w& UDC 621.867.24 : 622,647.21 DEUTSCHE NORM February 1982 reproduction, event pss ony wlth no exp pamianan ofthe IN Oautches latte Nermung 8. Ban ‘Continuous mechanical handling equipment Belt conveyors for bulk materials Bases for calculation and design es Stetigforderer; GurttOrderer flr Schittgiter; Grundlagen fir die Berechnung und Auslegung Supersedes February 1942 edition As itis current practice in standards published by the International Organization for Standardization (10), the comma ‘has been used throughout as a decimal marker. . Contents ae rose 1 Scope and purpoHe oe ees 111. Minimum bet action forces equies 2 Otherrelevancarandards | 1 for tne vansmison of the pulley feat peripheral forces 1 3 Senet ooo 2 axa Minimum on cin fri ei forthelimitation ofthe bet sajand for 5 Volume flow and mass flow . 7 5 correct and satisfactory belt guidance 12, 6 Resistances to motion and power require: 8.2 Loca belt traction force variations ‘ment in the steady operating condition... 6 in the upper strand (carrying side) 6.1" Resistancesto notion svsserssaves 6 andinthelowerstand (return side)... 12 8.1.1" Main resistance of the conveying wack 6 8.21" Stesdy operating conditions «0. 12 6.1.2. Secondary restanoas of incvivsl 82.2 Non-steady operating conditions». 12 parts of te Instlation 7&3. Ten foros and tense distances ©. 13 0.13 Sepersitann ote conieyer isd 84 Leal tat eacton fore te 8.14. Special vesttaces 8 Upper strand lerrying ie] and 6.2" Power requirement inthe inthe lower strand (return side)... 44 ‘Heady operating condition ........ 8 844" Non-steady operating conditions «| 14 7 Design and layout of the erving system 8 84.2 Steady operating conditions «=<. 14 7A" Lotion ofthe deing nits Hacerreeenepenteeereeenerg sie and number oférhing motos. 9 841° Nominate force nese ress ss 8 7A Roe 9 9.2 Cover plates eh CHa 7.1.2 Installations conveying uphill 9 ee eee eee ee ere 7.1.3 Installations conveying downhill... 9 11. Design and layout of transition curves 7.2. Starting, stopping and holding stationary 9 ‘and of transition lengths... . 18 ea stircie mr 2 ssa Teandon ewer ores 8 7.22. Stopping end holding stationary... 10 14.2. Transition lengths ...... 9 Belt traction forces and tensile forces... 10 Further standards 19 8.1" Required bek action forces sees 19 Notes ssa ‘20 1. Scope and purpose ‘This standard applies to belt conveyors for the conveying of bulk materials and it contains the basic principles for the calculation and design of such conveyors. It enables the most important characteristics of the msin components of the belt conveyor, such asthe driving, braking and belt tensioning equipment, and the conveyor belt itself, to be laid down in function of the specified conveying requirement. 2 Other relevant standards DIN 15207 Continuous conveyors; carrying idlers for belt conveyors, principal dimensions DIN 22 102 Conveyor belts with textile plies IN 22107 Continuous conveyors, carrying idler arrangements for belt conveyors, principal dimensions DIN 22109 Part 2 Convayor belts with textile plies for the hard coal mining industry — conveyor belts with two plies for underground use DIN 22112 Part 1 Belt conveyors for underground cost mining: carrying idiers, shapes and dimensions DIN 22131 Part 1 (Preliminary Standard) Conveyor belts with steel cord plies; dimensions and marking DIN 22131 Part 2. (Preliminary Standard) Conveyor belts with steel cord plies; quality requirements DIN 22131 Part3 (Preliminary Standard) Conveyor belts with steel cord plies; testing DIN 22131 Part 4 (Preliminary Standard) Conveyor belts with steel cord plies; belt joints Continued on pages 2 to 23 Sigg no Geman Sans OI Norman ah BeURVaG GON etn ‘DIN 22101 Engl. Price group 13 Soles No, 0113Page 2 DIN 22101 3. Concepts Belt conveyors within the meaning of this standard are continuous conveyors for bulk materials, with circulating con- veyor belts which feature tension members of textile or steel cord ply, and cover plates of rubber or plastic (e.9. ‘accordance with DIN 22 102, DIN 22 109 Part 2 and DIN 22131 Part 1 (Preliminary Standard) to Part 4 (Preliminary Standard). The conveyor beles are supported on carrying idlers (e.g. in accordance with DIN 18207 and DIN 22112 Pact 1) and driven or braked by friction grip via pulleys (arrangement of the carrying idlers e.g. in accordance with BIN 22 107. ‘The date apply to conveying in the upper strand (carrying side! side), the procedure is analogous. ‘conveying takes place in the lower strand (return 4 Symbols and u Table 1. Symbols and units Symbol Meaning Unit A Cross section of fill m2 Ay Partial cross section of the slope above the water fill m2 Az Partial cross section for 8 = O° (water fill) m2 Aor Effective contact area between bet cleaner and belt mm? B Belt width ram ¢ Coefficient forthe alLinclusive consideration ofthe secondary resistances 7 Dn Pulley diameter mm Exon Modulus of elasticity of all the load-carrying belt plies (belt core) Nimm F “Total of resistances of upper strand (carrying side) and lower strand (return side) | oN (“total of pulley peripheral fores) in the steady operating condition Fat Inertia resistance and frictional resistance between the conveyor load and the N tet in the zone ofa feeder point Fou Belt resistance to bending N Fer Fstiona resistance caused by belt cleaners N Pu “Total of main cesistances of upper stra (csrrying side) and iower strand N (oeturn side) Fy “Tota of secondary resistances N Fro ‘Camber resistance N Re “Total of the special resistances of uoper strand (carrying side and lower strané N (roturn sided Peas Frictional resistance between the material conveyed and the lateral chutes out N ‘the acceleration zone of feeder points Foaw Frictional resistance between the msteria conveyed and the lateral chutes within | N the acceleration zone ofa feeder point Pop ‘Tension at the axis of the take-up pulley N Fa “Total of slope resistance of the eorveyor load N Fou Pulley bearing resistance of iar pulleys N Facer | Peripheral force of one driving pulley N a Lift of the conveyor (Hf > 0 for uphill conveying, H <0 for downhill conveying) m I ass flow kale Taw Nominal mass flow als Ty Volume flow m/s dyw Nominal volume flow: m/s L Conveyor length stance between contras m > Total power atthe periphery ofthe driving pulleys) required by the resistances |W in the steady operating condition Pu Total power of the driving motors w Pane Nominal power of one driving motor w Ry Radiut of a concave transition curve m R Radius of a convex transition curve a 8 Safety factor 7 T Local belt traction force (strand force) NDIN 22101 Page, Table 1. (continued) Symbet Meaning Unie Te Tean belt sation force of upper stand (earring side) and the lower strand N return sel aT Difference between mean belt traction forge ig and minimum bel action ‘ force Tae : 1 Maximum bel traction fore (strand fore) atthe driving pulley N % Minimum Bele retion fore (stand force atthe driving pulley N 2 Accleration or deceleration respectively mist 8 Useful belt with omin een Internat ciameter between chute walls m on Coefficient forte calculation ofthe mates ofthe carrying ier reduced to - their periphery Chee Rankine factor (come tan? (45°— fas) - ene Coefficient forthe calculation ofthe camber resistance 2 caus | Coefficient forthe taking into overall ccount of the addtional resistance = between the terial conveyed andthe lateral chutes inthe feeding zones, Caused by the dynamic pressure ofthe mats flow fed in on Coefficient forthe determination ofthe minimum pulley diameter - ey Factor forte ascent of the belt onto the puley 7 e Factor fr the desant ofthe belt from the pulley a aay Thickness ofthe bel seraper materiel mm aon ‘Thickness ofthe bel core (cord diamaterin the case of tel cord ply belts) om e Base of natural logarithms 7 ex Distance from the centre fine ofthe bet pis atthe edge ofthe bet tothe mm neutral axis ofthe belt en Distance from the cenreslne ofthe belt plies atthe centre ofthe belt tothe rm neta axe ofthe belt t Hypothetial reton coefficient of the upper strand and ower strand - together 6 Acceleration due to gravity (g = 9,81 m/s?) m/s Pret ‘Maximum belt sag, related to distance between carrying idler centres - ® Bele traction force related o te belt with Nim ty Nominal rupture force ofthe bel related to the belt width Nin i Length ofa part section : ” ty Length ofthe acceleration path in the feeding zone m le Length of shell of the central idler in a three piece carrying idler arrangement mm ton Length of the lateral chutes in al Elongttion of bet in the part steton of length m i, Distance between carving lr centres inthe upper strand (carrying side) m q Distance between carrying der centes in the lower strand (etura idl m Em “Total ofthe rectneer moving masses and of the rotating masses reduced to ks theit periphery, which ae not driven or nt braked me Line fad resuting from the conveyor bet kai mi, Line toad resulting from the conveyor lad assuming a uniform tad distribution | kg/m cross the entre conveying stretch on Line toad resting from the nominal easing aim mi Line toad resting from the rotating carrying lets ofthe upper strand and aim lowerstrend together n Number of steps (on belt joints) Ee Pox Pressure betveon belt leaner and belt Nfmm? Ween Lott of strength in te bat joint - 0 Loss of strength to make allowance for the fatigue strength behaviour of belts 2Page 4 DIN.22 101 Table 1. (continued) Symbot Meaning Unit ” Reduction in strenath to make allowance forthe focal addtional elongations - in the belt "2 Reduction in stength to make allowance forthe peak loadings ofthe belt which | — do not oceur constantly ‘ Portion of the bott resting ona side pulley (applies only to two and three piece mm trouahed iter sets) ta Braking distance m S89 Take-up pulley travel m ty Braking time 5 » Conveying speed mis % Feeding (advance) speed of the conveyor load in the direction of conveying mls x Horizontal extension ofa concave transition curve m Ys Vertical extension of a concave transition curve m a Number of belt plies a an Number of motors installed - an Number of carrying idler sets in the upper stand or in the lower strand - tae Number of earring idler sets in the upper strand or in the lower strand - setat tit « ‘Angle of pulley bett wrep Sorrad 2 Equivalent ange of slope for the caleulation ofthe partial eross section Aya ° Barn Actual dynamic angle of siope of the material conveyed ° 6 Angle of inclination ofthe installation (4 > 0 for uphill conveying, 6 <0 for : downhill conveying) e Angle of tilt ofthe carrying idler in the upper strand or in the lower strand . dex Additional elongation (positive or negative) at the edge of the belt on concave or | — ‘convex transition curves AK. imiting value of 4 cx atthe contre of very long transition curves, - ey ‘Additional elongation (postive or negative) atthe centre of the belt on conceve - fr convex transition curves den, Limiting value of A ey atthe centre of very long transition curves - ees vera efficiency ofall transmission members between the motor shaft and - the pulley shaft a “Troushing angle of the material conveyed in the upper strand or in the lower . strand # Friction coefficient between bett and pulley i a Friction coefficient between belt and material conveyed - se Friction coefficient between material conveyed and lateral chutes a Bs Friction coefficient between belt and carrying idler - Hs Friction coefficient between balt and belt cleaner’ a e Bulk donsity of the material conveyed kim ° Effective filing ratio (@* Puen “P50 7 Poe Filing ratio corresponding tothe operating conditions of the conveyor - Ps Reduction factor of filling ratio for the theoretical totel cross section Ava in the - case of inclined installations Po Reduction factor offing ratio for the theoretical partial cross section of the - slope triangle A. «yin the cas of inclined installationsDIN 22101 Page 5 Table 2. Subseript Subscript Meaning A+ | during starting 8 during stopping ert required i ‘running subscript of the belt strand sections : inst installed insta | nonsteady operating condition (starting, stopping) max | maximum min | minimum ° ‘upper strand (carrying side) ste steady operating condition th theoretical u lower strand (return side) - ‘running subscript for the identification of the operating condition 5 Volume flow and mass flow The volume flow and mass flow of # belt conveyor installation shall be determined by the potential cross section of fll, and the latter is dependent on the dynamic angle of slope of the material conveyed, amongst other factors. However, 3 theoretical cross section of fill represents the initial quantity for the purposes of the calculation. This theoretical cross section of fil Axy shall be calculatd from the shape of the belt on the carrying idlers, ignoring the belt thickness, and from the shape of the bank of material. Itis, therefore, equal to the area of a polygon, formed by the generatrces of the carrying idlers (ignoring the clearance gaps between adjoining carrying idles), and by the idealized slope lines of the ‘moving material conveyed. It is determined by the length and arrangement of the carrying idlers(troughing angle, by the useful belt width b, and also by an equivalent angle of slope B, which defines a cross sectional equal in area to the actual cross section. The useful belt width b amounts to the velues belovr, in function of the actual belt width B: for B<2000mm = 0.9-8~ 60mm af for B> 200mm b= B~ 250mm In the case of one piace, two piece and threo piece carrying idler arrangements in horizontally Iaid belt conveyor instal- lations, the theoretical cross section of fill Aya equivalent to the actual cross section of fill can be determined as the sum ofthe partia cross sections A, plUS Az I, By making use of the angle f (see figure 1 and remarks): E ae ne (= hy) cos aft. SOB @ [oma 2 mo + mi) 08 8) a where / represents a hypothetical friction coefficient for the upper strand and the lower strand jointly, andé represents the mesn angle of inclination of the instalation, In the case of installation inclinations with 6 $15°, we can enter cos 6 = 1 in the above equation, If the upper strand and the lower strand are to be considered separately, equation (11) will epply analogously, using the appropriate individual values (see subclause 8.2.1). In the case of belt conveyor installations with filling ratios pin the range from 0,7 to 1,1, and with a relative belt sag ns S 1%, and equipped with carrying bearings and fitted with labyrinth seals, the value of f will be situated in the range from 0,012 to 0,035, depending on the ‘operating and installation conditions. No truly reliable values for f are available for unloaded belt conveyor installations: ‘these values can be either lesser or greater than those applying to the nominal loading cange. This must be borne in mind pprticutarly in the case of installations with a gentle inclination, for which the drives must be sized in accordance with the idling power requirement. ‘Table 3 features values of the coeff Of the opers tf for installations with filling ratios 9 i conditions and of the design characteristics (see also Notes). the range from 0,7 to 1,1 in function 3] Vierling, A.: Zum Stand der Berechnungsgrundlagen fir Gurtférderanlagen. Braunkohle, Wirre und Energie 19 (Con- tribution to the present state of the batie principles of calculation of belt conveyor installations. Brown coal, heat and energy 19) (1967) No. 9, pages 309-315VY DIN 22101 Page 7 Table 3. Standard values for the coefficient f for belt conveyor installations with ing ratios yin the range from 0,7 to 1,1 (see also Notes) Horizontal installations, also installations conveying uphill and down gentle inclines (with electric motor drives): = favourable operating conditions, e.g. good belt alignment, easy running carrying idlers 0.017 ‘and material conveyed at low speeds, with low internal frietion — installations constructed and operated in normal (standard) manner 0.020. — adverse operating conditions, e.g. dust laden atmosphere, low temperatures, material 0,028 t0 0,027 ‘conveyed exhibiting a very high internal friction, overloading, high speeds — extremely low temperatures, but otherwise normally operated and conventionally up to 0,035 constructed installations Installations conveying downhill ata steep incline 1) (drives operating as dynamos) 0,012 to 0,016 1) In the cace of installations conveying downhill ata steep incline ~ drives operating as dynamos ~ the adoption of a somewhat lower value for f will result in higher degree of safety in the design; in other cases ~ where the ives operate as motors — an enhanced safety of design is attained by adopting 2 higher value for /. 6.1.2. Seoondary resistances of individual parts of the installation The total of the secondary resistances Fy is taken into account by means of the coefficient C3): cate 02) In the case of filling ratios g in the range from approx. 0,7 to 1,1, and of a relatively low percentage of the secondary resistances in relation to the total resistance, the coefficient C can be taken from table 4 below. Table 4, Standard values for coefficient C for belt conveyor installations with filling ratios in the range from 0,7 to 1,1 Linm | 80 | 100 | 360 | 200 | 200 | 400 | s00 | 00 | 700 | 800 | 900 | 1000] 1500} > 2000 c 192 | 1.78 | 1.0 | 1.45 | 3.91 | 1.28 | 1.20 | 1.17 | 1.14 | 1,12] 4,10 | 4,00 | 1.06] 1.05 ‘On the other hand, if the secondary resistances represent a large percentage of the total resistance, e.g. in the case of installation lengths L <0 m, and of installations with more than one feeder point, it will be necessary to determine the secondary resistences individually, or the coefficient C respectively. In such cases, the individual components of Fx can be determined with the ald of the following relationships: Inertia resistance and frictional resistance between the materal conveyed and the belt in the zone of a feeder point Fat fa = 00) a) Frictional resistance between the material conveyed and the lateral chutes within the acceleration zone of a feeder point Hates by Fen a) forO 0, Fy > 0) = uphill conveying installations (F, > 0, Fy S 0) = downhill conveying installations (Fo $0, Fy >0) 7.1.1 Horizontal and slightly inelined installations In the case of belt conveyer installations with drives at the installation head and reer, but without intermediate drives, the belt traction forces will be minimum if the drive power is appropriately subdivided between head and rear. The ‘optimal power subdivision is equal to the quotient Fa/Fq of the forces for filling ratios p situated between 0,7 and 1,1 ‘along the entire stretch of the installation, The required total power of the driving motors can be calculated with the aid of the following equation: Prax Pret = 5) aes ‘The reted motor power actually installed is, as @ general rule, greater than the required power: Piginss2 Patert {f motors of identical nominal power are installed, we have: Prune 2 Pa en motors of differing nominal power are installed, we have: Prsinst= E Paar (28) 7A.2 Installations conveying uphill In such installations, the belt traction forces will be minimum if al the drives are arranged at the head of the installation, asquming that no intermediate drives are installed (see subclause 7.1.1). Equations (26), (27) and (28) apply to the powers Puset 2nd Pats. 7.4.3. Installations conveying downbill ' In these installations, itis essential to inctall the drives at the rear of the installation in order to obtain minimum belt ‘action forces, For the purpose of determining the total power of the drives, the required power of the driving motors must be caleulated as follows, depending on whether the drives operate as motors (Prngx > 0} of as dynamos (Praox <0): Pest = 22 for Pox > (29) Part Prac pes f0F Pras <0 (0) “The rated power of the motors actually installed is, a8 a general rule, greater than the amount of the required power: Prsnat 2 1Paeatl Otherwise equations (27) and (28) apply. 7.2. Starting, stopping and holding stationary 7.24 Starting In order to achieve minimum belt traction forces, itis necessary to limit the total pulley peripheral force on startup F,, generated at the drive end, during the run-up to full speed of the belt conveyor installation. However, the force 4, must not be allowed to decrease below 2 given minimum value in order to safeguard the positive control of the initia break- away and startup process, As a general rule, the following recommendations apply to large belt conveyor installations in particular: = The maximum pulley peripheral force on startup Fa max which arises should not exceed 1,3 to 1,7 times the force Fa accordance with equation (24) used for the determination of the installation design,Page 10 DIN 22101 = In order to accelerate the masses onthe stretch of the conveyor instalation, there should, however, be 2 force avaiable ‘under the most unfevourable start-up conditions (loading condition, distribution of load) which amounts to 20% at aN least of the total resistances tobe taken into account in ths case minus the inclination resistances (these consist of| the main cesistances, secondary resistances and special resistances), and which enables the installation to run up to {ull operating speed within & maximum permissible time calculated to avoid the thermal overloading ofthe drives 8). — The force FP, must be selected in such a way that the friction grip between the material corweyed anc the belt is ensured for the starting aeceleration a, corresponding to ssid force. In the case of fine-grained bulk material we have An £04" €08 Span $19 Spee)” B e (Senax > O in the case of uphill conveying, Bryax <0 in the case of downhill conveying) — The force Fa shall be inteodce into the belt slovly enough to ensure that the installation runs up to full operating snted under quasi steady conditions, and consequently with the smallest possible additional dynamic forces 7. 7.2.2. Stopping and holding stationsry “The operation of belt conveyor installations requires the provision of braking devices, 5a general rule, for the purpose of stopping the moving masses, and/or the provision of holding devices for the purpose of holding incline installations stationary under load, The following considerations apply to the design and dimensioning of the broking devices: ~ total required braking force Fy on the braked pulleys number and arrangement of brakes = braking frequency ~ energy of the rotating drive components to be absorbed by braking “The required braking force Fy must be determined for the most unfavourable braking conditions governed by the filing ratio g and by the distribution of the load in downhill and uphill stretches ofthe installation; in this connection, either the braking distance 6 or the braking time fp must be specified. This will in turn determine the braking retardation ap, wich mst be such thatthe tition grip between the meterial conveyed and the belt i retained intact. In tho cate of| fine-grained bulk material, we have the following relationship: {5} ts- 608 dnax + Sin asl” & @ (Smnox > Oin the cate of uphill conveying, bax <0 in the ease of dowiill conveying) Ie may be necessary to limit the total braking force to a given value Fy max, and consequently the braking retardation to 2 Timiting value 2p mag in order to reduce the Bet stresses to the weet posible figure, and algo to reduce the stresses ‘on other parts of the installation, and in order to retain intact the friction grip on the braked pulleys (se subclouse 8.1.1). As regards the design and dimensioning of holding devices, the maximum slope resistance Fx max lable to arse under maximum permissible loading conditions and most unfavourable 1oa6 distribution, shall be used 2s the base value, minus the main cesstonce arising under these conditions; for safety reasons, only the minimum main resistance anticipated must be entered in the eeleulation. If e number of mechanical holdback ratchets ate Used, each ingividual ratchet must be sized for the maximum holding force likely 0 arse, if 2 uniform load take-up isnot ensured 8 Belt traction forces and tensile forces ‘The belt traction force in a belt conveyor installation is a quantity which varies along the stretch (path) of the installation, = and which is governed by the following influences (soe figure 2): = length and local course of the installation ~ number and arrangement of driving pulleys characteristics of the driving and braking equipment tpye and arrangement of the belt tensioning device operating conditions (loading and movement conditions) “The belt traction force should be kept down to the lowest possible value in view of the stressing and layout of the belt and of other parts of the installation. 8.1. Required belt traction forces ‘The operation of belt conveyor installations requires minimum belt traction forces in order to enable the transmission of forces to the belt by friction grip on the driving pulleys, and also in order to limit the belt sag end to enable the belt to bbe guided correctly and satisfactorily. 6) Funke, H.: Zur Auslegung von Aniauthilfen fiir Gurtférderanlagen nach Entwurf OIN 22 101, Braunkohle 31 (Contri- bution to the design of starting aids for belt conveyor installations in accordance with draft Standard OIN 22 101. Brown coal 31) (1979) No. 6, pages 188-194. 7) Funke, H.t Zur Berechnung der instationsren Betriebszustinde von Férderbandantagen. Keli und Steinsalz 6 (Contri- bution to the calculation of non-steady operating conditions of belt conveyor instellations. Potash and rock salt 6) Oo (1974) No, 10, pages 362-371DIN 22101 Page 11 8.1.1 Minimum belt traction forces required for the transmission of the pulley peripheral forces, ‘The transmission of the total pulley peripheral forces Prax which arise during starting, braking, or in the steady operating condition by friction grip on the individual driven or braked pulleys requires certain given minimum belt traction forces at the ascent onto the pulley and at the descent from the pulley. In the case illustrated in figure 2, with the forces 7} and Ta and the associated maximum pulley peripheral force Fy2 max > 0, we have: Ty T= Framax (33) TyT2 se", (34) wherein armast be entered in “radian” units unit symbol rae). : te follows that ‘ Tybee: Raman With Com te «5 «9 TyZe1- Frames with opm 1+ Direction of conveying Fon Fa 2 Figure 2. Belt traction forces end pulley peripheral forces illustrated for @ conveyor installation with 2 two pulley head drive and three driving units ‘Table 5, Values for the factor cz of descent of the belt from the pulley in function of the angle of pulley belt wrap cr and of the friction coefficient x # 170° 175" voor | tse | r90° | tose | 200r | zose | 210 205 628 5.88 st sss | 599 524 5.10 497 o.10 290 art 262 | 254 247 2339 2132 2.26 015. 478 tes | 1,60 1.85 1,50 1.45 tat 1138 0.20 cr 444 1:10 1.08 1,03 O39 0196 O92. 0.25 os gs | ost or 7s 072 0.69) 67 030 970 oes | asi ose | 056 ose 0.52 0,50 0.95 oss 950 | 048 | o4s | o4e a2 2.40 0.38 040 Os o40 | 098 | oa6 | os 023 | oat 0,90 045, 038 ose | ast ozs | 028 | o26 | 025 0.24 ‘Table 6. Recommended friction coefficients 1 between conveyor belts fitted with rubber cover plates and pulley surfaces of differing finish for the design and layout of belt conveyor installations in the:steady operating condition ®} Paley surface Operating a Polyurethane Rubber Caramic naire Bearesel | Getontning | tet ing | fton ning fies {herringbone thertingbone | (porous, herringbone grooves) arooves) sfooves) oy 0.25 t0 0.4 0.35 1004 0,4 100.48 0,410 0,48 aoe ot 0.35 0,35 0,8 t0 0,4 (clean water) : * at wet (contaminated 0.95 to 0.1 o2 025008 0.35 with loam or lay) Grimmer, KeJ.: Der Einfluss von Trommelbeligen und Feuchtigkeit auf den Reibungsbeiwert zwischen Férdergurt und Antriebstrommel. Braunkohle, Warme und Energie 18 (Influence of pulley linings and of moisture on the friction ‘coefficient between the materiel conveyed and the driving pulley. Brown coal, heat and energy 18) (1966) No. 9, pages 925-332Poge 12 DIN-22101 “Table 5 features values for the factor cz of descent of the belt from the pulley for selected angles of pulley belt wrap and selected friction coefficients. The latter can be obtained from table 6 for conveyor belts with rubber cover plates and pulley surfaces of differing finish for the steady operating condition. Values for deviating conditions must be determined in accordance with the particular circumstances of each case. Friction coefficients for conveyor belts with PVC cover plates are given in the published technical literature). {In the case of more than one driven or braked pulley, it must be verified for each individual pulley and for all operating ‘conditions whether the friction grip is encured in accordance with equations (34), (38) and (38). In this connection it must be borne in mind that the total pulley peripheral forces F, Fa or Pp are distributed onto the individual pulleys in the proportion of the torques induced in said pulleys by the driving or braking devices. 8.1.2. Minimum belt traction forces required for the limitation of the belt sag and for correct and satisfactory belt guidance For the purpose of technical optimization of the belt conveyor installation, the calculated maximum relative belt $29 Mret, related to the distance between carrying idler centres, must be limited to values of less than 1% in the steady operating condition; a greater belt sag is tolerated in the non-steady operating conditions. The grester the conveying speed and the lumpier the material conveyed, the smaller shall the belt sag be. The following minimum belt traction forces are required for 2 given maximum belt sag and a given distance between carrying idler centres: Upper strand: 7 $+ 7) en “Ta (oaded) = Lower strand: Ti emily 8 hee If a given maximum value of ga is specified, differing disiences between carrying idler centres can be allocated to the belt traction forces reigning along the path of an installation, When these distances between centres are finally selected, the load-carrying capacity of the carrying idlers 10) and the natural frequency of the transverse oscillations of the belt must be taken into account") {mn order to ensure the trouble-fee operation of belt conveyor installations, it may be nocossary to arrange for the applica- tion of higher minimum belt traction forces in certain cases, viz: belts with e belt turn {reversat of direction) in the lower strend12) belts with a low degree of transverse rigidity inclined belt conveyor installations at the tower deflection pulley = belts with locally non-uniform force distribution across the width (see clause 11). 8.2 Local belt traction force variations in the upper strand (carrying side) and in the lower strand (return side) Bolt conveyor installations of appreciable length con incorporate stretches of differing inclinations and loadings. From the point of view of the correct sizing of the belt and of other parts of the installation, the proper appreciation of the course or pattern of the belt traction force along the length of the instalation, and in particular the ascertainment of the magaitude of the extreme values of the force, are very important factors. For the purpose of calculating the forces of the steady and of the non-steady operating conditions (starting, stopping), the force variations F; which apply to the individual sections of length ty with constant parameters dy, e,, ms and mj, must frst be datermined in the upper strand and in the lower strand, inthe direction of travel ofthe belt, before the local belt traction force 7 can be determined by summation of these forces and superimposition of the tensile force (soe subclause 8:3). 8.2.4. Steady operating conditions Belt traction force variations due to main resistances Fyy and slone resistances Feu In accordance with equations (11) and (18) we have: Frum fir 8+ [etki + (rig + mii) cos 8] (28) Feqise 8 (mg i) SIN} 69) {la the case of the unloaded bett strand, mi; = 0} ‘At present, it is not possible to give any precise indications on the values of the coefficients foi and fui in the above equations; these coefficients are dependent on the foading and on the belt traction, amongst other things. As an approxi mation, we can write: fim hanf (40) ' 8) Grimmer, KJ. and Thorman, 0.: Vergleich dor Reibungszahlen von Gummi- und von PVC-Férdergurten gogeniber der Anteiebstrommel Glickauf 103 (Comparison between the friction coefficients of rubber and PVC conveyor belts in contact with the driving pulley. Glickaut 103) (1967) No. 26, pages 1309-1311 10) VDL-Richtlinie 2341: Auswahl der Tragrollen fir GurtfBrderer. (VDI Guideline 2341: Selection of the carrying for bolt conveyors! 11) Vierling, A.: Zur Theorie der Banctérderung, ContinentakTransportbanddenst (Contribution tothe theory of belt conveying. Continental conveyor belt service} No. 8, third edition, Hannover 1972 Oehmen, K.H.: Berechaung der Dehnungsertelung in Férdergurten intolga Muldungsibergang, Gurtwendung und Seilunterbrechung. Braunkohle 31 (Calculation of the distribution of elongation in conveyor belts asa result of the passage over troughs, bait turns (reversals of direction) and rope discontinuity. Brown coal $1) (1878) No. 12, pages 304-402 ers’ 12) oODIN 22101 Page 13 Belt traction force variations due to secondary resistances Fi ‘The resistances Fy; consist mainly of the inertia resistances and frictional resistances Faut, Pen at feeder points, in accordance with equations (13) and (14). Bolt traction force variations due to special resistances Fs, The resistances Fi arise mainly as 2 result of the angle of tilt of the carrying idlers and/or from frictional resistances between the material conveyed and the lateral chutes (see subclause 6.1.4) ‘The following relationship is valid, as a general rule, for the resistances Fags in the upper strand and in the lower strand . as a result of the angle of tilt of the carrying idlers (see equation (19) and notes concerning the quantity ¢ns.): Frat asi" Ma Sin ej 008 Oj> 8 (te + mL) by ay O in the case of an unloaded strand) ‘As regards the resistances Pex; due to friction between the material conveyed and the lateral chutes, equation {20} must bbe used section by section. 8.2.2 Non-steady operating conditions During the starting and stopping process, the magnitude and pattem of the forces generated by the driving end braking devices on the one hand, and the breskaway resistances and resistances to motion of a belt conveyor installation on the other hand result in additional dynamic belt traction forces. These additional forces are 2 function of the following factors if we assume 2 belt acceleration independent of local conditions (see also Notes): = the total pulley peripheral forces F, during starting or Fg during stopping = the total acting resistances to motion (approximately equal to the resistances to motion F which obtain under steady operating conditions) z = the non-driven oF non-braked masses Em moving either in a straight line or with a rotary motion, For the frequently occurring case of the secondary resistances representing only 2 small proportion of the total resistance, the dynamic belt traction force variations Fixaat in the individual section i can be determined as follows with the zi of the belt acceleration a: ‘Stopping 42) inint = 2 (Cais + lg ma = Ls 43) 8.3. Tensile forces and tensile distances ‘Tensioning devices are required for the generation of the necessary belt traction forces (see subciause 8.1} and for the compensation of the elastic elongetions. The magnitude of the tensile forces will depend on the type and local arrange: rent of the tensioning device, and on the operating conditions of the installation which requires tensioning. In view of the design and construction expenses and complications involved, tensioning devices are installed for preference in those positions where the minimum belt traction forces in the steady operating condition are anticipated. In principle, 2 distinction is made between tensioning devices with a fixed take-up pulley and tensioning devices with a flying take-up pulley. Irrespectively of the type of tensioning device, the relationship below exists between the quantities which char- acterizeany given operating condition (identified by an asterisk"): local belt traction forces 7?'tx) and belt traction force variations F(x) (see subclause 8.2) minimum belt traction force Tin inn bl ation fore | steam oe run ane Fun bat etn ove variation 7% ~ Gite put tenn eitanc HeTia) ES Z “The most unfavourable opersting condition must be selected for the calculation used for sizing tensioning devices on the basis of equation (44) (tensile force F, and take-up pulley tensite distence ¢f,). If the tensioning device is installed at the spot where the minimum belt traction force T™ix reigns, the tensile force Fg, ‘at the take-up pulley wil be: Fap= 2: Thin 49) {In cates which deviate from the above, one must additionally take into consideration the force difference between the force at the spot where the teke-up pulley is actually installed and the force at the spot where Tiin reigns. In the case of tensioning devices with a fixed take-up pulley (see also Notes) the mean belt traction force Ts, isa constant parameter, independent of the operating condition: Th = Thin + AT const 4s) ‘This will result in the belt being operated with greater belt traction forces than those required according to subclause 8.1 under operating conditions which deviate from the most unfavourable operating condition. Thin 0TH = B- Exce (ayPage 14 DIN 22101 On the other hand, in the case of te ing devices witha flying take-up pulley (see also Notes the tensile forces will either remain the same under all operating conditions (e.g. in the ease of tensioning devices with a stretching weight), or they will be adjusted to the varying operating conditions by means of “adapted tensioning devices”. In both the above cases, suitably altered take-up pulley tensile distances sf, will result for the compensation of the elastic elongation: s-—e Thin + OTH eB Bice B- Box Jn order to ensure the necessary belt traction forces in every case, even under non-steady operating conditions, this type of tensioning device must exhibit an adequate tensioning sped. . 2b Direction of belt travel Leeconst «an Direction of belt travel i Tale its 1 Tt Head Upper strand: Rear Lower strand Head Figure 3. Belt trection forces in the upper strand and the lower strand of a belt conveyor installation 8.4 Local belt traction forces in the upper strand (carrying side) and in the lower strand (return side) ‘The belt traction forces in the steady and in the non-steady operating conditions of a belt conveyor installation are ecisive amongst other factors for the design and layout of: ~ the conveyor belt = the driving pulleys and deflection pulleys — the distances between carrying idler centres = the transition curves in the case of concave or convex belt conduction = the transition tengths at the start and finish of the conveyor belt troughings = the belt turns (changes of direction. ‘The maximum focal belt traction force likely to arise, which must be taken into consideration for the dimensioning of the belt (see subclaute 9.1) always occurs during one of the non-steady operating conditions. 8.4.1. Non-steady operating conditions For the purpose of determining the focal belt traction forces in the non-steady operating conditions, the minimum belt traction forces in accordance with subctause 8.1, the local belt traction force varia accordance with subclause 8.2.1 ‘and the additional dynamic belt traction forees in accordance with subclause 8.2.2 must be taken into consideration, ‘As regards the local minimum belt traction forces Trin a. oF Trin w. Fespectively, which arise during starting or stopping, respectively, the force Tan a is, 26 2 general rule, the determining one for the calculation of the tensile forees and for the ‘quantity Trin under steady operating conditions. 8.4.2 Steady operating conditions ‘The belt traction forces in the steady operating conditions are determined by the required local minimum belt traction forces in accordance with subclause 8.1, under the most unfavourable loading conditions, as well as by the local belt traction force variations in accordance with subclause 8.2.1, and they have a minimum Trg. However there is, 2 ‘general rule, a greater minimum Trin, dependent on the minima Trin, Of Tminn Which coeur under the non-steady con- ditions, and dependent also on the type of tensioning device used. This consequently results in higher belt traction forces ‘than those required under the steady operating conditions in accordance with subclause 8.1.eh Ay DIN 22101 Page 15 , 9 Design and layout of the conveyor belt “Tho tension members and cover plates of a conveyor belt must be selected according to the operating conditions. Their specification will be governed to 2 considerable extent by the characteristis of the bulk material conveyed (physical and chemical characteristics, grain structure) and by the application conditions of the belt (environmental influences, planned service life duration, mechanical stresses, e.g. at the feeder points) 9.1 Nominal rupture force *) ‘The following factors must be taken into consideration for the determination of the required nominal rupture force of * the belt ky = loss of strength in the belt joint rer, = maximum belt stress has in the steady operating condition, and associated safety factor Sas — maximum belt strese Raga in the non-steady operating condition, and associated safety factor Sinsa Each of the following equations must be satisfied for the determination of the nominal rupture force of the belt: Ane 38) a) ‘The values in accordance with table 7 below, which are valid for the static stresses according to the present state of the art, must be entered in the above equations for the loss of strength rvew- (On the other hand, the safety factors S.za and Sina, which are related to the rupture force in the joint, take into con- sideration the additional stresses which have not been encompassed or which are not capable of being encompased at the present time, The lsst-mentioned are taken into consideration in the form of reductions ro, ry and ra from the rupture force in the joint, in accordance with table 8: 1 Su eo 0) = Gott m2) 7 1 Seu 1 WF - Table 7, Veluet of lose of rupture foree ryexy in belt joints under static stressing Mat of ply") ‘Type of joint ew Non-disconnectable joints pcienaty Simple stepped joint (multilayer belts) ————> | fay, P Ipolyrnide) Joint with no loss of ply) 0 © (polenta) Belts with one ply (single ply} ~ —>| y ny Ain ae SSS Lea wT NS Idealization of the equivalent cross section of fill in {dealization of the equivalent cross se accordance with DIN 22 101 accordance with ISO 5048 6) Funke, H,: Zur Neufassung der Berechnungsgrundlagen fir Gurtférderer nach DIN 22 101, frdern und heben 28 (Comments on the new formulation of the caleulation principles for belt conveyors in accordance with DIN 22 101, conveying and hoisting 28) (1978) No. 13, pages 913-918, VYDIN 22101 Page 21. Reduction factor oe When using the determination equation (8), it must be borne in mind that the equivalent engle B = 18° used in large umber of calculations of the cross section of fill, represents a precautionary valve. In order not to be placed in the position of assessing far too low eross sections of fill by using this value in the case of inclined installation, it will be recessary to calculate the factor @s. which is dependent on the inclination, with an angle of slope ayn which accurately actual dynamic conditions. In borderline cases, e.g. for very low conveying speeds, and consequently close approximation to quasistatic conditions, the value of fayn can come close to the static angle of slope (the angle of internal static frietion). if accurate values are required in borderline cases, such values must be determined by tests under conditions which approximete the true application conditions as closely as possible. In DIN 22101, February 1942 edition, there was 2 table for the factor t (which is now designated gy in this standard) Which featured values situsted between 1,0 and 0,56 in function of the angle of inclination 8; however, the dependence fon the angle ayn andi on the shape of the belt trough was not indicated. Intensive investigations have now established that the values mentioned were based on a three piece carrying idler arrangement (troughing angle 4 situated between 20 and 30°) with carrying idlers of equal length, and it was possible as a result to relate the measured values to the angle Baye * 27,5° with the aid of equation (9) #5). Re subelause 6.1.1 “The main resistance of the upper strand and the lower strand consists of the following: rolling resistance of the carrying idles, fulling resistance due to belt penetration on the carrying idlers, oscillating flexure of the belt and fulling of the material conveyed. This main resistance is, therefore, a function of the traction force, speed, loading, width, troughing, and technological properties of the belt, and in addition of the diameter and spacing of the carrying idters, and also of the properties of the material conveyed and of the environmental conditions of the conveyor. The hypothetical friction coefficient / which characterizes the magnitude of the main resistance has 2 value of 0,020 in the case of conventionally designed installations which are operated in the nominal load range (filling ratios p situated between 0,7 and 1,1}: it can assume higher values in the following unfavourable cases: = in the case of conveyed materials which have a high internal friction = in the case of the following operating conditions: very dusty, wet and/or sticky = in the case of ambient temperatures lower than 20°C, the case of troughing angles A > 35° — in the case of belt speeds v > 5 m/s = in the case of carrying idler diameters < 108 mm = in the case of belt sags hae > 1% in the case of carrying idler spacings 1p <1 mor fy <3 m in the case of belts fitted with thick and soft cover plates in the case of incorcectly aligned installations Re subclause 6.1.2 When determining the frictional resistance between the material conveyed and the lateral chutes in the acceleration zone of @ feeder point, the coefficient csen must also be taken into consideration, in conjunction with the Rankine fector ‘of the chute (for indications on the magnitude of ayn, See notes relating to the reduction factor ¥g,). This coefficient characterizes the increase in resistance caused by the additional pressure on the chute walls as a result of the dynamic pressure of the mass flow fed in. The coefficient cgany. therefore, has a value equal to 1 for a transfer height of zero, and it increases gradually as the conveying speed and the drop height increase. When designing conventional types of belt con- vveyor installations, the product Csens » Crank is, therefore, entered as equal to 1, and when designing bin or hopper drawing belts with great loading heights, the coefficient cseny is entered as equal to 1. Re subolause 6.1.4 Resistances which only occur in certain given types of belt conveyor installation constru resistnces. In contrast to the secondary resistances, they cannot be encompassed by means of s lump sum or oversi characteristic value. Special resistances within the meaning of this definition include the resistance as a result of the angle of tilt of the carrying idles, the resistance along material guidance skirt boards and the resistance of equipment for the delivery of material along the path of the conveyor (see notes relating to the reduction factor Ysq for the determination Of the angle Baya in the Rankine factor Cpank)- Re subclause 8,2.2 A belt conveyor installation on which the rate of increase of the pulley peripheral forces is limited during the starting or stopping procedure, and on which the belt is in motion in the entire installation, exhibits a belt acceleration which is independent of location; it behaves in a quasi steady-state fashion, and enables the dynamic additional F5) See Page 20Page 22 DIN 22101 forces to be determined as mass forces. If one intends to calculate the non-quasi steady operating conditions of a belt Conveyor instaliation, e.g. the breakaway process, it becomes necessary to determine the dynamic adlitional forces which arise in this connection with the aid of very complex calculation methods (see footnote 7 in this connection). Re subclause 8.3 [As regards the calculation, a distinciton must be made between 2 tensioning device with fixed takewup pulley and a tensioning device with a flying take-up pulley. Tensioning devices with 2 fixed take-up pulley are devices on which the position of the criven and non-driven pulleys remeins unaltered for every operating condition of the conveyor. The desired adjustment of the tensile force is ftfected for example by means of spindles (screws) or jacks. Depending on the prevailing operating condition, a fixed take-up pulley will result in varying fores at the tensioning location, Conversely the total ofthe local belt elongtions in the upper strand and the lower stnd will remain constant; itis equal to twice the take-up pulley travel during the tensioning process (take-up pulloy travel tf) Lahn 2- shy = const Tensioning devices with a flying twkeup pulley are devices which generate tensile forces which are ether indapendent of the operating conditions, oF which are practieally constent, oF which ar suitably matchad to the pre- Veiling opersting conditions. This is achieved for example with the eid of stretching weights, pneumatic or hydraulic devices ane foree-controllad jacks in the caso of take-up pulleys with an adequate travel fifty. Their mode of operation is, therefore, characterized by the fact that the total of the local belt elongetions in the upper strand and the lower stand, and consequently the take-up pulley travel vary in magnitude: Loh {A linear celationship between the elaticelongations and the belt traction forces related to the belt width i assumed as 2 simplification for the ealeuation of Ali, 2 a general rue, and this is expressed by means of a mean modulus of elasticity forall the foad-bearing belt plies Exc. + Sp econst Re subclause 9.2 Because the relevant DIN Standards contain no date regarding the selection of the cover plate thicknesses, recommenda- tions in this respect have been incorporated in this standard. ‘The cover plate thicknesses on the pulley side of the belt are determined to a great extent by the tension bearer, whilst the plate thicknesses on the carrying side of the belt are determined mainly by the stressing of the belt by the material conveyed, and consequently by the following influencing quantities = nature of material conveyed: particle size and particle shape, density, abresiveness — leading conditions: drop height, resilience of the belt support, difference in speed between conveyor load and belt = loading frequency: frequency of belt circulation and planned operating time of belt, number of feeder points ‘The thickness of the carrying side must be at least equal to the thickness on the pulley side of the belt. In view of the resistance to motion of a belt conveyor installation, the cover plate thickness on the pulley side of the belt should be kept as low as possible. Re clause 10 ‘This clause has been incorporated in this standard because the relevant standards on conveyor belts do not contain any data on the minimum pulley diameters. It applies to the following: ~ conveyor belts with steel cord plies in accordance with DIN 22 131 Part 1 (Preliminary Standard) to Part 4 (Preliminary Standard) = conveyor belts with textile intermediate layers = conveyor belis with textile jn accordance with DIN 22 102 up to 20mm core thickness and up to 0,8 mm thick in aocordance with DIN 22109 Part 2. Explanations ‘This edition of OIN 22 10% represents a complete revision of the February 1942 edit belt conveyor installations have been expanded in respect of content by dete relating to the design and layout of the flriving system, by the calculation of the belt traction forces and of the tensile forces, and by the design and layout of, ‘transition curves and of transition lengths; in addition, these principles of calculation have been refined in accordance with the present state of conveying engineering practice. The equations are in principle presented in the form of quentity equations. 7 The formal structure of the standard has consequently been subdivided as follows, in accordance with the conventional ‘calculation procedure for the design and layout of belt conveyor installations: = volume flow and mass flow resistances to motion and power requirementDIN 22101 Page 23 ' design and layout of the driving system belt traction forces and tensile forces design and layout of the conveyor belt minimum pulley diameters layout of transition curves end of transition lengths “The above subdivision enables the code of practice to be used for certain clauses or sections only, if so desired. ‘The following ISO standards have been taken into consideration for the revision of this standard: . 1s0 5048 — 1979: Continuous mechanical handling equipment — Belt conveyors with carrying idlers ~ Calculation of ‘operating power and tonsile forces ‘The recommendations contained in the above dacument for the determination of; = the flow of material conveyed and the troughing cross section — the resistance to motion, the driving force and the power requirement = the belt traction force ‘are in accordance with the contents of this standard, with the following important exceptions: Im the ISO document, the cross section of fill of 9 troughed belt is composed of an equal sided trapezium or isosceles ‘triangle surmounted by 2 segment of circle, In this standard (see clause 5), the upper portion of the cross section of fill is idealized in the form of an isosceles triangle, in accordance with the German technical literature !), In the ISO document, the reduction factor lt for the reduction of the theoretical cross section of fill of horizontally in- stalled conveyor belt installations has been adopted for the calculation of the eross section of fill on inclined installations; this reduction factor F originates from DIN 22 101, February 1942 edition. However, this factor is a function not only of ‘the inclination of the installation but also of the dynamic angle of slope of the material conveyed, and consequently the reduction factor gsi, which takes both these influences into account, has been adopted in this standard (see clause 5) 18). According to the recommendations contained in the ISO document fer the calculation of the secondary and special resistances, the resistances due to the belt cleaners are deemed to be special resistances. However, as belt cleaners form part of the standard equipment of beit conveyor installations for bulk materials, the associated resistances have been allotted to the secondary resistances in this standard (see clause 6). 10 3870 — 1976: Conveyor belts (fabric carcass) with length between pulley centres up to 300 m, for loose bulk mate ials ~ Adjustment of take-up device In the above standerd, recommendations are given in respect of installations with distances between pulley centres up to 300 m and with belts with textile plies (fabric carcasses) on the required degree of adjustability of the tensioning device, ‘which are bated on overall (lump sum} values for the “permanent” elongation and the elastic elongation of belts with textile plies, With the aid of the relationships featured in this standard (soe subclause 8.3) it becomes possible to calculate with reasonable accuracy the elastic elongation of the belt and the associated take-up pulley travel in function of the pattern of the bolt traction force and of the belt characteristic quantities, 10 1120 ~ 1976: Conveyor belts ~ Determination of strength of mechanical fastenings — Static test method ‘The contents of the above standard correspond for the most part to the contents of DIN 22 110 Part 1 ~ Conveyor belts ‘with toxtile plies, determination of the static strength of belt joints (see subclause 9.1). ISO 3686 — 1976: Conveyor baits — Determination of minimum pulley diameters for belt conveyors ‘The recommendations contained in the above standard for the determination of minimum pulley diameters for belt con- veyor installations have been incorporated in this standard in more coneise form, and thei field of application has been restricted to the belts with textile and steel cord plies currently in use (see clause 10). 10/18 5293: Conveyor belts ~ Formula for transition distance on three equal length idler rollers ‘The above draft gives somewhat more detailed recommendations for the determination of the transition lengths than does this standard (see subclause 11.2], but ia principle it fs based on the same simplifying assumptions which were first made by Laier 16), Because the contents of this ISO document have not yet been officially released in their final version, it has not been incorporated in this standard. 5) See Page 20 16) Laier, O.: Ein Versuch zur rechnerischen Erfassung der 2usitzlichen Dehnung in der Muldungsetrecke von Férder- gurten, Braunkoble, Warme und Energie 18 (Attempt at the determination by calculation of the additionel elongation in the troughing section of conveyor belts. Brown coal, heat and energy 18) (1966) No. 1, pages 14-19.