Int. J. Mech. Sci. Vol. 30, No. 5, pp. 333-345, 1988 0020-7403,88 1;3.00+.

00
Primed in Great Britain. ~ 1988 Pergamon Press plc

SHELL STRENGTH OF CONVEYOR BELT PULLEYS: THEORY

AND DESIGN

Lu HONG-SHENG
Department of Mechanical Engineering, Xian Institute of Metallurgy and Construction Engineering, Xian,
Shaanxi, People's Republic of China.

(Received 16 November 1986)

Abstract--ln this paper, having established a new model according to the classical theory of shells, the
author has derived a group of analytical expressions for the displacement, stress resultants and stresses
in the shells of the driving and driven pulleys of a conveyor belt system. They show clearly the relations
between each parameter and the stresses. This supplies a theoretical base for accurate calculation. The
numerical results of two examples have been calculated by computer.

NOTATION

longitudinal coordinate of the cylindrical shell

tangential coordinate of the cylindrical shell
normal coordinate of the cylindrical shell
radius of the middle-plane of the cylindrical shell
relative longitudinal coordinate of the cylindrical shell, ct = ~'/R
relative tangential coordinate of the cylindrical shell, fl = [3'/R
relative normal coordinate of the cylindrical shell, ), = 7'/R
L distance between two spoke plates
0t1 relative distance between two spoke plates, cq = L/R
B longitudinal width of the loading area
q relative longitudinal width of the loading area, q = B/R
NI, N2 longitudinal and tangential membrane forces
QI, Q2 transverse shear forces at the cross section and at the longitudinal section
S12, S21 longitudinal shear forces at the cross section and at the longitudinal section
Mr, M2 longitudinal and tangential bending moments in the shells
Mr2, M2t longitudinal and tangential twisting moments in the shells
X,Y,Z intensities of the longitudinally, tangentially and radially applied loads
u,v,w components of longitudinal, tangential and normal displacements
E modulus of elasticity in tension and compression
v Poisson's ratio
h thickness of the cylindrical shell
C geometric parameter of the cylindrical shell, c 2 = h2/12R 2
V2 Laplacian V 2 = ~2/C'~t2"4- (32/~fl 2
FI~, ~) displacement function
Am.n coefficient of displacement double series
nm.a coefficient of applied load double series
friction coefficient between belt and pulley
D rigidity of the cylindrical shell D = Eh3/12(1 - v 2)
Zs, Zx tight and slack side tensions of the belt at the driving pulley
wrap angle of the belt
~a longitudinal stress of the cylindrical shell
tT# tangential stress of the cylindrical shell
shearing stress of the cylindrical shell

1. I N T R O D U C T I O N

The pulleys (Fig. l) on belt conveyors are key parts of a conveyor [1]. The thickness of the
pulley shell is calculated by a simple empirical formula. Although calculation by this method
is simple, a good economical design could not be achieved.
For calculation of the stresses in the shell of the driving and driven pulleys, the method of
finite elements cannot show clearly the relations between each parameter and the stresses.
Analytical methods are not used in practice.
333
334 Lu HONO-SHENG

/ f //////~/ / / / /~rZ-q

///////////////

FIG. 1. The pulley of welded construction. 1 shell of the pulley: 2 spoke plate: 3 wheel hub.

In this paper, having established a new model according to the classical theory of the shells,
a group of analytical expressions for the displacement, stress resultants and stresses in the
shells of the driving and driven pulleys is derived. They not only show clearly the relations
between each parameter and the stresses, but also show that a useful economic benefit can be
achieved by using the approach.

2. C A L C U L A T I O N OF THE DISPLACEMENTS AND STRESS RESUL~rANTS IN T H E

SHELLS OF THE DRIVEN PULLEY

Bend pulleys, tail-tightening pulleys and angle pulleys belong to the class of driven pulleys.
There is hardly any difference between the two pulling forces of the driven pulley belt. The
tight side tension is slightly greater than the slack side tension at the driven pulley. These two
tensions are regarded as the same, in order to simplify the calculation. The wrap angle of the
belt at the driven pulley is fl~, where flj = 7t + rio.
By considering the value of B to be approximately equal to the value of L, the applied load
can be expressed as:

['0, when ~ 1 >~~ ~>O: ~/'2 + flo < fl ~-<-7z ]

Z(a, fi) =]Z/RB," when ~ ~ ~ ~ 0; - ~/2 ~ fi ~-. ~/2 + flo). (1)
[0, w h e n ~ ~ > ~ > 0 : - n < C f l < - n / 2
The upper spoke plate of the cylindrical shell is used as the initial point for a (a is taken to
be positive when it is down as shown in Fig. 2); the horizontal centre line of the cylindrical
shell is used as the initial line for ~ (fl is taken to be positive when it is counter-clockwise: it is
an angle coordinate whose units are radians), zq = L/R:q = B/R.
The pulleys are rolled from steel plates, then welded at the contact edge. When the driven
pulley is operating, the cylindrical shell is not able to undergo plastic deformation, so that the
loading calculation for a driven pulley is regarded as a bending problem of an elastic
cylindrical shell.
The ends of the cylindrical shell are regarded as simply supported in order to simplify the
calculation. The normal cylindrical coordinate system of the three directions is shown in
Fig. 3.
When there is radial load Z(X = 0, Y = 0) only, the equilibrium equations can be
expressed in terms of the displacements U, V, W at the middle plane of the cylindrical shell,
and can be written in matrix form as follows {see Ref. [2]):
d2 l - v d2 l+v d2 (
?~ 2 + 2 ~1~2 ") C,3(Cfl V
l + v ?2 ~2 1--v ~.2
t2)
= G
?
--V -- c 2 V 2 V 2 q- 1
 Shell strength of conveyor belt pulleys 335

Z /.L.

Upper spoke plote

/
/
,i--

.,i---

,,l----

Q r

2R
a

FIG. 2. Equal pulling forces at the ends of the belt.

t~

' ---/ ! 1 o2

~MI2 QL

cl
FIG. 3. Internal forces in the shell.

A d i s p l a c e m e n t f u n c t i o n p o t e n t i a l F = F(ct, fl) can be used as follows:

633F ~3 F "

6~3F (~3F
v= ~ + (2 + , , ) ~ (3)

W = V2 V2F

S u b s t i t u t i n g into e q u a t i o n (2), the first t w o e q u a t i o n s are satisfied identically and the last
o n e is satisfied p r o v i d e d that
1 - v 2 O4F R 4
V2 V2 V2 V 2 F + C2 0~ 4 -- D Z(~t, fl). (4)
336 Lu H ONG-SHENG

Substituting e q u a t i o n s (3) into e q u a t i o n (2), we find that the stress resultants can be
expressed in terms o f F as follows:

Eh ~4F
N-
R ~o{2cfl 2

Eh ~4F
N-
R ?cd*
Eh d4 F
S- R d~3Pfl (S= S 12 = $21)

M1- R 2D(i~2 +v~

(~2) v2g2F
.. (5)

Me = - R 2 \ d f l e + ' ? ~ ) V ViF
D(I - v) d 2
MI 2 = R 2 d~dfl v2 v2 F

D d
Q -- R3 (~ V2V2V2F

Q . . . .D . ~ V 2 V2V2F
R 3 013

If the b o u n d a r y o f the closed cylindrical shell is simply s u p p o r t e d , F(~, fl) is in the form o f a
d o u b l e F o u r i e r series. Intrinsic functions o f ~ and fl are taken, respectively, as follows:
sin(mn~/ex l)andcosnfl(~l>lT>lO;nl>fl>-n)andm= 1 , 2 , 3 . . . . . n = 0 , 1,2 . . . . Thus
F(:~, fl) is expressed as follows:
J ,
Fl~,fl)= ~ V A,~,sinm~cosnl:;. {6t
m 1 n 0 0{1

The applied l o a d Z(c~, fl) is also expressed in the form o f a d o u b l e F o u r i e r series:

=
+. +. B,... sin - - - cos nfl. (7)
m 1 n 0 ~1

After simplifying, we find:

R4 * ' sin(mnc~/~)cosnfl
(8)
f ( ~ , fl) = D ,.~'l n=0

O w i n g to the o r t h o g o n a l i t y o f t r i g o n o m e t r i c functions and from e q u a t i o n (7), we find:

Bin. 0 - Z(c¢ fl) sin mn~ dc~dfl

~0~1 - n 9{1
(9)
Bm.n - 2 f = ' f = Z ( c ¢ l l ) sinmn--~..cosn/3dad/3
~1 0 n ~1

Substituting equation (1) into e q u a t i o n (9), we find:

2Z sinmn mn(n +fio~ ]

B,..o- nmRB 7-- s i n 2 \ ~ /
(I0)
B,,, -
• n2RB mn
sin--
2
sm - - -
2
sin n
i7 )+ flo + sin
 Shell strength of conveyorbelt pulleys 337

After simplifying, we find that the displacement expressions are:

/ , o \

U(oq fl) -- 2ZR2~ ~ vsln~-sln~-cos oq

rtDq ,.=1 m2[-fmrt~21| / 1-v2q

2 mrc . mn mrr~
~sin
~ - c ~-sln
o s +/ | n~l"] 4+ [ (7)
,,,=1,,=1 - - ---- 1~,v23 sinn +30
L\~I mTr / c2 J

+sinn~]c°snflI(°qn~2-Vl}L,,m
)n (lla)

4ZR2ct2 k k (2+v)
V(o~,fl)- lr4Dq m=l.= l \~,/
mR" . m~ . mll:o~ .

sin2-sln2-sln ~1 slnn3 I (rt) mr]

s,n,, (llb)
L \ 04. mrt / ~Y- J

2REZ t -~ fr~+flo"~
t ~ ) s l n • ~mrt . ~mrt-sIn
- sin . mrtoc

Wic<'lS)=~D~ ,.=1~ m[-(m~'~+l_,,=l ~I

Lt, )
+ ~ Y~ ~2 sin mrc . mTr mrrct
~ - sin ~ - sin ~1 cos nfl

"='"='mn[(mrt+n2cq) <*+ l-v=l/Fl + ("~<,'~l ~

L\Oq mTr / <~ JIL ',,~-~/j

. [sin,.(+,o)+sinTll (llc)
/
After using equations (5), we find that the expressions for the stress resultants are:
sin ~ - s i n - ~ s i n cosn/7
Nl (ct, fl) = 48(1 - - v2)RZot 2 k n C~1
rt4h2q =,n=lmm2p(mrc+n2oq) 'l'+~jl-v2~
L\ ~1 mTr

x [sinn(7+fl° ) x s i n 2 ] } (12a)

fr~+flo'~ • mrc . mrr mzt0~

N2(ct, fl) = 24(l_v2)RZ t~)sin~-sln sin-- ~c ~ - 0Cl

r~heq m=l~ mp("'~'~'+l-ve]

 II
× +
"~ r--I
r
II ~ I=
× I t~ i~ [ ' ~ J ~

~q~j + ~ ~ ii
X
X ÷
r - - I
× i~
i-o
+ ~ I i
t~
+
~i~ ~ - ] ~ + t-Jl~

~ + r - - l i
--. ~1= I ~1~
/'~--i i
~i~ I t~
~i~ ~ + i.~ ' ~ ~ _ _ i
+
~ +

bJl~
_ _ J
+
J ~ Y
+ ~ ~ '-
~i~ "~
~I I i +
i~

r--n!
y
+ :

t~
!-J

PJ t-J
r,
 Shell strength of conveyor belt pulleys 339

3. CALCULATION OF THE DISPLACEMENT AND THE STRESS RESULTANTS IN

THE SHELL OF THE DRIVING PULLEY
The pulling forces at the ends of the driving pulley belt are significantly different from each
other; the tight side tension is much greater than the slack side tension [4], as shown by:
Z s = Zxel,//, = ZxeUln+l~o).
W h e r e / / i s measured as shown in Fig. 4, i.e. w h e n / / = - g/2 (nadir), belt tension = Zx;
when fl = n/2 + flo, belt tension = Z s = Zxe~+~°~.
Applied load is expressed as:

0, when ~l > ~ > 0 ; ~ + f l o < f l ~ < n

jZ x n n
Zs(~, fl) = RBe~'('/2+I~),when 71 > ~ / > 0 ; -~<~/3~<~-+f10 (13)

{ 0, w h e n ~ l > ~ c ~ > 0 " - n ~ < f l ~ < "

~

After using equation (13), we find:

Bmo - 2Zx 1 [e.(~+/~o) - 1 ] s i n m n mn (14a)

n2RBm It ~ - sin ~ -

4Zx lc°sU'sinmn mn~ (2 ) (nn)]

B,,.n-n2RB # m ~sin 2-LeJ't~+/~")cos +nflo-Ul -cos ~-+ul ,
(14b)
where u~ = arctan n/~.
In the same manner as discussed above, we find the calculated expressions of displacement
in the cylindrical shell of the driving pulley under the applied load:
2R2Zx ~ mn mn mnc~
U(~, fl) - n2Dqp ,-- sin 2 - - s i n 2 - cos
m=l
~1

~7s

Upper spoke plate

\
o \

I:Ir

FIG. 4. Unequal pulling forces at the ends of the belt.

340 Lu HONG-SHENG

- v-~l-[e ~'l'~+/~o~- 1]
Lk n / \ m / n _1
xI ~ ; ,--,~ ~-2 n:Sl [(mT[ + n2~.!~ 4 _ !:::2 ]
L \,:~ , mn / c2 J

)
x .lt cos.,,1 (15a)

v(~, fit)
4 R 2 Z xD~q2# -- --"
, f: , f ,:
[ 2 + ,, +(n']=(7,]=]
\my \n/

mn mn mn7 .
ncos ul sin ~-- s i n ~ - s i n - - -sin nfit
Z Z O(I

L\ ~
+--m n +i.2 ]

(15b)

" 1 m n . m n . ran7
2R2Zx ~ rosin ~ s m ~ sm
W ( ~ , fit) -- n 2 D q l t ,.= l - - ~1

I e tdn+/~°)- 1 ~
= F[mzt 2
cos
a.
U 1 COS

l_v2~
nfit
/,F
L~, j ,~ _, +-c- J,,/L'\ m n /

(15c)

In the same manner as discussed above, we find the calculated expressions of the stress
resultants in the cylindrical shell of the driving pulley under the applied load:

Nl(°qfit) 48(l_v2)RZx~ 2 ~ , (n,eSin~-sln~ sin ~ - COSUlCOsnfit

L \ O~l mR: / ('" J

N2(7, fit) = 24(1 - v 2)RZx S_? r ["eei,l~+/~,,~-

"'i~ 1] ,~sin" m n . sin m n cos m n ~
n2h2q# ,,,-, m | [ m { ' ~ ' ~ _+ l -v" _ 2 2 ~,
L\~,/ F I

/1/7I" m~ m~
sin - - sin - - - cos
" 2 2 ~1 |ei,l~ +/~,,~cos ( n n nfito-., )
 Shell strength of conveyor belt pulleys 341

(n~
--COS ~ - + U 1
)]} (16b)

sin ~ - s i n ~ - c o s -cos ul sinnfl

48(1 - v2)RZxCtl ~~c ~. n CX1
S(=, fl) =
~z3h2q1.1 m=ln=l m2[( m~z_+nn2.cz,)x4+_l-v2 1
L\ °(1 mlr / c2 J
x
I e~'(~+Bo)cos
(~;+nflo-ul ) (~÷)J --cos +u~ (16c)

M I ( ct, fl)
2Z x
- a2qp
~ mzr. mzr.
msin~-sm~-sm
mrc~
al ~
[~](e~'t~+IJ°'-I
i

4 1 --V 2
=~ m~ + ~ c
\0~1 /]

)1}
+ 2 1+ -- - -

n=l \7[/ \m/ A

X COSUl COSt/fl
i~,,,,+,,o,,cos(~+n,o_u,
_cos(~_+
~4 ( -L~ +x , nW
nl~
- ~ 1) + )1
- ~--v27
- - - [ nT~ Ul (16d)

- 2Z x ~ m s i n ~mTz
- s i n ~ -mTz
sm " mTt~ ( v[eÈ(~+~°.)-l]. ___lc
2 - v2 + 2 ~ I v + (~)2(n)21
M2(°~, fl) 0~21q]A m~,__1 (X 1 ()'@'/~
"~4 q n_~,l
\cq /

Ie,U(~+flo)cos(2 --~-r/flo-/.,/1t - cos(2 -{-u1t I t

M,2( °~, fl) _ 4(1 - v)Z x = +, - - s i n ~ -mlt cos mTrct

-~ n s i n ~mn
V ~1
rcq~lP m=t .=l

~ ~)+~

4. CALCULATION OF THE STRESSES IN THE CYLINDRICAL SHELL ON THE

INTERNAL AND EXTERNAL SURFACES
T h e stresses in the shells on the internal and external surfaces are greater than the stresses
in the m i d d l e plane o f the shell at the same point.
The stresses in the cylindrical shell on the internal a n d the external surfaces can be
342 Lu H ONCr-SHENG

expressed as:

N1 6M1

N2 6M2
(17)
a~= h- _+ h 2

S 6M12

The plus sign is taken for the internal surface, the m i n u s sign is taken for the external surface.
The stresses change sign 2~i times per circumference and change from tension to
compression at the radial section of the outer surface at m i d - p o i n t of the cylindrical shell.
The stress curves shown in Figs (5) and (8) are similar to the stress curves of the outer shell
of the pulley in the belt conveyors, which were calculated in West G e r m a n y by the T P S 10
type p r o g r a m of the finite element method [3].
According to customary rules, the allowable stress of the cylindrical shell is:

m.x [,q,
where[a]=50Nmm : =50MPa.

5. EXAMPLES
Example 1
Basic design data for the cylindrical shell of the driven pulley are: R = 595 mm, L
= 9 0 0 m m , Z x = 132,480N, v = 0 . 3 , E = 2 1 0 × 109Pa,/3 o = 2 0 ' , f l ~ =z~+/3o = 180 + 2 0
= 200 ° = 3.49059 rad, # = 0.25, B = 1000 mm, h = 12 mm.
Calculation results. The principal stress a2 has a m a x i m u m value at /3 = 1.4833 rad., (i.e.
/3 = 85 °) a n d c~ = 1.0084 (i.e. L = ~R = 1.0084 × 595 = 600 mm).

a2max = 30.7 M P a ~<[ a ] = 5 0 MPa.

The curves of the principal stress a2 at a radial section on the outer surface of the
cylindrical shell are shown in Fig. 5, the curves of the principal stress a2 at the section are
shown in Fig. 6 a n d the curves of radial displacement at the axial section are shown in Fig. 7.

Example 2
Basic design data of the cylindrical shell of the driving pulley are: R = 595 mm, L
= 900 mm, Z s = 144,060 N , E = 210 x 1 0 9 Pa, v = 0.3,/30 = 40':,/3~ = n+/3o = 180 + 4 0
= 220 ° = 3.83959 rad, B = 1000 mm, h = 6 mm.
Calculation results. The principal stress a : has a m a x i m u m value at /3 = 1.3960 rad. (i.e.

(0") (0")
(40"~~~__~.~40.) ( 4 0 " ~ ~40 )

. ~ J ..~ 54.0 MPa ~ ~ ~ 5.59 MPa

c -t.sg o \(12o° (,2ool "112°°1

(140") / 1(180.I \ (140") 1(140)

n*w
4 0 . (180")
ri ~ \( )
(a) a-0.2522 (b) a-0.7563

FIG. 5. The curves of the principal stress a2 at a radial section on the outer surface of the cylindrical
shell.
 Shell strength of conveyor belt pulleys 343

/
OI - 3 , 5 5 -28,4 -29.6 -30.2 -29.6 -28.4 -3.55
i
-I0 i~ -27.9 -28.8 -30.1 -30.1 -28.8 - 27.9

-2o1- \

/9 =40*
-30I_
-4~ ='~'" ~ 0"--" ~ ° '

-I0 I 1.8 -35.5 -40.3 -41.9 -40.3 -35.5 -11.8

-20

-30

-40
B ,80"
-50

0.1261 I 0.3783 I 0.6305 I Q8823 [ 1.1324 I 1.3865 I

0.2522 0.5044 0.7563 1.0084 1.2605 I. 5126

FIG. 6. The curves of the principal stress a2 at an axial section on the outer surface of the
cylindrical shell.

0,2 -- 0.113551 0.134685 0.141089 0.154685 0.1t3551

0.I

0 t (:1
0.192267 0.270272 0.294521 0.270272 0.192267
E
0.3
0.2

0.t

i 0.5044 I 1.0084 i 1.5126

n (:1
0.2522 0.756.], 1.2625

FIG. 7. The curves of radial displacement W at the axial section.

(0*) (0*)
(20°) ~ ~20") (20")~,200)
( 4 0 " ~ 40") ( 4 0 " ~ 4 0 " ) .

(,0%
,,2oo,~.\ ~_.,.~ ~,9,9M~ (,20.,-,,~ j,:~26..Z~,,,~MPo
• (,40o;
(140") ( 1 6 0 " ) ~ 6 0 " ) (140") (160") ] (160") (140")
(180") (180.)
(a) a=0.7561 (b) =-1.0084
FIG. 8. The curves of the principal stress a2 at a radial section on the outer surface of the cylindrical
shell.
344 Lu H ONG'-SHENG

-I0

-20
• )
-30 * e ~ •

-27.4 -30.72 -30,64 -30.72 -2Z4

~ -40
-14.1 -30.6 -30.65 -30.65 -30.6 -141

0 cl
p . . . . . . , o...._ ° "'--- • • • • ° "-"~ ° """'° ~ °

-no _/9=i800 " ~ ~

-2.28 -3.92 -4.61 -3.92 -2.28

-20 - - -I.17 -3.24 -4.4`5 -4,4,5 -5.24 -I.17
0.1261 10.3783 0i630`5 0.8826 1.1344 1.5365
J I [
0 0.2572 0.5044 0.7`561 I .0084 1.262`5 I.`5126

FIG. 9. The curves of the principal stress ~z at an axial section on the outer surface of the cylindrical
shell.

0.068446 0.188647 0.236426 0.236426 0.188647 0.068446

0.3 -0.0 0.139717 0.218683 0.242876 0.218683 0,139717 0.0

0.2

0.1

0 P C1

E
0.3 0.013416 0.036679 0.050147 0,0,50147 0.036679 0,013416

0 . 2 -0.0 0.025927 0.04491 0.0`51936 Q044941 0.02`5927 0.0

0.1

#,. ~8o o

0.1261 I 0.3783 [ 0.630,5 i 0 . 8 8 2 3 I 1.1324 I 1.386,5

0.2522 0.5044 0.7,563 1.0084 1.2605 I.`5126

FIG. 10. The curves of radial displacement W at the axial section.

fl = 80 °) and c~ = 0.7560 (i.e. L = ~R = 0.7560 x 595 = 459 mm). O'2max= 41.9 MPa
~< [ a ] = 50 MPa.
The curves o f the principal stress a2 at a radial section on the outer surface o f the
cylindrical shell are shown in Fig. 8, the curves of the principal stress a2 at the section are
shown in Fig. 9 and the curves o f radial displacement at the axial section are shown in Fig. 10.

6. C O N C L U S I O N S

The author has derived a group o f analylical expressions for the displacement, stress
resultants and stresses in the shells o f the driving and driven pulleys. This supplies a
theoretical basis for accurate calculation.
Once a simple computer program has been written, the stress condition in the shells of the
driving and driven pulleys can be calculated quickly.
 Shell strength of conveyor belt pulleys 345

There is a maximum radial displacement Wmax at the shell centre of the axial section and
there are two minimum radial displacements l'Vmin at the ends of the shell of the axial section.
The useful life is affected by the changing frequency of stress, the magnitude of the stress
amplitude and the location. This is very important for the investigation of fatigue strength.
Computerized calculations show again that the locations of maximum and minimum stresses
are related to the parameters R, L and Z.
After computerized calculations of the data, the displacements U, V and Ware shown to be
accurate to five decimal places, and the stresses are accurate to three when m = 30 and n = 30.
This accuracy of the design calculation is satisfactory, and computerized calculation can
economize on costs. We therefore propose to use m = 30 and n = 30 under practical design
calculation.

REFERENCES

1. LI Yl-Yu, Mining Machinery. The Part on Hoisting and Haulage Machinery, p. 186. Publishing Press of
Metallurgical Industry, Peiging (1980).
2. PENG ZHAO-XING and YIN JI-YING, Theoretical and Experimental Research above the Strength of the Driving
Wheel on Multi-rope Friction Winder. J. North-East Engng Inst. l, 51 (1982).
3. C. LINDER, Use of Program TPS-10ofFinite Element to Calculate on Pulley of Belt. J. Braunkohle, Heft 3 (1975).
4. A. SPIVAKOVSKYand V. DYACHKOV,Conveyors and Related Equipment, p. 112. Peace Publishers, Moscow (1965).