not excessive.
SBR is a synthetic polymerisation product consisting of styrene and butadiene whose characteristics are similar to natural rubber.
Tensile strength and cut resistance are good. Abrasion, heat and ozone resistances are better than natural rubber.
10.7
Conveyor belt
Chloroprene Rubber CR
Nitrile Chloroprene
Rubber NCR
Note
The foregoing basic materials are main ingredients of cover rubber components. They provide the principal characteristics of each quality but can be
affected by the addition of other compounding ingredients to achieve requirements of standards and regulations.
Belt Description
100 m
800 mm
EP
400/3
4+2 mm
Belt Length
Belt Width
Material (carcase)
Nominal Tensile Strength
Number of Plies
Carrying Side Cover Thickness
Pulley Side Cover Thickness
Cover Quality
Belt Length
DUNLOP types
This number gives the nominal or breaking strength of the carcase in N/mm
of belt width. The values are Internationally Standardized.
125
630
Number of Plies
F
FERROFLEX Steelweave Belt
DLP DUNLOPLAST Monoply Belt
ST SILVERCORD Steelcord Belt
160
800
200
1000
250
1250
315
1600
400
2000
500
2500
80
100
125
160
200
250
315
400
The nominal tensile strength of the full thickness carcase is the sum of the
ply strengths rounded up to the next nominal tensile strength. The number
of plies is not indicated in specially described types such as DUNLOFLEX,
TRIOFLEX or DUNLOPLAST.
10.8
Design
After establishing the duty of the operation and the type of belt conveyor,
the main data may be determined.
Belt Speed
Belt Width
Carrying Idler Arrangement
Cross Sectional area of Load Stream
Conveyor Capacity
Speed V
v (m/s)
B (m) or (mm)
A (m2)
Q (t/h)
The belt or Conveying Speed V (m/s) must be appropriate for the material
composition and operation conditions.
The most economical installation is that having the highest belt speed consistent with the type of material and operating conditions.
Standard Values
Speeds V (m/s)
0.42 - 0.52 - 0.66 - 0.84 - 1.05 - 1.31 - 1.68
2.09 - 2.62 - 3.35 - 4.19 - 5.20 - 6.60 - 8.40
Recommended
Velocity (m/s)
Duty
v (m/s)
1.68
Mobile Conveyors
0.52 - 1.68
1.31
1.68
1.05 - 2.09
1.31 - 3.35
2.62 - 6.60
8.40
0.84 - 2.62
11.1
Design
Wherever possible a standard belt width should be selected. Type and granulometry of the materials determine the minimum belt width. After determining the belt type a check on troughability may be necessary under some
circumstances.
Belt Width B
Min. Width
(mm)
Sized
Lump Size K
400
500
650
800
1000
1200
1400
1600
1800
2000
50
80
130
200
250
350
400
450
550
600
Unsized
100
150
200
300
400
500
600
650
700
800
With unsized material the large lumps are embedded in the smaller granulated material.
Carrying Idler Disposition
The disposition of the carrying idler varies from application to application. The
number of idler rolls in a carrying idler set and troughing angle determine the
cross sectional area of the load stream and thus the conveying capacity.
Flat
Distance between
Carrying Idlers
Tx
Tx
h
lo
lu
2 Part
3 Part
Deep Trough
Garland
In deciding on the carrying idler spacing one has to take account of the load
limitation of the carrying idler (note: Refer to manufacturers specification).
After establishing the belt tension the belt sag between idler rollers has to be
checked.
The roller spacing has to be selected in such a way that the sag of a loaded
belt is no more than 0.5%-1.5% of the centre to centre distance. With return
side idlers one may allow approximately 2-3% sag.
Carrying Side
lo =
Tx * 8 * hrel
(m)
(mL + mG) * g
Return Side
lu =
Tx * 8 * hrel
(m)
mG * g
Tx
mL
mG
g
hrel
(N)
( kg/m )
( kg/m )
( m/s2 )
(-)
11.2
Design
Idler Rotation
Carrying Side
lo = 0.5 1.0 m
lo = app. 1.2 m
lo = 1.4 4.0 m
Return Side
lu = (2-3)*lo
Maximum approx 6 m
nR = 60 * v
DR
DR ( m )
v
( m/s )
(r.p.m. )
Roll diameter
Belt speed
Carrying Idlers
Impact Idlers
Return Run
Support Discs
51
63.5
88.9 108
156
133
180
159
215
193.7 219
250
290
120
138
180
215
250
150
290
Flat
Troughing Type
3 roll
Deeptrough
2 roll
300
400
500
600
650
800
1000
1200
1400
1600
1800
2000
2200
Garland
380
500
600
700
750
950
1150
1400
1600
1800
2000
2200
2500
200
250
315
340
380
465
600
700
800
900
1000
1100
1250
160
200
250
250
315
380
465
530
600
670
750
800
200
250
315
380
465
530
600
640
165
205
250
290
340
380
420
460
The length of the middle idler roll determines the cross sectional area of the
load and thus the conveying capacity.
The gap d between 2 adjacent rolls should not be greater than 10mm, with
belt widths B > 2000mm d = 15mm refer to DIN22107, carrying idler arrangements.
11.3
Design
11.4
Design
To determine the cross-sectional area of the load stream A, one may use as a
basis the geometric relationship which can be constructed from the troughing
angle , the usable belt width b and the angle of surcharge .
A1
A2
l1
l
b
B
Cross-Sectional Area of
Load Stream
A = A1 + A2
( m2 )
For 1, 2 and 3 roll carrying idler sets, the part cross-sectional area can be calculated as follows:
Part Cross-Sectional
Area
( m2 )
A2 = l1 * sin * [ l + l1 * cos ]
( m2 )
Troughing
Form
Forme dauge
Troughing
Angle
Angle
dauge
Load
Cross
SecSection
de chartion
Area A(m
A(M22))
gement
plat
Flat
0,0483
0.0483
44%
20
30
0.1007
0,1007
0,1145
0.1145
91%
104%
20
30
45
0.0935
0,0935
0,1100
0.1100
0,1247
0.1247
85%
100%
113%
20
30
45
0.0989
0,0989
0,1161
0.1161
0,1284
0.1284
90%
106%
117%
30/60
0,1329
0.1329
121%
CompariComparaison
son
Auge profonde
Deep
Trough
Note:
The values for the cross sectional area and the comparison are for a belt width B =
1000 mm and for an angle of
surcharge = 15.
Guirlande
Garland
11.5
Design
Conveying Capacity
( m3/h )
= 1 * 2
(-)
Degree of Filling 1
The degree of filling is dependent upon the characteristics of the load, e.g.,
the lump size, the surcharge angle and the working conditions, e.g, method
of loading, tracking or the reserve capacity etc.
Values for 1
Reduction Factor 2
The reduction factor 2 takes into consideration the reduction in part crosssectional area A1 as a result of the conveying gradient.
Gradient
2
Angle of inclination
15
20
25
0.89
0.81
0.70 0.56
Sticky material
1.00
0.93
Quantity conveyed
2 4
6
8 10 12 14 16 18 20 22
1.0 0.99 0.98 0.97 0.95 0.93 0.91 0.89 0.85 0.81 0.76
30
35
40
( t/h )
Theoretical value
Qm = Qv * *
( t/h )
Effective value
For the calculation of the conveying capacity for unit loads the following
formula applies.
Qst =
3600 * v
lst + ast
Load Stream
Qm =
mst * 3.6 * v
( t/h )
lst + ast
QV
( m3/h )
v
mst
lst
ast
( m/s )
( t/m3 )
( kg )
(m)
(m)
11.6
Design
This section deals with estimated values and relevant matters primarily to
enable the Project Engineer to provide a speedy assessment of requirements from the given service data. To make an optimum selection of the
conveyor belt and conveyor components it is recommended that detailed calculations be done in accordance with subsequent sections.
Power Requirements
With the aid of the following formulae, power requirements can be roughly
assessed. The accuracy is sufficient for normal installations with simple
straight-forward running conditions. From the power calculations, the belt
type can be closely determined. The actual nominal belt weight can be used
in the more precise calculation of the belt.
PT = P1 + P2 + P3
P1 =
P2 =
(kW)
CB * v + Qm
(kW)
CL * kf
H * Qm
(kW)
367
Additional Power
Installed Motor
(kW)
( t/h )
( m/s )
( kg/m )
( m-1 )
(m)
(m)
()
(-)
(-)
Duty
Width factor CB
Light
Medium
Heavy
3
22
110
500
Bulk Density
(t/m3)
Up to Ca. 1.0
1.0 to 2.0
Over 2.0
4
30
132
630
5.5
37
160
7.5
45
200
11
55
250
31
36
108
126
144
54
59
65
67
76
86
81
92
103
133
187
241
194
277
360
227
320
414
291
468
644
554
727
691
957
745
1033
11.7
Design
Length Factor CL
L (m)
10
12.5
16
20
CL
667
625
555
526
454
417
370
323
286
L (m)
25
32
40
50
63
80
90
100
150
CL
250
222
192
167
145
119
109
103
77
L (m)
200
250
300
350
400
450
500
550
600
CL
63
53
47
41
37
33
31
28
26
L (m)
700
800
900
1000
1500
2000
CL
23
20
18
17
12
kf
Working Conditions
Favourable, good alignment, slow speed
Normal (Standard Conditions)
B
v
lf
1.17
0.87 - 0.74
0.57
Trippers
(throw-off carraiges)
P (kW)
500
1000
> 1000
0.8 * v
1.5 * v
2.3 * v
Scrapers
(for installations L 80 m)
Scraper Type
simple, normal contact
0.3 * B * v
heavy contact
1.5 * B * v
1.8 * B * v
Material - skirtboard
0.16 * v * lf
Discharge plough
1.5 * B * v
(m)
( m/s )
(m)
Belt width
Belt speed
Length of material between skirtboard
11.8
Design
Belt Type
Breaking Strength
cv
PT
( N/mm )
Number of Plies
Drive
Pulley
Surface
Friction
Value
bare, wet
0.15
98
74
59 45
37
30
25
21
18
16
15
14
0.25
0.30
69
62
52
46
41 32
37 28
26
23
21
18
17
15
15
13
13
12
12
10
10
9
9
8
bare, dry,
lagged, wet
0.35
57
43
34 26
21
17
14
12
11
0.40
53
40
32 25
20
16
13
11
10
DUNLOFLEX
1.00
0.50
TRIOFLEX
1.00
0.67
SUPERFORT
Number of plies
0.70
0.50
0.67
0.75
0.80
0.83
FERROFLEX
0.90
DUNLOPLAST
0.90
1.00
0.95
0.90
Various
1
2
3
4
5
6
Factor cv
11.9
Design
Pulley Diameters
The pulley diameter for a conveyor belt depends upon the belt construction
(belt type, carcase material and thickness of carcase), the duty and the
method of splicing. One can differentiate between 3 pulley groups depending on pulley location and angle of wrap .
GROUP
A
B
C
APPLICATION
Pulleys in the areas of high belt stress.
Drive Pulleys
Pulleys in areas of low belt stress.
Tail Pulleys
Pulleys with an angle of wrap 90, Deflection or snub Pulleys
Tail Pulley
Snub Pulley
Bend Pulley
Drive Pulley
Snub Pulley
Tension Pulley
To determine the pulley diameter first ascertain the diameter of the drive
pulley with maximum tension.
DTr = CTr * d
d
CTr
Value CTr
( mm )
(-)
( mm )
Thickness of carcase (see Appendix C)
Value for warp material of carcase i.e. Belt type.
CTr
90
80
95
108
138
145
100
Polyamide (P)
DUNLOFLEX
TRIOFLEX
SUPERFORT
FERROFLEX
SILVERCORD
DUNLOPLAST
2 ply Belt
3 ply Belt
Multiply Belt (EP)
Steel Weave Type
Steel Cord Belt
Monoply Belt
The calculated pulley diameter is rounded up to the next higher standard diameter or if working conditions are favourable may be rounded down.
100
630
125
800
160
1000
200
1250
250
1400
315
1600
400
1800
500
2000
11.10
Design
Once the diameter of the largest pulley has been determined to a standard
size the diameter for pulley groups A, B, C can be obtained from the following
table.
Pulley
Diameter
DTr (mm)
100
125
160
200
250
315
400
500
630
800
1000
1250
1400
1600
1800
2000
100
125
160
200
250
315
400
500
630
800
1000
1250
1400
1600
1800
2000
100
125
160
200
250
315
400
500
630
800
1000
1250
1250
1400
1600
100
125
160
200
250
315
400
500
630
800
1000
1000
1250
1250
The diameters shown in the above table apply to belts operating at 60% 100% of allowable tension.
Utilisation Percentage
Tmax * S
kA =
B * kN
Tmax
S
B
kN
(N)
(-)
( mm )
( N/mm )
* 100
(%)
When the rated tension of the belt is not fully utilized, it is permissible to
reduce pulley diameter to 1 to 2 sizes smaller.
Degree of Utilization
Pulley Diameter
kA > 0.6 1
kA > 0.3 0.6
kA < 0.3
Diameters as table
Group A, B and C
Group A and B
Group C
Pulley Revolution
nT =
Pulley Loading
FT =
v * 60
( T/min )
*D
TA1 + TA2
( kg )
9.81
11.11
Design
TA1 + TA2
pT =
( N/cm2 )
D*B
With rubber lagged drive pulleys the average surface pressure limit is approximately 70 N/cm2. This limit is only reached on heavy drives and relatively
small pulley diameters.
Transmission Capability
360 * FU
p =
( N/mm2 )
*D**B
FA * D
( Nm )
2 * 1000
D
B
FA
v
FU
Troughing Transition
( mm )
( mm )
(N)
()
( m/s )
(N)
Pulley diameter
Belt width
Peripheral force at start-up
Angle of wrap
Speed
Peripheral force when running
The distance between a terminal pulley and the adjacent fully troughed idler
set at either the head or tail end of a conveyor is know as the transition distance. In this distance the belt changes from a fully troughed to a flat profile
or vice versa respectively. The belt stretches additionally at its edge zone and
buckling in the middle of the belt is also possible.
S
LM
Elevation of Pulley
To relieve the belt and edge stresses, the pulley may be raised slightly to the
value h (mm) (see Page 11.13).
h
Lred
The necessary transition length for tension distribution with or without pulley
elevation when designing can be estimated or taken from the table.
11.12
Design
LM = x * s * sin
Troughing Transition
( mm )
s2
h
Pulley Rise
* sin
=
B
( mm )
Lred = x * (s * sin - h)
LM
Lred
l
s
x
( mm )
( mm )
( mm )
( mm )
(-)
h
()
( mm )
( mm )
The pulley lift should not exceed the value h (mm) in order not to get a ski
jump effect. Lift-off from the centre roller is not desirable as this would
have an adverse effect on belt tracking.
Troughing Angle
Troughing
ST Belts
Lred1) (mm)
Textile belts
LM (mm)
Lred1) (mm)
20
30
30
40
45
30
45
410
550
665
850
1000
1190
1370
1550
1710
1920
600
800
970
1240
1470
1740
2000
2260
2500
2800
680
860
1020
1200
1380
1550
1720
1900
870
1100
1310
1540
1770
1990
2200
2450
950
1210
1440
1700
1950
2200
2430
2700
1350
1710
2040
2400
2750
3100
3432
3800
1900
2420
2870
3380
3890
4390
4860
5390
Belt Width
(mm)
500
650
800
1000
1200
1400
1600
1800
2000
2200
Belt Width
(mm)
800
1000
1200
1400
1600
1800
2000
2200
Troughing Angle
30
37
48
56
68
78
89
98
112
40
47
62
72
87
100
114
126
143
45
52
68
80
96
110
125
138
158
11.13
Design
In the transition from inclined to horizontal, the belt edge zone is subjected to
additional stretch. In order not to exceed certain limits, as a rule 0.8% additional stretch, the transition radius Re has to be dimensioned accordingly.
Carrying side
l0
Return side
S
Re
Re = x * s * sin
Convex Radius
s
x
( mm )
(-)
(m)
Curve Length
L = * * Re / 180
Number of Idlers
in Curve
z = /
(Pieces)
Idler Pitch
lo = L / z
(m)
()
()
(m)
ST Belts
Textile belts
20
30
45
30
45
500
650
800
1000
1200
1400
1600
1800
2000
2200
6.5
8.5
10.5
13.0
16.0
18.5
21.0
24.0
26.5
30.0
9.3
12.5
15.0
19.5
23.0
27.0
31.0
35.0
39.0
44.0
13.5
17.5
21.0
27.0
32.0
38.0
44.0
50.0
55.0
62.0
30.0
40.0
48.5
62.0
74.5
87.0
100.0
113.0
125.0
140.0
68.5
88.0
104.0
123.0
141.0
160.0
177.0
198.0
11.14
Design
With a concave vertical curve, the belt path goes from horizontal to incline.
At start-up or load change there may be a risk of the belt lifting off the carrying idlers in this region. This can lead to a reduction in pre-tension. If due
to special circumstances a brief lift-off can be tolerated then the lifting belt
can be restrained by rollers mounted above the troughing idlers. In any event
action must be taken to ensure that the belt does not lose load material.
Lx
Ra
Tx
ya
xa
Concave Radius
Tx
Ra =
Tx
mG
Co-ordinates of
Curve
Additional Stretch-buckling
(m)
mG * cos * g
(N)
( kg/m )
()
xa = Ra * tan
horizontal distance
ya = 0.5 * Ra * tan2
vertical distance
With a concave vertical curve, buckling of the belt edges and overstress of
the middle of the belt can occur. (To check calculation see Appendix I.5.)
11.15
Design
Belt Turnover
One method of solving belt cleaning problems on the return side run is the
use of belt turnover. This method is employed in inaccessible areas such as
conveyor bridges and tunnels. To avoid excessive strain in the edge region
of the belt, the turnover must be a certain minimum length, depending on the
method of turnover, belt type and belt width.
With textile belts up to a width of 1200 mm
and a thickness of 10 mm, the belt may be
turned over unguided and without support.
At the entry and exit points of the turnover
lengths, the belt is fed through a pair of rollers.
Un-guided Turnover
Lw
Guided Turnover
Supported Turnover
Turnover Lengths
for EP belts
Lw = 1.36 * B *
for ST belts
Lw = 1.55 * B *
245 = 24 * B
71 = 11.5 * B
(m)
(m)
free or with
support rollers
guided with a
middle roller
12 * B
16 * B
17 * B
18 * B
13 * B
19 * B
20 * B
22 * B
EP belts
DUNLOPLAST
FERROFLEX
ST. BELTS
For smooth running of the belt through the turnover stretch, a minimum belt
tension is necessary.
min. Tx =
Lw * mG * g
(N)
8*h
Lw
h
mG
B
(m)
(%)
( kg/m )
(m)
11.16
Design
Horizontal Curve
Within limits, belts are able to negotiate horizontal curves. To do this the carrying idlers on the inside of the curve are slightly raised by the angle R according to radius and belt tension by approximately 5-15.
The exact position has to be determined by adjustment.
RH
Inside of Curve
R
RH
l
RH = k * [ l + B * ( 1 l
B
R
k
( mm )
( mm )
()
()
(-)
) * cos ]
(m)
For design purposes the following radii may be selected being the smaller
permissible radii RH (m).
Belt width
(mm)
300
400
500
650
800
1000
1200 1400
EP belts
DUNLOPLAST
FERROFLEX
ST belts
20
42
-
26
56
-
33
69
-
42
89
134
146
52
110
165
180
65
137
206
224
72
165
248
270
Belt width
(mm)
2800
EP belts
DUNLOPLAST
FERROFLEX
ST belts
104
220
329
359
142
452
493
182
-
117
247
370
404
130
275
412
449
156
-
169
-
91
192
289
314
11.17
Basis of calculations
After the design of the installation and the main data has been determined an
exact calculation can be undertaken. Established installation components
can be checked and dimensioned. The belt selection can be undertaken
according to forces that have been established and other relevant
criteria.
Resistance to Motion FH
Main Resistance FH
(N)
Resistance due to moving the mass of idlers, belt and material on the carrying and return runs. Running resistance of idlers (bearing and seal friction). Resistance due to impressions made in the belt by idlers and the
flexing of the belt.
With gradients 18 Cos = 1.
Secondary Resistance FN
FN = ( C - 1 ) * FH
(N)
With normal installations with one loading point, the secondary resistance
can be calculated by using the factor C as part of the main resistance.
Factor C depends on the conveying length and can be taken from the table
on Page 12.3.
If the secondary resistance relative to the total resistance is high as for
instance with conveyors less than approximately 80 m long with several
loading points, a separate calculation is necessary.
FSt = H * g * mL
(N)
12.1
Basis of calculations
Peripheral Force FU
Working Conditions
(N)
For installations with one loading point, as a rule the following summation
applies:
Summation
(-)
(-)
(m)
( m/s2 )
( kg/m )
( kg/m )
( kg/m )
()
(m)
FS
(N)
(N)
Length factor
Artificial friction factor
Conveyor length
Acceleration due to gravity
Mass of the rotating carrying and return idlers
Mass of the belt
Mass of the load
Gradient of the installation with 18 cos = 1
Conveying height
H > 0 inclined conveying
H < 0 declined conveying
Sum of the special resistances. For separate calculations see Appendix.
12.2
Basis of calculations
Beiwert C
Coefficient
C
Factor C
L (m)
10
13
16
20
9.0
7.6
6.6
5.9
5.1
4.5
4.0
3.6
3.0
L (m)
25
32
40
50
63
80
90
100
120
2.9
2.6
2.4
2.2
2.0
1.92
1.86
1.78
1.70
L (m)
140
160
180
200
250
300
350
400
450
1.63
1.56
1.50
1.45
1.38
1.31
1.27
1.25
1.20
L (m)
500
550
600
700
800
900
1000
1500
2000
1.20
1.18
1.17
1.14
1.12
1.10
1.09
1.06
1.00
Frderlnge
m
Conveying
LengthLininmm
12.3
Basis of calculations
Friction Factor f
The friction factor f is used for the calculations of the resistances to motion. It
provides an estimate of the resistance to rotation of the idlers, the belt resistance (flexing and idler impressions) and material impression resistance.
Values for the factor f are dependent upon the working conditions and construction characteristics of the installation.
Horizontal, inclined or slightly declined
installations - Motor driven
Favourable working conditions,
easily rotating idlers, material
with low internal friction
and good tracking, good maintenance
0.017
0.020
Unfavourable conditions,
low temperature, material
with high internal friction,
subject to overload, poor maintenance
0.023 - 0.027
0.012 - 0.016
The above table values are relevant for v = 5 m/s and a temperature of
+ 20C.
Adjustments
f = c * f5m/s
v (m/s)
Factor c
0.80
0.85
0.90
1.00
1.10
T (C)
Factor c
f = c * f20C
+20
1.00
-10
-20
-30
1.07
1.17
1.28
1.47
For central European regions and normal working conditions the value of
f = 0.020 - 0.021 would be used.
In extreme temperatures such as those in tropical regions a value for
f = 0.017 would apply.
In extremely low temperatures a value for f up to 0.035 would be used.
12.4
Basis of calculations
The mass of rotating parts mR (kg/m) is calculated from the weight of the
rotating idler rollers on the carrying and return runs.
mRo
mR =
mRu
+
lo
mRo
mRu
lo
lu
( kg/m )
lu
( kg )
( kg )
(m)
(m)
Mass of rollers
mRo et mRu
For the masses mRO and mRu (kg). Applicable to standard rollers diameters
and belt widths 300 mm to 2200 mm. See table in the Appendix.
Roller Pitch
If this information is not available roller pitch values as per Page 11.3 may be
used.
63.5
88.9
108
133
159
193.7
219.1
51
57
63.5
88.9
108
133
Disc rollers
dia. mm.
120
133
150
180
180
215
215
250
The idlers and discs may vary from manufacturer to manufacturer. For location of disc rollers see Appendix M.1.
Mass of Belt mG
Belt weight per m
The mass of the belt mG is determined from the weights of the various belt
types.
mG = mG * B
mG ( kg/m2 )
B
(m)
( kg/m )
For the belt weights mG (kg/m2) of the DUNLOP-belt types see Appendix C.
12.5
Basis of calculations
The load mL is derived from the cross sectional area of the bulk load stream
Qm alternatively with piece loads, from the weight of one piece.
Qm
For bulk loads
mL =
( kg/m )
3.6 * v
mst
mL =
( kg/m )
lst + ast
Qm
v
mst
lst
ast
Peripheral Force FA
at Start-Up
( t/h )
( m/s )
( kg )
(m)
(m)
Loadstream mass
Belt speed
Weight of each piece
Length of each piece
Spacing of pieces
Recommendations
The maximum peripheral force FA should not be greater than approx (1.3 to
1.5) * Fu, the steady state running peripheral force.
In order to accelerate the masses on the conveying length, a force equivalent to a minimum of 20% of the motional resistances should be available.
The peripheral force FA should be applied to the belt over such a period of
time that the installation is maintained at almost a steady state and so accelerates with minimum additional dynamic forces.
At start-up with acceleration aA and peripheral for FA one should seek to
ascertain the friction cut-off value between material and belt ( perhaps also
when braking)
Friction cut-off
Material Belt
()
1
(-)
aA
( m/s2 )
( m/s2 )
12.6
Basis of calculations
Start-Up Factor kA
Rigid Couplings
FA = kA *
PN
v
kA
Flexible Coupling
PN * * 1000
( kW )
(-)
( m/s )
(-)
(N)
v
installed motor power
degree of drive efficiency
speed
start-up factor
KA = 2.0 to 2.2
if FA > FU * 2.5 then FA should = 2.5 * FU, (cut-off torque)
With this type of coupling the start-up torque of the motor is reduced.
PN
FA = kA * FU *
PM
kA
( kW )
(-)
(N)
PM
With hydraulic couplings the start-up torque can be regulated and limited to
the desired start-up factor and by doing this, depending on the size of the
installation, a near steady state running condition can be achieved.
FA = kA * FU
kA
(-)
(N)
start-up factor,
kA = 1.2 to 1.5
regulated by the volume of oil in the working circuit.
At start-up and braking the acceleration and deceleration forces of the mass
being moved have to be considered. If the drive elements (motor, coupling,
gears) and the non-driven pulley resistances are higher than the remaining
resistances, this has to be taken into account.
Acceleration aA
FA - FU
aA =
mRed
mAred
mred
( m/s2 )
L * ( mRed + 2 * mG + mL ) +
mAred +
mred
( kg/m )
( kg/m )
( kg/m )
Acceleration time
tA = v / aA
(s)
Acceleration Distance
sA = v * tA / 2
(m)
12.7
Basis of calculations
Peripheral Force FB
on Braking
Peripheral Force FB
aB = v / tB
( m/s2 )
Overun Distance
sB = v * tB / 2
(m)
FB = aB * L * ( mRed + 2 * mG + mL ) + FU + FT
FT
(N)
(N)
If a great proportion arises from the non-braked elements these forces must be
added.
FT = aB *
mred
(N)
PN
Braking torque of the Motor
MM = 975 * g *
( Nm )
n
The brake has to take account of the braking duty and delay.
Delay Moment
MV =
FB * B
( Nm )
MBr = MM + MV
n
B
FB
i
( T/min )
(-)
(N)
(-)
PT =
( Nm )
Motor revolutions
Friction value of brake disc
Peripheral force on braking
Transmission ratio
FU * v
( kW )
1000
PM = PT /
( kW ) FU > 0
Motor Power on
Braked Installation
PM = PT *
( kW ) FU < 0
PN
12.8
Basis of calculations
Degree of Efficiency
(Values)
Types of Drive
Wormgear drive
Toothed chain drive
V-Rope drive
Pulley motor
Normal coupled drive
Geared and hydraulic coupling
Hydraulic motor
0.7 - 0.8
0.9 - 0.95
0.95
0.96
0.94
0.90
0.86
Braked installations
0.95 - 1.0
3.0
37
250
4.0
45
315
5.5
55
400
7.5
75
500
11
90
630
15
110
18.5
132
Drive System
After the peripheral force FU has been ascertained and hence the drive power
PT requirement, the drive system, position and number of motors can be
established.
The single pulley head drive is the most common all drive systems. With horizontal and inclined conveyors these give the most favourable belt stresses
and with declined conveyors with gradients of 1 to 2 providing the peripheral force remains positive.
T1
FU
T2
Tail Drive
The preferred location of the drive on a declined conveyor is at the tail end.
The drive becomes a generator and acts as a brake.
T2
FUB
T3
T1
T4
P1
Fu
FU1
12.9
Basis of calculations
Total Power
( kW )
Fo (Primary force)
P1
= x
Distribution
P2
Fu (Secondary force)
Motor 2
P2 = PT / ( x + 1 )
( kW )
FU2 = FU / ( x + 1 )
FU1 = FU - FU2
(N)
(N)
With identical drives i.e. P1 = P2, T4 may be less than Tmin and the pretension
has to be increased accordingly.
Dual Pulley Head Drive
With high drive powers it is often necessary to distribute the available peripheral force over two pulleys. The angle of wrap can thus be increased to
approx 420.
Pulley 1
P1
T1
FU1
T2
Pulley 2
P2
FU2
PT = P1 + P2
Distribution
P2
e1 - 1
FU1
P1
FU2
( kW )
e2 - 1
e2 = x
Value for
factor x
see Table
Motor 2
P2 = PT / ( x + 1 )
( kW )
FU2 = FU / ( x + 1 )
FU1 = FU - FU2
(N)
As a rule the friction coefficient is taken to be the same for both pulleys.
12.10
Basis of calculations
Pulley 2
Angle of Wrap 1
= 0.25
160
170
180
190
200
210
160
170
180
190
200
210
2.00
1.90
1.83
1.77
1.71
1.67
2.20
2.10
2.02
1.95
1.89
1.83
2.40
2.30
2.20
2.12
2.06
2.00
2.60
2.48
2.38
2.30
2.23
2.17
2.80
2.67
2.57
2.48
2.40
2.33
3.00
2.86
2.75
2.65
2.57
2.50
= 0.3
160
170
180
190
200
210
160
170
180
190
200
210
2.31
2.22
2.15
2.08
2.02
1.97
2.53
2.43
2.35
2.28
2.21
2.15
2.76
2.66
2.57
2.48
2.41
2.35
3.00
2.89
2.79
2.70
2.62
2.55
3.26
3.14
3.03
2.93
2.85
2.77
3.53
3.40
3.28
3.18
3.08
3.00
= 0.35
160
170
180
190
200
210
160
170
180
190
200
210
2.66
2.56
2.48
2.41
2.35
2.29
2.92
2.82
2.74
2.66
2.58
2.52
3.20
3.10
3.00
2.92
2.84
2.77
3.51
3.39
3.29
3.19
3.11
3.03
3.84
3.70
3.59
3.48
3.39
3.31
4.18
4.03
3.91
3.80
3.70
3.61
2
2
2
Pulley 1
In practice the most favourable distribution of power does not often occur
because the norm is to use equal drive units. As a result of this the drive pulleys are not equally utilized. With unequal distribution of the total power,
the drive powers for individual pulleys are thus:
Total Power
PT = P1 + P2
FU1
P1
Distribution
=x
P2
( kW )
FU2
FU2 = FU / ( x + 1 )
FU1 = FU - FU2
(N)
(N)
12.11
Basis of calculations
Before the belt tensions are determined it necessary to check whether the
peripheral force of Pulley 1 or peripheral force of Pulley 2 are fully utilized.
Distribution
proportion
Utilization of
peripheral force
Belt stresses
P1/P2 > x
Pulley 1 full
utilization
P1/P2 x
Pulley 2 full
utilization
T2 = FU2 * c22
T1 = T2 + FU
1
c12 =
e1 - 1
1
c22 =
e2 - 1
This drive system is treated in the same way as a dual pulley head drive
system.
Pulley 1
P1
FU1
Pulley 3
P3
FU3
Pulley 2
P2
FU2
PT = P1 + P2 + P3
( kW )
Peripheral Forces
(N)
P1 + P2
FU1 + FU2
x
P3
FU3
FU3 = FU / ( x + 1 )
(N)
(N)
FU1
P1
=w
FU2
FU2 = Fk / ( w + 1 )
(N)
FU1 = Fk - FU2
(N)
The calculation of belt stresses is as described under Dual Pulley Head Drive.
Other Drive Systems
Besides the drive systems described further drive distributions and arrangements are possible. These are treated in a similar fashion.
12.12
Basis of calculations
Belt Tension
(N)
(N)
T1A = FA * c1A
T2A = FA * c2A
1
c1 = 1+
(N)
(N)
1
c2 =
e - 1
e - 1
At start-up of the installation the friction value increases slightly for a short
period of time, therefore calculate thus.
Friction value at start-up
A + 0.05
1
c1A = 1+
1
c2A =
eA - 1
eA - 1
Belt tensions thus calculated are not yet the belt tensions that will actually
occur when working. They may be used for estimating purposes on small
installations. For exact and ongoing calculations the following corrections are
necessary.
Depending on the type of take-up system, a correction of the belt tension is necessary.
With a fixed take-up the tension pulley is at a fixed location after tensioning.
The centre to centre distance does not change. Depending on changing
loads, the belt stretches and contracts within its elastic limits. The total elongation is constant. For all working condition, the sum of the belt tensions
has to be constant.
TWorking =
TStart-Up = Constant
The pre-tension has to be calculated and set so as to take account of the nonsteady state running conditions such as start-up and braking. The location of
the take-up pulley does not matter. It can be at the discharge end, the tail end
or the middle of the conveyor installation.
Return
T4
T3
Fv
T2
T1
Drive
12.13
Basis of calculations
Stress Distribution
The belt tensions on the bend pulleys are higher at rest than they are when
running.
T1
g
Runnin
TM
At Rest
T4
T3
T2
TM =
TB / 4
(N)
=
TA / 4
(N)
Because the length of the belt does not alter, the take-up is constant.
Take-up
sB = sA
SB
SA
( mm )
( mm )
( mm )
Take-up when running
Take-up at start-up
The pre-tension has to cater for start-up therefore all belt tensions increase by
the difference between running and start-up conditions.
Correction value
for fixed take-up
T =
TA -
TB
(N)
4
With a fixed take-up, all belt tensions when running are increased by the
correction value T.
1. Correction with
moveable take-up
With the movable take-up the belt length is not constant. With changes in
belt stress the take-up weight adjusts to the various belt elongations/length
changes. The belt tensions at the take-up location are always the same. The
take-up weight has to be calculated to cater for the non-steady state running
conditions such as start-up and braking. The belt tensions at the take-up
location are always higher than those necessary for the steady state running
condition.
The take-up weight can be installed at the drive, the tail or at any location.
T1
Fv
T4
T3
T2
Fv
12.14
Basis of calculations
Stress Distribution
The size of the take-up weight depends on the location of the take-up
system.
At rest
Running
T1
T4
T2
T3
Take-up tension
FV = T3 + T4
Take-up weight
GV = FV / g
or
FV = 2 * T2
(N)
( kg )
Because the tension weight is effective both at rest and during running, all
belt tensions increase by the correction value T.
Correction Value
2. Correction
T = TA2 - T2
(N)
The control of minimum belt tension. Tmin is necessary in order that the
belt sag between carrying idlers at the loading point does not exceed a certain value.
Tmin =
( mL + mG ) * lo * g
(N)
8 * hrel
hrel = h / lo
hrel =
hrel =
lo
(mm)
h
(mm)
Sag ratio
0.005 to 0.015 for carrying side
0.020 to 0.030 for return side
Distance between the carrying idlers
Belt sag (see Page 11.2)
If the loading T4 < Tmin the belt would sag between the idlers. To avoid this,
all belt tensions have to be increased by the correction value T.
Correction Value
T = Tmin - T4
(N)
12.15
Basis of calculations
Sequential Calculation
The tensions T1 to T4 are best determined according to the sequential calculation principle. This method enables the tension to be ascertained at any given
point on the installation as well as under certain working conditions such as
start-up and braking.
Force Distribution
The forces that affect the belt are determined according to their size and
direction in which they operate. Those are the secondary resistances which
arise at the loading point, friction resistances, the slope resistance and the
inertial resistances at start-up and braking.
The force diagram can be applied to the carrying side, return side as well as
to drive and return pulleys.
The point tensions T1 to T4 can be calculated from the condition
F = 0.
Fao
Fbo
T1
Fo
Fsto
FU
v
FN
aA
T2
aB
aB
Fu
Fbu
FUTail
Fau
FU
T1
T4
aA
T4
Fstu
T3
T2
T3
FUTail
Tail drive
Carrying side
Return side
with Head Drive
with Tail Drive
Individual Resistances
0 = T1 - T4 - FN - Fo - Fsto - Fao
0 = T3 - T2 - Fu + Fstu - Fau
0 = T1 - FU - T2
0 = T4 + FU Heck - T3
( m/s2 )
( kg/m )
( kg/m )
FH = f * L * g * (mR + 2 * mG * mL)
FN = ( C - 1 ) * FH
Fo = f * L * g * (mRo + mG + mL)
Fu = f * L * g * (mRu + mG)
Fsto = H * g * (mG + mL)
Fstu = H * g * mG
Fao = L * a * (mRedo + mG + mL)
Fau = L * a * (mRedu + mG)
Acceleration aA or deceleration aB
Reduced mass of carrying idlers
Reduced mass of return idlers
Reduced mass
mRed 0.9 * mR
12.16
Basis of calculations
Determination of the point tensions (T1 to T4 and TA1 to TA4 with the help of
individual resistances (for peripheral force FU 0. positive).
T1
FN
FU
T2
T4
T3
T2
T3
T4
T1
= FU * c2
= T2 + Fu - Fstu
= T3
= T4 + FN + Fo + Fsto
Control
TA2 = FA * c2A
TA3 = TA2 + Fu - Fstu + Fau
TA4 = TA3
TA1 = TA4 + FN + Fo + Fsto + Fao
Non-steady state working
T2 = T1 - FU
TA2 = TA1 - FA
The tensions T1 to T4 and TA1 to TA4 must be increased by T, if the following conditions apply:
1. With fixed take-up
2. With movable take-up
3. With minimum belt tension
if
TA >
T
if TA2 > T2
if Tmin > T4
To calculate braking forces the peripheral force FB on braking has to be determined. The sequential calculation for non-steady state working then begins
with
TB2 = FB * c2A
The inertial mass resistance Fbo and Fbu is determined with the deceleration
aB. The belt tension TB2 lies on the tight side of the drive pulley.
Otherwise the sequential calculation can be done along the same lines.
12.17
Basis of calculations
Tail Drive
T3
FN
T4
T2
FU
T2
T3
T4
T1
For FU 0
T1
= FU * c2
= T2 + Fu + Fo + Fsto
= T3
= T4 + Fu - Fstu
TA2 = FA * c2A
TA3 = TA2 + FN + Fo + Fsto + Fao
TA4 = TA3
TA1 = TA4 + Fu - Fstu + Fau
Control
T1
FN
FU
Tail Drive
(Braking)
T2
T4
For FU < 0
T3
T2
T3
T4
T1
= FU * c2
= T2 - Fu - Fstu
= T3
= T4 - FN - Fo + Fsto
TA2 = FA * c2A
TA3 = TA2 - Fu - Fstu + Fau
TA4 = TA3
TA1 = TA4 - FN - Fo + Fsto + Fao
Belt tensions non-steady state
working (start-up)
T2 = T1 - FU
TA2 = TA1 - FA
12.18
Basis of calculations
T1
FU1
T2
T4
FU2
T2
T3
T4
T1
For FU 0
T3
= FU1 * c2
= T2 + Fu - Fstu
= T3 - FU2
= T4 + FN + Fo + Fsto
Control
Correction
T2 = T1 - FU
TA2 = TA1 - FA
FU1
T4
For FU 0
FU2
T3
T2
T3
T4
T1
Belt Tension T2
The belt tension T2 is dependent on the destribution of the start-up force i.e.
of the utilization of the peripherical force by drive pulley 1 or 2.
Refer to page 12.12.
12.19
Basis of calculations
A belt conveyor can be divided into sections according to certain working and
topographical conditions with differing lengths and heights. The resistance to
motion for these sections can be calculated as previously with loading point
and discharge point or other special resistances being apportioned to the
section where the resistance occurs.
Section Calculation
Total Resistance
Peripheral Force
(N)
With varying conditions and changing loads on certain sections, greater or lesser resistance to motion can occur, e.g. belt force with continuous loading.
To determine these points, the resistances have to be ascertained under
various working conditions such as load run-on and run-off conditions and
running unloaded.
At the same time it can be established whether the installation has to be
driven by or braked by the motor.
L2
L3
L4
L1
sec
se
sec 4
c2
H3
H2
H4
sec 1
Continuous Load
Continuous Empty
Start of Loading
Ending of Loading
To determine the individual resistances the values of L and H have to be
substituted in the formulae by Lx and Hx of the respective sections.
Under certain circumstances the following working conditions may have to be
examined:
Inclined loaded sections.
Declined loaded sections.
12.20
Basis of calculations
After the belt width B (mm) has been established, the maximum belt tension
for the steady state and non-steady state working conditions is calculated,
the nominal breaking strength kN of the belt can be ascertained and the
belt type chosen.
Nominal belt strength steady
state working
kN =
Tmax * SB
( N/mm )
B * cv
Nominal belt strength
non-steady state running
kN =
TAmax * SA
( N/mm )
B * cv
Tmax
TAmax
cv
B
(N)
(N)
(-)
( mm )
The safety factor of the selected belt is determined and verified. For certain
running conditions there are laid down minimum safety values.
SB =
kN * B * cv
(-)
SA =
kN * B * cv
Tmax
Steady state
(-)
TAmax
Non-steady state
For textile and steel cord belts the following safety factor values can be
used:
Working Conditions
Drive Conditions
Steady state
Non-steady state
SB
SA
6.7
4.8
Normal
8.0
5.4
9.5
6.0
For mechanical joints and cold splices other factors apply (see manufacturers
recommendations).
12.21
Basis of calculations
For the selection and correct dimensioning of the belt type a number of criteria and principal influences need to be taken into account. Firstly is the
maximum belt tension decisive in the dimensioning of the carcase. It is
essential to observe the factors of safety for both the running and start-up
conditions. As well as these calculations, further conditions which could
influence the strength, number of plies and quality of the belt have to be
considered.
The belt nominal strength KN is rounded up to the next standard belt type.
When rounding down, the safety factor needs to be checked. Further Criteria
have to be observed.
Belt Safety
With the safety factor S the influence of the following are considered:
Additional stresses at curves
Overload at start-up
Tensile strength loss due to disproportionate contribution of the plies
Strength loss due to impact
Deleterious effects from penetration, ageing etc.
The values according to the table on page 12.21 should be observed. For the
start-up condition the value TAmax is used when calculating because at startup the friction values of the drive pulley increase for a brief period of time.
With smaller installations it is not always necessary to verify the calculated
value of SA.
Load support
Certain characteristics of the material load may in turn affect the belt width
dimensioning. The wider the belt and the heavier the load the higher the
strength and the thicker the belt construction irrespective of the calculated
strength requirement.
With the help of the Belt Selection Table (see page 12.25) the appropriate
belt type can be determined depending on the belt width, lump size and
bulk density. With a belt of a lesser type than that recommended there is no
guarantee of stable running.
Number of Plies
In the case of multiply belts such as the SUPERFORT range, the strength of
one ply is lost at the joint. With highly stressed and impacted belts this has to
be taken into account additionally. In general the carcases of wider belts
should contain more plies. This does not apply to special constructions such
as DUNLOFLEX and TRIOFLEX.
Impact energy
The impact energy due to the free fall height of material, can be reduced at
the loading point by means of deflection plates, chute and screen bars etc. If
this is not possible or only so to a limited extent more or higher strength plies
should be considered. In special cases a breaker ply is embedded in the carrying side cover to project the carcase.
High Temperature
When hot materials are to be conveyed the appropriate heat resistant quality rubber covers have to be selected. In so doing it is necessary to differentiate between the temperature of the load and the permissible temperature of
the belt. The carrying side cover should be thicker than normal and stronger
plies specified. In this way the heat absorption capability is increased and the
elongation due to the influence of heat is reduced.
Further influences are:
The belt speed and hence the heating up and cooling down periods.
The material lump size and the contact density on the carrying side cover.
Installation location (inside or outside, open or closed) and hence perhaps
the effect of a heat concentration.
12.22
Basis of calculations
Low Temperature
With extreme low temperature conditions account must be taken of the higher flexing resistance of the belt. Select the fiction factor f accordingly. The
cover quality should be one containing a high percentage of natural rubber.
Depending upon the compounding of the rubber, belts can be used down
to -30C (maximum to -40C). PVC belts down to -15C.
Troughability
With thicker and stronger belts it is necessary to verify whether the belt will
conform to the troughing angle of the idlers. For good troughing conditions
approx 40% of the belt width when running empty should be making tangential contact. Approximately 10% should make contact with the centre carrying
idler roller (Recommendation see Page 12.29).
Cover Thickness
When selecting belt covers, not only the quality appropriate for the load material has to be considered, but it is also necessary to ensure there is sufficient
thickness of cover on both the carrying and pulley sides of the belt. If the carrying side cover is much thicker than 3 times the pulley side cover there is
the risk of the belt curling at its edges. (Recommendations see Page 12.30).
With steep inclined conveying using profiled belts from the Chevron or High
Chevron ranges, a carcase should be selected that is 1 or 2 plies stronger
than calculated or in accordance with the belt selection table. By doing this
the running stability is improved especially under wet and frosty conditions.
This can also be an advantage with smooth surface belts which convey steeper than 12.
Normal cover qualities tend to swell even if the load to be conveyed has only
the smallest percentage of oil or fats and the rubber tends to soften. Account
has to be taken as to whether the oil or fat is mineral or vegetable based.
Also the temperature and possibly acidity has to be taken into consideration.
Food Stuffs
To convey food stuffs, the cover quality must comply with National and
International regulations. One has to differentiate between unpacked and
packed food-stuffs. The most important regulations at present are:
FDA/USDA: Food and Drug Administration U.S.
Unbedenklichkeitsempfehlung XXVII. BGA
British Code of Practice for Food Contact Applications.
Chemical Effects
Safety Regulations
12.23
Basis of calculations
Gallery Test
25
1200 x 90
sample
2000 x B
200
sample
sample
200
450
remaining piece
remaining piece
n = 190 10 min-1
Number of samples
6(3+3)
10 min
Time in Flame
45 s
15 min
Requirements
b) Individual <15
c) No ignition after air
current
a) No reignition
Residual piece full width
not affected
Method of Tensioning
Take-up Travel
The type of tensioning system and the amount of available take-up travel can
be important considerations when selecting the belt type having particular
reference to elongation behaviour.
12.24
Basis of calculations
In the first instance the belt is selected according to the tensile strength
requirements. In many cases types selected on this basis alone, would be
inappropriate because they do not take into account the belt width, the bulk
density and the material lump size. Tracking, sag and transverse stability
need to be taken into account. It is recommended that the belt type selected
should be verified according to the belt type reference number.
Material characteristics
Bulks Density
(t/m3)
Lump Size
(mm)
400
500
650
800
1000
1200
1400
1600
1800
2000
up to 1
0.5-10
1.1 - 1.5
100
+ 100
1
-
1
-
1
2
2
2
3
3
3
3
4
5
4
5
5
5
5
5
1.6 - 2.5
100
+ 100
2
3
3
3
3
4
4
4
5
6
5
6
5
6
5
6
over 2.5
100
+ 100
3
4
3
4
4
5
5
5
6
6
6
7
6
7
6
7
1. With a lump size over approximately 400 mm select one reference number
higher possibly.
2. With lump sizes over 100 mm it is desirable that approximately 30% fines
be present. Without such fines the load impact energy has to be taken
into account.
Belt Type
Reference
SUPERFORT
EP Multiply
DUNLOFLEX
2 Ply Belt
EP 200/3
D 200
EP 315/3
D 250
D 315
EP 250/4
EP 315/4
EP 500/3
EP 630/3
D 400
T 250
EP 400/4
EP 500/4
D 500
T 315
T 400
EP 315/5
EP 400/4
EP 500/5
EP 630/4
T 500
EP 500/5
EP 630/5
EP 800/4
T 630
EP 800/5
T 800
TRIOFLEX
3 Ply Belt
12.25
Basis of calculations
Load Demands
At the loading point the demands made of the belt are particularly high. The
load has to be accelerated to the belt speed and often at the same time it
changes in direction of travel and elevation. With coarse material and high
falls the carcase of the belt is subject to additional stresses. These have to be
taken into account when dimensioning the belt.
V
Vh
Ef = mst * g * Hf
V1
Vv
mst
g
Hf
( Nm )
( kg )
massof a piece (lump)
( m/s2 ) acceleration due to gravity
(m)
delivery height (free fall or via chute)
With the value Ef and with the help of the diagram on Page 12.27. an appropriate belt type can be selected.
Mass of a piece
mst = Vst *
( dm3 )
( kg/dm3 )
Vst
Material
Density
(kg/dm3)
Anthracite
Concrete (Gravel)
Brown Iron Stone
Brown Coal (Lignite)
Manganese Dioxide
Earth
Fluorspar
Gypsum Burnt
Granite
Timber, Green
Timber, Seasoned
Lime, Burnt
Limestone
1.5 - 1.7
2.2
3.5 - 4.0
1.2 - 1.5
5.0
1.3 - 2.0
3.2
1.8
2.5 - 3.0
0.7 - 1.3
0.4 - 1.0
2.3 - 3.2
1.9
Coke
Marble
Paper
Coal Briquette
Sandstone
Shale
Slag (Furnace)
Soapstone
Bituminous Coal
Rock Salt
Clay, Dry
Clay, Fresh
Tile
1.2 - 1.4
2.5 - 2.8
0.7 - 1.2
1.3
2.2 - 2.5
2.7
2.5 - 3.0
2.7
1.3 - 1.4
2.3 - 2.4
1.8
2.6
1.4 - 2.0
The surface condition of the material influences what effect the impact energy has. With soft rounded material the belt is less stressed compared with
that struck by hard sharp edged material.
Physical
Shape
Material
Correction
Vst = 0,52 * l3
Angular, irregular
such as limestone
and gravels
1.0-2.0 t/m3
Type according to
table. See page
12.27
Vst = l3
Vst = 0,192 * k3
k =3*l
Vst = 2 * l3
Vst = 0,136 * k3
k = 6 * l
Vst = l3
Vst = 0,083 * k3
k = 5,25 * l
k
l
Volumes Vst
If the mass of a piece of
material is not known, it can
be estimated from it volume.
With regard to physical shape
and by taking the edge length
1 or the diagonal measurement corner to corner k, the
volume Vst can be established
Density
(kg/dm3)
2l
State of Material
Material
1 type lower
k
0,5 * l
2l
Material Density
( kg )
12.26
Basis of calculations
Belt Selection
This diagram shows belt types in relation to impact energy and makes an allowance of safety over that of the critical impact energy which could otherwise
lead to damage.
40
00
30
00
20
00
00
00
75
ll E
50
Fa
(N
15
Ef
10
m)
ie
erg
0
40
0
30
0
20
0
15
0
10
0
50
2500/5
2000/5
1600/5
1000/4
800/4
630/4
4000
3150
2500
TRIOFLEX
2000
1600
1000
1250
800
1250
800
1000
630
500/3
SUPERFORT
3-5 ply
DUNLOFLEX
500
400/3
315
400
500
630
400
315/3
250
315
250/3
200
1250/5
Belt Type
Steel Cord
Height of chute
Impact Arrangements
The thickness of the covers also contributes to the reduction of the impact
energy and should be calculated to suit. (Recommendations see Page 12.30).
Cover Quality
The friction due to granulated material acceleration increases the abrasion and irregular lump acceleration causes more cover damage, grooves
and tears.
V1
V2
V
Abrasion length
Acceleration relating to friction
12.27
Basis of calculations
12.28
Basis of calculations
Troughability
B d * c * kW * cG
(m)
d
c
kW
cG
b3
b2
b 40% of B
b2 10% of
b
Troughing Angle
Factor c
20
25
30
35
40
45
0.64
0.71
0.77
0.83
0.89
0 .93
1.00
Test of Troughability
ST
Value kW
Factor cG
thickness of carcase
factor for troughing angle
value for carcase material
factor for belt weight
15
Material of Weft
Belt Weight
(kg/m2)
( mm )
(-)
(-)
(-)
10
12
14
16
18
0.29
20
22
24
26
28
0.50 0.47 0.44 0.41 0.38 0.37 0.36 0.355 0.35 0.345 0.34
The test of troughability may be carried out according to ISO R 703 (1975)
or DIN 22102 (1991).
A 150 mm long full width belt test piece is suspended, friction free, by means
of cords whose lengths are according to the belt width. After 5 minutes the
sag s is measured and the sag ratio s/B is determined.
Sag Ratio s/B (minimum values)
Suspension cords
Troughing Angle 20
Sag s/B
25
30
35
40
45
50
55
60
Belt sample
12.29
Basis of calculations
Cover Thickness
Loading Conditions
dM
(mm)
dZ
(mm)
dT = dm + dz
( mm )
Minimum thickness
For textile belts : 1 to 2 mm depending on fabric
For ST belts: 0.7 * cord diameter, minimum 4mm
Addition to minimum thickness
The value dz is determined from the sum of the rating numbers for different
loading conditions and material characteristics.
Loading Conditions
Favourable
Average
Unfavourable
< 500
500-2000
> 2000
< 30
30-60
60-100
good
normal
moderate
Rating Number
Influence Factor
Criteria
Loading condition
Favourable
Average
Unfavourable
1
2
3
Loading cycle
> 60
20 to 60
< 20
1
2
3
< 50
50 to 100
> 150
1
2
3
< 1.0
1 to 1.8
> 1.8
1
2
3
Abrasiveness
Slight
Average
Severe
1
2
3
fB =
Value dz
2*L
v
Sum of rating
numbers
5 to 6
7 to 8
9 to 11
12 to 13
14 to 15
(s)
Rating Number
dz (mm)
0 to 1
1 to 3
3 to 6
6 to 10
10
12.30
Basis of calculations
Take-Up
During running the conveyor belt has to accommodate the stress changes
that occur between start-up, running, full load running and running empty.
These result in elastic elongation of the belt and thus a change in belt length.
This difference between the elongation under the installed pre-tension with
the conveyor at rest and the total elongation under full load running conditions is the additional running elongation.
The elongation is not spread proportionally over the belt circumference but is
dependent upon the effective belt tension and the elongation behaviour of
the plies i.e. the carcase materials.
The length change resulting from the pre-tension and the running elongation
is accommodated by an appropriately dimensioned take-up unit (see Page
6.1).
The elongation of the belt increases with increasing temperature (hot material
and high ambient temperature). The take-up travel is calculated from the relation E = T/B/ (Hooks Law). This is calculated utilizing the average tensions
TMo on the carrying side run and TMu on the return side run.
Tension of
the fully loa
ded belt
ges =
T1 + T2
2*B*E
Length Changes
T3 + T4
+
=
2*B*E
T * L * 2
(-)
2*B*E
L
sp =
2*B*E
Take-up Travel Lengths
sp
T * L
(-)
(m)
(m)
(m)
(-)
( N/mm )
T * L
2*B*E
E
B
L
Lges
kD
kN
(m)
2
(m)
2 * B * kD * kN
Elastic modulus
Belt width
Conveying length
Belt length 2 * conveying length
Elongation value (see Appendix 1.2)
Nominal belt strength
( bl + el )
Sp = L *
(m)
100
bl ( % ) Permanent elongation
el ( % ) Elastic elongation
12.31
Calculation Example
Service Data
Belt Conveyor with a single pulley head drive conveying sand and gravel,
lump size up to 200 mm.
Capacity
Bulk Density
Degree of Filling
Conveying Length
Conveying Height
Belt Width
Troughing
Qm = 1000 t/h
= 1.5 t/m3
= 70%
L = 258 m
H = 17.9 m
B = 1200 mm
= 35 3 Roll
212
17.9
40
4.8
Short Calculation
Power Empty +
horizontal
Conveying
P1 =
cB * v + Qm
cL * kf
Width Factor
Length Factor
Factor
P2 =
cB
cL
kf
H * Qm
17.9 * 1000
367
PT = P1 + P2
Required
motor power
PM =
Installed
motor power
PN = 110 kW (selected)
= 77 kW
77
= 85.6 kW
0.9
k =
cR * PT
cv * v
EP 1000/4
15 * 77
= 917 N/mm
0.75 * 1.68
Friction factor cR
Breaking strength loss cv
used = 0.3
Belt with 4 plies
Belt selection
= 48.8 kW
367
Power at
drive pulley
Belt breaking
strength
= 28.2 kW
52 * 1
8 + 4 mm covers
Belt weight
25.4 kg
Carcase thickness 5.8 mm
13.1
Calculation Example
FU = C * f * L * g [ mR + ( 2 * mG + mL ) * cos ] + H * g * mL
Factor C = 1.37
Friction factor f = 0.02
22.3
19.3
+
1.2
mG = 25.4 kg/m
mL =
1000
= 165.3 kg/m
3.6 * 1.68
Peripheral Force
Incline
= 4.8
Start-up factor
kA = 1.5
(hydraulic coupling)
Non-steady state
FA = 45924 * 1.5
Power at pulley
PT =
45923 * 1.68
= 68885 N
= 77.2 kW
1000
drive degree of efficiency = 0.9
PT
Motor power
PM =
= 85.7 kW
0.9
PN = 110 kW (selected)
Tmin =
( mL + mG ) * g * lo
= 28061 N
8 * 0.01
With belt sag
Carrying side idle pitch
1%
lo = 1.2m
68885 - 45924
Acceleration
aA =
= 0.368 m/s2
tA =
= 4.56 s
0.368
Start-up distance
sA =
1.68 * 4.56
= 3.83 m
13.2
Calculation Example
Secondary resistance
Frictional Resistances
Carrying side
Return side
Slope Resistance
Carrying side
Return side
Inertial Resistance
Carrying side
Return side
= 19725 N
= 3237 N
Sequential Calculation T1 to T4
Running (steady state)
Control T1
T2 = FU * c2 = 45924 * 0.5
T3 = 22962 + 1768 - 4460
T4 = T3
T1 = 20269 + 4563 + 10566 + 33486
Sum
T1 = FU * c1 = 45924 * 1.5
TA2
TA3
TA4
TA1
Control TA1
TA1
= 22961 N
= 20269 N
= 20269 N
= 68884 N
= 132383 N
= 68884 N
= 26424 N
= 26969 N
= 26969 N
= 95309 N
= 175671 N
= 95309 N
TA1 = 95309 N
TA2 = 26424 N
TA3 = 26969 N
TA4 = 26969 N
2nd Adjustment
Belt Tensions
T1 =
T2 =
T3 =
T4 =
76675 N
30752 N
28061 N
28061 N
T = 163549 N
TA1 =
TA2 =
TA3 =
TA4 =
99637 N
30752 N
31297 N
31297 N
TA = 192983 N
13.3
Calculation Example
TA1 = 95309 N
TA2 = 26424 N
TA3 = 26969 N
TA4 = 26969 N
2nd Adjustment
Belt Tensions
T1 =
T2 =
T3 =
T4 =
Stipulation
76675 N
30752 N
28061 N
28061 N
TA1 =
TA2 =
TA3 =
TA4 =
96401 N
27516 N
28061 N
28061 N
T = 163549 N
TA = 180039 N
1. T4 = TA4
2. T4 Tmin
T = TA
T = (175671 - 132383) / 4 =
10822 N
T1 =
T2 =
T3 =
T4 =
95309 N
26424 N
26969 N
26969 N
79706 N
33783 N
31091 N
31091 N
= 175671 N
TA1 =
TA2 =
TA3 =
TA4 =
TA = 175671 N
2nd Adjustment
Belt Tensions
T1 =
T2 =
T3 =
T4 =
80797 N
34874 N
32183 N
32183 N
TA1 =
TA2 =
TA3 =
TA4 =
96401 N
27516 N
28061 N
28061 N
T = 180037 N
TA = 180037 N
Stipulation
1. T = TA
2. T4 or TA4 Tmin
Note
For Case 1 (tension weight at discharge) the belt tensions T1 and T2 would
suffice after Adjustment 1. To transmit the peripheral force FU friction cut off
wise. The condition T1/T2 e
would be fulfilled with = 0.3, A = 0.35 and
= 210 :
Running
Start-up
: T1/ T2
= 72347 / 26424 = 2.74 3
: TA1/ TA2 = 95309 / 26424 = 3.6 = e
With this condition however the belt would not have the desired degree of
sag of 1% at the tail end and fine grained material could escape under the
skirtboards at the loading point. The belt would undulate excessively resulting
in high wear and tear and extra energy consumption.
Sag without adjustment:
hd =
= 0.0118
23732 * 8
The degree of sag desired was 1%
13.4
Calculation Example
Belt Safety
S=
kN
cv
B
TX
kN * cv * B
TX
Working condition
Belt Safety S
Case 1 Case 2 Case 3
steady state
non-steady state
11.73
9.03
Take-up Travel
( N/mm )
(-)
( mm )
(N)
sp =
T * L
11.73
9.33
Case 1
Case 2
Case 3
2 * TA2
6265
2 * TA4
5720
T/4 * 2
9176
T in Case 1
at rest
running
at start-up
elongation value
( mm )
2 * B * k D * kN
Working condition
11.13
9.33
T = 4 * 30752 = 123008 N
T = 163549 N
T = 192983 N
kD ( - ) = 10.5
at rest
steady state
non-steady state
1259
1674
1975
1149
1674
1843
1843
1843
1843
DUNLOP-ENERKA
Safety Factors
Running
Start-up
Tail
Fixed Take-up
11.7
9.0
11.7
9.3
11.1
9.3
5387
6268
5500
5721
8955
9175
0.28
0.77
0.27
0.71
0.71
Pre-tension
Minimum
Maximum
kg
kg
Working elongation %
Total elongation %
13.5
Calculation Example
Pulley Diameter
DA = cTr * d
cTr
d
(-)
( mm )
Drive pulley
Bend pulley
Snub/deflection pulley
DA = 630 mm (selected)
DB = 500 mm
DC = 315 mm
1.68 * 60
v * 60
1.68 * 60v * 60
Pulley
nT =
= 51 =
U/min
nT = revolutions =
* DA
3.14 * 0.63
* DA
3.14 * 0.63
DA
(m)
DA
(m)
Trommeldurchmesser
FUA * DA
Maximum
torque
MA =
2
Pulley diameter
FUA
68885 * 0.63
68885
* DA
* 0.63
= MA =
==
21699 Nm
2
2 2
= 21699 Nm
Pulley loading
( TA1 + TA2 )
Drive
FAT =pulley
9.81
( TA1++30752
TA2 )
99637 + 30752
99637
F=AT =
= 13291 kg
==13291 Kg
9.81
9.81
9.81
( TA1 + TA2 )
pT = pressure
Surface
DA * B
( TA1 + TA2 )
130389
130389
2
p=T =
=
= 17.3 N/cm2
= 17.3 N/cm
63 * 120
63 * D
120
A*B
DA und B in cm
Troughing Transition
= 51 R/min
LM = x * s * sin
DA and B in cm
x=8
Factor for carcase
s = 367 mm Side idler roller contact made by belt
= 35
Troughing angle
Lift of pulley
for troughing 30
s2
h=
* sin
B
Reduced
transition length
s2
h=
3672B
=
3672
* sin
=
1200
* sin 35 = 65 mm
* sin 35 = 65 mm
1200
Lred = x * ( s * sin - h )
13.6
Calculation Example
Re = x * s * sin
Tx
Concave Vertical Curve
Ra =
29703
=
mG * 9.81 * cos
= 120 m
25.4 * 9.81 * cos 35
Co-ordinates of beginning
and end of the curve
17.9
sin =
= 4.8
= 0.0844
212
Ra
13.7
Calculation Example
Additional Tension
Adjustment
In the regions where the belt goes from flat to troughed, trough vertical and
horizontal curves or is turned over, additional stresses and strains occur at the
edge zones or in the belt centre. This can result in a reduction in the permissible minimum safety at the belt edges or belt centre. The tension can become
negative creating buckling at the centre or flapping at the edges. For additional information see Appendix 1.
The required values for the calculation for the belt safety running empty at
head and tail were extracted from the computer calculation.
Elongation at T1
(running)
0 =
Curve length
=
1
= 0.00814
10.5 * 11.7
3.14
* 35 = 0.61056
180
Additional elongation
Total elongation
K =
12002 * 0.61052
3672
*
16842
12002
367
* ( 0.5 -
) = 0.00705
3 * 1200
= 6.27 4
Smin =
no overstress
10.5 * 0.01519
Elongation at Belt Centre
Discharge Point
Min. safety at running empty
Smin = 25.8
Elongation at T1 empty
0 =
1
= 0.003692
10.5 * 25.8
Additional elongation
Total elongation
M =
12002 * 0.61052
3673
*
16842
= 0.0018049
3 * 12003
no buckling
Smin = 32.1
Elongation at T1 empty
0 =
1
= 0.0029669
10.5 * 32.1
Additional elongation
M = 0.0018049
Total elongation
no buckling
13.8
Calculation Example
Computer Calculation
DUNLOP-ENERKA
Firm
:
Project :
Position :
DATE 06.08.93
Musterman
Example
12
MATERIAL
Capacity
Conveying Length
Lift
belt Width
Belt Speed
1000 t/h
258.0 m
17.9 m
1200 mm
1.68 m/s
CONVEYOR BELT
Material
Density
Lump Size (mm)
Temperature
Surcharge Angle
DRIVE
PULLEYS
Drive Pulley
Tension Pulley
Snub Pulley
Max. Torque
Drive Pulley Rev
Load-Drive Pulley
Tension Pulley
Friction Factor
Drive Pulley
Weight
Safety Factor : Running SB = 11.7
: Start-up SA = 9.0
630 mm
500 mm
315 mm
21699 Nm
51.0 R/min
13290 kg
6268 kg
BELT SAG
Running
At Start-up
76667
30743
28061
28061
163532
99629
30743
31297
31297
192967
72349
26425
23743
23743
146260
95311
26425
26979
26979
175695
6268 kg
multiply
EP 1000/4
8 + 4 mm
RA
25.4 kg/m
IDLER ROLLERS
PRE-TENSION CRITERIA
Belt Type
Belt Type
Covers
Quality
Weight
5387 kg
Belt Elongation:
Under Pre-tension ....... 0.49 %
Working Elongation ..... 0.28 %
Total Elongation........... 0.77 %
Adjustments of
Transition Lengths
=
=
=
=
76667 N
34939 N
28061 N
28064 N
Discharge Full SB
Discharge Empty SB
Heck Full SB
Heck Empty SB
Dyn. Tensile Strength Smin
Transition Lengths
KD = 10.5
Belt EP 1000/4
=
=
=
=
=
Discharge L normal
Tail L normal
Discharge L reduced
Tail L reduced
Pulley Lift
11.7
25.8
32.1
32.1
4.0
Belt Edge
=
=
=
=
=
1686 mm
1686 mm
1170 mm
1170 mm
65 mm
Belt Centre
Troughing Transition
Criteria
Discharge L normal
Tail
L normal
Discharge L reduced
Tail
L reduced
0.01516
0.01001
0.01586
0.01071
6.28
9.51
6.01
8.89
0.00189
0.00116
0.00146
0.00074
No buckling
No buckling
No buckling
No buckling
13.9
Calculation Example
13.10
Slider Belts
The conveying of unit loads is generally done by slider belts with conveying
lengths up to about 100m. With heavy loads or long length conveying, the
belt is tracked over flat or slightly troughed idlers.
Drive Pulley
Carrying Side
Return Side
Idlers
Supporting Surface
The supporting or slider surface can be made from various materials with
different friction values e.g. steel, wood or synthetic.
Support Surface
To avoid a `suction effect with the belt, transverse slots can be made at
intervals in the supporting surface and perhaps relieving rollers fitted.
The belt width should be somewhat greater than the longest edge length of a
single piece except with pieces loaded in the direction of belt travel.
Belt Widths
Belt Width
Speed
The speed of the slider belt must be in keeping with the type of unit load. As
a rule V is from 0.2 to 1.5 m/s.
v=
l
( mm )
z*(l+a)
( m/s )
( m/s )
3600
l+a
v=
t
z
l
a
t
( pieces/hour)
(m)
(m)
(s)
14.1
Conveying Capacity
Qm =
l+a
z*m
( t/h )
1000
( t/h )
v
m
zm
z
L
Qm = 3.6 * v *
( m/s )
( kg )
( St/m )
( St/h )
(m)
zm * m
( t/h )
Belt speed
Mass of piece
Number each metre zm = L / ( l + a )
Pieces per hour
Conveying Length
Resistance to Motion
FU = Cg * ( Fo + Fu ) + Fst + FS
Peripheral Force
Secondary Resistances
(N)
The secondary resistances are independent of the installation length and only
occur at certain points. Only with relatively short installations is the value
greater that 1.
The secondary resistances are estimated using factor Cg. The value is dependent on the average surface loading. The effect of the secondary resistances
is considerably smaller than obtained from the friction value g between belt
and supporting surface.
Factor Cg
Conveying
Length
L (m)
2.5
5
10
25
50
>100
mG
pm =
For unit loads
B
mG
mL
B
b
l
mL
+
1.8
1.4
1.2
1.09
1.05
1
(kg/m)
(kg/m)
(m)
(m)
(m)
1.04
1.02
1.01
1
1
1
( kg/m2 )
mG + mL
pm =
( kg/m2 )
B
For bulk loads
14.2
Frictional Resistances
Frictional resistance occurs on the carrying and return side either sliding or
rolling resistance depending on how the belt is supported.
Carrying Side
Sliding
Fo = g * L * g * ( mL + mG )
(N)
On rollers
Fo = 2 * zR + 0.02 * L * g * ( mL + mG )
(N)
Sliding
Fu = g * L * g * mG
(N)
On rollers
Fu = 2 * zR + 0.02 * L * g * mG
(N)
Return Side
mL
mG
zR
g
Friction Value g
(kg/m)
(kg/m)
(pieces)
(-)
The average friction value between belt and supporting surface was determined thus:
Surface load p = 20 - 500 N/mm2
Speed
v = 0.2 - 0.8 m/s
Slider Bed Surface - Upper Surface Temperature (C)
-20
Cotton (bare)
EP (bare, impregnated)
Rubber covered
Cotton (PVC impregnated)
PVC (film)
PVC (smooth)
PVC (textured)
Temperature
Friction value g
1,4
0.75
0.30
0.70
0.30
0.60
0.60
0.55
0.50
0.55
0.60
0.70
0.65
PVC
Cotton Rayon
(bare)
B, Z, EP
1,2
1,0
0,8
0,4
0,2
Speed Surface
Loading
0.35
0.25
0.40
0.30
0.35
0.25
0.40
0.55
1.70
1.30
0.45
0.60
1.30
1.10
0.35
0.50
0.95
0.75
The friction value g is mainly dependent upon the combination of the belt
under side surface and the temperature, the speed and the surface loading.
-20 0 20 40 60 80 100
Temperature t in C
steel plate
hard synthetic
hard wood
0,8
0,8
0,6
Friction
value g
0,6
Friction
value g
Hard Wood
+18
With increasing temperature the friction value g increases with PVC running side surfaces and decreases
with fabric surfaces.
0,6
0.45
0.30
0.90
0.50
0.60
1.00
0.80
Synthetic
+18
0,4
0,2
0
0,2
0,4
0,6
0,8
steel plate
hard synthetic
hard wood
0,4
0,2
0
10
20 30 4050
100
14.3
Fst = H * g * mL
H
Special Resistance FS
(m)
(N)
The special resistances have to be calculated separately according to the conditions existing.
Resistance FA1
Resistance FAw
Resistance FAb
Resistance FMe
Resistance FSp
Resistance FLa
Skirtboard seals
Tripper (throw-off carriage)
Scraper
Knife edges
Unit load barrier
Load deflector
Resistance from side skirtboards used to channel the load stream (value).
FAl = 160 * lf
lf
Resistance FAw
(m)
FAw = z * k
Resistance FAb
(N)
z
k
(-)
(-)
number of trippers
factor
Belt Width
(mm)
300 - 500
650
800
1000
1200
>1200
1000
1500
2000
3500
4400
4700
1100
1700
2200
3600
5100
5400
Resistance FMe
(N)
(N)
z
B
(-)
(m)
Number of scrapers
Belt width
Resistances due to knife edges (value). Knife edges are used to change the
direction of very thin slider belts where particularly small transition gaps are
necessary. At such knife edges relatively high temperatures may develop, up
to approx. 150C.
FMe = z * 0.1 * B
(N)
z
B
(-)
(m)
14.4
Resistance FSp
Slider Surface
L1
FSp = l * g * L1 * mL * cos - mL * H1
Resistance FLa
Deflector
L1
l
(m)
()
(-)
H1
mL
(m)
( kg/m )
(N)
Hold-up length
Gradient of installation
Friction factor belt/load
This friction value can differ widely and depending on the load can be
greater than the friction value g between belt and slider surface.
Lift (or fall)
Load due to material
500
650-800
1000-2000
FLa (N)
800
1500
3000-3500
For light bulk and unit loads these values may be reduced. With sideways
transfer of the load, the belt is deflected in the opposite direction.
Appropriate tracking devices need to be built in.
14.5
Drive Power
PT =
FU * v
( kW )
1000
PT
Motor Power
PM =
Installed Power
PN
( kW )
( kW )
The motor power PN is selected from the standard list with the appropriate
rounding up or from existing stock.
Peripheral Force FA
(N)
PM
Note
FA = 2.6 * FU
(N)
This prevents excessive over-dimensioning of the motor and thus the use of
an overstrength belt.
Belt Tensions
The belt tensions are calculated from the peripheral forces FU et FA.
T1 = FU * c1
T1A = FA * c1A
(N)
(N)
The friction value depends on the running side of the belt and the surface
of the drive pulley.
Running Side
of belt
Rubbered
Fabric
Drive Factor c1
Drive Pulley
Condition
Friction
value
Lagged
dry
damp
0.30
0.25
Bare
dry
damp
0.22
0.20
Lagged
dry
damp
0.25
0.22
Bare
dry
damp
0.15
0.15
A = + 0.05
14.6
Belt Types
In selecting the belt type for a slider application, the tensile strength is
largely of secondary consideration because of the low stresses. Nearly
always the belts are over dimensioned. Transverse stability and the location of the belt are particular considerations.
As a rule a check on the factor of safety of the selected belt is sufficient.
kN * B * cV
Safety Factor
S=
10-12
Tmax
Tmax * S
Belt type
kN =
N/mm
B * cV
KN
B
CV
Tmax
S=(6-8)*
PM
Pulley Diameter
Often with slider belt installations, extremely small pulleys are used, for
example, to enable the bridging of gaps between two installations.
The advice of the belt manufacturer should be sought, particularly about problems of making the belt endless.
14.7
Bucket Elevators
With bucket elevators different bulk loads such as sand, gravel, chippings,
coal, cement, grain, flour, fertilizer etc. can be conveyed either vertically or
sloping upwards. Belts with buckets attached are used as the carrying
medium. With bucket elevators, great heights for example, over 100m can be
surmounted with high strength belts. They run with low noise levels and low
vibrations at a relatively high speed. They require only a small ground area
and are preferred in buildings, silos and warehouses.
Bucket Elevators
Discharge
Dchargement
Load volume
QV = 3.6 * v * *
VB
a
Tambour de
commande
Drive
pulley
Racleur
Scraper
Hauteur
Height
of dlvation
elevators
Rouleaux pour la
Support rollers
stabilisation de la bande
chute
Goulotte deFeed
chargement
Load mass
Qm = QV *
Bucket capacity
VB =
Weight of material
per bucket
Systme
de against
protection
Protection
contre
les poussires
falling
material
( kg )
3.6 * v *
(l)
(-)
( m/s )
(m)
( t/m3 )
The nominal capacity VB of the bucket is determined from the geometric dimensions and a horizontal
surface filling level (water filling).
The type of bucket is determined in the main by the material and the method
of discharge either by gravitational or centrifugal emptying.
Bucket Types
eB
eB
hB
hB
hB
DIN 15231
( litres )
3.6 * v *
Qm * a
Vm =
VB
v
a
PiedElevator
de llvateur
boot
( t/h )
QV * a
Tambour
depulley
renvoi
Return
eB
( m3/h )
DIN 15232
DIN 15233
eB
eB
hB
DIN 15231
DIN 15232
DIN 15233
DIN 15234
hB
DIN 15235
eB ( mm ) Bucket Projection
hB ( mm ) Bucket Height
For high speeds (V = 1.05 to 4.2 m/s) according to the type of material as a
rule the flat, flat hB rounded or medium deep buckets are used (centrifugal
discharge).
For low speeds (v = 0.42 to 1.05 m/s) the deep closed buckets are used (gravitational discharge). See also Page 15.3.
15.1
Bucket Elevators
Degree of Filling
The measure of the effective utilization of the bucket capacity, is the degree
of filling .
eff. bucket filling
=
nominal capacity
Major influences are: Method of loading
Speed
Bucket spacing
Bucket shape
Type of Material
Potatoes, Turnips, Onions
Grain, Barley, Rye
Earth, Sand - damp
dry
Sugar beet
Sliced beet
Fertilizer
Coal, Coke - large
fine
Gravel, Stone - large
fine
Sugar, Salt
Moulding sand - dry
Soya beans, Pulses
Cement
Speed
Degree of Filling
0.6
0.75
0.5
0.7
0.5
0.65
0.75
0.5
0.7
0.5
0.7
0.75
0.6
0.7
0.75
The speed depends upon the function of the bucket elevator, the type of
loading and discharge.
The following speeds are recommended:
Type of Bucket Elevator
V (m/s)
Up to 1 m/s
1 - 2 m/s
2 - 4 m/s
and more
15.2
Bucket Elevators
Loading
The loading i.e., the filling of the bucket can be done either directly or by
dredging action. Scoop loading is only possible with free flowing materials
and is to be recommended.
The bucket attachments and bucket brim are subject to arduous duty. With
direct loading the base area (boot) has to be kept clean. Danger of buckets
being torn off.
Scoop Loading
Discharging
Direct Loading
close pitch buckets
(continuous buckets)
Pole
Ple P
Direct Loading
l
ra
ri
(m)
n=
v * 60
( R.P.M. )
*D
n2
eB
S
G
=
=
=
=
895
=
4 * 2 * n2
rs
ri
rs
ra
l
g
l=
inner radius
centre of gravity radius
outer radius
pole distance
Centrifugal Discharge
With high speeds and light flowing loads or coarse granulated, hard materials.
Gravitational Discharge
With low speeds, heavy loads with large lumps or light dusty materials
Speed
Pulley Diameter
(mm)
300
400
500
630
800
1000
1200
1400
1600
High
Low
n (R.P.M.)
v (m/s)
n (R.P.M.)
v (m/s)
54
50
50
51
50
50
53
57
50
0.84
1.05
1.31
1.68
2.09
2.62
3.35
4.19
4.19
27
25
25
25
25
25
0.42
0.52
0.66
0.84
1.05
1.31
15.3
Bucket Elevators
Bucket Pitch
The bucket pitch depends on the speed, the bucket geometry, the type of
loading and discharge. With gravitational discharge, the bucket pitch can
be small. The material runs over the back of the preceding bucket.
a ca. bucket height hB
( mm )
a=
0.5 * * D
(m)
2 to 4
Bucket Pitch
Gravitational Discharge
Bucket Pitch
Centrifugal Discharge
Gravitational Discharge
Centrifugal Discharge
v > 1.2 m/s
Belt Width
Centrifugal Discharge
with staggered rows of
buckets
( mm)
Main Resistances FH
(N)
The main resistance is derived from the capacity and the height.
FH =
Qm * g * H
(N)
3.6 * v
Qm
H
v
g
( t/h )
(m)
( m/s )
( m/s2 )
Capacity
Height of Elevation
Speed
Acceleration due to gravity ( 9.81 )
15.4
Bucket Elevators
Loading Resistance FB
The method of bucket loading and the force required to accelerate the load to
conveying speed determines the loading resistance. FB is dependent upon
the speed. The loading resistance can be accounted for with sufficient accuracy using an additional height factor.
FB =
Qm * g * H0
(N)
3.6 * v
The following additional height factor values can be taken according to material and speed.
Type of material
(t/m3)
H0 (m)
<1
4 * v + 1.5
1 - 1.5
4*v+4
1.5 - 1.8
6*v+4
> 1.8
6*v+6
Rough of sticky
Clay, earth, broken stone
Secondary Resistance FN
The secondary resistance FN takes into account the frictional forces, flex resistances of the belt, pulley bearing resistance and acceleration to the circumferential speed of the drive pulley. FN is very small by comparison to the other
resistances and is adequately covered by the factor cN as part of the total
resistances.
FN = ( cN - 1 ) * ( FH + FB )
(N)
Qm * g * ( H + H0 )
FU = cN *
Peripheral Force FU
Qm
H
H0
cN
v
( t/h )
(m)
(m)
(-)
( m/s )
(N)
3.6 * v
Capacity
Elevating height
Additional height (see table)
Factor for secondary resistances
Speed
PT =
FU * v
PT
( kW )
PM =
1000
Drive Power at Pulley
Installed Power
PN
(-)
( kW )
Motor Power
15.5
Bucket Elevators
PN
Start-up Factor kA
kA = k *
Values for k
(-)
PM
Type of drive
2.2
1.4 - 1.6
1.25
From the preceding calculations, the bucket capacity, the bucket width and
thus the belt width can be determined. For further calculations especially that
for belt safety factor, the belt type has to be assessed as well as the weight
of the take-up (tension) pulley.
kN =
T1 * S
( N/mm )
(-)
( mm )
Safety Factor
S = 10 up to 60 C
S = 12 up to 80 C
S = 15 up to 150 C
Belt width
For the assessment of a belt type, initially the belt stress T1 can be approximately estimated.
Tension T1
T1 = FU + FSt + Tv + TT
Peripheral Force
FU = 3 *
Qm * ( H + H0 )
(N)
(N)
Slope Resistance
FSt = H * 9.81 * ( mB + mG )
(N)
Pre-Tension
Tv = c2 * kA * FU - FSt - TT
(N)
TT = GT * 9.81 / 2
(N)
mB
mG
( kg/m )
( kg/m )
Weight of Belt
mG (kg/m)
1
1 - 1.8
> 1.8
kA
(N)
c2
(-)
GT
( kg )
18.5 * B
11.5 * B
15 * B
kA = 1.8 - 2.2
kA = k * PN / PM (max 2.5)
k = 1.2 - 1.6
A = + 0.05
= 180
Weight of take-up pulley can be ascertained from the table or obtained from
exact data if available
15.6
Bucket Elevators
Weight GT (kg) of
Take-up Pulley
Pulley Width
(mm)
125
160
250
350
450
550
650
850
1000
1250
1400
315
16
20
25
40
42
50
55
65
80
100
110
20
25
30
45
60
70
75
90
100
115
125
27
35
45
70
75
80
95
115
140
160
175
35
45
55
90
115
130
150
180
200
230
260
45
60
80
125
160
190
210
250
300
350
370
70
80
115
180
230
300
350
450
540
670
750
1250
110
135
175
270
310
360
420
550
680
840
959
Once the belt type has been established, a back calculation can be done and
safety factors catered for.
After the belt nominal tension has been determined, a belt type can be selected and the factor of safety checked.
co
Ar
sion
mis
ans
f tr
Arc
w
on t itho
ran ut
sm ef
iss f
io
Eff
ec
tiv
t
ec
T1
T2
FU
FN
FH
T1 = FU + FSt + Tv + TT
(N)
TA1 = FA + FSt + Tv + TT
(N)
T2 = TA2 = FSt + Tv + TT
(N)
F
Tv St
FSt Tv
The necessary pre-tension for the power transmission is produced by the belt
weight, the bucket weight (empty), the weight of the take-up pulley and possibly additional tension by screw take-up or take-up weight.
Additional pre-tension
Tv = c2 * FU FSt
Tv
Tv
Take-up weight
GS =
2 * Tv
GT * 9.81
(N)
(N)
9.81
Gs
Power Transmission
e
T2
A
TA1
A
T2
(-)
(-)
15.7
Bucket Elevators
Safety Factor
After the calculation T1 and TA1, the safety factor whilst running and at startup can be checked.
SB kN *
SA kN *
T1
B
TA1
Safety at start-up
Working Temperature (C)
60 80 120 140
Values for SB
Bucket
Vulcanised to belt
Textile
Steel cord
8
8
Hole punched
according to DIN
Textile
Steel cord
10
10
8
12
14
9 to 10
15
Friction Value
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
e
1.37
1.60
1.87
2.19
2.56
4.00
3.52
4.11
Pulley
Surface
Wet
Damp
Dry
Cage Pulley
B
0.10
0.15
0.15
0.25
0.10
0.15
0.20
Drive Pulley
Bare
Lagged
A
B
A
0.15
0.25
0.30
0.25
0.30
0.35
0.35
0.40
0.45
B = Running
A = Start-up
15.8
Bucket Elevators
Belt Tension T1
The calculation thus far is based upon the work dependent belt tension.
Under certain circumstances it is the load dependent tension that determines the maximum tension T for the loaded state at rest:
The higher value of T1 is the determining factor for belt safety and belt type.
Qm
T1 = H * g * (
Number
of plies
+ mG + mB ) +
GT * g
3.6 * v
+ Tv
(N)
Belt Type
SUPERFORT
Pulley
Diameter
(mm)
S 315/3
S 400/3
500/3 S
400
S 630/3
315
315
S 400/4
S 500/4
630/4 S
630
S 800/4
S 1000/4
S 1250/4
Number
of plies
Belt Type
SUPERFORT
Pulley
Diameter
(mm)
S 630/5
S 800/5
S 1000/5
S 1250/5
S 1600/5
630
800
1000
1000
1200
S 1000/6
S 1250/6
S 1600/6
1000
1200
1400
400
500
500
630
800
800
When installing the buckets a slightly convex arc should be formed. Bucket
attachment using flat iron strips should be segmented. For spacing see
Appendix.
Table for Number of Plies
Load
Bulk Density
(t/m3)
Lump size (mm)
1 t/m3
light flowinge
grain, fertilizer
oil seed
= 1 - 1.5 t/m3
0 - 30 mm
0 - 60 mm
0 - 100 mm
1.5 t/m3
0 - 30 mm
0 - 60 mm
0 - 80 mm
200
Ply
type
3
4
4
4
4
5
5
5
5
5
5
5
5
5
5
5
5
5
6
5
6
6
6
6
6
6
6
6
EP 160
EP 200
5
4
4
5
5
5
5
5
6
5
6
6
6
6
6
6
6
6
6
6
6
EP 200
EP 250
Depending on type of bucket attachment and the pull through strength of the
bolts, additional numbers of plies may be required.
15.9
Bucket Elevators
Peripheral Force FU
The peripheral force FU can also be derived from the individual resistances.
FU = FH + FAw + FS + FBA + FBU
Lift resistance FU
FH =
(N)
H * Qm * g
(N)
3.6 * v
Qm
Loading resistance FAw
FAw =
3.6
Dredging resistance FS
* ( v1 + v ) * g
FS = fk * ws *
(N)
Qm * g
(N)
3.6
T1 + T2
Bending Resistance FBA
at drive pulley
FBA = 2 * x * ( 2 * y * B +
FBU = 4 * x * ( y * B +
Tv
( m/s )
( m/s )
(-)
(-)
(-)
(-)
D
d
( cm )
( cm )
*g
(N)
d
)*
*g
(N)
WS
ws (kpm/kp)
v1
v
fk
ws
x
d
)*
Curve
Load
1
2
3
4
5
Portland cement
Grain
Sand, Gravel
Cement, clinker
Bituminous coal
Density
(t/m3)
Lump size
(mm)
1.2
0.74
1.50
1.25
0.75
~ 0.05
2 to 5
2 to 10
5 to 20
18 to 30
v (m/s)
15.10
Bucket Elevators
Reduction Factor fk
a
tF = 0.224 *
a
eB
v
( mm )
( mm )
( m/s )
(s)
eB * v
bucket spacing
bucket discharge
speed
Reduction factor fk
Load
Ash (slag)
Barley
Basalt
Basalt lava
Beets
Blast furnace
slag - ground
Blast furnace slag
Briquette
Brown coal
Cement
Charcoal
Clay
Coal dust
Coke
Crushed coal
Earth
Fly ash
Granite
Gravel wet
Gravel dry
Gypsum
Lime
Limestone
Loam moist
Loam dry
Recommended
maximum
speed
v (m/s)
Bulk
Density
p (t/m3)
Fill
Factor
0.9
0.7
3.0
2.8
0.65
0.7
0.8
0.5
0.5
0.5
2.5
2.0
1.0
1.2
2.0
0.7
1.5
1.0
0.7
1.2
0.3
2.0
0.7
0.4
0.8
1.7
1.0
2.6
2.0
1.7
1.3
0.9
2.6
2.0
1.6
0.8
0.5
0.5
0.5
0.8
0.6
0.7
0.7
0.6
0.8
0.7
0.8
0.5
0.7
0.7
0.8
0.8
0.5
0.4
0.7
2.7
2.0
1.8
1.9
2.5
2.5
1.8
2.7
2.5
2.6
2.4
2.8
1.3
2.5
2.5
2.7
2.5
1.2
1.8
2.0
Load
Lump coal
Malt
Marble
Mortar Cement
Mortar Gypsum
Mortar Lime
Moulding sand
Oats
Potatoes
Pulses
Pumice
Pumice ground
Raw flour
Rye
Sand dry
Sand wet
Sawdust
Shell limestone
Slag coal
Slate
Sugar
Sugar beet chopped
Super phosphate
Volcanic limestone
Wheat
Bulk
Density
p (t/m3)
Fill
Factor
0.9
0.55
2.7
2.0
1.2
1.7
1.2
0.55
0.75
0.85
1.2
0.7
1.0
0.7
1.6
2.1
0.25
2.6
1.0
2.7
0.7
0.3
0.8
2.0
0.75
0.5
0.7
0.5
0.7
0.7
0.7
0.8
0.8
0.6
0.7
0.5
0.7
0.8
0.8
0.7
0.4
0.8
0.7
0.5
0.5
0.8
0.7
0.8
0.5
0.7
Recommended
maximum
speed
v (m/s)
1.5
3.0
1.2
2.0
2.0
2.0
2.5
3.0
2.0
2.9
1.8
2.7
3.5
3.0
2.5
2.5
3.0
1.4
2.0
1.2
2.7
3.0
2.5
1.6
3.0
15.11
Bucket Elevators
hhBB
DIN15231
15231
DIN
Flat buckets to DIN 15231 for light materials such as flour, semolina.
Width bB
(mm)
Projection
eB (mm)
Height
hB (mm)
80
100
125
160
200
250
315
400
500
75
90
106
125
140
160
180
200
224
67
80
95
112
125
140
160
180
200
1
0.15
0.22
0.32
0.48
0.65
0.86
1.5
0.33
0.48
0.70
0.95
1.30
1.80
0.64
0.96
1.30
1.75
2.40
3.25
Bucket
capacity
vB in litres
1.90
2.60
3.60
4.90
6.60
4.80
6.50
8.80
0.1
0.16
0.28
0.5
0.8
1.25
2.0
3.15
5.0--
Flat rounded buckets to DIN 15232 for light granular materials such as grain.
eBB
hhBB
DIN 15232
15232
DIN
Width bB
(mm)
Projection
eB (mm)
Height
hB (mm)
80
100
125
160
200
250
315
400
500
75
90
106
125
140
160
180
200
224
80
95
112
132
150
170
190
212
236
1.5
0.16
0.24
0.34
0.50
0.68
0.94
0.36
0.51
0.75
1.02
1.40
1.95
0.68
1.00
1.40
1.90
2.60
3.55
Bucket
capacity
vB in litres
2.10
2.80
3.85
5.30
7.20
0.17
0.3
0.53
0.9
1.4
2.24
3.55
5.6
9
5.20
7.10
9.60
Medium deep buckets to DIN 15233 for sticky material such as sugar cane.
Width bB
(mm)
eeBB
hhBB
DIN15233
15233
DIN
160
200
250
315
400
500
630
800
1000
Projection
eB (mm)
Height
hB (mm)
140
160
180
200
224
250
280
315
355
160
180
200
224
250
280
315
355
400
3
1.86
2.57
3.36
4.56
6.06
4
3.46
4.48
6.08
8.15
11.5
16.1
7.85
10.3
14.4
20.2
27.5
38.2
24.3
33.3
46.0
44.3
61.2
Bucket
capacity
vB in litres
0.95
1.5
2.36
3.75
6
9.5
15
23.6
37.5
Deep buckets flat rear wall to DIN 15234 for heavy pulverized to coarse materials
such as sand, cement, coal.
Width bB
(mm)
160
eeBB
200
250
hhBB
315
400
500
630
800
1000
DIN 15234
15234
DIN
Projection
eB (mm)
Height
hB (mm)
(125)
140
(140)
160
(160)
180
(180)
200
224
250
280
315
355
160
180
180
200
200
224
224
250
280
315
355
400
450
3
1.78
2.08
2.41
2.80
3.26
3.77
4.44
5.09
7.03
3.24
3.76
4.37
4.96
5.95
6.82
9.40
12.8
17.6
7.72
8.59
11.8
16.1
22.1
30.6
42.0
19.4
26.6
36.9
50.3
49.6
67.0
Bucket
capacity
vB in litres
1.2
1.5
1.9
2.36
3
3.75
4.75
6
9.5
15
23.6
37.5
60
Deep buckets with curved rear wall to DIN 15235 for light flowing or rolling materials
such as fly ash, potatoes.
Width bB
(mm)
eeBB
hhBB
DIN 15235
DIN
15235
160
200
250
315
400
500
630
800
1000
Projection
eB (mm)
Height
hB (mm)
140
160
180
200
224
250
280
315
355
200
224
250
280
315
355
400
450
500
3
2.28
3.07
4.14
5.59
7.72
4
4.15
5.56
7.41
10.4
14.1
19.2
9.46
13.0
17.7
24.1
32.5
44.5
21.4
29.0
39.3
53.5
Bucket
capacity
vB in litres
1.5
2.36
3.75
6
9.5
15
23.6
37.5
71.2
60
15.12
Bucket Elevators
Bucket Attachment
The bucket made of steel, plastic or rubber may be bolted to the belt. The
principal factor to consider is resistance the belt carcase has to bolt pull
through.
C
Bucket
b
i
d
d
n
Belt
In addition to this most commonly used method of attachment, there are a
number of special, partly patented possibilities such as attachment to rear
bolt mouldings, vulcanized on rubber plies or flexible steel plate.
Often to prevent dirt penetration and thereby reduce wear, soft rubber pads
are fitted between belt and bucket.
Endless Joint
butt strap
Angle joint
This type is the simplest and most cost effective but cannot be used in all
cases. The pulley diameter and the bending zone of the belt around the
angle, have to be taken into consideration.
15.13
Belt Width
B (mm)
Surcharge Angle
Volume Steam
QV (m3/h)
Belt Width
B (mm)
Surcharge Angle
Volume Stream
QV (m3/h)
300
5
10
15
20
4
8
11
16
1200
5
10
15
20
84
168
256
347
400
5
10
15
20
8
15
23
31
1400
5
10
15
20
115
232
353
479
500
5
10
15
20
12
25
38
52
1600
5
10
15
20
152
306
465
632
650
5
10
15
20
22
45
68
93
1800
5
10
15
20
194
391
594
807
800
5
10
15
20
35
71
108
147
2000
5
10
15
20
240
486
738
1003
1000
5
10
15
20
57
114
174
236
2200
5
10
15
20
300
604
916
1245
v = 1 m/s
inclination = 0
Surcharge Angle
300
0
10
15
20
14
20
24
28
18
24
27
30
20
26
28
31
21
26
28
31
400
0
10
15
20
28
41
48
55
37
48
55
61
40
51
56
62
42
51
56
61
500
0
10
15
20
46
68
80
92
62
81
91
101
67
85
93
103
70
86
93
101
650
0
10
15
20
82
122
143
165
111
145
163
181
121
151
167
184
126
153
167
182
129
151
163
176
800
0
10
15
20
129
192
225
259
174
228
255
285
190
238
262
288
198
240
262
285
202
238
256
275
1000
0
10
15
20
208
309
362
485
201
367
412
459
305
382
422
464
320
387
422
459
325
382
412
443
1200
0
10
15
20
306
455
532
613
413
539
605
673
449
561
620
681
469
568
620
673
477
561
605
650
1400
0
10
15
20
423
628
735
846
570
744
835
930
619
775
856
941
648
785
855
930
659
775
835
899
1600
0
10
15
20
558
829
970
1117
752
982
1102
1227
817
1022
1129
1242
856
1036
1129
1227
869
1022
1102
1186
1800
0
10
15
20
712
1058
1237
1425
960
1253
1406
1566
1042
1305
1441
1584
1092
1321
1441
1566
1109
1305
1406
1513
2000
0
10
15
20
885
1314
1537
1771
1193
1557
1747
1945
1295
1621
1790
1968
1356
1642
1790
1945
1378
1621
1747
1880
2200
0
10
15
20
1099
1632
1909
2199
1401
1934
2169
2415
1608
2013
2223
2444
1604
2039
2223
2415
1711
2013
2169
2334
v = 1 m/s
inclination = 0
Troughing Angle
35
40
Belt Width
B (mm)
20
30
45
A.1
Surcharge Angle
400
0
10
15
20
21
35
42
50
30
43
50
57
34
47
53
60
500
0
10
15
20
36
59
72
85
51
73
84
97
58
79
90
102
650
0
10
15
20
67
109
131
155
95
134
155
176
108
145
165
184
118
153
176
190
127
159
176
193
800
0
10
15
20
105
171
206
243
149
210
243
276
168
227
257
289
185
240
268
299
198
249
276
303
1000
0
10
15
20
173
280
336
394
246
344
396
449
278
370
419
469
304
391
436
484
326
407
448
492
1200
0
10
15
20
253
411
493
578
360
505
580
659
406
543
614
688
445
573
640
709
477
596
658
722
1400
0
10
15
20
355
572
685
803
504
703
806
915
567
755
852
954
622
797
888
984
666
828
912
1001
1600
0
10
15
20
472
758
906
1062
669
931
1067
1209
753
1000
1128
1263
825
1055
1175
1301
883
1096
1207
1323
1800
0
10
15
20
605
969
1159
1357
858
1194
1364
1546
965
1279
1443
1614
1057
1350
1502
1662
1131
1402
1543
1690
2000
0
10
15
20
750
1204
1439
1685
1064
1478
1694
1919
1197
1588
1791
2003
1311
1675
1865
2064
1404
1741
1916
2099
2200
0
10
15
20
948
1509
1801
2107
1343
1855
2121
2399
1509
1990
2241
2503
1650
2099
2332
2576
1765
2178
2393
2618
l1
Troughing Angle
30
35
40
Belt Width
B (mm)
20
45
v = 1 m/s
inclination = 0
A.2
Deep Trough
Belt Width
B (mm)
Surcharge Angle
20
Troughing Angle
30
35
40
45
1000
0
10
15
20
196
301
356
413
275
369
417
469
307
394
440
487
333
413
454
498
352
424
462
501
1200
0
10
15
20
286
441
521
605
401
540
612
687
449
577
644
714
487
605
666
731
516
623
678
737
1400
0
10
15
20
393
606
717
834
552
743
843
947
617
795
888
985
670
834
919
1008
711
859
936
1017
1600
0
10
15
20
512
794
941
1095
720
974
1107
1245
806
1043
1166
1295
877
1095
1209
1328
932
1131
1234
1342
1800
0
10
15
20
651
1012
1199
1396
917
1242
1410
1587
1026
1330
1487
1652
1117
1396
1541
1693
1188
1442
1574
1712
2000
0
10
15
20
807
1255
1488
1732
1136
1540
1750
1970
1272
1649
1845
2050
1384
1732
1913
2103
1473
1789
1954
2127
2200
0
10
15
20
1012
1567
1856
2158
1423
1922
2182
2454
1591
2057
2299
2552
1731
2159
2382
2615
1839
2228
2431
2643
Belt Width
B (mm)
Surcharge Angle
800
0
10
15
20
210
260
286
313
1000
0
10
15
20
345
425
467
510
349
427
468
510
1200
0
10
15
20
504
623
684
749
516
630
689
751
1400
0
10
15
20
702
864
948
1036
722
876
957
1041
1600
0
10
15
20
915
1132
1244
1362
947
1153
1260
1371
1800
0
10
15
20
1174
1449
1592
1741
1218
1476
1609
1749
2000
0
10
15
20
1466
1806
1982
2167
1527
1846
2011
2185
2200
0
10
15
20
1838
2255
2472
2699
1868
2252
2452
2661
l1
l < l1
v = 1 m/s
inclination = 0
Garland Idlers
= 60
= 30
b
B
Troughing Angle
25/55 30/60
l = l1 = l2
v = 1 m/s
inclination = 0
A.3
Belt Width
B (mm)
Surcharge Angle
800
0
10
15
20
151
208
237
266
169
216
241
266
187
226
244
266
1000
0
10
15
20
201
302
362
410
234
320
367
417
262
334
378
421
1200
0
10
15
20
252
410
489
576
295
435
511
590
338
464
532
601
1400
0
10
15
20
302
529
648
774
360
568
676
792
414
604
705
810
1600
0
10
15
20
352
662
824
993
421
709
860
1015
489
756
896
1040
1800
0
10
15
20
403
806
1018
1238
482
860
1058
1267
565
921
1105
1299
h1
v = 1 m/s
inclination = 0
= 80 - 90
Conveying of Sinter
A.4
Beldt Width
B (mm)
Surcharge Angle
CHEVRON
16 mm
Qv
(m3/h)
400
0
5
10
15
20
C 330/14
25
33
40
49
58
400
0
5
10
15
20
C 390/15Z
25
33
40
49
58
500
0
5
10
15
20
C 430/16
43
56
68
85
100
HC 450/32
48
63
78
94
110
600
0
5
10
15
20
C 530/16
65
86
106
128
151
HC 450/32
42
57
72
88
105
650
0
5
10
15
20
C 530/16
65
86
106
128
151
HC 450/32
42
57
72
88
105
650
0
5
10
15
20
HC 600/32
88
115
141
160
189
800
0
5
10
15
20
C 650/16
97
129
160
193
227
HC 600/32
78
105
132
160
189
1000
0
5
10
15
20
C 800/16
149
196
244
293
345
HC 1000/32
149
196
244
293
345
1200
0
5
10
15
20
C 1000/16
235
307
384
461
542
HC 1000/32
235
307
384
461
542
1400
0
5
10
15
20
HC 1200/32
348
454
562
673
789
1600
0
5
10
15
20
HC 1200/32
326
432
541
652
769
Chevron Profile
Chevron Profile
333
HIGH CHEVRON Qv
32 mm
(m3/h)
Multiprof
Note
With sticky materials, a surcharge angle ca.5 higher than that for smooth
surface belting can be used.
The table values are based on
v = 1 m/s
20 troughing
For Multiprof belts the values for CHEVRON belts are valid.
A.5
Effective width
B
10
15
200
300
400
500
600
700
800
900
1000
25
38
50
63
76
88
101
113
126
28
45
63
83
104
127
151
177
205
32
52
76
103
133
166
202
242
285
35
60
89
123
162
206
255
309
367
20
Effective
width
(mm)
10
15
20
38
67
103
145
194
249
310
379
454
200
300
400
500
600
700
800
900
1000
40
59
79
99
119
139
158
178
198
43
66
92
119
147
177
209
242
277
46
74
105
139
176
216
260
307
357
49
81
118
159
206
257
313
374
439
53
89
132
181
237
299
368
444
526
Surcharge Angle
10
15
200
300
400
500
600
700
800
900
1000
68
103
137
171
205
239
274
308
342
72
110
149
191
234
278
324
372
421
75
117
162
211
262
317
375
436
501
78
124
175
231
292
358
428
503
583
Surcharge Angle
20
Effective
width
(mm)
10
15
20
82
132
189
253
323
400
483
573
670
200
300
400
500
600
700
800
900
1000
126
189
252
315
378
441
504
567
630
129
196
265
335
406
480
554
631
709
132
203
277
355
435
519
606
696
789
136
211
291
375
465
559
658
762
871
139
218
304
397
496
602
714
832
958
Surcharge Angle
Surcharge Angle
A.6
Mass mR (kg)
Belt width B
(mm)
Idler Rollers
Flat Belt
63.5
88.9
108
133
159
193.7
300
flat
2 part
1.6
2.3
2.2
3.4
3.2
4.1
400
flat
2 part
3 part
2.0
2.6
2.9
2.7
3.7
4.4
3.9
4.7
5.4
5.6
6.6
7.3
500
flat
2 part
3 part
2.2
2.8
3.2
3.2
4.1
4.6
4.5
5.5
6.1
6.6
7.8
8.4
650
flat
2 part
3 part
4.0
4.7
5.4
5.5
6.3
7.0
8.0
9.0
9.8
10.8
12.1
13.1
800
flat
2 part
3 part
5 part
4.7
5.6
6.5
6.7
7.4
8.3
9.0
9.8
10.6
11.6
12.4
13.3
14.2
15.6
16.3
1000
flat
2 part
3 part
5 part
9.4
11.3
13.0
13.8
11.7
13.2
13.6
14.2
15.9
17.8
18.2
18.9
21.9
24.7
26.3
28.0
1200
flat
2 part
3 part
5 part
14.2
15.0
16.3
17.2
19.3
20.5
22.3
21.7
26.1
28.0
24.5
31.9
1400
flat
2 part
3 part
5 part
21.8
23.3
25.0
24.3
29.3
31.6
35.5
35.0
1600
flat
2 part
3 part
5 part
25.1
26.5
28.0
28.5
33.4
35.0
38.7
39.3
1800
flat
2 part
3 part
5 part
27.6
29.1
30.7
31.5
37.8
39.5
42.4
42.5
2000
flat
2 part
3 part
5 part
30.2
31.8
33.3
33.8
40.2
43.3
47.0
46.5
69.1
76.4
80.1
89.5
2200
flat
2 part
3 part
5 part
46.5
49.0
50.1
51.0
77.8
82.6
93.2
95.5
2 Part Idlers
3 Part Idlers
Return Idlers
219.1
88.0
97.1
111.0
111.8
B.1
Impact Idlers
To moderate the effect of impact cushion ring idlers may be installed at the
loading point.
Mass mR (kg)
Beldt width
(mm)
Tube-dia
(mm)
1000
1200
1400
1600
1800
2000
2200
88.9
108
108
108
133
133
133
Ring-dia
(mm)
156
180
180
180
215
215
215
21.1
32.8
40.5
45.0
71.1
77.6
84.1
Disc idlers can be installed on the return side run to reduce the effect of dirt
build-up.
To assist tracking of the belt it is recommended that guide rollers be installed
at ca. 50 m intervals.
Mass mR (kg)
Belt width
(mm)
Tube-dia
(mm)
Disc-dia
(mm)
Return idlers
1 part
3 part
400
500
650
800
1000
1200
1400
51.5
57.5
57.5
63.5
63.5
88.9
88.9
120
133
133
150
150
180
180
4.0
5.7
6.8
11.7
13.0
22.2
24.2
5.0
6.8
8.1
13.2
14.5
23.9
25.9
1600
108.0
180
215
31.9
42.0
33.9
44.5
1800
108.0
180
215
34.3
44.9
36.3
47.3
2000
108.0
180
215
38.3
48.8
40.0
51.8
2200
133.5
215
250
59.8
73.8
62.8
76.8
B.2
Belt type
(mm)
SUPERFORT Belts
STARFLEX belts
DUNLOFLEX belts
TRIOFLEX belts
FERROFLEX belts
Carcase
thickness
(kg/m2)
Carcase
weight
12
S 200/3
S 250/3
S 315/3
S 315/4
S 400/3
S 400/4
S 500/3
S 500/4
S 630/3
S 630/4
S 630/5
S 800/3
S 800/4
S 800/5
S 1000/4
S 1000/5
S 1000/6
S 1250/4
S 1250/5
S 1250/6
S 1600/4
S 1600/5
S 1600/6
S 2000/5
S 2000/6
S 2500/6
2.7
2.8
3.0
3.7
3.2
4.1
3.6
4.3
3.9
4.8
5.5
4.5
5.2
6.0
6.1
6.5
7.3
7.2
7.6
7.8
8.7
9.1
9.2
11.0
11.0
13.4
3.1
3.2
3.4
4.3
3.7
4.6
4.0
5.0
4.3
5.3
6.2
5.0
5.8
6.7
6.8
7.3
8.1
8.3
8.6
8.8
9.4
10.5
10.4
11.9
12.7
14.4
6.6
6.7
6.9
7.8
7.2
8.1
7.5
8.5
7.8
8.8
9.7
8.5
9.3
10.2
10.3
10.8
11.6
11.8
12.1
12.3
12.9
14.0
13.9
15.4
16.2
17.9
7.7
7.8
8.0
8.9
8.3
9.2
8.6
9.6
8.9
9.9
10.8
9.6
10.4
11.3
11.4
11.9
12.7
12.9
13.2
13.4
14.0
15.1
15.0
16.5
17.3
19.0
8.9
9.0
9.2
10.1
9.5
10.4
9.8
10.8
10.1
11.1
12.0
10.8
11.6
12.5
12.6
13.1
13.9
14.1
14.4
14.6
15.2
16.3
16.2
17.7
18.5
20.2
10.0
10.1
10.3
11.2
10.6
11.5
10.9
11.9
11.2
12.2
13.1
11.9
12.7
13.6
13.7
14.2
15.0
15.2
15.5
15.7
16.3
17.4
17.3
18.8
19.6
21.3
12.3
12.4
12.6
13.5
12.9
13.8
13.2
14.2
13.5
14.5
15.4
14.2
15.0
15.9
16.0
16.5
17.3
17.5
17.8
18.0
18.6
19.7
19.6
21.1
21.9
23.6
14.6
14.7
14.9
15.8
15.2
16.1
15.5
16.5
15.8
16.8
17.7
16.5
17.3
18.2
18.3
18.8
19.6
19.8
20.1
20.3
20.9
22.0
21.9
23.4
24.2
25.9
16.9
17.0
17.2
18.1
17.5
18.4
17.8
18.8
18.1
19.1
20.0
18.8
19.6
20.5
20.6
21.1
21.9
22.1
22.4
22.6
23.2
24.3
24.2
25.7
26.5
28.2
SF 250/2
SF 315/2
SF 400/3
SF 500/3
SF 500/4
SF 630/4
SF 800/4
SF 1000/4
1.5
1.9
2.5
3.0
3.5
4.1
4.6
5.3
1.8
1.9
2.9
3.2
4.0
4.4
5.4
6.1
5.3
5.4
6.4
6.7
7.5
7.9
8.9
9.6
6.4
6.5
7.5
7.8
8.6
9.0
10.0
10.7
7.6
7.7
8.7
9.0
9.8
10.2
11.2
11.9
8.7
8.8
9.8
10.1
10.9
11.3
12.3
13.0
11.0
11.1
12.1
12.4
13.2
13.6
14.6
15.3
13.3
13.4
14.4
14.7
15.5
15.9
16.9
17.6
15.6
15.7
16.7
17.0
17.8
18.2
19.2
19.9
D 160
D 200
D 250
D 315
D 400
D 500
D 630
D 800
2.3
2.7
3.0
3.2
3.7
4.1
4.5
4.8
2.7
3.1
3.6
3.7
4.3
4.7
5.0
5.5
6.2
6.6
7.1
7.2
7.8
8.2
8.5
9.0
7.3
7.7
8.2
8.3
8.9
9.3
9.6
10.1
8.5
8.9
9.4
9.5
10.1
10.5
10.8
11.3
9.6
10.0
10.5
10.6
11.2
11.6
11.9
12.4
11.9
12.3
12.8
12.9
13.5
13.9
14.2
14.7
14.2
14.6
15.1
15.2
15.8
16.2
16.5
17.0
16.5
16.9
17.4
17.5
18.1
18.5
18.8
19.3
T 315
T 400
T 500
T 630
T 800
T 1000
T 1250
4.0
4.4
5.0
5.5
6.0
6.5
7.2
4.8
5.3
5.9
6.5
7.2
7.8
8.1
8.3
8.8
9.4
10.0
10.7
11.3
11.6
9.4
9.9
10.5
11.1
11.8
12.4
12.7
10.6
11.1
11.7
12.3
13.0
13.6
13.9
11.7
12.2
12.8
13.4
14.1
14.7
15.0
14.0
14.5
15.1
15.7
16.4
17.0
17.3
16.3
16.8
17.4
18.0
18.7
19.3
19.6
18.6
19.1
19.7
20.3
21.0
21.6
21.9
F 500
F 630
F 800
F 1000
F 1250
F 1600
3.2
3.2
4.5
4.5
6.0
6.0
5.9
6.4
8.9
9.8
12.5
14.1
9.4
9.9
12.4
13.3
16.0
17.6
10.5
11.0
13.5
14.4
17.1
18.7
11.7
12.2
14.7
15.6
18.3
19.9
12.8
13.3
15.8
16.7
19.4
21.0
15.1
15.6
18.1
19.0
21.7
23.3
17.4
17.9
20.4
21.3
24.0
25.6
19.7
20.2
22.7
23.6
26.3
27.9
C.1
Belt width
(mm)
Belt Type
Profile
Cover Thickness
(mm)
Weight
(kg/m)
Type CHEVRON
Chevron Profile
400
400
500
500
600
650
650
800
1000
1200
S 200/3
S 200/3
S 200/3
S 200/3
S 200/3
S 200/3
S 400/3
S 400/3
S 400/3
S 500/4
C 330/16
C 390/15Z
C 330/16
C 430/16
C 530/16
C 530/16
C 530/16
C 650/16
C 800/16
C 1000/16
2+1
2+1
2+1
2+1
2+1
2+1
3 + 1.5
3 + 1.5
3 + 1.5
3 + 1.5
3.5
3.4
4.2
4.6
5.3
5.6
7.0
8.5
11.2
14.2
2+1
2+1
2+1
2+1
3 + 1.5
3 + 1.5
4+2
4+2
4+2
4+2
5.6
6.3
6.6
7.2
8.2
9.8
14.9
17.6
20.9
23.2
Type HIGH-CHEVRON
Chevron Profile
500
600
650
650
650
800
1000
1200
1400
1600
S 200/3
S 200/3
S 200/3
S 200/3
S 400/3
S 400/3
S 500/4
S 500/4
S 630/4
S 630/4
HC 450/32
HC 450/32
HC 450/32
HC 600/32
HC 450/32
HC 600/32
HC 800/32
HC 1000/32
HC 1200/32
HC 1200/32
Type MULTIPROF
Belt Width
(mm)
Belt Type
Profile Width
(mm)
550
650
800
1000
1200
S 200/3
S 200/3
S 400/3
S 500/4
S 500/4
500
500
650
800
800
5.7
5.7
7.7
10.3
10.3
Weight
(kg/m)
4.1
4.7
7.6
12.5
15.0
Multiprof
Profiled Belts
Belt Type
Cover Description
Total Thickness
(mm)
Weight
(kg/m2)
S 200/3
Herringbone profile
( 3 ) + 1 mm
6.4
6.6
S 200/2
Rufftop profile
( 3.5 ) + 1 mm
6.5
5.8
C.2
Slider Belting
Monoply Belts
DUNLOPLAST PVG,
Quality RS
Belt Type
Cover Description
Total Thickness
(mm)
Weight
(kg/m2)
S 200/2
GB-Standard
1.5 + 0 mm smooth
4.9
5.5
S 200/2
GB-Standard
3.5 + 0 mm Rufftop
6.9
6.2
S 200/2
GB-Standard
3 + 0 mm Herringbone
6.1
6.2
S 250/3
GB-Extra
1.5 + 0 mm smooth
5.0
5.6
S 250/3
GB-Extra
3.5 + 0 mm Rufftop
7.0
6.3
Belt Type
Carcase
Thickness
(mm)
5+3
6+3
7+3
8+3
8 + 4 10 + 4
4
5
6
7
8
9
10
14.85
15.80
16.80
18.00
20.00
22.00
24.00
16.25
17.20
18.20
19.40
21.40
23.40
25.40
17.65
18.60
19.60
20.80
22.80
24.80
26.80
19.05
20.00
21.00
22.20
24.20
26.20
28.20
20.45
21.40
22.40
23.60
25.60
27.60
29.60
DLP 630 RS
DLP 800 RS
DLP 1000 RS
DLP 1250 RS
DLP 1600 RS
DLP 2000 RS
DLP 2500 RS
Monoply Belts
DUNLOPLAST PVC
Belt Type
21.85
22.80
23.80
25.00
27.00
29.00
31.00
Cover Thickness
(mm)
Cover Thickness
(mm)
Weight
(kg/m2)
2+0
2+1
1.5 + 1.5
1.5 + 1.5
1.5 + 1.5
2+2
2+2
3+3
3+3
3+3
3
4
4
5
7
9
11
14
15
16
3.75
5.00
5.00
6.25
8.75
11.25
13.75
17.50
18.75
20.00
2+1
3 + 1.5
4+2
5+3
2+2
4
6
8
11
11
5.00
7.50
10.00
13.75
13.75
3 + 1.5
4+2
5+3
5+3
5+3
6
8
11
15
17
7.50
10.00
13.75
18.75
21.75
C.3
Belt Type
Cord Diameter
(mm)
10
ST 500
ST 630
ST 800
ST 900
ST 1000
ST 1150
ST 1250
ST 1400
ST 1600
ST 1800
ST 2000
ST 2250
ST 2500
ST 2750
ST 3150
ST 3500
ST 3750
ST 4000
ST 4250
ST 4500
ST 4750
ST 5000
2.7
2.7
3.1
3.6
3.6
4.1
4.1
4.4
5.0
5.0
5.0
5.9
6.3
6.9
7.4
7.6
8.2
8.6
8.8
9.6
9.6
10.7
16.4
16.9
18.4
19.4
19.8
20.5
21.0
22.2
23.5
24.0
24.6
28.0
29.4
30.1
32.6
34.6
36.7
38.1
39.8
41.7
43.3
45.1
18.6
19.2
20.6
21.6
22.0
22.7
23.2
24.4
25.7
26.3
26.9
30.2
31.6
32.3
34.8
36.8
38.9
40.4
42.0
43.9
45.6
47.4
19.8
20.3
21.7
22.8
23.2
23.8
24.3
25.5
26.8
27.4
28.0
31.3
32.7
33.4
35.9
37.9
40.0
41.5
43.2
45.0
46.7
48.5
20.9
21.4
22.9
23.9
24.3
24.9
25.5
26.6
28.0
28.5
29.1
32.5
33.9
34.5
37.1
39.1
41.1
42.6
44.3
46.2
47.8
49.6
22.0
22.5
24.0
25.0
25.4
26.1
26.6
27.8
29.1
29.6
30.2
33.6
35.0
35.7
38.2
40.2
42.3
43.7
45.4
47.3
48.9
50.7
23.1
23.6
25.1
26.1
26.5
27.2
27.7
28.9
30.2
30.7
31.4
34.7
36.1
36.8
39.3
41.3
43.4
44.9
46.5
48.4
50.1
51.8
27.6
28.1
29.6
30.6
31.0
31.7
32.2
33.4
34.7
35.2
35.8
39.2
40.6
41.3
43.8
45.8
47.9
49.3
51.0
52.9
54.5
56.3
Rubber Cleats
Form
Type
Designation
Measurements
(mm)
H
B
D
Weight
(kg/m)
Straight
T-Cleat
T 15/20
T 20/40
T 40/70
T 60/80
T 80/90
T 100/100
15
20
40
60
80
100
20
40
70
80
90
100
8
5
4
4
4
4
0.18
0.27
0.70
1.04
1.55
2.00
Sloping
T-Cleat
TS 50/65
TS 70/80
50
70
65
80
7
6
0.88
0.82
Bucket Cleat
B 80
B 110
80
110
80
80
1.90
2.90
Block Cleat
TB 25/11/ 36
TB 50/25/ 80
TB 75/10/ 80
TB 80/15/100
25
50
75
80
36
80
80
100
11
25
10
15
0.49
2.10
1.83
3.20
T-Cleat
Sloping T-Cleat
Bucket Cleat
C.4
Secondary Resistances
Resistance FAuf
(N)
vo
FAuf =
3.6
v
(m/s)
v0 (m/s)
Qm (t/h
Resistance FSch
* ( v - v0 )
(N)
Belt speed
Initial velocity of material in direction of belt travel
Capacity
FSch =
Qm2 *
330 * * ( v + v0 )2
(N)
b2
(-)
l
b
( t/m3 )
(m)
(m)
The length of the skirt plates should be not less than the acceleration
distance
lmin = v2 - vo2 / ( 2 * g * )
Resistance FGr
Scraper
Racleur
(-)
( N/mm2 )
( mm2 )
(N)
Scraper Thickness
(mm)
kR
B
kR
(N)
(m)
( N/m )
Belt width
Frictional resistance
Pressure (N/mm2)
normale
leve
15
20
20
25
340
450
1500
1875
30
2250
D.1
Resistance FGb
TT11
Tm
FGb = c * B * ( k +
TT22
Tm
d
D
c
(N)
( mm )
( mm )
(-)
( N/mm )
d
)*
(N)
D
Pulley bearing resistance for non-driving pulleys. These resistances like belt
bending resistances, are small and need be determined only in special cases.
Resistance FTr
Ta
dw
Tx
FTr = 0.005 * Tx *
GT
Tb
Tx
GT
Tb
Ta
dw
D
GT
( mm )
( mm )
(N)
(N)
D
( Ta + Tb )2 + GT2
(N)
D.2
Special Resistances
Special Resistances
The special resistances occur beyond the loading point area and can be calculated individually.
Resistance Fs
Rsistance due
Resistance
autilted
pincement
to
idlers
Carrying side
(N)
Return side
(N)
rouleaux
latral
wing idler
pincement
max. 4
tilt max. 4
Resistance FSch
ZRst
C
( pieces )
(-)
(-)
(-)
(-)
Frictional resistance from skirt plates beyond the loading point area
FSch =
Qm
v
l
b
C
Resistance FL
Deflector
C * Qm2 *
1316 * * v2
( t/h )
(-)
( m/s )
( t/m3 )
(m)
(m)
(-)
l
*
(N)
b2
capacity
friction value between material and skirt plate (for values see Page D1)
belt speed
bulk density
length of skirt plate
distance between skirt plates
factor for surcharge angle
= 5 C = 0.83
= 10 C = 0.70
= 15 C = 0.59
= 20 C = 0.49
Resistance FB
500
650 - 800
1000 - 2000
800
1500
3000 - 3500
650
Fixed tripper
Moveable tripper
E.1
Special Resistances
Resistance FMf
Resistance FBa
(m)
(N)
Factor k
(m)
(m)
(m)
( m/s )
(-)
(N)
H (m)
1.0
1.5
8.0
9.4
2.0
2.5
3.0
=1
= 1.2
= 1.3
3.5
4.0
4.5
5.0
5.5
6.0
Bunker or Silo
v
Drive
LB
E.2
1
c1 = 1 + c2 = 1 +
Factor c1
Factor c2
Value e
e
- 1
Friction coefficient
Angle
of wrap
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
160
170
180
190
200
210
220
230
240
3.10
2.90
2.71
2.54
2.39
2.26
2.14
2.02
1.92
1.92
1.78
1.66
1.55
1.45
1.36
1.28
1.22
1.14
1.34
1.24
1.14
1.06
0.99
0.93
0.87
0.81
0.76
0.99
0.91
0.84
0.74
0.72
0.67
0.62
0.58
0.54
0.76
0.70
0.64
0.59
0.54
0.50
0.46
0.43
0.40
0.60
0.55
0.50
0.46
0.42
0.38
0.35
0.33
0.30
0.49
0.44
0.40
0.36
0.33
0.30
0.27
0.25
0.23
0.40
0.36
0.32
0.29
0.26
0.24
0.22
0.20
0.18
360
370
380
390
400
410
420
1.14
1.10
1.06
1.03
0.99
0.96
0.93
0.64
0.61
0.59
0.56
0.54
0.52
0.50
1.40
0.38
0.36
0.35
0.33
0.31
0.31
0.26
0.25
0.24
0.22
0.21
0.20
0.19
0.18
0.17
0.16
0.15
0.14
0.13
0.13
0.13
0.12
0.11
0.10
0.10
0.09
0.08
0.09
0.08
0.08
0.07
0.07
0.06
0.06
0.07
0.06
0.05
0.05
0.05
0.04
0.04
430
440
450
460
470
0.89
0.87
0.84
0.81
0.79
0.48
0.46
0.45
0.43
0.41
0.29
0.27
0.26
0.25
0.24
0.18
0.17
0.16
0.16
0.15
0.12
0.11
0.11
0.10
0.09
0.08
0.07
0.07
0.07
0.06
0.05
0.05
0.05
0.04
0.04
0.04
0.03
0.03
0.03
0.03
Friction coefficient
Angle
of wrap
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
180
190
200
210
220
230
240
1.37
1.39
1.41
1.44
1.46
1.49
1.52
1.60
1.64
1.69
1.73
1.78
1.83
1.88
1.88
1.94
2.01
2.08
2.16
2.23
2.32
2.20
2.29
2.40
2.50
2.60
2.73
2.85
2.57
2.70
2.85
3.00
3.17
3.32
3.51
3.00
3.18
3.40
3.60
3.89
4.07
4.34
3.51
3.75
4.04
4.32
4.65
4.97
5.35
4.21
4.44
4.82
5.20
5.64
6.09
6.60
320
340
360
380
400
420
1.75
1.81
1.88
1.94
2.01
2.08
2.32
2.44
2.57
2.71
2.86
3.01
3.06
3.27
3.52
3.77
4.05
4.35
4.05
4.40
4.80
5.25
5.74
6.25
5.35
5.95
6.58
7.30
8.15
9.00
7.05
8.00
9.00
10.20
11.60
13.00
9.35
10.70
12.40
14.10
16.50
18.60
12.40
14.50
17.00
19.80
23.20
27.10
F.1
Belt Safety
The safety factor S is reduced by additional stresses which cannot be determined by calculation.
1
Steady State
SB =
1 - ( r0 + r1 + r2 )
1
Non-Steady State
SA =
1 - ( r0 + r1 )
With= the factor r0 and r2 the various additional stresses are determined.
Reduction r0
Reduction r1
This factor takes into consideration the influence of additional strains caused
by the belt flexing around pulleys, transition zones, belt turnovers and vertical
curves. The values of r1 apply to standard dimensioning of the pulleys and
transitions without belt turnover.
Reduction r2
This factor takes into account the peak stresses of temporary occurrence for
instance at start-up and stopping.
Time-Strength Behaviour
% de k
NV=
N *c V
Safety
ScuritSS
100
Facteur
perte
de tension
de rupture
dans
la jonction
Factor ccvV : =
Loss
of strength
at the
joint
(valeurs
voir page
G.2) G.2)
(values
see Page
90
80
70
60
r0
50
40
Dynamic
RsistanceTime-strength
dynamique dans le temps
30
3,5
r1
20
r2
10
SA
SB
5,4
8
Number
of rotations
rotations
nombre de
The
reductions
and safety
S apply to
EP belts, normal
running
Les above
rductions
r et lesrfacteurs
de scurit
S concernantles
bandes
EP
conditions.
sont valables pour des conditions de manutention normales.
G.1
Safety Factor
100%
r0 = 0.715 Basic reduction for dynamic stresses
and time-strength behaviour
Dynamic time-strength
28.5%
Taking into account all
additional stresses Smin
shall not be less than
S=
12.5%
S=
1 - ( r0 + r1 )
1
S=
1 - r0
SA = 5.4
1 - ( r0 + r1 + r2 )
Smin = 3.5
SB = 8
0%
Steady state working
Temporary occurrence
localised peak stresses
The values given are valid for a textile belt under normal working conditions.
working
conditions
B (Cotton)
P (Polyamide)
E (Polyester)
Steel Cord
{}
{}
basic
reduction
non-continuous
peak stresses
maximum stress
steady-state working
r0
r1
Sinsta
r1
r2
Ssta
favourable
normal
unfavourable
0.691
0.715
0.734
0.100
4.8
5.4
6.0
0.100
0.060
6.7
8.0
9.5
favourab le
normal
unfavourable
0.641
0.665
0.684
0.150
4.8
5.4
6.0
0.150
0.060
6.7
8.0
9.5
1) With extraordinary favourable installation conditions (for instance untroughed belt or belt
conserving start-up conditions) lower values for r1 and r2 can be used. The mathematical
inter relationship between the additional stresses and the values r1 and r2 is at present still
unknown.
Sinsta
Ssta
G.2
Stress-Strain Curve
Elastic Characteristics
When working a conveyor belt has to undergo constant load changes and
hence constant length changes. These are catered for by the elastic characteristics of the carcase and are also partly reduced by the take-up system. As a
result of constant stress changes, a fatigue and diminution of elasticity occurs
compared as with the as manufactured belt.
Stress-Strain Curve
The elongation behaviour of a belt can be determined with the aid of a stressstrain curve. The test piece is subject to a pre-tension of 0.5% of the nominal
tensile strength of the belt. It is then subjected to a test programm of 200
load cycles of between 2% and 10% of the nominal tensile strength of the
belt.
The following example is derived from the hysteresis loop thus obtained:
Initial Elongation
Permanent Elongation
0.42%
0.43%
Elastic Elongation
Total Elongation
0.88%
1.74%
10%
L - G Max. elongation
L - A Pre-tension elongation
L - E Elastic elongation
L - P Permanent elongation
Elastic elongation
0.886%
2%
Pre-tension
elongation
Permanent
elongation
0.433%
0.5%
H.1
Stress-Strain Curve
The quasi elastic area remaining above the 12% stress means an elongation
reserve for temporary or local occurring over-stresses such as at start-up,
braking, edge stresses at troughing transitions, terminal pulleys, belt turnover
and pulley build-up etc.
In addition to this over elongation results in a slow destruction of the plies or
carcase structure.
(%)
Safety Factor S
60
50
2,0
40
2,5
30
20
5
6
T1 A
T1 B
10
10
Permanent elongation bl.
0
10
Eastic elongation el
Elastic
B
A
zus.
(N)
(N)
(%)
(%)
(%)
(%)
H.2
Additional Stresses
For a flat untroughed belt with uniform tension distribution over its cross
section the belt safety can be calculated from the breaking or nominal tensile
strength of the belt and the working tension at point x.
Belt Safety
kN * B
S=
Tx
working tension
In reality the belt is subject to the effects of temporary and local additional
stresses in particular at the edge region and in the belt centre which are caused by such as:
troughing transitions
convex vertical curves
concave vertical curves
horizontal curves
belt turnover
Elastic Modulus E
E=
1
=
B*
E*
k
kN
Sx =
kN * B
E*
kN
kD
(%)
(-)
(-)
0 =
Tx
Tx
kN
=
E*B
Hysteresis loop of a conveyor belt
under initial tension
(%)
E * Sx
Belt elongation
Nominal belt strength
Elongation value of the belt
ges = 0 + K =
Belt centre
kN
ges = 0 - M 0
E * Smin
For further calculations the elongation value kD = E/kN is introduced.
With the geometric relations which result from belt tracking are
determined.
With Sx the actual belt stresses at point x apply.
With Smin the minimum permissible belt tension, that is to say, the dynamic time-strength behaviour, is considered.
With the elongation value kD the belt characteristics that is to say, the
elongation behaviour of the belt is taken into account.
I.1
Additional Stresses
Carcase
Working
Conditions
Smin
Textile belts
favourable
normal
unfavourable
3.2
3.5
3.7
ST-belts
favourable
normal
unfavourable
2.8
3.0
3.2
High belt elongations always occur if the belt is troughed or turned and the
belt tension Tx at this point is especially high for instance at discharge with
Tmax.
Therefore a check of Smin is recommended.
Buckling
Buckling occurs mostly at those points where the belt tension Tx is particularly low for instance at the tail when running empty.
A check of min is recommended.
60
Elongation Value kD
50
S T-
b el
ts
Elongation Value kD
40
30
Ferro
20
flex
D u nlo plast
Superfort
10
500
1000
2000
3000
4000
5000
The elongation values of the various Dunlop belt types may be taken from the
above diagram. They are values for the planning of an installation. In individual
cases the kD value of a certain belt type can differ from the values in the diagram. In separate cases it is recommended that the advice of our engineers
be sought.
I.2
Additional Stresses
Troughing Transition
S
l
Belt Edges
The belt edges are examined to maintain Smin, that is to say actual belt tensions present at discharge and tail.
1
Safety
Smin =Factor
kD * ges
zulssige Werte
sieheSSeite
min =.
permissible values
see Appendix I.2
kD * ges
ges Elongation
= 0 + K
Total
ges = 0 + K
0 = 1 / Elongation
( kD * SB )
Average
0 = 1 / ( kD * SB )
s2 * 2 1s
K =*Elongation
(
- )
Additional
L2 2 3 * B
kD
l
s
B
L
SB
Belt Centre
(-)
( mm )
( mm )
( mm )
(-)
( mm )
(-)
K =
s2 * 2
L2
1
*(
)
3*B
The belt centre is checked to determine whether the total elongation > 0
that is no buckling of the belt is expected.
Total Elongation
ges
= 0 - M 0
Average Elongation
0 = 1 / ( kD * Smin )
Additional Elongation
M =
Smin ( - )
s3 * 2
3 * B * L2
Safety factor with the lowest belt tension at discharge and tail with Tempty.
I.3
Additional Stresses
Troughing Transition
with Raised Pulley
S
h
l
L red
Belt Edge
1
Safety Factor
Smin =
kD * ges
Total Elongation
ges = 0 + K
Average Elongation
0 = 1 / ( kD * SB )
Additional Elongation
K = 1 - 2
1 =
2 =
s2 * 2
L2
1
*(
h * B * sin
)
3*B
l2
(1
)
B2
4 * Lred2
h
( mm )
Lred ( mm )
Centre of Belt
Permissible values
see Appendix I.2
lift of pulley
reduced transition length
Total Elongation
ges = 0 - M 0
Average Elongation
0 = 1 / ( kD * Smin )
Additional Elongation
M = 1 - 2
1 =
s2 * 2
L2
)
3*B
h * B * sin
1
2 =
1
*(
Lred2
l
)2
(1
B
I.4
Additional Stresses
Ra
Belt Edges
ges = 0 - K 0
Average Elongation
0 = 1 / ( kD * Sempty )
Additional Elongation
K =
s * sin
Ra
Belt Centre
s
*(1
)
B
ges = 0 - M
Average Elongation
0 = 1 / ( kD * SB )
Additional Elongation
s2
M = *
B
sin
Ra
1
Safety Factor
Smin =
Permissible values
see Appendix 1.2
kD * ges
I.5
Additional Stresses
Re
Belt Edge
Smin =
kD * ges
Total Elongation
ges = 0 + K
Average Elongation
0 = 1 / ( kD * SB )
Additional Elongation
K =
s * sin
Re
Belt Centre
Permissible values
see Appendix I2
s
*(1
)
B
ges = 0 - M 0
Average Elongation
0 = 1 / ( kD * Sempty )
Additional Elongation
M =
s2
B * Re
* sin
I.6
Additional Stresses
Horizontal Curve
Inside of de
Intrieur
curve
la
courbe
R
1
Safety Factor
Smin =
Total Elongation
ges = 0 K
Average Elongation
0 = 1 / ( kD * SB )
Additional Elongation
K =
Permissible values
see Appendix I2
kD * ges
B1
+ cos R + (
2R
Belt Edge
Inner Radius
Belt Edge
Outer Radius
RH
) cos( + R)
2R
ges = 0 - K 0
Average Elongation
0 =
1
kD * Sempty
I.7
Additional Stresses
Lw
Belt Turnover
Belt Edges
Tx
(N)
Sx
Lw
kN
(-)
(m)
( N/mm )
Smin =
Total Elongation
ges = x + K
x =
Sx =
kD * ges
1
kD * Sx
kN * B
Tx
B2
x = c *
Additional Elongation
Turnover Section
The length of the turnover section can be calculated once Sx and Smin are
determined.
Lw = c * B *
kD *
Sx * Smin
(m)
Sx - Smin
B
c
(m)
(-)
Belt Width
Factor c (see table)
Turnover
Factor c
Guided
Supported
1.55
1.36
1.36
1.13
Textile Belts
ST. Belts
Belt Centre
Lw2
Lw =
c*B
1.4
cV
(-)
kD
Sx *
(m)
cV
I.8
Roll Diameter
For transport purposes, conveyor belts are coiled on wooden cores or drums.
The length or weight of the belt determines the size of core to use.
Core Diameter dk
(mm)
Application
150
250
55
110
400
205
600
205
DR
DR
d
dk
L
1.27 * d * L + dk2
(m)
(m)
(m)
(m)
(m)
roll diameter
belt thickness
core diameter
belt length
Innenvierkant
Internal Hole
DR
DR =
2DR
DR
1.27 * d *
d*L
DR - dk
a =
+ dk2
(m)
* ( DR + dk )
(m)
Lw = a + Dk
Lw
DR =
(m)
2
1.27 * d * L + ( dk +
2
2
*a) -
*a
(m)
dk
( DR2 - dk2 )
DR
L=
(m)
2*d
J.1
Roll Diameter
Roll Diameter
in m
dk
Innenvierkant
Internal Hole
DR
L
(m)
20
30
40
50
60
70
80
90
100
120
140
160
180
200
220
240
260
280
300
320
340
360
380
400
0.44
0.50
0.56
0.62
0.67
0.71
0.76
0.80
0.84
0.91
0.98
1.04
1.10
1.16
1.21
1.26
1.31
1.36
1.40
1.45
1.49
1.53
1.57
1.61
0.46
0.54
0.61
0.67
0.72
0.77
0.82
0.87
0.91
0.99
1.06
1.13
1.20
1.26
1.32
1.38
1.43
1.48
1.53
1.58
1.63
1.68
1.72
1.77
0.49
0.57
0.65
0.71
0.77
0.83
0.88
0.93
0.98
1.06
1.14
1.22
1.29
1.36
1.42
1.48
1.54
1.60
1.65
1.71
1.76
1.81
1.85
1.90
0.54
0.64
0.72
0.80
0.87
0.93
0.99
1.05
1.10
1.20
1.29
1.38
1.45
1.53
1.61
1.68
1.74
1.81
1.87
1.93
1.99
2.05
2.10
2.15
10
11
12
0.56
0.67
0.76
0.84
0.91
0.98
1.04
1.10
1.15
1.26
1.36
1.45
1.53
1.61
1.69
1.76
1.83
1.90
1.97
2.03
2.09
2.15
2.22
2.27
0.58
0.69
0.79
0.87
0.95
1.02
1.09
1.15
1.21
1.32
1.42
1.52
1.61
1.69
1.77
1.85
1.92
1.99
2.06
2.13
2.19
2.26
2.32
2.38
0.61
0.72
0.82
0.91
0.99
1.06
1.13
1.20
1.26
1.38
1.48
1.58
1.68
1.76
1.85
1.93
2.00
2.08
2.15
2.22
2.29
2.36
2.42
2.48
J.2
Pulley Diameters
The pulley diameter in general depends upon the thickness of the carcase
(see Appendix C). In regions of low tension such as at the tail pulley or with
small angles of wrap such as snub pulleys (90) smaller pulley diameters may
be used.
Tail Pulley
Snub Pulley
Bend Pulley
Drive Pulley
Snub Pulley
Tension Pulley
Tension Pulley (take-up) see Tail Pulley
Pulley diameters
for belt types
SUPERFORT
STARFLEX
DUNLOFLEX
TRIOFLEX
FERROFLEX
S
SF
D
T
F
Belt Type
Pulley
A
S 200/3
S 250/3
S 315/3
S 315/4
S 400/3
S 400/4
S 500/3
S 500/4
S 630/3
S 630/4
S 630/5
S 800/3
S 800/4
S 800/5
S 1000/4
S 1000/5
S 1000/6
S 1250/4
S 1250/5
S 1250/6
S 1600/4
S 1600/5
S 1600/6
S 2000/5
S 2500/6
250
250
315
400
315
400
400
400
400
500
630
500
630
630
630
800
800
800
800
1000
1000
1000
1000
1200
1400
200
200
250
315
250
315
315
315
315
400
500
400
500
500
500
630
630
630
630
800
800
800
800
1000
1200
160
160
200
250
200
250
250
250
250
250
315
400
315
400
400
400
500
500
500
630
630
630
630
800
1000
Belt Type
de bande
CHEVRON Belts
Profile
(mm)
Belt Type
Pulley
Diameter
(mm)
SF 250/2
SF 315/2
SF 400/3
SF 500/3
SF 500/4
SF 630/4
SF 800/4
SF 1000/4
200
250
250
315
400
500
500
630
160
200
200
250
315
400
400
500
125
160
160
200
250
315
315
400
D 160
D 200
D 250
D 315
D 400
D 500
D 630
D 800
250
250
250
250
315
315
400
500
200
200
200
200
250
250
315
400
160
160
160
160
200
200
250
315
T 315
T 400
T 500
T 630
T 800
T 1250
315
400
500
630
800
1000
250
315
400
500
630
800
200
250
315
400
500
630
F 500
F 630
F 800
F 1000
F 1250
F 1600
500
500
630
630
800
800
400
400
500
500
630
630
315
315
400
400
400
400
Drive Pulley
(mm)
Bend Pulley
(mm)
Snub Pulley
(mm)
S 200/3
C
C
C
C
330/16
390/15Z
430/16
530/16
250
250
250
250
250
250
250
250
160
160
160
160
S 400/3
C
C
650/16
800/16
315
315
250
250
200
200
S 500/4
1000/16
500
400
250
Drive Pulley
(mm)
Bend Pulley
(mm)
Snub Pulley
(mm)
Belt Type
de bande
Diameter
Profile
S 200/3
HC
450/32
315
315
200
S 400/3
HC
HC
450/32
600/32
315
315
315
315
200
200
S 500/4
HC 800/32
HC 1000/32
500
500
400
400
250
250
S 630/4
HC 1200/32
500
400
315
K.1
Pulley Diameters
DUNLOPLAST DLP
PVC
RUBBER
Belt Type
Cover
Thickness*
Total
Thickness
Weight
Pulley minimum
Diameter
(mm)
(mm)
(kg/m2)
A
(mm)
B
(mm)
C
(mm)
2 +0
2 +1
1.5 +1.5
1.5 +1.5
1.5 +1.5
2 +2
2 +2
3 +3
3 +3
3 +3
3
4
4
5
7
9
11
14
15
16
3.75
5.00
5.00
6.25
8.75
11.25
13.75
17.50
18.75
20.00
100
100
200
250
400
500
500
630
800
1000
80
80
160
200
315
400
400
500
630
800
60
60
125
160
250
315
315
400
500
630
2 +1
3 +1.5
4 +2
5 +3
2 +2
4
6
8
11
11
5.00
7.50
10.00
13.75
13.75
160
250
315
500
500
125
200
250
400
400
100
160
200
315
315
3 +1.5
4 +2
5 +3
5 +3
5 +3
6
8
11
15
17
7.50
10.00
13.75
18.75
21.75
250
315
500
630
800
200
250
400
500
630
160
200
315
400
500
DLP 630 RS
DLP 800 RS
DLP 1000 RS
DLP 1250 RS
DLP 1600 RS
DLP 2000 RS
DLP 2500 RS
6 +3
8 +3
8 +3
10 +4
10 +4
10 +4
10 +4
13
16
18
21
23
25
26
16.25
20.00
21.00
26.25
27.00
29.00
31.00
400
500
630
800
800
1000
1000
315
400
500
630
630
800
800
250
315
400
500
500
630
630
DLP 630 DB RS
15 +5
27
31.00
500
400
315
Rubber-Quality
FDA
BLS
RA
K.2
Pulley Diameters
Belt
Type
ST 500
ST 630
ST 800
ST 900
ST 1000
ST 1150
ST 1250
ST 1400
ST 1600
ST 1800
ST 2000
ST 2250
ST 2500
ST 2750
ST 3150
ST 3500
ST 3750
ST 4000
ST 4250
ST 4500
ST 4750
ST 5000
ST 6000
ST 7000
Min. Cover
Thickness
Top
Bottom
(mm)
(mm)
5
5
5
5
5
5
5
5
5
5
5
5
5
6
6
7
7
7
8
8
8
9
9
10
5
5
5
5
5
5
5
5
5
5
5
5
5
6
6
7
7
7
8
8
8
9
9
10
Belt
Thickness
(mm)
Belt
Weight
(kg/m2)
Minimum
Pulley Diam.
A
B
C
(mm) (mm)
(mm)
12.5
12.5
13.2
13.8
13.8
13.9
13.9
14.7
15.3
15.3
15.3
16.4
16.8
19.0
19.6
22.0
22.4
22.8
25.6
26.2
26.6
29.0
30.4
33.3
16.40
16.92
18.37
19.39
19.79
20.45
20.98
22.16
23.48
24.01
24.63
27.98
29.38
32.29
34.81
39.05
41.14
42.61
46.51
48.40
50.05
54.08
60.69
68.50
630
630
630
630
630
630
630
800
800
800
800
1000
1000
1250
1250
1400
1400
1400
1400
1600
1600
1800
2000
2250
500
500
500
500
500
500
500
630
630
630
630
800
800
800
800
1000
1000
1000
1250
1400
1400
1600
1800
2000
400
400
400
400
400
400
400
500
500
500
500
630
630
630
630
630
630
630
800
800
1000
1000
1250
1600
Additional weight for each 1mm additional cover thickness: 1.12 kg/m2.
Belt thickness and belt weight apply to belt with the minimum cover thickness top and bottom.
K.3
Crowned Pulleys
bT
h
Ballige Trommel
Crowned
Pulley
bk
bz
bk
0,3 * b T
0,4 * b T
0,3 * b T
Cylindrical
Tapered Trommel
Pulley
Zylindrisch-konische
D
D1
D2
h
bz
B
D
h
bz
( mm )
( mm )
( mm )
( mm )
Kantento be
Edges
gut rounded
abrunden.
well
bT
Belt width
Pulley diameter
Taper
Width of cylindrical section
D1 - D2
f=
D1
f < 0.005 *
Taper h
Belt Width B
(mm)
bz
(mm)
B/bz
> 300
> 300 800
> 800
0.4 * B
0.5 * B
0.65 * B
2.5
2.5
1.5
Pulley Diameter
(mm)
< 200
> 200 400
> 400 800
> 800
Notes
L < 3000 mm
0.5
1
1.5
2
Taper h (mm)
L > 3000 mm
B 800 mm B > 800 mm
0.5
1.25
2
2.5
0.7
1.5
2.5
3
If the taper h is too great or if bz is too small differential belt tensions result
which has an adverse effect on belt life.
If the belt in the taper area does not make full contact this will lead to wear
and tear on the pulley side of the belt.
If the taper h is too great diagonal creases can appear in the belt. The tracking effect is reduced.
The transition from the cylindrical to the tapered part of the pulley must be
well rounded.
Crowned pulleys can also be lagged.
Belt
runof
Bandablauf
Empirical determinations:
The belt runs towards the slack
side.
The belt wanders towards the
side to which it first makes
contact with the pulley surface.
L.1
Supporting Discs on
Return Side Run
Rubber supporting discs on the return side run will behave as a belt surface
cleaner. These idlers sometimes influence the tracking of the belt in a negative manner.
Installation Instruction
Untertrum
BB Return
Run
b b b b b
c
a
Measurements
(Values)
Number of Discs
each
roller
total
end
Tube
Diam. R
(mm)
Disc
Diam. D
(mm)
51
120
57
133
140
57
133
30
130
14
63.5
150
1090
30
122
16
63.5
150
1200
1305
35
128
17
88.9
180
1400
1505
35
136
18
88.9
180
1600
1800
40
140
21
Belt Width B
(mm)
a
(mm)
b
(mm)
c
(ca. mm)
400
425
25
108
500
530
30
137
650
680
30
800
890
1000
180
108
215
180
1800
2000
40
145
22
108
215
180
2000
2200
40
156
24
108
215
M.1
Chemical Resistance
The conveyor belt must not only meet the mechanical and thermal demands
of the load but also be resistant to diverse chemicals. The chemicals can be
in liquid, solid form or gaseous form. In many cases the quantity, concentration and temperature of the substances being handled is not exactly known
or defined.
The chemical resistance of the belt will be judged by the swelling of the
covers. At ca. 8-10% swelling the physical properties decline, the belt loses
its working capability and its life will be reduced.
The reaction will intensify through higher concentration, also with relatively
low temperature, or with lower concentration and higher temperature.
Chemical
B
Acetic Acid 10%
Acetone
Ammonia 10%
Benzine
Benzol
Creosote
Diesel Oil
Drilling Oil
Ethylacetate
Formaldehyde 10%
Formic Acid 10%
Glycerine
Hydrochloric Acid 10%
Latic Acid 10%
Machine Oil
Methylalcohol
Oil, Heavy Swelling
Oil, Light Swelling
Phenol 10%
Pine Tar
Potassium Bichromate 10%
Sulphuric Acid 10%
Trichloroethylene
Urea 50%
Water 20C
Water 80C
+ = resistant
B
P
E
D
+
+
+
+
+
+
+
+
0
+
+
+
+
+
0
+
+
+
+
+
+
+
+
+
0 = limited resistance
Carcase Material
P
E
0
+
0
+
+
+
+
0
0
0
+
0
+
+
+
+
0
+
0
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
D
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
= not resistant
Cotton
Polyamide
Polyester
Aramid
N.1
Chemical Resistance
Condition
K%
C
100
10
10
100
10
100
100
100
100
50/50
100
10
40
40
10
100
10
50
100
3
3
100
2
10
100
100
100
38
10
100
100
100
10
10
30
30
10
10
100
100
10
10
10
10
100
100
100
100
100
100
100
100
100
10
10
20
20
80
20
20
20
80
20
20
20
20
20
20
80
80
20
20
20
20
20
80
20
20
20
20
20
20
20
20
20
20
80
80
20
80
30
80
20
20
80
80
20
80
20
20
20
20
20
80
80
20
80
20
80
20
NR
SBR
+
+
0
+
0
0
0
0
0
+
+
0
+
+
+
0
+
+
+
+
+
+
Basic Material
NBR
Butyl
NCR
0
+
0
+
0
0
0
0
0
+
0
0
+
+
+
0
0
+
+
0
+
0
+
+
0
0
0
+
0
0
+
0
+
0
+
+
+
+
+
+
+
+
+
+
+
+
0
+
+
+
+
+
+
+
0
+
0
+
+
+
+
+
+
+
PVC
0
+
+
+
+
0
+
+
+
+
0
+
+
0
+
+
+
0
+
+
0
+
+
0
0
+
0
+
+
+
N.2
Chemical Resistance
Chemical
Condition
K%
C
NR
SBR
Basic Material
NBR
Butyl
NCR
PVC
Pulp
100
100
10
10
10
50
10
20
80
20
80
20
20
20
80
0
+
+
+
0
+
+
+
+
+
+
+
0
+
+
+
0
100
40
10
10
40
10
10
10
100
100
100
100
50
10
50
10
100
100
100
100
100
50
100
100
20
20
20
80
80
20
80
20
80
20
20
80
20
20
80
80
20
80
20
20
20
20
20
80
0
+
0
0
+
0
+
+
+
+
+
+
0
+
0
0
+
+
+
+
+
0
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
0
+
+
+
K%
Concentration in %
NR
SBR
NBR
NCR
Butyl
PVC
Natural Rubber
Styrene Butadiene Rubber
Nitrile Rubber
Nitrile Chloroprene Rubber
Butyl Rubber
Polyvinyl Chloride
N.3
2
2 part Idlers
3 part Idlers
ce
tan
dis ween
t
be tions
sta
10
7
Drive
Pulley
Tail Pulley
ce
tan
dis ween
bet tions
sta
5
6
1. Drive Pulley
The drive pulley should be rubber lagged. The belt tension will be less, slip at
start-up under load, prevented, and the running of the belt stabilized.
2. Troughing Angle
If 3 part idlers are used, the troughing angle should not be greater than 20
and with 2 part idlers, greater than 25 (for jute sacks etc.)
3. Snub Pulley
The angle of wrap on the drive pulley should not be more than ca. 190. The
pressure on the profile caused by the snub pulley would otherwise be too
high such that the profile can be pressed through to the pulley side of the
belt. Changes in the direction of bending of the belt are not recommended.
4. Return Side
To improve the running of the return side belt, two idlers with reduced diameter and set next to one another, can be fitted.
5. Idler Spacing
On the carrying and return side run, as with smooth surface belts, standard
idlers are used. The idler pitch should not be divisible by the pitch of the
profile pattern on the belt.
6. Deflector
A plough scraper should be fitted immediately before the tail pulley so that
material does not get trapped between belt and pulley. Where there is back
flowing water on the pulley side of the return belt, a water scraper (plough
scraper) should be used.
7. Tail Pulley
8. Loading Height
The height of fall of material being loaded to the belt should be kept as small
as possible, the loading being in direction of belt travel.
9. Belt Sag
The belt must not sag excessively between idlers (pre-tension), otherwise the
load stream becomes broken up causing loss of conveying capacity and an
increase in power demand.
O.1
10. Cleaning
O.2
Conveyor belting can be made endless using the following jointing methods:
Hot Vulcanised
Warm Vulcanised
Cold Vulcanised
Mechanical Fastener
The durability obtained from these various methods depends on environmental conditions, splicing materials and the proficiency of the splicing personnel.
The advice of the belt manufacture should be observed particularly the special recommendations that apply to certain belt types and qualities.
With hot vulcanising, vulcanising presses are necessary. The vulcanisation
takes place under a certain pressure and depending on cover quality, at a certain time and temperature. In general the vulcanising temperature lies
between 140C and 155C. Vulcanisation times depend on the belt thickness
and are of 20 to 45 minutes duration. With almost all belt types, the best
results are achieved by the hot vulcanisation process with regard to strength
and the retention of strength after prolonged periods of usage.
With textile belts, depending on carcase construction there are the stepped
splice method (1 or more steps) and the finger splice method.
lv
lst
lst
lst
bt
Stepped Splice
la
lt
Finger Splice
"
Diagonal Splice
a = 200 - 300 mm
Chevron Splice
70 70 150
0,3*B
"
Hot Vulcanisation
Zig-Zag Splice
For Steel Cord Belts depending on tensile strength and the cord diameter
the 1 to 4 step splice is used. With this the cords are laid together in a particular design.
1 Step
2 Step
3 Step
P.1
Warm Vulcanisation
For the warm vulcanisation method, a press is likewise required. The joint can
however be constructed with shorter overlap lengths. The vulcanisation temperature lies between 100C to ca. 115C. For the warm vulcanising process
special vulcanising materials are required.
Cold Vulcanisation
With cold vulcanisation, the process takes place under ambient temperature
conditions. The optimum strength is reached in ca. 24 hours. The quality of
the joint is very dependent upon the ambient conditions, humidity, dustiness
etc. Expenditure on equipment and time is much reduced.
Mechanical Splice
The quickest and most cost effective joint is the mechanical splice. The
strength however is significantly lower than that of a vulcanised splice joint.
The mechanical fastener is well suited for quick emergency splicing or belt
damage repair.
Hinged Fastener
P.2
Material Characteristics
Material
Alum
Aluminium, coarse
Aluminium, fine
Aluminium - Oxide
Aluminium - Silicate
Aluminium - Sulphate (granular)
Aluminium - Turnings
Ammonium - Chloride (crysalline)
Ammonium - Nitrate
Ammonium - Sulphate, dry
Ammonium - Sulphate, granulated
Ammonium - Sulphate, wet
Anthracite Coal
Apples
Asbestos ore
Asbestos, shred
Ash, caustic salt
Ash, coal - dry 80mm and under
Ash, coal - wet 80mm and under
Ash, fly
Ash, fly coal slack
Asphalt
Asphalt, binder for motorways
Asphalt, broken
Asphalt, paving
Bagasse
Bakelite, fine
Ballast, broken
Barium carbonate
Barley
Barytes, coarse grained
Barytes, powdered
Basalt
Basalt lava
Bauxite, broken 80mm and under
Bauxite, earth broken
Bauxite, raw
Beans
Beet pulp
Beets
Bezonite, raw
Bicarbonate
Bituminous coal, fine or nuts
Bituminous coal up to 50mm
Blast furnace slag, broken
Blast furnace slag, granulated, damp
Blast furnace slag, granulated, dry
Bone meal
Bones
Borax, coarse
Bran
Brown Coal briquettes
Brown Coal, dry
Calcium carbide
Calcium oxide
Bulk
Density
(t/m3)
0.80 - 1.04
0.95 - 1.05
0.70 - 0.80
1.12 - 1.92
0.78
0.86
0.11 - 0.24
0.83
0.72
1.10
0.72 - 0.93
1.30
0.90
0.35
1.30
0.32 - 0.40
0.81
0.56 - 0.64
0.72 - 0.80
0.45 - 0.80
0.64 - 0.72
1.00 - 1.30
1.28 - 1.36
0.70
1.30
0.13
0.48 - 0.64
1.50 - 1.80
1.15
0.60 - 0.70
2.4 - 2.9
1.9 - 2.3
1.6 - 2.3
2.30
1.20 - 1.36
1.09
2.55
0.85
0.40
0.65
0.54 - 0.64
0.65
0.90 - 1.00
0.80
1.30 - 1.60
1.50
0.50 - 0.60
0.90
0.60
0.96 - 1.04
0.25 - 0.30
0.65 - 0.85
0.65 - 0.80
1.12 - 1.28
0.70
Surcharge
Maximum Angle of Inclination
Angle Smooth
height of profiles
()
Belts 6 mm 16 mm 32 mm
25
15
6
15
20
15
25
10
15
15
15
15
20
15
10
25
15
15
30
30
15
5
20
15
15
20
20
15
10
15
15
20
15
20
15
15
10
20
20
15
10
20
15
15
20
17
20
20
17
17
15
23
15
15
17
17
10 - 12
18
22
18
20
15
15
20
25
20
12
18
17
17
20
18
20
12
14
12
15
18 - 20
24
15 - 20
18
15
15
17
15
12
15
20
18
18
20
22
20
22
22
20
18
22
-
25
25
35
30
25
25
35
30
25
20
25
25
35
25
20
30
35
25
25
25
25
25
30
25
-
30
30
40
35
30
30
40
35
30
25
30
30
40
25
30
35
40
30
30
30
30
30
20
40
30
-
Recommended
Dunlop
Quality
RS
RA
RA
RA
RA - RS
RA - RS
RA - RS
RA
RA
RA
RA
RA
RE - RS
RE - RS
RE - RS
RE - RS
RA
RA
RA
RA - BV
RA - RS - RAS
RA - RS - RAS
RA
RA
RA
RA
RA
Q.1
Material Characteristics
Material
Carbon pellets
Carborundum up to 80mm
Casein
Cast Iron swarf
Cement, clinker
Cement, dry
Cement Mortar
Chalk, broken
Chalk, pulverised
Charcoal
Chestnuts
Chrome Ore
Clay, calcined
Clay, dry
Clay, dry
Clay, dry, lumps
Clay, wet
Clay, wet
Coal
Coal, anthracite up to 3mm
Coal dust
Coal, pelletized
Cocoa beans
Cocoa powder
Coffee beans, green
Coffee beans, raw
Coffee beans, roasted
Coke breeze up to 7mm
Coke, loose
Coke, petroleum calcined
Coleseed
Compost
Concrete, stone
Concrete, wet (Readymix)
Concrete with gravel
Concrete with limestone
Copper ore
Copper sulphate
Copra flakes
Cork, broken
Cork, fine
Cork, granulated
Cornmeal
Cotton seed
Cotton seed flock
Cryolite, dust
Cryolite, Lumps
Dicalcium Phosphate
Disodium Phosphate
Dolomite, broken
Dolomite, pieces
Earth, dry
Earth, excavated dry
Earth, wet
Earth, wet loamy
Bulk
Density
(t/m3)
0.35
1.60
0.60
2.08 - 3.20
1.20 - 1.30
1.20
2.00
1.35 - 1.45
1.10 - 1.20
0.35
0.80
2.00 - 2.24
1.28 - 1.60
1.60
1.60 - 1.80
0.96 - 1.20
2.00
1.80 - 2.00
0.95
0.95
0.06 - 0.11
0.32 - 0.40
0.55
0.50
0.55
0.45 - 0.65
0.30 - 0.45
0.40 - 0.56
0.37 - 0.56
0.56 - 0.72
0.65
0.80
2.08 - 2.40
1.76 - 2.40
1.80
2.00 - 2.20
1.92 - 2.40
1.20 - 1.36
0.40 - 0.60
0.10 - 0.20
0.20 - 0.25
0.19 - 0.24
0.60 - 0.65
0.4 - 0.5
0.35
1.20 - 1.44
1.44 - 1.60
0.69
0.40 - 0.50
1.60
1.44 - 1.60
1.60
1.12 - 1.28
2.00
1.60 - 1.76
Surcharge
Maximum Angle of Inclination
Angle Smooth
height of profiles
()
Belts 6 mm 16 mm 32 mm
5
10
15
20
15
10
10
15
15
15
5
10
15
15
15
15
15
15
10 - 15
20
10
10
5
10
5
5
20
20
20
5
15
10
15
15
15
10
15
15
10
10
20
15
15
10
10
15
15
15
15
15
22
18
20
8
17
15 - 18
20
8 - 10
17
18
15
28
15
20
15 - 18
10
18
5
12
20
12
5
5
20
18
18
15
15
18
10
15
15
17
15
17
17
15
15
10
17
15
17
20
20
20
22
20
20
20
20
20
20
20
20
22
20
20
20
25
23
25
30
30
30
30
25
30
30
25
30
30
25
30
35
25
25
25
25
35
25
25
25
27
25
25
25
25
30
30
25
30
30
30
30
30
30
30
30
30
40
40
30
35
35
30
40
30
35
30
30
30
30
35
30
30
30
32
30
30
30
30
35
35
40
30
45
30
Recommended
Dunlop
Quality
RA
RS
RA
RE - RS
RA
RA
RA
RE - RS
RA - RS
RA - RS
RA - BV
RA
RA
RA
RA
RA
RA
RA - RS - BV
RE - RS
RA
ROM - ROS
RE - RS
RA
ROM - ROS
RA
RA
RE - RS
RA
RA
Q.2
Material Characteristics
Material
Ebonite up to 13mm
Felspar, broken
Felspar, lump size 40-80mm
Felspar, screened to 13mm
Fertilizer
Filter cake
Filter mud
Fishmeal
Flaxseed
Flourcalcium 40-80mm
Flourcalcium, screened
Flourspar
Fly ash
Foundry waste
Fruit
Fullers earth, dry
Fullers earth, oil filter, burnt
Fullers earth, oil filter raw
Fullers earth, oily
Glass, broken
Grain
Granite, 40-50mm lumps
Granite ballast
Granite, broken
Granite, screened, up to 13mm
Graphite flock
Graphite, pulverized
Grass seed
Gravel
Gravel, dry
Gravel, wet
Green fodder
Ground nut kernels
Ground nuts, with shells
Ground nuts, without shells
Guano, dry
Gypsum, broken
Gypsum, burnt
Gypsum mortar
Gypsum, pulverized
Gypsum, sieved
Household refuse
Husks, dry
Husks, wet
Iron Ore, broken
Iron Ore, crushed
Iron Ore, pellets
Iron Oxide, pigment
Iron turnings (Swarf)
Kaolin, broken
Kaolin clay up to 80mm
Kaolin, pulverized
Kieselguhr
Kiln Brick
Bulk
Density
(t/m3)
1.04 - 1.12
1.6
1.44 - 1.76
1.12 - 1.36
0.90 - 1.20
1.15
0.60 - 0.80
0.55 - 0.65
0.70 - 0.75
1.76 - 1.92
0.56 - 1.68
2.50
0.45 - 0.80
1.12 - 1.60
0.35
0.48 - 0.56
0.64
0.56 - 0.64
0.96 - 1.04
1.30 - 1.60
0.60
1.36 - 1.44
1.40 - 1.80
1.52 - 1.60
1.28 - 1.44
0.60 - 0.65
0.45
0.22
1.44 - 1.60
1.40 - 1.50
1.80 - 1.90
0.35
0.35
0.30
0.35
1.12
1.35
1.80
1.20
0.95 - 1.50
1.45
0.80
0.45
0.90
2.00 - 4.50
2.16 - 2.40
5.00
0.40
2.00
1.00
1.00
0.70 - 0.90
0.17 - 0.22
1.60
Surcharge
Maximum Angle of Inclination
Angle Smooth
height of profiles
()
Belts 6 mm 16 mm 32 mm
20
15
10
10
5
5
15
15
10
10
20
15
15
10
5
5
10
15
20
10
10
18
15
10
10
10
15
10
22
22
15
5
20
20
30
5
17
18
20
15
12
14
14
17
15
15
15
20
18 - 20
12
15
15
15
15
17
18
10 - 15
14
14
12
15
15
18
17
15 - 20
20
20
18
12
19
19
20
15
17
25
25
20
25
18
20
8
22
20
25
-
25
30
30
35
30
30
30
35
25
30
25
30
25
30
25
30
30
35
30
35
25
30
20
25
25
30
20
25
25
30
25
30
30
30
25
30
25
30
30
35
20
25
25 - 30 25 - 30
Recommended
Dunlop
Quality
RS
MORS-ROM
MORS
RE - RS
RA
RA
RA
RA
RA
RA
RA
RA
ROM
ROM
RA
RA
RA
RA - ROS
RA - ROS
RS - RAS
RS - RAS
RA
RA
RA
RA - RS
Q.3
Material Characteristics
Material
Bulk
Density
(t/m3)
0.51
1.15
3.20 - 4.70
0.96 - 2.40
0.85
0.60
1.20 - 1.36
1.00 - 1.20
0.64
0.96
1.40 - 1.50
1.30 - 1.40
0.72
0.75 - 0.80
3.00
1.04 - 1.20
0.52
1.90
1.10
3.00
0.70 - 0.75
0.70
0.30 - 0.50
1.28
2.0 - 2.3
1.12
1.10
2.70
1.44 - 1.52
1.20 - 1.30
0.60 - 0.70
1.71
2.00
1.20
1.70
1.04
1.45 - 1.60
1.30 - 1.45
0.40
2.40
0.55
1.50
1.92 - 2.40
2.00 - 4.50
3.2 - 4.7
2.0 - 2.3
2.40
1.7
0.70 - 0.80
0.32 - 0.80
0.65 - 1.00
1.20
0.96
1.36
Surcharge
Maximum Angle of Inclination
Angle Smooth
height of profiles
()
Belts 6 mm 16 mm 32 mm
15
15
5 - 10
15
5
15
15
5
5
10
15
20
10
10
15
5
10
5
25
10
15
15
15
10
5
15
10
10
10
15
10
10
10
5
15
15
15
15
25
15
15
5
15
15
15
-
17
15
8 - 10
15
20
18
18
15
12 - 15
15
17
20
17
16
17
10 - 12
10
15
20
15
20
15
17
17
20
18
8
20
18
20
15
15
15
15
18
17
20
15
17
14
15
12
15
-
22
22
20
20
25
22
25
20
25
18
25
-
25
25
25
25
30
25
30
25
25
25
25
25
30
25
25
25
30
20
20
20
30
25
25
25
30
25
25
20
25
25
25
-
30
30
20
27
30
35
30
35
30
30
30
30
30
30
25
25
30
35
35
30
30
30
35
30
30
25
30
30
30
-
Recommended
Dunlop
Quality
RA - RS
RA
RA
RA
RA
RA - RS
RA - RS
RA
RA
RA
BV - ROM - BVO
-
ROS
RA - RS
RA - RS
RA
RA
RA
RS
RE - RS
RS - RAS
RA
RA
-
Q.4
Material Characteristics
Material
Phosphate, pulverized
Phosphate rock, broken
Plaster
Portland cement
Portland cement, loose
Potash
Potash
Potash, broken
Potash salts, sylvite etc
Potassium (Saltpetre)
Potassium chloride pellets
Potassium sulphate
Potatoes
Pulp, dry
Pulp, wet
Pumice stone
Pumice stone sand
Pyrites, Iron lump size 50-80mm
Pyrites, Iron Sulphide
Pyrites, pellets
Quartz, broken
Quartz, lump size 40-80mm
Quartz sand
Rape seed
Rice
Roadstone, Broken (Porphyry)
Rock salt
Rubber, dust
Rubber, pelletized
Rubber, reclaim
Run of mine coal
Rye
Salt, coarse
Salt, common, dry
Salt, common, fine
Saltpetre
Saltpetre
Sand and gravel, dry
Sand and gravel, wet
Sand, dry
Sand, foundry, prepared
Sand pebble, dry
Sand, wet
Sandstone
Sawdust
Sewage Sludge
Shale
Shale, broken
Shale dust
Shale, lump size 40-80mm
Sinter, blast furnace, dry
Slag, blast furnace
Slag, blast furnace, broken
Slag, porous, broken
Slate, broken
Bulk
Density
(t/m3)
0.96
1.35 - 1.45
1.70
1.50
0.96 - 1.20
1.35
1.10 - 1.60
1.20 - 1.35
1.28
1.22
1.92 - 2.08
0.67 - 0.77
0.75
0.20 - 0.25
0.40
1.20
0.70
2.16 - 2.32
2.00 - 2.50
1.92 - 2.08
1.60 - 1.75
1.36 - 1.52
1.70 - 1.90
0.80
0.70 - 0.80
1.50 - 1.70
1.00 - 1.20
0.60 - 0.65
0.80 - 0.88
0.40 - 0.48
0.80 - 1.00
0.70 - 0.80
0.70 - 0.80
0.64 - 0.88
1.12 - 1.28
1.10
1.70
1.50 - 1.80
1.80 - 2.10
1.30 - 1.60
1.44 - 1.60
2.00
1.60 - 2.00
1.36 - 1.44
0.20 - 0.30
0.64 - 0.80
2.70
1.44 - 1.60
1.12 - 1.28
1.36 - 1.52
1.50
1.50
1.28 - 1.44
0.60
1.40 - 1.55
Surcharge
Maximum Angle of Inclination
Angle Smooth
height of profiles
()
Belts 6 mm 16 mm 32 mm
15
10
20
15
10
10
15
15
15
15
10
15
15
15
15
5
5
15
10
10
10
10
15
5
10
10
5
10
10
15
10
20
5
15
15
20
15
15
15
10
15
15
15
15
18
15
17
20
12
15
12
17
15
15
15
17
17
12
8
20
15
20
20
20
18
15
17
17
15
16
18
20
17
17
15
20
17
18
15
18
15
15
15
17
20
20
20
15
12
22
22
20
25
20
20
25
20
20
25
20
25
-
25
20
30
25
30
20
25
25
25
25
25
25
25
25
25
20
30
30
25
25
25
35
30
30
30
25
30
30
25
30
25
35
30
25
25
25
30
25
25
25
30
30
30
35
25
30
25
30
30
30
30
30
30
25
25
35
35
30
30
30
40
35
35
35
30
35
35
30
35
30
35
35
25
30
30
30
30
30
Recommended
Dunlop
Quality
RA
RA
RA
RA - RS
RA
RA - RS
RA - RS
RA
RA
RA
RA
RA
RA
RA
RA
RA
RA
RA
RA
RA
RA - RS - RAS
ROM
RA - ROS
RA - RS - RAS
RA - RS - RAS
RA - RE
Q.5
Material Characteristics
Material
Bulk
Density
(t/m3)
0.24 - 0.40
0.15 - 0.35
0.90 - 1.20
0.88 - 1.04
0.32 - 0.56
0.65
1.12 - 1.28
0.40 - 0.75
0.80
1.60 - 2.40
1.50 - 1.80
1.40 - 1.60
1.55 - 1.70
0.88 - 1.04
0.60 - 0.80
0.80 - 0.96
0.90 - 1.50
0.70
0.40
0.20 - 0.25
0.88 - 1.04
0.80 - 1.20
1.30
0.90
0.80
2.00
1.60
0.96 - 1.12
0.90
0.75
0.55 - 0.65
0.30 - 0.40
0.60 - 0.85
0.16 - 0.48
2.40
1.60
2.56
0.48 - 0.56
0.16 - 0.24
3.70
Surcharge
Maximum Angle of Inclination
Angle Smooth
height of profiles
()
Belts 6 mm 16 mm 32 mm
10
10
5
15
15
15
10
10
5
0
15
18
15
15
5
10
15
10
10
5
10
5
15
15
15
15
12
18
17
15
18
15
15
15
19
15
12
20
18
18 - 20
18
17
19
20
17
10 - 12
14
20
15
20
12
15
17
17
17
18
22
20
22
20
16
20
20
25
25
20
22
18
-
25
25
20
25
25
20
22
25
25
20
25
25
25
30
30
30
20
30
30
20
20
20
25
25
20
25
30
25
30
30
25
27
25
30
30
30
35
35
35
30
35
35
25
30
30
25
30
Recommended
Dunlop
Quality
RA
RA
RA
ROS
RA
RA
RA
RA
RA
RA
RA - RS - RAS
-
ROM
RA - ROM
RA - RS - RAS
RA
RA
Q.6