SI (METRIC) UNITS Introduction Units of Force Useful Tables Frequently used Conversion Factors Comparison of Belt Tensions Comparison of Belt Tensions A in OTeTIw SIiNIntroduction Units of Force The Engineering Conference of The Conveyor Equipment Manufacturers Association carefully considered the possiblity of incorporating metric units into the 6” edition of Belt Conveyars for Bulk Materials. It was the Conference's decision that the 6* edition would be prepared in English units, Thete are many canversion programs and publications available for the understanding and use of $1 units, The reader is referred to IEE/ASTM Sl-10 Standard for the Use of the International System of Units (Ss The Modern Metric System as a reference. Appendix is presented as an abbreviated guide relevant to belt conveyor calculations. While a belt conveyor system is composed of many important parts, none is more economically important than the conveyor belt itself, which, in most cases, will represent a substantial pat of the intial cost. Therefore, the selection of the conveyor belt must be made with great care. In general, @ conveyor belt consists of three elements: top cover, carcass, and bottom cover, Figure 7 illustrates a cross section ofa typical belt. The primary purpose ofthe covers is to pratect the belt carcass against damage and any special deteriorating factors that may be present in the operating environment, The belt carcass cartes the tension forces necessary in staring and moving the loaded! belt, absorbs the impact energy of material loading, and provides the necessary stability for proper alignment and load support over idlers under all conditions of loading. F=Mxa m= 8 a= fsec? (acceleration) = 32.2ft/sec’ (acceleration due to gravity) W=Ibs (weight) Reconciling the units: The basic unit of force in the SI systems the newton, N. By definition 2 newton isthe force required to ‘accelerate on kilogram by one meter per second per second. Any expression for force in nevtons must have the units of kg-m/sec:, To calculate belt tension in SI unis itis necessary to express all of tl component values of tension in newtons, N, and weight in kilograms, kg, and linear measurements in meters, m, The derivation ofthe unit of force in SI units is as follows: F=Mxa a=mysec’ (acceleration) g=9.8 m/sec? (acceleration due to gravity) M=kg (weight) Reconciling the units: F=Mxa= (kg)x(mvsec”) = kg-m/sec” (defined as 1 newton, N)Useful Tables le. English ‘st Frequently used Conversion Factors able A. Comparison of Bett Tensions Tcleration dus Ww i t a 7 Tore Tenath velo mass per length Tae velocity ass per Tenth a7 Reet or gt Te abe 0.3088 288 cng 2.0929 745.69 5000 8.000 353586 9,900 ron 1,009) 2248 dB 20,600) 496 38.966 x Gas T3446 20.5 R992 42,0001 7928 ss 31261 0001 223,480 300,000 r 355.556 rewtona logan, Fe Klogram/ieter gin metersfoe m/s watt English pounds force BP bs haf velocity. fmm mass per length bal acceleration, Rise 2168, volute TorsepowenUseful Tables Cont. fable As “20000 m/s = 196.85 fpm ost m/s Comparison of. nis mm nla Belt Speeds to W on 15 205, 108 25 203 30 254 35 3.05 40 356 45, 428 5 457 55 5.08 65. 20 75. Ta Bo. 7. 85. 833 9.0 B64 35, 934 130 35APPENDIX NOMENCLATURE Basic Units Chapter 2 Nomenclature AUNLVIINAWO Chapter 3 Nomenclature Chapter 4 Nomenclature Chapter 5 Nomenclature Chapter 6 Nomenclature Chapter 7 Nomenclature Chapter 8 Nomenclature Chapter 9 Nomenclature Chapter 10 Nomenclature Chapter 11 Nomenclature Chapter 12 Nomenclature Chapter 13 Nomenclature Chapter 15 NomenclatureBasic Units all Chapters Chapter Two Basic Units Used — a Nomenclature is presented by Chapters because some terms are used with different meanings or units depending upor the context if there is 3 doubt over the description between the Nomenclature Appendix and the Chapter use the meaning based upon the context ofthe Chapter Those chapters with out specific calculations ar diagrams requiing explanation of terms are omitted from this Appendic urement Saber Description eceleration z Acceleration veto giaiy 322 eee ‘Angular measurement eg Degrees Angular measurement rad Radians Aiea i Squave et rea i Squaveinches ‘capacity ‘oh Tous per hour Goo If Foe ar weight bf Pounce ores Length or distance in Taches Length or distance fi Feet Power fe Pressure si Pounds force per squareinch Rotational Speed om Revolutions per minute Temperature oF Degrees Fahrenher Time Ti inutes Time ae ‘Seconds Time br Hout Velocity i Feet per minute Volume i abi Teet Tehaptera Symbol | —Deeciption “Ceara a Pulley Replacement Bitessing jon 8 idler Replacement Primary Sa Belt Wid, 39 nmi. C idler Replacement Seeonday side fa Belt Width, 24 in D Clearance Under Conveyor foi cleaning 2a inches E Bet Cleaner Sevvice — Renewal Belt with F ett Cleaner Service ~ Inspection Welghe 248. mia. oS + MDa © Personnel Passage. 30 nches x ‘Kiet Board Replacement Weght ewes Binches T STi Boare Adjustment inches r Personnel Access Opening HER Bu inches K Petsonnel Access Opening Width 24 inches L ‘vethead Clearance 8 inches mW Primary Belt Cleaner Location Concule Ranuaeturer OP Secondary Bet Cleaner Location Consult Manuracturer Ge Tertiary Bel Cleaner Location Consul ManuFacturer s Inepeetion Height Above Work Pliform 24 inches Ti Retum Belt Cleaner (Plow) Consult Manufacture v Dibble chute to Pulley clewance ie inehee 7 Bet Repair Area 2x Belt WaT wo RomChapter Three Khapters sae [beep Nomenclature B Tiler wing rol ncination ee) 9 | Baik Density Tonite [rar] Adhesive stress between bulk material and conveyor bel (OTT Bar icine -= decline] ® A ® ofthe bulk material (eg) or ad ae nlers 5 tatio expressed % Equivalent Fitron between bulk material and conveyor belt imenstoniess Tength of bet on center ole fy contactwith the mater Gn) Lengt af wing roller in comtact wth the belt el with in Length of bet elge without Buk wae Oa) Least of belt on wing roller in contact with the Acceleration due to gravity 32. hse axinum height ofthe balk sold onthe bel Teer spacing Maxinum bet speed before bulk sold sips on an inclined af dechned belt pm efore bulk solid spills on-an inclined of declined belt fom Maximum bet Chapter Four Chapter 4 Synbot_[ Deseo EE Nonendatie A actor used Tor salina the caluaton of a menstonies) Total matenalioeeeactonal aes secon design ereria i") Re__|- Gross seston area based onthe surcharge angle wih creular tp surface QB) fe Total Cross sectional aa loose profile based on angle of repose () fa Total rose eestional area skirted prof ry 1 factor used for singling the calculation of Az imensTonies) be ato of upper surface of bet above center dimensionless) ba ‘Arato of the material depth tothe bat width (dimensionless) 5 ato of upper surface of ble above wing rll= Dye Bae = £PE (dimensionless) a ar Tee ato of upper surface belt cage above wing rol iensionle Dow ato of surface bale ith materia contacto it above wing ol (nenaion=) n 2 factor used for spline the calculation of (ven iaximum depth oF matetal prole_Un) ign eapacty intone per hour (3h) Gpaxity ata00 pm GPF Ratio of effective radius of he top surlace ofthe materia based on angle al vepave compared to the belt width (imersonless) to Rao of elective rads of he top surface oF the materia based on Sucharge angle compared to BM, belt width idimensioriess) pacity design foctr for elucing the design Belt speed Gb ath between kit Troughing angle Gad or eal Bulk density of he material (O/T) =" ale of repose (a) or eB) a | Surcharge angle fea) or ee) Teter ‘ations (lmensontess)Chapter Five hapter 5 Nomenclature Bs (CEDIA ler Class org eh Aaveter Toles for bel 18 Wvough 48) Bs (CEDIA ler Class for 5 inch alareter oles for belts 18 through 48 fn) Ey Bekewiath tn) G ‘CEA ler Class ora oh daneter oles for bets 18 Hhvowsh AB 00) G {CEA Idler Chess org neh dlareter oles for belts 48 through 48 tn) Tee cen ler hss ors nch dometer ers fr bets 2a trough 60 Or) TET Greate ater food (1 Teal return air fod es (CENA ler Class for sich Alareter les for bats ay rough 72 OD veter roller for belts 24 through eer rollers for belts 36thvough 96 8) eter rollers for belts 36thvough 96 8) ier Spacing Facto (mensions) F Impact force Wu) Fe ea der € iB der Alder 56 ro ch eer rollers Tor bls Gohwough oe) for inch dlreter ral efor inch dneter rll for belts 6o through belts Goto Unit inact force dee for selecting lars (et) H Drop Reishi) TAL idler misalignment Load (60 ee ce @ Effect of oad on predicted bearing Me, (mensionless) 13a Effect of belt speed on predicted bearing Lx ie (dimensTonless) 16, Effect of ol dameter on predicted beating Le ie (dimensiones ny Effect of maintenance on pedicel bearing Life (dimensionless) Ket et of environment on predicted beating Loli (i Ka fect of trperature on predicted bearing Ly Life (dimensionless) Te Number of eparatinghours at 500 rpm that 99 percent of a papulaion ofa certain type oF bearing at a stated lod will tain or exceed before failure th) T Bel Tenston Us) T Bel tension carning ade TON) TT retttension return side (A TT tessin belt speed rm Weight ofa np Ob Bele weight WHR we ‘Wieghtof amp tines th drop helene Ta (TRY ment oF erin ef eating pats (bin?) (ax 2000) 604) HTTChapter Six LT Nomenclature E we wi, 3a Gi Tiler woughing angle ee) recive total deviation hom perpendicuarto beta Expected average instalation devia Ferenced rom center ellto perpendicular to ba wavel nh Erective misalgnment dve to intentional nchnation of ler fame &, Equation 632 On) | — nfo or average angle afncline ) ardeclie () in ahecton afmmovement aver he Hehe length Leah Intentional inclination of ler frame or wing allio din bat acking AD Belt wrap on pulley a per Figure 659 (adlans) ie angle Gea) | Positive (AT inveases tension snd negative () AT duces tension inthe diection af bale motion [Tension vais we rouse speed change) = = fom vsco-lastie deformation ot bok UO Tensioner aTyrequired atthe new spore [nti as befre the speed ehange WH) jue to potential and Kinetic energy = y+ Tn (HF. [Temporary or wansient active tension provided by the dive WD oe vansent iF ia fight nom ignment of gavand idler fl pt [change in bet tension tik orlawer the maveralandbet Bs Tension Toss Fom ler msafgnment (UD) Change inter Tain resistance [Main resistances = An AT Tans Av Aloo Tan See Aw for High) Tension change de to hulk mateisle moving beowesn the er (Bh Teasion change in ight or pulley a UDF [oat change in belt tension to cause steady Daspeed Total tension 15s rom wale resistances Might per ier TOD Teen Tension change due to pulley bea 00) [Tension change dveto bet bending onthe puley BCS Drag due slider beds 0b [Tension change due to bulk material sdingon sitboaris(H oH [Tension change veto the belt slang on skinboardseal Bd Change i belt speed GUND Change a belt velocity dun Tine nenalt Gan | Bverage cotenany belt 9g for fightin as a percentage ofthe Wer spacing percentage ofthe Wer spain [-Vericat drop between ers forfigntn Sliding Fiction factor between belt and the cleaner blade dimenstonless “ling Hetion coeFcent enueen Beltane be een sine) Acceleration (R/seca) fectve [effective misalignment due to manutactuing © [constant coefficient used in rubber characterization equations pei 628 Wimensionless) ation equations pe 6 ice Debween idler support points fa the direction of belt with, Refer to CENA Standard Dist 592, most current edition. i) Beltre Wing all enath Ga Trction asses subscript [constant oeicientussd in rubber araetevastion equations per G36 Mimensonless) jon equstione per 38 mension elt wth i) [Fiction variables fr siding Wiclon between conpanents Gimensionless) Function in Equation 6.8 linensiones mensions) Funetion in Equation 6.48 (mension [Frictional resistance om belt movement under cleaner pressure (Bay) Friction factor for sing between bel and cer material (dimension es)Chapter Six ___ Nomenclature Tin Design factor fr fetinal reststance due To ier misalignment (dimensiones) cw Idler rotating resistance load fctor Table 6.2 (dimensionless) Coe Fictional resistance fom garland idler self algnment (dimensionless) a | Skirboard Fition Factr(dimensionles) te ‘Sider Bed Sng ction Factor, Table 6.36, @mensionless) te Frictional esstance co the belt movement (DID Te Tr Pater ora foctor Gimensiote yes! dimer Depth af material siding on the siboardper igure G0 WW) Paley diameter Roll diameter ta) Base af naperion logarithms = 2738 [Rubber siiness propenty Table 285) SSS Longitudinal belt modulus fin) em “Average risalgnment filer axis to belt lngtodinal axe (ai Belt modulus (bind Efcency or power loss between dive and bel imensioniess) Eternal oad affecting AT units as needed r Coefficient of fiction betwen pulley surface and bell suiface (dimensionless) Fun | Efestvenovmal force between beltandeleaner (bin) t “anspor efcency elective fiction factor calculated by the change belt Tension per unt Tenth Alvida bythe combined weight of bulk mater, ele and idle ol per unt length (dimensionless) Fe | ectie normal fore between baltandeeal (BF) [Acceleration of giavity = 322 see) Belt cover tick Vertical iy dretion) of Right Teer late ction Ineeaseubecinte i Tndes foreach individual otating component indudng dive components (for pales) | TK Fron variables for internal energy toss (imensionless) Trig istoetasic characteristic of belt cover rubber Eavation 6.29 imensTonles) Radive of gyration of aflat round plate Seal torsional resistance per ol at s00 rpm Tale x9 00x Temperature carection fctor per Eauation 68 (dimensiones Torsional speed effect Table 9 ibm) i | ler rsietnes facto imensionlas) SSS Ke | Beit Resistance Factor imensioniess) t [Total conveyor path length, tailtohead MS le Dri distance | ret Tengih ofthe bal Ty rn TTengthofapartcuar conveyor segmentorfighen ri Bulk Tieton lated nzeessubserints | number of bet cleaners in fight n (dimensionless weno ed total conveyor TF ator nthe caleulation of wih a vale oF or 2 inensTonl m7 aerial ascharged during stopping (ons) | The subscript refers to one in a series of fights and pulleys making up an ene conveyor, Iypclly referenced fom the til pulley groaressing inthe dvection ofbelt movement Tension subscripts, relate to particular dive or bake pulleys [Bubscripts oa = 8 ted by commas for multiple dives i=. Tet umber of ols pr lle set (dimensionless) Tinear power seen by the bela pulley np) ini Far power fequed ofa cive component fo pulley nha) Be ver indentation parameter (dimension es)Chapter Six ET i Nomenclature a Tate weight or force uns Con hour or 1p ® ‘Speed reduction ratio (imensionles Correction betiveen actual 535 Jimensioniess) auton 6a, Resultant radial ld (vectors af belt tensions and pulley weight of pulley (bh) Lew ini ruler for posible wer belt uber Indentation resistance Tew nie ruliper fo possible ner der misalignment ora, Paley drag can vay 1 R= 0.67 (menstoness) Paulie for posibe lower material trampling loss due To bel sag Tow init rulipe Toe possible ler slider bed ion Low initrnliper for possible over skitboard drag Low nit riper for skit seal dag iimensionl Low mit rule form whee mc efers to vorious Main Resstances imenstonlesa auiplie sed to obtain the low end ofthe expected range a Pulte used te ebtan the low end of the expected range for torsion sped effect ultipier weed to obtain the low end ofthe expected range for fle load Fiction gin for active pulley (dimensionless) ETT ssumesTo-e, Ts tensfon in the direction of Ret waved (DT Tine intent being analyzed (500) Tension on the carry side ofthe primary drive paley 00 Tension the bell approaching ative pulley a (ED. Tension onthe return side ofthe primary dive pulley (GD. Teer Tram active pulley 5 cation additional tension contubutions Kom accessories (B/RI 5 elton tension esing rom the force to accelerate he material as HTS Te FCanveyor bet thickness Gnd Te For drive puleys Tis used intechangel Ta | _Teaslon change at an active paley=T i “bent operating temperature Te Rll or Pile diameteal runout a ini Tension Right ‘Avetage tension in fight or pulley QbA) Tension dus to the belt Nevure around pulleys and pale 5 addltion altional tension eentubutions(/ he active argue provided tothe pulley MI) Tension at takeup (TD sumed tobe ten Belt speed (min ot fom) The etal ravimam belt speed without causing materia WOM TURIN Tra eloty of material at point of impact with bet pm Tansient beltvelocty after tinet fom) font velocity (ean) Dietibutedeatemal vertical nae TF) Distriouted gravity load of bek alana lenath of bek UGH Total welght ofthe belt= Wiel (ty Weight of favheel thf) Effective Uanslatng weight of fipaheel (bh Toad distibubon factor Table 6.26 limensionle=) setance Ub) The rection athe waver ow Swinging weight oF idler (BF) Wi Weight of tating component (SF Ve Distibuted rat load of bulk mater song Tengihof he ek MUTT, Wer Total welght ofthe bulk materiaton the Delt= WL, (DF)Chapter Six Tehapteré Srp [esenpion Nomenclature Chapter Seven Direction subscipr + advection of Bek wave | Subsciptin apa P forfabric carcass belt for steel able bali constracion ection subseript nthe bel wih deci referenced fom Oat belt center Direction subscript in the bel thickness direction referenced from carving side Density ofthe bulk material (E470) ‘Specific weight of bulk material (DUTT [Tension added inTondingto continuously accelerate matedaliobeK speed) Tension added ding Fgh 10 conti ee Tension added due to belt cleaners and plows (bf) Tension added due wo discharge plow (oN) | Angle of impact oF material tothe bale relativet bet decton eah Tehapter7 Sb | beep Nomenclature a ‘Angle ln degrees that che slope makes with he orzontal @e@) * Protective covering for cords dung the eit bel fe 20 Gh) 2 ‘Ariourt of top overused or the sence Me of he bel c ‘amount oFbotton cover used forthe sevice Ie of Webel D Diameter ofthe cord (nh E [uber encapsulating the eel oe) a Thicaess of rubber to protedt the cons dung sevice ay Fe Frequency factor (win) He [ taovalentfeera) SSS He Totafeefal Q)—— H Vertical height ow loading hut H RMA rubber grade o [-Pinbbersede—SSCSCSCSCS~S~S~S~“~S~S~S L | conterto-centerlengih ofthe betcomeyer MO cl Paley Face width Gr) Pr Belt working swength TNO) v Belt speed. fomChapter Eight ll Nomenclature a Bel tension ales ea) Bele Tension angle = cow oma) (= ow from oh Wes) ‘Shaft deflection angle Gan) or adans ‘Moment aim for pulley (in) Bearlag centers tn) [Moment aim for shai veinfaveement in) Shak diameter Diameter of sat at hub Ow Diameter of shat side Young's modulus (29 wf for steel Gal Factor of safety (imensionlere) Area moment of inertia of safe o.ogso87 Surface fet 5 for machined shat (dimensionless) = 6 Relsiltyfctor= 0.857 (dmendonless) Temperature ‘for Zo" Fto + 400) Fcensionl Duty ace factor = ro raved eylicsiesses do not exceed 5 (inens Fatigue tess concer Bending moment Gab Bele modulus Meine on paley UB) Corrected shaft Fatigue li (65) hg tee tabulated ultinate tense avant Ge Vela strength G5 Torsional moment (Btn Tight side tension Slack ide tenon UP on-drven pulley tension bf) “Tension in counter lockvise drecion (OH Tension indockvise direction (ED, up ply weight ation factor (mens ResultantChapter Nine chapter 9 Nomenclature B | ler roughing anata ee) Te roriontal cave super elevation angle eat aT change in the ange ofthe bet between entering and eaving Te convex une eB) r The appropriate fiction factor between the beltand the cotrespandlag inside, center, or outside idler roll ofa horizontal curved belt (dimensionless) Length of the bel in contact with the belt onthe center roller ofan ler an a horizontal Be Modulus of elasticity ofthe conveyor belt fos per inch width er ply Qin-with ety) Belt with Length af the ele contact va he ell on Te side voller oF an ier on a hanaontal cure em Tenth af the hatin contact with the ele on the outside ler of an ler on hvisontl cua (a) e Point where concave vertical uve starts r Total accelerating force for concave vertical curve calculations, conveyor baded From tall 70 point oniy bf Resultant force, Ibe on ler a convex verical cue, produced by We bet enwion athe cave Resultant Force on lets at convea vertical curve, produced hy bel Tension at curve DT Resultant force on lets on a harzontal curve produced by ele tension nthe curwe (BY & ‘Motivating force for horizontal cut LS ine Tere recat toh i Taner re Beest Meson tiveness Ter spacing imum roughing Wer spacing on We cnve “Tension inducedin the ben by accelerating forces atany Aven par TDD Tal tension point ecurng seeeevation (Ef Bel tension atpoint¢or ed CBM “Tension at point ¢ during nova runing (06) ion (BF) Weight of be per fot UOT “al weight tobe accelerated bythe beltat point (bt) Weight of material per fo (7TH “al equivalent weight of al maving comayor part, oaluding dive and ave pulley, pls loaded portion Rom tal te pole (bt x cation of ponte for concave vertical caves deteonined For equation 5 au ®DChapter Ten Krapterso Sabet | — Des —_—_—==___= I Nomenclature ° ihe tur ae ‘Angle of repose ofthe bulk material ee) Comneyortacnation angle es) Coeteent of iston between belts dimentonle=) Maxima allowable cross-sectional area Reduced area used for molded clea Bele width (=) lactic modulus of bet (Tin-width pW) Nominal daweter ofa pipe or ube conveyor Reduction factor = kth (dimension eduction factor component, a fuchon ofthe Gerence between the angi OF surcharge angle dimensionless) Reduction factor component, a function ofthe canveyorIncination and the angle of repose (dimensionless Kemet 2 saath Beltinentation resistance Uf te in figure 42 (fen conservatively assumed as center rll engl Gnd N Normal load form; cover belt weight, eternal pressure to cover bat, crass rigidty othe cover bet and adil component of bet tension in cover belt D/T0 ma Number of driven belts = for caring belt only driven or 2 for both cover and cmrying bel shiven (dimensionless) P umber of bel plies fimensfonlesa Pi Belt working strength din wth) B T Rodi load = © (bt di F wen R Cove radius Chapter Eleven Safety factor on material backaling ine Local belt ension (bt) Average belt tension aGtoss bel at locaton of here enter tesion (ei weth) Ege tension Ub inwth) Material weight per fot (BHAT Tang of sandvien Bele nelnation el ye ew Timah roughing a Ichapter 13 Nomenclature Traps foe To Lamp fale Spring constant ofthe impact absorbing system (EEF Bulk materia fw eate oh) Blt tension resulting Wom the application of acessories (BF) Weight of he fvgest lamp in GBD,Chapter Twelve chapter 12 Nomenclature @ Tey angle Wo horns (oe Valley Bock plate angle (io honizontad “roughing angle ea) | Hooner arching anale a the base of he hopper atthe feeder shear olane Weal ‘Angle of nelne ofthe belt conveyor ta the ho Hectve angle of intemal ficvon = Tan(@) Gea) Distance fom the bal 138 tal de ‘skirtboaed hehe Gn) [Cross sectional area of materialonthe belt based on surchargeangle() sed on suchage anale Cross sectionalare of bu charge angle Toughed bet | pen aves at upstream end wheve the aire Induced ite the Wane pent cue tothe nS ing risteria Width of the Surcharge volume atthe rex ofthe Teed On) | Widttrof the surcharge volume atthe front of the feeder Gn) Bete wieth | Standard CEMA bettedge distanced) rth oF the owed at he start of he trajectory TaD [center of gravity ofthe cross section oF the ood shape [lunensionese) ‘verge material diameter G0 The pointw re the material tajetow Raves the bal Ginension | Worzomal dimension of material in contact with woughed partion ofa feeder betta) The force shear the materia as Kets the hopper ofa feeder (BN Be eration of gravity 92.2 (sec) |The stance Rom the belt othe opafthe oad shape) Height ofthe surcharge wolume at tha rear ofthe feeder () [eight ofthe surcharge volume atthe fiontofthe feeder in] Design opening height ofa feeder int Horsepower af a Feeder (hp) ilenting a feeder portion oF a Feder Balt Length of mat Vertical dimension of mateo n contact with Woughed portion ofa feeder ben Gi [Factor to estimate the shear strength of the bulk material at he srtboard wall (dimensiones Factor to estimate he Lengtvofthe sue volume inside the feed hop Length of material in comtact wih sloped portion of a woushed eeder Wer) Normal force on skitboard als i [Hydrostatic pressure on skirboards infeed hopper (Tin) Tapper (Te) Ver c | vertical load onthe feeder belt under the hopper with steady tate ow (BN) Volume of diaper Ti rina wansfer paint (7 [tail vertical oad on the feeder belt underthe hopper onstatup iN) alum of induces Rate of material flow Goh) fer pone (min) dive that results na segment of width C with anarea equal Asc a point where ateial trajectory begins th) [Radius of the puley f) Rods fom the center of pal [—veight ofmatematfeeN@ Thickiess ofthe bet in) [Total be tension of simple feeder estmatecsing the CEMA Nistor method Wo) he resistance (belt tension 1o shear the buk material fora simple feeder =u» Gh [Bete Tension requtedto remove material on Teeder dvethe buk material) Bele speed (pm)Chapter Twelve Tenapters2 —Spnbel | — besepon Nomenclature ve Tangential velocity of he cross-sectional center of ravi of toad shape (h/sec) ve The volume ofthe surcharge material) Falling bulk material stream velocity omy th benveen stboards (a) Vertical height of skitboard at the ear ol feeder papper Ga) TVertcal height of kitboard at raat of feder hopper On) Valley sce pate angle (fo horizontal eg) 7 | Angle between the vertical centering through ihe pula. tothe pointe, where the material starts es raectoy (ea) Chapter Thirteen Tenapter 5 a Nomenclature He The product oftoraa eae) Me Backstop ple rotational speed (om Total poverat dive location (hp) rm ‘Motor shaft revolutions per minute Gam Tiining the beltvith the toughing idles fs accomplished by shiting the der axis with respect po the path ofthe belt, commonly known as knocking idlers. This method is effective when the entire belt runs to one side along a fixed length of the conveyor. The belt can be centered by knocking — ahead (in the direction of belt travel) the end of the idler to which the belt uns (See Figure D.to). > _ wBelt Alignment Cont. Figure D.1o Correcting belt alignment Belt Travel Over Knocked Idler Belt Direction Conveyor \ Centerline : / Perpendicular to Belt Centerline Shifting idles inthis manner should be spread over a length of conveyor preceding the region of trouble, Inno event shall any idle be shifted more than 3/4 inch in any direction from its squared position NOTE: Compensation by idler knocking may have adverse effects on reversible belts; therefore, avoid knocking on eversible bets, Instead, use extreme care in intial alignment, Abel might be made torun straight with half the idlers knocked one way and hal the ther, but this would increase rolling friction between the belt and idler. For this reason, al idles must be intially squared with the path of the belt in accordance with the idler Alignment section ofthis standard, and minimum shifting should be used for training, If the belt is over-corrected by shifting idles, it shouldbe restored by moving the knocked ilers, not by sifting additional ilers inthe other direction EMPTY RUN-IN The conveyor belt should first be aligned (trained) without material load. Most alignment problems, with the exception of off center loading, will be detected during this empty run-in period. After ensuring that all elements have been aligned true stipulated in the leer Alignment section of this standard, the belt should be slowly inched along to provide indication of where corrections of the types described may be required. The fist corrections must be those at points where the belts in danger of being damaged. Once the belts clear of all danger points, a sequence of training operations, can be followed.Belt Alignment Cont. The best procedure to use in the training sequence isto start with the return run and work ‘toward the tail pulley. This ensures early centering of the belt on the tail pulley so that it can be centrally loaded. Normally the belt can be trained properly onto the tail pulley by manipulation of the return ilers, With the empty belt trained satisfactorily, good operation with load is usually assured. Disturbances thet appear with lozd are then usually due to off-center loading or to accumulation of material on snub pulleys and return idler IF all corrective measures have been applied, and a particular section of belt continues to run to one side along the entire conveyor length, it can be concluded that the belt may be cambered at that point or may have a splice that is not properly squared. The only corrective measure for a non-squared splice is to re-splice. On the other hand, slight camber in a belt may remove itself after an adequate run-in period under load. FULL LOAD RUN-IN ‘A belt may be considered properly aligned if ater eight hours of continuous operation under full design load, the belt edges remain within the width ofthe pulley face. Also, when extra wide face pulleys are used, a further criterion that the belt runs within the confines of the normal troughing, or return, idler should be followed. NoTE: Disc retum Idlers shall be exempt fram the above as the standard rll faces supplied are approximately equal tothe belt width. In this case, the belt shall be made to track within 14/2 inches ofthe conveyor centerline. Idler brackets shall not restrict this movement. To obtain the above alignment under load, it wil be necessary to ensure thatthe load is centered and that allbelt scrapers, plows, and skirt seals exert uniform pressure on the bet. Minor adjustments can be made to these devices to improve tracking Canying and return traning idlers should be considered in corectng belt alignment problems before rejecting the betting or splice. Helpfl Hints: ‘+ One person should be responsible for traning belts This person should supervise all adjustments + Periodically check the conveyor to be sure itis level. This requirement is apparent i the conveyor becomes misaligned with no apparent change in loading «+ After the belt is run in, an electrician should take readings on voltage, amperes, or wattage. This information can be used for future comparison and a quick trouble check. (Higher reedings inthe future may indicate excessive drag due to belt misalignment or frozen belt idler rolls) + Do not over train the belt. Overtraiing wil resuitin increased belt cover wear and increased power consumption.Skirtboard Adjustment Skirtboards are an important element of a wel designed belt conveyor. They help centralize and shape the load while minimizing spillage over the belt edges and helping to contain dust. The stel plates that foum the skirting (and any chute lining) shouldbe installed high enough to acid the risk of contact with te bet, yet low enough to protect the uber or urethane sealing stips from ‘excessive load pressure and material wear. The cross-sectional area of the chute should be checked carefully to make certain that the skirting and liner do ot interfere with flow, Iti critical that these steel plates be installed as a smooth, seamless layer that opens in the direction of elt travel, to minimize material entrapment and the risk of belt damage. Typical dimensions for clearance above the belt start at 3/810 1/2 inch above the belt at the tal and opento 3/4 t01 inch a the ext ofthe load zone. Axed to the bottom of the steel isthe skrtboard sealing system, which provides a light, flexible contact with the conveyor belt. This low sealing pressure will minimize friction white retaining all material within its boundaries. Excessive pressure will bum grooves in the belt rubber cover and, therefore, must be avoided. Excessive adjustment or downward pressure ofthe skirtboard seal can lead to accelerated wear ofthe sealing strip, and/or belt The maintenance of a lat and stable belt line in the loading zone i a key to effective sealing, Efforts, taken to avoid fluctuations in the bet line, including closely spaced idlers, bek support cradles, and spiral-wrapping of wing pulleys have generally proven helpful in controlling fugitive material. Idler Lubrication Modem conveyor idlers have evolved through better bearings, improved lubricants, and more effective als Likewise, the lubrication recuitements have changed to accommodate curtent designs. The following considerations should be reviewed when establishing a lubrication program tailored to a particular installa MANUFACTURER'S RECOMMENDATION The manufacturer's data can provide a solid basis for designing the lubrication program. TYPE OF LUBRICANT ‘The proper lubricant wil be heavily influenced by operating conditions, the operating environment, and the quality of maintenance program desired. Operating conditions such as operating speed, idle loading, type and size af material being handled, and numberof operating hours per year should be considered. The operating environment is one of the greatest contributors in determining the lubrication program. Temperature, dust, material abrasiveness, wash down techniques, and wash down frequency all affect the lubrication that flushes contaminants from the bearings. Special synthetic lubricants are available for subzero operating temperatures. IDLER CONSTRUCTION The type and efficiency of the seals directly reflect on the lubrication schedule. Following are several recommendations that will contribute to establishing a successful lubrication program: + Remove several idlers ftom service evey sik months, disassemble them, and inspect to determine if adequate lubrication has been attained, if migratory contamination and wear have occurted, rif pressure relief plugs are fouled. If these idlers demonstrate that adequate lubrication has been attained, they could be put back into service and the conveyor operated as, normal. if contamination was found inthis sampling, ll idlers on the conveyor should be lubricated. Also fouling of pressure relief plugs in sampling should encourage cleaning of ll plugs. + Thoroughly clean all grease fittings prior to lubricating the idlers to eliminate the possibilty of Contamination introduced during maintenance,Idler Lubrication Cont. Safety + Establish a good maintenance recordkeeping system. Record the date on which samples were token and the concition ofthe samples taken and verify trends that maybe occurring within the system. Also record idler failures, including location, to establish system trends and effectiveness ofthe lubrication program. The establishment ofa formal lubrication program as described above willincrease the likelihood of many years of successful, trouble-free operation ADJUSTMENTS, Conveyors by design often have significant potential sources of stored energy. Take ups and inclined (or declined) belts loaded with bulk material are tvo common hazards. It is important that ANSI lockout procedures be followed when making adjustments to bring conveyor machinery into tolerance (ref: ASME 815.1, B20.1, and ANSI 2244.) Adjusting rotating or moving components should be avoided. Only trained and authorized personnel who are aware ofthe hazards should be allowed to make such adjustments SAFETY LABELS CEMA Sofety Labels and Placement Guidelines were developed by the CEMA Safety Committee to provide for members and non-members consensus advice forthe selection and application of safety labels foruse ‘on conveyors and related material handling equipment to assis in accident prevention, Prior to operating the conveyar or any of the associated accessories or equipment all safety markings, guards and warnings must bein place in accordance with governmental regulations and site specific requirements Should any of the safety labels supplied by the equipment manufacturer become unreadable for any reason the equipment user is then responsible for the replacement and location of these safety labels. Replacement labels can be obtained from your equipment supplier or CEMA. CEMA Label Placement Guideline BH-1 is intended for bulk material handling conveyors. The Entice CEMA Safety Label Program is detailed in CEMA Brochure 20a -Safety Label Brochure which is available from CEMA5 E i 4 ie 3 I IDLER ROLL Aj' TEST PROCEDUR BELT CONVEYOR BELT CONVEYOR IDLER ROLL Aj' TEST PROCEDURE Forward Scope References Definitions Test Equipment Test Roll Conditions Test Procedures Reporting Roll Status after TestingForeword This appendix provides a proposed procedure for determining the A' component of the resistance to rotation ofa single belt conveyor dle roll. The procedure is intended to provide a vay of gathering data ‘ona uniform basis between various manufacturers tobe used for conveyor power calculations, 1. SCOPE This proposed CENA Standard applies to the laboratory measurement of the A component of the resistance to rotation of ‘dead’ or nion-rotating (Static) shaft belt conveyor idler rolls commonly used for the transport of bulk materials. This proposed standard test procedure applies to the steady state operation of rolls that have been run-in and isa statistical average in nature. The aim ofthis proposed standard is to determine an accurate average value forthe resistance to rotation (excluding beating resistance to rotation due to load) ofthe large cuantity of idler cols used in any belt conveyor, far pawer and belt tension calculation purposes. 2. REFERENCES 24 Applicable Publications: the following publications form a part of the specification to the extent specified herein. Unless otherwise indicated, the latest revision of CEMA publications shall apply. 2.12 CEMA Publication Belt Conveyors for Bulk Materials, 5" edition and lower. 2.23 CEMA Publication Belt Conveyors for Bulk Materials, 6" edition and higher. 2.1.4 CEMA Standard No. 02 Bulk Material Belt Conveyor Troughing and Retum idles, 3 DEFINITIONS The following definitions apply wherever the terms and expressions are used inthis document. 34 Resistance to Rotation - The resistance to rotation of an idler rol isthe torque or moment required to rotate the idler roll around a stationary shat. tis calculated as the scalar sum of all contact forces tangent tothe test surface and parallel to the circumference generated by a point on the test surface as it rotates, times the distance from the tangential force reaction to the centerline ofthe idler bearings. 3.2 K.—The ky value is the total resistance to rotation of bath the carying and return idles, in Ibs perfoot of conveyor length, as defined inthe CEMA Publication Belt Conveyors for Bulk Materials, 5 edition. The text from the 5" edition is included for reference inthe 6* edition as Appendix Itincludes the resistance of the beerings to rotation due to load on the rolls 3.3 Ai—The Aj value is the component of the total resistance to rotation in Ibs of the 3 rolls of a standard troughing idler and a portion of the return roll (ue to longer spacings) that is atributed to the resistance to turning due to the effects of al seals including any bearing seals, grease, including grease within the bearing, et. (in other words, al resistance to rotation that can not be attributed tothe bearing resistance to rotation due to load) tis used in the calculation of Ks in lbs per foot of conveyor length, as defined in the CEMA Publication Belt Corweyors for Bulk Materials, s* eition and lower. 3.4 Al~The Ai value is the component of the total resistance to rotation ofa single rol, that is, attributed tothe resistance to turning due tothe effects of all seals including any bearing seals, grease, including grease within the bearing, etc (in other words, al resistance to rotation that can not be attibuted to the bearing resistance to rotation due to load). It is used in the calculation of K., as defined in the CEMA Publication Belt Conveyors for Bulk Materials 6* edition. 3:5 Test Speed: The test speed is the standard CEMA speed in revolutions per minute (1pm) as provided in the load ratings for CEMA Standard Idlers. This is 500 rpm for all CENA Series. Reference CEMA Standard No 502 Bulk Material Belt Conveyor Troughing and Retum Idlers Q-3.6 Ambient Temperature- - The term ambient temperature refers to the temperature of the ait surrounding the test roll) during an test. The ambient temperature is to be 75°F +/-10%, 3.7 Basic Test- The basic testis performed at the Basic Test Speed, at Ambient Temperature and in accordance with all oer requirements of this proposed standard 4, TEST EQUIPMENT It is not the purpose of this proposed standard to detail the test equipment used. The test equipment shall be suitable to accurately measure the resistance to rotation of an unloaded idler rolls) during a basic test within +/-10%. 44 Test Methods - This proposed standard is intended to define the elements important to accurate and consistent measurement. Test machines wil vary but there ae two general methods with various sub-types that are considered acceptable It includes the following two basic test method types each with substypes: 4.42 Rotating Shell/Statc Shaft: Method Types A Inthe Rotating Shell Static Shaft method Types A, the shafts stationary and the shelis rotated This method most accurately replicates normal lubricant flow and rotation ofthe bearing rolling elements. However, the parastic losses are significant and need! to be accurately measured and subtracted from the measure value. ‘4421 Method Type At. ‘Measures the reaction moment at the idler shaft using force sensor or gauge and the result is converted mathematically to an A value, 4.4.2.2 Method Type A-2. Measures the reaction moment at the idler shaft using a reaction torque sensor or gauge and the result is converted mathematically to an AV value 4.1.2.3 Method Type A-3. Measures the input torque to the test machine by various methods and the result is converted mathematically to an value 4.1.3. Rotating Shaft/Static Shell Method Types B In the Rotating Shat/Staic Shell method Types 8, the shaft is rotated and the shell is held stationary. This method does nat accurately replicate narmal lubricant flow and rotation of the bearing rolling elements. However, the parasitic losses are not very significant and in most cases cane ignored, This method's overall accuracy is thus comparable to the Type A methods. 4.3 Method Type Be Measures the torque to turn the shaft using a rotary torque sensor or gauge and the result is converted mathematical to an A value. 4.3.2 Method Type B-, Measures the reaction force at the shell using a force type load cell or gauge and the result is converted mathematical to an A value, 4.1.3.3 Method Type B, Measures the reaction moment at the shell using a reaction torque sensor or gouge andthe result is converted mathematically to an A value.43 44 55 56 58 59 510 Multiple Roll Tests. To reduce the time and effort required for a complete test, multiple rolls may be tested at one time, where the test method type and test machine design allows. The A value for such atest willbe the total esstanceto rotation divided by the numberof ols inthe basictest (Le. a simple average). Alignment and Load Control £Allroll alignments and load control during testing must be maintained sothere site orno effect, con the measurement ofthe esistance to retatan, These test parameters are typically ‘Near zero axial load on rol ‘Near Zero normal load on rol ‘Near zero roll inclination angle. Instrumentation, ‘The instrumentation used for readout, recording andif applicable, mathematical manipulation of test data, must be sufficiently accurate and precise as to provide rolling resistance measurements within +/- 10%. TEST ROLL CONDITION The roll to be tested must bein new condition. Thats, either fesh off the production floor or from the warehouse. Ifthe ollis from warehouse stock, then the rollis to have been in stock less than year The roll may be any diameter, length, or type that falls within CEMA Standard No 502 Bulk Material Belt Conveyor Troughing and Return Idlers. Fortest methods Type A, the run-out ofthe test rol atthe point of rotating load support must be with 0.035 Inch Total Indicated Run Qut (TR). This isnot necessary where the Type A Method employs a data acquisition system that has the proven ability to mathematically compensate for roll TIR problems. This is nat necessary for Type B methods where the shel is held stationary. Allre-greaseable type rolls shal be properly greased with fresh grease before run-in. This means. rolls fresh from the production line and already properly greased maybe rurin direct Rlls from stock, which are over 3 months old orf there is any question ofthe date of their production, are to be fully purged and property re-greased with fresh grease, Section 5.4 doesn’t apply to sealed for life products The rolls o be un in at 500 rpm +/-20 rpm, for oo hours 4-10 hours, without load and in an ambient temperature of75°Fs/-20° Alter run-in, the rol isto have a thermal soak of st least 12 hours inthe thermal environment of the test location priarto the test being performed to achieve thermal equilibrium, If rundn is done within the thermal environment of the Ai test, the test may proceed directly {within 30 minutes). Run.n rolls may be tested up to 1 month after run-in, ifthere is more than a 30 minute delay between run-in and test, the usin rolls to be run for 30, minutes just prior to the A test being performed on it. Note: Any roll rework or other corrective action required should be undertaken before testing and with care not to change the run-in characteristics ofthe rll6. TEST PROCEDURES 6a Basic Test The Basic Test will consist of the Following 4 phases in sequence: 6.2.2 Initial Test Set-up 6.4.2. Approptiately warm-up the test machine and all instrumentation 6.1.2.2 Zero all instrumentation andjor record all instrumentation offsets 6.1.2.3 Determine all parasitic losses of the test machine. Measurement of parasitic loss(es) is very important and can be determined by different techniques depending on the equipment used. 6.4.3 Gross Resistance Measurement: 6.1.3 After running for § minutes measure resistance to rotation of the roll(s). 6.4 Check Vaicity 6.4 Check for changes in the zero or instrumentation offset 6.4.4.2 Determine that the total parasitic losses have not changed from 6.1.1.3 6.2.4.3 From petsonal observation and the results of 6.1.3.1 8.2 above determine if the testis a valid ane. 64.5 Data Manipulation: 6.1.5 Various types of machines and their instrumentation will hve different methods in which the data must be manipulated to arrive at the A test value. The method must be a scientifically valid one, 6.1.5.2 Make certain that the effect of all instrumentation offsets have been taken into account in reducingyincreasing the gross rotating resistance measured, 6.15. Also, make certain that al significant parasitic losses have been accurately determined and are subtracted fom the gross rotating resistance measured in 6.1.2 after instrumentation offsets have been taken into account. 6.15.4 If multiple rolls are tested divide the net resistance to ratation by the numberof alsin the basic testto gett A test result for the basic test. 6.25.5 AY results atthe test diameter shall be adjusted for the other standard CEMA rol diameters) by assuming the roling resistance is inversely proportional to the rll diameter. The test value shall be adjusted by the following equation: Al oa 6.2 Complete Test. A complete test will invoke statistically significant quantities of rolls, minimum of 20. Any combination ofall diameters kngths, and ral types may be used towards a complete statistical test. Homever, all ols must have the same construction details that would affect the A value Obviously all esults must be efered to one diameter forte statistical average being tested fr. A complete test will produce one result, a single A’ value, This value will be the average of allthe resistance to rotation measurements forall basic tests completed. Where multiple oll are tested ina single basic tet, the result is an average, The test results for each of these multiple rol tests may simply be averaged to arrive at a complete test average, the single Aj value.72 722 REPORTING Asa minimum the report shall consist ofthe following: Roll Identification. The following information forthe identification of each complete test should be recorded, if applicable: Manufacturer and/or Supplier. Brand name andor Trade Name and/or Roll Series CEMA Class, Roll Type(s) (steel, rubber disc, rubber ire, ete). Rolls) diameter(s) tested Grease detail. Standard construction details Any special construction details (ex. with splash guard, weather shield, stone guard, etc). Test Resuts The following complete test information shall be reported: A at the CEMA diameter tested A atall standard CEMA diameters forthe Class of rll. Test method type. Any special test details (ex. multiple roll tests, number of rolls pertest, et) Test month and year ROLL STATUS AFTER TESTING Tested rolls are to be considered stil in new condition and may be retuaned to stock.' Ei 4 = 5 is BELT CONVEYOR IDLER ROLL Kis' TEST PROCEDUR BELT CONVEYOR IDLER ROLL Kis' TEST PROCEDURE Forward Introduction Scope References Definitions Test Equipment Test Roll Conditions Test Procedures Reporting Roll Status after TestingForeword This appendix provides a proposed procedure for determining the Kis component of the resistance to rotation of a single belt conveyor iler rol. The procedure is intended to provide a way of gathering data ‘on a uniform basis between various manufacturers to be used for conveyor power calculations, a. INTRODUCTION 1a The kyvalueis the total resistance to otation of bath the carying and return idles, in bf per foot of conveyor length, as defined in the CEMA Publication Belt Conveyors for Bulk Materials, 5* edition, The text from the 5* edition is included for reference in the 6* edition as Appendix C. It includes the resistance of the bearings to rotation due to load on the rolls. Ki combined the fictional resistance of the idlers and the siding resistance between the belt and idler rolls 1.2 Avis used inthe sh edition asthe component ofthe total resistance to rotation in tbs ofthe 3 rolls ofa standard troughing idler and a portion of the return roll (due to longer spacings) thats attributed tothe resistance to turing due to the effects ofall seals including any bearing seals, grease, including grease within the bearing etc. In other words, al resistance to rotation that can not be attributed to the bearing resistance to rotation due to load. Ais used inthe calculation of Kin Ib per foot of conveyor length, as defined in the CEMA Publication Belt Conveyors for Bulk Materials, 5* edition and lower. 13 Combining load dependant rotational resistances and load independent resistancesin one factor, k,, results ina level of calculation precision that is less than satisfactory for many applications. In the 6" edition of Belt Conveyors for Bulk Materials the rotational resistance is broken down into key components that can be evaluated independently. In the 6* edition the Universal Method for calculating conveyor power recuirements the component Ki (in x tb) is the seal torsional resistance per roll at 500 rpm at a defined operating temperature. Ki isthe average value of k, obtained fiom testing a representative sample of idlrs fallowing the Ky’ test method, 2. SCOPE 2.1 This proposed CEMA Standard applies to the laboratory measurement ofthe Ki. component of the resistance to rotation of ‘dead’ or non-otating (static) shaft belt conveyor idler rolls commonly used for the transport of bulk materials. This proposed standard test procedure applies tothe steady state operation of als that have been usin and i a statistical average in nature. The aim ofthis proposed standard is to determine an accurate average value for the resistance to rotation ata defined rpm (excluding bearing resistance to rotation due to load) of the large quantity of idler rolls used in any belt conveyor, for power and belt tension calculation purposes. 3. REFERENCES 3.4 Applicable Publications the following publications form a part ofthe specification to the extent spectiedheten, Unless otherwise indicated, the latest evsion of CEMA publications shal appl, 3.2.2 CEMA Publication Belt Conveyors for Bulk Materials, 5" eition and lower. 3.13 CEMA Publication Bet Convers for Bulk Materials, 6* edition and higher. 34g CEMA Standard No. 502 Bulk Material Belt Conveyor Troughing and Retumn Idlers4. DEFINITIONS ‘The following definitions apply wherever the terms and expressions are used in this document: 4a Resistance to Rotation ~ The resistance to rotation of an idler rol is the torque or moment required to rotate the idler roll around a stationary shaft. tis calculated as the scalar sum ofall contact forces tangent tothe test surface and parallel tothe circumference generated by a point on the test surface as it rotates, times the distance from the tangential force reaction to the centerline ofthe idler bearings. This resistance is expressed in Chapter 6 ofthe 6 edition as a change in tension, Ts. To calculate AT itis necessary to obtain a value forthe factor, Ks that is representative ofthe idles to be used on the conveyor. 4.2 Test Speed - The test speed is the standard CEMA speed in revolutions per minute (1pm) as provided in the load ratings for CEMA Standard Idlers. This is 500 rpm forall CEMA Series, Reference CEMA Standard No 502 Bulk Material Belt Conveyor Troughing and Return Idlers, 43. Ambient Temperature: - The term ambient ternperature refers to the temperature of the air surrounding the test roll(s) during a Ki, test. The ambient temperature isto be 75°F 4/-102 4.4 Basic Test- The basic testis performed at the Basic Test Speed, at Ambient Temperature and in accordance with all other requirements ofthis proposed standard. 5. TEST EQUIPMENT It is not the purpose of this proposed standard ta detail the test equipment used. The test ‘equipment shal be suitable to accurately measure the resistance to rotation of an unloaded idler sols) during a basic tet within +/-0%. 5.1 Test Methods - This proposed standard is intended to define the elements important to accurate and consistent measurement, Test machines wll vary but there are two general methads with various subtypes that are consideted acceptable, It includes the folowing two basic test method types each with sub-types: 5.2.2 Rotating Shell Static Shaft: Method Types A: Inthe Rotating Shell/ Static Shaft method TypesA, the shaftis stationary andthe shellis rotated. This method most accurately replicates normal lubricant flow and rotation ofthe bearing rolling elements. However, the parasitic losses are significant and need to be accurately measured and subtracted from the measure value. 5.2.2.1 Method Type Aa. ‘Measures the reaction moment atthe idler shaft using a force sensor or gauge and the result is converted mathematically to a Ki," value 5.2.2.2 Method Type A-2. [Measures the reaction moment atthe idler shaft using a reaction torque sensor or gauge and the result is converted mathematically toa K.’ value 5.1.2.3 Method Type A-3, [Measures the input torque to the test machine by various methods and the result is converted mathematically to a Ky’ value. 5.1.3 Rotating Shaft/Static Shell: Method Types B: In the Rotating Shaft/Static Shell method Types B, the shaft is rotated and the shell is held stationary. This method does not accurately replicate normal lubricant flow and rotation ofthe bearing rolling elements, However, the parasitic losses are not very significant and in most cases can be ignored. This method's overall accuracy is thus comparable tothe Type methods.5.3. Method Type Ba. Measures the torque to tum the shaft using a rotary torque sensor or gauge and the result are comerted mathematically to a Ke’ value 5.1.3.2 Method Type B-2. Measures the reaction force at the shell using a force type load cell or gauge and the result is converted mathematically toa Ke value. 5.13.3 Method Type B:3. Measures the reaction moment at the shell using @ reaction torque sensor or gauge and the result is converted mathematically toa Ki value. 5.2 Multiple Roll Tests To reduce the time and effort required for a complete test, multiple rolls may be tested at one time, where the test method type and test machine design allows. The Kx’ value for such atest will be the total resistance to rotation divided by the number of cols in the basic test (Le. a simple average) 53. Alignment and Load Control. All roll alignments and load control during testing must be maintained so there is litle or no effect on the measurement of the resistance to rotation, These test parameters are typically: + Near zero axial load on roll. + Near zero normal load on rol, *# Near zero rllinclination angle 5.4 Instrumentation, The instrumentation used for readout, recording and if applicable, mathematical manipulation of test data, must be sufficiently accurate and precise as to provide rolling resistance measurements within +/- 10% 6 TEST ROLL CONDITION 64 The toll tobe tested must be in new condition, That is, ether fresh off the production floor or from the warehouse. Ifthe rolls from warehouse stock, then the roll is to have been in stock less than a year. 6.2 The roll may be any diameter, length, or type that falls within CEMA Standard No 502 Buk Material Belt Conveyor Troughing and Return Idlers 6.3 Fortest methods Type A, the run-out ofthe test rll atthe point of rotating load support must be with 0.015 inch Total Indicated Run Gut (IR). Ths isnat necessary where the Type A Method, ‘employs a data acquisition system that has the proven ability to mathematically compensate for rall TI problems, This is nat necessary for Type B methods where the shellis held stationary. 6.4 Allre-greaseable type rolls shall be properly greased with fesh grease before run-in. This means rolls fresh from the production line and already properly greased maybe run-in directly Rolls from stock, which are over 3 months old or if there is any question of the date of their production, are tobe fully purged and properly re-greased with fresh grease. Section6.4 doesn't apply to sealed for life products. 65, The ollis tobe runin t 500 pm +/- 10 rpm, for 300 hours +/-20 hours, without load and in an ambient temperature of 75¢F+/-20°.646 After run-in, the rolls to have a thermal soak of atleast 12 hours inthe thermal environment of the tet location prior to the test being peformed to achieve thermal equilibrium 67. Ifrumvinis done within the thermal environment of the Ki’ tes, the test may proceed directly (within 30 minutes) 6.8 Ruin rolls may be tested up to 1 month after run-in, 6.9 there is more than a 30 minute delay between run-in and test, the run-in rallis to be run for 30 ‘minutes just prior to the Ky’ test being performed on it 6.0 Note: Any rll rework or other corrective action required should be undertaken before testing and with care nat to change the run-in characevistis ofthe rol 7. TEST PROCEDURES 7a BasicTest. The Basic Test will consist of the following 4 phases in sequence: 7-42. Initial Test Set-up: 7-42 Appropriately warmup the test machine and al instrumentation, 7.42.2 Tevo allinstrumentation andjor record all instrumentation offsets 7.1.23 Determine all parasitic losses of the test machine. Measurement of parasitic loss(es) is very important and can be determined by different techniques depending on the equipment used. 7.13 Gross Resistance Measurement: 7.43.4 After running for s minutes measure resistance to rotation of the ral(). 7.64 Check Valicity: 7-44 Check for changes in the zero or instrumentation offset 7-144.2 Determine that the total parasitic losses have not changed fom 6.1.3. 7.4.3 From personal observation and the results of 6.1.3.1 &.2 above determine ifthe tests a valid ane. 7.45 Data Manipulation: 7.15.1 Various types of machines and their instrumentation will have different methods in which the data must be manipulated to arive at the Ke’ test value. The method must be a scientifically valid one. 7.15.2 Make certain that the effect of all instrumentation offsets have been taken into account in reducing/increasing the gross rotating esistance measured. 7.15.3 Also, make certain that ll sigifcant parasitic losses have been accurately determined and are subtracted from the gross rotating resistance measured in 6.1.2 after instrumentation offsets have been taken into account. 7.15.4 lf multiple rolls ate tested divide the net resistance to rotation by the numberof ols inthe basic test o get the Ki’ test esult forthe basic test. 7.15.5 Ki’ results atthe test diameter shall be adjusted fo the other standard CEMA rll diameter(s) by assuming the rolling resistance is inversely proportional to the rol diameter. The test value shall be adjusted by the following equation:72 Complete Test. ‘complete test wil involve statistically significant quantities of rolls, minimum of 20. Any combination of ol diameters, lengths, and rolltypes may be used towards a complete statistical test However al rolls must have the same construction details that would affect the Ki’ value. Obviously, all esults must be refered to one diameter forthe statistical average being tested for. A complete test will produce one result, @ single Ks’ value. This value will be the average of all, the resistance ta rotation measurements forall basic tests completed, ‘Where multiple ols are tested ina single basic test, the results an average, The test results for each of these multiple roll tests may simply be averaged to arrive ata complete test average, the single Ki value, 8. REPORTING As a minimum the report shall consist of the following: 81 Rollldentiication. 8.1.2 The following information for the identification of each complete test should be recorded, if applicable: 8.1.2.1 Manufacturer and/or Supplier 8.1.2.2 Brand name and/or Trade Name anc/or Roll Series. 8.1.2.3 CEMA Class. 8.1.2.4 Roll Type() (steel, rubber dist, rubber tire, et) 8.1.2.5 Rolls) diameter(s) tested. 8.1.2.6 Grease details, 8.1.27 Standard construction details, 8.1.2.8 Any special construction details (ex. with splash guard, weather shield stone guard, etc) 8.2 Test Results. 8.2.2. The following complete test information shall be reported 8.2.21 Kistest atthe CEMA diameters tested. 8.2.22 Kislona ata standard CEMA diameters forthe Class of rol tested. 8.2.23 Test method type, 8.2.2.4 Any special test details (ex. multiple rll tests, number of rolls per test, et 8.2.25 Test month and yeat 9. ROLLSTATUS AFTER TESTING Tested rolls are to be considered stil in new conditian and may be returned to stock,