Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.

03
Specifier Sheet and Recommendation Summary
01/07/15
Date

Telephone

Telefax

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com

e-mail

Copyright - Rulmeca Corp.

Project Name

Conveyor Reference

Standard Loading Conditions:

Conveyor Length (ft)
Tonnage Rate (tons/hour)
Belt Speed (fpm)
Material Lift Height (ft)
Ambient temperature (F) Min
Ambient temperature (F) Max
Initial Velocity of Material (fpm)
Number of Belt Cleaners
Number of Return Belt Scrapers
Length of Skirt Zone (ft)
Depth of Mat'l in skirt zone (in)
Number of Non-driven Pulleys
Elev. Above Sea Level (ft)
Mat'l, friction coeff

1000
800
300
-10
100
1
12
3
4
3300 ft

Coal, bitum. mined,

Bulk Density (pcf)

Size Consist

0.075

Coal, lignite, 45 pcf

REQUIRED POWER:
BELT PULL SUMMARY:
Standard Loading Belt Pull
Extra pull for Hopper (if any)
Extra pull for Slider Bed (if any)
Extra pull for Diverter or Tripper (if any)
TOTAL Required Belt Pull (Te):

44.9 HP
Force (lbs)
4,714

4,714

RECOMMENDED OPTIONS:

SPECIAL NOTES:
Minimum allowable belt width for lump size is 12 in
Minimum Acceptable Diameter is 14 in. *

Avg is 50% Max Lump Size

Max. Lump Size (in)

*A smaller pulley diameter may cause belt carcass or fastener damage.

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:

Material Surcharge Angle

Belt Width

25 deg.

Models Available:

Fabric

Power:
Belt Speed:

50HP

Belt Carcass Type

300 FPM

630

Idler Roll diameter

5 in

Face Width:

43.31 in.

42 in

CEMA Type
Troughing Idler Spacing
Angle of Wrap**

4 ft
180 degrees

Type of Take-up
Type of Belt
Drive Location

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY:

Partial (2/3)
Automatic

Power:
Belt Speed:

25 HP/each
300 FPM

2 ply, 225 piw

Head

Face Width:

43.31 in.

Type of Lagging

Elevating or Horizontal
Material Flow
well maintained
Condition of Idlers & Pulleys

Type of Dual Drive, if any

none

** This parameter is for either single or dual drive arrangement.

Models Available:
500

Power savings - 1 shift and 3 shift per day:

(Motorized Pulley compared to exposed motor, gearbox, V-belt conveyor drives)

Save: 9135 Kw-Hrs/Yr, 1 shift/day or 27404 Kw-Hrs/Yr, 3 shifts/day

Save: $731 /Yr, 1 shift/day or $2192 /Yr, 3 shifts/day @ $0.08/Kw-Hr

Special Loading Conditions:

1. For hopper feeder specify opening dimensions below.
2. For slider bed, specify bed length & type of bed mat'l below.

3. If belt is driven on return run, specify drive pulley location.

4. If belt has cleats and/or sidewalls show dimensions below.
5. If conveyor has a tripper, define tripper below.
6. If conveyor has diverter(s), define below.

1. Hopper Feeder Design Parameters

Hopper opening width (in)
Hopper opening length (in)

5. Tripper Design Parameters

Tripper length (ft)
Material lift height on tripper (ft)
No. of belt cleaners on tripper
Length of tripper skirt zone (ft)

2. Slider Bed Design Parameters

Slider Bed Length (ft)
Type of Slider Bed Material
Slider Bed Frictional Coefficient

4. Sidewall & Cleated Belt Parameters:

Sidewall & cleat height (in)
Thickness of sidewall (in)
Distance between cleats (in)
Thickness of cleats (in)
Extra Sidewall & Cleat Wt (incl above)

None

3. Drive Pulley Location ("return run" drive only)

Conveyor Length, tail to drive snub (ft)
Height, top of tail to bottom of drive (ft)

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Depth of material in skirt zone (in)

No. of non-driven pulleys on tripper
Estimated belt tension, Te (lbs)
Estimated factor, Ky

0.03

6. Material Diverter (Belt Plow)

No. of diverters that work simultaneously

1/7/2015 12:42 PM

Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03

Model Selector
01/07/15
Date

Telephone

Telefax

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com

e-mail

Project Name

Conveyor Reference

Copyright - Rulmeca Corp.

REQUIRED POWER:
BELT PULL SUMMARY:
Standard Loading Belt Pull
Extra pull for Hopper (if any)
Extra pull for Slider Bed (if any)
Extra pull for Diverter or Tripper (if any)
TOTAL Required Belt Pull (Te):

44.9 HP
Force (lbs)
4,714

4,714

Select Model
320H
Check Radial Load (to prevent
internal damage to pulley)
Maximum Allowable Radial Load
Estimated Maximum Radial Load**
Error: Selected model is incorrect.

Force (lbs)
7,868
10,466

Choose stronger or larger model to handle estimated radial load.

RECOMMENDED OPTIONS (if any):

SPECIAL NOTES (if any):

Minimum allowable belt width for lump size is 12 in
Minimum Acceptable Diameter is 14 in. *
*A smaller pulley diameter may cause belt carcass or fastener damage.

Check Pulley Diameter

(to prevent belt damage.)
Minimum Acceptable Diameter is 14 in.
Selected Diameter is 12.64 in
Error: selected diameter is incorrect.
Choose larger diameter to prevent belt or fastener damage.

Check Maximum Belt Tension

prevent belt damage)
Maximum Belt Tension (T1)
Allowable Fabric Belt Tension

(to
Force (lbs)
7,590
9,450

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:

Power:
Belt Speed:
Face Width:
Models Available:

50HP
300 FPM
43.31 in.
630

Belt Tension Calculation Summary

Te, effective belt tension
T2, to prevent belt/pulley slippage
T2, to limit belt sag to 2 %
T1, maximum belt tension

Force (lbs)
4,714
2,876
2,808
7,590

**Measured at Drive A in Dual Drive, if applicable.

Calculation for "Dual Drive on Carry Side" is under construction.

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY:

Power:
Belt Speed:
Face Width:
Models Available:

25 HP/each
300 FPM
43.31 in.
500

Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03

Bulk Handling Trajectory Calculator and Plotter
(based on CEMA 5th Edition)

1/7/15
Date

Phone

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com

Fax

Copyright - Rulmeca Corp.

Project Name
Conveyor Ref.

System Design Parameters:

Belt Width

Material Trajectory:

42 in

Small Pulley (scale: inches)

Troughing Idler Angle

35

Diameter Pulley (in)

13.26 in

Lagging Thickness (in)

0.31 in

Belt Speed

300 fpm

Surcharge Angle

25 deg.

Tonnage Rate (TPH)

Material Density (pcf)
Belt Thickness (in)
Distance to Chute Plate (in)

800
45
0.75
24

Angle of Conv. Inclination (deg)

350

39
36
33
30
27
24
21
18
15
12
9
6
3
0
-3
-6
-9
-12
-15
-18
-21
-24
-27

Alternate Belt Speed (fpm)

18
15
12
9
6
3
0
-3
-6
-9
-12
-15
-18
-21
-24

Design Trajectory - red line; Alternate speed - blue.

WARNING: Material cross section exceeds CEMA allowable maximum.

Calculated Results:
Calc'd mat'l height at centerline

9 in

Calc'd actual height of C.O.G.*

4 in

Calc'd actual mat'l cross section

CEMA Max Allow. height at center
CEMA Max Height of C.O.G.*
CEMA Max Allow. cross section

271.1 sq ft

Mat'l Cross Section at Pulley Face:

Small Pulley (scale: inches)
9

8 in

3 in
211.8 sq ft

3
0

Note:

18

15

12

-3

-6

-9

-12

-15

top of belt (based on actual cross section) to plot

-3
-18

This program uses actual C.O.G.* height above

trajectory. Height of C.O.G. for CEMA
max. allow. cross section is given for ref. only.

Design Cross Section - red line; CEMA max allow. - black line.
*C.O.G. = center of gravity of material, shown as and

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03

Material Cross Section Plotter
1/7/15
Date

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com

Fax

Phone

Copyright - Rulmeca Corp.

Reference Name
Conveyor Number

Cross Section at Troughing Idler:

Narrow Belt (scale: inches)

System Design Parameters:

Tonnage Rate (tph)
Belt Speed (fpm)
Bulk Density (lbs/cu ft)
Material Surcharge Angle

800
300
45

15

25 degrees

Belt Width

42 in.

Idler Angle

35 degrees

12
9

6
3

Material Geometry in Troughing Idler:

CEMA Max. Allow. Cross Section
Calculated Cross Section

-3
15

12

-3

-6

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

Warning: Specified Material Cross Section Exceeds CEMA Max. Allowable.

Material Geometry at Pulley Discharge:

Calculated Cross Section
Material Height at Centerline
Height of Center of Gravity (A1)
Assumed Edge Distance
Calculated Surcharge Angle
CEMA Max. Allow height at center
CEMA Max Height of C.O.G.
CEMA Standard Edge Distance

-9

-12

131%
3.2 in
0.8 in
11 in

-15

Calc'd Xsec/CEMA Xsec

CEMA Standard Edge Distance
Calculated Edge Distance
Calc'd Material Height at Centerline

1.5 sq ft
1.9 sq ft

2 sq ft
#DIV/0!
#DIV/0!
0.41 in
0 deg
7.8 in.
3.1 in.
1.61 in

9
6
SSX
3.1

3
0.00
0
-3

18

15

12

-3

-6

-9

-12

-15

-18

Note:
This program calculates height of actual C.O.G.*
by assuming that actual edge distance at pulley
face equals 1/2 of actual edge distance in troughed
section. Height of C.O.G.* for CEMA maximum
allowable cross section pulley face is given for
reference only.

Cross Section at Pulley Face:

Narrow Belt (scale: inches)

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

* C.O.G. = center of gravity of material

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1/7/2015 12:42 PM

Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03

Material Cross Section Plotter
1/7/15
Date

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com

Fax

Phone

Copyright - Rulmeca Corp.

Reference Name
Conveyor Number

System Design Parameters:

Tonnage Rate (tph)
Belt Speed (fpm)
Bulk Density (lbs/cu ft)
Material Surcharge Angle

800
300
45
25 degrees

Belt Width

42 in.

Idler Angle

35 degrees

Cross Section at Troughing Idler:

Wide Belt (scale: inches)
42
36
30

24
18
12

Material Geometry in Troughing Idler:

CEMA Max. Allow. Cross Section
Calculated Cross Section

-6
42

36

30

24

18

12

Cross Section at Pulley Face:

Wide Belt (scale: inches)
18
12
6

3.1

0.00

-6
48

42

36

30

24

18

12

-6

-12

-18

-24

-30

-36

-42

-48

Note:
This program calculates height of actual C.O.G.*
by assuming that actual edge distance at pulley
face equals 1/2 of actual edge distance in troughed
section. Height of C.O.G.* for CEMA maximum
allowable cross section pulley face is given for
reference only.

-6

2 sq ft
#DIV/0!
#DIV/0!
0.41 in
0 deg
7.8 in.
3.1 in.
1.61 in

-12

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

Warning: Specified Material Cross Section Exceeds CEMA Max. Allowable.

Material Geometry at Pulley Discharge:

Calculated Cross Section
Material Height at Centerline
Height of Center of Gravity (A1)
Assumed Edge Distance
Calculated Surcharge Angle
CEMA Max. Allow height at center
CEMA Max Height of C.O.G.
CEMA Standard Edge Distance

-18

-24

-30

131%
3.2 in
0.8 in
11 in

-36

-42

Calc'd Xsec/CEMA Xsec

CEMA Standard Edge Distance
Calculated Edge Distance
Calc'd Material Height at Centerline

1.5 sq ft
1.9 sq ft

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

* C.O.G. = center of gravity of material

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03

Design Parameter Summary
01/07/15
Date

Telephone

Telefax

e-mail

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com
Copyright - Rulmeca Corp.

Project Name

Conveyor Reference

Power Calculation Summary

Calculated power to drive conveyor belt:
Drive pulley bearing friction:
Power at motor:
Gear loss in motorized pulley:
Calculated power
Derate for high elevation
Derate for high temperature
Required Power for motorized pulley:

Symbol

Value

Te
ang
Cw
T2

4714 lbs
180 degrees
0.61
2876 lbs.

T1
T1 + T2
T_L
Tatype
Beltype
w
str
pstr
btr
Ai
Cs
H
Kt
Kx

7590 lbs
10466 lbs
Partial (2/3)
Automatic
2 ply, 225 piw
42 in.
9450 lbs.
80 %
3/16 to 7/16 in.
1.8 lbs
0.0754
0 ft
1.59
0.52 lbs/ft

Ky
L
Q
Si
Tac
Tam
Tb
Tbc
Te
Tm
Tp

0.03
1000 ft
800 tph
4 ft
290 lbs
69 lbs
0 lbs
210 lbs
4714 lbs
0 lbs
160 lbs

Tpl
Tsb
Ttr
Tx
Tyb
Tyc
Tym
Tyr
V
Wb
Wm
Sag
Ls
Hd

0 lbs
80 lbs
0 lbs
824 lbs
831 lbs
545 lbs
2541 lbs
286 lbs
300 fpm
12 lbs/ft
89 lbs/ft
2.0%

42.9
0.6
43.5
1.4
44.9

HP
HP
HP
HP
HP
HP
HP
44.9 HP

Definition of Terms
Te = effective belt tension at drive.
ang = angle of belt wrap around drive pulley(s).
Cw = "wrap factor", to determine slack side tension to prevent belt slippage on drive pulley.
T2 = estimated slack-side tension required to either keep belt from slipping on pulley surface
or maintain trough at allowable sag percentage, whichever is greater.
T1 = Te + T2
T1 + T2 = Sum of belt forces on drive pulley. NOTE: This is not a vector sum.
T_L = type of lagging specified for drive pulley(s).
Tatype = type of take-up specified to apply "slack-side tension".
Beltype = type of belt carsass specified.
w = belt width
str = tensile strength of specified belt.
pstr = percentage of available belt tensile strength used.
btr = thickness range of specified belt
Ai = belt tension required to overcome frictional resistance and rotate idlers.
Cs = skirtboard friction factor.
H = vertical distance that material is lifted or lowered.
Kt = ambient temperature correction factor.
Kx = factor to calculate frictional resistance of the idlers and the sliding resistance between
belt and idler rolls.
Ky = factor to calculate resistance of belt and resistance of load to flexure as they move over idlers.
L = length of conveyor.
Q = tons per hour conveyed.
Si = troughing idler spacing.
Tac = total of the tensions from conveyor accessories.
Tam = tension required to accelerate the material continuously as it is fed onto belt.
Tb = tension required to lift or lower the belt.
Tbc = tension required to overcome belt cleaner drag.
Te = effective belt tension at drive.
Tm = tension required to lift or lower conveyed material.
Tp = tension required to overcome resistance of belt to flexure around pulleys and resistance
of pulleys to rotate on their bearings.
Tpl = tension required to overcome belt plow drag.
Tsb = tension required to overcome skirtboard drag.
Ttr = tension required to overcome special loading condition(s.)
Tx = tension required to overcome carrying and return idler friction.
Tyb = total of tensions due to resistance of belt to flexure as it rides over carrying and return idlers.
Tyc = tension due to resistance of belt to flexure as it rides over carrying idlers.
Tym = tension due to resistance of material to flexure as it rides over carrying idlers.
Tyr = tension due to resistance of belt to flexure as it rides over return idlers.
V = design belt speed.
Wb = weight of belt per unit of length of conveyor.
Wm = weight of material per unit of length of conveyor.
Sag = recommended maximum sag percentage to avoid spillage in troughed section of belt.
Ls = Length of conveyor from tail pulley to Drive snub (for return run drive only)
Hd = Height of conveyor from top of tail pulley to bottom of drive pulley (for return run drive only)

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03

Bulk Handling Belt Conveyor Terminology
6508-B Windmill Way
Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com
Copyright - Rulmeca Corp.

Conveyor Profile
Initial Velocity of Material

Conveyor Cross Section in Skirt Zone

Belt Conveyor with Tripper

Hopper Feeder Conveyor

Cleated Belt with Sidewalls

Belt Conveyor with Two Diverter(s)

"CEMA" Idler Type Definitions

(Based on Conveyor Equipment Manufacturers Association Manual)

Belt Width
Idler Type >
Idler (deg) >
18
24
30
36
42
48
54
60
72
84
96

20
300
300
300
275
-

A
35
300
300
280
256
-

45
300
289
270
248
-

20
410
410
410
410
390
380
-

B
35
410
410
410
410
363
353
-

Idler Load Ratings* (lbs)

C
45
20
35
45
20
410 900 900 900
410 900 900 900 1200
410 900 900 900 1200
396 900 837 810 1200
351 850 791 765 1200
342 800 744 720 1200
750 698 675 1200
700 650 630 1150
1050
-

D
35
1200
1200
1200
1200
1200
1116
1070
977
-

45
1200
1200
1200
1200
1200
1080
1035
945
-

20
1800
1800
1800
1800
1800
1800
1800
1800
1800
1750

E
35
1800
1800
1800
1800
1800
1800
1800
1800
1674
1628

45
1800
1800
1800
1800
1800
1800
1800
1800
1620
1575

*These ratings are for three-equal-roll idlers and are based on a 30,000 hour minimum
BU bearing life at 500 RPM. BU bearing life represents the statistical point in hours where
a minimum of 90% of the bearings will still be functional with no increase in torque or noise.

Material Surcharge Angle Guide

(Based on Conveyor Equipment Manufacurters Association Manual)

Surcharge
Angle

Angle of
Repose

Description of Material

0 to 19

Uniform size, very small rounded particles, either very wet or very dry; such as dry
silica sand, cement, and wet concrete.

10

20 to 29

Rounded, dry polished particles, of medium weight, such as whole grain and beans.

20

30 to 34

Irregular, granular or lumpy materials of medium weight, such as anthracite coal,

cottonseed meal, and clay.

25

35 to 39

Typical common materials such as bituminous coal, stone, and most ores.

40+

Irregular, stringy, fibrous, interlocking material, such as wood chips, bagasse, and
tempered foundry sand.

30

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03

Conveyor Height Calculator

Inclined conveyor length (ft)

Angle of inclination (degrees)
Material lift height (ft)

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com
Copyright - Rulmeca Corp.

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