DIN - 22101-2011-Belt-Conveyors

DEUTSCHE NORM December 2011
DIN 22101
D
ICS 53.040.20 Supersedes
DIN 22101:2002-08
Continuous conveyors –
Belt conveyors for loose bulk materials –
Basis for calculation and dimensioning,
English translation of DIN 22101:2011-12
Stetigförderer –
Gurtförderer für Schüttgüter –
Grundlagen für die Berechnung und Auslegung,
Englische Übersetzung von DIN 22101:2011-12
Engins de manutention continue –
Transporteurs à bandes pour produits en vrac –
Principes de base pour le calcul et la conception,
Traduction anglaise de DIN 22101:2011-12
Document comprises 56 pages
Normenausschuss Bergbau (FABERG) im DIN

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DIN 22101:2011-12
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Contents Page
Foreword ......................................................................................................................................................... 4
1 Scope ................................................................................................................................................. 5
2 Normative references ....................................................................................................................... 5
3 Terms and definitions ...................................................................................................................... 6
4 Symbols and units ............................................................................................................................ 7
5 Volume flow and mass flow ........................................................................................................... 12
6 Resistance to motion and required power for the steady operating condition ....................... 14
6.1 General ............................................................................................................................................. 14
6.2 Primary resistances ........................................................................................................................ 15
6.2.1 General ............................................................................................................................................. 15
6.2.2 Determination of primary resistance FH ....................................................................................... 15
6.2.3 Determination of the hypothetical friction coefficient ................................................................ 16
6.3 Secondary resistances ................................................................................................................... 17
6.3.1 General ............................................................................................................................................. 17
6.3.2 Determination of individual secondary resistances ................................................................... 18
6.3.3 Approximate calculation of secondary resistances.................................................................... 19
6.4 Gradient resistance ........................................................................................................................ 20
6.5 Special resistances ........................................................................................................................ 20
6.5.1 General ............................................................................................................................................. 20
6.5.2 Determination of individual special resistances ......................................................................... 20
7 Design and layout of the drive system ......................................................................................... 21
7.1 General ............................................................................................................................................. 21
7.2 Location of the drive units, size and number of drive motors ................................................... 22
7.2.1 General ............................................................................................................................................. 22
7.2.2 Horizontal and slightly inclined installations .............................................................................. 22
7.2.3 Uphill conveying installations ....................................................................................................... 23
7.2.4 Downhill conveying installations .................................................................................................. 23
7.2.5 Installations with uphill and downhill sections ........................................................................... 23
7.3 Starting, stopping and holding ...................................................................................................... 23
7.3.1 Starting ............................................................................................................................................ 23
7.3.2 Stopping and holding ..................................................................................................................... 24
8 Belt tensions and take-up forces .................................................................................................. 25
8.1 General ............................................................................................................................................. 25
8.2 Required belt tensions ................................................................................................................... 25
8.2.1 General ............................................................................................................................................. 25
8.2.2 Minimum belt tensions required for the transmission of pulley peripheral forces ................. 25
8.2.3 Minimum belt tensions required for the limitation of the belt sag and for correct belt
guiding ............................................................................................................................................. 27
8.3 Local belt tension variations in the top and return strands ....................................................... 27
8.3.1 General ............................................................................................................................................. 27
8.3.2 Steady operating condition ........................................................................................................... 28
8.3.3 Non-steady operating condition.................................................................................................... 28
8.4 Take-up forces and take-up distances ......................................................................................... 29
8.5 Local belt tensions in the upper and lower strands .................................................................... 31
8.5.1 General ............................................................................................................................................. 31
8.5.2 Non-steady operating conditions.................................................................................................. 31
8.5.3 Steady operating condition ........................................................................................................... 31
DIN 22101:2011-12
9 Distribution of belt tensions across the belt width ...................................................................... 31

9.1 General ............................................................................................................................................. 31
9.2 Transition curves ............................................................................................................................. 32
9.2.1 General ............................................................................................................................................. 32
9.2.2 Distribution of the belt tension for textile conveyor belts ..........................................................34
9.2.3 Distribution of the belt tension for steel cord conveyor belts ....................................................34
9.3 Curves............................................................................................................................................... 35
9.3.1 Horizontal curves ............................................................................................................................ 35
9.3.2 Vertical curves ................................................................................................................................. 35
10 Design and layout of the conveyor belt ........................................................................................ 37
10.1 General ............................................................................................................................................. 37
10.2 Design and layout of the tension member .................................................................................... 37
10.3 Design and layout of cover layers ................................................................................................. 40
11 Minimum pulley diameter ............................................................................................................... 41
12 Design and layout of transition curves and vertical curve radii.................................................42
12.1 General ............................................................................................................................................. 42
12.2 Determination of the minimum transition length ......................................................................... 43
12.2.1 General ............................................................................................................................................. 43
12.2.2 Conveyor belts with textile plies .................................................................................................... 43
12.2.3 Steel cord conveyor belts ............................................................................................................... 43
12.3 Determination of the minimum radius of vertical curves ............................................................ 44
12.3.1 General ............................................................................................................................................. 44
12.3.2 Convex curves ................................................................................................................................. 44
12.3.3 Concave curves ............................................................................................................................... 44
13 Dimensioning of belt turnovers ..................................................................................................... 44
Annex A (informative) Explanatory notes .................................................................................................... 46
Annex B (informative) Explanations of relationship of this standard to international standards ........53
Bibliography .................................................................................................................................................. 55
DIN 22101:2011-12
Foreword
This standard has been prepared by Working Committee Fördergurte (Conveyor Belts) of the Normenaus-
schuss Bergbau (FABERG) (Mining Standards Committee).
Annexes A and B are provided for information and are informative.
This standard relates to the standards ISO 5048:1989, ISO/DIS 3870:1996, ISO 5293:1981 and
ISO 3684:1990 issued by the International Organization for Standardization (ISO) (see Annex B).
Amendments
This standard differs from DIN 22101:2002-08 as follows:
a) the method for calculating motion resistances has been extended to cover belt conveyors where the
number of sections relevant for the calculation varies for the top and bottom strands;
b) the start-up factor pA and braking factor pB are now defined;
c) the clause “transition curves” has been condensed by combining the theoretical principles common to
textile and steel cord belts;
d) in the clause on the design and layout of the conveyor belt a factor has been introduced to account for an
irregular distribution of belt tension across the belt width;
e) information on calculating the pulley load factor has been added in Clause “Minimum pulley diameter”;
f) Clause “Determination of the minimum transition length” has been completely revised;
g) normative references have been updated;
h) the standard has been editorially revised.
Previous editions
DIN BERG 2101 Part 1: 1933-07

DIN BERG 2101 Part 2: 1933-07
DIN BERG 2101 Part 3: 1933-07
DIN 22101: 1942-02, 1982-02, 2002-08
DIN 22101:2011-12
1 Scope
This standard is applicable to belt conveyor installations for conveying bulk materials, and contains the
principles relating to their design. The standard makes it possible to specify essential requirements applicable
to major belt conveyor components such as drives, brakes and take-up devices for particular conveying
conditions. The standard also gives a description of the design and dimensioning of the conveyor belt.
2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.
DIN 15207-1, Continuous mechanical handling equipment — Idlers for belt conveyors — Main dimensions of
idlers for belt conveyors for bulk material
DIN 22102-1, Conveyor belts with textile plies for bulk goods — Part 1: Dimensions, specifications, marking
DIN 22102-3, Conveyor belts with textile plies for bulk goods — Part 3: Permanent joints
DIN 22107, Continuous mechanical handling equipment — Idler sets for belt conveyors for loose bulk
materials — Principal dimensions
DIN 22109-1, Conveyor belts with textile plies for coal mining — Part 1: Monoply belts for underground
applications — Dimensions, requirements
DIN 22109-2, Conveyor belts with textile plies for coal mining — Part 2: Rubber-belts with two plies for
underground applications — Dimensions, requirements
DIN 22109-4, Conveyor belts with textile plies for coal mining — Part 4: Rubber-belts with two plies for above
ground applications — Dimensions, requirements
DIN 22110-3, Testing methods for conveyor belt joints — Part 3: Determination of time strength for conveyor
belt joints (dynamical testing method)
DIN 22112-1, Belt conveyors for underground coal mining — Idlers — Part 1: Dimensions
DIN 22112-2, Belt conveyors for underground coal mining — Idlers — Part 2: Requirements
DIN 22121, Conveyor belts with textile plies for coal mining — Permanent joints for belts with one or two plies
— Dimensions, requirements, marking
DIN 22129-1, Steel cord conveyor belts for underground coal mining — Dimensions, requirements
DIN 22129-4, Steel cord conveyor belts for use in underground coal mining — Belt joints — Dimensions,
requirements
DIN EN 15236-1 1) Steel cord conveyor belts — Part 1: Design, dimensions and mechanical requirements for
conveyor belts for general use
ISO 3684:1990-3, Conveyor belts — Determination of minimum pulley diameters
1) Translator ’s note. The German original is incorrect. The standard number should read “DIN EN ISO 15236-1”.
DIN 22101:2011-12
3 Terms and definitions

For the purposes of this document, the following term and definition apply.
3.1
belt conveyor
continuous belt conveyor for bulk materials with circulating conveyor belts which feature tension members of
textile or steel cord ply and cover layers of rubber or plastic supported on carrying idlers and idler stations,
and driven or braked by friction grip via pulleys and driving belts where appropriate
NOTE Conveyor belts with cover plates made of rubber or plastic are described e.g. in DIN 22102-1, DIN 22109-1,
1)
DIN 22109-2, DIN 22109-4, DIN 22129-1 and DIN EN 15236-1 . Idlers and idler sets are described e.g. in DIN 15207-1,
DIN 22107, DIN 22112-1 und DIN 22112-2.
DIN 22101:2011-12
4 Symbols and units

Table 1 — Symbols and units
Symbol Meaning Unit

A Cross section of fill m2
A1 Partial cross section above water fill m2 (mm2) a
A2 Partial cross section with β = 0 (water fill) m2 (mm2) a
AGr Effective contact area between cleaner and belt mm2
B Belt width mm
C Coefficient for the approximate calculation of total secondary resistance –
DTr Pulley diameter mm
ELGk Elasticity module related to the width of the belt N/mm
Fa Forces resulting from acceleration/deceleration under non-steady operating

N
conditions
FAuf Inertia resistance of material conveyed and frictional resistance between

N
material conveyed and belt at the feeding point
FE Indentation rolling resistance: Sum of all indentation rolling resistances in the

N
upper and/or lower strands
FE,3 Indentation rolling resistance for a 3-roller idler set N
F' E Indentation rolling resistance related to the belt width N/m
FGa Resistances of material transfer devices arranged along the belt conveyor path N
FGr Friction resistance caused by belt cleaners N
FH Primary resistance: Sum of all primary resistances in the upper and/or lower
N
strands
F' M,v Vertical force related to the belt width N/mm
Fn Normal force acting on an idler N
FN Secondary resistance: Sum of all secondary resistances in the upper and/or

N
lower strands
FR Running resistance of idlers: Sum of all running resistances in the upper and/or
N
lower strands
FRst Camber resistance: Sum of all camber resistances for an idler set N
FS Special resistance: Sum of all special resistances in the upper and/or lower
N
strands
FSch Friction resistance between material conveyed and lateral chutes outside the
N
acceleration zone of feeding points
DIN 22101:2011-12
Table 1 (continued)
Symbol Meaning Unit
FSchb Friction resistance between material conveyed and lateral chutes within the
N
acceleration zone of a feeding point
FSp Take-up force at the axis of the take-up pulley N
FSt Gradient resistance: Sum of all gradient resistances in the upper and/or lower
N
strands
FT Local belt tension (strand tension) N
FTm Mean belt tension of upper strand and lower strand N
FTr Total pulley peripheral force N
FT1 Belt tension (strand tension) of the belt running onto a pulley N
FT2 Belt tension (strand tension) of the belt running off a pulley N
FW Motion resistance: Sum of all resistances to motion in the upper and/or lower
N
strands
Im Mass flow kg/s
Im,N Nominal mass flow kg/s
IV Volume flow m3/s
IV,N Nominal volume flow m3/s
L Distance axis-to-axis m
PM Total power of drive motors kW
PM,N Nominal drive motor capacity kW
PW Total power at the periphery of the driving pulley(s) required due to the motion
kW
resistances in steady operation
Ra Radius of a concave vertical transition curve m (mm)a
Re Radius of convex vertical transition curve m (mm)a
S Safety factor related to the nominal breaking strength of the belt –
S0 Safety factor taking belt splice manufacturing characteristics into consideration –
S1 Safety factor taking into consideration expected belt life and operational
–
stresses on belt
Smin Minimum value for the safety factor, related to the minimum nominal breaking
–
strength of the belt
 Acceleration or deceleration m/s2
b Usable belt width mm
bR Length of the contact line between belt and idler face m
bS Part of belt lying on a side idler (only for 2- or 3-roller idler sets) mm
bSch Clear width between chutes m
ca Factor used in the numerical equation describing the indentation rolling

–
resistance determined in relation to the belt width
cb Exponent used in the numerical equation describing the indentation rolling

–
resistance determined in relation to the belt width
DIN 22101:2011-12
Table 1 (continued)
Symbol Meaning Unit
cK Coefficient for determination of the minimum dynamic splice efficiency

–
corresponding to the width related belt tension in the belt edges
cR Coefficient for calculating the masses of the idlers reduced to their periphery –
cRank Rankine factor –
cRst Coefficient for the calculation of camber resistance –
Coefficient for taking into account additional resistance between material
cSchb conveyed and lateral chutes in the feeding zones caused by dynamic pressure –
of the mass flow fed in
cTr Coefficient for the determination of the minimum pulley diameter –
cÜ Coefficient for the determination of the standard value for the minimum
–
transition length
dGk Thickness of the load-bearing longitudinal tension member (without outer warp
mm
layer or weft, for example)
e Base of natural logarithms (e = 2,718 28.....) –
eK Distance from the centre line of belt plies at the edge of the belt to the neutral
mm
axis of the belt
eM Distance from the centre line of belt plies at the centre of the belt to the neutral
mm
axis of the belt
Hypothetical friction coefficient for the approximate calculation of the total
f –
primary resistance to motion of the upper and lower strands
fi Hypothetical friction coefficient for the approximate calculation of the primary

–
resistance of a section of the upper or lower strand
g Acceleration due to gravity (g = 9,81 m/s2) m/s2
Height difference of a section of the upper or lower strand (h > 0 for uphill belt
h m
travel, h < 0 for downhill belt travel)
hK0 Distance from the belt edge to the deepest level of the trough mm
hK1 Distance from the belt edge to the pulley surface level mm
hrel Maximum belt sag related to spacing between carrying idlers –
hTr Lift of the pulley in the transition zone above the deepest level of the trough mm
k Belt tension related to belt width N/mm
kK Tension at belt edge related to belt N/mm
kM Tension at belt centre related to belt N/mm
kN Nominal belt breaking strength related to belt width N/mm
kN,min Minimum nominal belt breaking strength related to belt width N/mm
kt Reference dynamic splice efficiency N/mm
kt,rel Relative reference dynamic splice efficiency –
Difference between width-related belt tension at the edges and that at the
∆k N/mm
centre of the conveyor belt
l Length of a section of upper or lower strand m
lb Length of the acceleration path in the feeding zone m
DIN 22101:2011-12
Table 1 (continued)
Symbol Meaning Unit
lK Length of the belt edge in the transition zone m
lM Length of the central roller in a 3-roller idler set mm (m)a
lSch Length of lateral chutes m
lR Spacing between carrying idlers m
lÜ Length of transition zone m
lÜ,eff Reference length of transition zone for steel cord belts m
∆lÜ lÜ,eff − lÜ for steel cord belts m
lW Belt turnover length m
Total of translatorially moving masses and non-driven and non-braked rotating
Σm kg
masses reduced to their periphery
m'G Line load resulting from the conveyor kg/m
m'L Line load resulting from the material conveyed kg/m
m'L,N Line load resulting from nominal load kg/m
m'R Line load resulting from rotating idler parts kg/m
n Number of sections of the upper or lower strands of a belt –
Start-up factor related to the drive pulley: ratio of the total pulley peripheral
pA force at start-up FTr,A , to the force FW determined by the height and –
distribution of the material conveyed
Start-up factor related to the drive: ratio of the drive torque resulting from the
effective drive characteristics during the start-up phase of the conveyor and the
pA0 –
nominal torque corresponding to the rated power of the motors actually
installed PM,inst
Braking factor related to the brake pulley: ratio of the total pulley peripheral
pB force at braking FTr,B to the force FW determined by the height and distribution –
of the material conveyed
Braking factor related to the brake: ratio of the braking torque resulting from the
effective braking characteristics during the braking phase of the conveyor and
pB0 –
the nominal torque corresponding to the rated power of the motors actually
installed PM,inst
pGr Pressure between belt cleaner and belt N/mm2
Coefficient for the determination of primary resistances for the upper and lower
q –
strands
sB Braking distance m
sSp Take-up pulley travel m
tB Braking time s
v Conveying speed m/s
v0 Feeding speed in the direction of conveying m/s
zR Number of carrying idlers in one section (upper strand or lower strand) –
zRst Number of carrying idlers in one section (upper or lower strand) set at a tilt –
10
DIN 22101:2011-12
Table 1 (continued)
Symbol Meaning Unit
α Angle of pulley belt wrap ° or rad
β Equivalent angle of slope for the calculation of the partial cross-section A1th °
βdyn Dynamic angle of slope of the material conveyed °
Angle of inclination of a section of upper or lower strand, δ > 0 for uphill belt
δ °
travel, δ < 0 for downhill belt travel)
ε Angle of tilt of a side idler °
∆ε K Additional elongation (pos. or neg.) at the edge of the belt in concave or convex
–
transition curves, in relation to the neutral belt axis
∆εK∞ Limit of ∆εK at the centre of very long transition curves –
∆ε M Additional elongation (pos. or neg.) at the centre of the belt in concave or

–
convex transition curves, in relation to the neutral belt axis
∆εM∞ Limit of ∆εM at the centre of very long transition curves –
∆ε ∞ Difference of elongation at the belt edge and in the middle of very long
–
transition curves
ηges Overall efficiency of all transmission members between motor shaft and pulley
–
shaft
λ Troughing angle of the conveyor belt in the upper strand or lower strand °
µ Friction coefficient between belt and pulley –
µ1 Friction coefficient between belt and material conveyed –
µ2 Friction coefficient between material conveyed and lateral chutes –
µ3 Friction coefficient between belt and carrying idler –
µ4 Friction coefficient between belt and belt cleaner –
ρ Bulk density of material conveyed kg/m3
ϕ Effective filling ratio –
ϕ Betr Filling ratio corresponding to the operating conditions of the conveyor –
ϕ St Reduction factor of filling ratio for the theoretical total cross section of fill Ath in
–
the case of inclined installations
Reduction factor of filling ratio for the theoretical partial cross section A1,th in the
ϕ St1 –
case of inclined installations
a in some equations these variables are used with the unit mentioned in brackets.
11
DIN 22101:2011-12
Table 2 — Indices
Index Meaning
A At start-up
B At stopping (braking)
a Non-steady operation (start-up, braking)
eff Effective
erf Required
i Running index for belt strand sections
j Running index for belt deflection points (at pulleys)
inst Installed
m Centre idler
max Maximum
min Minimum
o Upper strand
s Side idler
th Theoretical
u Bottom strand
zul Allowable
* Index for identifying operating conditions
5 Volume flow and mass flow

The maximum volume flow and mass flow of a belt conveyor is determined by the potential cross section of
fill, which is dependent on the dynamic angle of slope of the material conveyed and on the feeding conditions,
among other factors.
To calculate the maximum volume and mass flow a simple equivalent geometrical cross section needs to be
found. This theoretical cross section A th is calculated from the shape of the conveyor belt on the carrying idlers
and from the shape of the slope formed by the material conveyed. Figure 1 shows this cross section for a belt
supported by a 3 roller idler set, which is commonly used.
Figure 1 — Theoretical cross section of fill in the case of horizontal conveyance

and a 3 roller idler set
12
DIN 22101:2011-12
The theoretical cross section of fill is dependent on the length and arrangement of the carrying idlers
(troughing angle), the usable belt width b and the equivalent slope angle β describing a cross section of the
same area as the actual one. In this case, the usable belt width b shall be calculated as a function of the belt
width B as follows:
B ≤ 2 000mm b = 0,9 × B − 50 mm (1)
B > 2 000mm b = B − 250 mm (2)
The usable belt width of belt conveyors with horizontal curves and inclined idlers installed to stabilize the belt
may be smaller.
With 1-, 2- and 3-roller idler sets in horizontal belt conveyors, the theoretical cross section of fill A th that is
equivalent to the real cross section of fill can be established using angle β as the sum of partial cross sections
A1,th and A2,th (see [1], Figure 1 and Annex A):
tanβ
A1,th = [ lM + (b − lM ) ⋅ cos λ ] 2 ⋅ (3)
4
 b − lM  b − lM
A 2,th = lM + ⋅ cos λ  ⋅ ⋅ sin λ (4)
 2  2
The selection of an equivalent slope angle depends on the material to be conveyed as well as on the length of
the conveying distance. In case of lacking experience in selecting an adequate slope angle, the following
standard values can be applied:
The value will be β = 20° for materials with normal flow properties. Values below β = 20° down to β = 0° will be
characteristic for nearly liquid materials. Equivalent slope angles of more than 20° can be applied only in case
of materials with high internal friction.
For 1-roller and 2-roller idler sets, the length of the central roller shall be taken to be lM = 0.
The following parameters can be calculated on the basis of the theoretical cross section fill:
Theoretical volume flow I V, th = Ath ⋅ v (5)
And on the basis of the effective filling ratio ϕ = ϕBetr ⋅ ϕ St (6)
the following can be calculated:
Nominal volume flow IV,N = ϕ ⋅ Iv,th (7)
Nominal mass flow Im,N = ϕ ⋅ ρ ⋅ Iv,th (8)
Line load resulting from nominal load m'L,N = ϕ ⋅ ρ ⋅ Ath (9)
The filling ratio ϕ Betr depends on:
 properties of material conveyed

 lumpiness
 max. edge length
 dynamic angle of slope βdyn (characterizing the actual dynamic property of the slope)
 operating conditions of the conveyor
 uniform material feeding
 tracking of the conveyor belt
 reserve capacity
13
DIN 22101:2011-12
For horizontal, straight conveyors, the theoretical cross section can be fully utilized if uniform feeding of
material and straightforward belt movement is ensured (ϕ = ϕ Betr = 1).
The reduction factor ϕ St takes into consideration the fact that the partial cross section A1,th is reduced under
sloped conveying conditions:
A1,th
ϕ St = 1 − ⋅ (1 − ϕ St 1) (10)
Ath
A properly aligned belt uniformly loaded with non-lumpy material and δ max ≤ β dyn can be calculated as follows:
cos2 δmax − cos2 β dyn

ϕSt1 = (11)
1 − cos2 β dyn
Applying Equations (10) and (11) it shall be borne in mind that the angle of slope for downhill conveying
cannot be higher than the actual dynamic angle of slope βdyn (see also Annex A) and that only the partial cross
section A2,th is available for conveying.
6 Resistance to motion and required power for the steady operating condition
6.1 General
The method described below for the determination of motion resistances, the required power, and the local
belt tensions yields fairly realistic results for state-of-the-art technology, even for complex conveyor
installations and all possible operating conditions.
Experienced design engineers can simplify the calculation method for ordinary belt conveyors with
manageable operating conditions and for those that do not require a high degree of accuracy, provided that
safety requirements are met.
Prior to calculating the resistance to motion, individual base values shall be estimated. These values shall be
checked and corrected, if necessary, after completing the calculation. The calculation shall be repeated as
many times as necessary to match the results with the input values.
During steady operation, the forces resisting belt movement (resistances to motion) FW are calculated by the
summation of friction, weight and mass forces. The required power for the conveyor PW is calculated as a
product of the total motion resistance of the upper and lower strands and the conveying speed v.
PW = FW ⋅ v (12)
For the calculation of motional resistances, the following parts are defined:
 primary resistance FH
 secondary resistance FN
 gradient resistance FSt
 special resistance FS
The sum of the above types of resistance to motion FW is equal to the total pulley peripheral force FTr to be
transmitted to the belt:
no nu
FW = ∑ FW,o,i + ∑ FW,u,i = FH + FN + FSt + FS = FTr (13)
i =1 i =1
14
DIN 22101:2011-12
The resistances shall be established for individual sections. Each section is characterized by the fact that
parameters such as the angle of inclination  i of the section, the hypothetical friction coefficients f i and the line
loads due to material to be conveyed m'R,i and the rotating idler parts m'L,i have constant values for both the
upper and lower strands. Hence it is advisable — particularly with regard to computer calculations — to assign
a running index i to the start points and end points of all part sections of the conveyor installation, starting from
the tail station toward the head station. Upper strand values shall be identified by index o, lower strand values
by index u (see Figure 2). In order to maintain the assigned descriptions, belt deflection points (at pulleys) and
their parameters shall be identified by index j (see Figures 5 and 6).
6.2 Primary resistances
6.2.1 General
Primary resistance occurs along the entire length of the conveyor path. The parameters of primary resistance
shall be determined for individual sections.
Figure 2 — Creation of belt sections and calculation of motion resistances for each section
in a steady operating condition
6.2.2 Determination of primary resistance FH
The primary resistances FH,i of all sections are to be determined separately for the upper and lower strands of
each individual section, in a simplified manner assuming a linear relationship between the resistance and the
moved load:
[ ′ i + (mG
FH, i = li ⋅ fi ⋅ g ⋅ mR, ′ i ) ⋅ cosδ i
′ + mL, ] (14)
The primary resistances of the upper strand sections FH,o,i and lower strand sections FH,u,i are indispensable
for the determination of belt tensions (see 8.3).
The primary resistance of the conveyor, i.e. the sum of primary resistances for the upper strand FH,o and those
for the lower strand FH,u can be calculated as follows:
no nu
FH = ∑ F H,o,i + ∑ F H,u,i = FH,o + FH,u (15)
i =1 i =1
Primary resistances for each section shall be calculated for the nominal loading range (filling ratio ϕ within the
range 0,7 to 1,1) along the entire conveyance path.
For belt conveyors with downhill and uphill sections, and for extreme loading conditions (non-uniform load,
partial loading or idling), the cumulative resistance determined under these conditions can deviate significantly
from that arising under nominal conditions.
15
DIN 22101:2011-12
6.2.3 Determination of the hypothetical friction coefficient
The selection of a hypothetical friction coefficient fi is of major importance as regards the magnitude of primary
resistances. This is especially important for conveyors with small gradient resistances. Attempts to be on the
safe side with calculations, together with a case-by-case inaccurate description of the operating features and
a wide range of possible values can lead to considerable over-dimensioning. In order to avoid disproportional
dimensioning, the friction coefficients fi are to be established as precisely as possible for the individual
sections. The values for f given in Table 4 can serve as guidelines in a global calculation of the sum of all
primary resistances in the top and bottom strands.
The friction coefficient fi of a section is defined mainly by the rolling resistance of the carrying idlers and the
indentation rolling resistance of the belt. Also the flexing resistance can have a large share in this, if the sag of
the conveyor belt is relatively large.
For a more precise determination of the friction coefficient fi aiming for a safe conveyor design combined with
a minimum investment and lower operational costs, the running resistance of the idlers and the indentation
rolling resistance can be measured for given parameters and the other resistances can be estimated (see [2],
[3], [4] and [5]).
With a normal magnitude of flexing resistance the running resistance of the idlers and rolling indentation
resistance of the loaded strand (usually of the upper strand) with a filling ratio ϕ within the range of
0,7 ≤ ϕ ≤ 1,1, generate between 50 % and 85 %, on average 70 %, of the primary resistance FH,o. They
amount to approx. 90 % of the primary resistance for the unloaded strand (usually that of the lower strand,
FH,u. Considering this following relationships apply:
1
Upper strand (loaded) FH,o = ⋅ ( FR,o + FE,o ) (16)
qo
1
Lower strand (unloaded) FH,u = ⋅ ( FR,u + FE,u ) (17)
qu
with 0,5 ≤ qo ≤ 0,85, on average qo = 0,7 and qu = 0,9.
Guidelines for estimating coefficient qo are given in Table 3.
Table 3 — Standard values for coefficient q0 for a filling ratio ϕ within the range 0,7 ≤ ϕ ≤ 1,1
Characteristic Values for characteristic

Relative sag hrel medium high, but ≤ 0,01 low
Internal friction of material conveyed medium high low
Running resistance of carrying idlers medium low high
Indentation rolling resistance medium low high
causes
reduction of increase of
Coefficient qo Standard value ≈ 0,7 coefficient qo
to
0,5 0,85
Equations (16) and (17) can be used to check the plausibility of, and if necessary adjust, the values of the
primary resistances determined using the hypothetical friction coefficients f i and the other resistances as in
Equations (14) and (15).
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DIN 22101:2011-12
If there are no values which have been obtained by measurement or on the basis of experience, or if only an
approximate dimensioning is intended, standard values for the hypothetical friction coefficient f can be
selected from Table 4 for estimating the total primary resistance of the upper and lower strands on the basis of
the operating conditions and design features (see also Annex A). These values are based on numerous
combined upper and lower strand measurements and for the following limiting conditions:
 3 roller fixed idler sets in the top run

 carrying idlers with antifriction bearings and labyrinth seals
 values of relative belt sag hrel ≤ 0,01
 filling ratio ϕ within a range from 0,7 to 1,1
Table 4 — Standard values for the hypothetical friction coefficient f for estimating
the total primary resistance in the upper and lower strands of conveyors
with a filling ratio ϕ within the range 0,7 to 1,1
Characteristic Values for characteristic

Internal friction of material to be conveyed medium low high
Belt conveyor alignment medium good bad
Belt tension medium high low
Operating conditions (dusty, sticky) medium good bad
Idler diameter 108 to 159 > 159 < 108
Spacing of upper strand idlers in m 1,0 to 1,5 < 1,0 > 1,5
Spacing of lower strand idlers in m 2,5 to 3,5 < 2,5 > 3,5
Belt speed in m/s 4 to 6 <4 >6
Troughing angle in ° 25 to 35 < 25 > 35
Ambient temperature in °C 15 to 25 > 25 < 15
causes
Friction coefficient f Standard value reduction of increase of
≈ 0,020 friction coefficient f
to
0,010 0,040
When the drives function as generators, an assumed smaller friction coefficient f leads to greater safety with
regard to the dimensioning; for drives functioning as motors this effect will be achieved by assuming a larger
friction coefficient f .
The application of these friction coefficients f in the calculation of primary resistances according to
Equation (14) is acceptable only if the calculation does not need to be very accurate.
6.3 Secondary resistances
6.3.1 General
Secondary resistances include friction resistances and inertia resistances arising only in some places on the
conveyor. Secondary resistances are calculated from several individual resistances.
The secondary resistances in the upper strand FN,o,i and in the lower strand FN,u,i are required for the
calculation of the belt tensions (see 8.3).
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DIN 22101:2011-12
The secondary resistance of the conveyor belt FN, i.e. the sum of secondary resistances in the upper strand
FN,o and in the lower strand FN,u, is calculated as:
no nu
FN = ∑ F N,o,i + ∑ F N,u,i = FN,o + FN,u (18)
i =1 i =1
6.3.2 Determination of individual secondary resistances
Inertia resistance of material conveyed and friction resistance between material conveyed and the belt in the
feeding zone
FAuf = Im ⋅ (v − v0) (19)
Friction resistance between conveyor belt and lateral chutes in the acceleration zone of a feeding point:
Figure 3 — Chute configuration
The following applies to feeding points with 3-roller idler sets and bSch > lM (see [6]):
2
 2 ⋅ Im
FSchb = c Schb ⋅ cRank ⋅  2
(
− bSch − lM ⋅ )
2 tan λ  ⋅ ρ ⋅ g ⋅ l b ⋅ µ 2 
  (20)
 (v + v 0 ) ⋅ ρ 4  2
bSch 
 for 0 ≤ v0 ≤ v
2
v − v0 2 
lb > lb,min =  (21)
2 ⋅ g ⋅ µ1 
with
 β dyn 
cRank = tan 2  45° −  (22)
 2 
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DIN 22101:2011-12
lM = bSch shall be applied for bSch ≤ lM
lM = 0 shall be applied for 2-roller idler sets
lM = bSch shall be applied for 1-roller idlers
The following approach applies to other types of idler set (e.g. 5-roller idler sets):
a) determination of the height of material pressing against lateral chute walls on the basis of the volume
flow and average conveying speed in the feeding zone (v + v0)/2.
b) determination of potential wall pressure caused by a fluid pressing against the side walls of the chute.
If applicable, multiply with cSchb and cRank.
c) determination of friction resistance from average wall pressure, friction coefficient and size of wall
areas
The following applies to belt conveyors of customary design:
cSchb ⋅ cRank = 1 (see Annex A)
As a general rule, the friction coefficients µ1 and µ2 are within the range from 0,5 to 0,7.
Friction resistance caused by belt cleaners
For the use of scraper bars as belt cleaners, the friction resistance can be determined as follows:
FGr = µ4 ⋅ pGr ⋅AGr (23)

2 2
As a general rule, the contact pressure pGr is within a range of approx. 0,03 N/mm to 0,1 N/mm , whereas the
friction coefficient µ4 approximately ranges between 0,6 and 0,7.
The total secondary resistance FN is the sum of the secondary resistances of each section.
no nu
FN = ∑ F Auf,o,i + FSchb,o,i + FGr,o,i + ∑ F Auf,u,i + FSchb,u,i + FGr,u,i = FN,o + FN,u (24)
i =1 i =1
Further secondary resistances are the bending resistance of the conveyor belt where it runs over a pulley and
the resistance of the bearings of non-driven pulleys. These secondary resistances are relatively small in
conveyors of customary design as compared with the above mentioned resistances and can be neglected in
almost all cases. If necessary, calculation equations can be taken from the referenced documents (e.g. [1]).
6.3.3 Approximate calculation of secondary resistances
If the portion of secondary resistances in the total resistance is small, e.g. with conveyor lengths L > 80 m and
conveyors with just one feeding point, an approximate calculation of secondary resistances FN from the
primary resistance FH applying coefficient C (see [1]) is permissible:
FN = (C − 1) ⋅ FH (25)
The coefficient C can be selected from Table 5:
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DIN 22101:2011-12
Table 5 — Standard values for coefficient C for belt conveyor installations

with filling ratios ϕ ranging from 0,7 to 1,1
L in m 80 100 150 200 300 400 500 600 700 800 900 1 000 1 500 ≥ 2 000
C 1,92 1,78 1,58 1,45 1,31 1,25 1,20 1,17 1,14 1,12 1,10 1,09 1,06 1,05
6.4 Gradient resistance
The gradient resistance of the conveyor belt and material conveyed can be calculated as follows for each
section:
(
FSt,i = h i ⋅ g ⋅ m' G +m'L,i ) (26)
The total gradient resistance of the conveyor FSt , that is, the sum of gradient resistances in the upper strand
FSt,o and in the lower strand FSt,u , is calculated as follows:
no nu
FSt = ∑ F St,o,i + ∑ F St,u,i = FSt,o + FSt,u (27)
i =1 i =1
applying
h i = li ⋅ sin δ i (28)
(for uphill belt travel: h i > 0 and δ i > 0; for downhill belt travel: h i < 0 and δ i < 0)
6.5 Special resistances
6.5.1 General
Special resistances are resistances that do not occur with all belt conveyors. These resistances are calculated
on the basis of several individual resistances (see Annex A).
The special resistances of a conveyor section i are composed of:
FS,i = FRst,i + FSch,i + FGa,i (29)
The total special resistance of a conveyor FS, i.e. the sum of the special resistances in the upper strand FS,o
and in the lower strand FS,u are calculated as follows:
no nu
FS = ∑ (F Rst,o,i + FSch,o,i + FGa,o,i ) + ∑ (F Rst,u,i + FSch,u,i + FGa,u,i ) = FS,o + FS,u (30)
i =1 i =1
6.5.2 Determination of individual special resistances
Camber resistance
The camber resistance which arises at an individual side carrying idler will depend on its normal force, on the
friction coefficient µ3 between the belt and the carrying idler, and also on the angle of tilt ε . The camber
resistance FRst,i in section i of the conveyor is then obtained from the total of individual camber resistances,
and taking the angle of inclination δ i of the installation into consideration:
zRst,i
FRst,i = ⋅ li ⋅ cRst,i ⋅ µ3 ⋅ sin ε i ⋅ cos δ i ⋅ g ⋅ (mG ′ i)
′ +mL, (31)
zR,i
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DIN 22101:2011-12
The friction coefficient µ3 depends on the angle of tilt ε . For angles ε > 5° it can reach a value of 0,5 (see [7]).
In Equation (31), the parameters cRst,i are dependent on the idler arrangement and, in the case of the upper
strand, on the geometry of the bulk material. In the case of 3-roller idler sets with rollers of equal length in the
upper strand, and with filling ratios ϕ within the range of 0,7 to 1,1 (see [7]) it follows:
cRst,o = 0,4 for λ = 30°
cRst,o = 0,5 for λ = 45°
The following applies to 2-roller idler sets in the (unloaded) lower strand:
cRst,u = cos λ
Friction resistance between the material conveyed and the lateral chutes outside the feeding points
With bSch > lM and 3-roller idler sets (see Figure 3) the relationship below applies:
2
 I
v ⋅ ρ
2
FSch = cRank ⋅  m − bSch (
2 tan λ 
− lM ⋅
4
 ⋅ )
ρ ⋅ g ⋅ lSch ⋅ µ2
2
bSch
(32)
 
As a general rule, the friction coefficient µ2 is within the range from 0,5 to 0,7.
lM = bSch shall be applied for bSch < lM;
lM = 0 shall be applied for 2-roller idler sets;
lM = bSch shall be applied for 1-roller idler sets.
Resistances FGa of material transfer devices arranged along the belt conveyor path
If, in special cases, material is discharged laterally along the conveying path, e.g. through scrapers serving as
belt cleaners, the forces occurring at these locations shall be taken into account as special resistances.
7 Design and layout of the drive system
7.1 General
The design and layout of the drive system comprises:
 the selection of the location and number of drives
 decisions relating to starting aids
 the sizing of the drive motors (rated output)
 the determination of the required braking forces (stopping and holding)
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DIN 22101:2011-12
7.2 Location of the drive units, size and number of drive motors
7.2.1 General
To minimize belt tension, the drive power is to be distributed among several drive pulleys situated at the head
and at the rear of the installation, and in certain cases among intermediate drives, unless there are other
considerations to be taken into account.
Such other considerations include:
 available space
 availability of energy
 driving and braking options
In order to ensure minimum belt tension, the type and arrangement of drives will depend heavily on the
magnitude and local distribution of motion resistances for the conveyor in a steady operating condition, FW,o
for the upper strand and FW,u for the lower strand. Variations in belt tension occurring in the direction of
belt travel can be calculated by adding the resistances of the conveyor sections i in accordance with
Equation (13).
no nu
FW = ∑ F W, o,i + ∑ F W,u,i = FW, o + FW,u (33)
i =1 i =1
In the case of extreme loading (non-uniform loading, partial loading or idling) of a belt conveyor with downhill
and uphill grade stretches, the maximum force Fw,max can deviate significantly from the force FW determined
for the nominal loading range (see 6.2.2):
FW,max = FW,o + FW,umax ≥ FW (34)
PW,max ≥ PW  (35)
This extreme power requirement shall be taken into consideration when selecting the type of drive system —
motor drives or generators — however, in due consideration of the thermal rating of the motors.
7.2.2 Horizontal and slightly inclined installations
FW,o > 0, FW,u > 0 (for uniformly loaded upper strand)
In the case of belt conveyors with drives at the installation head and rear, but without intermediate drives, the
belt tensions will be minimal if the drive power is appropriately distributed between the head and tail stations,
i.e. by a proportional distribution of the motion resistances occurring in the upper and lower strands. The
required total power of the drive motors can be calculated with the aid of the following equation:
P
PM, erf = W, max (36)
ηges
The rated motor power actually installed, i.e. the sum of the nominal powers of the individual motors PM,N
PM,inst = ∑ PM,N (37)
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DIN 22101:2011-12
is, as a general rule, greater than the required power
P M,inst ≥ P M,erf (38)
7.2.3 Uphill conveying installations
FW,o > 0, FW,u ≤ 0 (for uniformly loaded upper strand)
In such installations, the belt tensions will be minimal if all the drives are arranged at the head of the
installation, assuming that no intermediate drives are installed.
PM,erf and PM,inst can be calculated using Equations (36), (37) and (38).
7.2.4 Downhill conveying installations
FW,o ≤ 0, FW,u > 0 (for uniformly loaded upper strand)
In these installations, to obtain minimum belt tensions it is essential that drives are at the rear end of the
installation where the drive is achieved through generators. For the purpose of determining the total power of
the drives, the required power of the driving motors at the motor shafts shall be calculated as follows,
depending on whether the drives operate as motors (PW,max > 0) or generators (PW,max < 0):
P
PM, erf = W, max where PW,max > 0 (39)
ηges
PM,erf = PW, max ⋅ η ges where PW,max < 0 (40)
In this design stage it is not possible to precisely determine the overall efficiency ηges. For safety reasons,
within the estimated range a higher value for the overall efficiency is to be chosen for a generator drive than
for a motor drive.
As a rule, the rated power of the motors actually installed (see Equation (37)) is greater than the amount of
required power:
PM,inst ≥ PM,erf (41)
7.2.5 Installations with uphill and downhill sections
An appropriate arrangement of the drives for belt conveyor installations with uphill and downhill sections
ensuring minimum belt tensions can be suggested only if all actual operating conditions are taken into
account.
7.3 Starting, stopping and holding
7.3.1 Starting
In order to achieve minimum belt tensions, it is necessary to limit the total pulley peripheral forces on start-up
FTr,A generated at the drive end during run-up to full speed of the belt conveyor installation. However the force
FTr,A shall not be allowed to decrease below a given minimum value in order to safeguard the positive control
of the initial breakaway and start-up process. The following is recommended especially for large belt
conveyors
 The maximum pulley peripheral force on start-up FTr,A,max should not exceed 1,7 times the force FW,max in
accordance with Equation (34) used for the determination of the installation design. This means: the start-
up factor pA,max ≤ 1,7.
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DIN 22101:2011-12
 In order to break away and accelerate the masses in the upper and lower strands, however, the force
available under the most unfavourable start-up conditions (loading condition, distribution of load) should
equal at least 20 % of the primary, secondary and special resistances to be taken into account and ensure
the starting of the conveyor within the maximum time period allowed in accordance with the thermal rating
of the drives (see [8]).
The force FTr,A shall be suitably selected to ensure friction grip between the material conveyed and the
conveyor belt for the corresponding start-up acceleration a A . It follows for fine grained bulk material:
aA ≤ (µ1 ⋅ cos δ i,max − sin δ i,max) ⋅ g (42)
(for uphill belt travel: δ i > 0; for downhill belt travel: δ i < 0)
The force FTr,A should be introduced into the belt slowly enough to ensure that the installation runs up to full
operating speed under quasi steady conditions, and consequently with the small additional dynamic forces
(see [8] and [9]).
The start-up factor pA,0 related to the nominal torque of all drive motors shall be applied for the determination
of the start-up factor pA in accordance with the equation below, where there are relatively small mass inertia
torques of the rotating components of drives operating as motors in the steady operating condition, i.e. for
horizontal and uphill conveying installations:
PM, inst
pA = pA0 ⋅ (43)
PM
For designs according to Equation (35) the following shall be applied: PM = PM,erf
7.3.2 Stopping and holding
The operation of belt conveyor installations generally requires the provision of braking equipment to stop the
moving masses, and/or holding devices to hold inclined installations under load.
For the dimensioning of the braking equipment the following is to be considered:
 total required braking force FTr,B on the periphery of the braked pulleys or the braking factor pB (see 8.3.3)
FTr, B
pB = (44)
FW
 number and arrangement of brakes
 braking frequency and braking time or braking distance
 energy of the rotating drive components to be absorbed by braking
The required braking force FTr,B or the braking factor pB shall be determined for the most unfavourable braking
conditions governed by the filling ratio ϕ and by the distribution of the load in downhill and uphill stretches of
the installation with the relevant total motion resistance FW. In this connection, either the braking distance sB
or braking time tB is to be specified. This will determine the braking deceleration a B , which shall be such that
the friction grip between the material conveyed and the belt is maintained. In the case of fine-grained bulk
material, the following applies:
a B  ≤ µ1 ⋅ cos δi,max + sin δi,max ⋅ g (45)
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DIN 22101:2011-12
The braking factor pB0 related to the nominal torque of all drive motors shall be applied for the determination of
the braking factor pB in the case of relatively small mass inertia torques of the rotating components of drives
operating as motors in the steady operating condition, i.e. for horizontal and uphill conveyors with the power
PM of the drives:
pB0 PM, inst

pB = ⋅ (46)
2 PM
η ges
It may be necessary to limit the total braking force to a given value FTr,B,max, and consequently the braking
deceleration to a limiting value a B,max, in order to reduce the belt stresses and those on other parts of the
installation as much as possible, and in order to maintain the friction grip on the braked pulleys (see 8.2.2).
As regards the design and dimensioning of holding devices, the maximum gradient resistance FSt,max likely to
arise under the maximum permissible loading conditions and most unfavourable load distribution, shall be
used as the base value, minus the primary resistance arising under these conditions. For safety reasons, only
the minimum primary resistance anticipated shall be used in calculations. If a number of mechanical holding
devices are used, the loads shall be suitably distributed.
8 Belt tensions and take-up forces
8.1 General
The belt tension in a belt conveyor installation is a quantity which varies along the path of the installation, and
which is governed by the following influences (see Figure 5):
 length and course of the installation
 number and arrangement of drives
 characteristics of the driving and braking equipment
 type and arrangement of the belt take-up device
 operating condition (loading and movement conditions)
Belt tensions should be kept to the lowest possible value in view of the stressing and layout of the belt and of
other parts of the installation.
8.2 Required belt tensions
8.2.1 General
The operation of belt conveyor installations requires minimum belt tensions in order to enable the transmission
of forces to the belt by friction grip on the drive pulleys, to limit the belt sag and to enable the belt to be guided
correctly.
8.2.2 Minimum belt tensions required for the transmission of pulley peripheral forces
The transmission of the maximum pulley peripheral forces which arise during starting, braking, or in the steady
operating condition by friction grip on the individual driven or braked pulleys requires certain minimum belt
tensions at the point where the belt runs onto and off the pulley. In the case illustrated in Figure 4, with the
forces FT1 and FT2 and the associated maximum pulley peripheral force FTr,max > 0 the following applies:
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DIN 22101:2011-12
Figure 4 — Minimum belt tensions at the belt run-on and run-off point on the drive pulley
required to ensure transmission of the pulley peripheral force FTr,max
FT1 − FT2 = FTr,max (47)
FT1
≤ e µ ⋅α , (48)
FT2
where α is to be expressed in radians.
It follows that:
1
FT2 ≥ ⋅ FTr,max (49)
µ ⋅α
e −1
FT1 = FT2 + FTr,max (50)
In the case of more than one driven or braking pulley, whether or not the friction grip is ensured in accordance
with Equations (48) and (49) is to be verified for each individual pulley and for all operating conditions. In this
connection it shall be borne in mind that the total pulley peripheral forces FTr, FTr,A or FTr,B are distributed onto
the individual pulleys in proportion to the torques induced in said pulleys by the driving or braking equipment.
Table 6 gives preferred friction coefficients µ for the friction between belts with rubber covers and pulley
surfaces of different finishes to be used in the design of belt conveyors for the steady operating condition.
a
Table 6 — Recommended friction coefficients µ for the friction between belts with a rubber cover
and pulley surfaces of different finishes (see [10]) for the design of belt conveyor installations
for the steady operating condition
Friction coefficients µ
for pulley surfaces of
Operating
condition bright metal surface polyurethane rubber lagging ceramic lagging
(plain steel pulley) lagging with pores,
(arrow pattern) (arrow pattern) (arrow pattern)
dry 0,35 to 0,4 0,35 to 0,4 0,4 to 0,45 0,4 to 0,45
wet
0,1 0,35 0,35 0,35 to 0,4
(clear water)
wet
dirty 0,05 to 0,1 0,2 0,25 to 0,3 0,35
(with mud and clay)
a
For conveyor belts with a PVC cover approx. 10 % smaller friction coefficients shall be assumed.
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DIN 22101:2011-12
8.2.3 Minimum belt tensions required for the limitation of the belt sag and for correct belt guiding
For the purpose of technical optimization of the belt conveyor installation, especially as regards energy
efficiency, the calculated maximum relative belt sag hrel related to the distance between carrying idler centres
shall be limited to values lower than 0,01 in the steady operating condition. A greater belt sag is permitted in
the non-steady operating condition. The greater the conveying speed and the lumpier the material conveyed,
the smaller the sag should be. Greater conveying speeds require either considerably lower sag values or the
acceptance of higher primary resistances (see 6.2). The following minimum belt tensions are required for a
given maximum belt sag and a given distance between carrying idler centres:
g ⋅ ( m'L + m'G ) ⋅ lR,o

Upper strand (with load): FT,o,min = (51)
8 ⋅ hrel
g ⋅ m'G ⋅ l R,u
Lower strand: FT,u,min = (52)
8 ⋅ hrel
If a maximum value of hrel is specified, different distances between carrying idler centres can be allocated to
the belt tension occurring along the path of an installation. When these distances between centres are finally
selected, the load-carrying capacity of the carrying idlers and the transverse vibration behaviour of the belt
shall be taken into account (see [11]).
In order to ensure the trouble-free operation of belt conveyor installations, it may be necessary to maintain
higher minimum belt tensions in addition to the belt sag, especially for:
 belts with turnover in the lower strand (see [12])
 belts with a low degree of transverse rigidity
 inclined belt conveyor installations at the lower pulley
 belts with locally non-uniform force distribution across the belt width (see Clause 9)
8.3 Local belt tension variations in the top and return strands
8.3.1 General
From the point of view of the correct sizing of the belt and of other parts of the installation, sufficient
knowledge of the course or pattern of the belt tension along the length of the installation, and in particular the
magnitude of the extreme values of the force, is extremely important. Local belt tensions FT,i can be
determined by summation of the motion resistances FW, i (see Clause 6) and superimposition of the take-up
force (see 8.4) and, where applicable, the acceleration/deceleration force components Fa,i (see 8.3.3).
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DIN 22101:2011-12
Figure 5 — Pulley peripheral forces, resistances to motion and belt tensions

illustrated for a conveyor installation with no = nu = 2 sections and 4 pulleys
under steady operating condition
8.3.2 Steady operating condition

The calculation of motion resistances Fw,i for the individual sections of a belt conveyor installation in the
stationary operating condition is given in Clause 6.
8.3.3 Non-steady operating condition

During the starting and stopping process, the magnitude and pattern of the forces generated by the driving
and braking equipment, and the breakaway resistance and motion resistances of a belt conveyor installation
result in additional dynamic belt tensions. These additional tensions are a function of the following factors, if
we assume a belt acceleration independent of local conditions and, hence, quasi steady operating conditions
of the conveyor (see also Annex A):
 the total pulley peripheral force FTr,A during starting or FTr,B during stopping
 the total acting motion resistance (approximately equal to the motion resistance occurring under steady
operation FW)
 the masses moving in a straight line and the non-driven or non-braked rotating masses Σ m reduced to
their periphery
For the frequently occurring case where the secondary resistance represents only a small proportion of the
total resistance, the forces Fa,i resulting from acceleration or deceleration can be determined as follows for an
individual section i with the aid of the belt acceleration a :
starting:
F − FW F
a A = Tr,A = ( pA − 1) ⋅ W > 0 (53)
∑m ∑m
stopping:
FTr,B − FW FW
aB = = ( pB − 1) ⋅ <0 (54)
∑m ∑m
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DIN 22101:2011-12
Thus:
F = a ⋅ (c ⋅ m′ + m′ + m ′ ) ⋅ li
a ,i R,i R,i G L,i
(55)
Value cR,i depends on the design of the carrying idler. A standard value of cR,i = 0,9 can be assumed.
8.4 Take-up forces and take-up distances
Take-up devices are required for the generation of the necessary take-up forces (see 8.2) and for the
compensation of the elastic elongations. Such devices shall enable the compensation of elastic, plastic, and
thermal length variations of the belt, and additional lengths originating from the installation process and
reserve lengths. The calculation of the take-up distance provided below takes into consideration only the
portion due to elastic elongation of the conveyor belt.
The magnitude of the take-up forces will depend on the type and location of the take-up device, and on the
operating conditions of the belt conveyor. In view of the costs and time needed for construction and design,
take-up devices are preferably installed in those positions where the minimum belt tensions in the steady
operating condition are anticipated.
Other aspects to be taken into consideration include:
 availability of energy
 availability of space
 pre-tensioning force to be ensured under non-steady operating conditions
In principle, a distinction is made between take-up devices with a fixed take-up pulley and take-up devices
with a flying take-up pulley. Irrespective of the type of take-up device, the relationship below exists between
the quantities which characterize any given operating condition (identified by an asterisk *):
* * *
 local belt tensions FT, i and force variations Fw, i , Fa, i
* *
 mean belt tensions FT,m of belt tension distribution FT in accordance with Figure 6
*
 take-up pulley path sSp
For steady operating conditions, changes in belt tension will only occur as a result of the motion resistances
F *W, i , so that the following applies:
 FT,* i + FT,* i+1  * 

 * FW,i *
1 ⋅l = 1 ⋅ sSp
*
FTm =
2⋅ L
⋅ ∑ 
 2  i 2⋅ L ∑ F +
 T,i 2 
⋅l = B ⋅ E
i LGk ⋅
L
(56)
   
The most unfavourable operating condition shall be selected for the calculation used for dimensioning take-up
* *
devices (take-up force FSp and take-up pulley path sSp ) on the basis of Equation (56).
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DIN 22101:2011-12
Figure 6 — Belt tension in the upper and lower strand of a belt conveyor installation
with no = nu = 3 sections and 2 pulleys (steady operating condition)
*
If the take-up device is installed at the spot where the minimum belt tensile force FT,min occurs, the take-up
*
force FSp at the axis of the take-up pulley will be:
* *
FSp = 2 ⋅ FT,min (57)
In cases which deviate from the above, one must additionally take into consideration the difference between
∗
the force at the spot where the take-up pulley is actually installed and the force at the spot where FT,min
occurs.
*
In case of tensioning devices with a fixed take-up pulley (see also Annex A) the mean belt tension FTm is a
constant parameter, independent of the operating condition:
*
FTm = const (58)
This will result in the belt being operated with greater belt tensions than those required according to 8.2 under
operating conditions which deviate from the most unfavourable operating condition.
However, in the case of take-up devices with a flying take up pulley (see also Annex A) the take-up force will
either remain constant under all operating conditions (e.g. for gravity take-up devices) or will be adjusted to
the varying operating conditions by means of “adapted tensioning devices” (e.g. by adjustable take-up
* will result to compensate for the elastic
winches). In both cases, suitably altered take-up pulley paths s Sp
elongation:
*
* FTm
sSp = ⋅ L ≠ const (59)
B ⋅ ELGk
Take-up devices shall be suitably designed to prevent, as far as possible, the belt from sliding and slipping on
the drive pulley under non-steady operating conditions (see Annex A).
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DIN 22101:2011-12
8.5 Local belt tensions in the upper and lower strands
8.5.1 General
In general the belt tensions in the steady and in the non-steady operating conditions of a belt conveyor
installation are decisive for the design and layout of:
 the conveyor belt
 the drive pulleys and return pulleys
 idler spacing
 radii of horizontal and vertical curves
 troughing lengths at the transition from flat belt to troughed and from troughed to flat
 belt turnovers
 the design of other parts of the belt conveyor installation
The maximum local belt tension, which is to be taken into consideration for the dimensioning of the conveyor
belt, is determined taking into consideration all loading and operating conditions.
8.5.2 Non-steady operating conditions

For the purpose of determining the local belt tensions in non-steady operating conditions, the minimum belt
tensions in accordance with 8.2, the local motion resistances in accordance with Clause 6 and the additional
dynamic belt tensions due to acceleration and deceleration in accordance with 8.3.3 shall be taken into
consideration.
Of the local minimum belt tensions at start-up FT,min,A and at braking FT,min,B in general it is FT,min,A which is
decisive for the calculation of the take-up forces and the force FT,min in the steady operating condition.
8.5.3 Steady operating condition

The belt tensions in the steady operating condition are determined by the required local minimum belt
tensions in accordance with 8.2 under the most unfavourable loading conditions, as well as by the local belt
tension variations in accordance with 8.3, and they have the minimum FT,min. However, there is, as a general
rule, a greater minimum FT,min, dependent on the mimima FT,A,min or FT,B,min which occur during the non-steady
conditions, and dependent also on the type of take-up device uses. This consequently results in higher belt
tensions than those required under the steady operating condition in accordance with 8.2. The thus
established maximum belt tension FT,max is, as a general rule, the determining one for the calculation of the
conveyor belt. However, in the case of unfavourable transitions or curves, even local belt tensions smaller
than FT,max may cause the highest stress across the belt cross section (see Clause 9).
9 Distribution of belt tensions across the belt width
9.1 General
The mean belt tension k i, related to the belt width at the point i can be calculated in accordance with the
equation below
FT,i
ki = (60)
B
Almost all conveyor belts are designed as troughed belts in order to enable larger cross section fills. For this
purpose, the belts are reshaped from a flat belt into a troughed belt or vice versa (transition zone). In the
transition zones, the belt edges will travel a longer distance than the central zone of the conveyor belt.
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DIN 22101:2011-12
Consequently, the calculated belt tensions are non-uniformly distributed across the cross section of the belt;
and the edges are to bear a higher portion of the belt tensions than the central zone of the conveyor belt.
The same effect also occurs where troughed belt conveyors are routed through convex, vertical curves. If
troughed belts are routed through concave, vertical curves, the central zone of the belt will be subject to
higher tensions, whereas the belt tensions arising at the edges will be lower. In horizontal curves, one side of
the belt will be subject to higher tensions than the other one.
The geometry of the transition zone shall be suitably designed for the given belt tensions at the respective
spots so as to avoid impermissible high stress and to prevent compression across the entire cross section of
the conveyor belt.
The belt tensions are dependent on the geometry of the curve (radius) or transition zone (transition length,
trough angle, position of pulley surface relative to the deepest level of the trough). Therefore, the geometrical
considerations are of vital importance with regard to the design and layout of the conveyor belt.
The stresses in the conveyor belt are also dependent on its elastic characteristics and the belt tensions arising
in the relevant positions. Once the initial calculations required for the design and layout of the conveyor belt
have been carried out, the geometry of the transitions and curves of the belt conveyor and the characteristics
of the conveyor belt can be modified for further optimization (see Clause 12).
9.2 Transition curves
9.2.1 General
If there are no particular requirements, the standard value of minimum transition length for 2-roller and 3-roller
carrying idler sets shall be determined as follows:
lÜ,min = cÜ ⋅ hK1 (61)
with
cÜ = 8,5 for belts with EP textile plies
cÜ = 14 for steel cord belts
In this connection
hK1 = hK0 − hTr (62)
is the distance of the belt edge from the level of the pulley surface (see Figure 7). If the pulley is arranged at
a higher position, shorter transition lengths are possible, resulting in a reduction of the belt tensions at the belt
edge. The standard value of maximum pulley lift is hTr,max = 1/3 · hK0.
If the belt pulley is positioned at a lower position longer transitions will be necessary or result in higher belt
tensions at the edges and lower tensions in the central zone of the belt.
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DIN 22101:2011-12
Figure 7 — Transition length without pulley elevation (above) and with pulley elevation (below)
With the tension difference ∆k between the belt edge and the central zone of the belt according to Figure 8,
the width-related belt tension is calculated as follows:
Central zone of the belt:
bS
kM = k − ⋅ ∆k (63)
B
with
B − lM
bS = (64)
2
Belt edge
kK = kM + ∆k (65)
To avoid compression of the conveyor belt, the following applies:
km ≥ 0 (66)
The length of the belt edge lK is the decisive parameter for the magnitude of the occurring belt tensions (see
Figure 7).
l K = lÜ2 + hTr
2
+ 2 ⋅ bS2 − 2 ⋅ bS ⋅ (hTr ⋅ sin λ + bS ⋅ cos λ ) (67)
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DIN 22101:2011-12
Key
a) uniform distribution along the conveyor path outside the transition zones
b) non-uniform distribution in the transition zone
c) idealized distribution according to the approach in accordance with Equations (63) and (65)
Figure 8 — Distribution of belt tensions across the belt width in transition zones
9.2.2 Distribution of the belt tension for textile conveyor belts

Forced length variations of textile conveyor belts are almost completely compensated for in the transition
zone. Therefore, the determination of the elongations and tensions occurring is simpler than for steel cord
belts.
Provided the belt runs in the middle of the trough, the difference ∆k of the width-related belt tension at the belt
edge and in the central zone of the belt can be calculated for 2-roller and 3-roller carrying idler sets with the
aid of the equation below (see [13]):
lK − lÜ
∆k = ⋅ ELGk (68)
lÜ
where lk is taken from equation (67).
9.2.3 Distribution of the belt tension for steel cord conveyor belts
In contrast to the characteristics of textile conveyor belts, with steel cord belts forced length variations will be
compensated not only in the zone in which they occur, but also along considerably long portions of the
adjacent belt.
Due to the relatively small elastic elongation of the steel cords of steel cord conveyor belts, the transition
zones and convex curves have particularly serious effects on the stresses caused in the conveyor belt and
other parts of the belt conveyor installation. Therefore, it is necessary to calculate the stresses as precisely as
possible.
The stresses occurring with steel cord conveyor belts can be calculated very precisely thanks to the results of
pertinent research work (see [12] and [14]). The stress calculation method for steel cord conveyor belts is not
only based on the geometry of the transition zone and the modulus of elasticity, but also on the belt design
and modulus of shear of the rubber between the steel cords. This calculation is complex and therefore
requires electronic data processing.
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DIN 22101:2011-12
The rough calculation below can be applied to 2-roller and 3-roller troughed idler sets. The following
conditions are assumed for this purpose:
 The belt design is in accordance with DIN 22129-1 or DIN EN 15236-11) or along the lines of these
standards.
 The elastic properties of the belts correspond to the state-of-the-art.
 The selected length of the transition zone is not shorter than the standard value determined in
accordance with Equation (61).
In the calculation of the elongation of the conveyor belt, the elongation of the edge shall not be related to the
transition length lÜ but to the length lÜ,eff :
lÜ,eff = lÜ + ∆lÜ (69)
with
 hTr 
∆lÜ = 90 ⋅ (h K0 − hTr ) ⋅ 1 −  (70)
 3⋅h 
 Tr,max 
This, however, is based on the condition that there is at least a section of belt with a length lÜ,eff – lÜ to
compensate for length variations before or behind the next pulley. This condition is not fulfilled when there is a
convex curve directly adjacent to the transition zone. In this case lÜ,eff shall be approximated as lÜ, i.e.
∆lÜ = 0.
In analogy with Equation (68), the difference ∆k of the width-related belt tension k between the belt edge and
central belt zone is calculated as follows:
l K − lÜ
∆k = ⋅ ELGk (71)
lÜ, eff
with the width-related belt tension in the central zone kM in accordance with Equation (63) and that in the belt
edge kK in accordance with Equation (65).
Subclause 10.2 describes how the value of kK determined using Equation (65) is used in the design of tension
members.
9.3 Curves
In the following, a differentiation is made between horizontal and vertical curves, each with constant radii.
9.3.1 Horizontal curves
In the horizontal plane, changes of direction can only be accommodated to a limited extent, and they require a
quite extensive calculation (see [15]).
9.3.2 Vertical curves
In the case of convex belt guidance (see Figure 9) of troughed belts, additional elongations at the edge of the
belt and compressions of the belt centre will occur. These superimpose themselves on the elongations caused
by the belt tension in the form of positive and negative elongations, ∆ε K and ∆ε M.
In the case of concave belt guidance (see Figure 9), however, additional elongation of the belt centre and
compressions of the edge of the belt will occur. The absolute values of the resulting elongations are the same
as elongations in a convex curve of the same radius, as long as the belt is not lifted from the conveyor idlers.
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DIN 22101:2011-12
Figure 9 — Conveyor installation with concave and convex transition curves
In the case of short and medium curve lengths, the additional elongations resulting from convex and concave
transition curves can only be calculated with a relatively high level of complexity (see [16]); however, as far as
their magnitude is concerned they are always smaller than the limiting values ∆ε K∞ and ∆ε M∞ occurring in the
middle zone of very long curves independently of the construction of the belt, and can be calculated with the
aid of Table 7 and Figure 10 below.
Table 7 — Definition of the limiting values ∆εK∞ and ∆ε M∞
Transition curve
Limiting values
convex conkave
eK eK
+ −
∆εK∞ Re Ra
eM eM
− +
∆εM∞ Re Ra
Figure 10 — Aid to the calculation of the limiting values of elongation ∆ε K∞ and ∆ε M∞ at the centre
of long convex and concave transition curves
The distances eK and eM of the centre lines of the belt carcass from its neutral axis are illustrated in Figure 10.
The position of the neutral axis can be assumed in this case to pass through the centre of gravity of the belt
carcass.
The following approximation equation can be used for the calculation of the difference of elongations between
the belt edge and the belt centre for long transition curves and for 2-roller and 3-roller troughed idler sets, with
bS calculated in accordance with Equation (64):
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DIN 22101:2011-12
Convex curve:
eM + eK bS ⋅ sin λ
∆ε ∞ = = (72)
Re − eM Re − eM
Concave curve:
eM + eK b ⋅ sin λ
∆ε ∞ = − =− S (73)
Ra + eM Ra + eM
In design drawings the radius of vertical transition curves is frequently related to the upper edge of the centre
idler. In the equations above, Re − eM and Ra + eM give the radius of the middle of the tension member in the
belt. This difference from the middle of the tension member to the upper edge of the centre idler can be
neglected as insignificant compared to the curve radius.
∆k = ∆ε ∞ ⋅ ELGk (74)
By introducing this value ∆k in Equation (63) and Equation (65), the width-related belt tensions in the central
zone of the belt and at the belt edge can be calculated for textile and steel cord conveyor belts passing
through the curve.
|∆k| for short and medium curve lengths will be slightly smaller than the result of the above calculation.
The additional elongation of steel cord belts can be determined with sufficient accuracy for small and medium
curves as well by applying the method in accordance with [16].
Usually no excessive stresses will occur in the conveyor belt in concave curves with small radii, as the belt will
lift off the idlers (see 12.3.3).
10 Design and layout of the conveyor belt
10.1 General
The tension members and cover layers of a conveyor belt shall be selected according to the operating
conditions. Their specification will be governed to a considerable extent by the characteristics of the bulk
material conveyed (physical and chemical characteristics, grain structure) and by the application conditions of
the belt (environmental influences, scheduled service life, mechanical stresses, e.g. at the feeding points).
10.2 Design and layout of the tension member
The dynamic strength of the conveyor belt verified for vulcanized splices on a test stand according to
DIN 22110-3 shall form the basis for the selection of conveyor belts and splices. The design and layout shall
be based on the reference dynamic splice efficiency k t as defined in the above-mentioned test procedure
(see [5], [17], [18] and [19]).
The values of the dynamic splice efficiency are established for splices made and tested under ideal
conditions. Deviations from these conditions, either related to the situation or due to the operating conditions,
shall be taken into account by applying a safety factor S0, which shall be established in accordance with
Table 8. Chemical and physical stresses, influences of natural ageing, and the frequency of high tensions and
bending stresses are represented by factor S1 from Table 9.
At this stage, the design and layout shall be based on the highest belt tensions calculated for a belt cross
section in the steady operating condition.
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DIN 22101:2011-12
High belt tensions, which may arise temporarily when conveyor belts with partial loads are passing through
uphill and downhill stretches of the installation, shall be taken into account by carrying out a check in
accordance with Equation (79).
Table 8 — Determination of the safety factor S0 based on the classification

of belt splice characteristics
Characteristics of the belt splice Classification

Atmosphere normal dust-free dusty
Protection against solar radiation normal very good moderate
Air temperature moderate ≥ 18 °C and ≤ 22 °C < 10 °C or > 30 °C
Workspace normal roomy narrow
Qualification of technicians normal very good moderate
Quality of splicing materials normal fresh nearly expired
shelf life
Quality of vulcanizing equipment normal very good moderate
cause
reduction of increase of
Safety factor S0 1,1
safety factor to
1,0 1,2
Table 9 — Safety factor S1 based on the classification of operating conditions
Characteristics relevant to the dynamic strength

Classification
of belt and belt splices
Expected service life normal short long
Consequential damage due to failure normal small large
Chemical/physical stresses normal low high
Starting/stopping processes > 3/day and ≤ 3/day ≥ 30/day
< 30/day
Circulation frequency > 2/hour ≤ 2/hour ≥ 1/minute
< 1/minute
causes
decrease increase
Safety factor S1 1,7 of the safety factor
to
1,5 1,9
Hence the minimum dynamic splice efficiency k t,min of the belt and belt splice can be calculated as follows:
k t,min = cK ⋅ kK,max ⋅ S0 ⋅ S1 (75)
For coefficient cK the following applies:

for textile conveyor belts: cK =1
for steel cord conveyor belts: cK = 1,25: troughing transition zones
cK = 1: horizontal and vertical curves
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DIN 22101:2011-12
Figure The factor cK is chosen as 1,25 where the width related belt tension at the belt edge is calculated
according to the method shown in 9.2.3, whereas a more precise calculation method allows a value cK = 1.
1)
The relative dynamic splice efficiency k t,rel of a belt describes the portion of its nominal breaking strength k N :
kt
k t,rel = (76)
kN
The relative dynamic splice efficiency is characteristic for a certain belt type and its splices. Therefore, it is to
be incorporated in future product standards as a minimum requirement.
Table 10 contains the relative values of dynamic splice efficiency for several belt types. The following aspects
shall be taken into consideration for their application:
 The values for conveyor belts with textile plies are standard values based on practical experience. It is
likely that they will need to be corrected once a larger number of test results are available.
 The values for steel-cord conveyor belts have been determined in numerous tests and can be considered
as minimum requirements which need to be verified.
In the calculation of the minimum breaking force k N2) only the actual dynamic splice efficiency k t proven for
a certain belt type and a certain type of splice may be applied.
Table 10 — Values for the relative dynamic splice efficiency k t,rel
Nominal Relative dynamic

Belt design breaking Splicing splice efficiency a
Belt type
according to strength kN according to kt,rel
N/mm
Textile belts with one DIN 22102-3
DIN 22102-1 630 to 3 150 0,35
ply finger splice
Textile belts with two
DIN 22102-1 200 to 2 000 DIN 22102-3, with 0,35
plies and thick
intermediate tension
intermediate layer
member
Textile belts with DIN 22102-3, with
DIN 22102-1 315 to 3 150 0,30
more than two plies stepped splice
Textile belts with one
DIN 22109-1 800 to 3 150 DIN 22121 0,35
ply
Textile belts with two DIN 22121 with
DIN 22109-2 800 to 1 600 0,30
plies intermediate tension
member
Steel cord belts DIN 22129-1
1 000 to 5 400 DIN 22129-4 0,45
DIN EN ISO 15236-1
Steel cord belts Along the lines of
< 1 000 Along the lines of
DIN ISO 22129-1 0,45
> 5 400 DIN 22129-4
DIN EN 15236-1b
a Please note that it cannot be expected that the standard values are achieved with aged or used belts.
b Translator ’s note. The German original is incorrect. The standard number should read “DIN EN ISO 15236-1”.
2) The term “nominal breaking strength” cited in this context corresponds to the term “mimimum breaking strength” as
applied in DIN 22110-3.
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DIN 22101:2011-12
The minimum nominal breaking force kN,min is calculated as follows applying the highest value k K,max in
accordance with Equation (75) and Equation (76) under the steady operating condition:
k t,min S 0 ⋅ S1
kN,min = = cK ⋅ kK,max ⋅ (77)
k t,rel k t,rel
Taking the value k N,min calculated according to Equation (77) and the width-related mean belt force k at the
point of the value k K,max calculated according to Equation (60), the safety factor Smin related to the mean local
belt force can be determined:
k N ,min kK,max S 0 ⋅ S1
S min = = cK ⋅ ⋅ (78)
k k k t,rel
In order to avoid extreme stresses in non-steady operating conditions and under those conditions that may
arise when belts with a partial load are passing through uphill and downhill stretches of the conveyor
installation, it shall be checked that the following limiting conditions are met:
kt,min ≥ 1,1 ⋅ cK ⋅ kK,a,max (79)
If this is not the case, the dimensioning of the tension member shall be corrected applying a higher value
k t = 1,1 ⋅ cK ⋅ k K,a,max .
According to this method, the tension members of the conveyor belts are dimensioned exclusively on the
basis of tensile loads. It shall be checked whether they will provide sufficient resistance against additional
stresses and whether their transversal rigidity will be sufficient for supporting the bulk material. They are
therefore to be designed with a higher strength, if necessary.
10.3 Design and layout of cover layers
The thickness of cover layers shall be suitably selected dependent on the material so as to ensure its
protective function, even with progressing wear during the scheduled service life of the conveyor belt; the
surface structures of the tension member shall remain adequately covered (see also Annex A).
If DIN Standards and other normative regulations do not provide further details, the standard values for the
minimum thickness of cover layers indicated in Table 11 and corresponding allowances for the carrying side of
the belt as provided in Table 12 can be applied. Certain minimum thickness values are required if a belt
protection (transverse reinforcement) is incorporated in the conveyor layers. In order to avoid impermissible
cupping of the belt, the ratio of the thickness of the cover layer on the carrying side relative to the cover layer
on the running side should not exceed 3:1.
Table 11 — Standard values for minimum thickness of cover layers

on the carrying side and running side of the belt
Material of longitudinal tension Minimum thickness of cover layer

member (standard value)
B (cotton)
P (polyamide) 1 mm to 2 mm depending on the textile structure
E (polyester)
0,7 ⋅ dGk, at least 4 mm,
St (steel cords)
with transverse reinforcement possibly more than 4 mm
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DIN 22101:2011-12
Table 12 — Determination of the standard values for additions to the minimum thickness
of carrying side cover layers in accordance with Table 11
Addition to minimum
Characteristics and their Sum of assessment thickness,
assessment values mm
(standard values)
favourable 1
Loading
average 2 5 to 6 0 to 1
conditions
unfavourable 3
low 1
Loading
frequency
high 3
small 1
Maximum
particle size
high 3
low 1
Bulk density average 2 12 to 13 6 to 10
high 3
low 1
Abrasiveness average 2 14 to 15 > 10
high 3
11 Minimum pulley diameter

The method described here for determining the minimum pulley diameters follows ISO 3684:1990. The idea
behind the determination of minimum pulley diameters is directly linked with the expectations regarding the
service life of the conveyor belt and its splices. The minimum pulley diameters to be determined in accordance
with the method described in this clause allows the assumption that the endurance strength of splices will be
at least equal to the expected service life of the conveyor belt, provided that the splices are properly executed.
Smaller pulley diameters than those determined in accordance with the method described in this document
can lead to premature failure; they also facilitate wear and tear of pulley surfaces or lagging.
The minimum pulley diameters of a belt conveyor installation will be determined by the design and layout,
stresses and splicing method of the belt (see also Annex A). A distinction is made between the following
groups of pulleys when determining the minimum diameters:
 Group A: drive pulleys and all other pulleys in the zone of high belt tensions
 Group B: return pulleys in the zone of low belt tensions
 Group C: deflection pulleys (change of direction of belt travel ≤ 30°)
If DIN Standards and other normative regulations do not provide further relevant details, the minimum
diameters of Group A pulleys, for the four different groups of pulley load factors provided in Table 14, can be
determined as follows:
DTr = cTr ⋅ dGk (80)
The factor cTr is a parameter dependent on the material of the tension member according to Table 13 below:
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DIN 22101:2011-12
Table 13 — Parameter cTr for the determination of the minimum pulley diameter Dtr
Material of longitudinal cTr

tension member
B (cotton) 80
P (polyamide) 90
E (polyester) 108
St (steel cords) 145
Each diameter determined for Group A pulleys in accordance with the above description shall be rounded up
to the next standard value indicated in Table 14. The minimum diameters of Group B and C pulleys shall be
chosen in relation to the pulley load factor from Table 14 that is relevant for Group A.
Table 14 — Minimum diameter of Group A, B and C pulleys in relation to the utilization of the
maximum pulley load factor in the steady operating condition
Minimum diameter in mm (without lagging)
DTr kmax
Pulley load factor ⋅ 8 ⋅ 100 % a
as per kN
Equation over 100 % over 60 % to 100 % over 30 % up to 60 % up to 30 %
(80) Pulley group Pulley group Pulley group Pulley group
A B C A B C A B C A B C
100 125 100 100
125 160 125 100 125 100 100
160 200 160 125 160 125 100 125 100 100 100
200 250 200 160 200 160 125 160 125 100 125 125 100
250 315 250 200 250 200 160 200 160 125 160 160 125
315 400 315 250 315 250 200 250 200 160 200 200 160
400 500 400 315 400 315 250 315 250 200 250 250 200
500 630 500 400 500 400 315 400 315 250 315 315 250
630 800 630 500 630 500 400 500 400 315 400 400 315
800 1 000 800 630 800 630 500 630 500 400 500 500 400
1 000 1 250 1 000 800 1 000 800 630 800 630 500 630 630 500
1 250 1 400 1 250 1 000 1 250 1 000 800 1 000 800 630 800 800 630
1 400 1 600 1 400 1 000 1 400 1 250 1 000 1 250 1 000 800 1 000 1 000 800
1 600 1 800 1 600 1 250 1 600 1 250 1 000 1 250 1 000 800 1 000 1 000 800
1 800 2 000 1 800 1 250 1 800 1 400 1 250 1 600 1 250 1 000 1 250 1 250 1 000
2 000 2 200 2 000 1 400 2 000 1 600 1 250 1 600 1 250 1 000 1 250 1 250 1 000
a kmax is the mean width-related tension at the point of maximum belt tension in the zone of Group A pulleys in the steady operating
condition.
12 Design and layout of transition curves and vertical curve radii
12.1 General
Clause 9 deals with the calculation of belt tensions distributed across the belt width proceeding from the
specified design of transition curves or convex curves for the subsequent design and layout of the conveyor
belt. This clause deals with the calculation of suitable transitions and vertical curves suitable for a specified
belt type.
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DIN 22101:2011-12
12.2 Determination of the minimum transition length
12.2.1 General
The following applies to 2-roller and 3-roller carrying idler sets in accordance with the approach illustrated in
Figure 8 and Equation (77):
kN ⋅ k t,rel
kK,zul = (81)
cK ⋅ S0 ⋅ S1
B ⋅ k − bS ⋅ kK,zul
kM = ≥0 and (82)
B − bS
∆k = kK, zul − kM (83)
12.2.2 Conveyor belts with textile plies
With Equation (68):
lK − lÜ ∆k
= (84)
lÜ ELGk
Δk is calculated in accordance with Equation (83) applying Equations (82) and (81). In the latter equation the
parameter cK = 1,0 is to be used. According to Equation (84) it follows that:
2
hTr + 2 ⋅ bS2 − 2 ⋅ bS ⋅ (hTr ⋅ sin λ + bS ⋅ cos λ )
lÜ,min = 2
(85)
 ∆k 
 + 1 − 1
 ELGk 
The transition lengths thus calculated provide sufficient accuracy for textile conveyor belts.
12.2.3 Steel cord conveyor belts
Meeting the conditions mentioned in 9.2.3, the minimum transition length can be roughly determined as
detailed below.
With Equation (71):
l K − lÜ ∆k
= (86)
lÜ, eff ELGk
Δk is calculated in accordance with Equation (83) applying Equations (82) and (81). For the latter equation for
steel cord belts, the parameter cK is to be considered as explained in the comments to Equation (75).
According to Equation (86) it follows that:
∆k
lÜ,min 2 + hTr 2 + 2 ⋅ bS 2 − 2 ⋅ bS ⋅ (hTr ⋅ sin λ + bS ⋅ cos λ ) − ⋅ ∆lÜ
ELGk
lÜ,min = (87)
∆k
+1
ELGk
with ΔlÜ in accordance with Equation (70). A comparison of Equations (87) and (85) shows that the minimum
troughing length for steel cord belts can only be calculated by iteration.
43
DIN 22101:2011-12
Equation (86) and Equation (87) may be applied only if there is a piece of belt of sufficient length provided in
front of or behind the belt pulley to compensate for length variations. If there is a convex curve right after a
transition, for example, the above condition is not met. In this case lÜ,eff shall be replaced by lÜ so that lÜ,min
can explicitly be determined using Equation (85).
For more precise calculations in which elongations resulting from superimposition are to be taken into
consideration, it is recommended that the methods described in [14] and [16] be used.
12.3 Determination of the minimum radius of vertical curves
12.3.1 General
Additional elongations due to convex and concave transition curves can be calculated for small and medium
curve lengths only with a relatively great effort (see [16]); however their magnitudes will always be smaller
than the elongations arising in the middle of long curves. These elongations form the basis of the calculations
below.
12.3.2 Convex curves
Proceeding from the assumption that the belt tension in the central zone of the conveyor belt is equal to 0 and
the belt is operated with the maximum allowable edge tension kK,zul, the minimum radius of a convex curve can
be determined applying Equations (72), (74), (77), with cK = 1, as follows:
bS ⋅ sin λ ⋅ ELGk
Re,min = ⋅ S0 ⋅ S1 (88)
kN ⋅ k t,rel
12.3.3 Concave curves
In the case of concave belt guidance there will be additional elongations of the belt centre and compression of
the edge of the belt with magnitudes that will amount to the same magnitudes as the additional elongations
which arise in the case of convex belt guidance as long as the belt does not lift off the carrying idlers. This
lifting can be avoided if the following minimum radius is met under all operating conditions.
FT, i, max
Ra, i, min = (89)
′ ⋅ cos δ i
g ⋅ mG
13 Dimensioning of belt turnovers

Belt turnovers are helpful as they reduce the soiling and wear of the conveyor belt and improve belt tracking in
the lower strand.
The length and type of the belt turnovers are dependent on the following parameters:
 Belt width
 Belt weight
 Transverse rigidity
 Elastic characteristics
 Conveying speed
44
DIN 22101:2011-12
A distinction is made between the types of turnovers of the conveyor belt with different supporting principles
as illustrated in Figure 11:
Key
top: free turnover
middle: guided turnover
bottom: supported turnover
Figure 11 — Design variants for turnovers
Table 15 — Standard values for the dimensioning of turnover lengths lW
Minimum turnover length

Maximum lW
Type of belt turnover belt width for conveyor belts with
mm
cotton plies EP plies steel cord plies
Free turnover 1 200 8⋅B 10 ⋅ B –
Guided turnover 1 600 10 ⋅ B 12,5 ⋅ B 22 ⋅ B
Supported turnover 2 400 – 10 ⋅ B 15 ⋅ B
The standard values provided in Table 15 will be sufficient if the return strand is subjected to low belt tensions.
If this is not the case, a more precise calculation is to be carried out (see [12]).
45
DIN 22101:2011-12
Annex A
(informative)
Explanatory notes
General
After a 40-year validity, DIN 22101:1942-02 was completely revised and significantly expanded as
DIN 22101:1982-02, of which an official English-language version is also available. The next version was
published in 2002-08 with some formal and substantial shortcomings that required an early revision.
The working group responsible for revising DIN 22101:1982-02 was required to give a more simple description
of relationships, wherever possible. This task appeared to be unrealistic. In fact, the current descriptions are
even more complex than those given in the 1982 edition because of new knowledge which needed to be
incorporated. The working group came to the conclusion that comprehensive computerized calculations,
which are widely practiced, should be preferred in order to find improved technical and economical solutions.
Nevertheless, simplified calculation methods are referred to wherever feasible (i.e. in cases not requiring high
accuracy).
Re Clause 5
Theoretical cross section of fill Ath and equivalent angle of slope β
In the case of a troughed belt, the bulk material cross section comprises the “water cross section” and the
slope cross section lying above it. Amongst other factors, the shape of the slope will depend on the properties
of the bulk material conveyed (e.g. its lumpiness, internal friction, friction coefficient between the conveyor belt
and the material conveyed) and also on the operating conditions of the belt conveyor installation (e.g. type of
belt feed, tracking of the belt, frequency and duration of vibrations (jarring) of the bulk material conveyed). The
slope cross section which actually takes shape is markedly smaller than the cross section given by the static
angle of slope. A calculation of this actual cross section can therefore in general only be undertaken under
idealized assumptions. In the case of belt conveyor installations with a horizontal layout, in German technical
literature the slope cross section is nearly always idealized in the form of a triangular cross section, whilst in
International Standard ISO 5048:1989 it is idealized in the form of a segment of a parabola.
The working group considered the adoption of the approach according to ISO 5048 and its incorporation in
this revision, but finally refrained from this intention for the following reasons:
─ The latest editions of international and German standards use a triangular cross section as a basis (see
ISO 7189 or DIN 22200).
─ ISO 3435 uses the “angle of repose” instead of referring to the “surcharge angle” (as mentioned in
ISO 5048).
─ Hence it can be assumed that in its next revision, ISO 5048 will use an idealized triangular cross section.
Reduction factor ϕ st
When using Equations (10), (11) it shall be borne in mind that the equivalent angle β = 15° used in a large
number of calculations of the cross section of fill represents a precautionary value. In the case of inclined
installations, to avoid determining cross sections of fill that are considerably too small when using this value, it
will be necessary to calculate the factor φ st which is dependent on the inclination, with an angle of slope βdyn
close to the static angle of slope (the angle of internal static friction). If accurate values are required in
borderline cases, such values are to be determined by tests carried out under conditions which approximate
the actual application conditions as closely as possible.
Re 6.2
For the calculation of resistances, even complex equations are not excluded here, since computerized
calculations of this type are widely practiced.
46
DIN 22101:2011-12
In deviation from DIN 22101:1982-02 preference is given to the determination of resistances in each conveyor
section.
The simplest conceivable layout of a belt conveyor installation consists of two sections only: upper strand and
lower strand. Simplifying a belt conveyor installation with uphill and downhill part sections as an installation
with only two part sections may yield extremely false results.
Re 6.2.3
In order to enable a high degree of accuracy of design and layout, the hypothetical friction coefficient f should
be determined more precisely by measuring two major parts of the resistance to motion, i.e.
─ the indentation rolling resistance of the conveyor belt
─ the idler running resistance
and by giving an estimate of the remaining portions (see [5]).
The indentation rolling resistance is generally measured with a single idler under consideration of the
conveyor specific parameters. For the transformation to the indentation rolling resistance of a complete set
of idlers, the values of the normal forces acting on each idler must be known.
Figure A.1 shows schematically the idealized distribution of the normal forces and the indentation rolling
resistance resulting thereof for an idler configuration with three rollers of equal length in a horizontal and
straight conveyor [20].
Key
1 Bulk material
2 Direction of travel
3 Load over length on side idler
4 Load over length on centre idler
5 Related indentation rolling resistance on centre idler F'E,m
6 Related indentation rolling resistance on side idler F'E,s
Figure A.1 — Idealized distribution of the normal forces and the resulting indentation rolling resistance
for a 3-roller idler set with rollers of equal length
The dependence of the relevant indentation rolling resistance F'E on the vertical force F'M,v for a single idler
can generally be described using the following numerical equation [20]:
′ v ) cb
FE′ = ca ⋅ ( FM, (A.1)
47
DIN 22101:2011-12
Here the values ca and cb vary depending on the measured function of the relevant indentation rolling
resistance.
The indentation rolling resistance FE,3 acting on each idler of a 3-roller idler set is determined by integrating
the locally varying value of F'E along the contact line bR under consideration of the local line load. For the total
indentation rolling resistance acting on the idler set the following numeric equation applies [20]:
cb cb
 Fn,m  ca ⋅ bR,s  2 ⋅ Fn,s 
FE,3 = ca ⋅   ⋅ bR,m + 2 ⋅ ⋅  (A.2)
b  cb + 1  bR,s 
 R,m 
In order to demonstrate the importance of the indentation rolling resistance for a safe dimensioning while at
the same time minimizing investments and operating costs, Figure A.2 can be used as it shows examples of
the distribution of parts of motion resistances for long belt conveyors:
 Left column: belt conveyor installation with horizontal layout
 Right column: belt conveyor installation with approx. 5 % inclination
It should be borne in mind that, especially as regards the interpretation of the left column, in the future an
increasing use of energy-optimized belts will accordingly reduce the portion of the indentation rolling
resistance in the total resistance to motion. Furthermore, the information shown in Figure A.2 should not be
taken as basis for the design of conveyors, in view of the dependence of the single parts of the resistance to
motion on the operational and design-related parameters of the conveyor.
Key
Gradient resistances
Special resistances
Secondary resistances
Flexing resistance of the belt
Flexing resistance of the bulk material
Idler running resistance
Indentation rolling resistance
Figure A.2 — Comparison of the portions of resistance of two long belt conveyor installations
of identical design, with different inclinations
48
DIN 22101:2011-12
Re 6.3.2
For the secondary resistances a determination of each part is preferable to the determination of a generalized
value for the portion of the primary resistance.
In determining the friction resistance between conveyor belt and lateral chutes in the acceleration zone of a
 β dyn 
feeding point, not only shall the Rankine factor cRank = tan 2  45° −  , which has an effect on the pressure
 2 
exerted on the chute walls by the material in the chute zone, be taken into consideration, but also the
coefficient cSchb (information on the magnitudes of βdyn is given in the explanatory notes on the reduction factor
φ St). This factor characterizes the increase of the resistance due to additional pressure on the chute walls
caused by the dynamic pressure of the material flow of feed material. Consequently, the magnitude of the
coefficient cSchb will be equal to 1 for the transfer height 0; it then increases with rising conveying speeds and
dropping heights. For the design and layout of customary belt conveyor installations, the product will be
cSchb · cRank = 1, whilst the coefficient will be applied as cSchb = 1 for hopper discharge conveyors with high
loading heights.
Re 6.5
A distinction has not been made between special resistances arising along the entire stretch of the installation
and those occurring in individual sections only, as introduced by ISO 5048. The calculation approach detailed
in this standard requires the calculation of resistance values for individual sections which implies the
consideration of special resistances.
Detailed information on the magnitudes of the dynamic angle of slope βdyn in the Rankine factor cRank applied in
the calculation of the resistance arising at the material guide bars can be seen from the above comments on
the reduction factor φ st.
Re 8.3.3
A belt conveyor installation for which the rate of increase of the pulley peripheral forces is limited during
starting or stopping procedures, and where the belt is in motion along the entire installation, exhibits a belt
acceleration which is independent of location; it behaves in a quasi steady-state fashion, and enables the
dynamic additional forces to be determined as mass forces. If the non-quasi steady operating conditions, e.g.
the breakaway process, of a belt conveyor installation are to be calculated, it is necessary to determine the
additional dynamic forces which arise in this connection with the aid of very complex calculation methods
(see [9]).
Re 8.4
For the calculations, a distinction is to be made between take-up devices with a fixed take-up pulley and those
with a flying take-up pulley.
Take-up devices with a fixed pulley are devices on which the position of the driven and non-driven pulleys
remains unaltered for every operating condition of the conveyor. The desired adjustment of the tensile force is
effected, for example, by means of spindles (screws) or jacks. Depending on the prevailing operating
condition, a fixed take-pulley will result in varying forces at the tensioning location. Conversely, the total of the
local belt elongations in the upper strand and the lower strand will remain constant; it is equal to twice the
take-up pulley travel during the take-up process (take-up pulley path s*Sp).
∑ Δli = 2 ⋅ sSp
*
= const (A.3)
Take-up devices with a flying take-up pulley are devices which generate tensile forces which are either
independent of the operating conditions and practically constant, or which are suitably matched to the
prevailing operating conditions. This is achieved, for example with the aid of take-up weights, pneumatic or
hydraulic devices and force-controlled jacks in the case of take-up pulleys with an adequate travel facility.
Their mode of operation is, therefore, characterized by the fact that the total of the local belt elongations in the
upper strand and the lower strand and consequently the take-up pulley travel vary:
49
DIN 22101:2011-12
∑ Δli = 2 ⋅ sSp
*
≠ const (A.4)
For the calculation of Δli a linear relationship between the elastic elongations and the belt tensions k related to
the belt width is generally assumed as a simplification, and this is expressed by means of a mean width-
related longitudinal modulus of elasticity related to the belt ELGk.
Take-up forces that can be adjusted by suitable means shall be adjusted with an adequate speed in order to
avoid sliding and slipping on the drive pulleys. In this context, it may be helpful to adjust the take-up force to a
higher degree than the calculated one in order to ensure an adequate belt tension at any time.
Re Clause 9
The determination of belt tensions in accordance with DIN 22101:1982-02 solely focussed on mean belt
tensions. Non-uniform distribution of tensions over the width of a troughed belt as arising in transitions or
curves was accounted for by a deduction r1 introduced for this particular purpose. This, however, no longer
represents the state of the art in respect of the design and layout of conveyor belts with a high demand of
accuracy.
For the consideration and determination of additional elongations of the conveyor belt, a distinction shall be
made between belts with textile plies and steel-cord belts because of their extremely different elastic
characteristics.
Elongations of belt edges in the transition zones shall be calculated proceeding from the geometrical
approach suggested by Laier (see [13]). Applying this approach, length variations and — for conveyor belts
with textile plies — elongations and additional loads can be determined with sufficient accuracy. Length
compensations of steel-cord belts involve considerably large belt portions adjacent to the transition zone,
which is why higher belt tensions than those which actually arise will be calculated if the approach
recommended for conveyor belts with textile plies is applied to steel-cord belts. In the referenced literature
(see [12) and [14]) descriptions of safe methods for the precise calculation of steel-cord conveyor belts are
provided, which can be applied without problems using computerised support, provided that the mechanical
characteristics of these belts are available.
If no mechanical characteristics of the belt are available, empirical relationships are provided for conveyor
belts in accordance with DIN 22129-1 or DIN EN 15236-11) and steel-cord belts of similar design. These
relationships will enable a sufficiently precise prediction of the stresses arising in conveyor belts installed on
2-roller idlers and the more frequently used 3-roller idlers, in many cases. However, the relationships can only
be referred to as being correct if the elastic characteristics of the belt currently ensured according to common
practice, but not as specified in the applicable standards, are maintained, except for insignificant
modifications.
Re 9.2
The belt pulley should not be arranged at a level which is lower than the deepest trough level as this requires
greater transition lengths or may aggravate the non-uniform distribution of belt tensions across the cross
section of the belt. This also increases the load on idlers and bearings. There is also an increasing risk of
damage to the belt as the belt may run into the gap between the rollers of the carrying idlers.
Re 10.2
Deviating from DIN 22101:1982-02, the belt tensions arising in non-steady operating conditions are not
directly taken into consideration in the design and layout of the conveyor belt. Instead, one single limiting
condition has been specified which will be applicable only to extremely high stresses in the non-steady
operating conditions. Safety factors are to be selected (Table 8 of the previous edition of this standard) in
order to take the frequency of non-steady operating conditions into consideration. For this reason the
deduction r2 is no longer required for the global consideration of these stresses.
The load-bearing capacity of a conveyor belt is primarily dependent on the dynamic strength of the conveyor
belt and belt splices. DIN 22101:1982-02 accounts for this aspect by applying the factor r0. By testing the belt
in accordance with DIN 22110-3 the dynamic splice efficiency of the conveyor belt and the belt splices can be
50
DIN 22101:2011-12
determined. The characteristics of the belt splice manufacture are represented by the safety factors S0
provided in Table 8. The magnitude of stresses is expressed by the safety factor S1 to be selected from
Table 9. The values in Table 8 and 9 have been verified by comparison with the values obtained from existing
and proven heavy-duty conveyor installations.
The relationship of the safety factors S0 and S1 to the safety factor Smin in steady operation which is based on
the mean belt force over the width of the belt is given in Equation (78). Its use leads to the results in
Table A.1. From them the influence of belt specific parameters (k t,rel, S0) and conveyor-specific parameters
(S1, k K,max) on the safety factor Smin can be seen.
Table A.1 — Minimum values for the safety factor Smin related to the minimum nominal breaking
strength of the belt as a function of the parameters S0, S1, kt,rel , cK and k K,max
cK · k K,max / k
S0 * S1 / k t,rel
The safety factor S which is related to the nominal breaking strength of the belt k N, as opposed to the value
kN,min can be determined analogously to Equation (78) as:
kN
S = Smin ⋅ (A.5)
kN,min
Re 10.3
Because the relevant DIN Standards, International Standards and currently available drafts of European
Standards do not contain data regarding the selection of the cover layer thickness, recommendations in this
respect have been incorporated in this standard.
The cover layer thickness on the running side of the conveyor belt is determined to a great extent by the
tension member, or in some cases by the transverse reinforcement, whilst the cover layer thickness on the
carrying side of the belt is determined mainly by the stressing of the belt by the material conveyed, and
consequently by the following influencing quantities:
─ Nature of material conveyed: particle size and shape, density, abrasiveness
─ Loading condition: drop height, resilience of the belt support, difference in speed between bulk
material and conveyor belt
─ Loading frequency: frequency of belt revolutions and scheduled service life of the conveyor
belt, number of feeding points
The thickness on the carrying side shall be at least equal to the thickness on the running side of the belt.
51
DIN 22101:2011-12
Re Clause 11
The principle and general contents of the method of calculating minimum pulley diameters is identical with that
described in ISO 3684:1990. The design and layout according to the ISO Standard is based on the per-
centage of utilized RMBT (Recommended Maximum Belt Tension), which was defined in DIN 22101:1982-02
k k
as ⋅ S sta ⋅ 100 % . This standard defines this variable as N and derived from this, the pulley load factor is
kN 8
kmax
calculated as ⋅ 8 ⋅ 100% , where according to Table 14 k max is the mean width-related tension at the point
kN
of maximum belt tension in the zone of Group A pulleys in the steady operating condition.
This pulley load factor can have values higher than 100 %. Therefore, a fourth category has been introduced
for pulleys with loads exceeding the permissible values defined in DIN 22101:1982-02 and ISO 3684:1990.
Re Clause 13
This standard contains empirical values for minimum turnover lengths for different belt types and turnover
principles.
52
DIN 22101:2011-12
Annex B
(informative)
Explanations of relationship of this standard

to international standards
The following ISO Standards have been taken into consideration for the revision of this standard:
ISO 5048:1989 “Continuous mechanical handling equipment — Belt conveyors with carrying idlers —
Calculation of operating power and tensile forces”
The recommendations contained in the above document for the determination of
— the material flow and the troughing cross section
— the resistance to motion, driving force and power requirement
— the belt tensions
are in accordance with the contents of this standard, but for the following important exceptions.
In the ISO document, the cross section of fill of a troughed belt is composed of an equal sided trapezium or
triangle surmounted by a segment of a parabola. In this standard (see Clause 5), the upper portion of the
cross section of fill is idealized in the form of an isosceles triangle, in accordance with the German technical
literature. This approach has been maintained as it can be assumed that the standard ISO 5048:1989 — like
other ISO Standards — will also be revised to refer to a triangular cross section (see Annex A, explanatory
notes to Clause 5).
According to the recommendations contained in the ISO document for the calculation of the secondary and
special resistances, the resistances due to the belt cleaners are deemed to be special resistances. However,
as belt cleaners form part of the standard equipment of belt conveyor installations for bulk materials, the
associated resistances have been allotted to the secondary resistances in this standard (see 6.3).
The ISO document takes the maximum belt tension calculated as a mean value across the belt width as a
basis for the design and layout of the conveyor belt. It is expressly limited to simple, but frequently occurring
cases. The present standard accounts for non-uniform belt tensions distributed across the cross section of
troughed conveyor belts taking into consideration the endurance strength of the conveyor belt and belt splices
subject to dynamic loads.
ISO/DIS 3870:1996 “Conveyor belts for loose bulk-materials — Description of types and adjustment of
take-up devices”
In the above standard, recommendations are given in respect of different types of take-up devices. It defines
the standard values of elongation and other influencing variables for the calculation of the take-up distances
applicable to tension members of different materials. ISO/DIS 3870:1996, Annex A provides an option for the
determination of adequate take-up distances dependent on the belt tensions determined for a belt conveyor
installation. Applying the relationships provided in this standard (see 8.4), the elastic elongations of the
conveyor belt and the corresponding take-up pulley path can be determined with a relatively high degree of
accuracy proceeding from the distribution of belt tensions and the characteristics of the conveyor belt.
53
DIN 22101:2011-12
ISO 5293: 1981 “Conveyor belts — Determination of minimum on three idler rollers”
The above standard gives detailed recommendations for the determination of transition distances (transition
lengths). It is based on simplified assumptions which were made by Laier (see [13]). The present standard
does not give priority to the retroactive calculation of an adequate transition distance, but takes the maximum
belt tensions resulting from a given transition distance (or curve layout) as a basis for the design and layout of
the conveyor belt.
ISO 3684: 1990 “Conveyor belts — Determination of minimum pulley diameter”
The recommendations contained in the above standard for the determination of minimum pulley diameters for
belt conveyor installations have been incorporated in this standard in a more concise form adapted to their
field of application (see Clause 11). This standard does not contain any variables corresponding to the term
“recommended maximum belt tension” (RMBT), which had been introduced in ISO 3684. A pulley load factor
k k
has been introduced as max ⋅ 8 ⋅ 100 in % with the reference value N .
kN 8
Here kmax according to Table 14 is the mean width-related tension at the point of maximum belt tension in the
zone of Group A pulleys in the steady operating condition.
54
DIN 22101:2011-12
Bibliography
DIN 22103, Flame resistant steel cord conveyor belts — Requirements and method of test
DIN 22109-5, Conveyor belts with textile plies for coalmining — Branding
DIN 22109-6, Conveyor belts with textile plies for coalmining — Part 6: Testing
DIN 22110-2, Testing methods for conveyor belt joints — Part 2: Endurance running tests, determination of
running time of belt joints at conveyor belts with textile plies
DIN 22111, Belt conveyors for underground coal mining — Light construction
DIN 22112-3, Belt conveyors for underground coalmining — Idlers — Part 3: Testing
DIN 22114, Belt conveyors for underground coalmining — Heavy construction
DIN 22118, Conveyor belts with textile plies for use in coal mining — Fire testing
DIN 22120, Elastomere scraper plates for belt conveyors in hard coal mines
DIN 22200, Continuous mechanical handling equipment — Apron conveyors — Principles for calculation
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operating power and tensile forces
ISO 5293, Conveyor belts — Determination of minimum transition distance on three idler rollers
ISO 7189, Continuous mechanical handling equipment — Apron conveyors — Design rules
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Braunkohle. Wärme und Energie 19 (1967) No. 9, pp. 309–315.
[2] Schwarz, F.; Zum Eindrückrollwiderstand zwischen Fördergurt und Tragrolle.
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[3] Behrens, U.: Untersuchungen zum Walkwiderstand schwerer Förderbandanlagen.
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[7] Grimmer, K.-J.: Zwei ausgewählte Probleme der Bandfördertechnik.
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Braunkohle 31 (1979) No. 6, pp. 188–194.
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Belt Conveyor System.
Bulk Solids Handling 8 (1988) No. 5, pp. 567-579.
55
DIN 22101:2011-12
[10] Grimmer, K.-J.: Der Einfluss von Trommelbelägen und Feuchtigkeit auf den Reibungsbeiwert zwischen
Fördergurt und Antriebstrommel.
[11] VDI-Guideline 2341; Belt conveyors for bulk material — Idler rolls and idler roll distances.
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Gurtwendung und Seilunterbrechung.
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von Fördergurten.
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Geometry.
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Horizontalkurven. Part 1: Anmerkungen and Part 2: Verbesserungen zu herkömmlichen Berechnungs-
verfahren.
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[16] Oehmen, K. H.: Einfluß vertikaler und horizontaler Kurven auf die Dehnungsverteilung in Fördergurten –
Theorie und Anwendung.
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[17] Hager, M.: Stand der Entwicklung von Verbindungen hochfester Stahlseilgurte
Braunkohle 39 (1987) No. 7, pp. 251–253.
[18] Flebbe, H.: Dynamic Splice Strength-Design Criterion for Conveyor Belts
Bulk Solids Handling 8 (1988) No. 5. pp. 581–586.
[19] Hager, M. and H.v.d.Wroge: Design of Steel Cord Conveyor Belt Splices.
[20] Wennekamp, T.: Tribologie und rheologische Eigenschaften von Fördergurten
Dissertation Leibniz Universität Hannover 2008
56

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DEUTSCHE NORM December 2011

Document comprises 56 pages

Normenausschuss Bergbau (FABERG) im DIN

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9 Distribution of belt tensions across the belt width ...................................................................... 31

Annexes A and B are provided for information and are informative.

This standard differs from DIN 22101:2002-08 as follows:

b) the start-up factor pA and braking factor pB are now defined;

g) normative references have been updated;

h) the standard has been editorially revised.

DIN BERG 2101 Part 1: 1933-07

ISO 3684:1990-3, Conveyor belts — Determination of minimum pulley diameters

3 Terms and definitions

4 Symbols and units

Symbol Meaning Unit

Fa Forces resulting from acceleration/deceleration under non-steady operating

FAuf Inertia resistance of material conveyed and frictional resistance between

FE Indentation rolling resistance: Sum of all indentation rolling resistances in the

FN Secondary resistance: Sum of all secondary resistances in the upper and/or

Symbol Meaning Unit

ca Factor used in the numerical equation describing the indentation rolling

cb Exponent used in the numerical equation describing the indentation rolling

cK Coefficient for determination of the minimum dynamic splice efficiency

fi Hypothetical friction coefficient for the approximate calculation of the primary

∆ε M Additional elongation (pos. or neg.) at the centre of the belt in concave or

5 Volume flow and mass flow

Figure 1 — Theoretical cross section of fill in the case of horizontal conveyance

B ≤ 2 000mm b = 0,9 × B − 50 mm (1)

B > 2 000mm b = B − 250 mm (2)

Theoretical volume flow I V, th = Ath ⋅ v (5)

And on the basis of the effective filling ratio ϕ = ϕBetr ⋅ ϕ St (6)

the following can be calculated:

Nominal volume flow IV,N = ϕ ⋅ Iv,th (7)

Nominal mass flow Im,N = ϕ ⋅ ρ ⋅ Iv,th (8)

Line load resulting from nominal load m'L,N = ϕ ⋅ ρ ⋅ Ath (9)

The filling ratio ϕ Betr depends on:

 properties of material conveyed

cos2 δmax − cos2 β dyn

6.2 Primary resistances

6.2.2 Determination of primary resistance FH

6.2.3 Determination of the hypothetical friction coefficient

with 0,5 ≤ qo ≤ 0,85, on average qo = 0,7 and qu = 0,9.

Guidelines for estimating coefficient qo are given in Table 3.

Characteristic Values for characteristic

 3 roller fixed idler sets in the top run

Characteristic Values for characteristic

6.3 Secondary resistances

6.3.2 Determination of individual secondary resistances

FAuf = Im ⋅ (v − v0) (19)

Figure 3 — Chute configuration

lM = bSch shall be applied for bSch ≤ lM

lM = 0 shall be applied for 2-roller idler sets

lM = bSch shall be applied for 1-roller idlers

The following applies to belt conveyors of customary design:

cSchb ⋅ cRank = 1 (see Annex A)

Friction resistance caused by belt cleaners

FGr = µ4 ⋅ pGr ⋅AGr (23)

6.3.3 Approximate calculation of secondary resistances

The coefficient C can be selected from Table 5:

Table 5 — Standard values for coefficient C for belt conveyor installations

6.4 Gradient resistance

6.5 Special resistances