THE GEOMETRY OF CONVEYOR SET-OUT POINTS

It is becoming more common nowadays, for conveyor designers to be presented with a

conveyor layout that gives the vertical dimension of the conveyor with respect to the
terminal pulley centre-lines. This, of course, presents the designer with an extremely
frustrating problem, because the geometry of the system cannot be correctly defined
until the set-out points are finalised. While the horizontal dimensions to the terminals
are given to the centre-line of the pulleys that is simply because the set-out points pass
through the centre-line of the pulley, when horizontal dimensions are considered.
However, the vertical set-out points at the terminal pulleys will never pass through the
centre-line of the pulleys and the set-out points are some theoretical point, which is
determined as a function of the belt inclination at the terminals.

It is obvious that the pulley diameters in any conveyor system are unknown until the
tensions in the conveyor have been designed (even on a preliminary basis). The
ultimate selection of the pulley diameters is a result of iterations, based on the tensions
derived for the system. The exception, of course, is when the pulley diameters are
nominated as a result of rationalisation. However, even in the case of rationalised
pulleys, the overall geometry of the system must be determined about the set-out
points.

The basic system tensions are designed on the basis of the horizontal terminal pulley
centres, with the overall lift measured between the set-out points at the head and tail
(the terminals) of the conveyor. Since the pulley diameters at neither the head nor the
tail are known at the initial design stage, it is substantially incorrect to dimension the
vertical lift to the centre-line of the terminal pulleys. Thus, the layout as shown


is incorrect and can lead to a great deal of confusion and unhappiness.

In order to alleviate the apparent confusion surrounding the correct setting out of
conveyors and their internals, the following procedure should apply:

At the tail end

Horizontal
V
e
r
t
i
c
a
l

Set-out point
level +0,0
Belt slope
- 2 -

It is noted that the set-out point, which is given the value +0,0 at the tail pulley, is not at
the pulley centre-line, nor at the top of the pulley. The set-out point at the tail is the
theoretical point, as shown. Only when the belt line is horizontal, will the set out point
be at the top of the pulley. If it is required, the level at the centre-line of the pulley will
be determined from
cos
R
- 0 ., where refers to the belt inclination at the tail and R is
the pulley radius.

At the head end

Again, it is noted that the set-out point, which is at the level as determined from the
project requirements, is given with respect to the level at the tail pulley. Again, the level
is not at the pulley centre-line, nor at the top of the pulley. Only when the belt line is
horizontal, will the set out point be at the top of the pulley.

From this, the level to the centre-line of the pulley is determined simply by the
following,

cos
R
. P . O . S at Level
The level at all the other pulley locations, such as internal drive pulleys, bend pulleys,
take-up pulleys and so on are given to the centre-line of the particular pulley, since
these do not affect the overall system tensions but, indeed, are determined by them. In
keeping with the convention, the level at these pulleys will always be given with respect
to the level at the tail SOP. Thus, the profile that the designer would prefer would be as
follows.


Armed with such a profile, the design has a much greater chance of being right first
time.

Graham Shortt
brevissg@telkomsa.net
A

Pulley radius R
Belt slope
Overall lift is determined at S.O.P level and
is determined with respect to the set-out
point at the tail pulley
Horizontal
V
e
r
t
i
c
a
l


Slope Slope