Design Guide ast Horizontal Conveyors — Basic Design foo Engineering Guidelines, Ezition 104 - 101 Modular Belts typically change their length under varying operational conditions of temperature and load. The extra belt lenath is accommodated by providing en unsupported section of the retumn way for catenary sag (calculation of catenary force see also page 127), The design of the conveyor frame is dependent on the total belt length. A screw take-up is used on the idler shaft for initial adjustment of the catenary sag only and not for adjustment of the belt tension. Short conveyors (maximum 2 m (6 ft) In this case belt support on the return side can be omitted. Screw type take-up (TU) can be necessary for adjustment of catenary sag. Observe perfect parallel alignment of shafts Medium length conveyors (2 to 4 m (6 to 12 ft) Common design; belt on return way supported by slider frame (SR) or wear strips. Rollers (R1) can be used as well. A catenary sag near the driving sprockets is sufficient for maderate temperature changes, Long conveyors (over 4m (12 ft) Longer lengths and greater temperature changes y e— fequite more than one section for catenary sag. Special concern to vary the roller spacings over long conveyors, Admissible speeds of long conveyors: 900-1200 men | 560 rm (548) (s'45') “Yno-20) [up to 15 m (45 fy 50 m/min (750 fvimin) 18 = 26 m (45-757) | 30. m/min (90 f/min} ‘over 25m (757) [18 mfmin (45 foi) Gravity take-up For heavily loaded long belts anc/or high speed the catenary sags may not sufficiently tension the belt to prevent sprockets from disengaging. In such cases the gravity take-up (G) can be an adequate solution, Recommended tensioner weight: ‘andO.5' | 15 ko/m /10 ibyfe) belts [30 kgim (20 ibeDesign Guide fade Horizontal Conveyors — Drive Concepts HabgsiLINKe Engineering Guidelines Common head drive - Slider support on return way, or rollers alternatively + Uni-directional drive One motor (M) at conveyor end, pull action (driving sprockets are pulling the belt). Catenary sag (CA) only required on drive end (see also page 127). + Bi-directional drive Two motors (M), one at each conveyor end. Only ‘one motor is pulling, the other motor remains disengaged (clutch). Catenary sag (CA) at both conveyor ends. Bi-directional center drive Only one motor (M) placed in the middle of the belt retum. This system works well for bi-directional conveyors. In case of high loads a gravity take-up may be necessary for positive sprocket engagement. 00 | 1200 mm Optional solutions: pneumatic or spring loaded (gov ee) | | tensioning device. Since the driving force is applied on the return way of the belt, the shaft load will be two times the calculated belt pull Bi-directional head drive (push/pull action) f It is possible to apply one head drive motor for bidirectional reversible driving. For reverse driving (push action = pusher conveyor} the belt tension on the return way is 1.2 times higher than on the carryway. A screw type take-up {TU) or a pneumatic tensioning device is recommended. The shaft load will increase to: Support rollers and backbending diameter [[Balttye= mn] diameter Term = [atarnetar for oravity take-up] Face oaser ‘support rollers and center drive rollers sliding shoes for elevators _ idling rollers | RA min.) R2, R3 (min.) | SH (min.) Uimin) mm | inch mm_| inch mm | inch | mm | inch Serie M1200 50 2 7% | 3 150 / 2501 ye? | 0.72 50 z yoo | 4 150 / 2501 4016 “50 | 2 “to | 4 | 180/250" 16 100 4 150 | 6 150 / 250° 60 | 24 i004 160 | 6 180 / 250" [80 | 35 1 As large as possible; with sideguards min. 2 Nosebar transfer. In case an idling roller (U) is radius 250 mm (109 used in place of sprockets, a minimal diameter, is necessary. “Edition 104 - 102Design Guide Elevating Conveyors For the design of elevating conveyors the following basic rules have to be considered: M_ The driving shaft must be located at the top end of the conveyor or in a center-driven design Slider supports on the tansport side with parallel, serpentine or chevron wearstrips. Slider supports are preferred. For the majority of elevating conveyor applications, ‘lights end/or sideguards are used. In these cases belt edge slider supports are necessary. Belt with flights wider 600 mm (24’) have to be carried in their middle by a siider support strip (parallel or serpentine). (Fig. below, section x - x). Catenary sags follow the seme working principle as for horizontal belts but are positioned at the lower end of the belt {see also separate design recommendations) The radius of hold down and support shoes has to be 2 150 mm (6’). The radius should however be selected at the largest possible. For belts equipped with sideguards the minimum shoe radius (beck bending radius) has to be 250 mm (701) Since inclined conveyors are often heavily loaded, the catenary sag (CA) may not provide sufficient tension for safe engagement of the Griving sprockets. Therefore it is recommended to install a screw type take-up belt tensioner (TU) at the lower conveyor end (idle shaft U). For large temperature differences, a gravity take-up may be advisable. ST SR SF cA SH Tu fas HabasitLINK® Engineering Guidelines Edition Q104 - 103 Example of a straight inclined conveyor Ie 900 mm — 1200 mm (35° - 48") ‘SR For flighted belts the slider support on the return way can be equipped with wear strips at the belt edges [see Fig. below, section x-x). Example of inclined conveyor with horizontal end sections Ie 900 mm — 1200 mm (35"- 48") If the length of the horizontal section is longer than 1200 mm (487, slider supports are recommended, SR For flighted belts the slider support on the return way can be equipped with wear strips at the belt edges (see section x).Design Guide oo HabasitLINK® Engineering Guidelines Elevating Conveyors Backbending on elevators (Z-conveyors) b) Z-conveyors with center hold-down devices Elevators are usually equipped with flights. Therefore Hold down devices are available for 1" end 2° belts for backbending of Z-conveyors hold-down shoes (see also Product Data Sheet). For belt widths larger (SH) or rollers are used at the belt edge only. Ahold 2 m (80") two tracks are recommended. For guides down device in the center of the belt, acting from the _ use steel strips with HDPE lining or similar. top, is only possible by leaving a gap in center of the Min. back-bending radius R = 250 mm (107). flight row. In most cases this is however not possible oF not desirable. The belt tension creates lateral bending forces in the backbending grea. Degending on the load and the stifiness of the belt, wide bolts may tend to buckle. Solutions and recommendations: TTI a) Z-conveyors The applicable belt width without hold down device in the middle of the belt is limited. The limits are depending on the following criteria: © * Length of belt before backbending * Load on belt before backbending © Type of belt (belt thickness, module length, lateral belt stiffness} * Inclination angle & — The precise calculation of the allowable belt width == would be very complex. Therefore a simplified fikaoueais © ld doen ahoe general rule for dimensioning and design of the in bot center on belt edge conveyor frame is provided: 2? belts beltload | belt load | belt load <50% | 50-100% | <50% 05" belts belt load | belt load < 50% | 50~ 100% 1500 1000 7200 1000 700 (69) 39) (a7 (39) (28) 1200 ‘800 100% 800 500 jonger sect. knot recommended) (a7) (32) (39) (32) (20) Edition Q104 - 104Design Guide Elevating Conveyors Catenary sags for elevators For proper engagement of the sprockets on the drive. shaft (drive at discharge end, the belt must be kept under tension when it leaves the sprocket to the return side (back-tension). This can be achieved by a catenary sag of 900 to 1200 mm (35 to 50") length. The position of the catenary sag is depending on the inclination angle a, friction value between belt and return base and length horizontal sections. If the inclination angle exceeds a certain value, the belt will slip on its base downwards towerds the lower end. in this case the catenary sag needs to be installed at the lower belt end, This is the case for the majority of the inclined conveyors. It is possible 10 specifically calculate this critical point for every conveyor design. In most cases it may be sufficient to follow the rules below. Catenary sag on the lower conveyor end Condition A: le 2 900 mm (351) and |, < 900 mm (35') (must always be fullfilled) Condition 8: [angle a I >16 >I2 >20" In cases where |, < 900 mm (35%, or above condi- tions for the inclination a cannot be maintained, no catenary sag on the lower end is recommended. In this case maintain |, > 900 mm (35% and place the catenary sag on the upper end. For all other cases contact the Habasit Representative. Standard conception: Catenary sag on lower end haosD HabasitLINK® Engineering Guidelines Edition 104 - 105 Elevators without catenary sag On Z-conveyors catenary sags may not be accepted, neither on the upper nor on the lower horizontal belt section. This may be due to lack of space under the bottom conveyor end or too short horizontal sections. A tensioning device with fixed adjustement to the belt length as shown on the illustration above is not acceptable, since wear and temperature variations cause the belt length to change. it must be strongly recommended to use a selfadjusting tensioner device. This can be a soft spring type, gasloaded spring or pneumatic tensioner type. ‘The optimal lay out of the spring or pneumatic cylinder is depending on the belt type, conveyor width and temperature conditions. The minimum free movement of the tensioner must be min. 20% more than the calculated belt elongation between lowest and highest process temperature. The force should be as low as possible, but high enough to overcome eventual friction forces of the belt on its return way, ‘straigthen it and engage the sprockets safely. As a general rule the following tensioner force is proposed: | for 2" batt 30 kg (20 Io) {or 1.5" radius belt | 30 kg (20 fb) — for 1" and 0.5" 15 kg (10 fb)Design Guide Radius Belts Basics Radius belts create a pressure against the guide in the inner side of the curve. At the same time they tend to lift off from the support on the curve outside. This tendency increases with rising tension, increasing speed and with increasing angle. Therefore the design of radius belts require special attention to the following rules. R_ The minimum inner curve radius R is defined by the collapse factor Q of a particular radius belt: Q depends slightly on the belt width, see table below; typical values are: For M2540 and M3840: Q = 2.2 | For M2543: Q = 1.6 For best running conditions it is advisable to design the curves R of the conveyor near to the minimum radius. lo For proper tensioning of the belt in operation it needs a catenary sag. For this reason the belt section lp behind the driving motor must be straight on a length of preferably 1.5 - bo with a minimum of 1m (3 ft.). For different require- ments please contact the Habasit Representative. |, Aminimum straight section of 2 x belt width (2 - bo) is required between turns in opposite directions. No minimum straight length between curves of the same direction. lz At the belt end, near the idling shaft, a minimum straight length of 1.5 - bo is required. Collapse factor It is typical for the design of radius belts, that the collapse factor is smaller for very small belt widths be and increases until it is almost constant above a belt width of approx 1000 mm (40’). The accurate collapse factor for Habasit Radius belts can be calculated as follows: Quinte and K are typicel values for each belt design. rection of movement lB HabesitLINK® Engineering Guidelines Ezition 0104 - 108 +4 2at | 200 | 250 | “300 450 | 500 | 580) 600.) 650 | 700 | 750 | ete. ei 10) 12 7eh 20) 22) 26) 26 | Sete. 03 2.07 210) 212 | 214 | 215 | 216 | 217 | 218 | 218) 220 | etc 4.37 | 1.43 | 1.47 | 1.50 | 1.52 | 1.54 | 155 | 1.56.1 1.58 | 159 | 159 | 1.60 | etc 1.90 | 1.98 [2.03 [2.06 | 2.08 | 2.10 | 2.12 | 2.13 | 2.14 | [215 [2.16 [2.17 | 2.17 | ete. | aa 2t2 | 222 2.30 | 236 2.44 | 2.48 | 250 | 263 255 | 256 | 258| etc.Design Guide Radius Belts Hold down tabs Radius belts running around curves are radially pressed against the inner guide rail of the curve. Since the conveyors usually cannot be built at very high geometrical accuracy, the belt may tend to flip over at high loads or angles > 90°. At the inner edge the belt may move upwards while it is radially pressed against the guide rail and slip off. For this reason hold down edge guides must be used for the in- and outside guide of a curve. If the product is larger than the belt width or if side transfer over the belt edge is required, hold down tab modules are used instead of hold down guides. See also Product Data Sheets. Standard application (hold down edge guides) If no side transfer is required, L-shaped hold down edge guides can be used. Respect the min. gap between belt and guides. For sefety reasons (danger of injuries at end of profile) it, is advisable to apply this profile uninterrupted over the complete belt length. The material used for edge guides need to be low friction in contact with the particular belt material. Generally UHMW PE can be recommended. On the return way hold down tabs are needed as well. An economic solution is shown on the illustration beside. Also hold down edge guides can be used as for the top side. transport side i i 23 _wearstip oe 23 belt min 2-3 rz) | te Hi (0.12") ft | 8 return way | Hold down guides for belt with flights. Belts without flights follow the same design. HabasitLINK® Engingaring Gaceines ws Belts with hold down tabs (hook modules) Belts with hold down tabs are used for all applications where products must be moved transversally over the belt edge (side transfer). The use of hold down tabs is also conditional for the application of sideguards (see also Data Sheet sideguards in this manual) Note The hold down tabs should not be used for radial guidance or to support (guide) the belt on its return way. They can be worn away too quickly. min 2-3, min 2-3 (0.12) (0.124) transport side 7 mint.5 = (0.08!) wearstrip min23 0 min 2-3 Lotz) min 2-3 _(0.12') High speed applications For speeds > 40 m/min it is recommended to use prelubricated materials for radius guides. To keep the temperature low, prefer guide material with best possible heat conduction properties (eg. PA prelubricated). For further information and other dimensions see Design Guide Slider Support Systems.Design Guide Sprocket Evaluation HabeceNK® Engineering Guidelines Edition Q10¢ - 109, Dimensional requirements for installation - ‘C= belt pitch si slider support Number Polygon | Pitch dp | Art mm ‘Ao #1 mm (effective) oftesth effect (effective) Standard Special belt types thickness mm inch | mm inch | mm inch mm inch mm inch mm inch | mm inch 10 161 063 | 261 1.03 t 15 2671.05 | 36.7 1.44 ~ 7 24 45.11.78 | 55.1217 I 28 538 212 | 638257 —— 36 70.4277 | 804 3.17 a 247 097 | 347 137 | 357 141/372 1.46) 98.7 1.52 | 40.7 1.60 8 112 181 393 1,55 408 1.61/42.3 167) 44.3 1.75 io 143 | 463 182 473 1.86/488 1.92/60.3 1.98 623 206 2 (448 1.74 | 543 214 $532.18 568 224/683 2.50 60.3 2.97 18 60.4 298 | 704 277 9 287| 744 293) 764 9.00) 18 6842.69 | 784 3.09 | 809 5.19) 824 3.24 | 844 2.32 20 785 3.01 | 865 3.47 89.0 3.50) 90.5 3.56 | 92.5 2.64 [247097 | 35.7 141 374 147 23412 | 383 1.55 (413 169/410 162 "9831.49 | 47.31.86 [49.3 1.94/490 1.93 853218 |873.226|570 224 60.4 238 | 70.4 2.77 |73.4 2.89 71.4 281 684269 | 73.4 379 |@14.920/811 319; 7653.01 | €75 344 | 095 2.52|092 351 e 4201.65 | 60.0 2.96 | 630 2.48) 12 “6602.60 337 [870 3.48 16 901385 | 108.1 4.26 (11.14.37 134% | 102140 | 439 1,70 | 500 292 |602 257 | 7472.94 | 759 2.99) “[oa3% B05 367 [318.367 34% [197278 | 908 9.57 | 1066 420 1078474 19% | 2615 103 [122.7 449 | 1987 6.46 199.9 557 671 264, 827 326) [986 388 42.2 6.60 1468 5.78Design Guide Sprocket Evaluation Design recommendations ‘The correct adjustment of the belt support or shaft placement (Dimension A1} is important. Excessive noise, increased sprocket wear and engagement problems may result if the recommendations are not followed. Standard solution Gzbenpich Straight support guides are low cost and simple to | a produce, | The distance C between belt support and wear strip | allows the respective link row to adapt its position to t ‘the up and down moving sprocket circumference {polygon effect). Take care that guides do not touch ‘the sprockets. Optional For smoother belt run and best load support and ‘transmission at belt end it is recommended to bend the weer strips as shown. Take care that guides do not touch the sprockets. = HabasitLINK® Engineering Guidelines Edition Q104- 110 slider suppor Ay 1 Ao)Design Guide Sprocket Evaluation Sprocket installation, general oo {see also Product Data Sheets} re HabasitLINK® Engineering Guidelines Edition Q104 - 111 In order to allow the belt to expand/contract, only the (Tl rt center sprocket on each shatt is fixed. For shafts with 2 sprockets, the sprocket on the drive side is fixed. Various locking methods are possible: | sacar * Set screws and set collars _ _| Mainly used with round shafts on key-ways Type: Set screws and set collars Retainer rings For square shafts (no key-ways needed} + Retaining plate There should be @ gap of 0.3 mm (0.07') between simple low cost method for square shafts | I ; © sprocket hub and retaining device. All devices must be securely fastened, | retainer ring (circlip) Type: Retainer rings plate Type: Retaining plate Tracking of M5010, M5011, M5013, M5014 : taining ok The molded standard sprockets are tracking the belt, Welainina bins leaving some transversal clearance to the belt (approx. \ + 2.5 mm (0.107). This is of advantage in food sprocket applications with very critical cleaning requirements, g_ in the meat industry. For other applications it might be desirable to reduce this clearance in order to provide accurate tracking performance. The most ‘common way to do this is to use a pair of center | sistance ol sp sprockets instead of one only. These two sprockets are both located on the shaft in a fixed distance by ‘one center fixing plate of 20 mm (0.791) width Top-side drive for Spirals In exceptional cases spiral applications may require to drive the belt by engaging the sprockets from the top side of the belt instead of the bottom side. In this case specially adapted sprockets are needed. Such sprockets are available for M2540 and M2543, but not for M3840. For specific information please take contact with Habasit. 20-- 1mm rocket hubs