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Vol IV Issue II Article 12 PDF
Vol IV Issue II Article 12 PDF
E-ISSN 0976-3945
Research Paper
IV Year Student, 2IV Year Students, 3Assistant Professor, Mechanical Engineering Departments, KLU Guntur
ABSTRACT:
Belt conveyor is the transportation of material from one location to another. Belt conveyor has high load carrying capacity,
large length of conveying path, simple design, easy maintenance and high reliability of operation. Belt Conveyor system is
also used in material transport in foundry shop like supply and distribution of molding sand, molds and removal of waste.
This paper provides to design the conveyor system used for which includes belt speed, belt width, motor selection, belt
specification, shaft diameter, pulley, gear box selection, with the help of standard model calculation.
1. INTRODUCTION:
During the project design stage for the transport of
raw materials or finished products, the choice of the
method must favor the most cost effective solution
for the volume of material moved; the plant and its
maintenance; its flexibility for adaptation and its
ability to carry a variety of loads and even be
overloaded at times.
Basic drawing of a belt conveyor
Angle of repose
Angle of surcharge
Angle of surcharge :
The area of the section S may be calculated
geometrically adding the area of a circle A1 to that of
the trapezoid A2.
where :
IVT = conveyed volume at a conveyor speed of 1 m/s
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where:
qG = weight of material per linear meter
Iv= belt load t/h
v = belt speed m/s
qG is used in determining the tangential force Fu.
5.1.1. Maximum speeds advised:
where:
Iv = load capacity of the belt [ t/h ]
qs = specific weight of the material
Also defined as:
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Where:
5.2.4. Corrects loaded volume in relation to the
factors of inclination and feed:
In the case of inclined belts, the values of loaded
volume IVT [m3/h] are corrected according to the
following:
IVM = IVT X K X K1 [m3/h]
IJAET/Vol. IV/ Issue II/April-June, 2013/43-49
Where,
Rwd = Wrap resistance for drive pulley (230 N)
Rbd = Pulley bearing resistance for drive pulley (100
N)
Therefore,
.
PA = 23.028 +
= 23.028 + 0.396 = 23.424 kW
5.4. MOTOR POWER
The motor output power (shaft) is given by
P
PM = A
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.
N=
= 35.043rpm
.
5.7. DESIGN OF SHAFTS:
5.7.1. DRIVE PULLEY SHAFT DESIGN
Considering all the resistances (including wrap &
bearing resistances), we get the torque from the
following formula
!
PA =
"#
T=
.
=
[N=35.043 rpm at output]
.
= 6383 N-m
= 6.383 KN-m
Tension in the belt = T / r
=6.383/0.327
=19.51 KN
Now, consider
TE = 19.51 KN
We have,
T1 = Carrying side belt tension
T1 = TE [ , + 1]
+ -
Where,
= Drive coefficient = 1.66
= Angle of wrap= 2100 = 210 x
= 3.66 rad
.
= Coefficient of friction between drive pulley and
belt
= 0.35
.
T1 = 19.51 [ /.01 2 0.33 + 1]= 31.01 KN
+
-
Where,
= Overall efficiency by taking the power losses of
gear-box and couplings into account.= 0.94
Therefore,
.
PM =
.
= 24.49 kW
5.5 .MOTOR SELECTION
At present, all the motors are of 1500 rpm.
By referring the catalogue, the selected motor is of 37
kW/1500 rpm (Nominal power).
The shaft diameter of the motor is 60mm.
5.6. GEAR BOX SELECTION:
For gear box selection, we need to calculate the
reduction ratio.
Reduction ratio =
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Allowable shear stress (s) = 0 x Teq
A
0
!CD
d= B
E
0
.
0
3
=B
= 0.0115 m
= 115.5 mm
Case 2: Based on Equivalent moment (AT HUB)
Equivalent moment
Moment at C,
MCH = RCH x 0.35
= 20.814 x 0.35
= 7.2849kN-m
Moment at D,
MDH = RDH x 0.35
= 20.814 x 0.35
= 7.2849kN-m
Vertical loading
0 HCD
d= B
A 0
x Meq
I
0
.
0
3
=B
= 0.11 m
= 111.86mm
Case-3: Based on Deflection method
Deflection based diameter
O JK L M
d= B
Point load acting at C, RCV = FV/2 = 8.906/2 = 4.453
KN
Point load acting at D, RDV = FV/2 = 8.906/2 = 4.453
KN
Taking moment at A,
MAV = 0
(RCV x 0.35)+(RDV x (0.35+1.15))(RBV x1.85) = 0
(4.453 x 0.35) + (4.453 x 1.5) (RBV x 1.85) = 0
RBV = 4.453 KN
Similarly, RAV = 4.453 KN
Vertical moments
O
..
1 .
T
Therefore, d = B
= 106.44 mm
So, selected shaft size is 115 mm at bearing and 120
mm at hub.
5.7.2. TAIL PULLEY SHAFT DESIGN
Tail tension (Tt)
= T2 + [f x L x g x (mB + mR)] [H x g x mB]
= (11.5812 x 103) + [0.030 x 29 x 9.81 x (20 +10)]
[5.112 x 9.81 x 20]
= 10834.271
= 10.834 KN
Weight of the tail pulley (W) = 520 Kgs = 5101.2 N
= 5.1 KN
Moment at C ,
N
=
Resolving horizontal and vertical components
FH = Tt cos10.360 + Tt cos10.360
= 2 x Tt x cos10.360
= 2 x 10.384 x cos10.360
= 21.31 KN
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= 0.602 x 0.35
= 0.210 kN-m
Therefore,
Resultant moment at
C = 456 7 568
= 40.210 7 3.7275
= 3.73 KN-m
Resultant moment at
D = 45 7 58
= 40.210 7 3.7275
= 3.73 KN-m
Case-1: Based on moment
We know
M = MCR = MDR = 3.73 kN-m
Allowable bending stress (Gb)= 0 x M x Kb
0
H U
d= B
A
I
0
.T
0
.
3
=B
= 88.02 mm
Case-2: Based on Deflection method
Deflection based diameter
O JK L M
d= B
Moment at C,
MCH = RCH x 0.35
= 10.65 x 0.35
= 3.7275 KN-m
Moment at D,
MDH = RDH x 0.35
= 10.65 x 0.35
= 3.7275 KN-m
Vertical loading
N
Where,
WR = resultant loading
= 4P68 7 PQR
= 10.65 7 0.602
= 10.66 KN
a = Bearing centre to hub distance (mm)
L = Hub spacing (mm)
E = Youngs modulus for shaft (N/mm2)
= Allowable deflection (radians)
= 0.0015 rad to 0.0017 rad
= 0.0017 rad (max.)
Therefore,
O
.
1 .
T
d= B
= 89.53 mm
So, selected shaft size is 100 mm at bearing and 110
mm at hub
6. Components of belt conveyor:
6.1.1. Carrying Idler:
REFERENCES
1.
2.
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