CONVEYOR ELT” ESIGN. ANUAL ©CONTENTS. Page PREFACE 1-1, ‘Typical Belt Conveyor Arrangements . peat ae ved 12. Drive Arrangements . ei 13, Bat Take-up System 3 1-4, Conveyor Belt Analysis Sheet & Conveyor Belt Record .. a .4 1-5. Transport Material Size and Minimum Belt Width 6 ‘Ange of Incline oF Decline of Belt Conveyor . ‘ ‘ Belt Speed ; 7 ‘TRANSPORT CAPACITY 21, Calculation Formula... ‘i 8 2-2, CrossSectional Area of Load (A) 8 2-3, Surcharge Angle of Material 9 2-4, Apparent Specific Gravity of Material (9) . 9 25. Coefficient of Angle of Incline (6) : i 2-6, Caleulation Results for Cross Sectional Area of Load & Transport Capacity «0. .tsssc.ss ou CONVEYOR BELT DRIVING POWER CALCULATIONS Calculation Formulae... eect ‘ 2B ‘Additional Dats ..... edeteers 4 3-2-1. Friction Coefficient of Idlers (f) & Adjusted Horizontal Length of Conveyor (fo)... 2... 14 3-2-2, Tripper Driving Power (Pt) . . - Srsresperscenere scr iest 3.2.3, Weight of Moving Parts other than Transport Maria! (W). see AS 3-2-4, Weight of Rotating Parts of Carrier and Return Rollers (We & W;)---.. Hears 3-2-5, Pitch of Carrier and Return Idlers eee le eile tel ese t6- 3-2-6. Standard Belt Weights BELT TENSION CALCULATIONS 4a, 42. Conveyors in General 4-1-1 Blfectve Tension (Fp) - 2. TightSide Tension and SlackSide Tension (F, & F3) . 3. Tension due to Incline (Fs & Fy?) . -4, Minimum Tension (Fac & Fa, s. 6. Maximum Tension (Fmax) . . Additional Data. 4-1-6-1. Wrap Angie (0). 4-1-6-2, Priction Coefficient (y) 4-1-6-3, Drive Factor . tee ‘Axle Power and Tension: Example of Calculation itpelecdecte corn Calculation Formulae for Multiple-Pulley Drives (Single Drive at Head and na) ares ‘Theoretical Distribution of Effective Tension. . Distribution of Effeetive Tension between Motors 3. Calculation Examples ....... Comparison of Tensions Generated by Various Drive Systems.43. 44. 45, 41. Diagrams of Belt Tension Distributi 4-3-1, Horizontal Conveyor a. Head Drive b. Tail Drive ct eee PEPE etHe it a6: ¢. Head and Tail Drive 62.6.2 esse a Hse oae rate tives 26 4-3-2, Uphill Slope Conveyor a. Head Drive b. Tail Drive : Head and Tail Drive 4-3-3. Downhill Slope Conveyor»... 4-3-3-1, When Braking is Not Required . a. Head Drive i b. Tall Drive... «. Head and Tail Drive... 2, When Braking is Requited a. Head Drive b, Tall Drive «Head and Tall Drive Overland Conveyor . : 4-4-1. Calculation Procedures... 4-4-2, Calculation Example Acceleration Tension and Acceleration Time 4-5-1, Horizontal Conveyor . 4-5-2, Uphill Conveyor . 4-5-3. Downhill Comeyor . . Braking Tension and Braking Time 4-6-1, Braking Time (1) . 4-6-2. Determization of Braking Capacity 4:6-2-1. When Fp>0 4-6-2-2, When Fp <0. ‘Additional Resistance... 2... 4-7-1, Palout Resistance from Hopper (Fh) 4-7-2, Skietboard Friction Resistance (Fk) Design of Bucket Elevator Belt... es 4-8-1, Calculation Formule for Transportation Volume 4-8-2, Calculation of Maximum Belt Tension . 4-8-3, Additional Data Pe RSet eerie eset at ae 4-8-3-1. Lift Adjustment due to Scooping Force (ho) 4-8-3-2. Drive Coefficient ...... a 4-8-3-3, Bucket Loading Efficiency (@) DETERMINATION OF BELT SPECIFICATIONS Sl, $2. Calculation of Tensile Strength of Carcass... S-L-L, Steel Cord Belt ....- 02-0 .e S-1-2. Fabric Belt. Selection of Carcass . $.2-1, Tension Rating ... . 5-2-2 Minimum Number of Plits in Relation to Load Seppe 5-2-3, Troughability 2.60.0 se eee e eee eee ud5-3, 5-4, 5-5, 5-6, Belt Safety Factors . 5-3-1, Clastfication of Safety Factors. 2) Primary Safety Factor (SF). b) Tertiary Safety Factor (SF3) . ©) Minimum Safety Factor (SFmin) 5-3-2, Standard Safety Factor Values for Designing . a) Steel Cord Belt... ») Fabric Belt... : Determining the Thickness of the Rubber Cover . . S-4-1, ‘Thickness of the Top Rubber Cover a) Steel Cord Belt wee ee eee ees >) Fabric Belt. cet 5-42, Determining the Thickness of the Bottom Rubber Cover. Calculation of Approximate Weight of Conveyor Belt 5-51, Steel Cord Belt 5-5-2. Fabric Belt. Splicing 5-6-1. Steel Cord Belt... 5-6-2, Fabric Belt. . 4 5-6-3. Splicing Length. ... pa Packing... Fetal setae diseeaneoeestie bao. 5-7-1, Dimensions of Packing Drum. “49 5-7-2, Drum Markings . 7 CONVEYOR BELT DESIGN 6-2, 63, 64, 6S. CONVERSION TABLES . . Determination of Pulley Diameters... . 6. Steel Cord Belt... 06.0005 6-1-2. Fabric Belt... ... 000s ‘Troughing Transition Distance sane een eanenene + 6-2-1, When the Pulley Face is at One-Half the Depth of Troughing . 6.2.2. When the Pulley Fae s on the Same Level asthe Carrer Roler Minimum Bending Rad 6. ‘Convex Conver 6-3-2, Concave Conversion 6-3-3, Tension at Conversion Point . Determination of Turnover Distance eng) 6-4-1. Supporting the Intermediate Section witha Fat Roller. ein 6-4-2. Supporting the Whole Length of Turnover Distance with Support Rois Determination of Takes Length ; 6-5-1. Stee Cord Bet... 6-5-2. Fabric Bet. Determination of Take-up “Counterweight wna 1. PREFACE ‘The beit conveyor system is the most convenient and economical means of transporting materials in. bulk ‘As the conveyor belt alone takes up 15-50% of the tolal cost of the belt conveyor, great attention must be paid to the design and selection of the conveyor belt, Il be perfectly suited to its task and be ical as possible in operation If excessive emphasis is placed on safety measures, the conveyor will not only rise considerably in cost, it will also fail to justify this higher cost in terms of performance. On the other hand, if too much emphasis is placed on economy, there is the danger of shortening the life of the conveyor belt, 1-1. Typical Belt Conveyor Arrangements Feed erute Loading skirt N) h + Head outtey Consequently, it is most important that the design and selection of a suitable belt arrangement be studied and scrutinized from every angle. And the basis for achieving an ideal design is @ thorough knowledge of belt conveyor design methods. With this in mind we have produced the Bridgestone Conveyor Belt Design Manual This manual explains, step by step and in simple terms, the conveyor belt design concepts adopted by Bridgestone Tire Company. We hope that our customers will find it a useful tool in the design and selection of conveyor belts that are perfectly suited to their needs, Discharge chute seaative Ti putiey | + Troushing carrying ilers* Closely spaced ile ‘Srub pulley at loading pownt® imoset idles, eaquited Return idles *Teaning idler, a reauiced vertiest sraviy ekeup Figure 1 - Supporting Structure Designed to Suit the Normal Elements of a Belt Conveyor 1-2. Drive Arrangements (8) Single Drive (@ = 180°) (without snub alley) (2) Single Drive with Snub Pulley ‘A snub pulley is used to enlarge the ‘wrapping angle (6 = 190° ~ 240") () S Osh pier |(© Tandem Type Single Drive © ‘Although two pulleys are used, only fone acts as the drive pulley (9 = 190° ~ 240"), Tandem Drive @ GF the two drive pulleys placed adja cent to each other, only one drives + ‘one of the shafts ditecly. The other pulley-shaft is driven by gears or by chain or by V-Belt (6 = 360" ~ 420°). (© _ Dual Drive (© Primary ‘This is a system in which two drive pulleys are used, each of which is driven by separate motors, ‘Snub pulley Secondary ‘rive pulley (0 Multiple drive : It is possible to drive a belt conveyor at more than one place along its length. Two or mort pulleys, each driven by a separate motor, can be ‘used. This arrangement is most appli cable to longdistance and volume fil) Inauling as i reduces the conveyor’s frimary crive pulley =_— maximum tension and saves the mo- tors from overstraining, ‘Tertiary dye pulley eimary drive pulley Secondary dive pulley1.3, Belt Take-up System (Screw Type (®) Vertical Gravity Type U © Horizontal Gravity Type Mo: Motor for Take-up B : Break EC: Eddy current coupling TG: Speed detectig generator TO: Tention sensor (Mapnecel) ‘SPC; Speed controlerCONVEYOR BELT ANALYSIS SHEET (Separate Sheet Required far Each Conveyor) (NEWOR REPLACEMENT, ..... DATE. BELT DESIGNATION | LOCATION |. tie Reseed GENERAL CONVEYOR DATA "Bele with. - : mm ‘Horizontal © aistanca reecer ‘Maxcengle incline «- . esters Mi angie dealing =. eorees Overall ie ‘meter or 100. meter Bale apead. 22 Bet inate Tripper height = eres seater Alignment : Rete Is conveyor enclossd? | DRIVE DATA ‘*Losotion of drive ‘Nurmber of drive pulleys Arcot contact in degrees | ‘Are dive pulleys apded 7 [Motor type and horsepower peapeeeeeeeet Type of motor sting. cere CARRYING IDLERS. ‘*Troughing angle Equal length ‘Long center ro Other Spacing 01 Dismeter ¢ AETURN IDLERS. *Spacing Diameter : PULLEY DIAMETERS, Site see *Drive. | waite snus’ | Toke-up Tepper omer IL sPREVIOUS BELT HisToRY Belt dexrption: Size... Present bolt specification «> Present Belt Ras handled = <> : Deterbe completely present condition of belt” - Best previous serves || Moke and specification of best batt» Deseribe how thisbelt fale - « ‘sine niermation” anioacsrone BELT RECOMMENDATION * Misia ttormation required: owever, inorder to provide the bet recommendation, lower. ulimats Biting eos, shouts be comoleted. TAKE-UP DATA TYPE: sot or counemeiht “Travel ness W counterwaighe, weight 5 Location on eumeyor = 622.1 METHOD OF JOINING ‘Nuleanizes slice. MATERIAL DATA 2 mene TH satan lamp size ent fine fe eee “Temps. =| depress davees hax | ‘Abrasive character : Deserve any ol Condition (Other conditions| Loaping CONDITIONS Number of laading paints Locations = ; Incline angle of belt at tosdina point *Overal vertical 6rop of material onto belt | De oasing chutes: a Dischorge lnaiaction of bet wave Discrete cose bel Soest? ‘Center load on bel. «= Load ings on bel Fist? “Arg impact idles provided?” onrees +t This Information it abeoutaly inimenesble in making the best posible recammendation for & repiscerent conveyor bel Radius of ConcaveDESIGN CALCULATIONS Maximum Running Bek Tension... +--+. Rated Tension .. ale Batt Horsepower Required kw CCounterweight Requited ko CONVEYOR BELT RECORD4-5, Transport Material Size and Minimum Belt Width ‘The width of the conveyor belt varies in accordance with the transportation capacity of the conveyors as well a5 the lump sizes of the materials fo be trans: ported, ‘This means that if the lump sizes of the materials to be transported are large, the belt width must be pro- portionally wider, and vice versa, Table 1 shows the minimum widths of belts for specific lump sizes of materials to be transported, Columa A indicates lumps of approximately uniform size and Column B indicates lumps of mixed sizes. In B, belt widths have been calculated on the assu.nption that maximum lump sizes make up no more than 10% of the whole, TABLE 1. ransport Material Size and Minimum Bete Width [Lump Sizes nm) Minimo Bel Width x z ‘Gan Uniform Mixed a o 100 450 75 12s 300 as 150 600 10 200 1-6. Angle of Incline or Decline of Bett Conveyor ‘The angle of incline or decline is governed by the characteristics and shapes of the materials to be trans- ported. For example, a comparatively sleep stope can be safely adopted for transporting granular and other such stable materials, whereas a gentler slope is prefer- able for transporting unstable materials such as coal. ‘The maximum permissible angles of incline or decline for transporting materials of different characteristics and shapes on smooth-surfaced conveyor belts are given in Table 2. Note the following points: 1, When a weigher is used, it is preferable for the incline/dectine angle to be limited to less than 18°, regardless of the figures given in- Table 2. 2. When conditions at the site of installation or other factors make it impossible to keep within the maxi- mum allowable incline/decline angle value, a rough top, cleated or finned conveyor belt should be employed. 3. The incline/decline angle values given in Table 2 apply to operation under conditions where the belt surface is maintained in a comparatively clean con: dition. If the surface is wet or dirty, incline/dctine angles should be reduced by 2~5° from the given valuesi TABLE 2. ‘Angle of incline or Decline of Belt Conveyor Penile Materia Lamp Size wee ‘arate ©) cout ‘Over 100 men 15 Under 100 mm 16 Nowuniorm 18 Diy fine 20 Wet fine 2 Coke Uniform a Wonuniform 18 Fine 20 Conte | 150mm 2 100mm 20 50 mm 24 Rock Ores 100 am 1s 40~ 1¢0 mm 16-18 Under 10 mm 20 ow Over 100 mm 8 Under 100 mm 20 Limestone | Over 100 mm 8 Under 100 mm 20 Lime Fine 2B Cement Fine 2 sutphur Fine 2 Phosphate Ore | Over 100 mm 1s Under 100 min 8 Fine 30 Gravet Washed, uniform a Unwashed, omusifoem 5 Nowaniform 18 Sand Dry 1s Wet 20 For casting foundry) Fr Earth Dy 2» Wet 2 Wood on n Boxes 1s~25 20 salt 1-7, Bett Speed ‘The speed of the belt is limited not only by the trans port capacity of the conveyoi, but also by the belt width and the characteristics of the materials carried, Ik is most economical to use a narrow belt at high speeds, but generally it is easier to operate wide belts at high speeds than narrow belts. ‘Tables 3 and 4 give the maximum belt speeds in relation to specific transport materials and belt widths respec- tively. TABLE 3. Belt Speed ~ Maximum Belt Speeds ‘under Special Conditions eat Belt Speed (fring) Packages 1560 Palpwood (logs) 30 Maximum for Sorting Pulpwood 90~ 120 Handicap: Siow Discharge snd Speed-Down Operation Jet Slinger ~ Trimmers — Chargers ‘600~ 1,000 Portable Conveyors 80~ 140 Wheel Exewvators 20 ~ 360 Picking Belts 15~20 TABLE 4, Belt Speed ~ Maximum Belt Speeds unit n/n, ‘Beit Width (mam) A B c 400 180 150 150 450 210 180 140 500 240 180 180 600 240 210 200 240 210 200 | 270 0 20 70 40 ‘20 300 250 240 300 250 240 300 250 240 330 300 20 360 330 270 360 330 20 = 360 300 2,000 - 360 300 2,200 ~ 3,000 = 360 300 ‘A. Grains and other free flowing materials B. Overturden (eun of mine coal and other sich moderately sbrative materiale) (C. Hatd ore, rock and other very abrasive material2. ‘TRANSPORT CAPACITY ‘The transport capacity of 2 conveyor belt per unit time is governed by the belt speed, type of carter, angle of ineline/decline, characteristics and shapes of materials to be transported, ete. But for general pur poses the capacity can be calculated by the formula Biven below: 24. Calculation Formule t= 60Avys Where Qt: Transport capacity (tons per hour) (wonjhe) A: Cross-sectional area of load (m*) ¥ Bolt speed (am/min.) 7. Apparent specific gravity of material Conf ty angle of inetineldectine s+ Coefficier (table 8) 22, CroseSectional Area of Load “A” ‘The crosssectional area of load is as shown in the diagrams below, It is usually calculated from the top The following table gives numerical values in relation to the arrangement of the cartier rollers and the sur- charge angle of the transport material TABLE 5. Coefficient of Sectional Area “K’ section of the load, called the “arc,” and the base con tetionelkd the “caer tut asthe sen of | Gear | aah nchatne Angie eee) calevation is very complicated, & simpler formula is soe | Ane io » % sven here: Flt 0 {2s | o0ss1 | a0s0 Ak (093-005? vo {00609 | anges | 0.1259 15 | 0817 | a1i06 | oasoe Where 20 | 00363 | oines [cise Sectional area of load (m*) 2s [oats | onsen | o.t6or Coefficient of sectional area vim Tee Width of belt (m) see | auase_| arse volt 3s [ona [_oisee | ones? tourk f. a0 |_ craze | ones | aves 45 | o1sco | oave | cine so | oasse [ois | aime 35 | o1s7 | oavs6 | aus0? | vise [ aine | oaeso 30_| onze | oasse | 016s sue | 01336 | oases [019 ro, [50 | oawss [cane | 01996 oo | 01598 | oxv9o | 01989 ~ [70 [oness | oteos | osas AK (08b-0.051"