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System Information
Material Properties
Type .............................................................. Concentrado
Design Tonnage ..................................................... 800 t/h
Density ............................................................ 2000 kg/m3
Maximum lump size ................................................ 1 mm
Surcharge angle ......................................................25 deg
Belt Properties
Type ............................................................ Fabric (3-Ply)
Width ................................................................... 914 mm
Rating............................................................. 1000 N/mm
Speed ................................................................... 1,50 m/s
Top / bottom cover thickness ....................... 9,0 x 4,0 mm
Total thickness ....................................................... 19 mm
Weight (new / worn) ............................... 19,7 / 13,7 kg/m
Modulus ......................................................... 8.657 kN/m
Tape length ............................................................. 266 m
Belt cycle time ...................................................... 177 sec
Running
83,5
10,94
34,0
0,55
Tension Summary
Maximum tension (kN)
Minimum safety factor
Minimum tension (kN)
Maximum belt sag (%)
ABB
Momentary
106
8,66
29,7
0,65
Series name
Number of rolls
Trough angle (deg)
Type
Idler spacing (m)
Number of idler sets
Roll diameter
Roll rpm
Total drag (N)
Drag range (N)
Roll length
Shaft diameter (mm)
Rating (N)
Calc Idler Load (N)
L10 life1 (1000 hrs)
1
Carry
E6
3
35
Inline
1,00
124
152
188
12,5
27,6 - 28,9
336
25,0
8.007
3.129
350,0
Return
E6
1
0
Inline
3,00
40
152
188
4,2
9,6 - 9,7
1003
25,0
4.448
2.188
350,0
Drive Station
Type ............................................................. Squirrel cage
Synchronous RPM ........................................... 1500 RPM
Motor quantity / rating ................................... 1 / 90,0 kW
Total installed power ........................................... 90,0 kW
Empty / full power .................. (14 / 82%) 13,0 / 73,7 kW
Motor Voltage ......................................................... 400 V
Efficiency ................................................................ 95,5%
Maximum starting torque ......................................... 150%
Inertia - Motor .................................................... 2,0 kgm
Pulley lagging type ................................................ Rubber
Motor wrap angles....................................................... 180
Lagging friction factor (run / accel) ................. 0,30 / 0,34
Reducer ratio .......................................................... 33,940
Pulley shaft rpm ......................................................... 43,7
Take-up Data
Type ...................................................................... Gravity
Location ................................................. Head / Pulley #3
Required belt line tension..................................... 37,1 kN
Counterweight mass .......................................... 7,6 tonnes
Required pulley displacement ................................ 2,94 m
Dynamic displacement (incl thermal) .............. 0,32 m
Permanent elongation ...................................... 1,73 m
Splice length (1 included) ................................ 0,54 m
Clearance ......................................................... 0,35 m
Backstops
Backstop type ............................................. None installed
Flooded belt tonnage........................................... 1.538 t/h
Flooded (wm + wb) .......................................... 303,8 kg/m
Brakes
Brake type .................................................. None installed
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ABB
Running
34,0
34,0
Dynamic
32,9
29,7
Running
0,21
0,55
Dynamic
0,22
0,65
Demand
power (kW)
13
74
% Nameplate
14
82
Case
Din factor
0,0535
0,0297
Belt line
mass (kg)
34.492
52.391
Transition Lengths
Tail transition length (full trough) ......................... 1,54 m
Head transition length (full trough) ....................... 2,44 m
Head transition length (elevated 91 mm) ............... 1,12 m
Other Information
Loaded beltline mass (excluding motors) ......... 31.083 kg
Total inertia (ref HS shaft) ............................... 2,92 kgm2
Running
43,8
83,5
Dynamic
68,8
106
Running
20,86
10,94
Dynamic
13,29
8,66
Running
13,91
7,30
Dynamic
8,86
5,77
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ABB
Tail Arrangement
Head Arrangement
Maximum Pulley Tensions for any Load Case & Maximum Resultant Force
Steady State Tensions (kN)
Shaft Shaft Shaft
Wrap
Hub
stress Center
Pulley
Type Angle
Resultant
Slope safety
Def.
T1
T2
(deg)
Force
(min) factor (mm)
Motor 1
1
180
3,08
1,72
0,45
83,5
38,0
122
Pulley 2
3
90
5,80
1,66
0,72
38,0
53,8
Take-up Pulley
2
180
4,57
1,81
0,58
37,1
74,5
Pulley 4
2
90
3,63
2,29
0,46
38,3
54,4
Tail Pulley
2
181
5,26
1,58
0,66
34,0
68,5
T1
T2
106
38,7
38,6
37,1
40,0
44,6
Resultant
Force
144
54,3
75,9
57,7
91,1
Note: T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
1
2
3
Diameter
Lagging
with
Lagging Diameter
Thickness
Lagging
Type
(mm)
(mm)
(mm)
Face
Width
(mm)
Shaft
Material
Rubber
Rubber
Rubber
1050
1050
1050
SAE 1018
SAE 1018
SAE 1018
630
400
400
10,0
10,0
10,0
650
420
420
Shaft
Bearing
Bearing
Pulley &
Center
Center Plummer
Shaft
Diameter
Diameter
Distance Block
(mm)
Mass (kg)
(mm)
(mm)
170
125
110
135
100
90
1365
1285
1275
530
522
520
741
349
322
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ABB
Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures). Additionally they must include any other external loads
(wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the required live
load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes for the project.
The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and other
details. These forces must then be multiplied by the required dead load structural design safety factor requirements (typically
1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together to obtain the
total structural design forces.
The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for the
high friction case with 947 t/h have also been included. This specific load case results in 101% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 150% for this case. The maximum tension values have been
multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum tensions have
been reduced by 10%. The resultant force values include the vertical weight of the pulley.
Structural Live Loads - Includes case with 947 t/h under high friction steady state and dynamic conditions + 110% multiplier
Shaft
Wrap Hub
Pulley
Type
(deg) Slope
(min)
Motor 1
1
180
3,61
Pulley 2
3
90
5,87
Take-up Pulley
2
180
4,66
Pulley 4
2
90
3,84
Tail Pulley
2
181
5,79
Shaft
stress
safety
factor
1,68
1,66
1,81
2,29
1,58
Shaft
Center
Def.
(mm)
0,52
0,73
0,59
0,49
0,73
T2
37,1
32,6
32,7
33,4
33,9
26,5
Resultant
Force
70,0
49,6
63,1
50,2
52,0
T2
125
42,7
42,6
40,8
44,0
49,1
Resultant
Force
168
62,1
80,0
65,9
99,4
The idler stringer loading should be based on the flooded belt surge capacity of 1.538 t/h and 303,8 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
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ABB
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ABB
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ABB