Belt Conveyor Notes

University of South Australia School of GMC Engineering
TABLE of CONTENTS
MATERIALS HANDLING 2
BELT CONVEYORS 2
1. HISTORY 2
2. CAPACITY 2
3. ADAPTION TO GROUND PROFILE 2
4. ROAD BED 2
5. LEAST DEGRADATION OF MATERIAL 3
6. ENVIRONMENTAL CONSIDERATIONS 3
7. MINIMUM OF LABOUR 3
8. LIGHT WEIGHT OF CONVEYOR STRUCTURE 3
9. MUTIPLE GATHERING AND DISCHARGE POINT CAPABILITIES 3
10. MOBILITY AND EXTENSIBILITY 3
11. LOWEST POWER REQUIREMENT 3
12. VERSATILE POWER SUPPLY 4
13. CONTROL 4
14. EARLY WARNING OF FAILURE 4
15. SAFETY 4
16. ALL-WEATHER CAPABILITIES 4
SOME FUNDAMENTALS OF BELT DESIGN 4

1. INTRODUCTION 4
2. DEFINITIONS 4
3. COEFFICIENT OF FRICTION 5
4. TENSION RELATIONSHIPS 5
5. K VALUES 7
6. CAPACITY OF BELT CONVEYORS 9
7. LUMP SIZE 11
8. BELT SPEED 11
POWER REQUIREMENTS AND BELT TENSION 12

CONVEYOR POWER 12
BELT CARCASS SELECTION 13
EXAMPLE: 15
TAKEUP 17
CONVEYOR SAFETY 19
PERSONNEL PROTECTION DEVICES 19
BELT AND EQUIPMENT DEVICES 20
APPENDIX
CONVEYOR ARRANGEMENTS
TYPICAL TRAVEL PATHS
TYPICAL LOADING & DISCHARGE ARRANGEMENTS
APPLICATIONS OF CONVEYORS
Intro to CV & MN 1 BVC/10-03-03

Bulk Material Handling Notes
Conveyors
Introduction to Civil & Mining Engineering

MATERIALS HANDLING
BELT CONVEYORS
1. HISTORY
Transporting bulk materials by conveyor belt dates back to approximately 1795; most of these early installations
handled grain over relatively short distances.
The first conveyor belt systems were very primitive and consisted of leather, canvas, or rubber belt travelling over
flat or troughed wooden bed.
During the 1920’s, belt conveyors were used to haul run of mine coal over distances underground up to 8 km. The
conveyor belt consisted of multiple plies of cotton duck and natural rubber covers, which were the only materials
used to manufacture belting at that time.
During World War 11, natural components became so scarce that the rubber industry was forced to create synthetic
materials to replace them. Today belting is produced with an almost endless list of polymers and fabrics to meet
design requirements of any conveying situation.
The basic advantages of conveyors over other means of transport (such as truck, rail, skip-hoist, and aerial
tramway) for bulk haulage are numerous.
2. CAPACITY
Conveyor belts are claimed to have no equal in capacity among competing transport means. At belt speed of
5 m/s, a 1600-mm wide conveyor belt delivers more than 100 metric tons per minute of 1000-kg/m^3 material.
3. ADAPTION TO GROUND PROFILE

Conveyors can follow ordinary natural cross-country terrain by virtue of their ability to traverse relatively steep
grades ( up to & including 18 degrees, depending on the material being carried ). With the development of high-
tension synthetic fabrics and/or steel cable reinforcing members, one flight can extend for several kilometres.
4. ROAD BED
A belt conveyor system operates on its own bed of idlers, thus requiring a minimum of attention. Repair or
replacement is both fast and easy, and the cost of route maintenance is minimal.

Conveyors
5. LEAST DEGRADATION OF MATERIAL

The smooth ride of long centre roll conveyor belt systems produces little degradation of the material being
conveyed.
6. ENVIRONMENTAL CONSIDERATIONS
Electrically powered conveyor belt systems are quiet (an important feature in procuring right-of-ways and in
complying with the Occupational Health Safety & Welfare Act regulations). Belt systems can be covered to help
ensure clean air. They can even be buried out of sight for quiet, functional, & aesthetic reasons.
7. MINIMUM OF LABOUR
One man per 2 km of line is generally adequate in a properly designed belt conveyor system. Contrast this with the
number of drivers on a truck operation handling equal tonnage.
8. LIGHT WEIGHT OF CONVEYOR STRUCTURE

Low weight of load and conveyor structure per linear metre allows simple structural design bridging gullies,
streams, highways, or other similar obstacles. Likewise a conveyor structure on a hillside requires little excavation
and does not invite hazards from earth or rock slides. Because the structure is compact, it requires a minimum of
covering for protection
9. MUTIPLE GATHERING AND DISCHARGE POINT CAPABILITIES

These capabilities are important in mining or excavation, where two or more digging operations can feed to a
central loading point. At the discharge end, material can be dispersed in several directions from the main line. Or
material can be discharged along any part of any line by a tripper. Pendulum or caterpillar-mounted belts can be
swung in a 180-degree arc to follow a digging shovel or can be used on the discharge end for stockpiling.
10. MOBILITY AND EXTENSIBILITY

Modern modular conveyor lines can be extended, shortened, or relocated with a minimum of labour & time.
11. LOWEST POWER REQUIREMENT

Conveyors require the least power per tonne of any means of haulage. Decline conveyors, depending on degree of
slope, often generate power that can be fed back into the grid system for other uses.

Conveyors
12. VERSATILE POWER SUPPLY

Belt conveyors, which generally are powered by electric motors, can adapt to whatever fuel or power source that is
in greatest supply (such as coal, hydro-electric, natural gas, nuclear, and solar).
13. CONTROL
Properly designed conveyor systems have control reduced to push-button proportions and can be self-controlled by
interlocking limit switches
14. EARLY WARNING OF FAILURE

Generally, belts signal their failure from wear many months in advance. With proper safety devices and
safeguards, accidental damage can be minimized and contained.
15. SAFETY
Bulk material transport by conveyor belting is inherently safer than other methods, particularly in coal mines
where safety records show very favourable results with belt systems versus rail haulage.
16. ALL-WEATHER CAPABILITIES

For minimal cost, belt conveyors can be protected from rain, snow, and other inclement weather that could
adversely affect rail or truck haulage
SOME FUNDAMENTALS OF BELT DESIGN
1. INTRODUCTION
In both conveyor and transmission belting, a belt is driven by friction between the belt and drive pulley or pulleys. Certain
other design elements also are much the same whether power is being transmitted or materials transported
2. DEFINITIONS
Tension in a belt is a force acting along the length of the belt and tending to elongate it. Belt tension is measured in
Newtons. When the tension is referred to some unit of cross sectional area, it is known as unit tension and is measured in
kilo-newtons per metre (kN/m)
Torque is the effectiveness of a force to produce rotation about an axis and thus involves the size of the force and its
moment arm. Torque is the product of a force (or tension) and the length of the arm through which it acts and is expressed
in Newton-metres (N.m)

Conveyors
Energy & Work are closely related and are expressed in the same units. Work is the product of a force and the the distance
through which it moves/acts. Energy is the capacity for performing work. Each is expressed in joules, where a joule is
one Newton-metre. The energy of a moving body is
E = ½ mv^2 in joules
Where m = mass in kg., v = velocity in m/sec.
Power is the rate of doing work or transmitting energy. The mechanical power unit is the watt, which is defined as
one Newton-metre per second. Power expended for a period of time produces work, gives rise to the term kilowatt-hour.
3. COEFFICIENT OF FRICTION
If, as in the figure below, a body of weight (w) rests on a horizontal plane surface and a force (p) parallel to the surface is
juts enough to cause the body to be at the point of slipping, the ratio of p to w is the coefficient of friction (f) between these
two surfaces. Thus,
f = p/w
w
Coefficient of Friction
4. TENSION RELATIONSHIPS
Free turning
Idler pulley
TA
TA
TB
TB
If, in the above figs. The unbalanced tensions ( TA – TB ) is large enough to overcome the resistance, the pulley will
turn. The essential factors are the tension, the coefficient of friction, and the angle or arc of contact
Consider now an endless belt applied to two pulleys, and a turning moment or torque applied to the shaft of the lower
pulley, causes a torque to be applied to the shaft of the upper pulley
TA
TB
TA + TB

Conveyors
To find the relation of TA , coefficient of friction (f), and the arc of contact (α) in radians, refer to the fig. below which
represents a very small element of the belt. The tension in the belt at b is T and at a it is (T + ∆ T) due to friction. The
element ab subtends the very small angle ∆α.
r∆α
a b
T+∆T T
∆ α.
The forces are more clearly represented in the force diagram below, which shows that the force Fn between this portion of
the belt and the pulley is given by:
Fn = 2T Sin(∆ α./2) (since ∆ T is neglible)
T+∆T T ∆ T/∆ α. = f T [Sin(∆ α./2)/ (∆ α./2]
Taking limits as ∆ α approaches zero
DT/dα = f T
∆ α./2
Integrating, f dα = dT/T
Fn (
f α = loge [ TA /TB]
Force between belt & pulley
TA /TB = efα
The ratio of TA /TB is valid only under the conditions of (1) the belt is at the point of slipping & (2) centrifugal tension is
not included in TA or TB
Consider the case of a single drive conveyor with an angle of wrap/arc of contact = 180o = π radians, using a coefficient of
friction for a lagged drum = 0.35
TA
TB
fα
Then the tension ratio TA /TB = e = 2.718^(0.35*π) = 3.00 [ Note! e = 2.718 ]
Or consider a double drive conveyor with an arc of contact = 360o = 2π radians, and lagged drums
TA /TB = efα = 2.718^(0.35*2π) = 9.00
Head drum
Snub pulleys
Drive pulleys
Take up
pulley
counterweight

Conveyors
The fig. below illustrates the build up of the ratio of tensions with increasing arc of contact
(Reference: “Handbook of Conveyor & Elevator Belting” Goodyear)
Now utilising the factors above in determining the power that can be transmitted
For the single drive :
TA = 3* TB
For the double drive:
TA = 9* TB
Therefore if the slack side tension (TB) can be increased then a significantly greater power/work can be
achieved since Power = Te * S = [TA - TB ] * S = 2 * TB * S kW for the single drive &
= 8 * TB * S kW for the double drive
5. K VALUES
Design handbooks use a factor eg. K to tabulate the ratio of slack side tension to effective tension for the applicable
conditions of arc of contact, and coefficient of friction. K is then used in the determination of the slack side tension required
for driving with a given effective tension and specified operating conditions of:-
Type of take-up
Pulley surface (Coefficient of friction)
Arc of contact
Since
T1 / T2 = efα & T1 – T2 = T2 (efα - 1)
Then K = T2/(T1 – T2) = 1/( efα - 1) = 1/(R – 1)
Where R = ratio of tensions & K = T2/Te

Conveyors
VALUE OF DRIVE FACTOR K FOR SINGLE DRIVES
1. Arc of Manual Take up Automatic take up

contact
2. Bare Pulley 3. Lagged Pulley 4. Bare Pulley 5. Lagged Pulley
(degrees)
150 1.20 1.00 0.84 0.67
180 0.97 0.80 0.64 0.50
190 0.91 0.75 0.59 0.46
200 0.85 0.71 0.54 0.42
210 0.80 0.66 0.50 0.38
220 0.75 0.62 0.46 0.35
230 0.72 0.59 0.43 0.33
240 0.68 0.56 0.40 0.30
270 0.58 0.49 0.32 0.24
Column 2 is higher than column 4 by an amount sufficient to show 20% higher than T1, with manual takeup. Likewise,
column 3 is higher than column 5 to indicate a 20% higher T1 . This is done to provide a reserve for intermittent and
inaccurate tension control that goes with manual takeup and not because any actual difference in friction between belt &
pulley appears when a manual takeup is used. T1 is the tight side tension
Column 4 is based on f = 0.3
Column 5 is based on f = 0.35
From the derivation of the Factor K = 1/[R-1] it may be seen that an increase in the ratio of tensions due to increasing the
arc of contact, and the coefficient of friction, that the resultant increase in effective tension, is increased work potential, with
a complimentary reduction of the slack side tension.
Example:
Consider the following two systems with a single drive and an effective tension of 1 000 N
T1= 1500 N T1 = 1300N
Te = 1000N Te = 1000N
T2 = 500N T2 = 300N
From the table :
K = 0.5 for a Lagged Pulley with automatic takeup K = 0.3 for a lagged Pulley with automatic takeup
and an arc of contact = 180o And an arc of contact = 240o
∴ T2 = K* Te = 0.5 * 1000 ∴ T2 = K* Te = 0.3 * 1000
∴ T2 = 500N ∴ T2 = 300N
It may be seen that for the same belt speed and therefore belt power the manipulation of the arc of contact provides a lesser
requirement for belt strength, lesser loads on pulleys, shafts, bearings and the conveyor structure.

Conveyors
6. CAPACITY OF BELT CONVEYORS

CROSS-SECTIONAL AREA OF LOAD & TONNAGE CAPACITY
The volume capacity of a troughed conveyor belt is determined by the cross sectional area of the load that can be piled onto
the belt without excessive spillage either at the loading point or subsequently due to the small undulations of the belt in
passing over idlers.
This cross sectional area is affected by the screen analysis of the material, its moisture content, and the shape of the
particles. All of which influence the slope at which the material will stand.
Tonnage capacities are shown in the following table for normal bulk materials on three-roll, equal length idlers based on a
cross-sectional load area such as that indicated in the figure above
CROSS SECTIONAL LOAD AREA OF BULK MATERIALS ON THREE EQUAL ROLL IDLERS*
Width (mm) Area (square metres)

20 deg. 30 deg. 35 deg. 45 deg.
300 0.006 0.007 0.008 0.008
600 0.033 0.038 0.040 0.043
900 0.079 0.093 0.098 0.103
1000 0.099 0.116 0.122 0.129
1200 0.146 0.170 0.179 0.190
1800 0.342 0.398 0.419 0.444
2000 0.425 0.495 0.521 0.552
2400 0.619 0.721 0.759 0.804
3000 0.979 1.140 1.199 1.269
*25-deg. surcharge angle; D = (0.05W + 25) mm
The carrying capacity C = [Area X section of material (m^2) * Density of matl. (kg/m^3) * Belt speed (m/s)] * 3.6 t/hr
An approximation for Area X section = W^2/10 (m^2)
And belt width W > 2 * max. lump size

Conveyors
Tonnage capacities for normal bulk materials on three roll, equal length idlers based on the above cross sectional load area
are depicted for a range of idler configurations, material densities, belt widths & lump sizes
CAPACITY* OF NORMAL BULK MATERIALS ON THREE EQUAL ROLL IDLERS
Idler angle (deg.) Density (kg/m^3) Width (mm)
300 600 900 1200
20 800 18 94 229 421
1000 23 117 286 527
1200 27 141 343 632
1600 36 188 458 843
2400 54 281 687 1264
30 800 21 109 266 491
1000 26 136 333 613
1200 32 164 400 736
1600 42 218 533 981
2400 63 327 799 1472
35 800 22 115 280 516
1000 28 144 351 645
1200 33 172 421 774
1600 44 230 561 1032
2400 67 345 841 1549
45 800 24 123 298 548
1000 30 153 372 685
1200 36 184 447 822
1600 48 245 596 1096
2400 71 367 894 1644
Maximum Lumps Uniform 50 125 175 250
(mm) With fines 100 200 300 400
• Capacity in metric tonnes per hour for 1000 kg/m^3 @ 1 m/sec belt speed;
• surcharge angle = 25 deg. ;
• edge distance = (0.5 W + 25) mm
Capacities for other densities & speeds are obtained by direct interpolation [Note! The above is part only of a fuller
tabulation found in Goodyear Handbook of conveyor & elevator belting]
Example:
To find the capacity of a 900 mm belt carrying 1900 kg/m^3 material @ 3.0 m/sec. on 35 degree idlers
Capacity = 351 * 1900/1000 * 3/1 = 2000 tonnes / hour
[Note! Maximum uniform lump size should not exceed 175mm or 300mm with fines]
Method; enter the table for 35 deg. idler @ 1000kg/m^3 (351) multiply by the ratio of the densities & the ratio of
the belt speeds

Conveyors
7. LUMP SIZE
The width of belt required for a material containing large lumps is influenced in two ways by the size of the lumps.
• The cross sectional area of the load is reduced because the load initially must be kept from a greater distance
from the edge of the belt.
• The chute & skirt boards must be wide enough to pass any probable combination of lumps, which in turnsets
the minimum belt width, independent of capacity requirements. It happens occasionally that the belt width
required to handle lump size greater than that required for capacity. This condition can only be avoided by
crushing or by scalping off large lumps before delivering material to the belt.
MAXIMUM RECOMMENDED LUMP SIZE FOR VARIOUS BELT WIDTHS
Belt width (mm) Lump size (mm)
If uniform If mixed with 90% fines
300 50 100
400 75 125
500 100 150
600 – 650 125 200
750 – 800 150 250
900 175 300
1000 – 1050 200 350
1200 250 400
1350 275 500
1400 and over 300 600
8. BELT SPEED
Selection of proper belt speed is influenced by capacity required, by the resulting belt tension and power requirements, and
by limitations in the nature of the material being handled, eg. Degradation of friable materials, windage losses of light or
powdery materials, lump impact on carrying idlers, etc.
As far as capacity is concerned, it is desirable to select a belt speed that will result in a full belt. This produces a better
pattern of cover wear
Speed also has an effect on power requirement, particularly on belts with little or no incline. With tonnage rate held
constant, power requirement goes down as speed is decreased. This because the power to operate the belt and other moving
machinery varies directly with speed while the power to move the live load remains constant as long as the rate of loading
is fixed. The degree to which speed effects power requirements depends on the ratio of payload to gross load. The higher
the percentage of payload, the less effect speed will have on power requirements.
TYPICAL MAXIMUM BELT SPEEDS (METRES PER SECOND)
Belt width (mm) Run of mine coal & earth Hard ores and stone – primary crushed
300 - 500 1.5 – 2.0 1.5 – 1.8
600 - 1050 2.5 – 3.6 2.3 – 3.0
1200 - 2000 3.6 – 4.0 3.3 – 3.8

Conveyors
Typical maximum belt speeds for the following applications are:

Portable underground conveyors 1.3 – 2.2 m/s
Wheel excavators 4.6 – 5.0 m/s
Belts unloaded by plows 0.5 – 1.0 m/s
POWER REQUIREMENTS AND BELT TENSION
CONVEYOR POWER
The power to operate the conveyor is made up of three components;
Power to drive the empty belt Pe
Power to transfer the material Pm
Power to raise or lower the load Pr
∴ Pt = Pe + Pm (+ or -)Pr kW
Now Pe = Fc (L + tf) * 3.6QS/367 kW
& Pm = Fc (L + tf) * C / 367 kW
& Pr = CH/367 kW
Now in the term Pe the power to drive the empty the belt, is the term to allow for the mass of the moving parts, which
includes two lengths of belting and the frictional resistance of the idlers & terminal pulleys expressed as Q in terms of mass
per unit length ie. Kg/m.
For most mining type conveyors the frictional coefficient is taken as Fc = 0.03, and the terminal pulley/friction is expressed
as an additional length of the conveyor tf and is usually an allowance of 45m for conveyor lengths between 300 – 1200m
centre to centre distance.
L = centre to centre distance between Tail drum & Head pulley
C = Belt capacity in tonnes/hr, S = belt speed in m/sec
H = the net change in elevation in metres
AVERAGE VALUES FOR ‘Q’ FOR FABRIC BELTS
(Mass of moving parts, kg/m)
Belt width Idler diameter
(mm) 102 mm 127 mm 152 mm
600 30 34 41
750 36 46 52
900 45 54 64
1000 50 59 68
1200 70 84
1500 110
1800 133
2000 148
The mass of belting & idler spacing obviously affect the values in the above table, the values are average & conservative.
For closer determination use the following formula Q = 2B + wt/s1 + wr/s2 kg/m ; where B = belt mass kg/lineal metre,

Conveyors
wt & wr are the mass of the moving parts of troughing & return idlers respectively obtained from manufacturers catalogues,
and s1 & s2 are the spacing of the troughing & return idlers.
The driving unit motor power must take account of the motor & gearbox efficiency and is
Pd = Pt/η
Where η = efficiency of the motor & gearbox combined
= ηm * ηg
BELT CARCASS SELECTION

The composition of a conveyor belt can be considered in two parts
• The carcass, whether of fabric ply or steel cord construction, which must have sufficient strength to
handle the operating tensions and to support the load.
• The covers, which must have the required physical properties and chemical resistance to protect the
carcass and give the conveyor belt an economical life span
Fabrics which are commonly used as reinforcement in conveyor belts are listed in the table below
REINFORCEMENT FABRICS
Fabric designation Construction Strength range Major characteristics
Warp Weft available U.T.S.
kN/m/ply
KN Kuralon Nylon 150, 200, 250 Low elongation,
Reasonable impact
resistance
PN Polyester Nylon 100, 150, 200, Low elongation, good
impact resistance, an
150, 300
excellent general
purpose fabric
NN Nylon Nylon 200, 250, 300 High impact
resistance, moderate
elongation
PP Polyester Polyester 120 Low elongation , good
acid resistance
CC Cotton Cotton 65, 70 Moderate elongation,
relatively low
strength, general
purpose fabric, being
replaced by synthetic
fibre fabrics
Solid woven carcass Cotton/ Cotton/ Main use in
underground coal
Nylon Nylon 490, 525, 610,
mining, good fastener
Polyester/ Polyester/ 700, 875, 1050 holding & impact
resistance
Nylon Nylon

Conveyors
Cover Qualities
Various qualities & types of belt cover materials are used by manufacturers;
COVER COMPOUNDS (Example only)
Cover compound Major features Main market application
designation
Grade M AS 1332, resists cutting & gouging Toughest service where large & very
abrasive lumps are handled
FRAS (PVC) AS1332, meets fire resistance regulations Solid woven carcass belting in
underground coal mining
Allowable working tension

The allowable working tensions allocated the above fabrics by typical manufacturers are;
PLIED BELT CLASSIFICATIONS AND RECOMMENDED

ALLOWABLE WORKING TENSION
Strength classification Recommended Recommended

allowable working tension, allowable working tension,
vulcanised splices first quality fasteners
(kN/m/ply) (kN/m/ply)
CC65 7.9 6.0
CC70 8.8 7.0
KN150 15.8 12.5
KN200 21.0 16.8
KN250 26.0
NN200 12.3 12.3
NN250 15.8 15.8
NN300 26.0 21.0
PP120 12.3 9.8
PN100 10.5 8.5
PN150 15.8 12.5
PN200 21.0 16.8
PN250 26.0
PN300 31.0

Conveyors
EXAMPLE:
A conveyor design is required to transport a mineral ore at a bulk density of 1900 kg/m^3 a distance of 600 m up an incline
with a gradient of 1: 60 at the rate of 400 tonne/hr. Estimated max. lump size is 100 mm mixed with fines
Drive pulley
10 m
600 m
Find the belt width, speed, strength of belt required, and motor power required to drive the conveyor.
Since the capacity is a function of belt width & speed, it is necessary to select a first approximation of one then check for
the other and refine the first selection.
From the approximation A = W^2 / 10, selecting W = 1 m, then A ≈ 0.1 m^2
From C = A * ρ * S * 3.6 t/hr
S = 400 / [0.1 * 1900 * 3.6] = 0.58 m/sec [ too slow or the belt is too wide]
However we are now in the ball park
Lets try a 600 mm belt, carried on a three roll idler system @ 30o idler angle.
Entering the capacity table with a belt speed of 1 m/s it can be seen that the capacity range is 109 – 327 t/hr
for the density range 800 – 2400 kg/m^3
Interpolating within the table:
S = 400/218 * 1600/1900 * 1 = 1.55 m/s
∴ select belt speed S = 1.6 m/sec.
The belt width satisfies the criteria for lump size since max recommended with fines is 200 mm < 100 mm
Also the belt speed of 1.6 m/s is < 2.3 m/s recommended max [600 mm belt] belt speed for hard ores, primary crushed.
Power Requirements:
Pt = Pe + Pm + Pr
Know Pe for the empty belt selecting Q from the table, where Q = 2B + wt/s1 + wr/s2 kg/m for a 102 mm
dia. idler the mass of the moving parts Q = 30 kg/m
Also using Fc = 0.03 & tf = 45 m
∴ Pe = Fc (L + tf) * 3.6QS/367
= 0.03 ( 600 + 45 ) * 3.6 * 30 * 1.6 / 367 kW for the empty belt
= 9.11 kW
Now Pm = Fc (L + tf) * C / 367 kW
= 0.3 * 645 * 400 / 367 to move the material on the belt
= 21.09 kW
And Pr = CH/367 kW
= 400 * 10 / 367 kW to raise the material
= 10.89 kW

Conveyors
∴ Pt = 9.11 + 21.09 + 10.89 = 41.09 kW is the power required at the belt

Motor Power:
Assuming a motor efficiency of 95% & gear box efficiency of 90% then the
Motor power required Pd = 41.09/[ 0.95 * 0.9 ]
= 48.07 kW
∴ Select a motor with a power rating of say 50 kW
Belt strength required:

I f we assume a single drive with a snub pulley providing an arc of contact = 240o ( 4.19 radians ) and a
lagged drum, ie. A coefficient of friction = 0.35 then
T1/ T2 = eµα
∴ T1 = T2 * eµα = T2 * 2.718^ (4.19*0.35) = 4.33 T2
K = T2 / Te = 0.3
From the tables for K with arc of contact = 240o and a lagged drum assuming an automatic take up
Since K = 0.3
Now since Pt = 49.07 kW = Te * S
∴ Te = 48.07 / 1.6 = 30.04 say 30 kN
& since Te = 3.33 T2 = T1 – T2 = 30 kN then
T2 = 9.02 say 9 kN &
T1 = 39 Kn say 40kN
Using the allowable belt tension for a CC65 fabric carcass utilising vulcanised splices
The fabric rated at 7.9 kN/m/ply
Then 40/[0.6 * 7.9] = 8+ ply belt is required, a 600 mm 9 ply belt would have troughing problems, so we should
try another fabric, say PN150 with an allowable tension of 15.8 kN/m/ply
Checking the number of plys
N = 40/[0.6 * 15.8]
= 4+ say 5 ply
∴ A 5 ply PN150 belt 600 mm wide is required, driven by a 50kW motor using 30o idler angle with 102 mm dia.
equal length rollers.

Conveyors
TAKEUP
The purpose of takeup devices in belt conveyors establish and preferably to maintain a predetermined tension in the belt at
some critical point.
Often the critical point lies immediately following the drive since it is necessary to maintain tension at that point to prevent
slippage on the drive pulley.
“Takeup” devices derive their name from the fact that they take up changes in belt length. In taking up length, they maintain
tension, which is their primary purpose.
Types of Takeup
Generally of two types:
Manual & Automatic
• Manual takeups
Are usually screw operated and permit moving a pulley, usually the tail , to tighten the belt. These screw
devices give no indication of the tension they establish and are adjusted by trial methods until slippage is
avoided. They are unable to compensate for any length changes in the belt between adjustments and so
permit wide fluctuations in belt tension.
These imperfections are tolerable because of simplicity in short and lightly stressed conveyors eg.
Inclined conveyors < 30 metre centres and horizontal conveyors up to 100 metre centres.
• Automatic takeups
Maintain a predetermined tension at the point of takeup regardless of length changes resulting from load
change, stretch, etc. Usually, automatic takeup devices depend on gravity but are occasionally actuated by
a torque motor or by hydraulic pressure
Tail Pulley Takeup
Vertical Festoon Takeup

Conveyors
Movement Required of Takeup

Manual Takeup
If the belt is pulled up with clamps before fastening so that it is at or near its running tension, the amount
of movement used in establishing initial tension is reduced. Under such circumstances, a screw travel of 1
– 1.5 % of the centre distance is sufficient to give reasonable freedom from refastening problems.
Automatic takeup
Counterweight most common, the takeup travel requirements shown in the table below are applicable to
belts with vulcanised splices, operating at between 75% and 100% of the allowable working tension, and
with the starting tension limited to 150%.
For belts operating at between 50 – 70% of the allowable working tension, the travel distances in the table
may be reduced by 25%, whilst the travel distance for belts operating at < 50% if the allowable tension
can be reduced by 50%
GRAVITY TAKEUP TRAVEL
Centre to centre length of Travel in percent of conveyor centre distance (minimum)

conveyor (metres) CC NN KN, PN, PP
Up to 30 2.0 4.0 2.0
31 – 60 1.9 3.5 1.7
61 – 180 1.8 3.4 1.6
181 – 300 1.8 3.3 1.5
Over 300 1.8 3.3 1.3
Note: A practical minimum take-up travel should not be less than 1 metre
Note: In the case of the vertical festoon takeup the the takeup tension is Te*K, and the counterweight
required is twice the take up tension plus or minus the effect of the pulley and takeup carriage weight.

Conveyors
CONVEYOR SAFETY
Two Australian Standards apply:
AS 4024.1-1996 Safeguarding of Machinery Pt. 1: General Principles
AS 1755 – 1986 Conveyors – Design, construction, installation, and operation – Safety requirements
In safety two considerations are paramount:
• Safety for operating personnel & others near the conveyor including maintenance staff
• Devices that protect the belt and equipment
PERSONNEL PROTECTION DEVICES

Emergency Stop Switches
Should be placed where possible danger exists. These switch locations usually would be actuated by a pull wire/trip wire. In
addition to drive, takeup, and tail areas, it is customary to install pull wires alongside long centre conveyors. Switches are
spaced at 100m to 200m intervals. In cas of shutdown, lights located at the open switch facilitates location of the open
circuit.
Warning Horns:
Use of horns to warn that an idle belt is to be started, particularly on long centre conveyors. They should be sufficient in
number and located so that they can be heard at any place along the length of the conveyor. They should be sounded long
enough so that everyone has ample time either to clear the area or to pull the emergency cord in the event they will not be
clear.
Belt Crossover Stile:
Are particularly desirable on long centre conveyors where personnel may cross over from one side of the conveyor to the
other. This same location is also very useful in inspecting the top side of the belt. In no case should personnel be permitted
to go under the belt unless it is adequately protected with guards.
Cross-over Style (diagrammatic, steps & handrails omitted)

Pulley Guards:
Protective guards or screens need to be provided to prevent entanglement between the belt and drive, takeup, bend, and tail
pulleys. Operating or other personnel should not be permitted inside these guards unless the power is isolated and locked
out. Troughing idlers in locations of pinch points, eg. loading chutes, vertical bends, plows, dust covers or skirts and return
idlers shall be guarded unless they are < 0.6m or > 2.5m above any floor or platform.
Walkways:
To facilitate inspection & maintenance of belt conveyors, walkways should be provided on at least one side. They should be
structurally strong and should be adequate for the weight to be carried; the walking surface should be non-slip. Strong
handrails also are a necessity.

Conveyors
Protection Beneath Conveyors:

Many conveyors cross roads or pedestrian paths. Baffles of one type or another should be placed to catch any material that
might fall.
Lighting:
Mine conveyors are normally planned to operate 24 hrs. a day. Good, adequate lighting should be provided in all areas of
possible danger, even though they are adequately guarded. Long centre conveyors should have lighting strategically placed
along it’s length.
Training in Operation & Procedures:
Items to be stressed in training;
• Riding on belt is forbidden
• Do not clean the belt while it is in motion, this includes scraping pulleys, shovelling spillage from underneath the belt
or onto the belt.
• Do not permit repair work unless electrical switches are locked out and tagged
• Do not inspect a moving belt by feeling with hands or fingers.
• Do not wear loose-fitting clothes around revolving pulleys, shafts, couplings or chain/v-belt drives
BELT AND EQUIPMENT DEVICES

Limit Switches:
To protect against extreme lateral movement of the belt, possibly causing damage to the belt & supporting structure,
particularly at the drive, tripper, takeup and tail pulleys.
A limit switch at the takeup carriage at the end of its travel can be used to stop the belt either when it reaches it limit of
travel or failure of the belt.
Rip Protection:
Tramp/scrap iron that comes down a loading chute and penetrates the belt is a source of extreme damage. It can lodge
against an idler or other obstruction so that the movement of the belt makes a long rip. Removal of tramp iron by a large
suspended magnet or a metal detector warning of its presence reduces the risk. Further protection is provided by trip bars
with limit switches or electronic loops built into the belt with detectors placed at strategic locations, both systems shut down
the belt drive when an anomaly is detected.
Slip Protection:
Slipping of the belt on the drive pulley can be detected by the use of a centrifugal switch driven by direct contact with the
belt or from any idler pulley. When activated the switch stops the drive.
Sequence protection:
It is necessary to ensure that in case a belt is stopped all feeders or other belts loading onto it are also stopped. This can be
done by interlocking the electrical control, which ensures that the drive motor of the conveyor is running before the feeding
belts can start. This does not ensure that the belt itself is running unless a centrifugal switch used as for slip protection is
also wired into the control circuit of all feeders and belts loading the belt on which it is located.
Overspeed Protection:
Overspeed in downhill belts caused by overloading or other causes is again detectable with a centrifugal switch operated by
the belt, and when activated it operates the motor control, thus operating the sequence control that shuts down the feed to
the belt, and sets the brake on the drive unit.

Conveyors
Chute Plugging & Full Bin Protection:

When either of the above occurs material builds up against the belt and the discharge pulley and may damage the belt. A
limit switch operated by a flap hung in the chute or bin when plugged or full will stop the conveyor.
Overload Protection:
The drive motor is provided with its own electrical overload protection, but this is not always protection for the belt. On
highly stressed belts, motor current less than that for electrical over-load can be used to give visual or audible warning to
reduce the feed or shut it down
Takeup Protection:
Horizontal takeup carriages need to be protected from spillage that in combination with a sudden surge or belt movement
could cause the carriage to jump from its track unless restrained by guide-rails or similar stops.
Restraining Stopped Belts:
Conveyors with steep grades can run away if not properly restrained by brakes and/or anti-roll back devices, either separate
devices or built into the geared drive unit.
Transfer Point Monitor:
Conveyor belt systems can be damaged by malfunctions at transfer points, some operators in addition to plugged chute &
full bin protection install closed-circuit TV systems, transmitting back to a central control room, where rapid and effective
action can be taken, despite the remoteness from the operator.

Conveyors
ASSIGNMENT – Introduction to Civil & Mining Engineering

Re. Conveyors:
Answer the following questions:
1. In the application of belt conveyors, what do the following terms imply
(a) Road Bed

(b) Maximum incline
(c) Environmental advantages
(d) Troughing idlers
(e) Head pulley and drive
(f) Travelling tripper
(g) Angle of wrap
(h) Ratio of tensions
(i) Equivalent tension
(j) Surcharge angle
(k) Trough angle
2. What is the “rule of thumb” formula for determining

a) Cross sectional area of material on a troughed belt of width W
b) Maximum lump size in terms of W
3. Detail the factors involved in determining the ‘Q’ factor in the power formula for moving
the empty belt
4. Describe two forms of “Takeup” and their purpose in a conveyor installation
5. Detail four safety provisions in the two areas of a conveyor installation that protect;
a) Operating and maintenance personnel
b) The belt & equipment
Assignment due for handback Fiday 21st. March 2003

Conveyors

Belt Conveyor Notes

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Belt Conveyor Notes

Hochgeladen von

Copyright:

Verfügbare Formate

University of South Australia School of GMC Engineering

SOME FUNDAMENTALS OF BELT DESIGN 4

POWER REQUIREMENTS AND BELT TENSION 12

Intro to CV & MN 1 BVC/10-03-03

Introduction to Civil & Mining Engineering

3. ADAPTION TO GROUND PROFILE

Intro to CV & MN 2 BVC/10-03-03

5. LEAST DEGRADATION OF MATERIAL

8. LIGHT WEIGHT OF CONVEYOR STRUCTURE

9. MUTIPLE GATHERING AND DISCHARGE POINT CAPABILITIES

10. MOBILITY AND EXTENSIBILITY

11. LOWEST POWER REQUIREMENT

Intro to CV & MN 3 BVC/10-03-03

12. VERSATILE POWER SUPPLY

14. EARLY WARNING OF FAILURE

16. ALL-WEATHER CAPABILITIES

SOME FUNDAMENTALS OF BELT DESIGN

Intro to CV & MN 4 BVC/10-03-03

Intro to CV & MN 5 BVC/10-03-03

Fn = 2T Sin(∆ α./2) (since ∆ T is neglible)

T+∆T T ∆ T/∆ α. = f T [Sin(∆ α./2)/ (∆ α./2]

Taking limits as ∆ α approaches zero

Intro to CV & MN 6 BVC/10-03-03

(Reference: “Handbook of Conveyor & Elevator Belting” Goodyear)

Then K = T2/(T1 – T2) = 1/( efα - 1) = 1/(R – 1)

Where R = ratio of tensions & K = T2/Te

Intro to CV & MN 7 BVC/10-03-03

VALUE OF DRIVE FACTOR K FOR SINGLE DRIVES

1. Arc of Manual Take up Automatic take up

From the table :

∴ T2 = K* Te = 0.5 * 1000 ∴ T2 = K* Te = 0.3 * 1000

Intro to CV & MN 8 BVC/10-03-03

6. CAPACITY OF BELT CONVEYORS

Width (mm) Area (square metres)

*25-deg. surcharge angle; D = (0.05W + 25) mm

Intro to CV & MN 9 BVC/10-03-03

Intro to CV & MN 10 BVC/10-03-03

Intro to CV & MN 11 BVC/10-03-03

Typical maximum belt speeds for the following applications are:

POWER REQUIREMENTS AND BELT TENSION

Intro to CV & MN 12 BVC/10-03-03

BELT CARCASS SELECTION

Intro to CV & MN 13 BVC/10-03-03

Allowable working tension

PLIED BELT CLASSIFICATIONS AND RECOMMENDED

Strength classification Recommended Recommended

Intro to CV & MN 14 BVC/10-03-03

Intro to CV & MN 15 BVC/10-03-03

∴ Pt = 9.11 + 21.09 + 10.89 = 41.09 kW is the power required at the belt

Belt strength required:

Intro to CV & MN 16 BVC/10-03-03

Tail Pulley Takeup

Vertical Festoon Takeup

Intro to CV & MN 17 BVC/10-03-03

Movement Required of Takeup

GRAVITY TAKEUP TRAVEL

Centre to centre length of Travel in percent of conveyor centre distance (minimum)

Intro to CV & MN 18 BVC/10-03-03

PERSONNEL PROTECTION DEVICES

Cross-over Style (diagrammatic, steps & handrails omitted)

Intro to CV & MN 19 BVC/10-03-03

Protection Beneath Conveyors:

BELT AND EQUIPMENT DEVICES

Intro to CV & MN 20 BVC/10-03-03