Yokohama Conveyor Belts

CONVEYOR BELTS
TECHNICAL IN FORMATION
.c YOKOHAMA CONVEYOR BELTS
.li
TECHNICAL INFORMATION
Created by U Thaung Myint 11/22/2010 Monday
YOKC)HAMA CONVEYOR EEUS
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CHAPTER 1 HOW TO SELECT CONVEYOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 NAME OF EACH PART OF CONVEYOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 Drive System 6
. . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2 Take-up System 7
1.2 REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 SIZE OF CONVEYING MATERIAL & BELT WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 CONVEYING MATERIAL & CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
. . . . . . . . 1.4.1 Size of Conveying Material & Belt Width ... 9
. . . . . . . . 1.4.2 Calculation Formula of Conveying Quantity 9
. . . . . . . . . . . . . . . . . 1.4.3 Conveyable Inclination Angle 12
. . . . . . . . . . . . . . . . . . . . 1.4.4 Bulk Density of Materials 13
. . . . . . . . . . . . . . . . . . . . . . 1.4.5 Running Speed of Belt 12
1.5 CALCULATION OF REQUIRED POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . 1.5.1 Power required for operating unloaded belt 14
. . . . . . m . I -
-
1.5.2 Power for moving loaded material horizontally 14
. . . . . .
FA
1.5.3 Power required for elevating and lowering belt 14
. . . . . . . . . . . . . 1.5.4 Power required for moveable tripper 14
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L.
1.5.5Data 15
. .
7.6 CALCULA'i70N' OF BELT TENSION AND TAKE-UP WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6.1 Effective Tension . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6.2 Slack Side Tension . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6.3 Slope Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6.4 MinimumTension . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6.5 Running Resistance of Return Side Belt . . . . . . . . . . 20
1.6.6 MaximumTension . . . . . . . . . . . . . . . . . . . . . . . . 20
1.6.6.1 Belt Tension of Standard Conveyor Line Belt . . . . . 20
1.6.7 Multi-Drive System . . . . . . . . . . . . . . . . . . . . . . . . 23
1.6.7.1 Purpose of Multi-Drive System . . . . . . . . . . . . . . . 23
1.6.7.2 Procedure of Calculating Multi-Drive System . . . . . . 23
1.6.7.3 Explanation of Symbols of Multi-Drive System . . . . 24
1.6.7.4 Calculation Example of Multi-Drive System . . . . . . 24
1.6.7.5 Typical driving positions and tension distribution
of Multi-Drive System . . . . . . . . . . . . . . . . . . . . 25
Tension distribution of the typical dual drive system . 26
1.6.8 Tension distribution of the reversible conveyor . . . . . . . 27
. . . . . . 1.6.9 Accelerating Resistance and Accelerating Time 28
I
. . . . . . . . . . . . . . . . 1 ".I0 Calculation of Take-up Weight 28
1.7 BELT CARCASSSELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.7.1 Determination of Kind of Carcass and Number of Ply . . 31
1.7.2 Study of Maximum Plies for Troughing . . . . . . . . . . . 32
1.7.3 Study of Minimum Plies . . . . . . . . . . . . . . . . . . . . . 33
. . . . . . . 1.7.3.1 Problem of Sag due to Concentrated Stress 33
. . . . . . . . . . . . . . 1.7.3.2 Problem of Impact at the Chute 34
1.7.3.3 Problem of Load Support . . . . . . . . . . . . . . . . . . 34
1.7.3.4 Method for Determining Minimum Plies . . . . . . . . 38
1.8 MINIMUM PULLEY DIAMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.9 COVER THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.9.1 Fabric Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.9.2 Steel Cord Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.10 BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CHAPTER 2 HOW TO SELECT BUCKET ELEVATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 KIND OF BUCKET ELEVATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2 CALCULATION OF TEPISION TO BE APPLIED TO BUCKET ELEVATOR BELT . . . . . . . . . . . . . . . . . . . 42
2.2.1 Vertieal Type Bucket Elevator Belt . . . . . . . . . . . . . . 42
2.2.2 Sloped ~ y ~ e b u c k e t Elevator Belt . . . . . . . . . . . . . . 42
2.3 CALCULATION OF REQUIRED POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4 DETERMINATION OF'TENSION MEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4.1 Study from the Condition of Use . . . . . . . . . . . . . . . 4 3 4
2.4.2 Study of Carcass Strength against Maximum Tension . . 43
2.4.3 Study of Minimum Pulley Diameter . . . . . . . . . . . . . 44
. . . . . . . . . . . . . . . . . . . . 2.4.4 Studv of Bolt Efficiency 44
HOD OF SPLICING BUCKET ELEVATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.5.1 Lap Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.5.2 Splicing by Metalic Clamps . . . . . . . . . . . . . . . . . . . 45
2.5.3 Vulcanization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CHAPTER 3 EQUIPMENT OF CONVEYOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 PREVENTION OF IMPACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 PREVENTION OF DEPOSITE OF CAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3 PREVENTION OF CARRYING MATERIAL FROM BEING TRAPPED . . . . . . . . . . . . . . . .,. . . . . . . . . . . 52
I 3.4 PREVENTION OF CROOKED RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.6 PREVENTION OF ABNORMAL WEAR AT THE SKIRT. THE SCRAPER OR THE CHUTE POINT . . . . . . 55
3.6 DETECTION OF MATERIAL PILE-UP AT THE CHUTE OR DISCHARGING PQlNT . . . . . . . . . . . . . . . . . . . 56
3.7 VERTICAL CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.8 DISTANCE BETWEEN TROUGH TYPE ROLLER AND PULLEY AND THEIR DISPOSITION
(TRANSITION DISTANCE) . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.9 PREVENTION OF OVERLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3. 113 DISPOSITION OF CARRIER AND RETURN ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
CHAPTER 4 HOW TO USE CONVEYOR BELT PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
. CHAPTER 5 SPLICING METHOD AND REPAIRING METHOD FOR CONVEYOR BELT . . . . . . . 66
5.1 MERIT AND DEMERIT OF EACH SPLICING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2 SPLICING BY METAL FATENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3 SPLICING BY VULCANIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.3.1 Factory Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.3.2 Field Splicing (Multi-Ply Conveyor Belt) . . . . . . . . . . 68
5.3.3 Dimension for Steel Cord Conveyor Belt . . . . . . . . . . 69
5.3.4 Unicon Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.4 SPLICING BY NATURAL VULCANIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.5 REPAIR OF CONVEYOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.5.1 Small injury of cover rubber . . . . . . . . . . . . . . . . . . 72
5.5.2 Large injury of cover rubber . . . . . . . . . . . . . . . . . . 72
5.5.3 Small injury reaching carcass ply . . . . . . . . . . . . . . . . 72
5.5.3.1 Fabric Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.5.3.2 Steel Cord Belt . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.5.4 Large injury reaching carcass ply . . . . . . . . . . . . . . . 73
. . . . . . . . . . . . . . . . . . . . . . 5.5.5 Injury of Edge 73
CHAPTER 6 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
.&I LIFE EXPECTANCY OF CONVEYOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
'8.2 DIMENSION AND WEIGHT OF BELT PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
'k
6.2.1 Dimension and Weight of Wooden Drum Package . . . . 76
6.2.2 Dimension and Weight of Simple Wooden Drum Package 77
I
. VARIOUS TESTING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
. . . . . . . . . . . . . . . . . . . . . . . . . .
b 6.3.1 Separation Tester 78
. . . . . . . . . . . . . . . . 6.3.2 AMSLER's Type Tensile Tester 78
. . . . . . . . . . . . . . . . . .
i 6.3.3 SCHOPPER Tensile Machine
79
6.4 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
In order t o operate coriveyor belt efficiently, it is
necessary to analyze our customer's condition of
use and to select and design the belt in conformity
with the actual condition. The Yokohama Rubber
Co., Ltd. has now edited this "Technical Informa-
tion of YOKOHAMA CONVEYOR BELT" which
is to be the criterion of designing technique of
Conveyor Belt. We shall be very happy i f this book
will be of help for our customers when studying
and selecting Conveyor Belt.
"Before you read this book"
The techniques and types of Conveyor Belt are
ever progressing day by day making it necessary for
us to change parts of this book in future. So, please
make much use of this book taking into considera-
tion of the following points.
1. Calculation Method of Belt Tension
The calculation method of belt tension i s based
upon JIS (Japanese Industrial Standards) establi-
shed in 1965. But, there are some indefinite points
in JIS, which fequire user's decision. Consequently,
there are such portions in this book where values
and coefficients are determined in accordance with
our own idea.
2. Selection Method of Conveyor Belt
It i s almost impossible, when selecting belt, t o
catch the conditions of use and degree of
maintenance for each case. Accordingly, there are
some parts in this book where safety factor is
taken into account for selecting Conveyor Belt. If
the belt presently used by our customer is lower
with respect to the kind of belt carcass and number
'
of ply etc. then the selection method of this book
(or i f the belt i s used with satisfaction as-to the
belt life), it i s to be considered that the belt meets
with the actual condition of use.
I
w
4
1
3. Requirements for Selecting Belt
It i s fundamentally necessary to know the condi-
tion of use accurately and to select the belt
suitable for the condition of use so as to attain
long belt life. There are two stages in selecting belt,
viz. planning stage prior to using the belt and
studying stage regarding the belt already used.
( 1 ) When conveying material from A to B:
I t i s the most indefinite example, i f the desired
quantity to be conveyed i s known but the belt
width and running speed are not clear. I t i s
required in such a case to study line length,
belt width and belt speed dividing into several
plans.
(2) When the conveying quantity, conveyor length
and belt width are known:
It i s necessary to determine the running speed
of the belt.
(3) When al l the conditions are known:
I t i s required:-
a. to investigate i f the belt width i s adequate for
the maximum lump size of the conveying
material,
b. to investigate i f it i s possible to attqin the
maximum conveying volume depending upon
the belt width, kind of conveying material,
bulk density and belt speed,
c. to calculate the reqyired power and the maxi-
mum tension to be applied t o the belt,
'
d. to determine the kind of belt carcass and the
number of carcass ply to be expected from the
maximum tension as calculated above,
to investigate i f there i s no problem in convey-
ing the material and to study the maximum
number and minimum number of ply, and beat
resistance and chemical resistance,
f- to investigate the kind and thickness of cover
rubber and the breaker depending upon the
kind of material to be conveyed and the
cc:idition of use,
g. to study i f the kind and the construction of the
selected belt are suitable for the pqlley dia-
meter and the take-up system.
4. Necessary Properties of Conveyor Belt
The followings are the necessary properties of
convey or belt.
(1) Carcass strength sufficient for resisting working
tension
(2) Adhesion between each ply
(3) Wear resistance and cutting resistance
(4) Fatigue resistance
a. Resistance against repeated flexure by pulley
and variation of working tension
b. Resistance of cover rubber against deteriora-
tion due to sunlight, ozone and conveying
material
c. Resistance against deterioration of perform-
ance due to water permeation
d Resistance against concentrated stress due to
partial injury
(5) Troughability against carriers
When the lateral rigidity of the belt i s high, the
belt does not easily become adaptable to
carriers and i s liable to cause crooked running.
( 6) l mpact resistance
The resistance against the impact by conveying
material at the chute.
(7) Spliceability
(8) Elongation of belt during operation
Adaptability of take-up movement and elonga-
tion of belt.
CHAPTER 1
I HOW TO SELECT CONVEYOR BELT
1.1 NAME OF EACH PART OF CONVEYOR BELT
1.1.1 DRIVE SYSTEM (m)
Although there are different names of drive
-
( a)
system, our company takes the following classifica-
tion. U
a) Single Drive
b) Snubbed Single Drive
a) b) S~ngl e Drl ve
The pulley to be provided closely so as to
increase the wrapping angle of the driving
pulley is called as "snub pulley". The drive
system of this type i s called as "snubbed
single drive".
b) Snubbed S~ngl e Dri ve
c) Tandem Type Single Drive
This system drives only one shaft.
d) Tandem Type Drive
One shaft i s directly driven and another snan
receives the power through the gear br the
chain, thereby two shafts are driven.
c ) Tandem Type Single Dri ve
e)f) Dual Drive
Two shafts are driven respectively by a separate
motor. This system is used when two shafts are
closely positioned and the running resistance
between two shafts can be ignored.
g) h) Multi-Drive System
This i s the system for driving more than two dl Tandem ~ y p e Dri ve
shafts respectively by a separate motor, where
-
each drive i s positioned as apart as possible (for
example when driving the head and the tai l ).
a-
1 e ) f ) Dual Dri ve
I
g) h) Multi-Drive System
(a) Screw Type '
111
(b) Gravity Type
Horizontal Gravity Take-Up
(c) Carriage with Gravity Weight Suspended Type
(K) Automatic Tension Controling Type
Take-up System (Power Take-up)
@= ) Power Take-up System & Tension
Detector
Motor
\
Brake
Take-up carriage Tension Delector
/ Wire rooe /
1.2 REQUIREMENTS
When selecting conveyor belt the following require
ments should be satisfied.
a) Relation of the size and shape of conveying
material with the belt width.
'
bJ Relation of the desired conveying volume with
the belt width, carrier anglq and running speed
of belt.
c) Relation between the inclination angle and
slipping of conveying material
d) Relation between the tension to be applied to
the belt and the ultimate strength of the belt
e) Number of carcass ply suitable for use (Rela-
tion between required maximum and minimum
number of ply)
i)
Conveyor belt i s supported mainly by means of
carriers and the belt requires sufficient rigidity
to hold conveying material.
ii) Belt should adapt to carriers well so as not to
make crooked running.
iii) Belt shou Id have enough impact resistance,
because it i s subjected to the impact caused by
conveying material at the chute.
f) Wear out of the belt by conveying materials,
and the cover rubber and other construction of
the belt.
g) Other Requirements
i)
Fatigue due to flexure at the pulley
ii) Splicing method of the belt
SIZE OF CONVEYING MATERIAL & BELT WIDTH
The recommendable maximum lump sizes of the conveying material are as shown in Table 1.1
Maximum Lump Size (rnm) Maximum Lump Size (mm)
Belt Width Belt Width
(mm)
In case of 10% of load is In case of 10% of load is
(mm)
uniform lump size maximum lump size uniform lump size maximum lump size
i
350 50 100 1,500 305 505
400 50 125 1,600 330 550
450 7 5 150 1,800 355 610
500 100 180 2,000 380 660
600 125 205 2,200 430 760
750 150 255 2,400 455 81 0
900 175 305 2,600 485 865
-
1,050 200 355 2,800 510 910
1,200 250 405 3,000 580 1,010
1,350 280 450 3,200 6 10 1,065
<
I
1.4 CONVEYING MATERIAL & CAPACITY - -
1.4.1 SIZE OF CONVEYING MATERIAL & BELT WIDTH
When the size of conveying material is too large
t
in comparison with the belt width, various kinds of
trouble may take place during operation. So, it i s
,
desireable that the belt i s used in accordance with
the following standards as shown in Table 1.2
) [TGEjT] Maximum size of materid & minimumbdt
width (mm)
Max. diagonal l
en
g
th
100 150 200 250 300 400 500
of lump
-
! 1.4.2 CALCULATION FORMULA OF CONVEYOR CA-
I
PACITY
I
Conveyor capacity i s calculated in accordance
with the following formula. When the belt i s
inclined, it i s required to take into consideration of
t h ~ ~~mpensati on.
Qt = 6 0 . A . r - v . . . . . . . . . . . . . . . . . . . . . . . (1)
Qt : Conveyor capacity (t/h)
A : Loaded cross sectional area of conveying ma-
terial (m
2
) ... Refer t o Fig. 1.4.1 & Table 1.4.
7 : Bulk density of conveying material (t/m3)
... Refer t o Table 1.8.
v : Belt speed (mlmin.)
(-7) Flat belt ml.s) Troughed belt
Surcharge Angle
s
~ ~ 3 ) Value of K
Surcharge Angle
Trough Angle I 0" 20 30"
0 (Flat) 0.0292 0.059 1 0.0906
20 0.0963 0.1245 0.1 538
25 0.1 112 0.1285 0.1660
30 0.1248 0.1488 0.1757
45 0.1485 0.1698 0.1915
( - 4 ) Value of A (Load Cross Section)
Angle
Unit: 10-2rnz
Trough Angle
0" 20" 25' 30" 45"
Surcharge Angle \.
Belt Width (rnm \ 19" m0 30" 100 20 30 lo0 200 300 10" 200 300 10" 200 300
400 0.28 0.56 0.86 0.93 1.20 1.48 1.07 1.24 1.60 1.20 1.43 1.69 1.43 1.63 1.84
450 0.37 0.74 1.13 1.21 1.57 1.94 1.40 1.62 2.09 1.57 1.86 2.22 1.86 2.14 2.41
To be safe for design capacity of high speed belt (over 200m/min.), a lo0 surcharge angle had best be considered.
1.4.3 CONVEYABLE INCLINATION ANGLE
The conveyable inclination angle varies depend-
ing upon the nature and the shape of the material
to be conveyed, but the angles as shown in Table
1.7 are the norminal ones for the ordinary belt
with the through angle of 20". Table 1.7 -
Conveyable inclination angle
( - 7 3 CONVEYABLE INCLINATION ANGLE
Material Max. Angle
Cement (Powder) 22"
Coal (Crude) 16 - 18"
(Slack) 22"
Coke 18 -- 20" . - --
Concrete 12 - 26"
Sand 20"
Grain 20"
Gravel 15"
Lime (Powder) " 23"
Wood (Chip) 25"
(Log) 10"
Ore (Crushed) 20"
(Mixed)
(Luma)
Paper Package I 16"
*Paper Package 1 "25 -45"
Macadam (Crushed) 20"
(Mixed) 18"
(Lump) 16"
Salt (Powder, rock) 20"
Sand (Ordinary) 20"
(Dried) 15O
Stone Aggregate (Powder) 23"
Sulfar (Powder) 21"
* I n case of package conveyor belt.
1.4.4 BULK DENSITY OF MATERIALS
( - 8 ) Bulk density of materials
Material
Sand (Dry)
(Common)
(Wet)
(Foundry)
Gravel
Macadam
Limestone
Powdered Limestone
Clay (Dry)
(Wet)
Earth (Common)
(Wet)
Mud
Cement (Powder)
(Clinker)
(Portand Cement)
Concrete
Ammonium Sulphate (Dry-Wet)
Cinder
Coal Crude
Lump
Coke (Lump)
(Dust)
Gypsum
Quick Lime
Grains Soya beam
Rice
Wheat
Sugar Raw
Refine
Wood (Hardwood)
(Softwood)
(Hardwood)
(Softwood)
(Wet)
Woodchip
Pulp
Bark
Fuel wood
Lumber
Sawdust
wood AS^ (Dw)
(Wet)
Ore l ron
Copper
Zink
Potash
Nickel
Bulk Density
Bulk Density
cific Gravity) Brass
I
1.4.5 RUNNING SPEED OF BELT
Running speed of the belt is a principal factor
to increase the conveying quantity. But, the speed
is critical depending upon the nature of conveying
material.
1.5 CALCULATION OF REQUIRED POWER -
There are two methods of calculating required
power, viz. to calculate based upon experiment and
to calculate by respectively calculating frictional
force and gravity a t each portion of the belt and
also the effective tension to be applied to the belt.
But, the method based upon experiment is usually
employed, because generally the carrier weight and
other details are not clear.
Further, this calculation method i s classified
into DIN (German standard), Hetzel, Goodyear
and Goodrich systems. Although thet-e are slight
differences among them, it cannot be said which i s
definitely accurate.
Moreover, there i s no remarkable error in either of
them causing trouble with the belt.
The following formula i s in accordance with JIS
(Japanese l ndustrial Standards) established in
1965.
P : Required power (kW)
PI : No load power (kW)
P2 : Horizontal load power (kW)
P3 : Lifting load power (given with negative sigh
for descending belt) (kW)
f : Coefficient of rotational friction of the idler
W : Weight of moving part other than the convey-
ing material (kg/m)
v : Belt speed (mlmin.)
Q : Conveyor length (horizontal center distance
between head and t ai l pulleys) (m)
Q, : Corrected value of the center distance (m)
7 : Bulk density of conveying material (t/m3)
Qt : Capacity (tl h)
Qt = Qm . y Om: Conveying volume ( m3 /h)
h : Vertical height of ascending and descending
l i ft including the height of the tripper, i f any.
(m)
1.5.1 POWER REQUIRED FOR OPERATING UNLOAD
ED BELT
The required power i s not proportional to the
conveyor length. It i s because the abrasion loss of
pulley, skirt board and etc. and the energy loss
required for bending the belt exist without relating
to the conveyor length, particularly because of
which the conveyor length of the belt plus
compensated value i s experimentally propor-
tionated to the required power.
1.5.2 POWER FOR MOVING LOADED MATERIAL
HORIZONTALLY
1.5.3 POWER REQUIRED FOR ELEVATING AND
LOWERING BELT
Note: h he value becomes negative in case of
the lowering belt.
1.5.4 POWER REQUIRED FOR MOVEABLE TRIPPER
When the power required for operating the
moveable tripper is unkonwn actually, it i s
necessary to apply the required power in accord-
ance with Table 1.9.
The moveable tripper is such a tripper as to run by
taking power from the conveyor belt.
The required power of moveable tripper i s to be
preferably as shown in Table 1.9.
POWER REQUIRED FOR MOVEABLE
TRIPPER (Pt) (kW)
I
1.5.5 DATA
(1) Belt Weight (W, ) (kgl m)
f
i) The weight o f fabri c bel t is calculated i n
accordance wi t h t he f ol l owi ng formula.
W1 = Bel t Wi dt h (cm) x No. o f Pl y (P) x
Carcass Thickness (mm/P) + Top
Cover Thickness (mm) + Bot t ome
Cover Thickness (rnm) x p x 1/100 ..
. . . . . . . . . . . . . . . . . (6)
WI = Bel t Weight per mtr. length (kgl m)
p
= Coefficient depending upon ki nd of
bel t carcass.
-
- -
Kind of Carcass
Tensile Thickness
Strength
Carcass Designation ( ~ ~ l ~ ~ p ) (mm/P)
NV- 50 50 0.7
JNN-100 100 0.8
NN-120 120 0.8
NN-150
150 0.9
N N-200 200 1 .O
Nylon
NN-250 250 1 .I
Fabric
N N-300 300 1.2
N N-350 350 1.3
N N-400 400 1.4
NN-450 450 1.5
NN-500 500 1.6
NN-600 600 1.7
VN-100 1 00 1 .O
Vinylon
VN-120 120 1 .O
Fabric
VN-150 150 1.1
ii) I n case o f Steel Cord Conveyor Bel t calculation
is made i n accordance wi t h t he f ol l owi ng forrnu-
la. (Please refer t o our ST Bel t catalogue regard-
i ng t he standard value.)
WI = Bel t Wi dt h ( m) x Std. Value (kg/m
2
) ?
l ncrease or Decrease against Std. Cover Rubber
Thickness ( mm) x 1.2 (kg/m2 . . . . . . . . . (7)
(2) Idl er Weights
The idler referred here is made o f steel pipe, al-
through there are many other ki nds o f roller.
3-equal-roll Flat Type
Belt Width
Idler Diam. Troughing Return-Idler
(mm)
(mm) Idler(Kg/set) (Kglset)
400 89.1 6.6 5.0
450 89.1 7.1 5.4
500 89.1 7.5 5.9
600 89.1 8.3 6.8
750 114.3 13.2 1 1.6
900 1 14.3 15.1 13.4
1050 139.8 21.3 18.9
1200 139.8 23.6 21 .I
1400 165.2 36.6 32.6
1600 165.2 41.4 36.6
1800 165.2 47.4 42.5
2000 165.2 52.2 46.5
(3) Value of moving part, W for calculation (kglm)
When calculating actual required power, it i s
difficult to preliminarily know W value ac-
curately. So, a certain assumption i s to be set.
The standard value used by our company i s as
shown below.
WI : Belt Weight (kglm)
W'c: Weight of rotational part per set of carry-
ing idlers (kg)
Qc : Carrying idler spacing (m)
W'R: Weight of rotational part per set of re-
turn idler (kg)
QR : Return idler spacing (m)
Wc : Carrying idler weight (kglm)
WR : Return idler weight (kg/m)
Table 1.13 shows the medium values for the belt
weight of each width provided that the carrying
idler spacing i s 1.2 m and the return idler spacing i s
2.4 m. Special care must be taken for Steel Cord
Conveyor Belt, because the belt weight consider-
ably differs.
Weight
Belt Width Belt Weight WI of Moving Part
(mm) (Kglm) W (Kglm)
400 4.5 17
450 7 A 22
500 7.2
24
600 9 28
750 13 42
900 15.5
49
1050 23
72 .
1200 26 81
1400 33 112
1600 38
125
1800 46 150
2000 5 1 160
Note: Calculation is made in accordance with Was shown abow ir
principle. I t is necessary, however, to make recalculatior
accurately ascertaining the weight of carrying idler, returr
idler and belt tare in case of long span and high tensilt
strength belt.
(4) Coefficient of rotational friction of the idler (f ]
and corrected value of the center distance (Qo]
The Coefficient of rotational friction of idle1
( f ) i s not exactly kn0w.n because it depends i
upon the method of bearing seal of idler and j
working condition, but it- is nominally
shown in Table 1.14.
@bnstruction Character
of System
w m using idlers with
Minary rotational friction
mnce, of which installa-
bn is not so good.
-
n using idlers with (
&cularly little rotational (322 66
WTmyesistance,of which
allatisn condition i s
calculating braking n,, 156
"." . -
mx of lowering conveyor I
gutput of Electric Motor (Pm)
The output of electric motor i s calculated by
h e following formula.
i : Output of Electric Motor (kW)
: Required power (kW)
Efficiency of machine
1.6 CALCULATION OF BELT TENSION AND
TAKE-UP WEIGHT
1.6.1 EFFECTIVE TENSION
The difference between the tension on the tight
side and that on .the slack side i s called as
"effective tension". Namely, the'effective tension
i s created by transmitting motor power.
The effective tension (Fp) i s calculated in accord-
ance with the following formula.
FP : Effective Tension (kg)
P : Required Power (kW)
v : Belt Speed (mlmin.)
F1 : Tight Side Tension (kg)
F2 : Slack Side Tension (kg)
Fig. 1.9
1.6.2 SLACK SIDE TENSION
Slack side tension i s the minimum necessary
tension required for creating frictional force
corresponding to the effective tension on the
driving pulley.
1.6.3 SLOPE TENSION
Slope tension i s the tension to be created a t the
upper pulley by the belt tare when conveyor is
sloped and it is calculated in accordance with the
following formula.
p : Coefficient of friction between driving
pulley and belt (See Table 1. 15.)
0 : Angle of belt wrap at drive
e : Base of natural logarithm
1
- : Drive factor .... Refer to Table 1.16.
If assumed to be:-
1
@e - l = R R: Drive factor
F3 =WI Q1 si na=W,h .. . . . ...... . . . (12)
FJ : Slope tension while running (kg)
W, : Belt weight (kglm)
i?, : Length of the conveyor slope (m)
a : Angle of inclination (")
h : Li ft (m)
1.6.4 MINIMUM TENSION
It i s not advisable, from the standpoint of operat-
ing belt, that the belt sags too much between
idlers. The tension required for preventing such sag
is called as "minimum tension"
50 Qt
Carrying Side F4 = 8. Rc(= + Wl 1. . . ( 13.1 )
50
. . . . . . . . . . Return Side F4 = 8' 1 1 ~ W1 (13.2)
F, : Minimum Tension (kg)
R, : Carrying ldler Spacing (m)
W, : Belt Weight (kglm)
QR : Return ldler Spacing (m)
Whichever larger value of (13.1 ) or (1 3.2) shall be
taken up. In order to make the calculation simple
the carrying idler spacing i s determined as 1.2 m.
1.6.5 RUNNING RESISTANCE OF RETURN SIDE BELT
Although it is not necessary to take into considera-
tion of the running resistance in case of a short
belt, that of the return side belt should be
calculated when the conveyor belt is of long span
or a reversible one.
1.6.6 MAXIMUM TENSION
1.6.6.1 Belt tension of standard conveyor line belt
The method of calculating the maximum tension
to be applied to the belt differs depending upon
the driving system and the form of t he conveyor
line, so please calculate the maximum tension in
accordance with the following method respec-
tively.
FR = f (W, + WR (I1 + Ro) (kg) . . . . . . . . . . (15)
Drive at or near Elevating Conveyor with Drive at or near Head.
'"" "'
F, + Fp- FR
b) Horizontal Conveyor with Drive at or near Tail.
a @- FpR
I Or
T- F,
+F4 Use
, t he larger one for Fm
FP( I + R) -@
FM { or
F4 + F3 + Fp- FR
I
-@
I
FM=F~( I + R) or F, + F3 +Fp-FR Use the larger one for Fm
d) Elevating Conveyor with Drive at or near Tail.
\-
I
1
FM I F4 : Fa + Fp- FR -@
I
T- FP(;:N} FM
@- F, + Fp.
F ~ ( I +R)-FR+F~
Use the larger one for Fm
F4 + F3 + Fp- FR I
e) Lowering Conveyor with Tail End Drive.
[P, + P, < P, (Absolute rate)
(Hold back)
Fp( I + R) + F3 + FR
FM{ or Use the larger one for FH
Fp+ F, + F3 + FR
f)
Lowering Conveyor with Tail End Drive
IP, +P2 >P, (Absolute rate)
(No Hold back)
I
Use the larger one for Fr
g) Lowering Conveyor with Head End Drive.
[PI +P, <P3 (Absolute rate)
(Hold back)
Use the larger one for Fp
FPI ( I +R)
h) Lowering Conveyor with Head End Drive
[PI + P2 > Pa (Absolute rate)
(No Hold back)
@ FPR
I
@ F,+F, +FR-FP
I
&j~, + F3 + FR
Use the larger one for Fp
i) Elevating Conveyor with Drive located part
way down the slope in the return run.
Use the larger om for Frn
The running resistance on the return side ( FR) may be
omitted in other cases than long span or reversible belt for
a) - hl lines.
F,f is the effective tension in the case of horizontal no
1.6.7 MULTI-DRIVE SYSTEM
1.6.7.1 Purpose of Multi-drive system
In case of a comparatively horizontal and long span
line the value of the running resistance in the
return side becomes considerably large. In such a
case this system is good for reducing the return
side running resistance, which was absorbed at the
t ai l driving portion from the head driving portion. I
1.6.7.2 PROCEDURE OF CALCULATING MULTI-
DRIVE SYSTEM
(1) Obtain total required power, P.
(2) Obtain the running resistance in the carrying
side (Fc) and the running resistance in the
return side (F R ) respectively.
(3) Consider the number of standard motors to
satisfy the total required power, P. Further,
consider the t ai l motor with the power of more
than 0.4 times of the horizontal no load power,
P, and also corresponding to the required
number of motors having the standard power.
(4) The effective tension of each driving pulley
from each motor shall be considered similar.
(The consuming ampere of each motor shall be
checked and set so as to be equal after
installation).
(5) Calculate the necessary tension and the tension
to be applied to each portion of the belt in
accordance with (4).
1 2 belt.
1.6.7.3 EXPLANATION OF SYMBOLS OF MULTI-
DRIVE SYSTEM
The following symbols are used for the tension
calculation formula for obtaining the maximum
tension of the multi-drive system. These symbols
are in addition to those contained in JIS-6-8805.
Fp: Total effective tension (kg)
F ~ H : Head effective tension (kg)
F P H ~ F p ~ 2 : Effective tension of 1st and 2nd
head drives
F ~ T : Tail effective tension (kg)
Fc: Carrier side running resistance (kg)
FR: Return side running resistance (kg)
6 H: Angle of belt wrap at head drive (radian)
6 ~ : Angle of belt wrap at tail drive (radian)
p ~ : Coefficient of friction between head drive
pulley and belt
p ~ : Coefficient of friction between t ai l &e
pulley and belt
F1 H : Head tight side tension (kg)
FIT: Tail tight side tension (kg)
F ~ H : Head slack side tension (kg)
F ~ T : Tail slack side tension (kg)
FH 1.2 or F 1.2: Tension between I s t and 2nd head
drives
Wc: Carrying idler roller weight (kglm)
1.6.7.4 CALCULATION EXAMPLE OF MULTI-DRIVE
SYSTEM
Belt width: 900 mm Trough angle: 20"
Belt speed: 200mlmin. Carrying material: Limes-
Carrying quantity: 1500 t/h tone
Horizontal conveyor
(1) Obtain the required power.
PI = 0.06 x 0.022 x 76.3 x 200 x 51000 + 66 =
367
(2) Obtain the total effective tension (Fp), the re-
turn side running resistance ( FR) and the
minimum tension ( F, ).
FR = 0.022 x (25 + 6.3) x 5066 = 3,490 kg
Fc=f ( W, +WC+WM) (Q+Q, )+-W~h(kg) (16.2)
6120 x 733.7
F p = 200
= FPH + FPT = 22,451 kg
FR . . . . . . . . . . Refer t o the formula (1 5).
Qt Fc = Fp- FR = 18,961 kg
WM = 0.06.v (kglm) . . . . . . . . . . . . . . . . (1 6.3)
= 1,875 kg (Sag = 1 %) Qc = 1.0 m
- -- g ;
WM : Carrying quantity per mtr. (kgJm)
(3) Motors with the total ~apaci t y of 1,000 KW
shall be installed based upon the total required
power of 91 7 KW as calculated in (1 ).
f : Coefficient of rotational friction of the idler
(4) The following plans are considered for deter-
h: l i ft (m) mining the driving position and distributing the
Qt: Carrying quantity (tl h)
motors with the total capacity of 1,000 KW
Q: Horizontal conveyor length (m)
based upon the formula of "Horizontal no load
Q :
Corrected value of the center distance (m)
power PI x 0.4 = 278.1 x 0.4 = 120 KWH.
V : Belt speed (mlmin)
Plan 1 Plan 2
P:
Required power (s'haft horsepower) (kw)
drive at
Installed motor 200kW x 2 Sets 250kW x 2 Sets
1 1,226 kg
Installed motor 2OOkW x 2 Sets 250kW x I Set
;Iriv: at ' Effective tension F M 8,981 kg
ea
5,613 kg
Tail Installed motor 200kW x 1 Set 250kW x 1 Set
drive Effective tension Fm 4.490 ka 5.61 2 kn
in the driving positions and
=0.25, &1 = &2 =
the tension at
Tension at each point I Plan 1 I Plan 2
I I
Point A 1 21.956 ka 1 22.705 ka
Point B 12,975 " 1 1,479 "
FPHZ 8,980 " 5,613 "
. Point C 3.995 " 5.866 "
Point D 7,485 " 9,356 "
Fm 4.490 " 5.61 2 "
Point E 2,995 " 3,744 "
Fc 18,961 " 18,961 " .
1.6.7.5(A) Typical driving positions and tension r
distribution of the multi-drive system
( 1 ) Horizontal Conveyor with Drives at Head anc'
I
Tail
Whichever larger value of:
FM=FPT.RT+Fp-F~+Fa Or FI f Fs +FP-FR
I CHAPTER 1 ]
(3) Lowering Conveyor (No holdback) with Drives
at Head and Tail
F u = F p ~ . R ~ + FP- FR- F~: Or:F, +FP-FR-F~
(4) Horizontal Conveyor with Multi-Drive System
1
1 Or
@ F, +FP-FR-FPHI
e ~ 2 0 2 - 1
FP2 =
Fp (kg). . . . . . . . . (16.5)
eP202 e ~ ~ e ~ - 1
Whichever larger value of:-
FM= FPT .RT + Fp- FR or F4 + Fp- FR
Effective tension distribution of tandem drive
system:
e ~ 2 8 2 - 1
F p 2 =
&282eP18~ - 1
FP (kg)
When the frictional connection i s perfectly utilized,
the effective tension distribution of the tandem
drive system i s similar to that of the dual drive
system. There are problems regarding both tandem
and dual drive. So, please consult with us.
t
.& TENSION DISTRIBUTION OF THE TYPICAL DUAL
DRIVE SYSTEM
. ,
' Horizontal Convevor with Dual Drive at or near
1.6.8 TENSION DISTRIBUTION OF THE REVERSIBLE
CONVEYOR
1
1. Operation in reverse direction
F M= Fp2- & + FP Or F4 + FF- FR
2. Operation i n regular direction
a) I n case of F MR> F ~ N or F ~ N
FM=FPR(I+R)+F~N Or FIR+ FPR+FPN
b) In case of FMR<F~N or F4N
FM=FPN( I +R) or F, N+FCN
c) Other combinations may be considered, about
which calculation will be made by us upon
request.
1.6.9 ACCELERATING RESISTANCE AND ACCELE-
RATING TIME
The relation between accelerating resistance and
accelerating time, when starting the belt, is a:
shown below.
FA: Accelerating resistance (kg)
: Accelerating time (sec.)
The starting tension when starting the belt gently is
calculated as 135% of the maximum tension at the
time of normal loaded running (the accelerating
resistance i s 35% of the maximum tension at the
time of normal loaded running). The starting time
can be determined by the formula (19), which i s
developed from the formula (1 7).
50
v(Q+Q, ) (W, +-Qt)
t = 3v ....................... (18)
2 0 6 F~
1.6.10 CALCULATION OF TAKE-UP WEIGHT
(1 ) Types of take-up
There are screw type, gravity type, carriage with
gravity weight suspended type, and power take-up
type, about which please refer to 1.1.2.
(2) Calculation of Take-up Weight
2.1 The take-up weight i s fundamentally 2 times of
the tension applied to the take-up position.
2.2 Method of determining take-up weight depend-
ing upon the take-up position.
(c) Horizontal Conveyor with Drive at or near
Head and with take-up system provided a t Tail
(a) Horizontal Conveyor with Drive a t or near
Head and with take-up system provided a t
Head '-
, . .
Take-up weight = 2Fp- R or 2(F4 - FR)
rlh~hichever larger value)
Take-up weight =~(FP.R+FR) or 2F,
(whichever larger value)
~rizontal Conveyor with Drive a t or near
and with take-up system provided middle
1 1 ~ ~ d n between Head and Tail.
- F4-.FR
1 -
I ' I - I '
'
Take-upweight =2(FpqR+-Fa) or 2(F4 - T F ~ )
I
(whichever larger value)
@5iiii$z)
(a) Elevating Conveyor wi t h Dri ve at or near Head
(c) Elevating Conveyor wi t h Drive at or near Head
and wi t h Take-up System provided at Head
and Take-up System provided at Tai l
(b) Elevating Conveyor wi t h Drive at or near Head
I n case of (a):
and wi t h Take-up System provid& mi ddl e
Whichever larger value of 2FpR or 2( F4 + F3 -
port i on between Head and Tai l FR)
I n case of (b):
F3 = Wl h
Q'
F3' = W1 h-
Q
Consequently, t he take-up weight shall be which-
Q r
ever larger value of 2 [FPR +y ( FR - FB OT
2 [ F ~ +yr ( F3- FR) ]
I
I n case o f (c) :
Whichever larger value of 2(FPR + FR - F3) or
2F4
d
1.7 BELT CARCASS SELECTION
.7.1 DETERMINATION OF CARCASS AND NUMBER
OF PLY STUDY FROM TENSION
he maximum tension, FM to be applied t o the
e belt width is usually used for b Value. More
the number of ply shall be determined from
Standard Permissible Tension Table.
relation between breaking tension of the fiber
the standard permissible tension is called as the
In case of the fibrous tension layer:
b x n x B S
. . . . . . . . . . . . . (20)
SF: Safety Factor
FM: Maximum tension (kg)
b: Belt width (cm)
n: Number of ply
BS: Breaking strength of tension layer (kglcmp)
(b) In case of the steel cords tension layer:
FM x SF,
. . . . . . . . . . . . . . ST- NO=
b
(21)
FM :
SF, :
ST - No: Breaking Strength of Steel Cord
belt per 1 cm width (kg/cm)
Maximum Tension (kg)
1st Safety Factor (Safety factor
against maximum static load).
Generally more than 7.
Standard Permissible Tension for Vulcanized Splices
Carcass
Pexmissibl~ Tension
Designation
NV- 50 4.1 kglcm ply
NN-100 8.3 kglcm ply
NN--120 10.0 kglcm ply
0
.-
2
NN-150 1 2.5 kglcm ply
m
LL NN-200 16.6 kglcm ply
C
0
-
>.
z
NN-400 33.3 kg/cm ply
c VN-100 8.3 kglcm ply
0 0
- .-
$4
VN-120 10.0 kglcm ply
5 VN-150 12.5 kglcm ply
1.7.2 STUDY OF MAXIMUM PLIES FOR TROUGHING
When the belt i s not adaptable to the carrier angle,
it i s liable to cause crooked running. Ideally it i s
necessary that the belt touches the center roller
without being loaded. It i s quite indispensable in
the case of U-Type Conveyor. When the trough
angle i s 20" - 30, the belt will become adaptable
to the trough while using, even if the initial
condition of the trough i s slightly unsatisfactory. It
is, however, the matter of degree. It is required to
select less ply depending upon the trough angle.
Maximum Plies for Trough Angle of 20
.
\ Belt width I
NV- 50 1 With these widths and kjnds of canvas
there i s no problem as the maximum
NN-100 number of ply.
Maximum Plies for Trw* .Angle of 30
there i s no problem as the maximum
number of ply.
N N-500
- - - 4 5 6
N N-600
- - - 4 5 6
VN-100 4 4 6 7 8 8
VN-120 4 4 6 7 8 8
VN-150 3 4 5 6 7 8
1.7.3 STUDY OF MI NI MUM PLIES
Some degree of safety factor i s taken into
consideration when determining the minimum
number of ply. So, our users should employ the
specification of belt being actually used as the
proper specification, i f no trouble has been taken
place for more than two years in the past due to
the following causes.
Belt must be of over ply due to the concentrated
load given by big lumps of the material between
carriers and impact at the chute. Namely, the
number of ply should be determined finally after
studying the necessary number of ply for each item
as mentioned later.
1.7.3.1 Problem of Sag due to Concektrated Stress
Study of minimum number of ply against the
problem of sag being increased between carriers by
lumps of carrying material.
As t o the problem of sag it i s usual that the sag i s
applied in such a manner that it i s kept within 2%
of the carrier spacing. But, abnormal sag i s created
between two carriers when big lumps are loaded,
even i f the total carrying quantity i s unchanged.
Table 1.24 shows the minimum numbers of ply
against this problem.
1.7.3.2 Problem of Impact at the Chute
Study of minimum number of ply against impact
a t the chute, Various types of carrier are used a t
the chute such as ordinary carriers, cushion rollers
and zero pressure rubber tires etc. Further, the
materials may fall down between carriers or upon
carriers (or cushion rollers). When the impact i s
considered, i t s force must naturally be taken into
consideration. In this case the following factors
shall be taken up.
(a) Weight and Shape of Maximum Lump
Various shapes may be considered, but generally
they are to be considered quite irregular. (There i s
such an exceptional case like boulders before being
crushed).
(b) Dropping Speed
The dropping speed is affected by the dropping
height (height of chute).
(c) Chute Angle
Component of a force varies depending upon the
chute angle and the impact force against the belt
differs accordingly.
CT - ] Weight of Lump (kg)
1.7.3.3 Problem of Load Support
It i s stated in Para. 1.7.2, "Study of Maximum
Plies for Troughin" that the belt must be adaptable
to the carrier angle. I f the belt i s too soft, it may
be deformed and caught in the gap between 3-roll
troughing idlers because the carriejs are angular. In
such a case it i s feared that the belt will cause ply
separation. Table 1.27 shows the study of mini-
mum number of ply in such a case.
Table 1.23 Weight of Lump (kg)
When the actual weight of the lump i s known (or
can be calculated), i t s value is to be used. As an
expedient please use the following Table. -Please
note, however, that in this Table cubic materials
are used for the sizes up to 150 mlm, and rectan-
gular or plate like materials are used for the sizes of
more than 150 mm.
Bulk Density
(tonlm3
0.5
0.8
1 .O
1.2
1.5
2.0
2.5
Lump S;re (mm)
50
0.1
0.16
0.2
0.24
0.3
0.4
0.5
300
20
32
40
48
60
79.5
99.5
350
28
45
56.5
68
85
113
141
75
0.38
0.6
0.75
0.9
1.1
1.5
1.8
400
42.3
67.5
84.5
101
127
169
-
212
-
175
4.0
6.4
7.9
9.5
9.6
15.9
19.9
100
0.85
1.4
1.7
2.0
2.6
3.4
4.2
200
5.9
9.5
11.8
14.2
17.7
23.6
29.5
125
1.6
2.5
3.1
3.7
4.7
6.3
7.9
225
8.4
13.5
16.8
20.2
25.2
33.6
42
150
2.9
4.5
5.7
6.8
8.5
11.4
14.2
250
11.5
18
23
28
34
46
57.5
1.25 & 1.26 - Study of Minimum Number
use Table 1.23 for the weight of
rding the speed and the chute angle a
in standard fall shall be considered.
straight dropping.
Value of sin2 A
Chute angle Sin
2
A
15 0.067
20 0.1 17
25 0.179
30 0.250
35 0.329
40 - 0.413
45 0.500
50 0.587
55 0.671
60 0.750
65 0.821
70 0.883
Example of compensating the weight of carrying
material when using Table 1.26.
Actual lump weight: 20 kg, Chute construction -
Total fall: 2.0 m, Chute angle: 45, & Direct fall
height: 0.3 m.
If this formula i s used, it i s unable to design when
the chute condition i s unknown. So, it i s necessary
to investigate the condition of use. If it i s obliged
to design with the condition of use unknown, the
chute condition designed should be clearly stated.
When the condition of use i s unknown, the
standard calculation shall be made with the total
fall of 1.5 m, chute angle of 60" and the direct fall
height of 30cm from the extreme point of the
chute to the belt. In this case the compensation
value shall be 0.8 as calculated below.
(T-8 Ordinary Belt
Problem of Load Support
Spacing of carrying idler i s assumed to be 1.2 m.
The unit carrying quantity between carriers will
come into question. So, firstly calculate the
carrying quantity per mtr and make study by
putting the calculated quantity into Table 1.27.
Qt x 16.6
Carrying quantity per mtr. WM :
v
(kglm)
. . . . . . . . . . . . . . . . . . . . . (16-2)
Qt: Carrying quantity (tl h)
v : Belt speed (rnlmin.)
Note: I . Each figure above the oblique line I/) is me value in the
case of ordinary carrier and the figure below the oblique
line shows the value in the case of cushion roller or zero
pressure tire.
2. When the distribution of the maximum lump is more than
25%, please use the carcass of I ply over.
Carrying Quantity (kglm)
Carcass PI y
Belt Width
'1 00 100 38 90 1 54 901-1200
r
120 120 15 60 120 1 200 over
60 128 225 406 up to QOO
1 50 150 85 177 345 QOl"1209
1 28 255 1200 over
200 112 233 457
1
901-1200
I 1 2 5 0 I I 75 1 1 5 0 1 316. 1200 over
90 225 496 900
1 58 360 698
90 225 495 1200 over
126 315 693 1260 up to 900
350 221 504 978 901-1200
126 315 M3 over 1200 over
1.7.3.4 Method for Determining Minimum Plies
@TzFm8)
1.8 MINIMUM PULLEY DIAMETER
If the pulley diameter i s small, it i s advantageous
from the standpoint of equipment cost. But, the
smaller the pul!ey diameter and the thicker the belt
fabric, the more violent becomes the carcass
fatigue. So, the standard minimum required pulley
diameter was determined as below. Namely, the
values of head, drive and tripper pulleys are as
shown in Table 1.29. The tail take-up pulley i s to
be 80% of the standard value, and the values of
bend, rotation snub pulleys are 60% of the
standard values.
Safety Factor and Pulley Diameter:
The ratio of actual working tension to standard
permissible tension i s assumed to be A.
A =
Fb x 100..(23.1)
Std. Permissible Tension x n
Fb = - FM (kg)
b
FM : Maximum Tension (kg)
b: Width (mm)
~ t d . Permissible Tension = BS . . . . . . . (23.2)
SF Std.
BS: Breaking Strength (kg/cmP)
SF Std.: Std. Safety Factor
In case of ordinary carcass fabric:
For general use . . . . . . . . . . . . . . . . 12
. . . . . . . . . . . . . . . . For heat resisting 15
n: Number of plies
Obtain K value based upon A value in Table 1.29
and the minimum value shall be obtained by
multiplying the standard value by K%.
Note: When the value of more than 7pl y is selected in determining
the number of ply, the maximum number of ply in principle
shall be within 6 ply by selecting the carcass in one rank or
more.
(TABLE 1.30)
Std. Minimum Pulley Diameter (Head &
Drive Pulley) (unit: (mrn)
8P
No. of Plies
Fabric
\
6P 7P 3P 4P 5P
1.9 COVER THICKNESS
1.9.1 FABRIC BELT
It is very difficult to determine the kind and
thickness of cover rubber. For example, although it
is understood that the cover rubber of 6 mm thick
will be more advantageous than that of 5 mm thick
in i t s life expectancy, it i s unknown i f the latter
cover rubber will be damaged or to what extent i t s
life will be shorter than the former. (For heat
resisting and oil resisting uses it i s of cource
necessary to select the belt suitable for the use).
The following Table shows the nominal standard
thickness. However, the actual thickness' shall be
determined in accordance with the user's intention.
( ~ - 1 )
Cover Rtrbber Thickness for General Use
Thickness (mm)
Carrying Material
Top Cover Bottom Cover
(1) Non-abrasive materials 1.5 s 1.5
such as cereals, chips,
cotton, cement & dust
2 1.5
coal
3 1.5
(2) Slightly abrasive ma-
terials such as sand, soil
& small lump coal
(3) Limestone, refuse &
crushed stone of which
lump sizes are below 50
mm but angular, and
coke
(4) Crude coal, limestone, I
refuse & crushed stone
of which lump sizes are
over 50m/m, and angular
(5) Big lumps with much 1 6 1
specific gravity and an-
gular shape
Cover Rubber Thickness for Heat Resisting Use,
Top Cover (mm) Bottom Cover (mm)
1.5-3
1 case of the heat resisting cover it may be
msidered that the cover thickness (particularly of
1.9.2 STEEL CORD BELT
Please refer to our ST BELT catalogue.
p cover) is proportional t o i t s life. So, thicker
bar i s desireable, i f the budget allows.
1.10 BREAKER
I
I case of the oil resisting cover abrasion resistance
Efficiency of Neutral Breaker:
not r
e
q
uired
so much in many cases- So, the The neutral breaker is sometimes inserted as
bkness is t o be generally about 1.0 mm for both
shown below in order to avoid the progress of
rp and bottom cover. If the abrasion resistance i s
rubber cut, which is liable to take place in the
guall~ the thickness shall be
direction of thickness, when the carrying materials
4 mq-i.
are acute.
I
k i i e for using Feeder Belt:
m belt life i s short in case of the short conveyor
@m@
Nth like feeder belt. I t i s because the time cycle
- Neutral breaker
,$on thereby the cover rubber being damaged
dly. In such a case the measures to lengthen the I .-.- 1
kt life by making the cover rubber thicker in
one rank.
Examples of selecting cover rubber thickness and
breaker are as shown in the next TABLE. 1.34.
3 Covet Rubber Thickness 8 BreaW
Premise Condition Cover Thickness Nmwt
Max. lump Conveyor
diameter
'
N y h
'
length width Bottom m k W
(rnrn). hl (mmt
below 100 Ordintq " W W VN-120 4 3 - 4 1.5- 2 -
below I@ O~dinary rgjOO NN-2QIO k 5- 6 2 - 3 1 NB
50 0rrhar)t 60 450 VN-100 w' 3 2.0- 3.0 1.5 -
-I__------
50 Ordinary 50
460 NV- 80 4 5 - 6 2 - 3 INB
urum
I diem. 300 ( ( 30 1 7% 1 NV- @O 1 5 1 5 - 7 ( 3 1 IN0
L I f i some instance tihe intermediais breaker, NB ia: not i ~ m d .
r,
HOW T O
SELECT BUCKET ELmIATOR BELT
2.1 KIND OF BUCKET ELEVATOR BELT
There are two kinds of bucket elevator belt as
shown below.
Continuous Bucket Elevator Centri fugl Dischargts Elevator
-- I
r
2.2 CALCULATION OF TENSION TO BE
APPLIED TO BUCKET ELEVATOR BELT
The tension shall be obtained by making the
weight calculation as below.
2.21 VERTICAL TYPE BUCKET ELEVATOR BELT
FM = F1 = M+ N+ Q+ S + T
Fp = Q+S
F2 = M+ N + T
FM : Maximum tension applied to elevator
belt (kg)
F, : Tight side (loading side) tension of elevator
belt (kg)
Fp : Effective tension of elevator belt (kg)
F, : Slack side (unloading side) tension of ele-
vator belt (kg)
M : % of the total belt weight (kg)
N : 1/2 of the total bucket weight (kg)
Q : Weight of carrying materials to be loaded at
the maximum in al l the buckets in the load-
ing side (kg)
S : Resistance received by the bucket at boot
pulley (kg)
S = 2. Qt . D
v
Qt: Carrying quantity (t l h)
D: Boot pulley dia.meter (cm)
v: Belt speed (mlmin)
T : % of the weight of boot pulley and takeup
(kg) (Consequently, it i s not necessary to
add the weight, when the boot pulley i s of
screw fixed type.
2.2.2 SLOPED TYPE BUCKET ELEVATOR BELT
FM = F, = sina (M + N + Q + S + T)
Fp = sin& (Q + S)
FS = sin& (M + N + T)
a : Inclination angle of the line
#
1
2.3 CALCULATION OF REQUIRED POWER 2.4 DETERMINATION OF CARCASS AND
NUMBER OF PLY
Kind of carcass, i t s strength and number of ply
shall Be determined studying the following fac-
tors.
1) Kind of carcass for the condition of use
(carrying material, wet or d r ~ , temperature
etc.)
2) Carcass strength and number of ply against
maximum tension
3) Maximum number of ply (minimum pulley
diameter)
4) Minimum number of ply (efficiency of bolt)
P: Required power for driving pulley (kW)
2.4.1 STUDY FROM THE CONDITION OF USE
Conventionally, cotton fabric has been much used
for the bucket elevator belt. Recently, however,
vinylon fabric i s recommended as the tension
member for "YOKOHAMA" Bucket Elevator
Belt, because vinylon fabric has high strength and
l i t t l e elongation meeting with almost al l the
conditions of use.
So, please design your belt with this standard
fabric excepting some very special case.
24.2 STUDY OF CARCASS STRENGTH AGAINST
MAXIMUM TENSION
Kind of Carcass
Maximum Working Tension
VN-150 7.5 kglamp
VN-200
24.3 STUDY OF MINIMUM PULLEY DIAMETER
<m]
24.4 STUDY OF BOLT EFFICIENCY
The number of carcass ply shall be determined by
obtaining the efficiency of bolt E in accordance
with the following formula and then determining
the kind of carcass and the number of ply from
TABLE 2.3
Type of Continuous Bucket Elevator
E=0.7A ( WB + w ~ )
Type of Centrifugal Discharge Elevator
E = 0.88FA (WB + WM )
E: Efficiency of bolt
A: Distance as shown in the sketch (cm)
Coefficient F Grading
1 .O below 25 rnrn diarn.
1.3 below 50 rnrn diarn.
1.7 below 75 mrn diarn.
Wg :Unit weight of a bucket (kg)
WM Weight of carrying material in a bucket (kg)
F : Coefficient of carrying material according t o
' grading
2.5 METHOD OF SPLICING BUCKET ELEVATOR BELT
There are 3 methods of splicing the belt, viz. by
means of lap joint, metal clamp and vulcaniza-
25.2 BY METALIC CLAMPS
tion.
1
25.1 LAP JOINT
In general, this method is used for thin belt or
for temporarily splicing prior t o vulcanization.
.The lap length depends upon the kind and width
of fabric used for the belt carcass, but it i s
usually made 2 - 4 times of the bucket spacing.
Unlike the general conveyor belts, it i s very
difficult to calculate the splicing length of bucket
elevator belt. So, this method i s convenient. It i s
used in principle for splicing the light duty belt or
thin belt.
\
The belt edges are bolted between clamps as
sketched. It i s necessary to have the width of
clamp narrower than the belt width and to round
off the corner of the clamp.
25.3 VULCANIZATION
This method i s used for the high tension line belt
and also when it i s necessary to have smooth
running and longer belt life. There is such a
tendency, however, that the longer the operation
time the higher cost i s required.
When the take-up stroke i s insufficient, splicing
i s temporarily made by lap joint method. Some-
times, vulcanization splicing i s performed after
the initial elongation is eliminated. The method
of processing vulcanization splicing i s similar to
that of general conveyor belts.
Basic Idea for Equipment and Maintenance:
I t i s no exageration to say that the life of
conveyor belt depends upon the equipments and
i t s maintenance and control.
I t i s fundamentally necessary to take into con-
sideration of the following questions.
1. Prevention of impact.
2. Prevention of deposit of cake.
3. Prevention of carrying materials from being
trapped (in pulley portion and etc.).
4. Prevention of crokked running.
5. Prevention of abnormal wear a t the skirt,
scraper and chute.
6. Prevention (detection) of longitudinal tear.
7. Detection of carrying materials being block-
aded a t the chute and discharging point.
8. Curvature radius at the angle transition point
of the line.
9. Distance between trough type rollers and the
pulley, and their disposition. (Transition dis-
tance)
10. Prevention of overloading.
11. Disposition of carrier and return rollers.
I f the various kinds of machine and equipment
always operate properly, the belt will surely keep
i t s life longer and the satisfactory performance
can be achieved.
To perform daily inspection and control of the
equipments together with fully equipping so as to
satisfy the above stated questions i s the key to
extend the life of your belt.
3.1 PREVENTION OF IMPACT
(EExi )
There are various causes to damage the belt arlu
to invite an accident. Particularly, the chute i s
the portion where the belt i s mostly liable to
be damaged. If the construction of the chute i s
such that a large lump of material directly drops
upon the belt from a high place as shown above,
cutting and chipping of cover rubber and the
fatigue and cutting of carcass cannot be avoided,
making the life of belt very short, no matter how
good the construction of other parts may be.
I t is necessary to select and employ the construc-
tions as described below in order to prevent these
damages.
I
(a) To ininimize the chute fall
I f the distance of fall i s long, the construction as
shown below shall be employed so as to reduce
the impact strength.
1
@ Ladder Chute
@ Feeders
When, the feeders as shown below are equipped,
impact, wear and cut can be remarkably reduced.
The kind of feeder shall be selected in accordance
with the nature of carrying material and the
condition of installation.
c n ) Belr Feeder
Reciprocating Feeder
Ross Feeder
(b) There are following other methods to reduce
impact.
@To install Dead Stock (Stone Box).
2 To hang Curtain.
(3.5)
3 To apply Bar Screen at the end of chu
(Finer particles will be firstly put on the b
followed by larger lumps.)
(-1 Condition of Material Loading'
Skirt
I
(FiGm)
ning Direction of Belt
Skirt shall be equipped
in such a manner as
a < b or a' < b'.
4 To cut the chute end in V shape. (Finer
particles will be loaded first.)
5 To use Pneumatic or 0-pressure Rubber Tures
as the cushion rollers.
I n this case, however, the carrying materials
may jump up and be spilled because of their
direction good cushion. SO, it i s necessary to apply a
Of
cover over the upper surface of the chute.
6 To provide Air Spring or ordinary Spring on
the cushion roller rack.
3.2 PREVENTION OF DEPOSITE OF CAKE
The abnormal deformation due to the deposit of
( - 1
sediments of carrying materials (cakes) adversely
affects the belt similarly to the trapped materials,
which results in damaging carcass.
I t i s primarily necessary to perfectly clean the
belt after unloading the carrying materials so as
not to allow the cakes be deposited on the
surface of pulley and roller.
I t i s sometimes difficult, however, to perfectly
clean the belt depending upon the condition of
loading materials and etc. So, it i s necessary to
equip an iron scraper to each pulley so that the
cakes may not be deposited, even i f a little soiled
surface of the belt contacts the pulley and the
roller. In case of a long span belt there i s such a
@ m 2 ]
method as to turn over the return belt near the
head and t ai l portions so that the unsoiled lower
1
cover rubber may contact the return rollers. The
distance required for turning over the belt (which
varies depending upon the tension to be applied
to the belt at the point of turning over the belt)
i s said to be as listed below.
MORDSTEIN
Roller Type
Nylon Canvas Belt about 10 times of about 8 times of
belt width belt width
about 12.5 times about 10 times
ST Belt about 25 times about 20 times
Methods of Cleaning Belt:
(a) Belt Scraper
In general, rubber scrapers shall be provided a t ,
the discharging point as many as possible. I t i s
not advisable to use old belt, because small pieces
of carrying material may be trapped in between
canvas plies causing the belt wear.
Single plate type cleaner
Belt &
Single plate type cleaner
(b) Spiral Rubber Roller
This i s the roller provided with spiral rubber and
it is effective for some carrying material.
(c) Washing Type Cleaner
( F ~ Q
Return idler
Drain trough
1
Note: This is 8 very effective method, i f there is no problem in the disposal of water after washing.
(d) Nylon Brush Cleaning
This method i s effective when carrying dry
powder. I t i s advisable to provide a nylon brush
1- in such a manner that the point of i t s hair lightly
[ touches the belt surface. (No good effect can be
expected, i f the brush i s too strongly pushed
Lagainst the belt surface.) It i s further necessary t o
remove the powder trapped between the brush
.hairs in order to l et the belt work properly. (See
I Fig. 3.15)
(e) Washing Belt with Nylong Brush
This i s the combined method of Washing Type
Cleaner and Nylon Brush Cleaning, and it i s very
effective. It i s necessary, however, to take into
consideration of drainage. (See Fig. 3.16)
Nylon brush belt
Nylon brush plate
+
Drain
3.3 PREVENTION OF CARRYING MATERIAL FROM BEING TRAPPED
When the carrying materials are trapped in -as
( - 3
shown in Fig. 3.17, it will result in cutting the
carcass. So, it should be prevented by all means.
According to our experiments and actual results
it is found that the carcass is cut, when the
lumps of about 30 - 40 mm in size are trapped
in while carrying angular rigid material.
Generally, it i s necessary to equip the systems as
shown below, although the actual condition may
vary depending upon the limit of each line.
VShaped Scraper (2 - 3 stages)
C7
VShaped Scraper
\ Steel Plate
Pulley scraper concurrent
with Vshaped scraper
\
Rubber
Chute Switch
Steel Plate
Rubber
Deck Plate
Pulley scraper concurrent
with V-shaped scraper
U Side Cover (wire net)
Scraper
Prevention' of the materials from being trapped in
-4spxferrnedAy-meansafAescraper, V-shaped
,
scraper, deck plate and wire net pulley cover ( at
take-up portion etc.) as shown in Figs. 3.18 and
C
(a) Near chute and t ai l pulley
The chute i s the portion where trapping of
carrying materials takes place very of.ten. So, the
following arrangements shall be taken t o prevent
'
the materials from being spilled.
To make the trough angle of the belt larger
, particularly a t the chute portion. ( I t i s easily
done with ST Belt).
. The length of skirt shall be long enough for
allowing the materials stabilized.
To make the falling distance of the loading
materials as short as possible to prevent them
from being scattered.
.
To install the chute in such a manner that the
F
loading materials are placed in the center of
the belt.
Further, the following arrangements shall be
made so that the materials may not be trapped
i n , even i f $hey are spilled.
a To install a deck plate under the chute, 3
which length shall be longer than the skirt in
about 4 - 5 m.
To equip about 2 V-shaped scrapers a t the
lower side of the deck plate.
To equip a scraper (deflector) concurrent with
V-shaped scraper to the tail pulley.
To apply wire nets on the side.
By making these arrangements trapping of the
materials near the tail can be perfectly prevented.
(b) Near head
This portion i s liable t o cause trapping of the
- - - - - - - -
materials next to WCc3iuie,and it i s ner:essaryte--
have the following countermeasures.
To provide a chute switch for preventing
pile-up and overflow of the materials a t the
I
discharging chute. ( I f the materials overflow,
they will be spilled on the return belt, which
\
may cause trapping.
To equip 2 or 3 rubber scrapers concurrently
with the purpose of cleaning the belt after
unloading the materials.
To mount 1 or 2 V-shaped scrapers upon the
return belt.
To apply a deck plate between upper and
I
lower belt.
(c) Near drive
Maximum tension is applied to the belt before it
enters in the driving pulley and i f the materials
are trapped in near this portion, it i s liable to be
more badly damaged than in other places. It is,
therefore, necessary t o have the followong ar-
rangements.
To equip always a scraper t o the snubbed
pulley.
-c=_ad& plate near the driving portion.
-7---------
To apply a wire net at the side.
(dl Near take-up
I f a pulley cover and further a wire net are
applied in addition t o the deck plate, when the
take-up i s positioned immediately behind the
driving pulley as shown in Fig. 3.19, trapping of
the materials can be prevented in 100%.
3.4 PREVENTION OF CROOKED RUNNING
One of the main causes of the damages of conveyor
@ - )
belt i s the damage a t the edge due to crooked
running. The methods to correct and prevent the
crokked running are as follows.
( 1) To use self-aligning idler
There are several types of self-aligning idler based
upon various principles, each of which i s arranged
so that the running belt will be slowly .returned
back toward the center by means of rotation of the
roller, when the belt runs in one direction.
(2) To incline carrying idlers forwardly
It i s of the same sense as to use crowend pulley so
that the belt may always come to the center of the
pulley. The carrying idlers can be inclined by filling
the liner back-wardly of the supporting stems in
both sides. But, if they are inclined too much, the
belt will be excwdingty worn out by the rollers.
The height of the carrying idlers shall not be
changed in more than 3 - 5 mm.
\ Running direction of belt
This position, when the
spacer isinserted, is apart
from the end of the gauge
Gauge
in 35mm.
L Spacer
The position where the belt and carrier contact,
The position where the belr contacts the carrier,
when the carrier is located properly.
when the carrier is inclined.
- T n n i n g diiection of belt 1
Direction of the
force to keep the
belt in the center.
Position of carrier rollers and gauge
(3) Prevention of crooked running in the return
side
It i s very effective to use 2-roller idler (1 0"- 15"
Trough) in the entire or part of return idlers for
providing centering effect.
3.5 PREVENTION OF ABNORMAL WEAR AT THE SKIRT, THE SCRAPER OF THE CHUTE POINT
(FIG. 3.21) Methods of Skirt
Skirt board
Skirt rubber
L Cushion idler
(b) I t i s the object of providing the skirt to prevent
the materials loaded on the belt from spilling or to
properly shape the carrying materials. The size of
the skirt should be proper, otherwise an improper
skirt will cause spilling of the loaded materials and
the abnormal wear of the belt co<er.
(c) It i s necessary to have the skirt length in 2 - 4
times of the belt width, viz. usually 1.2 - 1.5 m
long, and further t o make it longer when carrying
larger lumps and with inclination. But, the length
may vary depending upon the kind of carrying
material, the type of chute and the inclination
angle of the belt, and theoretically the length must
reach t o the belt.
Further, it i s limited to such a case as to absolutely
prevent the materials from spilling out of the belt
4
-
that the skirt board i s to be mounted throughout
,
the belt length.
(d) Spacing of the skirt shall be 213 - 314 of the
belt width and it i s proper to make it narrower
(a) The skirt i s provided so as to eliminate the spill
when the carrying materials are lumpy.
of the loading materials and to stabilize the It must be specially taken care that the skirts are I
materials on the belt. But, the carrying perfor- mounted in such a manner that their shapes fan
mance may be fully exhibited or on the contrary out in the running direction of the belt. I f they are
the belt may be damaged, depending upon the way mounted in narrower relation in the running
of installation. I f the pressure against the belt, at direction, the carrying materials are caught bet-
the time of installation, i s too strong, irregular ween the belt and the skirt resulting in the damage
)
abrasion takes place in the longitudinal direction of of belt.
the belt thereby sometimes exposing the carcass.
Further, when there i s a gap between the belt and
the skirt, the carrying materials may be caught in
(e) Trapping of the materials can be reciuced by
the gap causing premature wear of the belt and
making the distance between the skirt and the belt
damaging the belt.
in the running direction very close in this side and
a little open in the forwarding direction. The
distance shall be open in about 2 cm per mtr of the
( m a skirt length.
Running direction Skirt board
Chute
I b
Shall be equipped in such a manner as a < b. f
Relation between chute and belt width
3.6
DETECTION OF MATERIAL PILE-UP AT
THE CHUTE OR DISCHARGING POINT
I f the chute or discharging portion i s piles up with
the carrying materials, it i s feared that the belt will
be badly damaged due to slipping and trapping of
the materials.
In general, there is such a method as t o equip a
battledore type limit switch on the upper portion
of the chute, which will be operated, when the
chute i s piled up, and stop the belt.
(FiExzi]
Balledore type limit switch
3.7 VERTICAL CURVES
I
The conveyor line i s not always straight but it
sometimes rises up from horizontal or becomes
horizontal from horizontal or becomes horizontal
from inclination.
When the line rises up from horizontal, it makes
concave curve and the belt will IifGoff the idlers, if
the curvature radius i s small, thereby causing
crooked runnina or saillina of the carrvina mater- 1
" ., - , . ,
ials.
Lift off the idlers at the curve
When the line becomes horizontal-from inclination,
it makes convex curve and the belt will be caught
between carrying idlers, i f the cukature radius i s
small, thereby causing ply separation.
Consequently, it is necessary to prevent the belt
injury by having the curvature radius of larger than
the standard value at the transition point and
disposing the carrying idlers accordingly.
Liable to cause separation due to buckli
(a) Concave Curve
In case of the concave curve the belt may be
floated, i f the vertical component of a force a t the
transition point i s larger than the hang tension of
the belt due to i t s tare (or belt weight + load
weight). So, it i s necessary to dispose the carrier
rollers with the curvature radius making both of
them equal or making the former larger. Further,
the belt will be in the utmost floatable condition
when it is started with the carrying materials
loaded just ahead the transition point. It i s
required that the tension at the belt edge shall not
be minus. ( I f the tension at the edge is minus, the
edges will be hung down causing the material spill.)
I t is necessary to design with the curvature radius
larger than obtained in accordance with the
following formula.
r =
F (Curvature radius with which
(W1 . cos a empty. belt will not lift off)
r =
F (Curvature radius with
(W, + WM ) cos a which loaded belt will
not lift off.)
(b) Convex Curve
To the approximately center line of the depth of
the trough type belt the tension i s applied as it i s a t
the portion, to the lower portion less tension i s
applied, and to the upper portion above the center
line much more tension i s applied. Cqnsequently, it
is necessary, when deermining the radius of
curvature, to take into consideration of the two
points that the abnormal tension will not be
applied to the belt edge and that buckling will not
be caused as the result of minus tension at the
center of the belt.
(1) Minimum radius of curvature (MinR) to pre
vent the conveyor belt edge from being applied
with more than the permissible tension.
(2) Minimum radius of curvature (MinR) to pr e
G
vent buckling with the tension at the center of the
conveyor belt width being maintained in more tha
n
zero.
L
r: Curvature radius (m)
F: Tension at transition point (kg)
W, : Belt weight (kg/m)
WM : Load weight (kg/m)
a: Transition angle
8 : Trough angle
Fk: Permissible tension (kglcm)
1 1
General Fabric Belt: BS x- -BS x-
10.5 10
I
ST Belt: BS x -BS x-
6.5 6
BS: Breaking Strength (kglcm)
Fx: Tension at transition point (kglcm)
b: ~ e l t wi dt r ( m)
F, :
1/50 Value of BS
E: Carcass modulus (kglcm)
It i s necessary to take up the larger value of (1)
and (2) obtained.
When it i s difficult to have the radius of curvature
as calculated, it i s necessary to take such counter-
measures as to make the trough angle at the
transition point shallow or to adjust the position to
mount carrier roller.
3.8 DISTANCE BETWEEN TROUGH TYPE ROLLER AND PULLEY AND THEIR DISPOSITION
(TRANSITION DISTANCE)
(1 ) Distance between trough type roller and pulley
When the distance (Q), where the belt troughed by
the carrying idlers becomes flat, i s short, abnormal
tension i s created locally inside the belt thereby
fatigueing the belt carcass in a long run.
I t i s necessary t o take it into consideration
particularly with such a line where the tension
becomes maximum at the head pulley. (Generally,
this type i s most popular.)
(2) I t i s required t o dispose the carrying idlers as
shown below in order to minimize the effect upon
the belt edge. The above Table shows the values
based upon this disposition. I f different, it i s
necessary t o have longer distance.
I
(Disposition of idler at head)
The following Table shows the kind of carcass,
trough angle and tension t o be applied thereto
respectively.
Nylon Fabric Belt Vynilon Fabric Belt ST Belt
20 30 35 45 20 30 35 45 20 30 35 45
90 - 100 0.8b 1.3b 1.4b 1.9b 1.lb 1.6b 1.8b 2.6b 1.6b 2.6b 3.lb 4.2b 1
75 -- 90 0.7b 1.2b 1.3b 1.8b 1.0b 1.5b 1.7b 2.4b 1.lb 1.7b 2.0b 2.7b ~
0.7b l . l b 1.2b 1.6b 0.9b 1.4b 1.6b 2.lb 1.0b 1.4b 1.7b 2.3b
i
50 -- 75
I
Below 50 0.6b 1.0b I . l b 1.4b 0.8b 1.3b 1.4b 1.8b 1.0b 1.4b 1.7b 2.3b I
Nore: The tension (%) is the rate of tension, to be actually applied at the competent portion, against the standard permissible tension.
t
3.9 PREVENTION OF OVERLOADING
When materials are loaded on the belt in more than
scheduled carrying quantity, they are liable to be
I spilled, and the tension to be applied t o the belt
! becomes much more than scheduled and the
predetermined safety factor is reduced. I f it is
continued for a long period of time the belt life at
the spliced part must be shortened.
Consequently, it i s necessary t o arrange that the
quantity of material t o be charged does not exceed
the scheduled quantity.
Usually, the charging quantity shall be restricted
by regulating the carrying quantity by means of
Merrick's Conveyor before charging the material or
making the sectional area of the inlet of the chute
fixed.
There is such a method as t o provide a system t o
raise an alarm when overloaded.
3.10 DISPOSITION OF CARRIER AND RETURN ROLLERS
In case of a long conveyor system the equipment
eost i s largely affected by the spacing of carrying
idlers. But, i f the number of carrying idlers i s
reduced too much, sag am6unt of the belt i s
increased thereby increasing the running resistance
and the wear of the belt heavily. Trough may not
be formed between carrier rollers causing the
material spill. The sag amount of the belt i s
determined in accordance with the following
formula and it shall be kept, by experience, within
1 - 2% of the idler spacing.
The sag amount i s the function of the weight OT
carrying material, belt tare, idler spacing and belt
tension, and has the following relation.
The formula for claculating the sag amount
between carriers:
6 : Sag amount (mm)
The following calculation will be made assuming
that the sag amount (I[) i s to be maintained within
1% of the carrier spacing (Qc).
QC
T=-(W, +WM)
8
P
C
(WI + WM) 0.01
QC - 8T
8 1
Incaseof:- - - -
Q 100
1 Qc
-- -
100- 8T( Wl +WM)
T= - loo 11, (w, +WM) =- loo Q, (W, + -- Qt
8 8 0.06V
v: Belt speed (mlmin)
Qt: Capacity (tl h)
WI: Belt tare (kg/m)
Disposition of Carrier Roller:
WM : Weight of carrying material (kglm)
The belt tension remarkably varies from the head
QC : Carrying idler spaceing (m)-
t o the tail. Further, it varies depending upon the
F4: Belt tension on the competent part (kg)
weight of belt, capacity, and belt speed, but the
standard carrier spacing i s as listed in the followina
Table.
( - 1 Standard Carrier Spa~ing (m)
Bulk Density of Carrying Material (tlrn3 )
Belt width (rnrnl Return Roller
0.5 0.8 1 2 1.6 2.6 2.0
300 1.5 1.5 1.5 1.35 1.35 1.35 3.0
450 1.5 1.5 1.5 1.35 1.35 1.2 3.0
600 1.5 1.35 1.35 1.2 1.2 1.2 3.0
750 1.5 1.35 1.2 1.2 1 . O 1 .O 3.0
900 1.35 1 35 1.2 1.2 1 .O 1 .O 3.0
1050 1.2 1 2 1 .O 1 .O 1 .Q 1 .O 3.0
1200 1.2 1.2 - 1 .O 1 .O 1 -0 0.9 2.7 -- 3
1500 1.2 1 .o 1 .a 1.0 1 .o 0.9 27. - 3
1700 over 1.2 1 .O 1.0 0.9 0.9 0.9 2.7 -- 3
HOW T O USE CONVEYOR BELT PROPERLY
There are various kinds of trouble, liable to take
place while using conveyor belt. I t i s the key for
accomplishing the belt life to preliminarily find out
the trouble, to treat it promptly and to prevent an
accident in the bud.
The causes inviting .an accident may have been
created unawares due to the wear and deterioration
of every portions of the belt during i t s long use
even with the line seemingly operating satisfac-
torily. So, such causes should be found and treated
earlier. It i s necessary t o arrange so that the
abnormality can be promptly and accurately found
by performing periodical inspection from the
beginning of the operation and realizing the
suitation of the line and the condition of use.
Items for recording the periodical inspection of
each conveyor i s the date of inspection, name of
the inspector, of each conveyor i s the date of
inspection, name of the inspector, appearance of
the belt (top and bottom cover, edge and spliced
part), running condition (croooked running, off-
center running, takeup operation status, deposit of
cake and trapping of the material) and condition of
attached equipments (rotational condition of cush-
ion idlers, carrying idlers and return idlers, attach-
ment situation of the skirt rubber and also the
condition of cleaner).
Further, the phenomenon of the trouble and i t s
causes and the cou ntermeasures shall be recorded
together.
Phenomenon
1. Belt runs to pne side
when it comes to a
certain place.
2. A certain portion of
the belt maker cro-
o ked running
throughout the total
length of frame.
Causes
A. A part of the conveyor frame i s
curved.
B. Several idlers in front of the
leaned portion are not adjusted
properly.
C. Build-up of material on the
pulley or idler in the leaning
side.
D. Idlers do not rotate well.
E. Head, tail or take-up pulley is
distorted.
F. Tripper i s distorted.
A. Spliced part i s distorted.
B. Belt body is distorted locally.
Countermeasures
A. Inspect the curved portion by stretching a
thread. Correct its verticality and horizon-
tality.
B, Adjust the hori t~ntal i ty and the perpendicu-
larity against the forwarding direction. If they
are not still corrected, incline the roller end in
the leaning side toward the forwarding direc-
tion. (Inclination angle is less than 2%).
C. Remove the cakes, and inspect and properly
treat the cleaner. Equip a cleaner, i f it is not
equipped yet.
D. Exchange the rollers. Retighten the stud bolt,
i f it i s loose.
E. Adjust each pulley.
F. Correct the distortion, even i f it i s very slight.
A. Resplice the belt if it scrubs the frame or if
the carrying materials spill. (Watch the condi-
tion for some time, because it will be cor-
rected gradually).
B. Install self-aligning idler. Adjust t ai l pulley.
Exchange the belt locally.
3. Entire belt makes
crooked runnhg a-
long the totalelength
of the frame.
A. Conveyor frame i s distorted.
B. Carrying materials are leaned
to one side. Crooked running
often takes place when the
grading of the materials r e
markably varies and large
lumps are contained.
C. Carrier roller or return roller is
one-sided1 y lowered.
D. Wind and rain.
E. Carcass i s affected by moisture
due to the edge damage.
F. Sunshine (I f the wn shines
upon one side of the f r m , the
iron thereof will be abnormally
expanded.)
G. Troughability of the belt is
inferior.
A. Strengthen the foundation and the frame
support. Adjust the frame throughout its
length. Such crooked running i s liable to take
place particularly when the ground base
changes.
6: Improve the chute so that the materials may
be loaded in the center. Adjust the construc-
tion of chute so that larger pieces of material
may be placed upon fine particles and the
load may be balanced in both sides.
C. ~easure horizontality and perpendicularity of
all the idlers and correct the abnormality.
~: ~ons t r uc t a windbreak or improve the belt
cover.
E. Investigate the cause of damage and improve
the improper part. [Refer to 7.Al
F. Avoid the direct sunshine by applying a cover.
Apply coating to deflect the light.
G. Use the belt temporarily until it becomes
adapted to the idler, or change the specifica-
tion.
Phenomenon
4. Injury of top rubber
cover
Causes
H. Belt raises up off troughing
idler, bowing toward load.
4. Improper direction of the
chute.
3. The speed of the load does not
conform to the running speed
of the belt at the chute.
C. The fall of the chute i s too
much.
D. The length and the mounting
position of the skirt are impro-
per.
E. Belt sag at the skirt i s too
much.
F. Build-up of material on the
pulley or idler.
3. The chute i s piled up with the
loading materials.
4. Maintenance of scraper or skirt
rubber i s improper.
I. The spilled materials are piled
up on the return side scrubbing
the belt.
1. Cushion idler, or return idler,
or carrying idler does not ro-
tate properly.
Countermeasures
H. This i s liable to take place when the belt
surface is swollen with oil.
Remove source of oil, if possible. Select
proper oil-resisting belt for Replacement.
A. It i s desireable that the falling direction of the
material from the chute i s similar to the
forwarding direction of the belt.
B. I f the both speeds largely differ, the load slips
as it i s placed upon the belt and it is liable to
wear the cover rubber. So, it i s desireable to
adjust the direction and the speed of the load
in conformity with the belt.
C. The impact by lumps of the material shall be
alleviated by using a moveable bar and provid-
ing a pocket at the chute, providing a feeder
belt and minimizing the chute angle.
D. Skirt board shall be widened in the forwarding
direction of the belt and making the gap
between the belt slightly larger. Equip the
skirt board up to the portion where the
carrying materials are stabilized on the belt.
E. ~ a k e the spacing of cushion idlers narrower
and increase the weight of take-up.
F. Inspect the scraper. Care must be taken to
keep the scraper plate in order, as the scraper
is liable to cause abnormal wear locally. If
there i s no scraper yet, it must be equipped.
G. Enlarge the chute portion. Restudy the chute
angle. Equip a pile-up detection device.
H. I t is not advisable to use old belt, because fine
particles of the carrying material are caught
between the fabric. Replace it with the rubber
plate for i t s exclusive use.
I. The materials may be spilled due to leaned
loading, crooked running, change of ground
and improper arrangement of the chute etc. I t
i s therefore necessary to prevent the respec-
tive cause.
J. These idlers shall be periodically adjusted and
cleaned. Each of them often causes improper
rotation due to the environmental deteriora-
tion.
Phenomenon
5. Abnormal wear of
the bottom cover
rubber
-
8. Injury of the belt
carcass
Causes
A. Slip a t the drive pulley.
B. lmproper rotation of idler and
self-aligning.
C. Wear due to trapping of fine
particles.
D. The effect of the forwardly
inclined roller is too much.
E. lmproper curvature radius at
.the transition point of the con-
vex curve. l mproper transition
distance among pulley and
troughing idler.
A. Impact by big lumps at the
chute is severe.
B. Trapping of lumps of the carry-
ing material between belt and
pulley.
C. Abnormal deformation of the
belt locally due to the build-up
of material.
D. Safety factor is decreased be-
cause the starting time is too
short, take-up weight is too
heavy or the belt i s overloaded.
E. Buckling,
Buckling
F. lmproper transition distance
between pulley and through
carrier.
G. Belt is caught and torn by the
frame due t o crooked running.
H. Flexural fatigue of the belt is
too heavy because of the small
diameter of pulley.
--
Countermeasures
A. Investigate the operation of take-up. Apply
rubber lining on the driving pulley. Widen the
wrapping angle using snubbed pulley.
B. Similar to 4.5.
C. Inspect the mounting of skirt rubber and
cushion idler, and the mounting position of
V-shaped cleaner, when the spilled materials
are caught in the tail pulley.
D. The forwardly inclined idler serves to prevent
crooked running of the belt. But, if it is
inclined too much, it is liable to cause
abnormal wear. When the abnormal wear i s
taken place, the inclination angle of the idler
shall be reduced.
E. Reinvestigate the convex curve. Enlarge the
distance between belt pulley and troughing
idler. Change the mounting position of idler.
Change into gradually decreasing type
trougtiing idler.
A. Take the countermeasure as described in 4.C.
Inspect cushion roller. Adjust the environ-
ment of the chute.
B. Equip scraper, deck plate and etc.
C. Refer to 4.F. lnspect the abnormal wear of
the scraper. It i s possible to equip spring type
constantly operating scraper and manual type
scraper in parallel.
D. It i s necessary to restudy the specification of
the belt and the conveyor system.
E. Idler shall be changed, because the distance
and the spacing of idlers may be sonietimes
wide. Reinvestigate the curvature radius of the
convex curve.
F. Take the countermeasure 5.E.
G. Take countermeasures to prevent crooked
running and off-center running.
H. Replace the pulley with that of standard
diameter. It is necessary to restudy the belt
specification. Refer to Para. 1.8.
Phenomenon
7. Abnormal injury of
belt edge.
8. Separation of the
cover stock at the
splicbd part:
9. Fabric cut along the
step or ply separa-
tion at spliced part.
10.Abnormal crooked
running of the
spliced part only.
Causes
A. The edge portion i s distorted
due to crooked running or off-
center running and torn with
fixed spacing.
B. lmproper tripper.
A. lnferior finish of the cover
stock portion.
3. lnferior adhesion.
C. lmproper working 'environ-
ment.
A. Lower ply is cut unnecessarily
too much.
B. lnferior adhesion.
C. Excessive curtail of the work-
ing time.
A. Centering at the time of splic-
ing process is improper or the
splicing part i s slipped out at
the time of processing.
Countermeasures
A. Enlarge the allowance of the frame in the
direction of width.
B. Even slight distortion of th6 tripper shall be
adjusted, because belt i s liable to float from
the idler causing off-center running.
A. Buff the overflaw properly.
B. Investigate the material used, vulcanizing press
and working procedure, and take proper
countermeasures. Repair the part or replace
the belt.
C. If the dust flies during the working time
making it unable to perform perfect work,
necessary countermeasures shall be taken.
A. Resplice.
A. Standard working procedure shall be followed
at the time of splicing.
. . SPLICING METHOD AND REPAIRING METHOD FOR
CONVEYOR BELT
-
5.1 MERIT AND DEMERIT OF EACH SPLICING METHOD
Splicing methods of conveyor bel t are largely
divided i nt o 3 methods, viz. b y means of metal
fasteners, heat vulcanization and self vulcanization.
The meri t and demeri t o f each method are as
described below.
Mechanical Splice Heat Vul cani zati on
Self Vul cani zati on
I 1
(1) N o special techni que is re-
quired.
(2) Can be respliced in a short ti me.
(3) Relatively in-expensive.
(1) Shorter l i f e t han vul cani zati on
splicing.
(2) Spl i ci ng ef f ect (parti cul arl y
dynami c ef f ect ) is l ower t han
t hat o f vul cani zati on method.
(3) When carryi ng powder it spills
sometimes f r om t he spliced
part.
(4) Spliced par t is weak against h o t
materials and wat er permeation.
(5) Li abl t t o damage rollers and
pul l eys and produce noise.
( 1 ) Spliced par t has strength o f 2
- 3 ti mes o f mechanical
splice.
(2) Spliced part is smoot h pro-
vi di ng good ef f i ci ency t o scra-
per and ski rt.
(3) Li t t l e accident.
(4) Li t t l e ef f ect upon carcass
when carryi ng h o t material.
(5) Good i mpact resistance.
(6) Li t t l e spi l l o f carryi ng materi -
als.
(7) Idlers and pul l eys are n o t i n-
jured.
( 1 ) Long wor ki ng t i me and ski l -
lfulness are required, and t ool s
are heavy.
(2) Const ruct i on cost is rel ati vel y
high.
(3) Requi re longer allowance of
bel t l ength f or splicing.
(1) Easier t o per f or m t han heat
vul cani zati on and n o t many
tool s are required.
(3) Has similar mert i s o f (I), (2),
( 6) . (7) o f heat vulcanization.
( 1 ) Has nearl y medi um demerits
o f ( I ) , (2), (3) o f heat vulcani-
zati on and mechanical splice.
(2) Rel i abi l i t y o f the result of
wor ki ng is sl i ghtl y i nf eri or t o
heat vulcanization.
5.2 METAL FASTENERS
The followings are typical ones.
1 ALLIGATOR Lacing
This type of fastener has been most popularly
used.
(m)
- -
2 FLEXCO
There is a problem of flexibility in the longitudinal
direction. Recently Hinge Type is sold.
Lacing
15
20
25
27
35
45
55
Flexible No. 1 Belt Thickness (mm) I Min. Pulley Diam. (mm)
Belt Thickness (mm)
3 - 4
4- 5
5- 6
6- 7
7- 8
8- 0
10-12
3. NILOS
I
This i s the fishhook type fastener and has good
flexibility in both longitudinal and lateral direc-
.
tion. I t has good adaptability to the pulley. Special
driving tool i s required.
65 12 -- 14
75 14 - 16
1 00 over 16
Nilos Hook No. Belt Thickness (mm)
5.3 SPLICING BY VULCANIZATION
There are two cases of splicing, viz. (1) belts are
prespliced in the factory before shipment, and (2)
belts are shipped in rolls and they are spliced on
the spot bi/ means of an electric heater type
portable vulcanization press.
5.3.1 Factory Splicing
Relatively short belts are spliced in the factory and
shipped to the user for mounting to his conveyor
system. The splicing method does not differ from
that of field splicing, but it is required to deter-
mine the length of belt ordered carefully.
5.3.2 Field Splicing (Multi-Ply Conveyor Belt)
1. Method of making steps
Kind of Fabric Length of Step (S) (mm)
NV-50, NN-120
NN-100, VN-120
VN- 100,
NN- 500 500
NN- 600 600
Stripping from Top cover side Stripping from Bottom cover side
ey side)
Same as top cover side
Sectional view of the belt of which bath ends are
joined together (before vulcanization)
2. Calculation of splicing length (L)
L = 0.4b+S (n-1) - 15 (mm)
L: Splicing length (mm)
b: Belt width (mm)
n: Number of ply
S: Length of step (mm)
5.3.3 DIMENSION FOR STEEL CORD CONVEYOR
BELT
Please refer to our ST BELT catalogue regarding
splicing pattern.
1-step overlap method (showing 2 sets)
1. Method of making step
1.1 Singleply
1.2 Two plie
2-step overlap method (showing 1 set)
Step Length (S)
2. Step Length ( S)
Steel Cord Diameter
(mmd
2.0
2.4
2.9
3.3
3.9
4.3
4.6
5.7
6.3
7.1
8.3
9.1
10.0
11.3
12.4
S
(mml
300
300
300
300
350
350
3 50
500
650
700
800
900
1000
1100
1250
3. Calculation of splicing length (L) (mm)
Single ply:
L = 0.4b + S
Two plies
L = 0.4b + 2s
Kind
UN-150
UN-200
U N-300
UN400
UN-500
UN-600
S (mm)
200
200
300
200
250
300
5.4 SPLICING BY NATURAL VULCANIZATION
This i s the method for splicing the belt using self
vulcanization material (Trade name of 0-Pack)
developed by Yokohama Rubber Co., Ltd.
1. Range of application
Multi-ply Belt
VN, NN-100 UN-200
VN, NN-120 UN-300
Fabric I Step Length (S) I Spline Method
NV-50
VN, NN-100
VN, NN-120
- - - - -
Note: Because tie rubber is not used, the edge portion shall be
thickly stripped preliminarily and made flat on the same
level with the canvas surface in the next buffing operation.
UN-200
UN-300
3. Calculation of Splicing Length (L)
The length required for splicing i s calculated in
accordance with the following formula.
L=0. 4b+( n- 1)S+30
The preparation procedure of stripping the belt i s
similar to that of heat vulcanization process.
1. Classification of materials used and special
feature
1) Bonding of carcass to carcass, rubber to rubber,
and carcass to rubber can be performed using
same kind of cement. Namely, there i s no
difference in bonding edge portion and carcass,
and in splicing multi-ply belt and UNICON
belt.
2) Tie rubber i s not used.
3) Initial adhesion strength is excellent, so it i s
possible to use the belt shortly after splicing.
2. Classification of use of Q-Pack
1 ) Primer cement: Q-Pack-A
2) Final coating cement: Q-Pack-B + Q-Pack-C
(10:l )
3. Splicing procedure
1) Firstly align the center so that the splicing part
may not be curved.
2) Mark off the steps. (Refer t o Table 5.8
regarding the allowance for steps).
3) Strip off the steps.
(Rubber remained in concave form shall be
removed by a knife).
4) Buff the surface previously cut by a knife. It i s
not necessary to buff the surface not cut by a
knife, for example, stripped surface on which
coating i s remained.
150 mm
I
(Poor)
Step Splice
200
300
(Good)
Overlap Splice
5) Clean the surface with rubber gasoline or
toluole.
Note: Dry the cement until its solvent
smell vanishes.
6) Apply the primer cement, Q-Pack-A on the
surface to be spliced and dry the cement
perfectly.
Note: Dry the cement until its solvent smell vanishes.
7) Apply the final coating cement, Q-Pack-B +
Q-Pack ( 10: 1) twice and dry it.
~ i t e : Dry the cement un ti / its fluidity inside the cement dis-
appears. Particularly, the first cementing shall be perfect-
ly dried. I t is desirable to dry the cement perfectly, i f it
is within the extent to be able to splice the belt.
8) Affi x both ends of the belt together and apply
pressure by means of a hand roller or a
hammer.
9) Cut through the butt surface by a knife along
the dotted line as shown below and make the
joint of.cover rubber concave.
~ u t t surface
Butt surface
Note: I. Confirm that there is no gap on the butt surface
resulting from the &in t separation.
2. I f there is a slight gap, cut through the surface up to
the dotted line as shown above.
3. Take care that the butt joint of the cover rubber is
always concave.
10) Apply the primer cement and the final coating
over the butt surface thoroughly.
Even when the cover rubber or the carcass of belt
is injured due to some cause, it i s possible to
extend the life of belt, i f it i s repaired immediately.
5.5.1 Small injury of cover rubber
I t i s satisfactory i f the environment of the injured
portion i s buffed and PANGIT i s filled in said
portion.
5.5.2 Large injury of cover rubber
Strip off the cover rubber only as shown in Fig. 5.7
and repair the part by means of heat vulcanization.
Injured portion
,/'
Knife
(Put bias)
5.5.3 SMALL INJURY REACH1 NG CARCASS PLY
5.5.3.1 Fabric belt
Cut off the injured plies in step up to the injured
portion as shown in Fig. 5.8 and repair the part by
inserting new fabric. In such a case concentrated
stress i s applied to this portion making the injury
grow further. So, it is safe t o consider that the belt
strengih will be reduced in about 3 times of the
width of the injured fabric.
r Cover rubber
- 1st ply
2nd ply
Angle and dimension of carcass fabric
1st ply
/ F#z
I
I I
I /
I
Repair of small injun/ of carcass fabric
L- Canvas ply
5.5.3.2 Steel cord belt
Repair the injured portion by means of vulcaniza-
tion after inserting a new reinforcing cord for each
2 cut-off cords as shown in Fig. 5.7.
Inserted corc
Inserted cord
/
5.5.4 Large injury reaching carcass ply
(larger than 113 of the width of belt)
When the strength i s lowered down than that of
the spliced part, even if the injury was repaired as
described 'in 5.5.3.1, the repaired portion shall be
removed and spliced again.
5.5.5 Injury of edge
Remove edge rubber of the injured portion as
shown in Fig. 5.10 and insert new edge rubber, and
then repair it by means of heat vulcanization.
Repair of belt edge
The ideal life of conveyor belt i s accomplished
when the cover rubber has been worn out uniform-
ly and the carcass exposed. I t i s seldom, however,
that the belt i s used in such a manner. There are
various factors affecting the belt life, but it i s very
difficult to estimate them. It i s because various
factors such as speciality of the conveyor line,
elements of the conveyor system, elements of the
carrying materials as well as adaptability of the
belt, condition of climate, heat, and chemicals, and
also the condition of maintenance mixedly affect
the life of belt.
Mr. Hetzel discloses eridurable carrying quantity in
his "Belt Conveyors and Elevators" taking into
consideration of the main factors concerning the
life of belt.
CLL. I.?*
Calculation formu la:
Endurable gross carrying quantity = Endurable
carrying quantity x Coefficient of durability
rate
(m) Endurable Carrying Quantity
Example of calculation (assuming that the condi-
tion of use i s to be as follows)
Kind of carrying material : Crude coal (inclined-
conveyor)
Loading point : 1 point (outdoor)
Thickness of top cover. : 6.4 mm, (gravity type
rubber take-u p)
Width of belt : 1050
Carrying quantity : 650 t l h
Conveyor length : 350 m
Driving system : Single head driving
Consequently, the following calculation will be
made in accordance with Table 6.1.
Endurable carrying quantity = 940 x l o4 ton
Endurable gross carrying quantity = 840 x 104 x
(c) (dl (bl (a) (d) (dl (dl (dl
1.0 x 1.0 x 1.4 x 1.2 x 0.9 x 1.0 x 1.0 x 1.2 =
=94Ox 104 x 1.81
= 1,700 x l o4 ton
Remarks:
(c): Carrying material, (d): Loading point, (b): Top cover
thickness, (a): Tensile strength, (d): Inclined conveyor, (dl:
Place of installation, (dl: Driving system, (dl: Take-up
If the daily production of coal is assumed to be
5,000 ton, the period of durability will be:-
I
T = 'f700 x 104 = 3,400 days = 9.3 years
5,000
Unit: lo4 tons
- - - - -
Belt Width
Conveyor Length <Center to center distance> (m)
(m) Durability Rates
(a) Tensile Strength of Cover Rubber
Tensile Strength of Cover Rubber
( Kslcm2 )
100 -- 140
180-215
250 -- 285
< --
(d) Durability Rates under Various Conditions
Durability Rate (%I
100
120
140
(b) Thickness of Top Rubber Cover
Operating Condition
Thickness of Top Cover Rubber (mm)
I Durability Rate I%)
Durability Rate (%)
Loading Point 1 I 100
Loading Point 2
Tripper 1
Indoor Installation 1 120
80
80
Inclined Conveyor
Outdoor Installation
With Roof (Outdoor Installation) I 110
90
100
' Single Drive at Head I 100,
Tail or Intermediate Drive
(n) Durability Rate depending "pon Kind of
, ,
Carrying Material
Tandem Drive
Screw Type Take-up
Gravity Type Take-up
80
100
120
Kind of Carrying Material
Coal . 4. Large lump
Coal Small lump
Coal Fine
Coke Large lump
Coke Small lump
Coke Hot
Ore -200mm9
Ore - 50mm9
Ore Fine
Rock Large lump
Rock & Gravel Small lump
Clinker Cold
Clinker Hot
Slag
Zinc Slag
Gravel
Cement Cold
Cement Hot
Grains
Salt
Durability Rate (%I
100 - )
120
130
50
60
10
60
80
90
7 0
80
70
20
80
50
90
100
40
200
80
6.2 DIMENSION AND WEIGHT OF BELT PACKAGE
The package of belt at the time of shipment i s
6.2.1 DIMENSION AND WEIGHT OF WOODEN DRUM
classified as follows depending upon i t s gross PACKAGE
weight and dimension.
Calculation formula of drum dimensions:
Diameter of Drum:
Remarks: The outside diameter of package shall be within 3.3
times of i t s width so as to stabilize the package.
L x c
= l\j d2 +
0.0785
+ cr
Outside Diam.
of Package
below 1.8 m diam.
above 1.8m diam.
Simple
Package
Wooden Drum
Package
D : Drum diameter (cm)
d : Core diameter (cm)
L : Belt length (m)
c : Overall thickness of belt (mm)
cr : Lateral piank thickness + allowance
(usually 10- 15cm)
Gross Weight
below 3 ton or
above 3 ton or
Width of Drum:
Width of drum = Width of belt + 25 cm
Gross Weight:
G=W1 x L x p
WI: Weight of belt (kglm)
L : Length of belt (m)
p : Coefficient of drum weight only (1.2)
(FIG.)
Grain
6.2.2 DIMENSION AND WEIGHT OF SIMPLE WOODEN
DRUM PACKAGE
Steel tape
Hessian doth
L x c
Package O.D. =
1\1 d2 + 0.0785
+ 5 c m
Wi dt h of Package = Wi dt h of bel t + 1 0 cm
Gross Weight = Wt x L + 30 kg
( ) Relation of Belt Thickness and Belt Length with Reeled Diameter of Belt
balt length (feet)
6.3 VARIOUS TESTING DEVICES
6.3.1 SEPARATION TESTER
Maximum capacity: 50 kg
Tolerance: +-2% against specified load
Velocity: 25 2 1.5 mmlmin,
50 * 2.5 mmlmin
This i s used for testing adhesion between fabric
plies, rubber layer and fabric ply, and rubber
layers.
6.3.2 AMSLER'S TYPE TENS1 LE TESTER
Maximum capacity: 10 ton
Variable capacity:
10 ton, 5 ton, 2 ton, 1 ton,
0.5 ton
Tolerance: + I % against specified load
Velocity: (variable by hand valve)
Max. 150 mmlmin
This i s used for testing tensile strength and
elongation of rubber, cloth and metal, and also for
testing compression.
6.3.3 SCHOPPER TENSILE MACHINE
Maximum capacity: 50 kg
Variable capacity: 25 kg
Tolerance: 2% against specified load
Velocity: 200 k 10 mmlmin
300 + 15 mmlmin
500 * 25 mm/min
This machine i s used for testing tensile strength
and elongation of vulcanized rubber.
capacity: Temperature tolerance in heating tank =
52C
Adjusting range of temperature in heat-
ing tank = 2 1C
This i s the machine for simulating the ageing of
material by heating the materiaLSlt i s further used
for the t est including the measurement of heat,
volume reduction, and moisture content.
6.4. CONVERSION TABLE
6. 4. 1 LENGTH
Unit mm cm m in ft Y d mile (stat.) km Mile (Naut.)
mm 1 0.1 0.001 0.03937 0.0032808 0.0010936 6.214x10-' 0.00001
~~~~~
cm 10 1 0.01 0.3937 0.032808 0.01 0936 6.21 4x1 om6 0.0001
m 1000 100 1 39.37 3.28083 1.0936 6.21 4x1 om4 0.001
~n 25.4 2.54 0.0254 1 0.0833 0.02778 1.578~1 0-5 2.54~1 0-'
ft 304.8 30.48 0.3048 12 1 0.3333 1.894~1 o - ~ 3,084~1 c4
~d 914.4 91.44 0.9144 36 3 1 5.682x10-~ 9,114~10-~
mile (Stat.) 1609347.0 160934.7 1609.35 63360 5280 1760 1 1.60935 0.869
km I00000 1000 39370 3280.83 1093.6 0.62137 1 0.54
mile (Naut.) 1852000 185200 1852 1.151 1.852 1
6. 4. 2 MILLIMETER- Inch
6.4.3 WEIGHT
Kilograms Ounces (Avoir.) Pounds Tons
Unit
kg OZ I b Metric Long Short
kg 1 35.274 2.20462 0.001 0.0009842
0.001 102
0 2 0.02835 1 0.06250 2.835~ 1 2.790~ 1 Om' 3.125~ 1
Ib 0.45359 16 1 4.536~ 1 o - ~ 4.464~ 1 o4 0.00050
Metric 1 000 35274 2204.6 1
t Lang 101 6.05 35840 2240 1.12 1 1.01 605
Short 907.1 85 32000 2000 0.9071 9 0.89286 1
6.4.4 WEIGHT PER UNIT LENGTH 6.4.5 DENSITY
I I 1 I I
Unit I glcm I kglm 1 Iblin 1 Iblft I Iblyd
glcm
kglm
Iblin
lblft
) 6. 4. 6 POWER
1
10
, I I
178.579
14.8816
Iblyd
6.4.7 PRESSURE
0.10
1
Horsepower
French (metric) 1 English (Japanese)
17.8579
1.48816
4.96054
Unit
g/cm3
kg/m
3
Ib/in
3
Ib/ft
3
0.0056
0.056
kW
1
0.08333
0.49605
kg-'"/sec
Bar
1
0.9807
0.06895
1.0725
1.01 33
glcm
1
0.001
27.6797
0.01602
0.0672
0.671 97
0.201 59
2.01 59.
12
1
0.02788
kglm3
1000
1
27679.7
16.0184
36
3
Kilograms per Sq.
Centimeter
(kglcm2
1.01 97
1
0.07031
1.0037
1.0332
0.3333
Long tons per sq. Feet
(t/ft2
0.9324
0.9144
0.06429
1
0.9447
Pounds per sq. inch
(lb/in2 )
14.50
14.22
1
1 5.56
14.70
Iblin
3
0.0361 3
3.613~10-~
1
5. 787~10-~
1
Standard Atmosphere
Pressure (760mm)
0.9869
0.9678
0.06805
1.0585
1
Ib/ft
3
62.4283
0.06243
1728
1
6.4.8 TRIGONOMETRIC FUNCTIONS OF ANGLES
6.4.9 ANGLE
lu
Note: 180 = n Radian = 3.14 Radian
s ~n
.2588
.2672
.2756
.2840
-2924
.3007
.3090
.3 173
.3256
.3338
.3420
.3502
.3584
.3665
.3746
.3827
.3907
.3988
.4067
.4 147
.4226
.4305
.4384
.4462
.4540
.4617
.4695
.4772
.4848
.4924
.5000
.5075
COB
.9659
.9636
.96 13
.9588
.9563
.9537
.95 1 4
.9483
.9455
.9426
.9397
.9367
.9336
.9304
.9272
.9239
.9205
.9171
.9 136
.9 100
.go73
.9036
.8908
.8969
.89 10
.8870
.8830
.8788
.8746
.8704
.8660
.8616
Angle
1" 0'
30
2
30
3
30
4
30
5
30
6
30
7
30
8
30
9
30
10
30
1 1
30
12
30
13
30
14
30
Degree
Radians
tan
.2680
.2773
.2868
.2962
.3057
.3153
.3249
.3346
.3443
.3541
.3640
.3739
.3839
.3939
.4040
.4142
.4245
.4348
.4452
.4557
.4663
.4770
-4877
.4986
.5095
.5206
.53 1 7
.5430
.5543
.5658
5774
.5890
sin
.0175
.0262
.0349
.0436
.0523
.0611
.0698
.0785
.0872
.0959
.I045
.I 132
.I219
.I305
.I392
.I 478
.I 564
-1651
.I737
.I822
.I908
.I994
.2079
.2 164
.2250
.2335
.24 1 9
.25M
0"
0
cos
.9999
.9997
.9994
.999 1
.9986
.9981
.9976
,9969
.9962
.9954
.9945
.9936
.9926
.99 14
.9903
.9890
.9877
.9863
.9848
.9833
.98 16
.9799
-9782
.9763
.9744
.9724
.9703
.9682
60"
1.05
30"
0.523
tan
.0175
,0262
.OM9
.0437
.0524
.0612
.0699
.0787
.0875
.0963
.I051
.I139
.I228
.I317
.I405
.I495
1 584
.I 673
.I 763
.I853
.9 144
.2035
.2 126
.22 17
.2309
.240 1
.2493
.2586
90"
1.57
Angle
15"
30'
16
30
17
30
18
30
19
30
20
30
2 1
30
22
30
23
30
24
30
25
30
26
30
27
30
28
30
29
30
30
30
120"
2.10
420"
7.33
180"
3.14
57.35"
1
210"
3.67
1"
0.01745
360"
6.28
6. 4. 10 VALUES OF e P 8
- Y ;;m - e@
0.10 0.15 0.20 0.25 0.30 0.35
180 1.369 1.602 1.875 2.194 2.5W 3.005
190 1.393 1.644 1.940 2.29 1 2.704 3.191
200 1.418 1.688 2.010 2.393 2.850 3.393
210 1.443 1.733 2.081 2.500 3.002 3.607
220 1.468 1.779 2.1 56 2.61 2 3.165 3.835
230 1.494 1.826 2.232 2.728 3.334 4.084
240 1.520 1.875 2.31 1 2.850 3.514 4.333
1 360 1.875 2.567 3.51 4 4.81 3 6.587 8.958
i--= -
370 1.908 2.635 3.638 5.027 6.942 9.588
380 1.941 2.704 3.768 5.248 7.31 1 10.185
390 1.975 2.776 3.901 5.483 7.705 10.84
400 2.01 0 2.850 4.040 5.727 8.120 11.51
410 2.046 2.925 4.185 5.984 8.558 . 12.25
420 2.081 3.003 4.332 6.250 9.01 3 13.01
430 2.1 18 3.083 4.485 6.528 9.500 13.83
440 2.155 3.165 4.645 6.820 10.01 14.70
450 2.193 3.249 4.81 0 7.126 10.55 15.62
460 2.232 3.335 4.982 7.444 11.12 16.62
470 2.27 1 3.424 5.160 7.777 11.72 17.60
480 2.31 1 3.51 3 5.341 8.1 18 12.34 18.76
6.4.1 1 TEMPERATURE
5
C = (F - 32) x-
dJA
6. 4. 12 SIZE OF FIBER
1) Count (N) : Count shows how many times (768,l m (840yd) a particular yarn i s when it
weights 1 Ib. (453,6 gr.).
2) Denier (d. Denier) :
3) Conversion of count and denir
69 THE YOKOHAMA RUBBER CO ,LTD
MAIN PRODUCTS: TYRES & TUBES, BELTS, HOSE, SHIP FENDERS, ADHESIVES, INDUSTRIAL-RUBBER PRO-
DUCTS, METALLIC PRODUCTS, AERONAUTICAL & MARINE PRODUCTS, ETC.
HEAD OFFICE: 36-1 1, SHIMBASHI 5 CHOME, MINATO-KU, TOKYO 105, JAPAN
TELEX: J24673 YOKORUCO / C.P.O. Box 1842, TOKYO 100-91, JAPAN.
I
-LIAISON REPRESENTATIVES' OFFICES:
I
BE1 RUT: P.O. BOX 361 1, BE1 RUT, LEBANON
DOSSELDORF: 4 DOSELDORF, GRAF-ADOLF STRASSE 72, WEST GERMANY
I
LONDON: BOW BELLS HOUSE, BREAD ST., (CHEAPISIDE) LONDON, E.C.4, ENGLAND
VANCOUVER: 270 SEYMOUR RIVER PLACE, NORTH VANCOUVER B.C., CANADA
LOS ANGELES: 1530 CHURCH ROAD MONTEBELLO, CALI FORNIA 90640, U.S.A.
SYDNEY: P.O. BOX 540 G.P.O. SYDNEY, N.S.W., AUSTRALIA
HOUSTON: YOKOHAMA TIRE CORPORATION 8042 KATY FREEWAY, HOUSTON, TEXAS 77024, USA.
--CHICAGO: 12-6 PARKWAY TOWERS 7171, W. GUNNISON ST. HARWOOD HEIGHTS ILL, 60656 U.S.A.
Printed in J q m (RE! 7507) ( 7409SPC
Created by U Thaung Myint 11/22/2010

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