Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.

23
Specifier Sheet and Recommendation Summary 01/21/14 Date 6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com
Copyright - Rulmeca Corp.

Telephone

Telefax

e-mail

Project Name

Conveyor Reference 100 500 300 -10 100 1 12 3 4 3300 ft

0.128

Standard Loading Conditions:

Conveyor Length (ft) Tonnage Rate (tons/hour) Belt Speed (fpm) Material Lift Height (ft) Ambient temperature (F) Min Ambient temperature (F) Max Initial Velocity of Material (fpm) Number of Belt Cleaners Number of Return Belt Scrapers Length of Skirt Zone (ft) Depth of Mat'l in skirt zone (in) Number of Non-driven Pulleys Elev. Above Sea Level (ft) Mat'l, friction coeff Bulk Density (pcf) Size Consist Max. Lump Size (in) Material Surcharge Angle Belt Width Belt Carcass Type Idler Roll diameter CEMA Type Troughing Idler Spacing Angle of Wrap** Type of Lagging Type of Take-up Type of Belt Drive Location
Limestone, pulv.,dry,

REQUIRED POWER: BELT PULL SUMMARY: Standard Loading Belt Pull Extra pull for Hopper (if any) Extra pull for Slider Bed (if any) Extra pull for Diverter or Tripper (if any) TOTAL Required Belt Pull (Te): RECOMMENDED OPTIONS:

7.3 HP Force (lbs) 731

731

SPECIAL NOTES: Minimum allowable belt width for lump size is 12 in Minimum Acceptable Diameter is 10 in. *
*A smaller pulley diameter may cause belt carcass or fastener damage.

Limestone, crushed, 90 pcf Avg is 50% Max Lump Size

2 25 deg. 36 in Fabric 5 in C 4 ft 180 degrees Full Lagging Manual 2 ply, 225 piw Head

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY: Power: Belt Speed: Face Width: 7.5HP 300 FPM 37.4 in. Models Available: 220, 320, 400, 500, 630

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY: Power: Belt Speed: Face Width: 5.5 HP/each 300 FPM 37.4 in. Models Available: 220, 320, 400, 500

Elevating or Horizontal Material Flow well maintained Condition of Idlers & Pulleys

Power savings - 1 shift and 3 shift per day:

(Motorized Pulley compared to exposed motor, gearbox, V-belt conveyor drives)

Type of Dual Drive, if any

none

** This parameter is for either single or dual drive arrangement.

Save: 1180 Kw-Hrs/Yr, 1 shift/day or 3541 Kw-Hrs/Yr, 3 shifts/day Save: $94 /Yr, 1 shift/day or $283 /Yr, 3 shifts/day @ $0.08/Kw-Hr

Special Loading Conditions:

1. For hopper feeder specify opening dimensions below. 2. For slider bed, specify bed length & type of bed mat'l below.

3. If belt is driven on return run, specify drive pulley location.

4. If belt has cleats and/or sidewalls show dimensions below. 5. If conveyor has a tripper, define tripper below. 6. If conveyor has diverter(s), define below.

4. Sidewall & Cleated Belt Parameters: Sidewall & cleat height (in) Thickness of sidewall (in) Distance between cleats (in) Thickness of cleats (in) Extra Sidewall & Cleat Wt (incl above) 5. Tripper Design Parameters Tripper length (ft) Material lift height on tripper (ft) No. of belt cleaners on tripper Length of tripper skirt zone (ft)

1. Hopper Feeder Design Parameters Hopper opening width (in) Hopper opening length (in) Number of Hopper Openings 2. Slider Bed Design Parameters Slider Bed Length (ft) Type of Slider Bed Material Slider Bed Frictional Coefficient None

3. Drive Pulley Location ("return run" drive only) Conveyor Length, tail to drive snub (ft) Height, top of tail to bottom of drive (ft)

Depth of material in skirt zone (in) No. of non-driven pulleys on tripper Estimated belt tension, Te (lbs) Estimated factor, Ky 6. Material Diverter (Belt Plow) No. of diverters that work simultaneously

0.03

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.23

Model Selector 01/21/14 Date

Telephone

Telefax

e-mail

Project Name REQUIRED POWER: BELT PULL SUMMARY: Standard Loading Belt Pull Extra pull for Hopper (if any) Extra pull for Slider Bed (if any) Extra pull for Diverter or Tripper (if any) TOTAL Required Belt Pull (Te): 7.3 HP

Conveyor Reference

6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com

Copyright - Rulmeca Corp.

Force (lbs) 731

Select Model 320M Check Radial Load (to prevent internal damage to pulley) Force (lbs) Maximum Allowable Radial Load 4,496 Estimated Maximum Radial Load** 4,001 Selected model is appropriate for estimated radial load. Check Pulley Diameter (to prevent belt damage.) Minimum Acceptable Diameter is 10 in. Selected Diameter is 12.64 in Selected diameter is appropriate for specified belt. Check Maximum Belt Tension prevent belt damage) Maximum Belt Tension (T1) Allowable Fabric Belt Tension (to Force (lbs) 2,366 8,100 Force (lbs) 731 585 1,635 2,366

731

RECOMMENDED OPTIONS (if any):

SPECIAL NOTES (if any): Minimum allowable belt width for lump size is 12 in Minimum Acceptable Diameter is 10 in. *
*A smaller pulley diameter may cause belt carcass or fastener damage.

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY: Power: Belt Speed: Face Width: Models Available: 7.5HP 300 FPM 37.4 in. 220, 320, 400, 500, 630 Belt Tension Calculation Summary Te, effective belt tension T2, to prevent belt/pulley slippage T2, to limit belt sag to 2 % T1, maximum belt tension

**Measured at Drive A in Dual Drive, if applicable.

Calculation for "Dual Drive on Carry Side" is under construction.

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY: Power: Belt Speed: Face Width: Models Available: 5.5 HP/each 300 FPM 37.4 in. 220, 320, 400, 500

Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.23 Bulk Handling Trajectory Calculator and Plotter
(based on CEMA 5th Edition)

1/21/14 Date

Phone Project Name Conveyor Ref.

Fax

6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com

Copyright - Rulmeca Corp.

System Design Parameters:

Belt Width Troughing Idler Angle Diameter Pulley (in) Lagging Thickness (in) Belt Speed Surcharge Angle Tonnage Rate (TPH) Material Density (pcf) Belt Thickness (in) Distance to Chute Plate (in) Angle of Conv. Inclination (deg) Alternate Belt Speed (fpm) 350 36 in 35 13.26 in 0.31 in 300 fpm 25 deg. 500 90 0.75 24 18 15 12 9 6 3 0 -3 -6 -9 -12 -15 -18 -21 -24 39 36 33 30 27 24 21 18 15 12 9 6 3 0 -3 -6 -9 -12 -15 -18 -21 -24 -27 Design Trajectory - red line; Alternate speed - blue.

Material Trajectory:
Small Pulley (scale: inches)

Calculated Results:
Calc'd mat'l height at centerline Calc'd actual height of C.O.G.* Calc'd actual mat'l cross section CEMA Max Allow. height at center CEMA Max Height of C.O.G.* CEMA Max Allow. cross section Note: This program uses actual C.O.G.* height above top of belt (based on actual cross section) to plot trajectory. Height of C.O.G. for CEMA max. allow. cross section is given for ref. only. 5 in 2 in 84.7 sq ft 7 in 3 in 152.6 sq ft 9 6 3 0 -3 -18 -15

Mat'l Cross Section at Pulley Face:

Small Pulley (scale: inches)

Design Cross Section - red line; CEMA max allow. - black line. *C.O.G. = center of gravity of material, shown as and

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.23 Material Cross Section Plotter
1/21/14 Date

Phone

Fax

6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com

Copyright - Rulmeca Corp.

Reference Name Conveyor Number

System Design Parameters:

Tonnage Rate (tph) Belt Speed (fpm) Bulk Density (lbs/cu ft) Material Surcharge Angle Belt Width Idler Angle 500 300 90 25 degrees 36 in. 35 degrees
6 3
15 12 9

Cross Section at Troughing Idler: Narrow Belt (scale: inches)

Material Geometry in Troughing Idler:

CEMA Max. Allow. Cross Section Calculated Cross Section Calc'd Xsec/CEMA Xsec CEMA Standard Edge Distance Calculated Edge Distance Calc'd Material Height at Centerline 1.1 sq ft 0.6 sq ft 58% 2.9 in 6 in 5.4 in

0 -3
-15 -12 -9 -6

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

-3

12

15

Material Geometry at Pulley Discharge:

Calculated Cross Section Material Height at Centerline Height of Center of Gravity (A1) Assumed Edge Distance Calculated Surcharge Angle CEMA Max. Allow height at center CEMA Max Height of C.O.G. CEMA Standard Edge Distance 0.6 sq ft 4.4 in 1.8 in 3.02 in 33 deg 6.6 in. 2.7 in. 1.44 in

Cross Section at Pulley Face: Narrow Belt (scale: inches)

9 6 3 0 -3
-18

1.80

2.7

Note: This program calculates height of actual C.O.G.* by assuming that actual edge distance at pulley face equals 1/2 of actual edge distance in troughed section. Height of C.O.G.* for CEMA maximum allowable cross section pulley face is given for reference only. * C.O.G. = center of gravity of material

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.23 Material Cross Section Plotter
1/21/14 Date

Phone

Fax

6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com

Copyright - Rulmeca Corp.

Reference Name Conveyor Number

System Design Parameters:

Tonnage Rate (tph) Belt Speed (fpm) Bulk Density (lbs/cu ft) Material Surcharge Angle Belt Width Idler Angle 500 300 90 25 degrees 36 in. 35 degrees
18
12

Cross Section at Troughing Idler: Wide Belt (scale: inches)

42
36 30

24

Material Geometry in Troughing Idler:

CEMA Max. Allow. Cross Section Calculated Cross Section Calc'd Xsec/CEMA Xsec CEMA Standard Edge Distance Calculated Edge Distance Calc'd Material Height at Centerline 1.1 sq ft 0.6 sq ft 58% 2.9 in 6 in 5.4 in

6 0
-6

-42

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

-36

-30

Material Geometry at Pulley Discharge:

Calculated Cross Section Material Height at Centerline Height of Center of Gravity (A1) Assumed Edge Distance Calculated Surcharge Angle CEMA Max. Allow height at center CEMA Max Height of C.O.G. CEMA Standard Edge Distance 0.6 sq ft 4.4 in 1.8 in 3.02 in 33 deg 6.6 in. 2.7 in. 1.44 in
18 12
6 0

Cross Section at Pulley Face: Wide Belt (scale: inches)

-24

-18

-12

-6

1.80

2.7

12

18

24

30

36

42

-6 -48 -42
-36 -30 -24 -18

-12

-6

12

18

24

30

36

42

48

Note: This program calculates height of actual C.O.G.* by assuming that actual edge distance at pulley face equals 1/2 of actual edge distance in troughed section. Height of C.O.G.* for CEMA maximum allowable cross section pulley face is given for reference only. * C.O.G. = center of gravity of material

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.23

Design Parameter Summary 01/21/14 Date 6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com
Copyright - Rulmeca Corp.

Telephone

Telefax

e-mail

Project Name

Conveyor Reference

Power Calculation Summary

Calculated power to drive conveyor belt: Drive pulley bearing friction: Power at motor: Gear loss in motorized pulley: Calculated power Derate for high elevation Derate for high temperature Required Power for motorized pulley: 6.6 0.2 6.9 0.4 7.3 HP HP HP HP HP HP HP 7.3 HP

Symbol
Te ang Cw T2 T1 T1 + T2 T_L Tatype Beltype w str pstr btr Ai Cs H Kt Kx Ky L Q Si Tac Tam Tb Tbc Te Tm Tp Tpl Tsb Ttr Tx Tyb Tyc Tym Tyr V Wb Wm Sag Ls Hd

Value
731 lbs 180 degrees 0.8 1635 lbs. 2366 lbs 4001 lbs Full Lagging Manual 2 ply, 225 piw 36 in. 8100 lbs. 16 % 3/16 to 7/16 in. 1.8 lbs 0.128 0 ft 1.59 0.49 lbs/ft 0.04 100 ft 500 tph 4 ft 266 lbs 43 lbs 0 lbs 180 lbs 731 lbs 0 lbs 78 lbs 0 lbs 86 lbs 0 lbs 78 lbs 71 lbs 50 lbs 194 lbs 21 lbs 300 fpm 9 lbs/ft 56 lbs/ft 2.0%

Definition of Terms
Te = effective belt tension at drive. ang = angle of belt wrap around drive pulley(s). Cw = "wrap factor", to determine slack side tension to prevent belt slippage on drive pulley. T2 = estimated slack-side tension required to either keep belt from slipping on pulley surface or maintain trough at allowable sag percentage, whichever is greater. T1 = Te + T2 T1 + T2 = Sum of belt forces on drive pulley. NOTE: This is not a vector sum. T_L = type of lagging specified for drive pulley(s). Tatype = type of take-up specified to apply "slack-side tension". Beltype = type of belt carsass specified. w = belt width str = tensile strength of specified belt. pstr = percentage of available belt tensile strength used. btr = thickness range of specified belt Ai = belt tension required to overcome frictional resistance and rotate idlers. Cs = skirtboard friction factor. H = vertical distance that material is lifted or lowered. Kt = ambient temperature correction factor. Kx = factor to calculate frictional resistance of the idlers and the sliding resistance between belt and idler rolls. Ky = factor to calculate resistance of belt and resistance of load to flexure as they move over idlers. L = length of conveyor. Q = tons per hour conveyed. Si = troughing idler spacing. Tac = total of the tensions from conveyor accessories. Tam = tension required to accelerate the material continuously as it is fed onto belt. Tb = tension required to lift or lower the belt. Tbc = tension required to overcome belt cleaner drag. Te = effective belt tension at drive. Tm = tension required to lift or lower conveyed material. Tp = tension required to overcome resistance of belt to flexure around pulleys and resistance of pulleys to rotate on their bearings. Tpl = tension required to overcome belt plow drag. Tsb = tension required to overcome skirtboard drag. Ttr = tension required to overcome special loading condition(s.) Tx = tension required to overcome carrying and return idler friction. Tyb = total of tensions due to resistance of belt to flexure as it rides over carrying and return idlers. Tyc = tension due to resistance of belt to flexure as it rides over carrying idlers. Tym = tension due to resistance of material to flexure as it rides over carrying idlers. Tyr = tension due to resistance of belt to flexure as it rides over return idlers. V = design belt speed. Wb = weight of belt per unit of length of conveyor. Wm = weight of material per unit of length of conveyor. Sag = recommended maximum sag percentage to avoid spillage in troughed section of belt. Ls = Length of conveyor from tail pulley to Drive snub (for return run drive only) Hd = Height of conveyor from top of tail pulley to bottom of drive pulley (for return run drive only)

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.23 Bulk Handling Belt Conveyor Terminology
6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com
Copyright - Rulmeca Corp.

Conveyor Profile Initial Velocity of Material

Conveyor Cross Section in Skirt Zone

Belt Conveyor with Tripper

Hopper Feeder Conveyor

Cleated Belt with Sidewalls

Belt Conveyor with Two Diverter(s)

"CEMA" Idler Type Definitions

(Based on Conveyor Equipment Manufacturers Association Manual)

Belt Width Idler Type > Idler (deg) > 18 24 30 36 42 48 54 60 72 84 96

20 300 300 300 275 -

A 35 300 300 280 256 -

45 300 289 270 248 -

20 410 410 410 410 390 380 -

B 35 410 410 410 410 363 353 -

Idler Load Ratings* (lbs) C 45 20 35 45 20 410 900 900 900 410 900 900 900 1200 410 900 900 900 1200 396 900 837 810 1200 351 850 791 765 1200 342 800 744 720 1200 750 698 675 1200 700 650 630 1150 1050 -

D 35 1200 1200 1200 1200 1200 1116 1070 977 -

45 1200 1200 1200 1200 1200 1080 1035 945 -

20 1800 1800 1800 1800 1800 1800 1800 1800 1800 1750

E 35 1800 1800 1800 1800 1800 1800 1800 1800 1674 1628

45 1800 1800 1800 1800 1800 1800 1800 1800 1620 1575

*These ratings are for three-equal-roll idlers and are based on a 30,000 hour minimum BU bearing life at 500 RPM. BU bearing life represents the statistical point in hours where a minimum of 90% of the bearings will still be functional with no increase in torque or noise.

Material Surcharge Angle Guide

(Based on Conveyor Equipment Manufacurters Association Manual)

Surcharge Angle 5 10 20 25 30

Angle of Repose 0 to 19 20 to 29 30 to 34 35 to 39 40+

Description of Material Uniform size, very small rounded particles, either very wet or very dry; such as dry silica sand, cement, and wet concrete. Rounded, dry polished particles, of medium weight, such as whole grain and beans. Irregular, granular or lumpy materials of medium weight, such as anthracite coal, cottonseed meal, and clay. Typical common materials such as bituminous coal, stone, and most ores. Irregular, stringy, fibrous, interlocking material, such as wood chips, bagasse, and tempered foundry sand.

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Rulmeca Motorized Pulley Power Calculation Program - Standard Version 7.23 Conveyor Height Calculator

Inclined conveyor length (ft) Angle of inclination (degrees) Material lift height (ft)

6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com

Copyright - Rulmeca Corp.

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