Professional Documents
Culture Documents
The conveyor belt calculations of different parameters are very important for designing a conveyor system. This article will discuss some important
conveyor belt parameter calculations procedure with a practical example.
Ads by Google
Weighing Equipment www.mt.com/weighing-equipment
Balances, Scales and Weighing systems by METTLER TOLEDO!
The belt conveyor is used for conveying different materials from one location to another. The different components of a belt conveyor system
typically are electric drives, pulleys, idlers, and a long belt. A simple conveyor system may look like below:
Belt tension: The belt of the conveyor always experience a tensile load due to the rotation of the electric drive, weight of the conveyed
materials, and due to the idlers. The belt tension at steady state can be calculated as:
Where,
Tb is in Newton.
f = Coefficient of friction
L = Conveyor length in meters. Conveyor length is approximately half of the total belt length.
Note: The article “Design an Idler for a Conveyor Belt System” has detailed explanation about how to calculate idlers spacing.
Power at drive pulley: The power required at the drive pulley can be calculated from the belt tension value as below:
Pp = (Tb*V)/1000……………..eqn.1.3
Where,
Pp is in KW.
Belt tension while starting the system: Initially during the start of the conveyor system, the tension in the belt will be much higher than
the tension in steady state. The belt tension while starting can be calculated as:
Tbs =Tb*Ks………………..eqn.1.4
Where,
Tbs is in N.
Sizing of the motor: The minimum motor power can be calculated as:
Pm = Pp/Kd………………eqn.1.5
Where,
Pm is in Kw.
Kd = Drive efficiency.
Where,
A is in m/sec2
Belt breaking strength: This parameter decides the selection of the conveyor belt. The belt breaking strength can be calculated as:
Where,
Bs is in Newton.
Cr = friction factor
Input data:
Calculation:
First, we will use the eqn.1.2 for finding out the load due to idlers:
We will use the eqn.1.1 for finding out the belt tension in steady state:
The belt tension while starting the system can be calculated by using the eqn.1.4:
For calculating the power at drive pulley, we will use the eqn.1.3:
Pm = 116.35/0.9 = 129.261 Kw
We will use the eqn.1.6 to find out the acceleration of the motor:
= 0.429 m/sec2
Lastly, we will use the eqn.1.7 to find out the belt breaking strength:
This Bs value is used to select the conveyor belt from the manufacturer’s catalogue.
Conclusion
The conveyor belt calculations methodology discussed in the article is to be used only for the guidance on calculating the initial conveyor design
parameters; the final design must be validated by using the FEA or other similar tools before building the prototype.
Reference
The idlers are an important part of a belt conveyor system; they provide stability to the conveyed materials. There are mainly three types of idles used
in the industry namely, flat idlers, trough idlers, and garland idlers. In this article we will discuss only the flat type belt conveyor idler design.
Typically, the following inputs are used for starting up the design process of the flat idler:
The following design equations are used across the industry for calculating the different design parameters of the flat idlers:
S = (8*T1*H)/ (mb+ml)*g…………..1.1
Where,
S is in meters
T1= Belt tension near the idlers as shown in the picture (N)
Where,
mb is in kg/m.
N = (60*V)/ (Π*D)……………1.3
Where,
N is in RPM.
F= (10*W*S*g)/ (36*V)…………1.4
Where,
F is in Newtons
b= (8*F*L)/ (3*Π*D3)………………..1.5
Where,
Now, let’s see how to use the basic design equations for actual design purpose. We will take the following data as input:
First, we will calculate the weight of the conveyed material using the eqn.1.2 as:
Now, to calculate the spacing between the two idlers we will use the eqn.1.1
S=(8*50000*0.015)/(15+165.34)*9.81 = 3.391 m
The diameter of the idler can be calculated from the eqn.1.3 as below:
Total load acted on each idler can be obtained from the eqn.1.4 :
F=(10*1000*3.391*9.81)/(36*1.68)=5500 N
Maximum bending stress applied on each idlers can be obtained from the eqn.1.5 as below:
If the maximum bending stress calculated from the above equations is higher than the accepted limit of the bending stress then, you have to
reconsider the input assumed parameters, for example you may have to set the lower idler speed or you have to think of the lower belt sag value, so
that idler spacing got reduced and so the load per idler.
Conclusion
There are three types of idlers used in the conveyor industry, out of which only the flat belt conveyor idler design calculations are discussed here
theoretically. We have not used the factor of safety in the design calculations here, or in other words the factor of safety is considered as one through
out the calculations. The theoretical calculations are ideal for the preliminary design. FEA tools like Ansys or Pro Mechanica should be used for the
final virtual validation of the design.
References