Belt Conveying of Bulk Solids

Overview of Main Resistances

Dr Craig Wheeler
Senior Lecturer, School of Engineering
Associate Director, TUNRA Bulk Solids Research Associates
The University of Newcastle, Australia.

Overview of Presentation 2

Main resistances of belt conveyors

• Idler roll rotating resistance
• Indentation rolling resistance
• Bulk solid and belt flexure resistance
• Idler roll misalignment

Influence of key conveyor variables

• Bulk solid properties
• Belt speed and sag
• Idler roll diameter and spacing

CEMA 6th Edition

Design Optimisation

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 Main and Secondary Resistances 3

FH3

FN1 FH2 FH1 FH4

FN2 FN2
Main Resistances Secondary Resistances
FH1 Indentation rolling resistance of the belt FN1 Charging resistances
FH2 Belt flexure resistance FN2 Wrapping resistance of the belt
FH3 Material flexure resistance around the pulleys
FH4 Rotational resistance of the idler bearings
and seals

Main Resistance – Friction Factors 4

ISO5048 - Artificial Friction Factors

= 0.017 for well aligned conveyors with smoothly running

idlers and bulk materials with low internal friction
= 0.020 for normal applications
= 0.023 to 0.027 for unfavourable operating conditions,
dusty environments and materials with high internal
friction and occasional overloading

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 Distribution of Motion Resistances 5

Short Horizontal Conveyor 4.5

((approx.
pp 80m long)
g)
4

Extraordinary 3.5

Resistances Indentation Rolling

5% Resistance

COEFFICIENT C
33% 3

2.5

Belt Flexure
Secondary
Resistance 2
Resistances
3%
47%
1.5
Bulk Material
Idler Bearing
Flexure Resistance
Resistance
9% 1
3% 10 100 1000 10 4

CONVEYOR LENGTH L (m)

Reference: Hager and Hintz, The Energy Saving Design of

Belts for Long Conveyor Systems, BSH pp. 172 1993.

Distribution of Motion Resistances 6

Long Horizontal Conveyor 4.5

((approx.
pp 1000m long)
g)
4

Secondary Extraordinary 3.5

Resistances Resistances
9% 1%
COEFFICIENT C

3
Idler Bearing
Resistance
6% 2.5

Bulk Material
2
Flexure Resistance
18%
1.5
Belt Flexure
Indentation Rolling
Resistance
Resistance
5% 1
61% 4
10 100 1000 10

CONVEYOR LENGTH L (m)

Reference: Hager and Hintz, The Energy Saving Design of

Belts for Long Conveyor Systems, BSH pp. 172 1993.

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 CEMA Standard Method (5th Ed. and Prior) 7

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CEMA Standard Method (5th Ed. and Prior) 8

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 CEMA 6th Ed. - Universal Method 9

Where all apply

pp y to the effect in flight
g or p
pulley
y ‘n’ and;
∆Tn (lbf ) = Total change in belt tension to cause steady belt speed
∆ THn (lbf ) = Change in belt tension to lift or lower the material and belt
∆ Tamn (lbf ) = Tension added in loading to continuously accelerate material to belt speed
∆ Tssn (lbf ) = Tension change due to the belt sliding on skirt board seal
∆ Tisn (lbf ) = Change in tension from idler seal friction
∆ TiWn (lbf ) = Change in tension from idler load friction

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CEMA 6th Ed. - Universal Method 10

∆ Tbin (lbf ) = Tension increase from visco-elastic deformation of belt

∆ Tmn ((lbf ) = Tension loss from idler misalignment
g
∆ Tsbn (lbf ) = Drag due to Slider Beds
∆ Tsn (lbf ) = Tension change due to bulk materials sliding on skirtboards
∆ Tmn (lbf ) = Tension change due to bulk materials moving between the idlers
∆ Tpxn (lbf ) = Tension change due to belt bending on the pulley
∆ Tprn (lbf ) = Tension change due to pulley bearings
∆ Tbcn (lbf ) = Tension added due to belt cleaners and plows
∆ Tdpn (lbf ) = Tension added due to discharge plow

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 11

Rotating Resistance of Idler Rolls

Long Overland Belt Conveyors 12

Given: ac = 2m and ar = 4m
El Abra Overland Conveyor - Chile
30,750 Carry Side Idlers 14.5km long and 1,600mm wide
5 175 Return
5,175 R t Side
Sid Idl
Idlers 9,500t/hr Copper Ore

Given: ac = 2m and ar = 4m
21,750 Carry Side Idlers
3,625 Return Side Idlers

Channar Overland Conveyor

y - Australia
10.1km and 10.4km (9km Horizontal Curve)
1,050mm wide, 2,200t/hr Iron Ore

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 Components of Idler Roll Rotating Resistance 13

Frictional Drag of the

Labyrinth Seal Contact Lip Seals
Viscous Drag

Frictional Drag of the

Contact Lip Seals Friction of the Rolling
Elements in the Bearings

Reference: Mesco Idlers 2004

Labyrinth Seal Viscous Drag 14

Typical Labyrinth Seal Configurations

(a) Axially aligned labyrinth seal (b) Radially aligned labyrinth seal

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 Labyrinth Seal Viscous Drag 15


2

1
R2 R R1 L1,2 M lab
R2 R R1 L1,2

(a) Axially aligned labyrinth seal

Provided the dynamic viscosity of the lubricating grease is constant throughout
the labyrinth seal the total moment acting due to the viscous drag is
 
 
 L R2 L 3, 4 R 32 L 2 m 1, 2 m R 22 m 1 
 1, 2 1
M lab  4   ........   (1)
   R1  
2   R 2   R  
2

 1     1   3   1   2 m 1   
   R 2     R 4     R 2 m   
   

Labyrinth Seal Viscous Drag 16

L1,2

2

R2
R 1
R1 M lab

(a) Radially aligned labyrinth seal

  R 42 R4   R 44
 R4   4
  ....   R 2 m  R 2 m 1
4 
 (2)
M lab    1  3
2  L 1, 2 L 1, 2   L 3, 4 L 3, 4
 


 L 2 m 1, 2 m L 2 m 1, 2 m





While the resistance force per roll due to the labyrinth seal, Flab is

4M lab
Flab  (3)
D

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 Bearing Friction (SKF) 17

The total friction moment for each bearing Mbrg, may be obtained by adding the
no-load moment M0, and the load dependent moment M1. Given the base oil
viscosity, ν and the rotational speed, n then SKF gives
M 0  f 0  10  7 n  3 d 3m provided n  2000
2
(4)

Where; fo = 1.5 to 2.0 for single row deep groove ball bearings
d m  0.5d i  d o  (5)

and, M1  f1Fr d m (6)

Given the radial force, Fr the load dependant friction factor, f1 for deep groove
ball bearings is  0.6Fr 
0.55
f 1  f   (7)
 C 0 
Where; f = 0.0008 for 62 series & 0.0009 for 63 series deep groove ball bearings
C0 = static load rating of the bearing given by bearing manufacturer

4M brg
M brg  M 0  M1 (8) and Fbrg  (9)
D

CEMA 6th Ed. - Universal Method 18

Idler Seal Friction

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 CEMA 6th Ed. - Universal Method 19

Idler Seal Friction

Where:
∆Tisn (lbf ) = Change in tension in flight ‘n’ from idler seal friction
KiV (in x lbf/rpm) = Torsional speed effect-see Table 6.19
Kis (in x lbf ) = Seal torsional resistance per roll at 500 rpm-see Table 6.19
KiT = Temperature correction factor per Equation 6.18
nr = Number of rolls per idler set
V (ft/min) = Belt speed
Dr (in) = Roll diameter
Sin (ft) = Idler spacing in flight ‘n’
n
Lin (ft) = Length of flight ‘n’
TF (°F) = Ambient operating temperature

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CEMA 6th Ed. - Universal Method 20

Idler Seal Friction

Max values
@ 500rpm.

If possible, the torsional resistance at the actual rotational speed should be obtained, in this case
and substituted directly as Kis with Kiv set to 0.0. Likewise, test values at expected operating
temperature should be used so that KiT can also be set to 1.0.
The above formulas apply to the running state but the breakaway condition may be estimated by
use of a temperature 40°F
40 F less than ambient in the KiT formula.
Rris = 0.20 with RriV = 0 should be applied where appropriate if the default values of Kis and Kiv
from Table 6.19 are used.

Rrxx are low limit multipliers.

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 CEMA 6th Ed. - Universal Method 21

Idler Seal Friction

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CEMA 6th Ed. - Universal Method 22

Idler Load Friction

Where:
∆TiWn (lbf ) = Change in tension in flight ‘n’ from idler load friction.
CiW (in x lbf/lbf ) = Torsional load effect, Table 6.21
Wb (lbf/ft) = Belt mass per unit length
Wm (lbf/ft) = Bulk material mass per unit length
Use RriW = 0.67. Where Rriw is a multiplier used to obtain the low end of the
expected range for idler load friction.

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 Idler Roll Rotating Resistance Test Facility 23

Idler Rotating Resistance Measurement 24

TRim Drag

FV

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 Typical Experimental Results 25

152mm Idler Roll at 6m/s

16 40 16 40
Rotating Resistance Bearing Temperature Rotating
g Resistance Bearing
g Temperature
p
14 35 14 35

12 30 12 30

Temperature (Deg C)

Temperature (Deg C)
10 25 10 25

Force (N)
Force (N)

8 20 8 20

6 15 6 15

4 10 4 10

2 5 2 5

0 0 0 0
0 5 10 15 20 0 5 10 15 20
Time (mins) Time (mins)

20oC Ambient Temperature 0oC Ambient Temperature

Typical Breakdown of Components 26

Bearing Rolling
Elements
6%
Outer Dust Seals
27%

Bearing Lubricating
Grease
46%

Labyrinth and Inner

Seal
21%

Total Rotating Resistance = 3.2N

@ 200C, v = 4m/s and 250N Vertical Load

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 Idler Roll Rotating Resistance

Fidler  f v , D ,,P r , d m ,TG .......

•Belt Speed: v ↑ → Fidler ↑
•Idler Roll Diameter: D ↑ → Fidler ↓
•Radial Load: Pr ↑ → Fidler ↑
•Mean Bearing Diameter: dm ↑ → Fidler ↑
•Grease Temperature: TG ↑ → Fidler ↓

Summary 28

• Factors influencing the rotational resistance of the idler rolls

include:
- Bearingg type
yp (deep
( p ggroove ball or tapered
p roller))
- Seal type and configuration
- Grease viscosity
- Ambient temperature
- Rotational speed
- Load
• While it is ppossible to theoreticallyy approximate
pp the rotatingg
resistance, where possible idler rolls should be tested at simulated
operating conditions, rather than a standard speed and ambient
temperature.

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 29

Indentation Rolling Resistance

Indentation Rolling Resistance 30

ASYMETRIC PRESSURE
DISTRIBUTION

BELT DIRECTION

IDLER SHELL

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 Stress-Strain Relation 31

For Example; Metals

Elastic response is due to the large
cohesive interatomic forces (atomic
crystalline structures).

p ; Oil
For Example;
Composed of molecules which
exert weak attractive forces.

32

Stress-Strain Relation

For Example: Polymers

Resulting from the movement of thread-like long chain
molecules, called macromolecules. Shape changes involve
rearrangement on various scales, and thus time scales.
1.Gross long-range contour rearrangements achieved
 / slowly.
2.Rearrangements on a more local level, achieved rapidly.
3.Reorientation of bonds on the chain backbone on the
atomic scale.

Note: The amplitude ratio and the phase lag both vary with
frequency.

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 Belt Indentation Rolling Resistance 33

(2D Viscoelastic Finite Element Analysis)

Top Cover

Belt Carcass Uniform Pressure Distribution Bottom Cover

Indentation Pressure Distribution

Analysis Zone Idler Roll Radius

Belt Flexure Radius

Belt Indentation Rolling Resistance 34

(2D Viscoelastic Finite Element Analysis)

• The stiffness matrix {K} must allow for the strain history in
the constitutive relations of a viscoelastic material.
• The
Th constitutive
tit ti forms
f off the
th viscoelastic
i l ti stress
t strain
t i relations
l ti
in terms of the shear G1, and the bulk relaxation moduli G2 are:
deij  
 G1 t   
t
sij  d
d
d kk  
 G2 t   
t
kk  d
d
Where; sij  ij  13 ij kk and; ij = stress tensor
 ij = strain tensor
eij  ij  13 ij kk sij = deviatoric stress
eij = deviatoric strain

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 Belt Indentation Rolling Resistance 35

(2D Viscoelastic Finite Element Analysis)

T 1, 3

2 4 6
1 3 5 7

T 2, 7

Typical Row of Elements

T 2, 7

G1(T
( 1, 3)
G1(t) 
T 1, 3

G1(T 2, 7)

Time (t)
Shear Relaxation Modulus

Viscoelastic Measurement 36

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 Dynamic Rubber Property Tests 37

10000.00

1000.00

100.00
E' and E'' (MPa)
and tan

E' (MPa)
10.00 E'' (MPa)
tan delta

1.00

0.10

0.01
1.E-03 1.E+03 1.E+09 1.E+15 1.E+21

Frequency ()

o  E  
E    cos  , E    o sin  , tan  
o o E  

Belt Indentation Rolling Resistance 38

(2D Viscoelastic Finite Element Analysis)

300
Asymmetric Pressure 2m/s
Distribution 4m/s
Conveyor
y Belt 6m/s
250
Bottom Cover

200
Pressure (kPa)

Belt Direction 150

100
Asymmetric
Contact Zone
50
Idler Roll
0
-8 -6 -4 -2 0 2 4 6 8
Contact Length (mm)
Ø150mm idler roll under a simulated vertical
load of 2500N/m

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 Belt Indentation Rolling Resistance 39

(2D Viscoelastic Finite Element Analysis)

Indentation profile for a Ø150mm idler roll under a

simulated vertical load of 2500N/m
0 35
0.35
2m/s
4m/s
0.30
6m/s

0.25
dentation Depth (mm)

0.20

0.15

0.10
Ind

0.05

0.00

-0.05
0 20 40 60 80 100
Analysis Length (mm)

Indentation Rolling Resistance Measurement 40

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 Indentation Rolling Resistance Measurement 41

FTOT
Belt Direction

TBRG

FH

FV

FEA vs Experimental Results 42

Indentation rolling resistance force versus vertical force, Vb = 2m/s

40
100mm Dia FEA
N/m)

35 100mm Dia Exp

p
Indentation Rolling Resistance Force (N

125mm Dia FEA

125mm Dia Exp
30 150mm Dia FEA
150mm Dia Exp
25

20

15

10

0
0 500 1000 1500 2000 2500

Vertical Force (N/m)

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 University of Newcastle – Steel Cord Belt Indentation Rolling
Resistance Measurement Facility 43

Indentation Rolling Resistance Measurement 44

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 Contact Pressure Distribution 45

y
z
x

.............

σy

Contact pressure distribution at belt and roll interface

for a loaded steel cord conveyor belt.

Static 3D Finite Element Analysis 46

• The model incorporates the three different

Top Cover
rubber compounds and the steel cable.
• The model is composed entirely of eight node
bricks and six node wedges, with
approximately 16,400 brick elements in total.
• Non-linear analysis undertaken using Strand
Insulation 7 FEA Software.
Rubber

Bottom Cover

Steel Cord

FEA Model

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 Pseudo 3D FEA 47

Steel cord belt under a simulated load of 5kN/m with a Ø150mm roll.

Apparent bottom
cover thickness

Contact Pressure Distribution 48

Asymmetric Pressure
Conveyor Belt
Distribution
Bottom Cover

Belt Direction

2D FEA Viscoelastic Model Side View

Centreline
of Cord

Bottom View

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 Static FEA Results 49

Bottom cover surface stress for a range of conveyor idler roll diameters
Centreline of Cable

(a) Ø125mm idler roll - 5kN/m load. (b) Ø150mm idler roll - 5kN/m load.

(c) Ø175mm idler roll - 5kN/m load. (d) Ø200mm idler roll - 5kN/m load.

Pressure Measurements 50

TekScan pressure sensor Experimental Setup

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 Pressure Measurements 51

TekScan pressure measurement results for a Ø125mm roll

under a simulated load of 5kN/m.

FEA predicted 740kPa for peak stress directly beneath the steel cord and
480kPa for the minimum stress at the midpoint of the cord spacing.

Pressure Measurements 52

TekScan pressure measurement results for a Ø125mm roll

under a simulated load of 5kN/m.

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 Indentation Rolling Resistance

Find  f v , D , Pn ,.......

•Belt Speed: v ↑ → Find ↑

•Idler Roll Diameter: D ↑ → Find ↓
•Normal Load: Pn ↑ → Find ↑

CEMA 6th Ed. - Universal Method 54

Viscoelastic Deformation of Belt

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 CEMA 6th Ed. - Universal Method 55

Viscoelastic Deformation of Belt

CEMA 6th Ed. - Universal Method 56

Viscoelastic Deformation of Belt

The load on the idler affects the amount of energy loss. Since the load supported by the idler is
not uniform along the width, wi is provided for the load distribution on various troughing angles.

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 CEMA 6th Ed. - Universal Method 57

Viscoelastic Deformation of Belt

Rrbi is the low limit multiplier for possible lower belt rubber indentation resistance.

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CEMA 6th Ed. - Universal Method 58

Viscoelastic Deformation of Belt

40
ndentation Rolling Resistance (N/m)

6" Dia Roll

35
5" Dia Roll
30 4" Dia Roll
25

20

15

10

5
In

0
0 500 1000 1500 2000 2500
Vertical Force (N/m)

CEMA - Fabric Belt, V = 2m/s, h = 5mm, Tf = 20oC

Note: Characteristics for one rubber compound.

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 FEA vs CEMA 6th Ed. 59

40 40

ntation Rolling Resistance (N/m)

100mm Dia FEA
6" Dia Roll
Indentation Rolling Resistance Force (N/m)

35 100mm Dia Exp 35

125mm Dia FEA
125mm Dia Exp
5" Dia Roll
30 150mm Dia FEA 30 4" Dia Roll
150mm Dia Exp
25 25
20 20
15 15
10 10

Inden
5 5
0 0
0 500 1000 1500 2000 2500
0 500 1000 1500 2000 2500
Vertical Force (N/m)
Vertical Force (N/m)

60

Belt and Bulk Solid Flexure Resistance

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 Bulk Solid and Belt Flexure Resistance 61

Act Act A
Pas
B
A to C: Belt C
Opening y D
E

z
vb x
Pas
Act
Pas

C to E: Belt
Closing

Belt and Bulk Solid Flexure Resistance 62

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 Conveyor Belt Deflection 63

Fixed Edge Free Edge

y
Pz

z Tx
Guided Edge x
Fixed Edge

4w 4w 4w 2w

Dx  2 H  D y  Pz  x , y   Tx
x 4 x 2 y 2 y 4 x 2

Where 2H  4Dxy  y Dx  x Dy
Gt3 Ex t3 E y t3
and Dxy  , Dx  , Dy 
12 121  x y  121  x y 

Earth Pressure Theory - Retaining Walls 64

Fm
Fm
 

Fi Fw
w
i
i  w
a Fw p 

Fi
Active Stress State Passive Stress State

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 Continuum Approach - Bulk Solid Flex. Resistance 65

(Krause and Hettler)

Belt
l Belt
Fms Fms
Opening Closing
 

Fip
a i
i Fia p
β β w Fsp
Fsa w

Active Stress State Passive Stress State

Transverse Active and Passive Stress States 66

Act Act

Belt Opening
p g

Active to Passive
Transition
vb Pas Pas

Belt Closing

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 Longitudinal Active and Passive Stress States 67

Passive Stress
State

Bulk Solid
Compressing

Passive to Active Active Stress

Transition
vb State

Bulk Solid
Dilating

Bulk Solid Flexure Resistance 68

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 Bulk Solid Flexure Resistance 69

Bulk Solid and Belt Flexure Resistance 70

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 Iron Ore - Longitudinal Cracks 71

Belt and Bulk Solid Flexure Resistance 72

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 Influence of Conveyor Belt Speed and Sag 73

0.0070
1.00%

e Factor,
0.0060 1.50%
Bulk Solid Flexure Resistance 2.00%
0.0050

0.0040
fbs

0.0030

0.0020

0.0010
B

0.0000
0 2 4 6 8 10
Belt Speed, v (m/s)

(belt width = 1.2m, idler spacing = 3.0m,

i = 35o,  = 1000kg/m3, w = 30o)

Influence of Bulk Solid Int. Friction and Idler Roll Spacing 74

0.0070
e Factor, fbs

2.0m
0.0060 2.5m
3.0m
0 0050
0.0050
Bulk Solid Flex. Resistance

0.0040

0.0030

0.0020

0.0010

0.0000
25 30 35 40 45
Kinematic Internal Friction Angle,
i (Degrees)

(belt speed = 5m/s, belt width = 1.2m,

sag ratio = 2%,  = 1000kg/m3, w = 30o)

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 Bulk Solid Flexure Resistance

Fbs  f v , B , s , ac ,  ,i ,.......

•Belt Speed: v ↑ → Fbs ↑

•Belt Width: B ↑ → Fbs ↑
•Sag Ratio: s ↑ → Fbs ↑
•Idler Roll Spacing: ac ↑ → Fbs ↑
•Bulk Density: ρ ↑ → Fbs ↑
•Int. Frict. of Bulk Solid: i ↑ → Fbs ↑

CEMA 6th Ed. - Universal Method 76

Load and Tension Dependent Friction

The belt sags in the span between adjacent idlers similar to a catenary. The sag causes material
deformation and energy loss. Therefore, the tension and tension loss are interrelated so that
predicting the sag and tension change becomes an iterative process.

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 CEMA 6th Ed. - Universal Method 77

Material Trampling Loss

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CEMA 6th Ed. - Universal Method 78

Material Trampling Loss

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 CEMA 6th Ed. - Universal Method 79

Material Trampling Loss

olid Flex. Resistance Factor,, fbs

0.014
2.0m
2 0m
0.012 2.5m
0.010 3.0m

0.008

0.006

0.004

0 002
0.002
Bulk So

0.000
0 10 20 30 40 50
Ave. Angle of Repose (deg)

Belt width = 1.2m, sag ratio = 2%,  = 1000kg/m3

80

Idler Roll Misalignment

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 CEMA 6th Ed. - Universal Method 81

Idler Alignment Friction

• Idler roll axes are generally considered perpendicular to
the direction of belt travel.
• In most cases some misalignment will be present
resulting in transverse slip between the idler roll and the
belt.
• Resulting transverse force components average
themselves out in both transverse directions so that the
belt tracks satisfactorily.
• Idler sets are often intentionally misaligned during
commissioning to track belts.

CEMA 6th Ed. - Universal Method 82

Idler Alignment Friction

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CBSPT University of Newcastle 41

 CEMA 6th Ed. - Universal Method 83

Idler Alignment Friction

Where: Tmn (lbf )= Tension loss in flight "n" from idler misalignment
Cim = Design factor for frictional resistance due to idler misalignment
Cbi = Friction factor for sliding between belt cover and idler material
eim (in/in) = Average misalignment of idler axis to belt longitudinal axis
Ae (in)
(i ) = Effective
Eff ti total
t t l deviation
d i ti fromf perpendicular
di l tto belt
b lt travel
t l
 Aei (in) = Expected average installation deviation referenced from center roll
 Aem (in) = Effective misalignment due to manufacturing variation
 Aet (in) = Effective misalignment due to intentional inclination of idler frame it, Eq 6.32
it (in/in) = Intentional inclination of idler frame or wing roll to aid in belt tracking
As (in) = Distance between idler support points in the direction of belt width
 (deg) = Idler troughing angle
Bw (in) = Wing roll length
Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CEMA 6th Ed. - Universal Method 84

Idler Alignment Friction

Figure 6.32
The equation of effective idler
misalignment
sa g e t due to idler de
inclination for fixed frame idlers.

Default values for design are as follows;

Cbi = 0.5 sliding friction factor for steel roll on rubber belt cover
Cbi = 0.75 sliding friction factor for rubber roll on rubber belt cover
Aei (in) = 0.375 for permanent rigid structure with angular alignment procedures
= 0.5 when installed without alignment measurement
= 0.75 in. when mounted on independent, imprecise footings
= 1.5 for movable or unstable footing, roof hung, etc
Aem (in)= 0.1 for variation from parallel of wing rolls to the center roll
it (in/in) = 0 (tangent of inclination angle in degrees)
ASC (in2) = Total cross sectional area for a three roll idler set

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

CBSPT University of Newcastle 42

 Measured Friction Coefficient, Cbi 85

Belt Idler Roll - Measured Friction Coefficient

140
Painted Surface
Surface, New Belt
Belt, Dry
y = 0.4474x
120 Painted Surface, New Belt, Wet y = 0.4415x
Steel Surface, New Belt, Dry
Steel Surface, New Belt, Wet
y = 0.426x
Pulling Force (N)

100 Linear (Painted Surface, New Belt, Dry )

Linear (Painted Surface, New Belt, Wet)
Linear (Steel Surface, New Belt, Dry )
Linear (Steel Surface, New Belt, Wet)
80
y = 0.3735x
60

40

20

0
0 50 100 150 200 250 300
Normal Force (N)

CEMA 6th Ed. - Universal Method 86

Idler Alignment Friction

With;

For equal roll idlers a default value may be used;

It should be noted that the tension required to overcome idler tilt varies strongly
with the load on the wing roll and the actual load should be calculated and used
for precise prediction of tension changes.
Rrim = 0.67.

Ref: Belt Conveyors for Bulk Materials, CEMA 6th Ed, 2007.

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 87

Main Resistance Measurement

Experimental Verification of Models 88

600mm Wide Belt

1200mm Wide Belt

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 Measurement Apparatus
Vertical Force Measurement
89

Belt Direction

FV

Knife Edge
Rocker Support

RV

Vertical Load Cell

Measurement Apparatus
Horizontal Force Measurement
90

Belt Direction

ST
S-Type Load
L dC Cellll

FH RH

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 Experimental Results 91

160
No Bulk Solid Bulk Solid on No B/S Bulk Solid on Belt No B/S
Running Belt Running Running

140

120
FN1

FN2
FN3
100
Force (N)

80 1 Normal
2 Normal
3 Normal
60

40

20

0
0 200 400 600 800 1000 1200
Time (s)

Normal Force Measurements

Experimental Results 92

12
No Bulk Solid Bulk Solid on Belt No B/S Bulk Solid on Belt No B/S
Running Running Running

10

FH1
8
FH2 FH3
Force (N)

1 Horizontal
6
2 Horizontal
3 Horizontal

0
0 200 400 600 800 1000 1200
Time (s)

Horizontal Force Measurements

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 Experimental versus Predicted Results 93

25 25
Indentation Rolling Resistance Indentation Rolling Resistance
Idler Rotating Resistance Idler Rotating Resistance
Longitudinal Bulk Solid Flexure Longitudinal Bulk Solid Flexure
Transverse Bulk Solid Flexure Transverse Bulk Solid Flexure
Belt Flexure Resistance Belt Flexure Resistance
20 Total Measured 20 Total Measured

15 15

Force (N)
Force (N)

10 10

5 5

0 0
1.0 1.5 2.0 2.5 3.0 3.5 1.0 1.5 2.0 2.5 3.0 3.5
Belt Speed (m/s) Belt Speed (m/s)

Gravel Bauxite

Example - Varying Idler Spacing 94

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 Example - Varying Idler Spacing 95

20 20
1.0m/s 1.0m/s
1.5m/s 1.5m/s
2.0m/s 2.0m/s
2.5m/s 2.5m/s
15 3.0m/s 15 3.0m/s

m)
35 /
3.5m/s C
Curve R
Representing
ti 35 /
3.5m/s

Force / Unit Length (N/m

Minimum Resistance
Force (N)

10 10

5 5

0 0
500 700 900 1100 1300 1500 500 700 900 1100 1300 1500
Idler Spacing (mm) Idler Spacing (mm)

Horizontal force versus idler Horizontal force per unit length

spacing versus idler spacing

Evolutionary Optimisation - Conveyor Design 96

Potential conveyor designs are written in

terms of a series of parameters known
as genes.

Given performance specifications, an

initial population of candidate designs is
randomly generated (ac, vb, D, ).

The individual designs in the population

are evaluated (Annual Equivalent Cost),
and ranked according to performance
(known as fitness).
Conveyor designs which perform well are
No used to generate (breed) a new population
Optimum soln. (of conveyor designs), passing on their
reached? genes to the new generation with small
Yes induced errors (known as mutations).
Output: Optimum
conveyor design.

CBSPT University of Newcastle 48

 Economic Analysis (A. Roberts) 97

600

540
A$/m)

480
Structure
Annual Equivalent Cost (A

420

360

valent Cost (A$/m)

300 Belt
1500
240
1200
Energy
180
900

Annual Equiv
120 600
Idlers
60 300
Gear Reducer & Motor
0
0 1.0 2.0 0 1.0 2.0
Belt Width (m) Belt Width (m)
Cost per unit Length for a Horizontal Steel Cord Belt Conveyor
Q = 1000 t/hr, L = 1000m,  = 850kg/m3

Annual Equivalent Cost of Capital Items 98

Belt 
Abelt  k 2 B c1  c 2 T1
c3
/ L Plus!
Structure (covers, walkways,..)
Drive 
Adrive  k3 c4  c5 PM
c6
/ L Pulleys

Gearbox 
Ag / box  k 4 c7  c8TR
c9
/ L Take p
Take-up
Transfer Stations
Idler Rolls
Carry Side 
Acarry _ idlers  k5 c10  c11 D c12  c13 qm  qb  14  c15 B c16 / L
c

Return Side 
Areturn _ idlers  k 6 c17  c18 D c19
 c20 qbc21  c22 B c23
/ L
Where: k2…6 = annual equivalent cost coefficients
c1…23 = initial cost coefficients B = belt width
T1 = max belt tension L = conveyor length
PM = installed motor power TR = rated torque
D = idler roll diameter qm, b = mass per unit length

CBSPT University of Newcastle 49

 Annual Equivalent Cost - Conveyor Belt 99

Belt / L
Abelt  k 2 B c1  c 2 T1
c3

 k c  c P  / L
c6
Drive A drive 3 4 5 M

 k c  c T  / L B
Where: k2 = annual equivalent cost coefficient C 123
1,2,3 = initial cost coefficients
c9
Gearbox T1 Abelt tension
= allowable g / box 4 7 8 R = belt width
Idler Rolls L = conveyor length
CarryPNSide Acarry _ idlers  k 5 c10  c11 D
Belt Cost vs Belt Width PN Belt
c12
c13vsqOperating
Cost 
c14  c15 B c16 / L
m  qbTension 
$500
Return Side PN650/4 'M'
PN800/4 'M'

Areturn _ idlers  k 6 c17 $600
c18 D c19  c20 qbc21  c22 B c23 / L
$500
800mm
1200mm

$400
1600mm

Belt Costt (A$/m)

PN1360/4 'M'
Belt Costt (A$/m)

$400 2000mm
$300
$300
$200
$200

$100 $100

$- $0
0 500 1000 1500 2000 40 60 80 100 120 140
Belt Width (mm) Operating Tension (kN)

Annual Equivalent Costs 100

• Costs can be divided into two categories:

• Capital Costs - Drive system
- Belt
- Idlers
- Structure
• Operating Costs - Labour
- Repairs and maintenance (idler roll life)
- Energy (motion resistances)

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 Component Life - Idler Rolls (Jilek and Rozentals) 101

The time in hours for the first 10% of centre idler rolls to fail Lc, is given by:

0.4974 D  Pr 
Lc   
v  Pa 
While the time in hours for the first 10% of troughing idler rolls to fail Lt, is given by:

0.8552 D  Pr 
Lt   
v  Pa 
Where: D = Idler roll diameter [mm] v = Belt speed [m/s]
Pr = Rated bearing load [N] Pa = Actual bearing load [N]
μ = 3.0
3 0 for ball bearings and 3
3.3
3 for roller bearings

Notes: (1) Calculations are based on fatigue life and represent upper limit of service life. Wear
caused by contamination often prevent this life from being reached.
(2) Fatigue life is inversely proportional to speed, ie; doubling speed will halve life.
(3) Halving idler spacing will double cost, but increase fatigue life 23=8 times.
(4) Emphasise should be placed on bearing selection (Pr/Pa ratio).

Annual Equivalent Energy Cost 102

Aenergy  k1t a ec PA

k1 = annual equivalent cost coefficient taking into account inflation and

annual escalation rate of energy
ta = annual hours of operation

ec = initial unit cost of electricity

PA = actual power

CBSPT University of Newcastle 51

 Annual Equivalent Energy Cost 103

Motion resistance models

• Idler roll rotating resistance
• Bulk solid and belt flexure resistance
• Indentation rolling resistance

Evolutionary Optimisation - AEC Example 104

Consider a Straight Horizontal Conveyor.

- System Requirements:
• Throughput = 2000 t/hr
• Transport Length = 2000 m
• Design Life = 10 years
• Utilisation = 60%

- Bulk Material Characteristics:

• Internal Friction Angle = 35o
• Bulk Density = 1250 kg/m3
• Conveyor Surcharge Angle = 20o

CBSPT University of Newcastle 52

 Evolutionary Optimisation Program - AEC
Performance Requirements: Bulk Material Conveyor Belt
transport distance, throughput, Characteristics: eg: bulk Properties: belt flexure
Inputs estimated hours of operation density, surcharge angle and dynamic rubber
per annum and design life. and internal friction. cover properties.

Bulk Material and Belt Flexure

Motion Resistance is calculated using measured
Resistance belt and bulk material properties. Data is
Data stored as a function of troughing angle,
belt speed, width and sag.

Material Flex. Resistance vs Belt Width and Velocity 106

0.5% Sag
1.0% Sag
1.5% Sag

CBSPT University of Newcastle 53

 Evolutionary Optimisation Program - AEC
Performance Requirements: Bulk Material Conveyor Belt
transport distance, throughput, Characteristics: eg: bulk Properties: belt flexure
Inputs estimated hours of operation density, surcharge angle and dynamic rubber
per annum and design life. and internal friction. cover properties.

Bulk Material and Belt Flexure Indentation Rolling Resistance is

Motion Resistance is calculated using measured calculated using measured dynamic
Resistance belt and bulk material properties. Data is rubber properties. Data is stored as a
Data stored as a function of troughing angle, function of normal load, belt speed,
belt speed, width and sag. and idler roll diameter.

Indentation Rolling Resistance vs Belt Velocity and Load 108

Dia_127mm
Dia_152mm
Dia_178mm

CBSPT University of Newcastle 54

 Evolutionary Optimisation Program - AEC
Performance Requirements: Bulk Material Conveyor Belt
transport distance, throughput, Characteristics: eg: bulk Properties: belt flexure
Inputs estimated hours of operation density, surcharge angle and dynamic rubber
per annum and design life. and internal friction. cover properties.

Bulk Material and Belt Flexure Indentation Rolling Resistance is

Motion Resistance is calculated using measured calculated using measured dynamic
Resistance belt and bulk material properties. Data is rubber properties. Data is stored as a
Data stored as a function of troughing angle, function of normal load, belt speed,
belt speed, width and sag. and idler roll diameter.

An initial population of potential solutions is seeded by randomly

AEC selecting values for each of the design variables. Initial work has involved
Optimisation optimising belt width, idler roll diameter, idler spacing and troughing angle.
Process Variables are typically selected between user defined boundaries.

(Cont.)

Individual solutions are evaluated using an objective function

that evaluates the cost (AEC) of the conveyor system.

Systems that have a low AEC, are then used to generate (or
breed) a new population, passing on their design variables
(genes) to the next generation. The breeding method:
•selects the best solutions (individuals) from the population and
AEC breeds them randomly by averaging their genes. genes
Optimisation •the best solutions are returned to the population to ensure
Process the maximum fitness does not decline, and
•to ensure the gene pool is fully explored random mutations are
also made to the new solutions.

Parent (1) Parent (2) Offspring

Potential conveyor configurations are ranked according to cost
ac
(AEC). Breeding 3.00solutions
new m 3.50 m
is repeated 3.25 the
until m population
converges to an optimal solution
solution.
vb 5.0 m/s 5.8 m/s 5.4 m/s
Design dataD for the
127 mm conveyor
optimum 127 mm 127 mmis then made
configuration
Outputs available for the user,o along with the calculated oannual equivalent
 cost 35 component.
35 for each major o 35
….. … … …

CBSPT University of Newcastle 55

 Optimisation Results - Belt Width vs AEC 111

Idler Roll Diameters = Ø178mm

Carry Side Spacing = 3.6m

700

600
AEC (A$/m)

500

400

300

200
0.8 1 1.2 1.4 1.6 1.8 2
Belt Width (m)

Optimisation Results - Idler Roll Spacing vs AEC 112

Belt Width = 800mm

Idler Roll Diameter = Ø178mm
Bulk Density = 1250kg/m3
380

360
Annual Equivalent Cost (A$/m)

340

320

300

280

260

240
0.50 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

Carry Side Idler Roll Spacing (m)

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