Vous êtes sur la page 1sur 26

Propritaire:

Consultant:

OCP

JACOBS Engineering

OCP GROUP
Web: www.ocpgroup.ma

Imm. 5 - Znith Millenium - Lot. Attaoufik


Route Nouaceur - Sidi Marouf
Casablanca - 20270 Morocco
Tl: +212 (0)5 22 87 70 00 / +212 (0)5 22 87 71 50

Bureau d'Etude:

Contractant:

EMPI

DLM

Route El Ain Km 4
Immeuble RAWDHAN
Tel: (+216) 74 264 180 // (+216) 74 610 780
Web: www.empi.tn // www.group-ips.com

Route de Rabat - Km 9, Ain Seba - B.P. 2613


Casablanca MAROC
Phone : + 212(0) 5 22 66 96 00
Fax
: + 212(0) 5 22 35 54 65

MEA EXPANSION
MEA EXTENSION: Alimentation de la 7me ligne

Note de Calcul Mcanique convoyeur CVL'

DLM B-28-1- PE0101_Note de Calcul Mcanique


Ref.: Convoyeur CVL'_MEC32801_00_20151101
Rev.
00

Author
Date
15/12/2015

OCP:
Checked

Name
AFE

Date
15/12/2015

Approved
Name
WKT

Date
15/12/2015

CONFIDENTIAL Any disclosure of this information is strictly forbidden without EMPI prior authorization

Name
WBN

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
SOMMAIRE
1

PAGE DE GARDE

SOMMAIRE

1- OBJET

2- DOCUMENTS & NORMES DE REFERENCE

2-1- DOCUMENTS DE REFERENCE

2-2- NORMES DE REFERENCE

3
3
3
4

3- DONNEES DE CALCUL
3-1- GROUPE DE COMMANDE
3-2- PHILOSOPHIE DE CONCEPTION
4- CALCUL DE LA PUISSANCE DU MOTEUR

4-1- POWER CALCULATION

14

4-2- SECONDARY & SPECIAL RESISTANCE

17

5- CHARGES SUR TAMBOURS

18

6- DIMENSIONNEMENT DU GROUPE DE COMMANDE

18

6-1- CARACTERISTIQUES MOTEUR

19

6-2- CARACTERISTIQUES REDUCTEUR

19

6-3- SPECIFICATION D'ACCOUPLEMENT

19

6-4- SPECIFICATION SYSTME DE FREINAGE

19

6-5- SPECIFICATION CHASSIS

20

7- VERIFICATION DES AXES & MOYEU TAMBOURS

22

8- VERIFICATION DES PALIERS

24

9- VERIFICATION DES ROULEAUX

26

10- VERIFICATION RAYON DE COURBURE CONCAVE

27

11- VERIFICATION RAYON DE COURBURE CONVEX

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101

1- OBJET
L'objectif de cette note de calcul est la vrification des diffrents composants du transporteur bande
RB2, savoir:
- Vrification Puissance de Commande
- Vrification des Caractristiques & de la Tension de Bande
- Vrification des Diffrents Tambours
- Vrification des Diffrents Paliers
- Vrification des Diffrentes Stations de Rouleau
2- DOCUMENTS & NORMES DE REFERENCE
2-1- DOCUMENTS DE REFERENCE
B-28-6- PE0101_Plan d'Ensemble Table de Rception Convoyeur CVL'_MEC32801_00_20151101

2-2- NORMES DE REFERENCE


ISO5048 (1989): Engins de manutention continue. Transporteurs courroie munis de rouleaux porteurs Calcul de la puissance d'entranement et des efforts de tension.
3- DONNEES DE CALCUL
3-1- GROUPE DE COMMANDE
Le groupe de commande sera considr comme tant un systme moto-rducteur avec un
accouplement Arbre plein avec accouplement flexible pour la connection avec tambour de commande.
L'efficacit globale du groupe de commande est calcule comme suit:

- Efficacit Moteur:
- Efficacit Accouplement:
- Efficacit Rducteur:
- Efficacit Totale:

Couple de Dmarrage Moteur:

Sans Accouplement
Hydraulique

Avec Accouplement
Hydraulique

0.97
0.98
0.95
0.90

0.97
0.95
0.95
0.88

2.40

1.50

3-2- PHILOSOPHIE DE CONCEPTION


La puissance minimale requise pour entrainer le systme de convoyeur bande est calcule en faisant
la somme des puissances suivantes:
- La charge de la bande et des stations de rouleau vide
- La charge pour translation de la matire.
- La charge pour soulvement de la matire.
- Les charges divers lments de la bande (Points de dcharge, Racleurs, etc.) intgres dans
le facteur "C".
- L'efficacit du groupe de commande.

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
4-1- Power Calculation
CONVOYEUR CVL': D1:630 / D2:500

Belt Design Summary


Pm (kW)
P Pm
Fvmin (daN)
r
Fv Fvmin
r1
FvminS (daN)
rS
Fv FvminS
rS 1
dmax (mm)
CRm (N/mm)
d 2 dmax
Wu CRm
dmaxS (mm)
CRmS (N/mm)
d 2 dmaxS
Wu CRmS

311.29
OK
6,022
0.831
OK
OK
6,971
0.997
OK
OK
847
778
OK
OK
1,017
653
OK
OK

Required Motor Power Necessary to transmit to the belt


Check of Motor Power
Minimum Required Counterweight
Belt Slipping Coefficient
Check of Counterweight
Check of Belt Slipping
Start-up Minimum Required Counterweight
Start-up Belt Slipping Coefficient
Check of Counterweight @ Start-up
Check of Belt Slipping @ Start-up
Maximum Belt Elongation
Minimum Required Tensile Strength
Check of Belt Elongation Length
Check of Belt Tensile Strength
Start-up Maximum Belt Elongation
Start-up Minimum Required Tensile Strength
Check of Belt Elongation Length @ Start-up
Check of Belt Tensile Strength @ Start-up

Working Condition
OCP Standard
Medium Weight and Lump Size Material
Handled Material Definition
Phosphate
Brut

<-Material Designation

35 <-a: Material Angle of Repose (Deg)


15 <-q: Material Surcharge Angle (Deg)
1200 <-r: Material Density (kg/m3)
9.81 <-g: Standard Gravity Acceleration (m/s)
Belt Definition
3600 <-Q: Maximum Belt Design Capacity (Ton/h)
3.8 <-v: Belt Speed (Tab.4&5&6) (m/s)
1400 <-B: Belt Width (mm)
EP800/4 <-Carcass Style
800 <-Wu: Belt Resistance at Break (N/mm)

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
1 <-z: Maximum Belt Elongation During Service (Load = 10% of Belt Resistance at Break) (%)
10 <-fs: Belt Required Safety Factor
7 <-fss: Belt Required Safety Factor at Starting
6 <-ttc: Top Cover Thickness (mm)
4 <-tbc: Bottom Cover Thickness (mm)
1.2 <-rr: Rubber Average Weight (kg/[mxmm])
1.5 <-S1: Maximum Sag Along the Carrying Section (%)
1.5 <-S2: Maximum Sag Along the Return Section (%)
87.15 <-L: Belt Length Center-To-Center (m)
13.5 <-d: Maximum Belt Inclination (Deg)
Idlers Definition
159 <-dc: Carrying Idlers Diameter (mm)
Tern <-Carrying Idlers Type
35 <-l: Idlers Inclination Angle (Deg)
159 <-dr: Return Idlers Diameter (mm)
Couple <-Return Idlers Type
1.250 <-ac: Distance Between Carrying Idler (Tab.12) (m)
3.000 <-ar: Distance Between Return Idler (Tab.12) (m)
Upper Flight Definition
7 <-Nu: Upper Flight Number
No.

Pulley

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

D1
NA
NA
D2
D5
D4-1
D3

Qu,n
Lu,n (m)
(Ton/h)
3600
2.808
3600 81.436
3600
1.750
0
1.156
0
0.800
0
41.644
0
0.000

Hu,n (m)
0.674
19.551
0.420
0.278
-0.214
-9.998
3.165

b u,n
(Deg)
13.50
13.50
13.50
13.50
-15.00
-13.50
90.00

Ncu,n

Nru,n

3
66
7
0
0
0
0

0
0
0
0
0
14
0

<-Qu,n: Flight Capacity (Ton/h)


<-Lu,n: Flight Length (m)
<-Hu,n: Flight Height (m)
<-b u,n: Flight Slop (Deg)
<-Ncu,n: Carrying Idler Number Per Flight
<-Nru,n: Return Idler Number Per Flight

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
Lower Flight Definition
3 <-Nl: Lower Flight Number
No.

Pulley

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

D5
D4-2
D3

Ql,n
b l,n
Ll,n (m) Hl,n (m)
(Ton/h)
(Deg)
0
0.790 0.000
0.00
0
43.394 -10.418 -13.50
0
0.000 3.366 -90.00

Ncl,n

Nrl,n

0
0
0

0
14
0

<-Ql,n: Flight Capacity (Ton/h)


<-Ll,n: Flight Length (m)
<-Hl,n: Flight Height (m)
<-b l,n: Flight Slop (Deg)
<-Ncl,n: Carrying Idler Number Per Flight
<-Nrl,n: Return Idler Number Per Flight

Pulley & Motor Definition


315 <-P: Installed Motor Power (kW)
2,100 <-d: Counterweight Elongation Course (mm)
7,000 <-Fv: Counterweight Value (daN)
210 <-j: Belt to Drive Pulley Contact Angle (Deg)
0.35 <-m: Friction Coefficient Between Belt & Pulley (Tab.10)
1.3 <-w: Starting Motor Coefficient
0.88 <-h: Mechanical Efficiency Coefficient for the Transmission (Tab.8)
Type 2 <-Type of Belt Conveyor
Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System

T1

j
T2

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
Empty Belt & Idlers Weight Computation
6.5 <-qbc: Belt Carcass Weight for square Meter (Tab.13) (kg/m)
18.5 <-q: Belt Weight per square Meter (kg/m)

q qbc rr ttc tbc

44.3 <-qc: Carrying Idler Unit Weight (Tab.11) (kg)


35.2 <-qr: Return Idler Unit Weight (Tab.11) (kg)
Friction & Length Coefficient
0.03 <-f: Idlers Friction Coefficient (Tab. 9)

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
Forces Necessary for Movement of Belt

F1,n f Ln q
qc N c ,n qr N r ,n
1000

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

F2,n fLn

Qn
3.6v

F3,n

Qn H n
B
q
Hn
3.6v
1000

Upper Flight
Lower Flight
F1u,n
F2u,n
F3u,n
F1l,n
F2l,n
F3l,n
(kg)
(kg)
(kg)
(kg)
(kg)
(kg)
6.1688 22.168 194.87 0.6138
0
0
150.99 642.92 5651.4 48.501
0
-269.83
10.663 13.816 121.44
0
0
87.179
0.8982
0
7.1881
0
0
0
0.6216
0
-5.5519
0
0
0
47.141
0
-258.94
0
0
0
0
0
81.974
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
<-F1,n: Flight Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)
<-F2,n: Flight Forces Necessary for Translation of the Load (kg)
<-F3,n: Flight Forces Necessary for the Elevation of the Load (kg)

266
679
5,610
-134
755.96

<-F1: Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)
<-F2: Forces Necessary for Translation of the Load (kg)
<-F3: Forces Necessary for the Elevation of the Load (kg)
<-Ft,L: Tail Losses Between Take Up & Drive Pulley (kg)
<-FNS: Total Secondary & Special Resistance (daN)

FNS FN FS

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
Total Force and Motor Power Calculation
7,310 <-Fmin: Total Periphery Force Necessary to transmit to the belt (kg)

Fmin F1 F2 F3 FNS
272.51 <-Pa: Theorical Motor Power Necessary to transmit to the belt (kW)

Pa gFmin v
311.29 <-Pm: Required Motor Power Necessary to transmit to the belt (kW)

Pa

Pm

P Pm

OK

Tension Calculation (During Operation)


7,257 <-F: Installed Periphery Force (daN)

hP
v

0.384 <-K: Friction Factor

1
e 1
mj

10,041 <-Tu,1n: Nominal Tight Side Tension (daN)

Tu ,1n F K 1
2,784 <-Tl,1n: Nominal Slack Side Tension (daN)

Tl ,1n FK
2,650 <-Tv1: Minimum Tension to Allow the Motion Transmission (daN)

Tv1 Tl ,1n Ft , L
3,011 <-Tsup: Minimum Tension For Max Sag of Carrying Idler (daN)

Tsup

ac qB
Q

8S1 1000 3.6v

648 <-Tinf: Minimum Tension For Max Sag of Return Idler (daN)

Tinf

ar qB
8S2 1000

6,022 <-Fvmin: Minimum Required Counterweight (daN)

Fv min 2Max Tv1 ; Tsup ; Tinf


850 <-Tv: Take-Up Over tension (daN)

Tv

Fv
Ft , L Tl ,1n
2

10,890 <-Tu,1: Maximum Tight Side Tension (daN)

Tu ,1 Tu ,1n Tv
3,634 <-Tl,1: Maximum Slack Side Tension (daN)

Tl ,1 Tl ,1n Tv

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
0.831 <-r: Belt Slipping Coefficient

Tu ,1
Tl ,1e mj

Fv Fvmin

OK

r1

OK

Tension Calculation (During Start-up)


9,434 <-Fs: Installed Periphery Force at Starting (daN)

Fs

wh P
v

13,053 <-Tu,1nS: Start-up Nominal Tight Side Tension (daN)

Tu ,1nS Fs K 1
3,619 <-Tl,1nS: Start-up Nominal Slack Side Tension (daN)

Tl ,1nS Fs K
3,485 <-Tv1S: Start-up Minimum Tension to Allow the Motion Transmission (daN)

Tv1S Tl ,1nS Ft , L
6,971 <-FvminS: Start-up Minimum Required Counterweight (daN)

Fv min S 2 Max Tv1S ; Tsup ; Tinf


15 <-TvS: Start-up Take-Up Over tension (daN)

TvS

Fv
Ft , L Tl ,1nS
2

13,067 <-Tu,1S: Start-up Maximum Tight Side Tension (daN)

Tu ,1S Tu ,1nS TvS


3,634 <-Tl,1S: Start-up Maximum Slack Side Tension (daN)

Tl ,1S Tl ,1nS TvS


0.997 <-rS: Start-up Belt Slipping Coefficient

rS

Tu ,1S
Tl ,1S e mj

Fv FvminS

OK

rS 1

OK

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
Belt Tensile Strength Check (Operation Case)

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Upper Flight
Tu,n
DTu,n
(kg)
(kg)
223
10,890
6,445 10667
146
4221.8
8
4075.9
-5
4067.8
-212
4072.8
82
4284.6
0
4202.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Lower Flight
Tl,n
DTl,n
(kg)
(kg)
1
3,634
-221 3634.1
87
3412.8
0
3500
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

DTu ,n F1u ,n F2u ,n F3u ,n


DTl ,n F1l ,n F2l ,n F3l ,n
Tu ,n 1 Tu ,n DTu ,n
Tl ,n 1 Tl ,n DTl ,n
Notes
Tension will be Regulated via Material
Trampling Losses Addition
The Tension in Pulley Remains inchanged

10,890 <-Tmax: Maximum Belt Tension (daN)


847 <-dmax: Maximum Belt Elongation (mm)

d max L

Tmax 10
B Wu

778 <-CRm: Minimum Required Tensile Strength (N/mm)

CRm f s

Tmax
B

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
d 2 dmax

OK

Wu CRm

OK

Belt Tensile Strength Check (Start-up Case)

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Upper Flight
Lower Flight
Tu,nS
Tl,nS
DTu,n
DTl,n
Pulley
Pulley
(kg)
(kg)
(kg)
(kg)
D1
223
13,067
D5
1
3,634
NA
6,445 12844 D4-2
-221
3634.1
NA
146
6398.9
D3
87
3412.8
D2
8
6253
0
0
3500
D5
-5
6244.9
0
0
0
D4-1
-212
6249.8
0
0
0
D3
82
6461.6
0
0
0
0
0
6379.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

13,067 <-TmaxS: Start-up Maximum Belt Tension (daN)


1,017 <-dmaxS: Start-up Maximum Belt Elongation (mm)

d max S L

Tmax S 10
B Wu

DTu ,n F1u ,n F2u ,n F3u ,n


DTl ,n F1l ,n F2l ,n F3l ,n

Tu ,n 1S Tu ,nS DTu ,n
Tl ,n 1S Tl ,nS DTl ,n
Notes
Tension will be Regulated via Material
Trampling Losses Addition
The Tension in Pulley Remains inchanged

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
653 <-CRmS: Start-up Minimum Required Tensile Strength (N/mm)

CRmS f ss

Tmax S
B

d 2 dmaxS

OK

Wu CRmS

OK

Pulleys Tensions

No.

Designation

D1

Zx
(kg)
13,067

D2

6,253

D3

3,413

D4-1

3,634

D4-2

3,634

D5

3,634

Zs
(kg)
3,634

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
4-2- Secondary & Special Resistance

Loading Parameters Material Definition


2 <-e: Tilte Angle of Idler (Deg)
0.4 <-Ce: Trough Factor
0.35 <-m0: Friction Coefficient Between Belt & Carrying Idlers
0.6 <-m1: Friction Coefficient Between Belt & Material
0.6 <-m2: Friction Coefficient Between Belt & Skirtplate
0.6 <-m3: Friction Coefficient Between Belt & Belt Cleaner
1200 <-r: Material Density (kg/m3)
9.81 <-g: Standard Gravity Acceleration (m/s)
3600 <-Q: Maximum Belt Design Capacity (Ton/h)
3.8 <-v: Belt Speed (m/s)
1400 <-B: Belt Width (mm)
87.15 <-Le: Length of Installation Equiped with Tilted Idlers (m)
18.5 <-q: Belt Weight per square Meter (kg/m)
30000 <-p: Pressure between belt cleaner and the belt (N/m)
0.0315 <-A: Contact Area Between between belt cleaner and the belt (m)
1.5 <-v0: Velocity Component of the Conveying speed of the material handled (m/s)
3 <-l: Length of Installation Equiped with Skirt Plate (m)
1.05 <-b1: Width Between Skirtplates (m)
21 <-d: Belt Thickness (mm)
2.63 <-d: Medium Belt Inclination (Deg)
Pulleys Parameters
No.

Pulley

Di
(mm)

Ni
(kg)

Zxi
(kg)

Zsi
(kg)

d0i
(mm)

D1

630

15,962

13,067

3,634

170

D2

500

12,519

6,253

140

D3

500

3,635

3,413

100

D4-1

400

3,635

3,634

100

D4-2

400

3,635

3,634

100

D5

400

3,744

3,634

100

7
8
9
10

<-D1: Drive Pulley


<-D2: Tail/Return Pulley
<-D3: Take up/Counter Weight Pulley
<-D4: Bend/Deviation Pulley(s)
<-D5: Snub Pulley(s)

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
Special Resistance Calculations 4- CALCUL DE LA PUISSANCE DU MOTEUR
263 <-qG: Mass per Meter of Material Handled (kg/m)

qG

Q
3.6v

0.83 <-Iv: Belt Capacity (m3/s)

Iv

Q
3.6 r

117.53 <-Fe: Resistance due to Idler tilting (daN)

Fe Ce m0 Le qB qG g cos d sin e
92.43 <-FgL: Resistance due to Friction between Material Handled and Skirtplates (daN)

FgL

m2 I v2 r gl
v 2b12

56.70 <-Fr: Friction Resistance due to Belt Cleaner (daN)

Fr Apm3
266.66 <-Fs: Total Special Resistance (daN)

Fs Fe FgL Fr
Secondary Resistance Calculations due Skirtplates, Inertial and Frictional Resistance
1.04 <-lb,min: Skirtplate Equivalent Length (m)

lb,min

v 2 v02
2 g m1

230 <-FbA: Inertial and Frictional Resistance at the Loading Point (daN)

FbA I v r v v0
66 <-Ff: Frictional Resistance between Handled material and the skirtplate in the acceleration Area (daN)

Ff

m2 I v2 r glb ,min
v v0 2
2 b1

Secondary Resistance Calculations due Pulleys

F d

F1i 9 B 140 0.01 i


B Di

No.

Pulley

Fi
(N)

F1i
(daN)

D1

81,918

30

D2

61,342

D3

33,480

D4-1

5
6
7
8
9
10

FTi Ni g

FTi
(daN)

Fti
(daN)

31

12,281

17

20

3,566

35,651

26

3,566

D4-2

35,651

26

3,566

D5

35,645

26

3,673

Fti 0.005

d 0i
FTi
Di

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL
DE
LAPulley
PUISSANCE
DU MOTEUR
<-Fi: Average Belt
Tension at
the
(N)
<-F1i: Wrap Resistance between belt and Pulley (daN)
<-F1i: Wrap Resistance between belt and Pulley (daN)
<-FTi: Vectorial Sum of the Forces Applied to Pulley (daN)
<-Fti: Pulley bearing resistance (daN)
159 <-F1: Total Wrap Resistance between belt and Pulley (daN)
34 <-Ft: Total Pulley bearing resistance (daN)
489.30 <-FN: Total Secondary Resistance (daN)

FN FbA Ff F1 Ft
Applicability of C Equivalent Method
755.96 <-FNS: Total Secondary & Special Resistance (daN)

FNS FN FS

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101

5- CHARGES SUR TAMBOURS

Type 2

<-Type of Belt Conveyor


Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System

EP800/4 <-Carcass Style

D1

Dp
(mm)
Tab.13
630

170

15,962

D2

500

140

12,519

D3

500

100

3,635

D4-1

400

100

3,635

3,634

364

D4-2

400

100

3,635

3,634

364

D5

400

100

3,744

3,634

364

No.

Designation

d
(mm)

N
(kg)

j
(Deg)

a
(Deg)

210

7
8
9
10

<-D1: Drive Pulley


<-D2: Tail/Return Pulley
<-D3: Take up/Counter Weight Pulley
<-D4: Bend/Deviation Pulley(s)
<-D5: Snub Pulley(s)

b
(Deg)

Zx
(kg)

Zs
(kg)

Fv
(kg)

q
(kg)

13,067

3,634

942

6,253

564

3,413

7,000

414

15

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
6- DIMENSIONNEMENT DU GROUPE DE COMMANDE

6-1- SPECIFICATIONS DU MOTEUR


Puissance installe (kW)
Standard de construction
Facteur de puissance minimale cosj
Facteur de service
Start-up/Nominal Absorbed Current Ratio (Is/In)
Tension d'alimentation
Vitesse de rotation (rpm)
Frquence
Degrs de protection IP (IEC 60034-5)
Classe d'isolation
Temprature de design
Mthode de refroidissement selon IEC 60034-6
Protection thermique
Environment de travail
Matriau de construction du stator
Matriau de construction Supports/oreilles de levage
Matriau de construction de la boite de jonction
Position boite de jonction
Type
Poids approximatif (kg)

315
IEC60034
80%
1,5
6.8
525V/3Ph
1500
50Hz
IP55
Class F
50C
IC0A1
PT100
Poussireux
Cast Iron
Fonte
Fonte
au dessus du moteur
Cage d'cureuil
1500

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
6- DIMENSIONNEMENT DU GROUPE DE COMMANDE
6-2- SPECIFICATION DU REDUCTEUR
Standard de construction
Type
Diamtre du tambour (mm)
Vitesse de la bande (m/s)
Vitesse de rotation /petite vitesse (rpm)
Couple rducteur (Nm)
Puissance rducteur (kW)
Rapport de rduction
Temprature de design du rducteur
Nombre d'heure de service/jour (hr)
Facteur de Service
Type d'arbre grande vitesse
Type d'arbre petite vitesse
Type 1: Arbre plein
Type 2: Arbre creux avec disque
Type 3: Arbre creux avec clavette
Peinture
Sonde de temprature
Indicateur de niveau d'huile
Trous de regards avec clapets
Carcasse du rducteur
Antidvireur
Orientation de l'arbre de sortie (droite/gauche)
Poids approximatif (kg)

AGMA
Axes perpendiculaires, Arbre
plein
630
3.8
115
26,112

315
13
50C
24H
1,5
Type 1
Type 1

Intrieure & Extrieure


N/A
oui
Oui
Les carters du rducteur en
deux parties moules
N/A
Droite
790

6-3- SPECIFICATION D'ACCOUPLEMENT


Type d'accouplement
Chambre de retardement
Rapport (couple de dmarrage transmissible/couple nominal)

Hydraulique
Oui
1,5 1,6

6-4- SPECIFICATION SYSTME DE FREINAGE

Type de frein
Temps de freinage maximale (s)

Frein sabot commande


lectromagntique
5

6-5- SPECIFICATION CHASSIE GROUP DE COMMANDE


Peinture
Matriaux
Construction

Intrieure & Extrieure


Acier Carbone
PRS

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
7- VERIFICATION DES AXES & MOYEU TAMBOURS

Pulley Parameters Definition


Pulley Shell
No.

Designation

Flange & Hub Parameters

Driven Shaft Parameters

Dp
(mm)

d
(mm)

N
(kg)

Type

Lp
(mm)

ts
(mm)

tf
(mm)

Lf
(mm)

th
(mm)

dho
(mm)

dhi
(mm)
Tab.23

Driving Shaft Parameters

Gear Box & Motor Parameters

WL
(kg)
Tab.23

PN
(N/mm)
Tab.23

d1
(mm)
Tab.16

Li
(mm)

k
(mm)
Tab.16

EA
(mm)

b
(mm)

Dq
(mm)

Lq
(mm)

Dm
(mm)

Lm
(mm)

Dw
(mm)

Lw
(mm)

n
(tr/min)

P
(kW)

MTP
(Nm)

Wd
(kg)

200

165

165

162

742.5

160

907.5

115

315

26111.84

2633.5

D1

630

170

15,962

Type 1

1600

10

10

1400

20

300

225

7.75

115

200

1360

88

1920

D2

500

140

12,519

Type 2

1600

10

10

1400

20

260

190

4.9

130

170

1360

79

1920

D3

500

100

3,635

Type 2

1600

10

10

1400

20

210

145

2.6

145

130

1360

57

1920

D4-1

400

100

3,635

Type 2

1600

10

10

1400

20

210

145

2.6

145

130

1360

57

1920

D4-2

400

100

3,635

Type 2

1600

10

10

1400

20

210

145

2.6

145

130

1360

57

1920

D5

400

100

3,744

Type 2

1600

10

10

1400

20

210

145

2.6

145

130

1360

57

1920

7
8
9
10

<-Dp: Pulley Diameter (mm)


<-d: Shaft Diameter (mm)
<-N: Equivalent Load Applied From Belt Conveyor (kg)
<-Lp: Pulley Shell Length (mm)
<-ts: Pulley Shell Thickness (mm)

Hub Material Parameters Definition


C45+QT <-Hub Material Designation (Per EN10083-2)
200,000 <-Eh: Hub Modulus of elasticity (MPa)
430 <-Syh: Hub Yield Strength (MPa)
650 <-Suh: Hub Ultimate Limit Strength (MPa)

<-tf : Pulley Flange Thickness (mm)


<-Lf : Distance Between Flange (mm)
<-th: Hub Thickness (mm)
<-dho: Hub Outside Diameter (mm)
<-dhi: Hub Inside Diameter (mm)
<-WL: Locking Devices (kg)

<-PN: Pressure Applied From Locking Device to Hub (N/mm)


<-d1 :Shaft Inside Diameter (mm)
<-Li: Shaft Inside Portion Length (mm)
<-k: Distance From Plummer Block Axis to Shaft End (mm)
<-EA: Distance Between Plummer Blocks (mm)
<-b: Distance From Plummer Block Axis to Gear Box (mm)
<-Dq: First Shrink Disc Diameter (mm)
<-Lq: First Shrink Disc Length (mm)
<-Dm: Second Shrink Disc Diameter (mm)
<-Lm: Second Shrink Disc Length (mm)
<-Dw: Third Shrink Disc Diameter (mm)
<-Lw: Third Shrink Disc Length (mm)

<-n: Gear Box Output Speed (r/min)


<-P: Motor Nominal Power (kW)
<-MTP: Moment Transmitted from Gear Box (Nm)
<-Wd: Approximatif Drive System Weight (kg)

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
7- VERIFICATION DES AXES & MOYEU TAMBOURS
Shaft Material Parameters Definition
C55+N <-Shaft Material Designation (Per EN10083-2)
200,000 <-Es: Shaft Modulus of elasticity (MPa)
420 <-Sys: Shaft Yield Strength (MPa)
700 <-Sus: Shaft Ultimate Limit Strength (MPa)
Design Parameters
1400 <-BW: Belt Width (mm)
3.8 <-v: Belt Speed (Tab.4&5&6) (m/s)
1.5 <-SF: Factor of Safety
0.8 <-Ka: Surface factor
0.897 <-Kc: Reliability factor
1 <-Kd: Temperature factor
1 <-Ke: Duty cycle factor
0.63 <-Kf: Fatigue stress concentration factor
1 <-Kg: Miscellaneous factor
0.88 <-h: Mechanical Efficiency Coefficient for the Transmission
1.3 <-w: Starting Motor Coefficient
Type 2 <-Type of Belt Conveyor
Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System
Pulley Parameters Definition

d
Kb

25.4

Wp

No.

0.19

S
S f ka kb kc kd ke k f k g us
2

D
D L t 7850 2
p

p s

Designation

Wp
(kg)

2ts d ho2
2

Kb

Sf
(MPa)

32 SF M b 3 M TT

Sf 4 S ys
2

d min 3

M TT

MTT
(Nmm)

ag
(mm)

Mb
(Nmm)

dmin
(mm)

Stress
Check

rd

tan(a)/0. Defl
Check
005

dho,min
(mm)

Hub
Stress
Check

D1

942.26 0.69684 110.262

3E+07

260

3.5E+07 169.774

OK

0.998672

0.4121

OK

295.955

OK

D2

564.02 0.72303 114.405

260

1.6E+07 128.708

OK

0.9193425 0.70269

OK

259.589

OK

D3

414.41 0.77076 121.958

260

4635327 83.4297

OK

0.8342972 0.78377

OK

205.958

OK

D4-1

364.35 0.77076 121.958

260

4635327 83.4297

OK

0.8342972 0.78377

OK

205.958

OK

D4-2

364.35 0.77076 121.958

260

4635327 83.4297

OK

0.8342972 0.78377

OK

205.958

OK

D5

364.35 0.77076 121.958

260

4775244 84.2608

OK

0.8426085 0.80743

OK

205.958

OK

8
9
10

EA L f
2

d ho,min d hi

Mb

W
N
ag d b Lw
2
2

S yh PN

tan a

64 Nag EA ag
4 Es d 4

S yh PN

Dq2
d ho2 d hi2
D2
D2
d12
d2
t f 7850 2
th 7850 2WL
L1 7850
EA k b L1 7850 Lq 7850 m Lm Lq 7850 w Lw Lm 7850
4
4
4
4
4
4

M For Type 1
wh TP
0 For Type 2

ag

<-Wp: Pulley Weight (kg)


<-Kb: Size Factor
<-Sf: Allowable Bending Stress (MPa)
<-MTT : Moment Transmitted to Pulley Taking into Consideration Drive System Efficiency & Starting Torque (Nmm)
<-ag (mm)
<-Mb: Bending Moment Applied to Shaft (Nmm)
<-dmin: Minimum Shaft Diameter Imposed by Stresses (mm)
<-rd: Minium Shaft Diameter to Nominal Shaft
<-tan(a): Shaft Deflection Ratio
<-dho,min: Minimum Hub Diameter (mm)

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
8- VERIFICATION DES PALIERS
Spherical Roller Bearing
Bearing Mounted on Smooth Shafts, Design Standard ISO113:1999 & Tapered Bore Bearing

Design Parameters Definition


3.8 <-v: Belt Velocity (m/s)
50 <-T: Maximum Design Temperature (C)
90 <-R: Bearing Degree of Reliability (%)
1.5 <-Cd: Dynamic Load Factor
50,000 <-L10M: Minimum Bearing Rating Life operating hours Based on 500rpm (h)
Type 2 <-Type of Belt Conveyor
Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System
Plummer Block Characteristics
d
(mm)

N
(kg)

Plummer Block Designation


Tab. 14

D1

Dp
(mm)
630

170

15961.619

BND2234 22234 CCK/W33 D170

D2

500

140

12518.652

BND3228 23228 CCK/W33 D140

D3

500

100

3634.6952

BND2220 22220 EK D100

D4-1

400

100

3634.6952

BND2220 22220 EK D100

D4-2

400

100

3634.6952

BND2220 22220 EK D100

D5

400

100

3744.4083

BND2220 22220 EK D100

No.

Pulley Ref.

1
2

7
8
9
10

<-Dp: Pulley Diameter (mm)


<-d: Shaft Diameter (mm)
<-N: Equivalent Load Applied From Belt Conveyor (kg)

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
8- VERIFICATION DES PALIERS

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
8- VERIFICATION DES PALIERS
Bearing Rating Life Check
10

v x1000 x 60
n
Dp

N
Pr Cd
2

C 3
L10
Pr

No.

n
(rpm)

Pr
(N)

Bearing Designation
Tab.14

115.20

117,438

22234 CCK/W33

C
(N)
Tab.15
1120000

145.15

92,106

23228 CCK/W33

915000

145.15

26,742

22220 EK

181.44

26,742

181.44

181.44

L10 h

106

L10
60n

L10 hE

n
L10 h
500

L10
(MR)

L10h
(h)

L10hE
(h)

L10hE
L10M

1840

266138

61,317

OK

2108

241998

70,252

OK

425000

10092

1158784

336,394

OK

22220 EK

425000

10092

927028

336,394

OK

26,742

22220 EK

425000

10092

927028

336,394

OK

27,549

22220 EK

425000 9139.410579 839541.0857 304647.0193

7
8
9
10

<-n: Number of Revolutions per Minute of the Roller (rpm)


<-Pr: Dynamic Load Applied to Bearing (N)
<-C: Basic Dynamic Load Rating (N)
<-L10: Basic Rating Life (Million Revolution)
<-L10h: Basic Rating Life operating hours (h)
<-L10hE: Equivalent Bearing Rating Life operating hours Based on 500rpm (h)

OK

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
9- VERIFICATION DES ROULEAUX

Idler Definition

Type

Idlers
Type

l
(Deg)

d
(mm)

ID01

Impact

Tern

35

ID02

Carrying

Tern

35

ID03

Transition

Tern

ID04

Return

Couple

No.

Ref

1
2

a
(m)

Bearing

159

0.3

6305-2RS1

Hc
(m)
1.4

159

1.25

6204-2RS1

20

159

6305-2RS1

10

159

6204-2RS1

5
6
7
8
9
10

<-l: Idlers Inclination Angle (Deg)


<-d: Idlers Diameter (mm)
<-a: Distance Between Idler (m)
<-Hc: Discharge Height (m)
Material & Design Condition Definition
Over 16
hours per
day

<-Service Life

Abrasive or
Corrosive
Material

<-Environment Factor

20,000 <-L10M: Minimum Bearing Rating Life operating hours Based on 500rpm (h)
9.81 <- g: Standard Gravity Acceleration (m/s)
Belt Carcass Definition
3600 <-Q: Maximum Belt Design Capacity (Ton/h)
3.8 <-v: Belt Speed (Tab.4&5&6) (m/s)
1400 <-B: Belt Width (mm)
EP800/4 <-Carcass Style
6 <-ttc: Top Cover Thickness (mm)
4 <-tbc: Bottom Cover Thickness (mm)
1.2 <-rr: Rubber Average Weight (kg/[mxmm])
150 <-dL: Maximum Material Lump Size (mm)
1200 <-r: Material Density (kg/m3)
Load Factor Computation
1.0272 <-Fd: Impact Factor (Material Lump Size) (Tab. 17)
1.2 <-Fs: Service Factor (Tab. 18)
1 <-Fm: Environment Factor (Tab. 19)
0.978 <-Fv: Speed Factor (Tab. 20)

OCP
MEA EXPANSION
Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
B-28-1- PE0101_Note de Calcul Mcanique Convoyeur CVL'_MEC32801_00_20151101
9- VERIFICATION DES ROULEAUX
Belt Weight Computation
<-qbc: Belt Carcass Weight for square Meter (kg/m)
6.5
25.9 <-qb: Belt Weight Per Linear Meter (kg/m)

qb qbc r r ttc tbc B


263

<-qm: Material Weight Per Linear Meter (kg/m)

qm

Q
3.6v

Idler Roller Speed Check

v x 1000 x 60
d

Pi g Q

Hc
8

aqb g If Re turn
Cs

a qb qm g Else
1
1
Pr Cs Fd Fs Fm Fv Fp PF
i p
2
2

C
L10
Pr

L10 h

106
L10
60n

L10 hE

n
L10 h
500

Cs (N)

Fp
(Tab.21)

Pi (N)

Pr (N)

C (N)
(Tab.22)

L10
(MR)

L10h
(h)

L10hE (h)

456

850

0.67

5,222

2,093

22,500

1,243

45,386

41,432

L10hE

L10M
OK

456

3,543

0.67

1,431

12,700

699

25,525

23,301

OK

ID03

456

5,669

0.6

2,050

22,500

1,321

48,252

44,048

OK

ID04

456

762

0.5

230

12,700

169,138

6,175,919

5,637,927

OK

No.

Ref

n
(rpm)

ID01

ID02

3
4
5
6
7
8
9
10

<-n: Number of Revolutions per Minute of the Roller (r/min)


<-Cs: Static Load Applied to Troughing Set (N)
<-Fp: Participation Factor of Roller Under Greatest stress
<-Pi: Impact Load Due to Chute Applied to Troughing Set (N)
<-Pr: Dynamic Load Applied to Bearing (N)
<-C: Basic Dynamic Load Rating (N)
<-L10: Basic Rating Life (Million Revolution)
<-L10h: Basic Rating Life operating hours (h)
<-L10hE: Equivalent Bearing Rating Life operating hours Based on 500rpm (h)