CONVEYOR DRIVE SIZING

Customer : SIME DARBY Quotation No. : 4854/DCH/09/LOW

Project : KERDAU POM Date : 4/8/2009
Subject : FFB INCLINED CONVEYOR Page : 1 Of 1

ONLY CHANGE THE VALUE IN

INPUT INFORMATIONS :
MILL CAPACITY 60 MT/HR.

CONVEYOR TYPE / LOCATION FFB (FFB, SFB)

Horizontal Parts 28 m
Inclined Parts 15 m
Inclined Angle 30 ˚
FFB Flow Rate 180 MT/Hr.
Linear Speed : Minimum Maximum
Chain Speed (m/min.) 16 m/min. 22.5 m/min.
Sprocket RPM = 5.00 RPM = 7.03 RPM

Drive Speocket 6 " Pitch 21 Teeth

Total Force = 44.03 kN

Total Torque Required = 22,426 Nm

DRIVE : GEAR BOX & HYDRAULIC MOTOR SIZING

GEAR BOX SIZING

Drive Required = 2 Drive (Single Drive Or Twin Drive)

For Each Drive, Torque = 11,213.05 Nm

Gear Box Selected : 307 L3, i = 113

* Gear Box Model : 305, 306, 307, 309, 310, 311, 313 or 314
Refer data sheet of gear box 307 ,nominal torque@ n2.h 100,000 hrs = 10,500 Nm
Maximum rated torque, M2max = 16,800 Nm
= 1.50 * Minimum Safety Factor 1.75
Calculated Safety Factor
SAFETY FACTOR TOO LOW !!!
Mills Operation Time = 20 hrs/day 300 days/year
From Table n2h = 100,000
Bearing Life, h = 3.33375 Years

HYDRAULIC MOTOR SIZING

Hydraulic Motor Torque = 99.23 Nm
Operating Pressure, P (Bar) = 139 bar *MAXIMUM PRESSURE : A2FM MOTOR
Motor Selected = A2FM 45 X 2 Unit 350 BAR

POWER UNIT SIZING

a) PUMP SIZING
Hydraulic Pump Capacity = 54.79 cc/Rev. Required
* Pump Selected : A10VSO 71 (Adjust to 55 cc)
* Hydraulic Pump Model : 28, 45, 71, 100 OR 140

b) ELECTRIC MOTOR SIZING

Power (kW) Required = 20.11 kW

Motor Selected = 22 kW
 CONVEYOR DRIVE SIZING
Customer : SIME DARBY Quotation No. : 4854/DCH/09/LOW
Project : KERDAU POM Date : 4/8/2009
Subject : FFB INCLINED CONVEYOR Page : 2 Of 2

ONLY CHANGE THE VALUE IN

INPUT INFORMATIONS :
Horizontal Parts 28 m
Inclined Parts 15 m
Inclined Angle 30 ˚
FFB Flow Rate 180 MT/Hr.
Linear Speed : Minimum Maximum
Chain Speed (m/min.) 16 m/min. 22.5 m/min.
Chain Speed (m/s) 0.27 m/s 0.38 m/s
Chain Speed (m/hr.) 960 m/hr. 1350 m/hr.
Sprocket RPM
Linear Speed (m/s) X 60 (Sec.)
RPM =
πXD
= 5.00 RPM = 7.03 RPM
Drive Speocket 6 " Pitch 21 Teeth
Sprocket Circumference 3200.4 mm = (πD)
Sprocket Ø = 1.02 m
Sprocket rarius, r = 0.51 m

FFB Flow Rate (T/hr.)

Conveyor Average Load =
Chain Speed (m/hr)
180
=
960.0
= 0.1875 Tons/meter
= 187.5 kg per meter length of conveyor (Assume conveyor fully loaded)
Horizontal Load = Length X Average Load
= 5.25 Tons
= 5,250 kgs
= 52.50 kN
Vertical Load = Length X Average Load
= 2.8125 Tons
= 2,813 kgs
= 28.13 kN
Total Mass (Horizontal+Vertical) = 8,063 kg
Total Load (Horizontal+Vertical) = 80.63 kN
Assume µ = 0.25

Total Force Calculations :

1) Horizontal Element Force = Mass X µ
= 13.125 kN
2) Incline Element Force
a) 1st Part (Sliding) = µR
= µ X Load X Cos (Angle)
= 6.09 kN
b) 2nd Part (Lifting) Force = Mass X Sin (Angle)
= 14.06 kN
3) Acceleration Force, F=ma Where m = total mass (N), a = acceleration time (sec.)
Assume time to accelerate from 0 m/sec. to 0.27 m/sec. = 0.2 sec.
Therefore, a = 1.33333 m/s²
m = 8,063 kg
Hence, acceleration force, F = 10750 N
= 10.75 kN
Total Force = (1) + (2a) + (2b) + (3)
= 44.03 kN

Total Torque Required = Total Force(N) X Sproket Radius (m)

= 44.03 X 0.51
= 22,426 Nm
 CONVEYOR DRIVE SIZING
Customer : SIME DARBY Quotation No. : 4854/DCH/09/LOW
Project : KERDAU POM Date : 39911
Subject : FFB INCLINED CONVEYOR Page : 1 Of 2

GEAR BOX & HYDRAULIC MOTOR SIZING

GEAR BOX SIZING

Drive Required = 2 Drive (Single Drive Or Twin Drive)

For Each Drive, Torque = 11,213.05 Nm

Gear Box Selected : 307 L3, i = 113

* Gear Box Model : 305, 306, 307, 309, 310, 311, 313 or 314
Refer data sheet of gear box 307 , nominal torque@ n2.h 100,000 hrs = 10,500 Nm

Maximum rated torque, M2max = 1.2 X Mn2 (n2.h = 10,000)

= 1.2 X 14,000 Nm
= 16,800 Nm

16,800
Calculated Safety Factor =
11,213

= 1.50 * Minimum Safety Factor 1.75

SAFETY FACTOR TOO LOW !!!
From Table n 2h = 100,000
n2 = 5.00 RPM 20 hrs/day
h = 20,002.50 Hrs 300 days/year
Bearing Life, h = 3.334 Years

HYDRAULIC MOTOR SIZING

Gear Box Torque Required = 11,213.05 Nm
Gear Box Ratio = 113 : 1

Hydraulic Motor Torque = Gear Box Torque / Ratio

= 99.23 Nm

1.59 X Vgm (Displacement) X P (Bar)

Torque (motor) =
100

If Hyd. Motor displacement, Vgm = 45 cc/rev. selected, * Hydraulic Motor Model :

28, 45, 63, 80 or 125
Torque(motor) X 100
Operating Pressure, P (Bar) =
1.59 X Vgm (Displacement)

99.23 X 100
=
1.59 X 45

= 139 bar *MAXIMUM PRESSURE :

A2FM MOTOR : 350 BAR

Motor Selected = A2FM 45 X 2 Unit

V (Motor) Selected = 45 cc/rev 2 Unit

POWER UNIT SIZING

a) PUMP SIZING

Sprocket RPM = 7.03 RPM

Total Flow Required = Sprocket RPM X Ratio X Motor (cc) X 90% Efficiency
By Hydraulic Motor = 79,443.19 cc/min
= 79.44 l/min.

Electric Motor RPM = 1,450 RPM

Hydraulic Pump Capacity = 54.79 cc/Rev.

* Pump Selected : A10VSO 71 (Adjust to 55 cc) * Hydraulic Pump Model :

Pump Capacity = 55 cc/Rev. 28, 45 or 71
= 79.75 l/min

b) ELECTRIC MOTOR SIZING

Pressure (Bar) X Flow (l/min)
Power (kW) =
550 (Factor)

139 Bar X 79.75

=
550
= 20.1 kW
Motor Selected = 22 kW