Rulmeca Motorized Pulley Power Calculation Program - Metric Version 5.

37
This is a worksheet only. It is to be hidden from view.

Customer Name
Conveyor Number
Conveyor Length (m)
Load (T/hour)
Belt Speed (m/s)
Material Lift Height (m)
Ambient temperature (deg C) Min
Ambient temperature (deg C) Max
Initial Velocity of Material (m/s)
Number of Belt Cleaners
Number of Belt Ploughs
Length of Skirt Zone (m)
Depth of Mat'l in skirt zone (mm)
Number of Non-driven Pulleys
0 Kg/m

37.1
110
1
1.6
-20
40
0
2
2
8
200
2
0

Elevation (Km above sea level)

1.0
Type of Material
Iron Ore 200 lbs/cu ft
Belt Width (mm)
650
Belt Carcass Type
Fabric
Idler Roll diam (mm)
108
CEMA Type (A,B,C,D,E)
E
Troughing (carrying) Idler Spacing (m)
1
Required Belt Pull, Te =

7803 N

RECOMMENDED DRUM MOTOR

JOKI Model(s):
400, 500
$0

ALTERNATE DUAL DRIVE OPTION

JOKI Model(s):
220, 320, 400, 500, 630
$0
0

RECOMMENDED OPTIONS:
1. Mechanical Backstop
SPECIAL NOTES:

Engineering Design Data:

Ai
Cs
H
Kt
Kx
Ky
L
Q
Si
Tac
Tam
Tb
Tbc

11.12 N
0.276
1.6 m
1.41
3.48kg/m
0.019
37.1 m
110 mtph
1m
4975 N
31 N
89 N
1138 N

330287566.xlsx 09/20/2016 07:33:56

Tm
Tp
Tpl
Tsb
Ttr
Tx
Tyb
Tyc
Tym
Tyr
V
Wb
Wm

479 N
225 N
1138 N
2698 N
0N
1778 N
99 N
56 N
216 N
43 N
1 m/s
6 kg/m
31 kg/m

Calculated power to drive conveyor b

Drive pulley bearing friction:
Power at motor:
Gear loss in motorized pulley:
Calculated power for JOKI
Derate for high elevation
Required Power for motorized pulley

(Note: JOKI models above are based on 50 Hz power.)

Power savings for 3 shift/day, 50 week/yr operation

(JOKI pulley compared to gearmotor & V-belt drive)

Save: 1946 Kw-Hrs/Yr, 1 shift/day or 5838 Kw-Hrs/

Te

7803 N

330287566.xlsx 09/20/2016 07:33:56

Save: 169 /Yr, 1 shift/day or 508 /Yr, 3 shifts/day

8.5 kW
700 mm
OMMENDED DRUM MOTOR
11 kW
1 m/s

NATE DUAL DRIVE OPTION

5.5 kW/ea
1 m/s

7.80 kW
0.15 kW
7.96 kW
0.51 kW
8.46 kW
0.00 kW
8.46 kW

bove are based on 50 Hz power.)

shift/day, 50 week/yr operation

to gearmotor & V-belt drive)

Yr, 1 shift/day or 5838 Kw-Hrs/Yr, 3 sh

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ift/day or 508 /Yr, 3 shifts/day @ 0.0

330287566.xlsx 09/20/2016 07:33:56

Specifier

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 5.37

Specifier Sheet and Recommendation Summary
Client: Babak Mes

09/20/16
Date
www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group

Telephone

Telefax

e-mail
Go to Design Parameters

50KTPA Bioleach SX/EW Plant

Project Name

200-CV-08
Conveyor Reference

Go to Trajectory Sheet

Standard Loading Conditions:

Conveyor Length (m)
Tonnage Rate (metric tons/hour)
Belt Speed (m/s)
Material Lift Height (m)
Ambient temperature (C) Min
Ambient temperature (C) Max
Initial Velocity of Material (m/s)
Number of Belt Cleaners
Number of Return Belt Scrapers
Length of Skirt Zone (m)
Depth of Mat'l in skirt zone (mm)
Number of Non-driven Pulleys

37.1
110
1
1.6
-20
40
0
2
2
8
200
2

Elevation Above Sea Level

Material, fric coeff
Belt Width

REQUIRED POWER:
BELT PULL SUMMARY:
Standard Loading Belt Pull
Extra pull for Hopper (if any)
Extra pull for Slider Bed (if any)
Extra pull for Diverter or Tripper (if any)
TOTAL Required Belt Pull (Te):

Troughing Idler Spacing

Angle of Wrap**
Type of Lagging
Type of Take-up
Type of Belt

Bulk Density (Kg/m3)

Iron ore pellets,
Condition of Idlers & Pulleys

Iron Ore,

Ashes, coal, dr

Bauxite, groun

Cement, Portla

Cement clinker

Clay,
Coal, ceramic,
bitum. m

Coke, (broken
ground f
Cullet

Grains,wheat,c
Gravel, bank ru

650 mm
Fabric
108 mm
E
1.0 meters
200 degrees
Full Lagging
Manual
3 ply, 330 piw

CEMA Type

###

RECOMMENDED OPTIONS:
1. Mechanical Backstop

2.5

Idler Roll diameter

Force (N)
7,803
0
0
0
7,803

SPECIAL NOTES (if any):

1.0 Km

Belt Carcass Type

8.5 kW

2,080

need maintenance

** This parameter is for either single or dual drive arrangement.

Go to Design Parameters

Iron Ore, pul

Limestone,

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:

Phosphate
roc
Salt,
dry fine,

Power:

11 kW

Models Available:

Sand,
bank
Wood dry,
chips,

Belt Speed:

1 m/s

400, 500

Face Width:

700 mm

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY:

Power:

5.5 kW/ea

Models Available:

Belt Speed:

1 m/s

220, 320, 400, 500, 630

Face Width:

700 mm

Power savings - 1 shift and 3 shift per day:

(Motorized Pulley compared to exposed conveyor belt drives)

Condition of Idlers &

Save: 1946 Kw-Hrs/Yr, 1 shift/day or 5838 Kw-Hrs/Yr, 3 shifts/day

Save: 169 /Yr, 1 shift/day or 508 /Yr, 3 shifts/day @ 0.087 /Kw-Hr
Minimum Acceptable Diameter is 355 mm
*A smaller pulley diameter may cause belt carcass or fastener damage.
This calculation does not check pulley/belt traction.

Special Loading Conditions:

Belt Strength (lbs

Go to Design Parameters

1. For hopper feeder specify opening dimensions below.

2. For slider bed, specify bed length and type of bed material below.

3. If belt has cleats and/or sidewalls show dimensions below.

4. If conveyor has a tripper, define tripper below.
5. If conveyor has diverter(s), define below.

1. Hopper Feeder Design Parameters

Hopper opening width (mm)
Hopper opening length (mm)

0
0

2. Slider Bed Design Parameters

Slider Bed Length (m)
Type of Slider Bed Material
Slider Bed Frictional Coefficient

Theoretical Be

None

3. Sidewall & Cleated Belt Parameters:

Sidewall & cleat height (mm)
Thickness of sidewall (mm)
Distance between cleats (mm)
Thickness of cleats (mm)
Extra Sidewall & Cleat Wt (incl above)

Belt Width=
piw =

0
0
0
0
0 Kg/m

Belt Strength=
###
200 degrees
180 degrees
200 degrees
210 degrees

4. Tripper Design Parameters

Tripper length (m)
Material lift height on tripper (m)
No. of belt cleaners on tripper
Length of tripper skirt zone (m)
Depth of material in skirt zone (mm)
No. of non-driven pulleys on tripper
Estimated belt tension, Te (N)
Estimated factor, Ky

220 degrees

0
0
0
0

240 degrees

360 degrees (d

420 degrees (d

0
0
0
0.03

Bulk Density C

330287566.xlsx, Specifier, Page 5 of 10

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Rulmeca Motorized Pulley Power Calculation Program - Metric Version 5.37

Model Selector
Client: Babak Mes
0
0

09/20/16
Date
www.rulmecacorp.com

www.rulmeca.com
Copyright - Rulmeca Group

0
Telephone

0
Telefax

0
e-mail

50KTPA Bioleach SX/EW Plant

Project Name

200-CV-08
Conveyor Reference

REQUIRED POWER:

8.5 kW

BELT PULL SUMMARY:

Standard Loading Belt Pull
Extra pull for Hopper (if any)
Extra pull for Slider Bed (if any)
Extra pull for Diverter or Tripper (if any)
TOTAL Required Belt Pull (Te):

Force (N)
7,803
0
0
0
7,803

Select Model

Check Radial Load (to prevent internal

damage to pulley)
Force (N)
Maximum Allowable Radial Load
40,500
Estimated Maximum Radial Load
18,727
Selected model is appropriate for estimated radial load.
0

Check Pulley Diameter

(to prevent belt damage.)
Minimum Acceptable Diameter is 355 mm
Selected Diameter is 400 mm
Selected diameter is appropriate for specified belt.

RECOMMENDED OPTIONS (if any):

1. Mechanical Backstop

SPECIAL NOTES (if any):

(This calculation does not check pulley/belt traction.)

0

Go to Design Parameters

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:

Power:

11 kW

Models Available:

Belt Speed:

1 m/s

400, 500

Face Width:

700 mm

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY:

Power:

5.5 kW/ea

Belt Speed:

1 m/s

Face Width:

700 mm

Models Available:
220, 320, 400, 500, 630

Check Belt Tension

Maximum Belt Tension (T1)
Allowable Belt Tension
0

Force (N)
13,265
37,833

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 5.37

Design Parameter Summary
Client: Babak Mes
0
0

09/20/16
Date
www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group

0
Telephone

0
Telefax

0
e-mail

50KTPA Bioleach SX/EW Plant

Project Name

200-CV-08
Conveyor Reference

Power Calculation Summary

Return to Specifier Sheet

Calculated power to drive conveyor belt:

Drive pulley bearing friction:
Power at motor:
Gear loss in motorized pulley:
Calculated power
Derate for high elevation
Derate for high temperature
Required Power for motorized pulley:

Symbol

Value

Te
ang
Cw
T2
T1
T1 + T2
T_L
Tatype
Beltype
w
str
pstr
btr
Ai
Cs
H
Kt
Kx

7803 N
200 degrees
0.7
5462 N
13265 N
18727 N
Full Lagging
Manual
3 ply
650 mm
8445 N
35 %
8 to 14 mm
11.12 N
0.276
1.6 m
1.41
3.48kg/m

Ky
L
Q
Si
Tac
Tam
Tb
Tbc
Te
Tm
Tp

0.02
37.1 m
110 mtph
1m
4975 N
31 N
89 N
1138 N
7803 N
479 N
225 N

Tpl
Tsb
Ttr
Tx
Tyb
Tyc
Tym
Tyr
V
Wb
Wm

1138 N
2698 N
0N
1778 N
99 N
56 N
216 N
43 N
1 m/s
6 kg/m
31 kg/m

7.8 kW
0.2 kW
8.0 kW
0.5 kW
8.5 kW
0.0 kW
0.0 kW
8.5 kW

Definition of Terms

Return to Specifier Sheet

Te = effective belt tension at drive.

ang = angle of belt wrap around drive pulley(s).
T2 = estimated "slack-side tension" required to keep belt from slipping on pulley surface.
T1 = Te + T2
T1 + T2 = Sum of belt forces on drive pulley. NOTE: This is not a vector sum.
T_L = type of lagging specified for drive pulley(s).
Tatype = type of take-up specified to apply "slack-side tension".
Beltype = type of belt carsass specified.
w = belt width
str = tensile strength of specified belt.
pstr = percentage of available belt tensile strength used.
btr = thickness range of specified belt
Ai = belt tension required to overcome frictional resistance and rotate idlers.
Cs = skirtboard friction factor.
H = vertical distance that material is lifted or lowered.
Kt = ambient temperature correction factor.
Kx = factor to calculate frictional resistance of the idlers and the sliding resistance between belt and idler
rolls.
Ky = factor to calculate resistance of belt and resistance of load to flexure as they move over idlers.
L = length of conveyor.
Q = tons per hour conveyed.
Return to Specifier Sheet
Si = troughing idler spacing.
Tac = total of the tensions from conveyor accessories.
Tam = tension required to accelerate the material continuously as it is fed onto belt.
Tb = tension required to lift or lower the belt.
Tbc = tension required to overcome belt cleaner drag.
Te = effective belt tension at drive.
Tm = tension required to lift or lower conveyed material.
Tp = tension required to overcome resistance of belt to flexure around pulleys and resistance of pulleys to
rotate on their bearings.
Tpl = tension required to overcome belt plow drag.
Tsb = tension required to overcome skirtboard drag.
Ttr = tension required to overcome special loading condition(s.)
Tx = tension required to overcome carrying and return idler friction.
Tyb = total of tensions due to resistance of belt to flexure as it rides over carrying and return idlers.
Tyc = tension due to resistance of belt to flexure as it rides over carrying idlers.
Tym = tension due to resistance of material to flexure as it rides over carrying idlers.
Tyr = tension due to resistance of belt to flexure as it rides over return idlers.
V = design belt speed.
Wb = weight of belt per unit of length of conveyor.
Return to Specifier Sheet
Wm = weight of material per unit of length of conveyor.

330287566.xlsx, Design Parameters, Page 7 of 10

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Rulmeca Motorized Pulley Power Calculation Program - Metric Version 5.37

Conveyor Height Calculator
Inclined conveyor length (m)
Angle of inclination (degrees)
Material lift height (m)

100
18
30.9

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Copyright - Rulmeca Group

Return to Specifier Sheet

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 5.37

Bulk Handling Belt Conveyor Terminology
www.rulmeca.com

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Return to Specifier Sheet

Conveyor Profile

Copyright - Rulmeca Group

Return to Specifier

Conveyor Cross Section in Skirt Zone

Initial Velocity of Material

Return to Specifier

Belt Conveyor with Tripper

Return to Specifier

Return to Specifier

Hopper Feeder Conveyor

Return to Specifier

Cleated Belt with Sidewalls

Return to Specifier

Belt Conveyor with Two Diverter(s)

"CEMA" Idler Type Definitions

Return to Specifier

(Based on Conveyor Equipment Manufacurters Association Manual)

Belt Width
Idler Type >
Idler (deg) >
460
610
760
915
1070
1220
1370
1525
1830
2130
2440

A
35
136
136
127
116
-

20
136
136
136
125
-

45
136
131
122
112
-

20
186
186
186
186
177
172
-

B
35
186
186
186
186
165
160
-

45
186
186
186
180
159
155
-

Idler Load Ratings* (kg)

C
20
35
45
408
408
408
408
408
408
408
408
408
408
380
367
386
359
347
363
337
327
340
317
306
318
295
286
-

20
544
544
544
544
544
544
522
476
-

D
35
544
544
544
544
544
506
485
443
-

45
544
544
544
544
544
490
469
429
-

20
816
816
816
816
816
816
816
816
816
794

E
35
816
816
816
816
816
816
816
816
759
738

45
816
816
816
816
816
816
816
816
735
714

*These ratings are for three-equal-roll idlers and are based on a 30,000 hour minimum
BU bearing life at 500 RPM. BU bearing life represents the statistical point in hours where
a minimum of 90% of the bearings will still be functional with no increase in torque or noise.

Return to Specifier
Return to Trajectory Sheet

Material Surcharge Angle Guide

(Based on Conveyor Equipment Manufacurters Association Manual)

Surcharge
Angle

Angle of
Repose

Description of Material

0 to 19

Uniform size, very small rounded particles, either very wet or very dry; such as dry silica sand,
cement, and wet concrete.

10

20 to 29

Rounded, dry polished particles, of medium weight, such as whole grain and beans.

20

30 to 34

Irregular, granular or lumpy materials of medium weight, such as anthracite coal, cottonseed
meal, and clay.

25

35 to 39

Typical common materials such as bituminous coal, stone, and most ores.

40+

Irregular, stringy, fibrous, interlocking material, such as wood chips, bagasse, and tempered
foundry sand.

30

330287566.xlsx, Terminology, Page 9 of 10

09/20/2016 07:33:56

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 5.37

Bulk Handling Trajectory Calculator and Plotter
(based on CEMA 5th Edition)
Client: Babak Mes
0
0

0
Phone
Project Name
Conveyor Ref.

www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group

0
Fax

Return to Specifier

50KTPA Bioleach SX/EW Plant

200-CV-08

System Design Parameters:

Belt Width

Material Trajectory:
Small Pulley (scale: 75 mm/increment)

650 mm

Belt Widt

Troughing Idler Angle

35

Pulley La

Diameter Pulley (mm)

516
mm
500

Lagging

Lagging Thickness (MM)

8 mm
8

Belt Speed

1.03 m/s

Surcharge Angle (degrees)

25 deg.
25

Tonnage Rate (MTPH)

Actual Be

110
2,080

Material Density (Kg/m3)

Belt Thickness (mm)

Distance to Chute Plate (mm)

700

Angle of Conv. Inclination (deg)

Alternate Belt Speed (m/s)

0
1.4

Print This Sheet

Go to Large Pulley Sheet

Go to Overview Sheet

Calculated Results:
Calc'd mat'l height at centerline
Calc'd actual height of C.O.G.*

64 mm
26 mm

Calc'd actual mat'l cross section

1.4 sq m

CEMA Max Allow. height at center

107 mm

CEMA Max Height of C.O.G.*

43 mm
4.1 sq m

CEMA Max Allow. cross section

Design Trajectory - solid red line; Alternate speed - dotted blue.

Surcharge angle (deg

Tonnage Rate (metric tp
Belt Speed (fpm)
Material Density (kg/cu
Area A (sq ft)

Mat'l Cross Section at Pulley Face:

Small Pulley (scale: 75 mm/increment)

Pulley Diam Lagged (

Pulley radius Lagged (
Belt Thickness (in)
Radius to Belt Top (in

Note:
This program uses actual C.O.G.* height above
top of belt (based on actual cross section) to plot
trajectory. Height of C.O.G. for CEMA
max. allow. cross section is given for ref. only.

Design Cross Section - dotted red line; CEMA max allow. - solid black line.
*C.O.G. = center of gravity of material, shown as and

330287566.xlsx, Page 10 of 10

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