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"Design Conveyors PDF
"Design Conveyors PDF
Research Paper
DESIGN AND SELECTING THE PROPER CONVEYOR-BELT
Konakalla Naga Sri Ananth1, Vaitla Rakesh2,
Pothamsetty Kasi Visweswarao3
5.1. Belt speed: The quantity of material per linear meter loaded on
Very high speeds have meant a large increase in the the conveyor is given by the formula:
volumes conveyed. Compared with the load in total
there is a reduction in the weight of conveyed
material per linear meter of conveyor and therefore where:
there is a reduction in the costs of the structure in the qG = weight of material per linear meter
troughing set frames and in the belt itself. The Iv= belt load t/h
physical characteristics of the conveyed material are v = belt speed m/s
the determining factor in calculating the belt speed. qG is used in determining the tangential force Fu.
With the increase of material lump size, or its 5.1.1. Maximum speeds advised:
abrasiveness, or that of its specific weight, it is
necessary to reduce the conveyor belt speed.
Considering the factors that limit the maximum In the past the inclination of the side rollers of a
conveyor speed we may conclude: troughing set has been 20° . Today the improvements
When one considers the inclination of the belt in the structure and materials in the manufacture of
leaving the load point; the greater the inclination, the conveyor belts allows the use of troughing sets with
increase in the amount of turbulence as the material side rollers inclined at 30° / 35°.
rotates on the belt. This phenomenon is a limiting It may be observed however that the belt width must
factor in calculating the maximum belt speed in that be sufficient to accept and contain the loading of
its effect is to prematurely wear out the belt surface. material onto the belt whether it is of mixed large
The repeated action of abrasion on the belt material, lump size or fine material.
given by numerous loadings onto a particular section In the calculation of belt dimensions one must take
of the belt under the load hopper, is directly into account the minimum values of belt width as a
proportional to the belt speed and inversely function of the belt breaking load and the side roller
proportional to its length. inclination as shown.
5.2. Belt width: 5.2.2Minimum belt width:
The optimum belt speed, the determination of the belt
width is largely a function of the quantity of
conveyed material which is indicated by the design of
conveyed belt.
In practice the choice and design of a troughing set is
that which meets the required loaded volume, using a
belt of minimum width and therefore the most
economic.
5.2.1. Calculation of Belt width:
In the following section, the conveyor capacity may 5.2.3.Loaded volume IM:
be expressed as loaded volume IVT [m3/h] per v= 1 The volumetric load on the belt is given by the
m/sec. formula:
The inclination of the side rollers of a transom (from
20° to 45° ) defines the angle of the troughing.
Troughing sets at 40° / 45° are used in special cases, where:
where because of this onerous position the belts must Iv = load capacity of the belt [ t/h ]
be able to adapt to such an accentuated trough. qs = specific weight of the material
Also defined as:
Where:
5.2.4. Corrects loaded volume in relation to the IVM is the loaded volume corrected in relation to the
factors of inclination and feed: inclination and the irregularity of feeding the conveyor in
In the case of inclined belts, the values of loaded m3/h with v = 1 m/s.
volume IVT [m3/h] are corrected according to the IVT is the theoretic load in volume for v= 1m/s.
K is the factor of inclination.
following: K1 is the correction factor given bythe feed irregularity.
IVM = IVT X K X K1 [m3/h]
The inclination factor K calculated in the design, The output rpm is calculated using the formula,
must take into account the reduction in section for the
V=
conveyed material when it is on the incline.
Where,
Diagram gives the factor K in function of the angle of
D = Diameter of driving pulley
conveyor inclination, but only for smooth belts that
= 630 + 12 + 12 = 654 mm [According to IS, 630
are flat with no profile.
mm diameter of driving pulley is suitable for the
Factor of inclination K:
motor of power which is less than 50 kW & 24 mm
(12 + 12) extra diameter is provided due to lagging of
the pulley]
.
⇒ 1.2 =
.
⇒N= = 35.043rpm
.
5.7. DESIGN OF SHAFTS:
5.7.1. DRIVE PULLEY SHAFT DESIGN
Considering all the resistances (including wrap &
bearing resistances), we get the torque from the
following formula
!
PA =
In general it is necessary to take into account the "#
⇒T=
nature of the feed to the conveyor, whether it is
.
constant and regular, by introducing a correction = [N=35.043 rpm at output]
.
factor K1 its value being :
= 6383 N-m
• K1 = 1 regular feed = 6.383 KN-m
• K1 = 0.95 irregular feed Tension in the belt = T / r
• K1 = 0.90 ÷ 0.80 most irregular feed. =6.383/0.327
If one considers that the load may be corrected by =19.51 KN
the above factors the effective loaded volume at the Now, consider
required speed is given by: TE = 19.51 KN
IM = IVM x v [m3/h] We have,
Given the belt width, one may verify the relationship T1 = Carrying side belt tension
between the belt width and the maximum lump size ξ
T1 = TE [ µ, + 1]
of material according to the following: + -
Rwd = Wrap resistance for drive pulley (230 N) T2 = Return side belt tension
Rbd = Pulley bearing resistance for drive pulley (100 T2 = T1 - TE
N) = 31.01 – 19.198
Therefore, = 11.812 KN
.
PA = 23.028 + W = weight of the drive pulley
= 23.028 + 0.396 = 23.424 kW = 750 Kgs = 7357.5 N = 7.357 KN
5.4. MOTOR POWER
The motor output power (shaft) is given by
P
PM = A
η
Where,
η = Overall efficiency by taking the power losses of
gear-box and couplings into account.= 0.94 Resolving horizontal and vertical components
Therefore, FH = T1 cos10.360 + T2 cos19.64
.
PM =
. =30.504+11.124
= 24.49 kW = 41.6285 KN
5.5 .MOTOR SELECTION FV = T1 sin10.360- T2 sin19.640+ W
At present, all the motors are of 1500 rpm. = (31.01 sin10.360) –(11.812 sin19.640) +7.3
By referring the catalogue, the selected motor is of 37 = 5.576 - 3.97 + 7.3
kW/1500 rpm (Nominal power). = 8.906KN
The shaft diameter of the motor is 60mm. Horizontal loading
5.6. GEAR BOX SELECTION:
For gear box selection, we need to calculate the
reduction ratio.
Reduction ratio =
As the motor is of 1500 rpm,
Input rpm = 1500 rpm
IJAET/Vol. IV/ Issue II/April-June, 2013/43-49
Ananth et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945
Point load acting at C, RCH = FH/2 = 41.628/2 = Where Kb = bending service factor = 1.5
20.814 KN Kt = torque service factor = 1.25
Point load acting at D, RDH = FH/2 = 41.628/2 = Therefore, Teq = 47.44 = 1.5 7 6.278 = 1.25
20.814 KN =13.64kN-m
Taking moment at A,
Allowable shear stress (τs) = 0 x Teq
∑MAH = 0 A
0
!CD
⇒ (RCH x 0.35) + (RDH x (0.35+ 1.150)) – (RBH x ⇒d= B
τE
1.850) = 0
0
.
0
⇒ (20.814 x 0.35)+(20.814 x 1.5)– (RBH x 1.850) = 0 =B
⇒ RBH = 20.814 KN
3
Therefore, d = B
Similarly, RAV = 4.453 KN
Vertical moments
1 .
T
= 106.44 mm
So, selected shaft size is 115 mm at bearing and 120
mm at hub.
5.7.2. TAIL PULLEY SHAFT DESIGN
Tail tension (Tt)
Moment at C , = T2 + [f x L x g x (mB + mR)] – [H x g x mB]
MCV = RCV x 0.35 = (11.5812 x 103) + [0.030 x 29 x 9.81 x (20 +10)] –
= 4.453 x 0.35 [5.112 x 9.81 x 20]
= 1.558kN-m = 10834.271
Moment at D, = 10.834 KN
MDV = RDV x 0.35 Weight of the tail pulley (W) = 520 Kgs = 5101.2 N
= 4.453 x 0.35 = 5.1 KN
= 1.558kN-m
Resultant moment at C = 456 7 568
=47.2849 7 1.558 = 7.44kN-m
Resultant moment at D = 45 7 58 =
47.2849 7 1.558 = 7.44kN-m
Case-1: Based on Equivalent torque Resolving horizontal and vertical components
We know FH = Tt cos10.360 + Tt cos10.360
T= 6278 Nm = 6.278kN-m = 2 x Tt x cos10.360
M = MCR = MDR = 7.44kN-m = 2 x 10.384 x cos10.360
Equivalent torque Teq = 45 = >? 7 @ = > = 21.31 KN
IJAET/Vol. IV/ Issue II/April-June, 2013/43-49
Ananth et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945
d= B
1 .
T
= 89.53 mm
So, selected shaft size is 100 mm at bearing and 110
Point load acting at C, RCV = FV/2 = 1.204/2 = 0.602 mm at hub
KN 6. Components of belt conveyor:
Point load acting at D, RDV = FV/2 = 1.204/2 = 0.602 6.1.1. Carrying Idler:
KN
Taking moment at A,
∑MAV = 0
⇒ (RCV x 0.35) + (RDV x (1.5)) – (RBV x 1.85) = 0
⇒ (0.602 x 0.35) + (0.602 x 1.5) – (RBV x 1.85) = 0
⇒ RBV = 0.602 KN
Similarly, RCV = 0.602 KN 6.1.2. Impact Idler:
Vertical moments
REFERENCES
1. Steel Exchange India Ltd, “Belt Conveyor,” A.P, India.
2. V.B.Bhandari “Design of Machine Element,” Tata
McGraw Hill publishing company, eighth edition (2003).
3. R.S.khurmi & J.K.gupta “Design of machine
elements.”Eurasia publishing house(pvt.)Ltd,fivth
edition.
4. Design of shaft using Concept In design of machine
element by Susmitha (K L University)
5. Design and its Verification of Belt Conveyor System
using concept by Bandlamudi.Raghu Kumar Asst.
Professor (KL University)
6. CEMA (Conveyor Equipment Manufacturers
Association) “Belt Conveyors for Bulk Materials,
Chaners Publishing Company, Inc. 6thedition.
7. J.B.K. Das and P. L. Srinivas Murthy, “Design of
Machine Element,” (Part-II), Sapna Book House,
Bangalore, third edition (2007)
8. Fenner Dunlop “Conveyor Handbook” conveyor
belting,” Australia (June 2009)
9. Mathews “Belt conveyor,” FKI Logistex publication,
Cincinnati, ohio
10. J. B. K. Das and P. L. Srinivasa Murthy, “Design of
Machine Element,” (Part-I), Sapna Book House,
Bangalore, third edition
11. Design Data Book By PSG College of Technology.