1. Scope and purpose . 2 Other relevant standards 3 Concepts 4. Symbols and units 5 Volume flow and mass flow 6 Resistances to motion and power require- ‘ment in the steady operating condition . 6.1 Resistances to motion . 5.1.1 Main resistance of the conveying traci 6.1.2 Secondary resistances of indiviual ‘arts of the installation 6.1.3. Slope resistance of the conveyor load 6.14 Special resistances 6.2. Power requirement in the steady operating condition 7 Design and fayout of the driving system 7.1. Location of the driving units, size and number of driving motors Horizontal and slightly inclined installations 7.1.2 Installations conveying uphill 7.43 Installations conveying downhill 7a 7.2 Starting, stopping and holding stationary 721 Starting : 7.2.2. Stopping and holding stationary 8 Bolt traction forces and tensile forces . 8.1 Required belt traction forces . 1. Scope and purpose Continuous mechanical handling equipment Belt conveyors for bulk materials Bases for calculation and design Stetigidrderer; Gurtforderer fir Schiitgiter; Grundlagen fli die Berechnung lund Auslegung As it is current practice in standards published by the International Organi. /has been used throughout as a decimal marker. Contents Page 18.1.1 Minimum bett traction forces required 1 for the transmission of the pulley 2 peripheral forces 3 8:1.2. Minimum bete trection forces required g for the limitation ofthe belt sag and for correct and satisfactory belt guidance 8.2. Local belt traction force variations in the upper strand (carrying side) the lower rand (eeturn side) Non-steady operating conditions 9 Design and layout of the conveyor belt 11 Design and layout of transition curves 6 6 and it 8.2.1 Steady operating conditions 8.2.2_Non-steady operating conditions 7 83 Tensile forces and tensile distances 8 84 Local belt traction forces in the 8 ‘upper strand carrying side ang in the lower strand (return side] 8 841 8 8.4.2. Steady operating conditions 2 9.1. Nominal rupture force 9 92 Cover plates 9 10 Minimum pulley diameters 9 9 and of transition lengths 9 114 Transition curves 19 11.2 Transition lengths 10 Further standards 10 Notes . OIN 22.101 " 2 2 12 13 13 14 14 14 15 15 16 16 18 18 19 19 20 Supersedes February 1942 edition 1 for Standaraization [1SO), the comma ‘down in function of the specified 2 Other relevant standards DIN 15207 DIN 22102 DIN 22107 DIN 22 109 Part 2 plies for und DIN 22112 Part 1 DIN 22131 Part 1 (Preliminary DIN 22131 Part 2 (Preliminary DIN 22131 Part 3 7°" 29131 Part 4 (Preliminary ‘This standard applies to belt conveyors for the conveying of bulk materials and it contains the basic principles for the csloulation and design of such conveyers, It enables the most important characteristics of the main components of ‘the belt conveyor. such as the driving, braking and bett tensioning equipment, and the conveyor belt itself, to be laid conveying requirement. Continuous conveyors; carrying idlers for belt conveyors, principal dimensions Conveyor belts with textile plies Continuous conveyors, carrying idler arrangements for belt conveyars, principal dimensions Conveyor belts with textile plies for the hard coal mining industry ~ conveyor belts with two. ferground use Belt conveyors for underground coal mining; carrying idlers, shapes and dimensions Conveyor belts with steel cord plies; dimensions and marking cord plies; quality requirements (Preliminary Standard} Conveyor belts with stoel cord plies; resting Standara) Standard} Conveyor belts with s Standard Conveyor belts with steel cord pli belt joints Continued on pages 2 to 23Page 2. DIN 22 101 3. Concepts Belt conveyors within the meaning of this standard are continuous conveyors for bulk materials, with circulating con: veyor belts which feature tension members of textile or steel cord ply, and caver plates of rubber or plastic [e. in accordance with DIN 22102, DIN 22 109 Part 2 and DIN 22131 Part 1 \Preliminary Stendard) to Part 4 (Preliminary, Standard). The conveyor belis are supported on carrying idlers le.9, in accordance with DIN 15207 and DIN 22112 Port 1) and driven oF braked by friction grip via pulleys (arrangement of the carrying idlers e.g. in accordance with DIN 22 107) ‘The data apply to conveying in the upper strand (carrying side); if conveying takes place in the lower strand return side), the procedure is analogous. 4 Symbols and units Tobie 1. Symbols and unite Symbol Meaning T uni A Cross ection of il | me ay Partial eros setion ofthe slope above te wate ill m2 a Partial eros tection for 6 = O° (water fil) | om? ee Effective contact area between belt cleaner and belt mt B Bek with mm c Goeticent for the alLnlusve consideration of the secondary resistances | Dry Pulley diameter j mm Frew Modulus of elasticity ofall the load-carrying belt plies (belt core) }Némm F Total of resistances of upper strand (carrying side} and lower strand (return side) | N (+101 of pulley peripheral forces) in the steady operating conction Prat Inertia esistanes and fictional resetane between the conveyor load and the N batt in the zone of a feeder point Fou Belt resistance to bending N For Frictional resistance caused by belt cleaners N Fa Total of main resistances of upper strand (carrying sie) and lover strand N (retuned) Total of scondary resistances N Camber resistance N Tota of the special resistances of upper sand (carrying sel and lower strand N (eau sie) Frictional resistance betwesn the maturial conveyed and the lates chutes out- ‘ side the acceleration zone of feeder poins aS Frictional resistance between the material conveyed and the lateral chutes within | —N ‘the scceleration zone ofa feeder point Fp Tension atthe axis of the take-up pulley | ow me Total of sope resistance of the conveyor load lon Fra Pulley bearing resistance of idler pulleys } oN Fiser Peripheral force of one driving pulley [oN iH Life ofthe conveyor (> 0 fer uphillconveying, 4 <0 for éownhill conveying) | m ny Mast flow kas Tax Nominal mass flow kis wy Volume flow mts Iw Nominal volume flow mils L Conveyor enath~ distance betwaen centres m P Total power atthe periphery of the diving pulleys] requited by the resistances |W in the steady operating condition Pu Total power ofthe driving motors w Pros Nominal power of 1m 8 diving motor w R, Radius of a concave transition curve m R Aadiut of a convex transition curve a s Safety factor e T Local belt traction foree (stra fore) Npin 2210 Page 3 Table 1. (continued) ‘Symbol Meaning, { Unit Tr ‘Mean bel action force of upper arand earying side) andthe lover sand v tretan il | | Difference between mean belt traction force Tm and minimum belt tection | N | force Tex i j n Maximum bel traction force (strand force) a the driving pulley N % Minimum belt traction Force (strane fore) at te driving pulley Dos a ‘Acceleration or deceleration respectively | 2 seul bet win Psa Internal diameter between chute walls en Coetiient forthe ealeulation of the masses of the carrying ils reduced to . their perihery Ranki 2 (ago Paen cna ankine actor (cea = an? (ase A) - cna Coefficient for the calculation ofthe camber resistance - cease | Coefficient forthe taking into overall gecount of the editional resistance = | — Betweon the material corwoyed and the lateral chutes in the feeding Zones Caused by the dynamic pressure ofthe mae flow fed in om Goeficien forthe determination ofthe minimum pulley ciameter i ct Factor for the scent ofthe belt onto the pulley } 2 e Factor forthe descent ofthe belt from the pulley : aay Thicknes of the bat sraper materi on doe Thickness ofthe belt core leord ameter in the case of stl cord ply belt) om ; Base of natural logarithms - ex Distance from the centre line of the bet plies at the edge of the belt to the = reusal axis ofthe bet ex Distance from the centredine of the belt lis atthe centre ofthe bet fo the im neutral axis ofthe belt 7 Hypothetical friction coefficient ofthe uoper strand and lower strand - together * Acceleration du to gravity (g= 9,81 m/s2) mkt hea Maximum bel sg, elated 20 cistance between carrying idler centr - ® Bett action foree related to the bet with Nf Nomina upture force ofthe bel elated to the belt with Ni Length of apart section m Length of the ateleration path inthe feeding zone m Length of shel ofthe central ile in a three piece carrying idler arrangement an Length ofthe lateral chutes é Elongation of belt in the part section of length 7 Distance between carrying idler eentes in the upper strand (carrying ie) ” Distance between carrying ile centres in the lower strand (return side) m Total ofthe rectinese moving masies and ofthe rotating mates reduced 0 is thelr periphery, which are not driven or not braked mis Line load resuting fom the conveyor bet kam mi Line fo resulting from the conveyor load assuming @ uniform lead distribution | kam across the entre conveying seth mix Line fad resulting from the nominal loading ken me Line lad resulting from the rotating carrying idlers ofthe upper strand and kg/m lowerstand together , Number of step (om bel joints) - Poe Pressure between bet cleaner and belt Nimm2 "eb Loss of strength in the belt joint * a Les of strength to make allowance fr the fatigue strength behaviour of belts -Page 4 DIN 22101 Table 1. (continued) sym ming [one . eduction i ivarqi to waka alowane for he orl attoalelreadons | inte bat . Recucton istongth o ae aloware forthe peak lodng faba btwn |= donot corr consenty : Porton of he bet esting on aide ply lpi onl oto ad thee ice | eam roused arse) : Broking distance . ey Take up puey trove e ty Braking time | s o Conveying speed | mis. U9 Feeding (advance) speed of the conveyor load in the direction of conveying 1 mis e fora exon ofc conmave weston eave z ei ‘Verda extension ot coneave arin cure 4 Ee Number of betas : te Number of motor installed : 5 Mra of erying ir sinh user Sree or hte tower sean = cee | Number of enrying ile st inthe upper vend orn the lowe sand = maeat y ingle of pulley belt wrap | evra ; ee omen ete eee |e fem | acteleynamie angle of slope of the metrl conveyed : 3 fang oftncnon ofthe etalaton (2> Dior oil conveying, 8 200mm B— 260mm In the case of one piece, twa piece and three piece carrying idler arrangements in horizontally laid belt conveyor instal lations, the theoretical cross section of fill Ay equivalent to the actual cross section of fill can be determined as the sum Of the partial cross sections A. an plus Aen], by making use of the angle B (see figure 1 and remarks) tang o Ara = [et (= tad - 608 J) @ bat Arw= [e+ cos 2] sind o In the case of bulk materials which exhibit a normal banking behaviour, and the actual equivalent angle of slope of which is not known, a precautionary value f= 15° can be entered in equation (2) In the case of one piece and two piece carrying idler arrangements, the length of the central idler fy; must be entered as zero in the equations. Figure 1. Theoretical cross section of fill in the case of horizontal conveying and of a three piece carrying idler arrange: ment with Idlers of equal length 4) Vierling, A.: Quantitative Folgerungen aus Férderbandmessungen — Erginzung der Berechnungsgrundlagen =. Braun: kohle, Wirme und Energie 11 (Quantitative conclusions derived from conveyor belt measurements ~ Supplementation of the basic principles of calculation — Brown coal, heat and energy 11) (1959) No. 7, pages 253-259Page § DIN 22101 ‘The following avantities shall be calculated from the theoretical cross section of fil, with the aid of the effective filing ratio = Prete Pst theoretical volume flow Iw = Aue o nominal volume flow Fey = Paar” Bsc" Fok 8 nominal mass flow ani = Paar’ 5c" 0° Fuse 6 see" 95° O° Ate ” {In the above formulae, the filling ratio @pgir Is 8 quantity determined by the properties of the materia! conveyed (lummoi ‘ness, max. edge length, the angle of slope Baya which characterizes the actual dynamic banking behaviour) and by the ‘operating conditions of the belt conveyor installation (uniformity of material feed, rectilinear run of the belt, availasility Of 3 given reserve conveying capacity. In the case of a uniform material feed and of a rectilinear belt run, the theoretical crass section of fll ean be completely utilized in horizontal belt conveyor installations (yes = 1) ‘The reduction factor gx takes into account the fact that the partial cross section 4 mis reduced in the case of con veying uphill or downhill: line toad resulting from the nominal loading iy Au 1 Eos) ® os ae {nthe case of properly aligned installations which are loaded uniformly with a conveyed material which isnot very lumpy, and where 8 max & Baya, we can vite [25 rox 605" Faye = 005 fay ‘When using equations (8) and (9) above, it must be bore in mind thatthe angle of inclination, in the case of uphill or downhill conveying, can at the very maximum only be equal to the actual dynamic angle of slope Baym (see also Notes) and that in such a case only the partial eross section 42 m, remains available for conveying purposes. es: @ 6 Resistances to motion and power requirement in the steady operating condition ‘The forcas (resistances) which oppose the motion of a belt conveyor installation comprise friction forces, weight forces ‘anc mass forces in the steady operating concition. The power requirement of the conveyor is expressed as the product (of these resistances to motion multiplied by the belt speed. 6.1 Resistances to motion For the aurpose of calculating the resistances, these are subdivided inte main resistances, secondary resistanees, slope resistances and special resistances; the total of these resistances to motion is equal to the peripheral force F to be tran ‘mitted from the driving pulley to the belt: Fa Fut Ext Foot Fy ro 6.1.1. Main resistance of the conveying track ‘The main resistance Fix of the upper strand and the lower strand shall be determined in 3 simplified manner for the unper strand and the lower strand jointly under the assumption ofa linear relationship between the resistance and the moving load 2) fog [m+ (2+ mig + mi) cos 4] an where f represents 8 hypothetical friction coefficient for the upper strand and the lower strand jointly, andd Fepresents the mesn angle of inclination of the installation. {In the case of installation inclinations with 6 <15°, we ean enter cos é = 1 in the above equation '¥ the upper strand and the lower strand are to be considered separately, equstion (11) will apply analogously, using the appropriate individual values (see subclause 8.2.1). In the ease of belt conveyer installations with filling ratios in the range from 0,7 to 1,1, and with a relative belt 539 fiz S 1%, and equipped with carrying idlers mounted on antifriction bearings and fitted with labyrinth seals, the value of f will be situated in the range from 0,012 to 0,035, depending on the ‘operating and installation conditions. No truly reliable values for f are available for unloaded belt conveyor installations: ‘these values con be either lesser or greater than those applying to the nominal loading range. This must be borne in mind Particularly in the case of installations with a gentie inclination, for which the drives must be sized in accordance with the idling power requirement. ‘Table 3 features values of the coefficient / for installations with filling ratios in the range from 0,7 te 1,1 in funetion (of the operating conditions and af the design characteristics (see aiso Notes) 2) Vierling, A: Zum Stand der Berechnungsgrundiagen fr Gurtforderaniagen. Braunkohle, Warme und Energie 19 {Con- tribution to the present state of the basic principles of calculation of belt canveyor installations. Brown coal, heat and energy 19) (19671 No. 8, pages 309-315DIN 22101 Page 7 ‘Table 3. Standard values for the eoetficient / for belt conveyor installstions with filing ratios .p in the range from 0,7 10 1,1 (se also Notes) [Horizontal instatotons, alo installations conveying uphill and down: ene inetnes | twit electric motor arves ~ favourable operating conditions, e.g. good belt alignment, easy running carrying idlers- | 0017 \ and material conveyed at low speeds, with low internal friction | | — instalvionsconstrted and operated in normal standard) manner | ozo | averse operating conitoe, eg. dur laden atmosohere, low temperatures, material | 0023 100027 | Conveyed exhibiting very hgh internal ction, overloading, igh spe | | ~ extremely low temperatures but otherse normally operated and conventionally | wtoooas | Constructed instalaans | Instalations conveying dawrhil ata seep incline 1) (dives operating as dynamos [sora o0r6 1) In the cate of installations conveying downhill at a steep incline — drives operating as dynamas ~ the adoption Cf a somewhat lower value for f will result in a higher degree of safety in the design; in other cases ~ where the drives operate as motors — an enhanced safety of design is attained by adopting a higher value for 7. 6.1.2 Secondary resistances of individual parts of the installation ‘The total of the secondary resistances Fy ig taken into account by means of the coefficient C3) Fy care 12 i ay In the case of filling ratios @ in the range from approx. 0,7 to 1,1, and of a relatively low percentage of the secondary resistances in relation to the total resistance, the coefficient C can be taken from table 4 below. Table 4, Standard values for coefficient C for bolt conveyor installations with filling ratios yin the range from 0,7 t0 1,1 tinm | 80 | 100 | 180 | 200 | 200 | 400 | 500 | ooo | 700 | coo | 000 | 1000] 5001 _a8c0 € [naz fara [156 | 145 | 191 | 15 | 120 | ta7 | 114 | 112 | 1.10 | 108] 108 | 108 (On the other hand, if the secondary resistances represent a large percentage of the total resistance, e.g in the case of installation lengths L <0 m, and of installations with more than one feeder point, it will be necessary to determine the secondary resistances individually, or the coofficient C respectively. In such cases, the individual components of Fy: can be determined with the aid of the following relationships: Inertia resistance and frictional resistance between the material conveyed and the belt in the zone of a feeder point Frat In: = 0) 03) Frictional resistance berween the material conveyed and the lateral chutes within the asceleration zone of a feeder point Ma tbog by Feeab= Cs’ Crank” AE. o (ay Bs oe 2 foroctmse a) = * 4 > bm BoE a For belt conveyor installations of conventional type we can write: Cen * Crane = 1 (see Remarks) ‘The friction coefficients uy and 12 are, as 8 general rule situated in the range from approx. 0,5 to 0,7. Frictional resistance caused by belt cleaner In the case of belt cleaning by means of scraper bars, the frictional resistance is given by: For= Ha Por’ Ace c ‘As a general rule, the parameter Pr is situated in the range from approx. 0,03 to 0,1 Nmm?, and the friction coef- ‘icient sg is situated in the range from approx. 0,6 t0 0,7. 3) Vierling, A.: Die Nebenwiderstinde von Gurtférderanlagen. férdern und heben & (The secondary resistances of belt conveyor installations. Conveying and hoisting 8) (1858) No. 8, pages 489-495 and 603, +4) Grimmer, KJ. and Thormann, D.: Zur Problematik der Kraft und Bewegungsverhiltnisse des Schitgutes an Aufgabe- stellen von Férderbandanlagen. fSrdern und heben 17 (Problems connected with the force and motion conditions of ‘the bulk material at the feeder points of belt conveyor installations, Conveying and hoisting 17) (1967) No. 5 pages 345-351.Page 8 DIN 22101 Belt resistance to bending gy on its passage over the pulleys, pulley bearing resistance F2q of idler pulleys ‘These secondary resistances are in nearly avery instance negligible in comparison with the resistances previously mentioned: Hf necessary, calculation formulae can be abtained from the technical literature on the subject (see e.g. footnote 3) By virtue of the equations (121, (13), (14) and (15), the secondary resistances Fyy and the coefficient C can now be written as follows: Fy = Faut + Foon + Fort Fon + Fra 03 C14 Fat Fen + Fort Foo + FrolF, a7 6.1.3 Slope resistance of the conveyor load Fo He g: mi, (ray (> 0 for uphill conveying, 4 <0 fer downhill conveying) 6.1.4 Special resistances ‘The individual component parts of the special resistances Fs can be determined with the aid of the relationship below: Camber resistance ‘The camber resistance which arises at an individual side carrying idler will depend on its normal force, on the friction coefficient ig between the belt and the carrying idler, and also on the ancle of tlt e ‘The camber resistance Fs of an individual belt strand of the installation will, therefore, amount to the values below, obtained from the total of the individual resistances, and taking the angle of inclination 6 of the installation into con sideration: Upper strand: Fasio= + L- crato* Hs" Sin e+ COS S+ g- (mig + mi) Feo ete «3 LL: epate: Ha” Sin ¢- 608 3 g- mG Lower strand: Fass “The frietion coefficient us is, asa general rule, situated in the range from approx. 0,5 to 07. tn the above relationships, the parameters ena ace dependent on the carrying ile arrangement, and inthe case of the upper strand, the parameter is dependent in addition on the geometry of the bulk materia. Inthe cae of thre piece carrying idler arrangements with carrying icles of equal ength in the upper stran, and with filing retios ein the range from 0,7 to 1,1 we have 8 eaato= Os for A= 30° erat = 05 for A= 45° ln she case of two-piece troughed carrying ide inthe (unloaded) lower strand, we have) Frictional resistance between the material conveyed and the lateral chutes outside the feeder points Bate 8 tech marke Bey Frc (20) in the above relationship, cron of approx. 0,5 t0 0,7. Resistances of devices for the delivery of goods along the conveying path {in certain special cases where 2 side delivery of goods takes place atong the conveying path, eg. by means of stripping or scraping deviees, the forces which are generated theraby must be taken into account in the form of additional special 6.2. Power requirement in the steady operating condition ‘The power required atthe periohery of the driving pully(s) by a uniformly loaded bet conveyor installation at filing ratios in the range from 0,7 to 1,1 amounts to: eo Co ef a: [mig (2 mig + mi): c08 A] +H. g mit Fs (22) In the cate of angie of inclination of the installation 3 S15", we can enter cos 5 1 in the above equation 7. Design and layout of the driving system. “The design and layout of the driving system comprises — the selection of the location and number of drives decisions relating to starting aids ~ the sizing of the driving motors (rated output) — the determination of the required braking forces (stopping a belt conveyor installation and holding it stationary 5y Grimmer, Kl: Zwei ausgewahite Probleme der Bandtordertechnik. Fortschrittberichte VDI-Zeitschrift (Two selected problems of belt conveyor engineering, Progress Reports, VOI Journal), Series 13, No. 10, September 1968DIN 22101 Page 9 7.1 Location of the driving units, sie and number of driving motors The subdivision of the drives onto several driving pulleys situated at the head and at the rear of the installation, anc in Certain cases siso onto intermediate drives, will be determined on the basis of minimum belt traction forces on the belt conveyor installation, inasmuch 35 no other considerations stand in the way, and it will, therefore, depend to a very large {extent on the belt resistaness in the steady operating condition ~ Fin the upper strand and Fy in the lower stran¢ — {see subciause 6.1). The changes in bale traction farees in the direction af travel of the belt which are caused the'=by be calculated by the appropriate use of equation (10) by summation of the resistance camponent parts which are sileceted ‘0 the sections of the installation with constant installation and operating parameters 6, e1, mi, and mia; (soe aleo sub. clause 8.2.1) ‘The following relationship applies: Fe fot @3) In the case of non-uniform loading, partial load running or idling of a belt conveyor installation with downhill and uphill grade stretenes, the force F determined for the nominal loading range (filling ratio g situated in the range fom 0,7 t9 1,1) may be exceeded to s considerable degree: Fr! = [Fo + Fulmex2 Fl 2a [Parl 2 [PI 5) Depending on the megnitude and on the (plus or minus) sign of F and F., 2 distinction is made between the following installation variants when the upper strand is uniformly loaded ~ horizontal and slightly inclined installations (Fy > 0, Fy > 0} — uphill conveying installations (F, > 0, Fy <0) = downhill conveying installations (Fy $0, Fu > 0} 7.1.1. Horizontal and slightly inclined installations 'n the case of belt conveyor installations with drives atthe installation head and rear, but without intermediate drives, ‘he belt traction forces will be minimum if the drive power is appropriately subdivides between head and rear. ‘The optimal power subcivision is equal to the quotient Fy/Fy of the forces for filing ratios @ situated between 0,7 and 1,1 along the entire stretch of the installation. The required total power of the driving motors can be caleulated with the aid of the following equation ®, Pater 8) Tees ‘The rated motor power actually installed is, as @ general rule, greater than the required power: Prins: 2 Pater f motors of identical nominal power are installed, we have: Patios = 2a Pun en If motors of differing nominal power are installed, we have: Prcin = E Pats a) 7.1.2 Installations conveying uphill In such installations, the belt traction forces will be minimum if all the drives are arranged at the head of the installation, assuming that no intermediate drives are installed (see subelause 7.1.1) Equations (261, (27) and (28) apply to the powers Pate and Papin. 7.1.3. Installations conveying downhill {in these installations, iis essential to install the drives at the rear of the installation in order to obtain minimum belt ‘traction forces. For the purpose of determining the total power of the drives, the required powar of the driving == ‘must be calculated as follows, depending on whether the drives operate as motars (Pmnax > 0) oF as dynames {Prony < O} Pras Pact for Pygs >0 (2 "aes Pet = Pra Mee FF Pe <0 a ‘The rated power of the motors actually installed is, sa genera rule, greater than the amount of the required powor Paina 2 Poet Otherwise equations (27) and (28) apply. 7.2. Starting, sopping and holding stationary 7.24. Starting |i order to achieve minimum belt traction forces, itis necessary to limit the total pulley peripheral force on startup Fs, generated at the drive end, during the run-up to full speed of the belt conveyor installation. However, the force Fy, must Not be allowed to decrease below a given minimum value in order to safeguard the positive control of the initial break: away and startup process. As a general rule, the following recommendations apply to large belt conveyor installations in particular: ~ The maximum pulley peripheral force on startup Fa max which arses should not exceed 1,3 to 1,7 times the force Fa in accordance with equation (24) used for the determination of the installation design.Page 10 DIN 22 = In order to accelerate the masses on the stretch of the conveyor installation, there should, however, be 2 force aveilabie Under the most unfavourable startup conditions (leading condition, distribution of load) which amounts to 20% st least of the total resistances to be taken into account in this case minus the inclination resistances (these consist of ‘the main resistances, secondary resistances and special resistances), and which enables the instalation to run up to {ull operating speed within a maximum permizsile time calculated to avoid the thermal overloading of the drives 3) = The force Fx, must be selected in such @ way that the frietion grip between the material conveyed and the belt is ensured for the starting acceleration a corresponding to said force. In the case of fine-grained bulk material we have: 8 en (Bmax > 0 in the e232 of uphill conveying, Smax <0 in the case of downhill conveying) = The force Fy shall be introduced into the belt slowly enough to ensure that the installation runs up to full aperating speed under quasi steady conditions, and consequently with the smallest possible additional dynamic forces 7 24S lis 098 bax 8in 6 7.2.2. Stopping and holding stationary ‘The operation of belt conveyor installations requires the provision of braking devices, as a general rule, for the purpose of stopping the moving masses, and/or the provision of holding devices for the purpose of holding inclined instaliazions stationary under load. “The following considerations apaly to the design and dimensioning of the braking devices: — total required braking force Fy on the braked pulleys — number and arrangement of brakes braking frequency ~ eneray of the rotating drive components to be absorbed by braking, ‘The required braking force F'g must be determined for the most unfavourable braking conditions governed by the filling ratio and by the distribution of the load in downhill and uphill stretches of the installation; in this connection, either ‘the braking distance &p or the braking time fy must be specified. This will in turn determine the braking retardation cs, ‘which must be such that the friction grip between the material conveyed and the belt is retsined intact. In the case of fine-grained bulk materia, we have the following relationship: [5| Oin the case of uphill conveying, Snax <0 in the case of downhill conveying) It may be necessary to limit the total braking force to a given value Fp max. and consequently the braking retardation to 4 limiting value ay max. in order to reduee the belt svresses to the lowest possible figure, and also to reduce the stresses Con other parts of the installation, and in order to retain intact the friction grip on the braked pulleys (see subclause 8.1.1) As regards the design and dimensioning of holding devices, the maximum slope resistance F5¢ max liable to arise under ‘maximum permissible loading conditions and most unfavourable load distribution, shall be used as the baze velue, minus ‘the main resistance arising under these conditions; for safety reasons, only the minimum main resistance anticipated must be entered in the calculation. Hf a number of mechanical holdback ratchets are used, each individual ratchet must be size for the maximum holding Force likely to arse, if 3 uniform load take-up isnot ensured. 8 Belt traction forces and tensile forces “The bett traction force in a bett conveyor installation is 8 quantity which varies along the stretch (path) of the instalation, and which is governed by the following influences (see figure 2) = length and local course of the instalation = number and arrangement of driving pulleys = characteristics of the driving and braking equipment = tpye and arrangement of the belt tensioning device - operating conditions (loading and movement conditions) “The belt traction force should be Kept down to the lowest possible value in view of the stressing and layout of the belt and of other parts of the installation. 8.1. Required belt traction forces ‘The operation of belt conveyor installations requires minimum bel traction forces in order to enable the transmission of forces to the belt by friction grip on the driving pulleys, and also in order to limit the belt sag and to enable the belt to bbe guided correctly and satisfactorily 5) Funke, H.: Zur Auslegung von Anlaufhitfen fir GurtfSrderanlagen nach Entwur DIN 22101. Braunkohle 31 (Contr bbution to the design of starting aids for belt conveyor installations in accordance with draft Standard DIN 22101, Brown coal 31) (1979) No. 6, pages 188-194. 7) Funke, H.: Zur Berechnung der instationdren Betriebszustinde von Férderbandanlagen. Kali und Steinsalz 6 (Contri- bution to the calculation of non-steady operating conditions of belt conveyor installations. Potash and rock salt 6) 11974) No. 10, pages 362-371eo DIN 22101 Page 11 8.1.1 Minimum belt traction farces required for the transmission of the pulley peripheral forces “The transmission of the total pulley peripheral 4arces Fmmae which arise during starting, braking, or in the steady operating condition by friction grip on the individual driven or braked pulleys requires certain given minimum belt traction forces St the ascent onto the pulley and at the descent fram the pulley. ta the case illustrated in figure 2, with the forces Ty land T and the associated maximum pulley peripheral force P12 max > 0, we have Tyo Tes Fy wherein a must be entered in “radian” units (unit symbol: rad), Ie follows that: 1 T2¢2" Framax With ¢2= TET erent Ty34+ Framax with Figure 2. Belt traction forces and pulley peripheral forces illustrated for a conveyor installation with a wo pulley head drive and three driving units “Table S, Values for the factor ¢> of descent of the belt from the pulley in function of the angle of pulley belt wrap & and of the friction enefficiont “ - wo | we [veo | wee | soo [tose | aoe [20s | aioe 305 eos] ae | yee | se | ee | G8 | am O10 za | 271 as | zar | aso | 292 | 225 cs | ta | ise | te) tm | ies | ar | iss 020 wa | waa | {os | tes | 099 | ces | ose 62s oar | oes ) arr | ove | or | oe | oor 030 os? oss | ose | 056 0,54 os2 | 0.50 038 oz | 080 | ose | oat | om2 | 040 | on oo oa | O40 ose | oa | oss | ost | oso Os Lest | ose eas | 028 | ozs | 028 | ozs ‘Tobie 6, Recommended friction coefficients 1 between conveyor belts fitted with rubber cover plates and pulley surfaces Of differing finish for the design and layaut of belt conveyor installations in the steady operating condition 3) Pulley surface Operating Polyurethane Rubber Ceramic conditions friction lining friction lining friction lining (herringbone (herringbone | (porous, herringbone grooves) grooves) grooves) oy 03510 0,4 0,35 1004 0410 0.45 0,4 10 0,45 cane on 0,35, 038 0351004 wot {contaminated 0,05 to 0.1 02 025003 025 with loam or clay) | 9 Grimmer, Kod. Der Einfluss von Trommelbeligen und Feuchtigkeit auf den Reibungebeiwert zwischen Fordergurt und Antriebstrommel, Braunkehle, Wérme und Energie 18 (Influence of pulley linings and of moisture on the frietion coefficient between the material conveyed and the driving pulley. Brown coal, heat and eneray 18) [1966) No. &, pages 325-332Page 12. DIN 22101 rable & features values forthe factor 69 of Gescent ofthe belt from the pulley for selected angles of pulley bet wag and coon ration eoofficients, The latter can oe obtained from table 6 for conveyor belts with rubber cows Piss at saree sa faces of differing finish forthe neady operating endition. Vales for deviating conditions mis! determined Fe ec particulr eteumstances ofeach caz, Friction eoaficiants for conveyor bats with PVC cover plates are given in the published technical fiterature vaathe eace of more than one driven or braked pulley it ust be verified for each individual pulley and ior a0 Opera ae ca cihather the fretion grip is ensured in accordance with equations (24), (35) and (36). In e's connecting conditions vin ae dhat the total pulley peripheral forcas FZ af F are cetrisuted onte the individual pulls in {he provortion of the torques induced in said pulleys by the driving or braking devices Bo. imum bett traction forsee required forthe imitation of te belt sagand for corect and satisfactory belt duane tps purpose of technical optimization of te belt conveyor instalation, the calculated maximum easve Hel 3 ats Fea noes ctance betweon carrying tale centres, raust be ented to values of las than 1°¢ in he mao CrancSS ela toe pelt ays tolerated inthe non-steady operating conditions, The gree the conveying ssa or the one 2 Saqeril conveyed, the smaller shall the belt 5 be, The following minimum belt eraction Fores 2 required fora given maximum belt sag and a given distance between carrying idler centres: Upper strand: To= Ber + rig) fo (oaded) ee go mest 8 ha a given maximum value of fg is specified, ditfering distances between carrying ides cartes ca Se allocated to the Te ere tigning aloes the path of an installation. When these distances berwoen centres v0 aly sce et ee ety ofthe carrying wlers 0) and the natural frequercy ofthe ‘ransterse osilaions of the Belt ‘must be taken into account"). en Lower strand: T. Fae ensure the trouble-free operation of belt conveyor installations it may be necessary to arrange for the applicar ‘ion of higher minimum belt traction forces in certain cases, viz: ~ blts with a belt turn (reversal of direction) in the lower strand 2) = belts with a low degree of transverse rigidity — inclined belt conveyor installations at the lower deflection pulley belts with locally non-u form force distribution across the width (soe clause 11). 32 Loca bet traction force variations in the upper strand (corrying sie) and in the lower strand retrn side) att conveyor inallations of aporciabe length can incorporate stretches of differing inclinations ane loadings. From sae saint of view of the correc sizing of the belt and of other parts ofthe installation, the prope! ‘appreciation of the Te Poin Monn of te belt traction force along the length of the instalation, ond in partcuas the ssretaect of cour aade ofthe extreme values ofthe free, are very important factors, For the purpos: of AAel ACTS the forces of the moana Of tne non-steady operating conditions (starting, stopping), the fore variations Fy whves sORly the a ea onc of tng wth eonstant parameters Op, fi, iy and mii must iste determined fhe SPAT strand ire eases cand in the sivection of travel of the bet, before the Leal bel eration foree 7 can Be etermined se mmation of these forces and superimposition of the tensile force (see subclause 63) 8.2.1. Steady operating conditions Bole traction force variations due to main resistances Fy and slope resistances Fos tn accordance with equations (11) and (18 we have! Fai fi 8+ [eit Ome + mip 008 di] h a) Fagg (tg + mi sin =I co) (in the ease of the unloaded belt strand, mi, = 0) ‘At present, itis not possible to give any precise indications on the values of the coefficient ft and fy in the above reer ese coetficents are dependent onthe loading and on the bet waction, amongst other ‘in. ‘As an approxi ‘mation, we ean write foi fas F o 3) Grimmer, Kid. and Thormann, D.: Verleich der Reibungszahlen von Gummi und von FYE Forecaure sgegeniber See panel Glekaut 108 (Comparison between the friction coefficients of rubber and PC conveyor belts ae atset with the driving pulley. Gliekaut 103) (1967) No. 26, pages 1309-1311 10) Vor Richtinie 2341: Auswahl der Tragrollen fir Gurférderer. (VDI Guideline 341: Selection of the earrying idlers” for belt conveyors) 11). Vierling, A.: Zur Theorie der Bandforderung, Continental-Transportbanddienst (Contribution to the theory of belt Maaveving, Continental conveyor belt service) No. 8, third edition, Hennover 1972 12) Oahmmen, K. HL: Berechnung der Dehnungsvertellung in Férdergursen infolae Muldunasibersio, Gurtwendung und Se A Grounkanle 31 (caleclation of the distribution of elongation in convey bets «suf he owsaye over troughs, belt turns (reversals of direction) ané rope discontinuity Brown coal 31) (1979) No. 12, pages 394-402a DIN 22107 Page 13, Belt traction force variations due to secondary cesistaneas Fs “The resistances Fy; consist mainly of the inertia resistances and frictional resistances Faust, Fsanp at feeder points, in accordance with equations (13) and (14) ‘Beit traction force variations due to special resistances Fs, “The resistances F's, arise mainly a8 a result of the angle of silt of the carrying idlers and/or from frietional resistances between the material conveyed and the lateral chutes see subclause 6.1.4) “The following relationship is valid, a a general rule, fer the resistances Fz. in the upper strand and in the lower strand as. result of the angle of tilt ofthe carrying idlers (see equation (18) and notes concerning the quantity crs) nati Ens" Ha sin = 608 8;- 8+ (me + mL) by ay (mj; = 0 in the case of an unloaded strand) ‘As regards the resistances Fga due to friction between the material conveyed and the lateral chutes, equation (20) must bbe used section by section, 8.2.2 Non-steady operating conditions During the starting and stopping process, the magnitude and pattern of the forces generated by the driving and braking Series on the one hand, ang the breakaway resistances and resistances to motion of a belt conveyor installation on the Sther hand result in additional dynamic belt traction forces. These additional forces are 2 function oi the following factor, if we assume a belt aoceleration independent of local conditions {see also Notes) = the total pulley peripheral forces F, during starting or Fs during stopping = the total acting resistances to motion (approximately equal to the resistances to motion F which obtain under steady operating conditions) = the non-driven or non-braked masses Zim moving either in a straight line or with a rotary mation. For the frequently occurring case of the secondary resistances representing only a small proportion of the total resistance, the dynamie belt traction force variations Fiaza: in the individual section i can be determined 2s follows with the aid of ‘he belt acceleration a Starting Stopping Fy-F Fo-F i Soa ape G<0 y Fins @ ops + HG + MLD = 3) 8.3. Tensile forces and tensile distances TTansioning devices ere requted for the generation of the necessary belt traction forces (see aubelause 8.1) end for the Compensation of the elastic elongations. The magnitude of the tense forces will depend on the type and local arrange, Sront of the vensioning device, and on the operating concitions of the instalation which requires tensioning. In view of {he design and construction expenses and complications involved, tensioning devices are installed for preference jn those positions where the minimum belt traction forces in the steady operating condition are anticipated. in principle, Statinetion fs made between tensioning devices with a fixed take-up pulley and tensioning devices with 2 flying take-up pulley, lrespectively of the type of tensioning device, the relationship below exists between the quantities which char- Scterize any given operating condition [identified by an asterisk ") local belt traction forces Tf'(x) and belt traction force variations Fif'{x) (see subctause 8.2) minimum belt tection force Tin ) mean belt traction force Tis | of the belt traction force distribution Ty" in accordance with figure 3 smean belt traction fores variation STi ‘take-up pulley tensile distance 58 1 (TT 1 5 (Tete). ye es (ree By a a 2 iD aL E(n 3) L Thin + STa= B> Eck a 2E “The most unfavourable operating condition must be selected for the calculation used for sizing tensioning devices on the basis of equation (44) (tensile force Fg, and takeup pulley tensile distance sp) If the tensioning device i installed at the spot where the minimum belt traction force Tin reign, the tensile force Fy at the take-up pulley will be Fp 2+ Thin “5 In cases which deviate from the above, one must additionally take into consideration the force difference between the force at the spot where the take-up pulley i actually installed and the force at the spot where Tin reigns. In the case of tensioning devices with a fixed take-up pulley. (see also Notes) the mean belt traction force Ti, ig a constant parameter, independent of the opersting condition: Tha= Thin + ATR = const as “this wil result in the belt being operated with greater belt traction forees than those required according to subclause 8.1 Under operating conditions which deviate from the mast unfavourable operating concition.Page 14 DIN 22101 ee ares ene ere ee ot erator overs wee HUW MOH sig U cn me av cee eras oe or te ferees will either remain the sare under all operating conditions (e.g. in the case of tensioning devices with * sai ia aig), or they wil be adjusted to the varying operating conditions by means of “adapted tensioning devicss Fee ae eine cases suitably altered take-up pulley tansile distances 85, will rest for the compensation of che elastic. elongation: Ta Thun t AT = A pw TS. beconst an B- Exe B- Eick tn order to ensure the necessary belt traction fores in avery case, even under non-staady operating conditions, this type of tensioning device must exhibit an adequat= tensioning soeed. 2b Direction of belt travel Direction of belt travel Heed Upper strand Rear ‘Lower strand Head Figure 3, Belt traction forces in the upper strand and the lower strand of a belt conveyor instaliaion 6.4 Local belt tration forces in the upper strand (eatrying side and in the lower strand (return side) “The belt traction forces in the steady and in the non-steady operating conditions ofa belt conveyor installation are decisive amongst other factors for the design and layout of = the conveyor belt the driving pulleys and deflection pulleys — the distances between carrying idler centres — the transition curves in the case of concave or convex belt conduction = the transition lengths at the start and finish of the conveyor belt troughings = the belt turns (changes of direction] “The maximum loesl belt traction fore ikly t arise, which must be taken into consideration forthe dimensioning ofthe Tal lose subclause 9.1) always cccurs during one of the non-steady operating conditions 8.4.1. Non-steady operating conditions Far the porpone of determining the local belt traction forces in the non-steady operating conditions, the minimum Slt Fee eee, asordanee with sobelouse 8.1, the local belt traction fore variations in ascordance with sube|ause 0-9-1 eect refatclonal dynamic belt traction forces in accordance with subclause 8.2.2 must be taken Into consideration. ins rogards the local minimum belt traction forces Trina of Tring. respectively, which arise during sting f SCPH Te aeration the force Togs 1.28 2 genera ule, the determing ane For the calculation of the tert forens and for she quantity Trin under steady operating conditions. 8.4.2. Steady operating conditions “The belt traction forces in the steady operating conditions are determined by the required leeal minimum belt wacton Faas eeeeicnce with ubclause 8.1 under the most unfavourable foading conaltions, as wel a by the Joa! Pelt ree force variations in accordance with subcleuse 8.2.1, and they have a minimum Trin, However there is 5 & aaarer alos peatr minimum Thay, dependent onthe minima Trin a Twin 3 which occur under the now stay Sor sent ey Jeuaadent azo on the typeof tensioning cevice used Thi consequent results in higher belt traction frees hon those required under the steady operating conditions in accordance with subclause 8.1a DIN 101 Page 15 9 Design and layout of the conveyor belt “The tension members and cover plates of a conveyor Delt must be selected according to che operating conditions. Theit spesification will be governed te a considerable extent by the characteristics af the bulk material conveyed (physical and Semnical cherecteristics, grain structure) and by the application conditions of the belt (environmental influences, planned service life duration, mechanical stresses, eg. atthe feeder points) 9.1. Nominal rupture force *) ‘The following factors must be taken into consideration for the determination of the required nominal rupture force of the belt ye = oes of strength in the belt joint rex = maximum belt stress. in the steady opersting condition, and atsociated safety factor Su = maximum belt st2s5 naa in the non-steady operating condition, and asseciated safety Factor Sinsa Each of the following equations must be satisfied for the determination of the nominal rupture force of the belt: Bee “s) 9) “The values in accordance with table 7 below, which are valid for the statie stresses according to the present state of the ‘art, must be entered in the above equations for the loss of strensth rv» On the other hand, the safety factors Saq and Swaaa, which are related to the rupture force in the joint, take into con. sideration the additional stresses which have not been encompassed or which are not capable of being encompassed at the present time, The lasvmentioned are taken into consideration in the form of reductions ro, r, and ra from the rupture 4oree in the joint, in accordance with table 8: 1 Sua 60) =e) 1 5) 1 +1) ‘ Sioa ‘Table 7. Values of loss of rupture force ryew in belt joints under static stressing Macerial of ply "I Type of joint ee Non-disconnectable joints Bia Simple stepped joint (multilayer belts) te, Joint with no toss of ply 2) 0 P polyamided e IE ever Belts with one ply (single ply) <03 Disconnectabie joints 3 Stepped box joints St (steel cords) umber of steps $2 ° | number of steps n 23 | 0.05-(n -21 1) Code letters in accordance with DIN 22 102and DIN 22 131 Part 1 (Preliminary Standard) 2} e.g. in the case of two ply belts in accordance with DIN 22109 Part 2 3) Values in accordance with DIN 22 109 Part 2 if no test values are available In table 8, the value rp represents a basic reduction which takes into account mainly the fatigue strength behaviour of the bolt and is dynamie stressing. Favourable operating conditions with low 7o values are characterized by relatively small buditional stresses due to the conveyor load {physical and chemical properties, low transfer heights), also by @ low Gwitching-on frequency (small number of startups) and by good maintenance of the plant and an absence of stresses de te octrome environmental influences. Such low ro values can also be entered in the calculation for belts in respect of wihich a relatively short service life is planned. “The reduction r takes into consideration the influence of additional elongations in the belt which arise asa result of belt Geflections on pulleys, the commencement and termination of troughings, chenges of direction and transition curves In the case of normal sizing of pulley diameters and of transition curves and transition lengths (see clauses 70 and 11), the 7 values featured in table & can be adopted for belt conveyor installations without bett turns (changes of direction), 7) The concent “nominal rupture force” used here corresponds to the concept “minimum rupture force” used in the conveyor belt standards of the hard coal mining industry and in the official regulations for the mining industry.Page 16 DIN 22107 ‘table 8, Minimum values of safety factors S ind of reductions r related to the belt joint ae acon oa eso am | Sarasa |r nig cow | Serine | boas | as | ne A ny [Som | oT Sa Sam \t pemuaoe | 2088 ea g eareniaa || [femme | Ears | ovo soso | 2080 B totamice || | Termerale | 207% | | semmanan\| [iam | 388 | sone | $85] aor | = rem awe | See 38 | Ty in the cus of exceptionally Faourable installation cond art Ja. a non-troughad belt or a starting behaviour aon cee the belt sparingly), reduced values for ru ane U2 Ct a Sgopted. The mathematical relationship wii ro adctonal sreazs andthe values, ra Howes AON yet known at the present time 2 Coa letter in cordance with DIN 22 102 and O1N 2279) ‘art 1 (Preliminary Standard “The rp reduetion takes into consideration peak bel oad 1G, ahich de not eccur permanently (2.8 ring sarung 2° The ye values featredin table make allowance (8 B iignal stresses which arise im the case of ‘conventional sroppinjayout of the staring and braking esuipment (5° ‘subelause 7.2). 8.2. Cover plates “The thicknesses of the cover plates must be selected if unetion of the material in such 2 way that thei BOTS EE The thickessered in respect ofthe abrasive wear to hen =) ot pe sabjected Guring the entire planned service ffs fata evan case, the surface scares of the Seng me aust remain adequately covered aver (ste is OF ar a there are ro appropriate data 220% re rdarde ori other speciiations, the sander Notes i sued in table 9 for the minimum thickness of the cover Slate and the corresponding aitional emounts eee ain table 10 forthe carrying side can be adopted. -ronte 9, Standard values forthe minimum thickens the Secs onthe carving side anc on the pulley $6° ‘Material of ply") Standard value 8 (cotton! P (polyamide! E (polyester) 4x0 2mm depending on the structure of the woven fabric 07 dau, but at least 4mm Ty ode eter in accordance with DIN 22 102 and DIN 22131 Part 1 (Preliminary Standaré) fer rin nes BS Py ear of working belt protecting deviees into the cover PSS ere ro ave any unde aching ofthe bet in the ca 8 sas bets, the ratio of cover plate thickness on the Conky in ice to plate thickness onthe pulley side should Nok See This imitation does not 88 general le ‘apply 10 steel cord belts 10. Minimum pulley diameters “the pulley diameters ofa bet conveyor nsalasion wit Os “gotermined by the design and layout, stressing and iTS The pe the belt Se also Notes. A cstnetion is made Be“weeh ee fellowing grouns of pulleys when determining the minimum diameters ae aan: driving pulleys and all other pues in the zone of celatively high belt traction forees Group B: deflection pulleys in the zone of elatvey [OW ‘pelt traction forces Group B: caer (change of ccection of bet travel 20°)DIN 22101 Page 17, Table 10. Determination of the standard values for the additional amounts on the carrying side to the minimum thickness in accordance with table 9 coe | [SL favourable [1 | | tevcing, [awa [2 a | infrequent 1] | nn oe Oo 10 fine 1 | coarse 3] { | heavy 3 slight al Insofar as no relevant data are contained in DIN Standards or other specifications in this connection, the minimum dia & meter of a pulley of group A for maximum belt traction forces situated in the range 0,60 < =~ -Suq S1/can be deter ‘ined 3 folows: * Dre ¢re: doe (62) “The factor en: isa parameter dependent on the material of the tension member according to table 11 below. Table 11. Parameter en, for the determination of the minimum pulley diameter Dy Material of tension member o in the longitudinal direction 9) ied 8 (cotton) 80 P polyamide! 90 E (polyester) 108, ‘t (stel cords) 145: 1) Code letters in accordance with DIN 22102 ‘and DIN 22 131 Part 1 (Preliminary Stancard} ‘Apulley diameter calculated in this way must be rounded to the nearest standard value in accordance with table 12 below. In ‘he case ofa relatively low rate of utilization of the maximum permissible belt traction force ty /Ssza, and also in the case Cf pulleys of groups 8 and C, the smaller diameters of table 12 are permissible.Page 18 DIN 22101 Table 12. Minimum diameters of pulleys of groups A, B and C in function of the rate of utilization of the maximum permissible helt traction force in the steady operating condition ‘Minimum Giameter in mm fithous fition linings) Dex Rate of uation ofthe maximum semble ble action ores [E> . Suq 10094] in accordance ew lwithequotion (52}] over 60% to 100% over 30% 10 60% up 10.30% Pulley croup Pulley group Pulley roup aien ema A eT ce as s 100 100 | / 125 428 | 100 | 100 ' | 4160 wo | 128 | 100 | 325 | 100 100 | 100 200 oo [A eienk | tioek | etreom |\fe zen! atoo. ae etz5je)| ei2s)a| 6 00 250 250 | 200 | 160 | 200 | vo | 125 | seo | 160 | 125 315, 315 | 250 200 250 200 | 160 200 200 | 160 400 400 | 315, 250 sts | 250 | 200 250 250 200 500, soo | 400 | ais | so | ars | 250 | ets | ats | 250 630 630 | soo | 400 500 400 a5 400 | 400 38 800 500 | go | 500 | ea | 300 | 400 | s00 | 500 | 400 1000 100 | 800 | ¢90 | 200 | 630 | so | so | 620 | soo 1260 1250 | 1000 | 200 | 1000 | sco | so | 800 | 00 | 00 waco | aad) vaso | s000 | 1250 | sooo | e00 | 1000 | 1000 | soo +600 teoo | 1250 | too | i250 | i000 | soo | 1000 | 1000 | spo 1800 yoo | 1400 | 4250 | 1400 | 4250 | 1000 | 1250 | 1250 ) 1000 2000 2000 | 1600 i280 | te00 | 1250 | wooo | 1250 | i280 | 1000 11. Design and layout of transition curves and of transition lengths “The wansition curves and the transition lengths of troughed belts must be dimensioned in funetion of their geometry, of the prevailing belt traction force T and of the belt design and construction in such a way that the total stress of the belt jn the joint does not exceed the values below, even in the case of the extra elongations which arise: — in the non-steady operating condition, the value from (1 —r9) {1 —ryesy) +e — in the steady operating condition, the value fram (1 — rq —Fa)- (1 =rvees) “ss ‘See table 8 for values of rq andr In addition, the greatest amount of the negative additional elongation under all operating conditions must be smaller than ‘the elongation values eaused by the cespecitive local belt traction forces T. Bacause the additional stresses of the belt are ‘not confined to the geometric reaches of the transition curves and transition lengths, but act beyond them, superim positions onto other additional stresses can arise. 11.1. Transition eurves In the horizontal plane, changes of direction are only capable of being accommodated to a limited extent, an require a relatively invalved and cumbersome calculation '3) 14}, (On the other hand, major changes of direction in the vertical plane are quite cammon in belt conveyor installations (see figure 4) |-Et Direction of conveying E | Figure 4. Convex (radius R) and concave (radius Fy) transition curve 13) Grimmer, Ka. and Seumer, B.: Auslegung und Betrieb kurvengingiger Farderbander mit normalen Férdergurten. Teil 1: Theoretische Grundlagen, fOrdern und heben 22 (Layout and operation of snaking conveyor belt installations ‘with standard conveyor belts. Part |: Theoretical principles, Conveying and hoisting 22) (1972) No. 3, pages 107-112. 14) Qehmen, K.H.: Einfluss vertikaler und horizontaler Kurven au die Dehnungsverteilung in Fordergurten — Theorie tnd Anwendung. Braunkehle 31 (The influence of vertical and horizontal curves on the elongation distribution in Famimine halte = Phanri and nrantinal annficatinn Berman anal 2H [17Q) Na 1 nance AO. 3AR,on Page 19 In the case of convex belt conductance of troughed belts, there will aise additional elongations of the edge of the bolt and contractions of the belt centre, which superimpose themselves on the olongations caused by the belt traction force in the form of positive and negative elongations eq and Acyq. On the other hané, in the case oF conc & elt conductance, there will arise additional elongations of the belt centre and contractions of the bel& edge, which will ‘mount to the same magnitudes as the additional eloneations which arise in the case of eanvex belt conductance on cor dition that the belt does not lift off the carrying idlers. “The additional elongation resulting from convex and concave transition curves are only capable of being calculated! with a relatively great ceal of complexity in the case of short and medium curve lengths "4; as far as their magnitude is con Gemed, they are, however, always smaller than the fimiting values Ag. and &ey., which arise in the middle zone of Very long curves, and which are independent of the construction of the belt, and can be calculated with the aid of table 13 and figure 5 below. Table 13. Definition of the limiting values x Acg and Mey, \ Transition eure Pesrere|eencata ‘Neutral plane of belt plies axe [+] - R | 1 tem, | - St | + : R | Re Figure 5. Aid to the cslculation ofthe limiting values of elongation A ti and 7 ‘A.ty, at the cantre of long convex and concave transition curves “The distances ex and ey, of the centre lines of the belt plies from their neutral plane are illustrated in figure 8. The position of the neutral plane can be assumed in this case to passthrough the centre of gravity of the belt plies, ‘The following relationships apply to two piece and three piece troughed belts: wee (tS) san ws eg= So 8 in 4) “The possible lift-off of the belt from the carrying idlers inthe case of con eave belt conductance (see figure 4) can be avoided if the following minimum radius is adhered to under all operating conditions: Tr Reo 6 em -The minimum reaches of the concave zone in section i of a belt conveyor installation (see figure 4} are therefore those specified below: aim Rass tan co) i 2 Ru: tan? 1.2 Transition lengths Positive and negative additional elongations occur in the troughing commencement and termination stretches of conveyor belts, which superimpose themselves onto the elongetions arising from local belt traction foroes 2). In eases where the ‘roughing transition lie in the interaction zone of transition curves, the elongations which result from superimposition rust be taken into account in the calculation. Further standards DIN 22103 Non-readily flammable conveyor belts; requirements, testing DIN 22104 ‘Antistatie conveyor belts with textile plies; requirement, testing DIN 22108 Conveyor belts with textile plies; determination of the impect bending eneray DIN 22109 Part 1 (at present at draft stage) Conveyor belts with textile plies for the hard coal mining industry; single ply PVC conveyor belts for underaround applications DIN 22110 Part 1 Conveyor belts with textile plies; determination of the static strenath of belt joints DIN 22110 Part2_ [at present at draft stage) Conveyor belts with textile plies; testing of the service life duration of belt joins 12) See Page 12 14) Soe Page 18Page 20, DIN 22101 DIN 22114 Belt conveyors for coal mining underground; lightweight supnorting structure DIN 22113 Belt conveyors for underground applications carrying idles; determination of running frition Fores DIN 22114 Belt conveyors for coal mining undersround; heavy duty supporting structure DIN 22118 (at present at draft stage) Conveyor belts with textile plies for hard coal mining undersround; technical fireproofing requirement, testing DIN 22120 ‘Soraper band for belt conveyors Previous editions DIN BERG 2101 Part 1: 07.33% DIN BERG 2101 Part 2 and Part 3: 07.33 DIN 22 101: 02.42 Amendments ‘The February 1942 edition has been revised in its en ty. Notes Re clause 5 Concepts Inthieclause, theconeept conveyor \o.ad isintroduced to characterize the inert properties of the bulk material cree the concept material conveyed. isused exclusively in conjunction with the properties of she bul aay such as density, Internal fiction, dynamic angle of slope anc similar characteristics. By introducing the concept er ee ipad . a contribution nas been made tothe efforts aimed at the standardization of the designations vied Soeeeeelats handling technology. In addition, the possibilities of a mixup or confusion Between the Concepts material conveyed and conveyor belt are thereby reduced. “Theoretical cross seetion of fil Ay, and equivalent angle of slope 6 “The bull material eross section, in the case of a troughed belt, comprises the “water eross section” and the slopé cross Teuton Ivingabove The shape the slope will depend amongst other factors on the properties of the bulk mareris oes see lsat tumpness, interna frition, fiction coeicent between the conveyor belt and the material conveyea) at ws da epersting conations of the belt conveyor installation {e.. type of belt feed, rectilinear running of the bel aoe sod duration of vibration (arin) of the bulk material conveyed. The slope eres section which actualy takes creer kedly smaller than the cross section given by the static ange of slope. @ ealeuation of this actual Grose sre scam theretore, as general rule, only be undertaken under idealizing assumptions. nthe cass of Sere ar a inctalations with a horizontal layout, the slope cross section in the German technical literature is neatly eae se yedived in the form of @ triangular cross section, whilst in International Standard 180 8048 its idealized in he Fee aeanesent of ica, tthe angles ofthe triangle and ofthe tangent respectively ate suitably selected 2 theos src) ar oes etion Ac of equal size wil result in both cases ee figure below). In order to arsve at approximersly Se sore er een using either of these tw calculation formulations, the tangent ange (surcharge angle) Qin 150 588 Se a cind sta value of 15 times the angle 8 of the triangle in this standard: 9 = 1,5 «8 1). Because the calculation Tus Oe ecient tangle sea i simpler than the determination of an equivalant segment of circle area from fe chord Tungth and its tangent angle, the procedure specified in SO 5048 has not been incorporated In this standar {dealization of the equivalent eross section of fill in Ideatization of the equivalent cross section of fill in accordance with OIN 22 101 ‘accordance with ISO $048 Tey Fanee Tis Zur Neufooung der Berchnungsgrundlagen fer Gurttorderer nach DIN 22 101, fSrdemn und heben 2H Testes on the new formulation of the calculation principles for belt conveyors in accordance with DIN 22 10%, conveying and hoisting 28) {1978} No. t3, pages 912.972,DIN 22101 Pege Reduction factor os When using the determination equation {91 it rmust be borne in mind thatthe equivalen angle B= 15° used in large umber of calulaions of the eros section of fll repreents@ precautionary value. In order not zo be placed in the Dosttion of ausssing far too ost eroussetions of fill by using this value in the case of inclined installations, i wil be Aeutaty to eatculate the factor gee svhih is dependent on the inelination, with an angle of slope Baya which accurately fooresents the actual Gynamie candiions, In borderline cass, e.g, fer very low conveying speeds, and consequently @ ote approximation to Guasi-xatie cancion, the vlue of fym can came close to the static angle of slope (the angle of internal statis fiction) f accurate values ave required in borane cases, such values must be determined by tests under Conditions which approximate te true application conditions as closely as possible In OIN 22 101, February 1942 ecition, tne wns a table fr the factor & which is now designated gs, inthis standard) ich featured values stuated detwaer 1,0 and 0.83 in function ofthe angle of incination 8; however, the dependence tn the angle Gays an on 2he shape ef tre belt trough was not indicated, intensive Invetigations have now established {hot thet voluss mantionaa wore bated on a three pieze carrying icler arrangement (tousbing angle 2 situated beeen 20 and 30° with carrying isers of aqual length, and 1 vas posible as @ result 0 relate the measured values to the angle Bay = 27.5" with tre ai of equation (9) 5) Re subclause 6.1.1 “The main resistance of the upper strand and the lower strand consists of the following: rolling resistance of the carrying idlers, falling resistance due 20 belt penetration on the carrying idlers, oscillating flexure of the belt and fulling of the material conveyed, This main resistance is, therefore, 2 function of the traction foree, speed, loading, width, troughing, land technological properties of the belt, snd in addition of the diameter and spacing of the carrying idlers, and also of ‘he properties of the materiel conveyed and of the environmental conditions of the conveyor. The hypothetical friction coefficient f which characterizes the magnitude of the main resistance has a value of 0,020 in the ease of conventionally designed installations which are operated in the nominal load range (Filing ratios q situated between 0,7 and 1,1);itean assume higher values in the following unfsvourable cases = in the case of conveyad materials which have a high internal friction — in the cate of the following operating conditions: very dusty, wet and/or sticky case of ambient temperatures lower then 20°C = in the case of troughing angles 4 > 35° = in the case of belt speeds »> 5 mis = ig the case of carrying idler diameters < 108mm = in the case of belt $296 ims > 1% — in the case of carrying idler spacings ly <1 mor ly <3 m. — in the case of belts fitted with thick and soft cover alates — in the cate of incorrectly aligned installations Re subclause 6.1.2 When determining the frictional resistance between the material conveyed and the lateral chutes in the acceleration zone of 2 feeder point, the coefficient cgay, must also be taken into consideration, in conjunction with the Renkine factor Baym v2 nich influenees the pressure on the chute walls asa result of the bulk material in the zone eoaa (8 2 of the chute (Jor indications on the megnitude of Bara, #2e notes relating to the reduction factor @ee). This coefficient Characterize: the inerease in resistance eaused by the additional pressure on the chute wals as 2 result of the dynamic Drezsure of the mass flow fed in, The coefficient eax, therefore, has a value equal to 1 fora transfer height of z2ro, and. ie increases gradually as the conveying speed and the drop height incresse. When designing conventional types of belt con- vveyor installations, the product Cseny » Cane is, therefore, entered as equal to 1, and when designing bin or hopper drawing belts with great loading heights, the coefficient cca is entered as equal to 1 fe subelause 6.1.4 Resistancat which only occur in certain given types of belt conveyor installation construction are classified as speval resistances. In contrast to the secondary resistances, they cannot be encompassed by means of a lump sum or overall ‘Characteristic value. Special resistances within the meaning ofthis definition include the resistance asa result ofthe anale Gf tilt of the carrying idlers, the resistance along material guidance skirt boards and the resistence of equipment for the Gelivery of material along the path of the conveyer (see notes relating tothe reduction fector Ps« for the determination Of the angle Bay in the Rankine factor xan) Re subclausa 8.2.2 |A belt conveyor installation on which the rate of increase of the pulley peripheral forees is limited during the starting or stopping procedure, and on which the belt is in motion in the entire installation, exhibits a bett acceleration wich is iadependent of location: it behaves in a quasi steady-state fashion, and enables the dynamic additional 5) See Page 20Page DIN 22101 forces to be devermined as mass forces, If one intends to calculate the non-auasi steady operating condivions of 2 Pat corntayor instalation, e.g the breakoway process, it becomes necessary to determine the dynamic additiona\ Forces wnich, Savoy tic connection withthe ai of very complex ealeulation methods (see footnote 7 in this connection) Re subclause 8.3 fs mpares the calculation, a dstincton must be made between a tensioning device with a fixed take-up pulley and tensioning device with a fiying take-up pulley. Tonsigning devices with a Tixed takeup pulley are devices on which the position ofthe criven and non ofc Puller ainain unaltered for every operating condition of the conveyor. The dered adjustment ofthe wane {Ff aay oe sxarnple by means of spindles (screws) or jacks. Depending on the prevailing operating condition,» Chee Teruo pulley wall cesult in varying forces atthe tensioning location. Conversely the total of the local belt elonsarions wee? erateand and the lower strand will remain constant; it is equal to twice the take-up pulley travel during the tensioning process (rake-up pulley travel sf): Laka 2- sfp= const ‘Tensioning devices witha flying takeup pw lle y_ are devices which generate tensile Foes which art eet saeeere of the operating concitions, or which ae practically constant, or which ae suitably mauened re we Or doer ncemraing conditions. ‘This is achiew for example with the aid of stretching weights, pneumade of HYSTaLTS aan oe ei ce controled jacks inthe eae of take-up pulleys with an adequate travel facility. Their mode of operavion Ta teres cris Dy the fat thatthe total ofthe local bet elongations in the upper strand and the lower strand and consequently the take-up pulley travel vary in magnitude: Taha 2- shy const [A tinwar relationship between the elastic elongations and the belt traction forcss related to the belt width is assumed os a nea eaton forthe ealelation of lj, aba genera rule, and this is expressed Dy means of a mean modulus of elastity for ail the toad:-bearing belt plies Brox. Fe subslause 9.2 Casas the relevant DIN Standards contain no data regarding the selection ofthe cover plate thicknesses, recommender tions in this respect have been incorporated in this standard, Tre cover alate thicknesses onthe pully side ofthe belt are determined to a great extent by the tension bearer, Wise Fe sate Pickncoss onthe earring sie ofthe belt ae determined mainly bythe stressing ofthe belt by the materi conveyed, and consequently by the following influencing quantities = nature of material conveyed: particle size and particle shape, density, abrasiveness = leading conditions: fron height, resfence of the belt upport, difference in speed between conveyor 'oad ‘and belt = loading frequency: jrequensy of belt circulation and planned operating time of belt, number of feeder points Fhe aniceness ot the carrying side must beat least equal to the thickness on the pulley sie ofthe belt In view of the The thickest Sotion of a belt conveyor installation, the cover plate thickness on the pulley sie of the belt should be kept as low as possible. Re clause 10 “This clause has been incorporated inthis standard because the relevant standards on conveyor belts do not contzin any data on the minimum pulley dismeters. It applies to the following: conveyer batts with steel cord plies in accordance with DIN 22124 Part 1 (Preliminary Standard to Parc (Preliminary ‘Standard = cervor belts with textile plies in accordance with DIN 22102 up to 20m core thickness and up to 0,6 mm Eick invermediate layers — conveyor belts with textile plies in accordance with DIN 22109 Part 2 Explanations Tae cation of DIN 22101 represents @ complete revision ofthe February 1942 edition, The principles of ealulation of This eco ot Rutations have been expanded in respect of content by date relating tothe desian and layous of Sm aoe eo aveyom by the calculation of the belt action forees and ofthe tensile fores, and by the design and vet of oo oye ot transition lengths n addition, these principles of calculation have been refined in secorsones reer ioe casmnt state of conveying engineering practice. The equations are in principle presented in the form of quan ty equations. saton ructure of the standard has consequently been sblvided as follows, in accordance with the conventional caleulation procedure for the design and layout of belt conveyor installations — volume flow and mass flow — resistances to motion and power requirementDIN 210% Page 23 = design and layout of the deiving system ‘belt traction forces and % sile forces — design and layout of the conveyor belt = minimum pulley diameters ~ layout of transition eurves and of transition lengths ‘The above subdivision enables the cade of practice to be used for certain clauses or sections only, if so desired. ‘The following ISO standards have been taken into consideration for the revision of this standard 180 5048 ~ 1879: Continuous mechanical handiing equipment — Belt conveyors with carrying idlers ~ Calaulation of operating power and tensile forces ‘The recommendations contained in the above document for the determination of — the flow of material conveyed and the troughing cross section = the resistance ta motion, the driving force and the power requirement = the belt traction foree are in accordance with the contents of this standard, with the following important exceptions: In the ISO document, the cross section of fill of a troughed belt is composed of an equal sided trapezium or isosceles triangle surmounted by a segment of circle. In this standard (see clause 5), the upper portion of the cross section of fill is idealized in the form of an isosceles triangle, in accordance with the German technical literature ') In the ISO document, the reduction factor f for the reduction of the theoretical cross section of fill af horizontally in stalled conveyor Belt installations has been adapted for the calculation of the cross section of fill on inctined installations: this reduction factor k originates from DIN 22 101, February 1942 edition. However, this factor is @ function not only of the inclination of the installation but also of the dynamic angle of slope of the material conveyed, and consequently the reduetion factor s., which takes both these influences into account, has been adopted in this standard (see clause 5) 15) ‘According to the recommendations contained in the ISO document for the calculation of the secondary and special resistances, the resistances due to the belt cleaners are deemed to be spacial resistances. However, as belt cleaners form bart of the standard equipment of belt conveyor installations for bulk materials, the associated resistances have been allotted to the secondary resistances in this standard (see clause 6). 1S0 3870 ~ 1976: Conveyor belts (fabric carcass) with Fength between pulley centres up to 300 m, for loose bulk mate- rials — Adjustment of take-up device In the above standard, recommendations are given in respect of installations with distences between pulley centres up to 300 m and with belts with textile plies (fabric carcasses) on the required deoree of adjustability of the tensioning device, ‘which are based on overall (lump sum) values for the “permanent” elongation and the elastic elongation of belts with ‘textile plies, With the aid of the relationships featured in this standerd (see subelause 8.3) it becomes possible to calculate with reasonable accuracy the elastic elongation of the belt and the associated take-up pulley travel in function of the pattern af the belt traction force and of the belt characteristic quantities 1S0 1120-1976: Conveyor belts — Determination of strength of mechanical fastenings ~ Static test method ‘The contents of the above standard correspond for the most part to the contents of DIN 22 110 Part 11 — Conveyor belts ‘with textile plies, determination of the static strength of belt joints (see subclause 9.1) 180 9684-1976: Conveyor belts ~ Determination of minimum pulley diameters for belt conveyors ‘The recommendations contained in the above standard for the determination of minimum pulley diameters for belt con- ‘veyor installations have been incoraorated in this standard in more concise form, and their field of application hes been restricted to the belts with textile and steel cord plies currently in use (see clause 10}. 1SO/DIS 5293: Conveyor belts — Formula for transition distance on three equal length idler rollers ‘The above draft gives somewhat more detailed recommendations for the determination of the transition lengths than does this standard {see suclause 11.2), but in prineple itis based on the same simplifying estumptions whicn were first made by Laior 5). Because the contents of this {SO document have not yet been officially released in ther final version, it has not been Incorporated in this standard WB) See Pog: 20 18) Laier, D.: Ein Versuch zur rechnerischen Erfessung der 2usitzlichen Dehnung in der Muldungsstrecke von Frer- gurten. Braunkoble, Wérme und Energie 18 (Attempt at the determination by calculation ofthe additional elongation inthe troughing section of conveyor belts. Brown coal, heat and energy 18) (1966) No. 1, pages 14-18,