APRON FEEDER DESIGN

Description Unit.

1.0 Input data - 1

1.1 Belt feeder name / identification
1.2 Belt width B mm
1.3 Belt speed for this design, steady state v mps
1.4 Guaranteed capacity Qg mtph
1.5 Design capacity Qd mtph
1.6 Belt feeder carrying run inclination to horizontal δ degree
1.7 Feed zone length, along carrying run L m
1.8 BF pulley c/c distance, along carying run L1 m
1.9 Feed zone mid point to head pulley c/c distance along belt L2 m
1.10 Skirt board length beyond feed zone Lsk m
1.11 Material handled name
1.12 Material bulk density for this design γ kg/mᶟ
1.13 Material lump size, corner to corner, max mm
1.14 Skirt board net width, feed zone exit end We m
1.15 Skirt board net width, feed zone inlet (rear) end Wi m
1.16 Skirt board height exit end of feed zone he m
1.17 Skirt board height inlet (rear) end of feed zone hi m
1.18 Dynamic pressure factor C2 (i.e.ratio column height at exit end/We)
1.19 Static pressure factor C2 (i.e.ratio column height at exit end/We)
1.20 Material repose angle φ degree
1.21 Friction coefficient between skirt plate and material μs
1.22 Impact idler set rotating mass per set Mii
1.23 Carrying idler set rotating mass per set Mic
1.24 Return idler set rotating mass per set Mir
1.25 Impact idler set quantity Nii
1.26 Carrying idler set quantity Nic
1.27 Return idler set quantity Nir
1.28 Belt carcass name
1.29 Belt carcass type, (enter 1 for fabric and 2 for steel cord)
1.30 Belt carcass thickness mm
1.31 Belt cover thickness, top and bottom mm
1.32 Belt total thickness Bt mm
1.33 Belt mass per meter Mb kg/m
1.34 Drive pulley diameter including lagging D1 mm
1.35 Drive pulley shaft diameter at bearing d1 mm
1.36 Friction coefficient between belt and drive pulley μ
1.37 Belt wrap angle around drive pulley θ1 degree
1.38 Drive pulley rotating mass kg
1.39 Belt average tension at drive pulley Fb1 N
1.40 Non-drive pulley quantity, (usually 1 or 2) N2
1.41 Non-drive pulley diameter, including lagging D2 mm
1.42 Non-drive pulley shaft diameter at bearing d2 mm
1.43 Non-drive pulley rotating mass each average kg
1.44 Belt average tension at non-drive pulley Fb2 N
1.45 External scraper (ExtSc) quantity Ne
1.46 ExtSc blade/s rubbing area on belt total/asembly Ae m2
1.47 ExtSc blade/s pressure area on belt (usually 50000) Pe N/m2
1.48 ExtSc friction cum cleaning coefficient μe
1.49 Internal scraper (IntSc) quantity Ni
1.50 IntSc blade/s rubbing area on belt total/asembly Ai m2
1.51 IntSc blade/s pressure area on belt (usually 50000) Pi N/m2
1.52 IntSc friction cum cleaning coefficient μi
1.53 Drive effciency fraction fraction of 1 (including drive pulley) η
1.54 Drive motor rated (nameplate) Wm kW
1.55 Drive motor "actual" speed, at motor rated load N rpm
1.56 Drive motor peak torque, during starting TQsm Nm
1.57 Drive motor rated torque TQm Nm
1.58 Drive motor mk Im kgm2
1.59 Gear box ratio (enter 30 for 30:1) i
1.60 Gear box mk2 Ig kgm2
1.61 Flexible input coupling mk2 Ic1 kgm2
1.62 Flexible output coupling mk2 w.r.t output shaft Ic2 kgm2
1.63 Allowable belt sag%, steady state (enter 1 for 1%) Sagc
1.64 Allowable belt sag%, starting state (enter 2 for 2%) Sags
1.65 Material layer velocity factor w.r.t he=We
1.66 Impact idler set pitch, feed zone pc m
1.67 Return idler set pitch pr m
1.68 Conveying artificial friction coefficient f
1.69 Material layer height beyond feed zone h m

2.0 Output data - 1

2.1 Belt speed v mps
2.2 Ratio he/We
2.3 Velocity factor at exit K
2.4 Exit top layer velocity mps
2.5 Feeder capability for capacity mtph
2.6 Material internal friction angle basic φi degree
2.7 Material internal friction coefficient μm
2.8 Friction coefficient material & belt μb
2.9 Elevation expansion gradient, skirt board Ge
2.10 Plan expansion gradient, skirt board Gp
2.11 Elevation expansion angle θ degree
2.12 Plan expansion angle β degree
2.13
2.14
2.15 Equivalent block mass, dynamic Med kg
2.16 Equivalent block mass, static Mes kg
2.17
2.18
2.19 Material mass in skirt board Ms kg
2.20 Material mass per metre, beyond feed zone Mm kg/m
2.21 Carrying run rorating mass per metre Mc kg/m
2.22 Return run rotating mass per metre Mr kg/m
2.23 M-value for sag, at feed zone exit point dynamic kg/m
2.24 M-value for sag, at feed zone inlet point dynamic kg/m
2.25 Drive factor C3
2.26 Drive factor C22
2.27 Drive factor C1
2.28 Output coupling speed rpm
2.29 Moving mass M1, w.r.t belt line M1 kg
2.30
2.31 Moving mass M2, w.r.t belt line M2 kg
2.32 Total moving mass M1+M2 kg
2.33
2.34
2.35 Flow from rear half feed zone ƩZT% %
2.36 Flow from forward half feed zone % %
Resistances dynamic condition
2.37 Resistance Rsh, shear at interface Rsh N
2.38 Rankine factor Kr or K
2.39
2.40
2.41 Resistance Rsk1, by skirt plates, feed zone Rsk1 N
2.42 Resistance Rsk2, by skirt plates, beyond feed zone Rsk2 N
2.43 Resistance Rsk3, by skirt rubber Rsk3 N
2.44 Resistance Rcc, carrying run conveying Rcc N
2.45 Resistance Rslc, slope carrying Rslc N
2.46 Resistance Ra, material acceleration Ra N
2.47 Resistance Rpi, force from shear plane Rpi N
2.48 Resistance Rpb, force from back plane Rpb N
2.49 Resistance Rps, force from skirtplate Rps N
2.50 Carrying run resistance Rc total, dynamic Rc N
2.51 Return resistance, converying Rcr N
2.52 Return run resistance, slope Rslr N
2.53 Return resistance, ext.scraper Rce N
2.54 Return resistance, int scraper Rci N
2.55 Return resistance, turning Rt N
2.56
2.57
2.58
2.59
2.60 Return resistance Rw, wrap, fabric belt Rw N
2.61 Return resistance Rw, wrap, steel cord belt Rw N
2.62 Return run resistance Rr, total, dynamic Rr N
2.63 Total resistance Rf=Rc+Rr, steady, dynamic Rf N
Resistances static condition
2.64 Resistance Rsh, shear at interface Rsh N
2.65
2.66 Resistance Rsk1, by skirt plates, feed zone Rsk1 N
2.67 Resistance Rsk2, by skirt plates, beyond feed zone Rsk2 N
2.68 Resistance Rsk3, by skirt rubber Rsk3 N
2.69 Resistance Rcc, carrying run conveying Rcc N
2.70 Resistance Rslc, slope, carrying Rslc N
2.71 Resistance Ra, material acceleration Ra N
2.72 Resistance Rpi, force from shear plane Rpi N
2.73 Resistance Rpb, force from back plane Rpb N
2.74 Resistance Rps, force from skirtplate Rps N
2.75 Carrying run resistance Rc, total, static Rcs N
2.76 Return run resistance Rr, total, static Rrs
2.77 Total resistance Rfs=Rcs+Rrs, static Rfs N
2.78 For C2 static < C2 dynamic, static worst resistance design Rfsw N
2.79
Power / kW steady - continuous operation
2.80 Power required at drive pulley periphery pk1 kW
2.81 Power required at motor shaft pk2 kW
Tension basic values to transmit power
2.82 Steady state tractive pull P = Rf P N
2.83 Head end steady state T1a N
2.84 Head end steady state T2a N
2.85 Tail end steady state T3a N
2.86 Tail end steady state T4a N
2.87 Feed zone exit point steady state tension Txa N
2.88 Drive peak force at motor shaft, w.r.t belt line F2 N
2.89 Belt feeder peak acceleration a m/sec2
2.90 Moving mass return run Mrr N
2.91 Starting peak tractive pull on belt Ps N
2.92 Head end starting T1sa N
2.93 Head end starting T2sa N
2.94 Tail end starting T3sa N
2.95 Tail end starting T4sa N
2.96 Feed zone exit point starting tension Txsa N
Resistances static condition
2.97 ƩT = T1a + T2a + T3a + T4a N
2.98 ƩTs = T1sa + T2sa + T3sa + T4sa N
2.99 Addition in each steady state tension N
2.100 Head end steady state T1aa T1aa N
2.101 Head end steady state T2aa T2aa N
2.102 Head end steady state T3aa T3aa N
2.103 Head end steady state T4aa T4aa N
2.104 Feed zone exit point, steady state Txaa N
2.105 Tsag minimum, steady dynamic feed zone exit N
2.106 Tsag minimum, steady dynamic feed zone inlet N
2.107 Tsag minimum, starting dynamic feed zone exit N
2.108 Tsag minimum, starting dynamic feed zone inlet N
2.109 Value for addition in tensions N
2.110 Value for addition in tensions N
2.111 Value for addition in tensions N
2.112 Value for addition in tensions N
2.113 Highest of cl.2.109 to 2.112 N
2.114 Head steady state, final T1 N
2.115 Head steady state, final T2 N
2.116 Tail steady state, final T3 N
2.117 Tail steady state, final T4 N
2.118 Feed zone exit, steady, final Tx N
2.119 Head starting, final T1s N
2.120 Head starting, final T2s N
2.121 Tail starting, final T3s N
2.122 Tail starting, final T4s N
2.123 Feed zone exit, final Txs N
 AE-02
1940
0.2
750
975
0.0
3.04
4.76
3.1
1.6
Pirocloro ore
1850
30
1.200
0.700
0.6
0.6
2.5
2.5
38
0.45
102
102
114
8
3
4
 Chain apron
1
0.5
0.5
1
425
800
200
0.75
180
700
55000
1
700
140
410
18400
0
0.001
1
0.6
0
0.001
1
0.6
0.9
37
1770
499.0819209
199.63276836
0.30743
236.56
0.01344
 0.035
0.5
6
6
0.5
0.37
1.5
0.13
0.5

0.2
0.500
0.75
0.15
959.04
34.2
0.6795992982
0.7135792631
0
0.0822368421
0
4.7012450048

12982.066667
12982.066667

3205.68
1354.1666667
235.71428571
95.798319328
 8417
4421
10.5507822
0.104703466
1.1047035
7.4822
12158.033333

306086.67341
318244.70674

79.166666667
20.833333333

86549.739316
0.2378830779

18958.126409
777.09978723
417.6
26761.953699
0
39
0
-1858.563658
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128192.04185
3161.4687
0
0.0006
0.0006
 36.8

15.100714286
NA
3213.3706143
131405.41246

86549.739316

18958.126409
485.68736702
417.6
26761.953699
0
39
0
-1858.563658
-3452.913707
127900.62943
3213.3706143
131114
210248.65994

26.281082492
29.201202769

131405.41246
145164.0146
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16971.972749
16971.972749
140900.49788
295157.04802
0.1933965422
2679.4
212599.98155
234859.93648
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25991.512247
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227171.36739

192866.56223
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42817.690556
46031.061171
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10000
10000
184223.10302
52817.690556
56031.061171
56031.061171
179959.58631
244859.93648
32259.954938
35991.512247
35991.512247
237171.36739