THE DESIGN OF SCREW TAKE-UPS

In the selection or specification of screw take-up units on smaller conveyors, it is often the case
that very little consideration is given to the actual construction of the units. Normally, the take-up
is simply specified as a “Manual Screw” with usually only the required take-up movement
specified. The details of the take-up are essentially left to the suppliers.

The force required at the take-up is determined by the conveyor design. The force is most often
equal to the tail tension in the conveyor system. Obviously, if the take-up is located away from
the tail, the take-up force will be determined by the tension at the point of application. For
example, when the drive is located internally at ground level (as for a small stockpile feed
conveyor, when it is required to remove the drive from the cantilevered head end), the take-up
could be located outbye of the drive and the take-up force would be very nearly equal to T2.

The total force at the take-up pulley should ideally be shared equally at each screw.
Thus PA = 0,5·Ttu where PA refers to the axial load on each screw. However, to cater for the
inevitable misalignment and uneven tensioning, it is proposed that the axial load on each screw
is stated as PA = 0,8·Ttu. (1)

The preferred screw take-up for general conveyor use is the type with a protected screw. The
take-up operates by rotating the screw (often made of stainless steel), which engages with a
phosphor bronze nut, integral with the pulley bearing pedestal and slide. The construction of the
units varies between suppliers, but are essentially of two types, where the screw is partially
protected (see figure 1, courtesy of Dymot), or the screw is totally covered with saddle to carry
the pulley bearing (see figure 2). The pulley bearings would be standard plummer blocks that
are attached to the saddles.

Figure 1. Typical partially protected screw (Dymot)

Figure 2 Typical Protected screw with Bearing Saddles

The alternative is to use an exposed screw, when the screw is under tension and the nut is
rotated to move the housing. See figure 3, courtesy of Martin Engineering. In the case of the
exposed screw, it is more likely that the nut will be simply supplied as a standard Grade 8.8 (or
better) nut, which may have a brass thrust washer behind it to facilitate turning.

However, some designs have a swivel at the bearing housing, when the screw is again rotated
to generate the axial force. The major disadvantage of this type is that the screw will be
subjected to significant bending forces during the rotation of the screw, as a result of the
possibly long overhang and the likelihood of deforming the screw is much greater, depending on
the screw diameter, of course.

Figure 3. Exposed Screw and Frame (Martin Engineering

The bearing housings for the exposed screw type have to be carefully specified. The standard
THD housings are very useful, especially for larger bearings.

It is also likely that the protected screw would be lubricated with grease, while this is less likely
for the exposed screw type. In any event, the screws will need reasonably regular maintenance,
to ensure that they are not seized, bent, rusted, corroded or caked with fugitive material or dust.

Selected ISO Screw Thread Data

Selected ISO screw thread data is given in Table 1 below. The range is selected to be the most
likely to be used for screw take-up units.

Screw
Pitch d×10-3
Size D
M20 2,5 17,294
M24 3,0 20,752
M30 3,5 26,211
M36 4,0 31,670
M42 4,5 37,129
M48 5,0 42,587
M56 5,5 50,046
M64 6,0 57,505

Table 1. Selected ISO Screw Thread Data

Based on ISO 261 – Coarse threads
Friction and Torque

The friction factor between the steel screw and the nut (either bronze or steel), will, of course,
depend on the nut material, the finish of the screw, the clearances between the screw and the
nut and the presence or otherwise of lubrication. Generally the standard 6H/6g fit in accordance
with ISO 965/1 would be adequate and not result in unnecessary resistance to rotation. Some
typical values for the friction factor K are shown in Table 2.

Material
K
Screw Nut
Steel 0,2 to 0,3
Steel
Bronze 0,12 to 0,16

Table 2. Friction Factor K

The torque required to render a given axial load may be determined from the following
 p + (π ⋅ D ⋅ K )  D
Q = PA ⋅   ⋅ N·m. (2)
 (π ⋅ D ) − (K ⋅ p )  2

Here, Q = Torque N·m

PA = Axial Force N
p = Screw thread pitch M
D = Screw major diameter M
K = Friction factor -

Example

Given the tail tension of 5,80 kN, then from equation 1, PA = 0,8×5,8×103 = 4640 N per screw.
Assuming the screw is a standard M24 with p = 3,0 mm and a bronze nut with K = 0,14
( ) ( )
 3 × 10−3 + π × 0,14 × 24 × 10−3  24 × 10−3
Q = 4640 ×  × = 10,067 N·m from equation 2
( −3
) (
 π × 24 × 10 − 0,14 × 3 × 10 
−3 
) 2

This torque may be utilised to set the belt tension and can help to align the pulley shaft.

The maximum torque that can be applied to a screw is determined by

π ⋅ d3 ⋅ σ s
Qmax = N·m. (3)
16
The shear stress should not be much greater than σs = 100 MPa.
 3 ⋅5 ⋅ p 
The minor diameter of an ISO M-series thread is determined by d = D −   m, (4)
 8 
 
while the thread pitch for M24 is p = 3,0 mm

  3 × 5 × 3 
Using our example, for M24, d =  24 −    × 10 − 3 = 0,02075 m.
  8 
  
 π × 0,020753 × 100 × 106
Then Qmax = = 175,48 N·m. On the face of this, the screw appears to
16
be adequate for our example.

Protected Screw

When the torque is applied to the screw (as in a protected screw take-up), it will result in a
torsional deflection of the screw itself. This is so because the screw length is usually many times
greater than the diameter.

584 ⋅ Q ⋅ L s
The torsional deflection of a solid round shaft is given by α Q = degrees. (5)
d4 ⋅ G
The torsional modulus of elasticity for steel is accepted as 80 GPa., while a generally
acceptable limit for the torsional deflection is given as αQ = 0,26°/m length.

Thus, the maximum length of the screw (and by implication, the maximum take-up distance)
α ⋅ G ⋅ d4
would be determined by L s = Q m. (6)
584 ⋅ Q

For our example, with Q = 10,067 N·m, the maximum length of the screw must be limited to
0,26 × 80 × 109 × 0,020754
L= = 0,649 m (say 650 mm) which rather limits the take-up length.
584 × 10,067

  3 × 5 × 3. 5  
If the screw is specified as M30, p = 3,5 mm and d =  30 −    × 10 − 3 = 0,02621 m.
  8 
  
The torsion as before must alter to cater for the diameter and pitch alterations. Thus, the torsion

becomes Q = 4640 
( ) ( )
  3,5 × 10 − 3 + 0,14 × π × 30 × 10 − 3  30 × 10 − 3 
×  = 12,393 N·m and
 ( ) ( )
 π × 30 × 10 − 3 − 0,14 × 3.5 × 10 − 3 
 2 

0,26 × 80 × 10 × 0,02621
9 4
L= = 1,356 m (say 1,360 m) which is a significant increase. It must
584 × 12,393
be noted that the change in screw diameter will imply a change in thread pitch and therefore a
change in the required torsion.

From this, it can be seen that the specification of the take-up length with screw take-ups needs
to be more closely determined.

Exposed Screw

In the case of an exposed screw, the axial force is normally generated by rotating the nut, with
the screw rotationally static. The nut is usually made from steel and it follows that the friction
factor K is likely to be greater than the value for steel on bronze, as noted in table 2 above.

Using our example, with K= 0,25 and using the M24 screw, it follows that
( ) ( )
 3 × 10−3 + π × 0,25 × 24 × 10−3  24 × 10−3
Q = 4640 ×  × = 16,298 N·m.
( −3
) (
 π × 24 × 10 − 0,25 × 3 × 10 
−3 
) 2

This value is significantly greater than the torque values obtained using a bronze nut. However,
in an exposed screw, the use of a bronze nut is not really practical.
Since the nut is rotated, the torsion in the screw itself will be minimal and may be ignored.

Based on the minor diameter as determined earlier, the stress in tension in the screw is
4 ⋅ PA × 10 −6
determined by σt = MPa. (7)
π ⋅ d2

Using the value of PA = 4640 N·m per screw and d = 0,02075 m for the M24 screw, the stress in
4 × 4640 × 10 −6
the screw in tension will be found by σ t = = 13,72 MPa.
π × 0,02075 2

If an allowable stress in tension is accepted as (say) σt = 140 MPa, it can be seen that the
screw is adequately sized.

Metric Trapezoidal Thread

It may be useful to consider using trapezoidal threaded screws, especially for screw take-ups
that will need larger diameter screws. These could be useful in both the protected screw take-up
as well as the exposed screw take-up. It is to be noted that Acme threads and Metric
Trapezoidal threads to DIN103 are not interchangeable. Acme threads are based on a flank
angle of 29° and the pitches are, of course, imperial. Metric Trapezoidal threads have a flank
angle of 30° and the pitches are metric.

Some standard values for Metric Trapezoidal (Acme) threads are given in table 3 below: The
range is limited to that most likely to be used on conveyor screw take-ups.

D×10-3 P×10-3 t×10-3

22, 24, 26, 28 5 2,75
30, 32, 36 6 3,25
40, 44 7 3,75
48, 50, 52 8 4,25
55, 60 9 4,75
65, 70, 75, 80 10 5,25
85, 90, 95, 100 12 6,25

Table 3. Selected thread data for Trapezoidal screws to DIN 103

Here t refers to the thread depth, which includes the top clearance for the nut

It is unlikely that screws of major diameter less than D = 22 mm will be used.

The minor diameter d = (D – 2·t)×10-3 m (8).

It is noted that the thread height t as shown in Table 3 incorporates a clearance.

Using our example and assuming a protected trapezoidal threaded screw of D = 24 mm

(to compare this with a standard ISO M24 screw), the load on the screw will be as
determined before, namely PA = 4640 N. The pitch of the ø24 mm screw (Tr24×5) is
given as 5 mm and the thread depth is given as 2,75 mm.

Using K=0,14 to compare with the M24, it follows that

 ( ) ( )
 5 × 10−3 + π × 0,14 × 24 × 10−3  24 × 10− 3
Q = 4640 ×  × = 11,595 N·m.
( −3
) (
 π × 24 × 10 − 0,14 × 5 × 10 
−3 
) 2
From equation 7, the minor diameter d = (24 − (2 × 2.75)) × 10−3 = 0,0185 m.

Thus, from equation 6, the maximum length of the screw based on torsional deflection
0,26 × 80 × 109 × 0,0185 4
may be found from L s = = 0,359 m and 360 mm would be a
584 × 11,595
practical value. As can be seen, for the Tr24×5 compared to the M24×3, the standard
ISO thread renders better results than the trapezoidal screw thread.

Again, if we increase the screw to Tr30×6, the pitch is 6 mm and the depth of thread is
3,25 mm from table 2. Then the value of d = (30 − (2 × 3,25)) × 10−3 = 0,0235 m and the

torque becomes Q = 4640 × 

( ) (
 6 × 10−3 + π × 0,14 × 30 × 10−3 )  × 30 × 10 −3
= 14,302 N·m
( −3
) (
 π × 30 × 10 − 0,14 × 6 × 10
−3
)  2
Thus, the maximum length of the screw based on torsional deflection may be found
0.26 × 80 × 109 × 0,0235 4
from L s = = 0,759 m and a value of 760 mm would be adequate.
584 × 14,302

From this, it can be seen that the use of trapezoidal screws for protected screws does
not necessarily result in a longer screw travel. Indeed, the use of trapezoidal threads
actually reduces the take-up in most cases. For these reasons, the specification of
trapezoidal threads to DIN 103 must be approached with some caution.

Graham Shortt
April 2018
Krugersdorp
List of equations

No Description Equation Unit

1 Axial load on each screw PA = 0,8·Ttu N
The torque required to render a  p + (π ⋅ D ⋅ K )  D
2 Q = PA ⋅   ⋅
 (π ⋅ D ) − (K ⋅ p )  2
given axial load N·m

The maximum torque that can π ⋅ d3 ⋅ σs

3 Qmax = N·m
be applied to a screw 16
The minor diameter of an ISO  3 ⋅5 ⋅ p 
4 d = D−  m
M-series thread  8 
 
The torsional deflection of a 584 ⋅ Q ⋅ L s
5 αQ = degrees
solid round shaft d4 ⋅ G
The maximum length of the α ⋅ G ⋅ d4
6 Ls = Q m
screw for torsional deflection 584 ⋅ Q
The stress in tension in the 4 ⋅ PA × 10 −6
7 σt = MPa
screw π ⋅ d2
The minor diameter of a
8 d = (D – 2·t)×10-3 m
trapezoidal screw