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SERVICIO DE FABRICACIÓN E INSTALACIÓN DE


NUEVOS CHUTES EN FAJAS OVERLAND

MEMORIA DE CALCULO MECÁNICA

FAJA CS-001

03016-IM-MC-001

Preparado por:

Sistemas de Transporte de Materiales S.A.

Rev. Fecha Detalles o Propósito de la Revisión Preparado Revisado Aprobado


0 30-06-2016 Para Información CA JG RS

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INDICE

1. System Information .......................................................................................................................................... 3


1.1. Material Properties .......................................................................................................................................... 3
1.2. Belt Properties ................................................................................................................................................. 3
1.3. Idler Set Data ................................................................................................................................................... 3
1.4. Drive Station .................................................................................................................................................... 3
1.5. Take-up Data .................................................................................................................................................... 4
1.6. Backstops ......................................................................................................................................................... 4
1.7. Brakes .............................................................................................................................................................. 4
1.8. Reducer Information ........................................................................................................................................ 4
1.9. Motor Torque .................................................................................................................................................. 4
1.10. Starting and Stopping ................................................................................................................................ 4
1.11. Tension Ratios .......................................................................................................................................... 4
1.12. Transition Lengths..................................................................................................................................... 4
1.13. Estimated Splice Data ............................................................................................................................... 4
2. Conveyor Profile ............................................................................................................................................... 5

3. Conveyor Load Cases ........................................................................................................................................ 7

4. Take-up Displacement Summary ....................................................................................................................... 8

5. Pulley Details ................................................................................................................................................... 9

6. Belt Flap Summary ......................................................................................................................................... 11

7. Material Loading Profiles................................................................................................................................ 12


7.1. Material Properties ........................................................................................................................................ 12

8. Idler Specifications ......................................................................................................................................... 13

9. Element Summary Details ............................................................................................................................... 15


9.1. Tension Summary ........................................................................................................................................... 15

10. Power Summary ............................................................................................................................................. 16


10.1. Element Summary Details ....................................................................................................................... 16
10.2. Min/Max Tension Summary per Element ................................................................................................. 16
10.3. Te Tension Summary per Load Cases ....................................................................................................... 18
10.4. Pulley Summary Table - All Cases............................................................................................................. 18
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1. System Information
Calculation method .................... CEMA 7th (default)
Conveyor Length / Height ......................... 10 / 0,0 m
Material lift ...................................................... 0,0 m
Ambient temperature ....................................... 35 °C
1.1. Material Properties
Type ........................................................ Unspecified
Design Tonnage ........................................... 1500 t/h
Density ................................................... 1800 kg/m3 Flooded belt tonnage ................................. 1.500 t/h
Maximum lump size ..................................... 127 mm Flooded (wm + wb) ................................... 214,7 kg/m
Surcharge angle .............................................. 20 deg
1.3. Idler Set Data
1.2. Belt Properties Carry (wing
Return
Manufacture ......................................... Fabric 630/3 / center)
Type ...................................................... Fabric (3-Ply) Series name Series 30 Series 25
Width ......................................................... 1372 mm Bearing 6306 6305
Rating ....................................................... 630 N/mm Number of rolls 3 2
Speed .......................................................... 2,21 m/s Trough angle (deg) 20 15
Top / bottom cover thickness .............. 8,0 x 4,0 mm Type Inline Inline
Total thickness ............................................... 16 mm Idler spacing (m) 0,60 2,65
Weight (new / worn) ...................... 26,3 / 18,3 kg/m Number of idler sets 16 4
Modulus ................................................. 6.061 kN/m Roll diameter 127 127
Tape length ....................................................... 21 m Roll rpm 333 333
Belt cycle time ..................................................... 10 s Total drag (N) 10,5 7,1
Drag range (N) 10,5 - 10,5 6,7 - 6,8
Tension Summary Running Momentary Roll length 138 / 1159 741
Maximum tension Shaft diameter 30,0 25,0
15,6 19,6
(kN) (mm) Dynamic
Minimum safety 29,6 23,4
55,37 44,16 capacity (kN)
factor 350,0 /
Minimum tension (kN) 8,25 6,48 L10 life1 (1000 hrs) 350,0
350,0
Maximum belt sag (%) 1,15 1,32 Shaft deflection
Cross Sectional Loading (min) 0,02 / 8,06 2,24
1L
10 life above which 95% of idlers exceed
Material mass (wm) ................................. 188,4 kg/m
Combined mass (wm + wb) ....................... 214,7 kg/m
1.4. Drive Station
Edge distance (required / actual) ........................ N/A Type ...................................................... Squirrel cage
Synchronous RPM .................................... 1800 RPM
Cross sectional area ............................................ N/A
Motor quantity / rating .......................... 1 / 30,0 kW
Cross sectional loading (utility / total) ................ N/A
Total installed power ................................... 30,0 kW
Bed depth ............................................................ N/A
Empty / full power ........... (48 / 63%) 14,4 / 19,0 kW
Frame Size .................................................. IEC 200M
Motor Voltage .................................................. 380 V
Efficiency ......................................................... 95,5%
Maximum starting torque ................................ 150%
Inertia - Motor ........................................... 0,3 kg·m²
Pulley lagging type ........................................ Rubber
Motor wrap angles .............................................. 180
Lagging friction factor (run / accel) .......... 0,30 / 0,34
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1.5. Take-up Data Allowable (dynamic) .......................................... 2,91


Type .................................................................. Fixed Starting tension ratio ......................................... 2,90
Location ............................................. Tail / Pulley #2 1.12. Transition Lengths
Steady state tension......................... 10,7 to 11,1 kN Transition method ....................................... CEMA 7
Momentary tension ......................... 9,86 to 12,3 kN Tail transition length (inline) .......................... 1,70 m
Head transition length (inline) ....................... 1,70 m
Required pulley displacement ....................... 0,92 m 1.13. Estimated Splice Data
Dynamic displacement (incl thermal) ......... 0,00 m Splice type 2-Step
.......................................................

Permanent elongation ................................ 0,14 m Splice step length ......................................... 250 mm


Splice length (1 included) ........................... 0,53 m 22 degree bias angle .................................... 555 mm
Clearance .................................................... 0,25 m Total splice length ...................................... 1055 mm
1.6. Backstops Other Information
Backstop type ..................................... None installed Loaded beltline mass (excluding motors) ... 3.355 kg
Total inertia (ref HS shaft) ........................ 0,47 kg·m2
1.7. Brakes
Brake type .......................................... None installed Demand Power (kW)
% Motor
1.8. Reducer Information Demand Nameplat
Case
Manufacture ............................................. Santasalo power e
.................................................................Framesize Empty - Normal Frict. 14,4 48,0
Reducer ratio.................................................. 27,430 Full - Normal Frict. 19,0 63,5
Catalog reducer ratio ..................................... 28,340 Din Factor and Total Equivalent Mass
RPM (High Speed) .................................... 1800 RPM Case Din factor Belt line
RPM (Low Speed) ...................................... 65,6 RPM mass (kg)
........................................Configuration Shaft Mount Empty - Normal Frict. 0,0299 4.112
Number of stages .................................................... 3 Full - Normal Frict. 0,0173 5.817
Service factor ....................................................... 1,4
Power rating ....................................................... 75,9 Maximum Belt Tensions (kN)
1.9. Motor Torque Case Running Dynamic
100% Motor Torque - High Speed............... 162 N·m Empty - Normal Frict. 13,1 15,4
Motor Shaft Torque - Running (FN) ............ 102 N·m Full - Normal Frict. 15,6 19,6
Motor Shaft Torque - Starting (FN) ............. 242 N·m Belt Safety Factor
100% Motor Torque - Low Speed ............ 4.432 N·m Case Running Dynamic
Low Speed Shaft Torque - Running (FN) 2.627 N·m Empty - Normal Frict. 65,89 56,03
Full - Normal Frict. 55,37 44,16
..

Low Speed Shaft Torque - Running (Max) 2.627 N·m


Low Speed Shaft Torque - Starting (FN) 4.754 N·m Splice Safety Factor
...

Low Speed Shaft Torque - Starting (Max) 4.754 N·m Case Running Dynamic
1.10. Starting and Stopping Empty - Normal Frict. 43,93 37,35
Start control ............................ ........
Constant torque Full - Normal Frict. 36,92 29,44
Start time ................................................ 0,7 to 1,1 s
Operational stop control .................................... Minimum Belt Tensions (kN)
Drift
Operational stop time Case Running Dynamic
.............................
1,5 to 1,8 s
Emergency stop control ..................................... Empty - Normal Frict. 8,25 6,48
Drift
Emergency stop time Full - Normal Frict. 8,66 6,76
.............................. 1,5 to 1,8 s
Material buildup in chute................................ Maximum Belt Sag (%)
0,2 m³ Case Running Dynamic
1.11. Tension Ratios Empty - Normal Frict. 1,04 1,32
Allowable (running) ............................................ 2,57 Full - Normal Frict. 1,15 1,27
Running tension ratio ......................................... 1,80
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2. Conveyor Profile
Overall length = 10 m - Overall height = 0,0 m - True Length = 10,1 m

Pulleys

Pulleys - Top View


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Maximum Pulley Tensions (without any additional safety factors)


Wrap Steady State Tensions (kN) Momentary Tensions (kN)
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-LT 180 15,6 8,66 24,3 19,6 10,3 29,9
Take-up Pulley 2-LT 180 11,1 23,7 12,3 25,7
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

Pulley Shaft Results


Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Pulley # Safety Slope at Deflection L10 Life T1 T2 Shaft Force Angle Torque Moment
Factor Hub at Center Tension Tension
(min) (% span) 1000 hrs (kN) (kN) Mass (kg) (kN) (deg) (kN·m) (kN·m)
1 2,94 6,93 0,062 500 26,7 11,1 592 38,3 189 4,4 3,0
2 3,94 5,56 0,050 500 14,2 16,0 592 30,7 349 0,6 2,4
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,10 on high tension
pulleys, and a multiplier of 1,25 on all other pulleys. A steady state case at 100% motor power has also been included.

Pulley Geometry Details (Pulley Types)


Lagging Diameter Face Shaft Bearing Bearing Pulley
Lagging Diameter with Center Plummer
Center Bearing Shaft
Type Type (mm) Thickness Lagging Width Diameter Diameter Distance Block Series Bearing
(mm) (mm) (mm) (mm) (mm) (mm) Mass (kg)
1 Rubber 610 16,0 642 1448 100 80 1658 518 22218 614
2 Rubber 610 10,0 630 1448 100 80 1658 518 22218 614

Pulley Shaft Information


Yield Tensile Fatigue Hub Hub Bearing Fillet Overhung Overhung
Locking Shaft Center to Fillet Moment
Type Device Material Strength Strength Strength Diameter Distance Distance Radius Load Arm
(MPa) (MPa) (MPa) (mm) (mm) (mm) (mm) (kN) (mm)
1 XT-40 SAE 1045 310,0 626,7 282,0 100 1340 63 30 0,0 0
2 XT-40 SAE 1045 310,0 626,7 282,0 100 1340 63 30 0,0 0
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3. Conveyor Load Cases


During the course of operation, the conveyor experiences different operating conditions at various frequencies.
Normal operating conditions, such as steady state running, loading and unloading, and other common load cases
are designated as Design Level 1. Unusual operating conditions, such as when all incline or decline section are
simultaneously loaded, are defined as Design Level 2. These design levels allow easy summarization of the
various possible loading conditions.

For this conveyor, there are two Design Level 1 loads, which are:

1. Empty
2. Fully Loaded

In the load case figures, the red line is the conveyor profile and the blue line indicates positions that are loaded.

Empty

Fully Loaded
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4. Take-up Displacement Summary

1. Type ....................................................................................................................................... Fixed


2. Location .................................................................................................................. Tail / Pulley #2
3. Steady state tension .......................................................................................... .... 10,7 to 11,1 kN
4. Momentary tension ............................................................................................. .. 9,86 to 12,3 kN

Take-up Pulley Displacement Summary


1. Dynamic displacement (incl thermal) ................................................................................. 0,00 m
2. Permanent elongation ........................................................................................................ 0,14 m
3. Splice length (1 included) ................................................................................................... 0,53 m
4. Clearance ............................................................................................................................ 0,25 m
5. Required displacement ....................................................................................................... 0,92 m
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5. Pulley Details
The following table lists recommended pulley design tensions. The first column lists belt tensions for bearing L10
life and pulley fatigue stress calculations. Belt tensions for the fatigue design criterion are based on all design
level 1 cases and dynamic conditions. Running tensions have an added multiplier of 1,10 on high tension pulleys,
and a multiplier of 1,25 on all other pulleys. A steady state case at 100% motor power has also been included.

Pulleys are also to be design for the structural design tensions. For structural design tensions, the
pulley manufacturer is to ensure that the pulleys will be adequate to meet these worst case conditions.

Pulley Design Tensions (added safety factors as described above)


Wrap Fatigue Design Tensions (kN) Structural Design Tension (kN)
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Motor 1 1-LT 180 26,7 11,1 38,3 24,2 11,6 36,3
Take-up Pulley 2-LT 180 14,2 30,7 15,1 32,5

Required Pulley Diameter (Tension based on a safety factor of 10)


Required
%
Pulley Location Pulley Wrap Diameter Pulley % Running Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Motor 1 Tail (5) 1 - LT 180 610 315 18 23
Take-up Pulley Tail (8) 2 - LT 180 610 315 15 15

Pulley Shaft Stress Analysis (Individual Pulleys)


Hub Hub Fillet Fillet Fillet Von Hub Von Overhung
Shaft Slope
Pulley Type Safety at Hub Bending Torsion Bending Torsion Mises Mises Von Mises
# Factor Stress Stress Stress Stress Stress Stress Stress
(min)
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
1 1 2,94 6,93 31,0 22,6 31,3 44,1 49,9 82,5 0,0
2 2 3,94 5,56 24,9 3,0 25,1 5,8 25,4 27,0 0,0
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Running Drive Tensions by Load Case (kN)


Motor 1
Load Case Resultant
T1 T2
Force
Empty - Normal Frict. 13,1 8,25 21,4
Full - Normal Frict. 15,6 8,66 24,3

Pulley Tension Summary - All Load Cases and Conditions


Load Case Running Starting O-Stop E-Stop
Pulley T1 T2 T1 T2 T1 T2 T1 T2
ID Description
(kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN)
Empty - Motor 1 13,1 8,25 15,4 6,48 11,8 9,14 11,8 9,14
EM-N Normal
Frict. Take-up Pulley 10,7 12,2 10,0 12,6 11,1 12,1 11,1 12,1
Full - Motor 1 15,6 8,66 19,6 6,76 12,3 10,3 12,3 10,3
FL-N Normal
Frict. Take-up Pulley 11,1 12,6 9,86 12,0 12,3 13,4 12,3 13,4
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6. Belt Flap Summary


Belt flap may occur when the natural frequency of the belt matches the rotational frequency of the idlers. If belt
flap is severe, it can destroy the idlers and increase the demand power of the conveyor. Belt flap should be
avoided.

The belt flap ratio is defined as the rotational frequency of the idler divided by the natural frequency of the belt.
If this ratio is equal to an integer (i.e. 1, 2, 3) then the idler may induce transverse vibrations at the natural
frequency mode and result in resonance.

The chart below shows the flap ratio along the length of the conveyor. The solid green line shows flap mode of
the empty belt under the normal friction case. The shaded pink areas should be avoided.

*
Belt flap resonance occurs at flap ratios 1, 2, 3, and 4
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7. Material Loading Profiles Material 1 on Idler Set 1

7.1. Material Properties


Type ....................................................... Unspecified
Design Tonnage ........................................... 1500 t/h
Density .................................................... 1800 kg/m3 Tonnage ...................................................... 1500 t/h
Maximum lump size .................................... 127 mm Belt speed ................................................... 2,21 m/s
Surcharge angle .............................................. 20 deg Material mass.......................................... 188,4 kg/m
Edge distance (required / actual) ........... 98 / 66 mm
Material 1 on Idler Set 3 Cross sectional loading (utility / total) . 126 % / 68 %
Bed depth ..................................................... 121 mm

Tonnage ....................................................... 1500 t/h Empty Idler Set 2


Belt speed ................................................... 2,21 m/s
Material mass ......................................... 188,4 kg/m
Edge distance (required / actual) ........... 98 / 66 mm
Cross sectional loading (utility / total) . 126 % / 68 %
Bed depth .................................................... 121 mm
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8. Idler Specifications

Idler Specifications for Idler Type 1: 3 Roll Trough Idler


Center Wing
Roll angle (deg) 0 20
Roll diameter (mm) 127 127
Roll length (mm) 1159 138
Shaft diameter (mm) 30,0 30,0
Bearing series 6306 6306
Maximum roll RPM 333 333
Min life (1000 hrs) 350 350
95% life1 (1000 hrs) 350 350
Shaft deflection (min) 8,06 0,02
Total idler mass (kg) 28,1
Rotating mass (kg) 18,0
Wk2 for set (kg·mm²) 64.649

Idler Specifications for Idler Type 2: Vee Roll Idler


Roll angle (deg) 15
Roll diameter (mm) 127
Roll length (mm) 741
Shaft diameter (mm) 25,0
Bearing series 6305
Maximum roll RPM 333
Min life (1000 hrs) 350
95% life1 (1000 hrs) 350
Shaft deflection (min) 2,24
Total idler mass (kg) 24,4
Rotating mass (kg) 17,8
Wk2 for set (kg·mm²) 65.152
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Idler Specifications for Idler Type 3: 3 Roll Trough Idler


Center Wing
Roll angle (deg) 0 20
Roll diameter (mm) 127 127
Roll length (mm) 1159 138
Shaft diameter (mm) 30,0 30,0
Bearing series 6306 6306
Maximum roll RPM 333 333
Min life (1000 hrs) 350 350
95% life1 (1000 hrs)
Shaft deflection (min) 10,00 0,02
Static load capacity (kg) 1957,0 1957,0
Dynamic load capacity (kg) 29600,0 29600,0
Total idler mass (kg) 28,1
Rotating mass (kg) 18,0
Wk2 for set (kg·mm²) 64.649

Idler Spacing and Count Summary


Type 1: 3 Roll Type 2: Vee Type 3: 3 Roll
General
Trough Idler Roll Idler Trough Idler
Idler spacing (m) 0,60 2,65 0,28
Number of idler sets 16 4 2
Number of rolls 48 8 6
Total drag (N) 10,5 7,1 14,9

Idler Life and Shaft Deflection Summary-Carry Side


Wing L10 Center L10 Center
Idler Wing Shaft
Vertical Idler Shaft
# Station (m) Length (m) Radius (m) Spacing Type Life Life Deflection Deflection
(m) (hours) (hours) (min) (min)
1 0,0 0,5 0,60 1 350.000 350.000 1,86
2 0,5 0,5 0,60 1 350.000 350.000 1,86
3 1,0 0,8 0,28 3 350.000 350.000 10,00
4 1,8 7,8 0,60 1 350.000 350.000 8,00
5 9,6 0,5 0,60 1 350.000 350.000 8,06
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Idler Life and Shaft Deflection Summary-Return Side


Wing L10 Center L10 Wing Shaft Center
Idler
Vertical Idler Shaft
# Station (m) Length (m) Radius (m) Spacing Type Life Life Deflection Deflection
(m) (hours) (hours) (min) (min)
7-8 10,1 10,0 2,65 2 350.000 2,24

9. Element Summary Details

9.1. Tension Summary


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10. Power Summary

10.1. Element Summary Details


Summary of Conveyor Elements
Vertical Idler
Station Elevation Length Height Slope Idler
# Name Radius Spacing
(m) (m) (m) (m) (deg) Type
(m) (m)
1 0,0 0,00 0,5 0,00 0,00 0,60 1
2 Skirtboards Only 0,5 0,00 0,5 0,00 0,00 0,60 1
3 Loading Point 1,0 0,00 0,8 0,00 0,00 0,28 3
4 Skirtboards Only 1,8 0,00 7,8 0,00 0,00 0,60 1
5 9,6 0,00 0,5 0,00 0,00 0,60 1
6 Motor 1 10,1 0,00 0,6 -0,64 ---
7 10,1 -0,64 5,0 0,00 0,00 2,65 2
8 5,1 -0,64 5,0 0,00 0,00 2,65 2
9 Take-up Pulley 0,0 -0,64 0,6 0,63 ---

10.2. Min/Max Tension Summary per Element


Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 12,6 12,2 0,16 13,4 12,0 0,16
2 Skirtboards Only 12,6 12,2 0,16 13,4 12,1 0,16
3 Loading Point 12,6 12,2 0,59 13,3 12,0 0,61
4 Skirtboards Only 13,7 12,3 1,15 13,7 12,0 1,16
5 15,6 13,1 1,01 19,3 11,9 1,27
6 Motor 1 15,6 13,1 0,00 19,6 11,8 0,00
7 8,66 8,25 1,04 10,3 6,48 1,32
8 11,1 10,7 0,80 12,5 9,45 0,91
9 Take-up Pulley 11,1 10,7 0,00 12,3 9,86 0,00
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10.3. Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N)


EM-N FL-N
Total (Beltline) 4.708 6.786
Total (Power) 6.502 8.612

Lift Force 0 0
Frictional Drag 4.708 6.786
Motor Pulley/Reducer Drag 1.794 1.827

Rolling Resistance 27 159


Material+Belt Flexure 0 2
Idler Bearing Drag 217 218
Idler Alignment 14 61
Pulleys & Accessories 3.702 3.702
Loading Point 749 2.645

Mechanical Losses 493 526


Motor Pulley Drag Componets 1.301 1.301

10.4. Pulley Summary Table - All Cases

Pulley Geometry Details


Type 1 2
Lagging Type Rubber Rubber
Diameter (mm) 610 610
Lagging Thickness (mm) 16,0 10,0
Diameter with Lagging (mm) 642 630
Face Width (mm) 1448 1448
Shaft Center Diameter (mm) 100 100
Bearing Diameter (mm) 80 80
Bearing Center Distance (mm) 1658 1658
Plummer Block 518 518
Pulley & Shaft Mass (kg) 592 592
Locking Device XT-40 XT-40
Hub Center Distance (mm) 1340 1340
Hub Diameter (mm) 100 100
Bearing to Fillet Distance (mm) 63 63
Fillet Radius (mm) 30 30
Shaft Material SAE 1045 SAE 1045
Yield Strength (MPa) 310,0 310,0
Fatigue Strength (MPa) 282,0 282,0

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