CONVEYOR CALCULATION SHEET draft.xls

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CALCULATION SHEET

No. PARAMETERS SYMBOL FORMULAR VALUVE Unit

BMCR I. INPUT DATA

1 INSTALLATION

Troughing Type 3 roll

Capacity Design Q 1,000 t/h

Conveying Length L 258.0 m

Lift H 17.9 m

Belt Width B 1,200 mm

Belt Speed v 1.68 m/s

Length of middle carrying roll I Idler length if 3 or 5 roll 465 mm

Troughing Angle λ 35 Degree

Incline Angle δ 4.8 Degree

2 MATERIAL

Material Name MEDIUM

Density ρ 1.50

Lump Size mm

Temperature 35

Surcharge Angle β 15 Degree

3 CONVEYOR BELT

Friction Coefficient of Pulleys μ 0.30

-Friction Coefficient of Pulleys at Start-Up 0.35

-Angle of Wrap 1 at Pulley Drive 1 210 Degree

Angle of Wrap at Snub Pulley 1 0 Degree

Angle of Wrap 2 at Pulley Drive 2 210 Degree

Angle of Wrap at Snub Pulley 2 0 Degree

Drive factor 0.50

-Drive factor at Start-Up 0.38

-Drive factor at Pulley -Drive 2 0.50

Drive factor at Pulley Drive 2 at Start-Up 0.38

4 FACTORS

Gravitational Acceleration g 9.81

Effective Degree of Filling φ 0.70

- Degree of Filling Normal working conditions 1

- Gradient of the installation 0.70

-Width Factor 277 kg/m

Length Factor 52

Working Conditions Factor 1

-Efficiency of the drive η For drives with fluid couplings 0.90

-II. DESIGN

1 CAPACITY

Loading width of outer rolls 282.50 mm

Load stream width b 1,030.00 mm

Cross-Sectional Area of load Stream A 0.1705

Cross-Sectional Area of load Stream for 5 roll NA

- Troughing Angle 2 0 Degree

Conveying Capacity

- Theoretical value 1,546.86 t/h

- Effective value 1,082.80 t/h

2 POWER REQUIREMENTS

Power for empty & load over the Horizontal 28.18 kW

Power for Lift or Fall 48.77 kW

Power for trippers, skirtboard friction, ploughs 0.00 kW

Power at Drive Pulley 76.95 kW

Required Motor power 85.50 kW

Slected Motor 110 kW

3 BELT TYPE

Friction Value Factor μ = 0.3 15

Breaking Strength Loss at Joint Factor Number of plies 0.75

Belt breaking strength k 916.12 N/mm

Material (carcase) EP

Nominal Breaking Strength Belt Class 1,000 N/mm

Number of Plies 4 ply

Carrying side Cover thickness 8 mm

Pulley side Cover thickness 4 mm

Cover Quality X

- Belt weight 25.40 kg/m

- Carcase thickness d 5.80 mm

4 PULLEY DIAMETER

Drive Pulley Calculation 626.40 mm

- Type of Belt Material Contruction SUPERFORT (Multiply Belt EP)

- Belt Material Factor 108

t/m3 o_C μA α₁ α12 α2 α₂₁ c1 c1A c₂ c2A m/s2 φ = φ1 * φ2 φ1 φ2 CB C_L m-1 kf I₁ m2 A5 m2 Q_m Qm' Qm' = Qm*φ P1 P2 P3 PT PT = P1+P2+P3 PM P_N CR C_V k_N Cv D'Tr D'Tr=d*CTr CTr

(2)

Tail Pulley, Tension Pulley B 500 mm

Snub Pulleys, Bend Pulleys etc. C 400 mm

Pulley revolutions 51 R/min

5 IDLER

Values for Idler Spacing

- Belt sag ratio 0.01

- Carrying side Application 1.2m 1.2 m

- Return side 2.0 m

Idler Diameter 133.0 mm

- Idler Rotation Not be greater than 650 rpm 241 r.p.m

Idler Length 465 mm

Mass of one set of carrying idler rollers 22.3 kg

Mass of one set of return idler rollers 19.3 kg

III. CALCULATION

1 Peripheral Force at Steady state working

Length Factor C 1.37

Friction Factor f 0.02

Mass of the rotating carrying and return idlers 28.23 kg/m

Mass of the belt 25.40 kg/m

Mass of the load 165.34 kg/m

Main Resistance 12,331.91 N

Secondary Resistance 4,562.81 N

Slope Resistance 29,034.23 N

Special Resistance 0.00 N

- Resistance caused by forward tilt of idler rollers 0.00

+ Carrying side + Return side

- Resistance from skirt places beyond - Resistance due to sideways discharge - Resistance due to trippers

- Resistance from skirting material beyond - Resistance to motion of bunker drag-out belts

Peripheral Force at Steady state working 45,928.94 N

Drive Motor at Pulley 77.16 kW

Required Motor Power 85.73 kW

Motor Power on Braked Installation NA kW

Installed Motor Power Selected Motor Power 110 kW

Min. Belt Tension for Control 28,068 N

2 Peripheral Force at Non-Steady state working

Type of Coupling Hydraulic Coupling

Start-up Factor 1.50

Pre Non-steady state 68,893.41 N

Peripheral Force at Start-Up (Non-steady state) 68,893.41 N

Acceleration 0.368

- Reduced mass of idlers 25.41 kg/m

- Reduced mass of drive elements 0.00 kg/m

- Reduced mass of non-driven (bend pulleys etc.) 0.00 kg/m

Acceleration Time 4.56 s

Acceleration Distance 3.83 m

3 Peripheral Force on Braking state

Braking time s

Acceleration #DIV/0!

Over-run distance 0.00 m

Reduced mass of the non-braked elements or pulleys kg

Non-braked elements force #DIV/0! N

Peripheral Force #DIV/0! N

4 Individual Resistances Main Resistance 12,331.91 N Secondary Resistance 4,562.81 N Friction Resistance - Carrying side 10,596.06 N - Return side 1,774.22 N Slope Resistance - Carrying side 33,494.44 N - Return side 4,460.21 N Inertial Resistance - Carrying side 19,724.02 N - Return side 3240.45 N 5 Belt Tension

A Drive System Single Pulley Head Drive

Runing - Steady state working

- Distribution for Head and Tail Drive NA

- Distribution for Dual Pulley Head Drive NA

-Total Peripheral Force 45,928.94 N

nT

hrel hrel = h/Io

Io Iu Iu = (2-3)*Io DR nR LR m_Ro mRu FU m'R m'G m'L F_H FN FSt FS F_S FSO FSU FSch FL FB FMf FBa FU PT PM PM PN Tmin FA k_A F'A FA aA m/s2 m'_Red m'Ared m'red tA sA tB aB m/s2 s_B mred FT FB FH FN Fo Fu Fsto Fstu Fao Fau x1 x1 = Fo/Fu x₂ FU

(3)

- Peripheral Force Pulley 2 NA N Total Power 77.16 kW - Motor 1 77.16 kW - Motor 2 NA kW Tension 22964.47 N Tension 20278.47 N Tension 20278.47 N Tension 68931.78 N Control 68893.41 N

Start Up - Non Steady state working

- Distribution for Head and Tail Drive NA

- Distribution for Dual Pulley Head Drive NA

-Total Peripheral Force 68893.41 N

- Peripheral Force Pulley 1 68893.41 N

- Peripheral Force Pulley 2 NA N

Total Power 115.74 kW - Motor 1 115.74 kW - Motor 2 NA kW Tension 26455.07 N Tension 27009.52 N Tension 27009.52 N Tension 95386.85 N Control 95348.48 N Braking state

B Belt Tension Correction (1st Adjustment) Correction with Fixed Take-up

Belt tension at rest 33113.30 N

Average belt tension at start-up T 43965.24 N

Correction value for Fixed Take-up 10851.94 N

Belt Tension Correction 79783.72 N

33816.41 N

31130.41 N

Check conditional Satisfied

Correction with Moveable Take-up

Location of Take-up Installed at the Tail

Take-up Tension 40556.94 N

Take-up Weight 4134.24 kg

Correction value for Moveable Take-up 6731.05 N

29695.52 N

27009.52 N

C Control of Minimum Belt Tension (2st Adjustment) 28067.97 N

Take-up Type Moveable Take-up

Belt Tension at Carrying side minimum 27009.52 N

Correction value 1058.44 N

30753.96 N 28067.97 N 28067.97 N 96445.29 N 27513.51 N 28067.97 N 28067.97 N

Belt Safety Factor

Steady state 11.73

-Non-Steady state 9.33

-Take-up Travel

Elongation value of the belt 10.50

-Rest state 1149.45 mm

Steady state 1675.07 mm

Non-Steady state 1843.83 mm

Troughing Trainsition 1686.31 mm

- Factor for carcase x Textile belt x=8 8.00

- Portion of belt in contact w/ side idler rollers s ST. belt x=16 367.50 mm

- Lift of Pulley h 64.55 mm

Reduced transition length 1169.88 mm

Convex Vertical Curve

- Factor for carcase x Textile belt x=125 125.00

- Convex Radius steel cord belt x=400 26.35 m

- Curve Length L 71519.14 m

- Deviation per idler α 2.00 Degree

- Number of Idlers in Curve z 3.00 Pieces

- Idler Picth Io 23839.71 m

Concave Vertical Curve

- Length from loading to curve Lx 40.00 m

- Belt tension at start of curve Tx 29710.77 N

- Concave Radius Ra 145.56 m FU2 PT P1 P2 T2 T2 = FU*c T3 T₄ T₁ T₁ x1A x1 = Fo/Fu x2A FUA FU1A FU2A PTA P_1A P2A TA2 T2 = FU*c TA3 TA4 T_A1 TA1 TM ∆T ∆T = T - T_M T1 T2 T3 T4 ∑T = ∑T_A FV GV GV = FV/g ∆T ∆T = TAi - Ti T₁ T2 T3 T4 TAi = Ti Tmin ∆T ∆T = T_min - T_i T1 T2 T₃ T4 TA1 TA2 T_A3 TA4 Tmin ≤ Ti S_B SA sp kD sp sp sp LM Lred Re

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CALCULATION SHEET

REMARKS INPUT DATA

Use for analysis Select in Table 1 Select in Table 3 Select in Table 31 Select in Table 20 Select in Table 21 Select in Table 22 Select in Table 23 Select in Table 30 Select in Table 24 Select in Table 4 Select in Table 25 Select in Table 26 Select in Table 5 Select in Table 6 Select in Table 7 Select in Table 7 Select in Table 8 chua hieu Appendix C Select in Table 27

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Select in Table 10 Select in Table 10 1% Normal installation Appendix B Select in Table 3 Appendix B Appendix B Select in Table 28 Select in Table 29 chua hieu Appendix E Select in Table 11 FA ≤ 2.5*FU

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26455.0683701915 27009.5229994644 27009.5229994644 95386.8476269095 95348.4755842319 38.37 30752 13213.24 Increased for Running

82145.02 36177.71 33491.71

Inc. for Running

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STANDARD IDLER DIA. (mm)

Carrying Idlers

Impact Idlers

Return Idlers

Support Idlers

300

51

400

63.5

120

500

88.9

138

650

108

156

150

800

133

180

180 1000

159

215

215 1200

193.7

250

250 1400

219.1

290

290 1600

1800

2000

2200

CALCULATION FOR START-UP kA

Motor/coupling type

Rigid Couplings

Flexible Coupling

Hydraulic Coupling

Location of Take-up

Installed at the Head

Installed at the Tail

Take-up Type

Fixed Take-up

Moveable Take-up

STANDARD

WIDTH (mm)

(10)

STANDARD IDLER LENGTH (mm)

Troughing Type

Flat

2 roll

3 roll

Deeptrough

5 roll

300

380

200 -

-

-400

500

250

160 -

-500

600

315

200 -

-600

700

340

250 -

-650

750

380

250 -

-800

950

465

315

200

165 1000

1150

600

380

250

205 1200

1400

700

465

315

250 1400

1600

800

530

380

290 1600

1800

900

600

465

340 1800

2000

1000

670

530

380 2000

2200

1100

750

600

420 2200

2500

1250

800

640

460 Garland (5 roll)

Belt Width B

(mm)

(11)

MATERIAL CARCASE

SYMBOL

PLY MATERIALS

1.5 B

Cotton (Natural fibre)

2.2 P

Polyamide (Synthetic fibre)

3 E

Plyester (Synthetic fibre)

4 EP

Plyester - Polyamide (Synthetic fibre)

5.5 D

Aramid (Synthetic fibre)

7.5 F

Steel Weave (Ferroflex)

11 ST

Steel Cord (ST belt)

15

18.5

22

30

37

45

55

75

90

110

132

160

200

250

315

400

500

630

STANDARD

ELECTRIC

MOTOR (KW)

(12)

COVER THICKNESS GAUGES (mm)

COVEYOR LOAD/DUTY

CARRYING SIDE

125 Light packayge conveying

2

160 Gravel, Earth, Potash etc.

2 - 4

200 Ore, Ballast, Coal

4 - 8

250 Slag

4 - 8

315 Coarse ballast, coarse Ore

8 - 12

400 Large lump Coal

8 - 12

500

630

800 1000

1250

1600

2000

2500

NOMINAL BREAKING

STRENGTH (N/mm)

(13)

COVER THICKNESS GAUGES (mm)

COVER GRADE - DIN 22102 (April 1991)

PULLEY SIDE

COVER GRADE

W

X

Y

Z

2

18

25

20

15 2 - 3

Breaking elongation %

400

450

400

350 2 - 3

90

120

150

250 2 - 3

3 - 5

Tensile strength N/mm

2

_min.

Abrasion loss mm

3

_max.

(14)

Diameter Of Pulley Groups (mm)

A

B

C

100

100 -

-125

125

100

-160

160

125

100

200

160

125

250

200

160

315

250

200

400

315

250

500

400

315

630

500

400

800

630

500

1000

800

630

1250

1000

800

1400

1250

1000

1600

1250

1000

1800

1400

1250

2000

1600

1250

100 ₃

c

-Standard Pulley

Diameter

Pulley

Diameter

DTr (mm)

(15)

Drive location

Single Pulley Head Drive

Tail Drive

Head and Tail Drive

Dual Pulley Head Drive

(16)

For Smooth Belt

Gradient

BELT WIDTH

LIGHT

MEDIUM

HEAVY

2

1

UP TO CA. 1.0

1.0 TO 2.0

OVER 2.0

4

0.99

300

31

36 -6

0.98

400

54

59

65

8

0.97

500

67

76

86

10

0.95

650

81

92

103

12

0.93

800

108

126

144

14

0.91 1000

133

187

241

16

0.89 1200

194

277

360

18

0.85 1400

227

320

414

20

0.81 1600

291

468

644

22

0.76 1800

-

554

727 2000

-

691

957 2200

-

745 1033

WIDTH FACTOR C

_B

φ

₂

(17)

(18)

L (m)

WORKING CONDITIONS

3 667 Favourable, good alignment, slow speed

4 625 Normal (Standard conditions)

5

555

6

526

8 454 Extremely low temperature

10

417

12.5

370

16

323

20

286

25

250

32

222

40

192

50

167

63

145

80

119

90

109

100

103

150

77

200

63

250

53

300

47

350

14

400

37

450

33

500

31

550

28

600

26

700

23

800

20

900

18 LENGTH FACTOR C

_L

WORKING CONDITIONS FACTOR f

_k

C

_L

Unfavourable, dusty, low temperature, overloading,

hight speed

(19)

1500

12

(20)

ADDITIONAL POWER VALUES

BELT WIDTH B

1.17 <=500

1 <=1000

0.87 - 0.74

>1000

Scraper type

0.57 simple, normal contact

heavy contact

multifunctional fac scraper

Material - Skirtboard

beyond loading point

Discharge plough

WORKING CONDITIONS FACTOR f

_k

f

_k

TRPPERS

(throw-off carraiges)

SCRAPERS

(For installations L<=80m)

Bulk density ρ ≤ 1.2

Angle α = 30

o

_{- 45}

o

(21)

(22)

ADDITIONAL POWER VALUES

P (kw)

Drive Pulley Surface

0.8*v

1.5*v

bare, wet

0.15

2.3*v

rubber lagged, wet and dirty

0.25

Scraper type

0.3

0.3Bv

bare, dry, lagged, wet

0.35

1.5Bv

rubber lagged, dry

0.4

1.8Bv

1.5Bv

Friction Value Factor C

_R

Friction value

μ

(23)

(24)

Belt Width B (mm)

300 400 500 650 800 1000 1200 1400 1600 1800 2000 2200

98 74 59 45 37 30 25 21 18 16 15 14

69 52 41 32 26 21 17 15 13 12 10 9

62 46 37 28 23 18 15 13 12 10 9 8

57 43 34 26 21 17 14 12 11 9 8 8

53 40 32 25 20 16 13 11 10 9 8 7

(25)

(26)

Breaking Strength Loss at Joint Factor Cv

DUNLOP Belt Type

Splice Type Ply Rating

DUNLOFLEX

2 ply overlap 100%

1 1 ply overlap 50%

0.5 TRIOFLEX

3 ply overlap 100%

1 2 ply overlap 67%

0.67 SUPERFORT

Number of plies 1

0.7

2

0.5

3

0.67

4

0.75

5

0.8

6

0.83 FERROFLEX

Zig-Zag Splice Joint

0.9 DUNLOPLAST

Finger Splice Joint

0.9 Steel Cord Belts

Splice 1 and 2 step

1 3 step

0.95 4 step

0.9 Various

Mechanical Joints: Refer to Manufacturer

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VALUE CTR

LENGTH FACTOR C

Material of Carcase in Warp or Belt Type

L(m)

C

Polyamide (P)

90

3

9

DUNLOFLEX (2 ply Belt)

80

4

7.6

TRIOFLEX (3 ply Belt)

95

5

6.6

SUPERFORT (Multiply Belt EP)

108

6

5.9

FERROFLEX (Steel Weave Type)

138

8

5.1

SILVERCORD (Steel Cord Belt)

145

10

4.5

DUNLOPLAST (Monoply Belt)

100

13

4

16

3.6

20

3

25

2.9

32

2.6

40

2.4

50

2.2

63

2

80

1.92

90

1.86

100

1.78

120

1.7

140

1.63

160

1.56

180

1.5

200

1.45

250

1.38

300

1.31

350

1.27

400

1.25

450

1.2

500

1.19

550

1.18

600

1.17

C

Tr

(29)

800

1.12

900

1.1 1000

1.09 1500

1.06 2000

1

(30)

0.017 Normal installation, normal material

0.02 0.023 - 0.027

0.012 - 0.016

Note:

With v <> 5 m/s

v (m/s)

Factor c

2

0.8

3

0.85

4

0.9

5

1

6

1.1 With T < 20°C

T (°C)

Factor c

+20°

1 0°

1.07 -10°

1.17 -20°

1.28 -30°

1.47

Horizontal, inclined or slightly declined installations - Motor driven k

(for v = 5m/s and +20

o

_C)

Favourable working conditions, easily rotating idlers,

material with low internal friction and good tracking,

good maintenance

Unfavourable conditions, low temperature, material

with high internal friction, subject to overload, poor

maintenance

Installations with steep declines creating

regenerative conditions

a) With other speeds the following applies:

f = c * f

_5m/s

b) With other temperatures the following applies:

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(32)

Degree of Efficiency

Types of Drive

η

Operating Condition

Wormgear drive

0.7 - 0.8

Toothed chain drive

0.9 - 0.95

V-Rope drive

0.95 Dry

Pulley motor

0.96 Wet (Clean)

Normal coupled drive

0.94

Wet (dirty mud, clay)

Geared and hydraulic coupling

0.9 Hydraulic motor

0.86 Braked installations

0.95 - 1.0

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Pulley Surface

0.35 to 0.4

0.4 to 0.45

0.1

0.35

0.35 0.35 to 0.4

0.05 to 0.1

0.2 0.25 - 0.3

0.35 Friction Coefficient μ

Plain Steel

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