Date: 02nd June 1999 BELT CONVEYOR PROGRAM AS PER IS 11592

1.

DIMENSIONAL DETAILS OF A PROFILE :Calculations of effective tension for following six profiles can be worked out in this program. I. Horizontal ii. Inclined

iii.

Horizontal & Inclined

iv.

Inclined & Horizontal

v.

Horizontal, Inclined & Horizontal

vi.

Inclined, Horizontal & Inclined

In all the above profiles, input parameters such as centre to centre length, lift & inclination (if applicable), have to be entered. After receiving these inputs, the program will give its output in the form of total developed length, total lift and inclination (whatever applicable, respectively). 2. 35o, Various options for troughing angle, used in a program are 20 o, 30o, 45o. Repose angles for various materials will be , with respect to their (material) characteristics and hence surcharge angle with respect to repose angle will be as follows :Contd..2/-

..2.. Angle of Repose 0 - 20o o 21 - 30o 31o - 40o 41o & Upwards Angle of Surcharge 5o 10o 20o 30o * Repose Surcharge 30 - 35 ---20o} 35 - 40 ---25o} I.S. But we have in the program, summed up the range in between as (30o - 40o ---> 20o)

There are six troughing angles as per I.S., sited above. But generally preferred are 20o, 30o, 35o & 45o (shall options be placed for all the six possibilities ?). 3. Now, to decide whether the material being conveyed is sized / unsized to select the proper belt width :-

If only capacity & lump size is given, then referring table back select B.W. and proceed further with the help of Belt Width. Select Unsize as a Default & Sized can also be selected,if given. e.g. as given below :Belt (mm) Width Max. Lump Size (mm) Uniform Size Unsize (Sized) dimension) 0 75 0 76 - 100 101 101 - 125 151 125 201 126 - 180 231 181 - 200 331 201 - 250 381 251 - 360 431 361 - 380 531 381 - 410 681 (Max. 100 150 200 230 330 380 430 530 680 800

400 500 600 650 800 900 1000 1200 1400 1600

If capacity & lumpsize = 190 Program will select unsized as default i.e. 200 & select the belt width as 600 mm. ..3/-

..3.. DETERMINATION OF LUMP SIZE FACTOR :CONDITION 1. 2. 3. 4. 5. lump 6. Lump Size Lump Size LUMP SIZE FACTOR 0 1 2 3 4

< 10 mm < 25 mm

Quantity of largest lump <20% of max. permissible lump size Quantity of largest lump < 60% of max. permissible lump size Unsized (Largest lump size)

max. permissible

Sized (Largest lump size)

max. permissible lump

DETERMINATION OF ABRASIVENESS FACTOR :Non - Abrasive Mildly - Abrasive Abrasive Very Abrasive 1 2 3 4

Speed factor Abrasiveness

Lumpsize

Factor

Factor

LIMITATIONS TO MAXIMUM BELT SPEEDS :Speed of the material to be conveyed, is limited by the belt width & seleceted speed factor as follows. If we enter a speed on higher side, the program will display a message of not accepting it. Speed Factor 1 2 3-4 5-6 7-8 400 2.5 2.3 2.0 1.65 1.45 500 2.5 2.3 2.0 1.65 1.45 600 3.0 2.75 2.38 2.0 1.75 BELT WIDTH (mm) 650 800 900 1000 3.0 2.75 2.38 2.0 1.75 3.5 3.2 2.75 2.35 2.05 3.5 3.2 2.75 2.35 2.05 4.0 3.65 3.15 2.65 2.35 120 0 4.5 4.12 3.55 3.0 2.62 140 0 4.5 4.12 3.55 3.0 2.62 1600 4.5 4.12 3.55 3.0 2.62

..4..

..4/-

Volume bulk density (lower value) is used to check capacity and power density (upper value) to determine the final power requirements.Values of volume and power densities, angles of surcharge and repose can be changed, if requried. CAPACITY CALCULATIONS :Basic formula for calculating capacity :Capacity (Q) TPH = Area of Cross Section x Belt Speed x 3600 x Vol. bulk density x Incln. Fac (m2) (m/sec) (T/m3)

[This comes into picture only for conveyors having inclination

& Values are provided in the program as per the graph in IS-11592 (Pg.15)]. The main three parameters i.e. capacity, Belt Speed and Area (Belt Width) are dependent on each other. Any of the two parameters are known, third can be calcuated as per above formula. i. ii. iii. If Data given is :Capacity (TPH), Belt Speed (m/sec.) Belt Width (mm), Capacity (TPH) Belt Width (mm), Belt Speed (m/sec.) Program will select Min. Belt Width (mm) Min. Belt Speed (m/sec.) Max capacity (TPH)

Calculations for area of cross-section as per IS-4776 (Part - I)

W = A + 10 B, W in mm , in degrees. S (mm) = 0.5 (B-W) - (0.05 + 25) R (mm) = 0.5 W + S Cos S Total Area (A)= 10-6 [S Sin (W + S Cos ) + 0.5 R2 (2 - SIN 2 ] Here is in radian i.e. multiple by /180 ...5/-

..5.. Eg. B = 800 mm, W= 315 + 10 = 325 mm, = 300, = 10 S = 0.5 (800-325) - (0.05 x 800 + 25) = 172.50 mm R = 0.5 x 325 + 172.5 Cos 30) = 1796.60 mm Sin 10 Area (A)=10-6[172.5 Sin 30 (325+172.5 Cos30) + 0.5 (1796.6) 2(2x10x /180 - Sin 20)]

Area(A) = 0.0522 m TABLE FOR W :Belt Width (mm) 400 500 600 650 800 900 1000 1200 1400 1600

A (i.e. Roller Length) (mm) 165 200 235 250 315 350 380 465 530 600

Standard width of Belt are as in mm :BELTING SELECTION :-

400, 500, 600, 650, 800, 900, 1000, 1200, 1400 & 1600

Belt selection i.e. rating, duty will be as per Dunlop Catalogue. As we know belt width, we will check both for adequate load support (on basis of power density) and for adequate troughing of empty belt (on basis of Troughing angle) which selects Primary Belt i.e. Belt rating. ...6/-

...6... Belt Maximum designation recommended working tension (Vulcanised Splice) Type General Duty Rating 250/2 315/3 400/3 500/3 630/3 630/4 800/4 1000/4 1250/4 1250/4 1400/5 1600/5 1800/6 250/2 315/3 400/3 500/3 630/3 630/4 800/4 Duty = (kN/ m) 25 31 40 50 63 70 90 110 140 140 155 180 190 25 31 40 50 63 70 90 Nominal carcass thickness Nominal carcass weight Max. B.W. Min. B.W. (mm) for (mm) for adequate adequate load support troughing of (Mtrl empty belt Density T/m3) Upto Upto Upto 20 30 45 1.0 1.5 2.5 idlers idlers idlers 650 600 450 400 400 450 1000 1050 1200 1200 1400 1600 1800 1800 1800 2000 2000 2000 900 1200 1200 1400 1400 1800 1800 800 900 900 1000 1200 1400 1400 1600 1800 1800 2000 2000 650 1000 1000 1200 1200 1400 1600 650 650 800 800 900 1000 1200 1400 1600 1800 1800 2000 500 800 800 900 1000 1200 1400 400 500 500 500 500 500 500 650 650 650 800 800 450 500 500 500 500 500 650 450 500 500 500 500 500 650 650 800 800 900 900 450 500 500 500 500 650 800 500 500 500 500 650 650 800 800 900 900 1000 1000 500 500 600 600 650 800 900

(mm) 2.1 3.1 3.3 3.7 3.9 4.9 5.6 6.0 6.9 8.0 8.8 9.8 11.9 3.2 4.2 4.4 4.7 4.9 6.7 7.1

(kg/ m2) 2.1 3.2 3.4 3.8 4.2 5.2 5.8 6.5 6.9 8.3 8.8 9.8 11.9 3.4 4.5 4.7 5.1 5.5 7.2 7.7

Extra Duty

Heavy Duty

General / Extra / Heavy

First we select General Duty. If rating is out of range of General Duty, program can go for another Duty. ...7/-

..7.. Now to select Cover thickness, Nirlon Catalogue is referred. We have loading Cycle = 2 x Conveyor Developed Length (m) (Sec) Belt Speed (m/sec.) If this value lies in between 2 standard value, select lower value of loading cycle w.r.t. material abrasiveness & lump size (mm). Table gives for top cover thk. (mm) Generally recommended top cover gauge (mm) Material abrasiveness Non-abrasive Abrasive Very abrasive

Loading cycle (=2L) 2 (Seconds)

Lump size (mm)

-15 +1 5 -50 3.0 2.5 2.5 2.0 2.0 2.0 1.5 1.5 1.5 +50 -150 5.0 4.0 3.0 3.0 2.5 2.5 2.0 2.0 2.0 +15 0 8.0 6.0 5.0 4.0 3.0 3.0 3.0 3.0 3.0

Lump size (mm)

-15 3.0 3.0 2.5 2.5 2.0 2.0 2.0 1.5 1.5 +1 5 -50 5.0 5.0 4.0 4.0 3.0 3.0 2.5 2.5 2.5 +50 -150 6.0 6.0 5.0 5.0 4.0 4.0 3.0 3.0 3.0 +15 0 9.5 8.0 7.0 6.0 5.0 5.0 5.0 4.0 4.0

Lump size (mm)

-15 4.0 3.0 3.0 2.5 2.5 2.0 2.0 2.0 2.0 +1 5 -50 6.0 6.0 5.0 5.0 4.0 4.0 3.0 3.0 3.0 +50 -150 8.0 8.0 7.0 7.0 6.0 6.0 5.0 5.0 4.0 +15 0 11.0 9.5 9.5 8.0 7.0 7.0 6.0 6.0 5.0

15 30 45 60 90 120 180 240 Over 240

2.5 2.0 1.5 1.5 1.5 1.5 1.5 1.5 1.5

For Bottom cover thickness w.r.t. material abrasiveness is Non- abrasive : 1.5 mm Abrasive : 2 mm Very Abrasive : 2.5 mm We can also enter top/bottom cover thickness as per requirement. Now, to calculate Belt mass :Mb = Constant x (top cover + bottom cover )+Nominal carcass x Belt Width (Kg./m) factor thk(mm) thk (mm) Wt. (Kg/m 2) (mm) 1000 ..8/-

..8.. Constant Factor Table :Temperatur e 75 120 180 200 -Grade M24 HR SHR UHR FR Factor for calculating better mass 1.1 Standard Value 1.21 = 10% > Std. Value 1.265 = 15% > -----1.375 = 25% > -----1.32 = 20% > ------

Mass of material is calculated as Mg (Kg./m) = 1000 Q V = Belt speed in min./sec. V Q = Volumetric Conv. Capacity (m3/s) = (c/s area) A x V. = Vol. Bulk density of material (t/m 3) Driving Force Calculation: Peripherial force required on driving pulley (s) TE = R + RS + RSP + RSL used when inclined conveyor used only when L < 80m) R= main resistance (N) = f.L.g [Mc + Mr + (2M B + MG) Cos . [Used only for inclined convayor andIt is omitted when < 18] Where, f = artificial co-efficient or friction, usually 0.03 as a default Range 0.016 - 0.030. It can be fed manually also. L(m) = conveyor length (distance between centre) g (m/s2) = 9.806, Accn. due to gravity. Mc (Kg/m) = Mass of revolving idler parts along carrying side of conveyor per meter. Mr (Kg/m) = Mass of revolving idler parts along return side of conveyor per meter. (Deg.) = Angle of conveyor from horizontal line. 1. ...9/-

..9.. 2. Rs = Secondary resistance (N) = Ra + Rska + Rw + Rb Where Ra (N) = Q.1000. (V-Vo) Assum Vo = O m/s. (Gen Vo = V x Cos) - Inlet chute angle with belt = 90 Friction resistance between handled material and skirt plate in acceleration area, Rska = 2. Q2 .1000 .g .la

(V
0.7

+ VO2 )

b1 2

2 =Co-efficient of friction between material and skirt plate = 0.5 to la = Acc length at loading area (m) = V2 - Vo2
n

(0.6 = Default )

2g.1 1 = Co-efficient of friction between material and belt = 0.5 to 0.7 0.6 = Default b1 (m) = Inter skirt plate width = 2/3 B (in m) Rw(N) - Wrap resistance between belt & pulley (N) - From below table : Take-up Screw VGT HGT Pulley Tight side 230 230 230 Slack Side 175 175 175 Other pulley Rw

Snub + = 140 545 Snub + 2 bend + take-up = 965 560 Snub + 4 bend + take-up = 1,245 840

Rb = Pulley bearing resistance (N) = Rw/2 (assume) 3. RSp = Sp. Resistance (N)= Rsp1 + Rsp2 = Ri + Rsk + Rbc Where, Ri = Resistance due to = g Ci 0 Li (mB + mG) Cos Sini idler tilting (N) Ci = Trough = 0.4 upto 30 trough Factor = 0.5 above 30 upto 45 trough o = Co-efficient of friction between carrying idler & belts = 0.3 to 0.4 = 0.35 default ..10/-

..10.. Li (m) = Length of installation equipped with tilted idler = Developed conveyor length (m) i = gen 2 - option to be changed. skirt Rsk (N) = Resistance due to friction between handled material and

plates = 22 Q la 2. 1000 .g. lsk V2 b12 lsk = length of installation equipped with skirt plate excluding la = (3 - la)(m) x no. of feed points in a conveyor. Rbc (N) = Frictional resistance due to belt cleaners. = A1 P 3 P = Pressure between belt cleaner & belt = 3 x 10 4 to 3 x 105 N/m2 Default 3 = 0.6 to 0.7 between belt & belt cleaner. 0.65 Default. A1 = Area of contact between belt & belt cleaner (m 2) = 4. 10 x B(m) 1000 + 2 x 10 x B(m) 1000

RSL = Slope resistance in N = MG Hg - If conveyor is inclined. H (m) = Lift of conveyor between loading and discharge end.

If wrap angle over head pulley and other pulley also are not specified, then the program will select the following tabulated value. PROFILE NO.
SCREW (S)

(I)
VGT (V) HGT (H) S

(ii)
V H S

(iii)
V H S

(iv)
V H

(v)
S V H S

(vi)
V H

Head Pulley <------------------------------------------180 ---------------------------------------> a. w/o <------------------------------------------210 ---------------------------------------> Snub b.with Snub Snub <----------------------30 Default & (20,30,40) options------------------------> Pulley Bend ---90 90 -90 90 90 - 90 90 Pulley + + + of of of

incln.

incln ..11/-

incln

..11.. Wrap angles for tail & take-up pulley will be always equal to 180 . T1 = TE E +1 Default e-1 E = Acceleration co-efficient = 1.2 (Range 1.2 - 2. 0) Default = Friction co-efficient between driving, pulley & belt = 0.4 (0.4 - 0.45) Now following ratio is checked and it should be less than 80% T1 < 80% Belt width (m) x Tmax Dunlop catalogue If it exceeds 80%, the program displays a message and goes on the higher side to select new rating. If belting is not available in that duty then change the duty, appearing on the screen in belting module. The procedure is continue till safe belting is selected. Now, with the belt width of this selected belting again Te is calculated and checked whether T1/Tman is less than 80%. Once the belting is finalised, then, depending on the % value of T1/Tmax, pulley diameters are also decided in conjunction with carcass thk. of selected belt as follows :Carcass thk. (mm) from - upto & including Hea d (H) 2.8 - 3.5 3.6 - 4.4 4.5 - 5.5 5.6 - 7.0 7.1 - 8.8 8.9 - 11.1 323 400 500 630 800 1000 60 - 80% 30 - 60 % 0 - 30%

Tail/TU/ Bend (T) 273 323 400 500 630 800

Snub(s ) 219 273 323 400 500 630

H 273 323 400 500 630 800

T 219 273 323 400 500 630

S 219 219 273 323 400 500

H 219 273 323 400 500 630

T 219 273 323 400 500 630

S 219 219 273 323 400 500

Pulley diameters are decided only after belting selection is finalised. ..12/-

..12.. POWER REQUIREMENT :PDP Power required at driving pulley (s) (kw) PDP (KW) = TE.V option 1000 If this value 30 0.75 (Normal) Also

> 30 - 0.925 (Helical)

to change.

Motor O/P power (Shaft) = PM(KW) = PDP/GB = _____ KW. Motor KW required = PM x Motor service factor. (1.15 default value option open to charge) Adopt motor or next higher rating (KW) This will be rated KW. GEAR BOX SELECTION :To consider peripheral speed of the belt, while selecting gear box pulley dia = Bare pulley dia + 2 Lagging thk + (top + bottom) + carcass thk.

]
(mm) (mm) (mm)

= _____ mm/1000 = ____ m

Drive pulley RPM = 60 x belt speed (m/sec) = ____ rpm x pulley dia (m) Gear Box ratio = 1440 = Drive pulley rpm Now as the gearbox type is selected, to arrive at proper size, the program follows the following path.

..13/-

...13... GEAR BOX

Worm Helical Solid shaft Solid shaft Hollow shaft Foot mtd Shaft mtd Hollow shaft KBN/KCN NU SMM Foot mtd FSM Foot mtd KBH/KCH It will go downward SBN/SCN Shaft mtd while selecting. Shaft mtd KBA/KCA SBH/SCN SBA/SCA (This program will go from B to C i.e. from double to triple reduction to select correct GB size and ratio). A separate gear box screen is introduced, which on getting the correct data selects suitable gear box size. Default Gear box selection is based on - Option I & II Type of Gear box - Worm, Helical, Bevel Helical Shafting - Solid & Hollow Foot mounting Shaft mounting Service factor - 1.5 (Default option open to change. Option I. min. power required for gear box = Rated KW x Gear box S.F. 0.75 = _____ HP : or : Absorbed kw = Pm x 2.5 = ______ HP Greater of the 2 will be 0.75 selected Rated kw = Rated kw x 1.25 = _____ HP 0.75 Min. power required for G.B. = _______ x Gear box S.F. 1.5 default, option = _______ HP to change ?

Bevel Helical

..14/-

..14.. 1. WORM : Now, the gear box ratio calculated will not be always equal to or tally with standard ratios available. Hence, the program always selects the previous / lower gear box ratio. Now, with respect to this gear box ratio & min. power requirement, the program selects the correct gear box size. Due to reduction in gear box ratio, belt speed of conveyor will rise. Hence the conveying capacity will increase for same belt width. There will also be a change in motor power requirement which increases from its original value. Hence, gear box screen is continued with : Required gear box ratio Gear box size Actually selected / standard gear box ratio --> Change in speed Change in HP/new HP Capacity increased/descreased Here the program will always display the lower gear box ratio selected. But if needed, we can select higher ratio and check whether the capacity get satisfied or not. As we change ratio the corresponding changes will also be observed on the screen. Only the ratios available in that particular series will be displayed. HELICAL / BEVEL HELICAL :Now, the gear box ratio is selected & gear box size is also selected. Check for thermal capacity i.e. heating effects. 1. Gear units without additional cooling when Motor KW PG1 x FW (If this satisfies then additional cooling is not required or else it is required.) PG1 = Thermal capacity wihtout additional cooling (Power table) Fw = Factor for ambient temperature (Table) 2. Gear unit with fan possible when, Motor KW PG2 x FW (If this satisfies then fan cooling is sufficient or else fan cooling is not sufficient.) PG2 = Thermal capacity with fan (Power table) ..15/-

..15.. 3. Gear unit with built in cooling coil possible when Motor Kw PG3 x FW (If this satisfies then further cooling coil is sufficient or else further cooling is not sufficient.) PG3= Thermal capacity with built-in cooling coil.

4.

Gear unit with built-in cooling coil & fan possible & also put oil cooler neccesary. Motor KW PG4 x FW PG4 = Thermal capacity with built-in cooling coil & fan. If this satisfies then, cooling coil & fan is required or else then, external oil cooler is necessary. This portion is explained as follows :Required gear box ratio : 1440/D Selected one : ____ (let it be x) Drpurpm changed : 1440/x Speed changed : x Dr dia x Drpurpm changed / 60 KW changed (If any) : Te(N) x speed changed / 1000 Capacity increased = Area x increased speed x 3000 x bulk density xk f COUPLING SELECTION :I. delay Input coupling : (3 types - fluid, pin & bush & geared) a. Fluid coupling - check, whether the coupling is with or without chamber. See motor KW selected. Select the coupling with rating equal to or greater than the above motor KW at 1450 rpm. b. Pin & bush / Geared coupling :Input coupling torque = 716 x rated motor HP x Cplg. S.F. x 9.81Nm 1440 1.5 default, option can be changed Select the greater value among motor shaft dia & gear box input shaft dia W.R.T. this greater value decides the keyway portion in hub as per the table given below :...16/-

..16.. Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Shaft dia (mm) (From - upto & includes) 23 - 30 31 - 38 39 - 44 45 - 50 51 - 58 59 - 65 66 - 75 76 - 85 86 - 95 96 - 110 111 - 130 131 - 150 151 - 170 171 - 200 201 - 230 Key way portion in hub (mm) 3.3 3.3 3.3 3.8 4.3 4.4 4.9 5.9 5.4 6.4 7.4 8.4 9.4 10.4 11.4

Following two conditions are checked :Shaft dia at motor as well as i/p gear box should be min. bore of coupling. make it round figure max ------- ---------Now, (keyway portion +10 mm) x2 + Greater value among < Hub outside dia in hub the 2 shaft dia This value is entered in the cplg. database. The program will select, the correct coupling size satisfying above 3 conditions of torque min & max. bore & hub outside dia criterion. II. Output coupling :-

O/P coupling torque = 716 x rated motor HP x Cplg. S.F. x 9.81-Nm 1440 / G.B. ratio 1.5 default, option can be changed. Select the coupling with greater torque, next to calculated above and display the size.