Beltconv (1) - Cema

Belt Conveyor Calculations as per CEMA
1. Following six profiles are introduced in the conveyor program me:

2.
Horizontal (i)
Inclined (ii)
(v)
Horizontal, Inclined &
Horizontal
(iii)
Horizontal +
Inclined
(iv)
Inclined +
Horizontal
(vi)
Inclined, Horizontal & Inclined
The program calculates all the dimensional details, after receiving the values of certain
input parameters, with respect to the selected profile.
(i)
(ii)
Input parameters to be provided for profile no.: c/c Horizontal length (m)
c/c Horizontal length (m)
Inclination (Deg) / Lift (m)
(iii) & (iv) c/c Horizontal length (m)

Length of horizontal portion (m),
(v)
(vi)

Horizontal lengths (m)
Length of horizontal portion (m)
Base lengths (m)
Lift (m) / Inclination (Deg)
Internal calculations are based on pounds, feet/inches system, but input
parameters are always fed in SI units (ex. metres)
All final dimensional details are determined here itself and the same
values will be carried on in futher calculations.
2.
Following material characteristics are entered:Volumetric & power densities - These values are taken from CEMA for
respective materials. Sometimes for a material, two values are given, then lower
value is considered as volumetric density and the higher one as power density.
Volumetric bulk density is used to check capacity & power density to determine the
final power requirements.
Angles of surcharge & repose are also entered / taken from database as per
CEMA. Five options for angle of surcharge are 00, 100, 150, 200, 300.
Values of volume & power densities, angles of surcharge & repose can be
changed if required.
3.
Troughing angle is selected out of 4 alternatives (200,300,350,450).

Capacity calculations :Basic formula for calculating capacity is Capacity (Q) TPH = Area of cross x Belt sppeed x 3600 x vol. bulk density
section (m2)
(m/sec)
(T/m3)
x Inclination factor
This comes into picture only for conveyors having inclination & values are provided in
the program as per graph in IS-11592.
Capacity
Belt Speed
These three parameters are interdependent. If two

Area
are known, third can be calculated.
(Belt width)
Area of cross-section can be calculated with known valves
of Belt Width (inches), troughing and surcharge angles & the procedure for calculating
this area is taken from CEMA. Hence, we can conclude that,
If Data given is of :-
Program will select
(i) Belt width, capacity
Min. belt speed (m/sec)
(ii) Belt width, Belt speed
Max. capacity (TPH)
(iii) Capacity, Belt speed
Min. belt width (mm)
Belt width range consists of following belt widths in mm :400, 500, 650, 750, 800, 900, 1000, 1200, 1400, 1600.
4.
Belting Selection :Belt selection i.e. rating, duty will be as per DUNLOP catalogue
only.Min.belt widths for adequate troughing of empty belts for 35 0 troughing
2
angle are kept same as those for 450 troughing angle.

top/bottom cover thicknesses, Nirlon catalogue is referred.
Belting gets selected as follows -
For determining
Belt width (mm) - Known value/ given by the client

Duty - General/Extra/Heavy
Default option
If we want to change this default option in the beginning itself, we can. If rating
is out of the range of general duty, the program clearly indicates so on the
screen, conveying that the user has to go for higher duty.
Material abrasiveness, temperature - Known parameters
Temperature
75
120
180
200
Grade
M24
HR
SHR
UHR
FR
Factor
1.1
1.21
1.265
1.375
1.32
for calculating belt weight

Std. value
10 % more on std value
15 %
25 %
20 %
This information is provided by Mr.Nair of M/s Ashish

Enterprises on 18.09.98.
Knowing belt width, material density (power density) and troughing angle, it checks
both criteria of adequate load support and adequate troughing of empty belt, & then
selects Primary belting (Belt rating).
If material density exceeds 2.5 T/m3, same values of belt widths for 2.5T/m 3 are
assigned.
It also calculates top cover thickness of the belt -
Loading cycle = 2 x conv. developed length (m)

Belt speed (m/sec)
= _________ sec
If this value lies in between two standard values, select lower value of loading cycle
with respect to material abrasiveness & lump size.Bottom cover thickness with respect
to material abrasiveness is as follows :Non-abrasive
1.5 mm
Abrasive
2 mm
Very abrasive
2.5 mm
We can also enter top/bottom cover thicknesses as per requirement.
After selecting min. belt rating, now we can calculate belt weight -
Wb = constant factor x [top cover thk(mm) +Bottom cover thk(mm)]+Nominal

carcass weight (kg/m2)
X Belt width (mm) X 0.6722
1000
=------lbs/ft
5.
6.
Weight of material is calculated as follows Wm =

Capacity (TPH)
x 1000 x 0.6722 = ________ lbs/ft.
3600 x belt speed (m/sec)
Idler rating :Max. Idler spacing by default is entered as per table in IS-11592. Option
is open to reduce this spacing as per the client requirement.
Belt Width (mm)
Carrying Idler spacing (m) for

material density of
0.4-1.2 T/m3
1.2-2.8 T/m3
Return Idler spacing

(m)
400
500
600
650
750
800
900
1000
1200
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
3
3
3
3
3
3
3
3
3
1400
1600
1.0
1.0
0.75
0.75
3
3
Now, Idler load (Il) = (Wb + Wm)Si

= ___________ lbs
Adjusted load = Il x K1 x K2 x K3 x K4
Belt Speed correction factor
Service factor
Lump Adjustment
Environmental & maintenance factor
factor
[K2 = 1.06, K3 = 1.2] These two values are freezed.
K1 = If the values of lump size (inches) and material density fall in between two
standard values, then select the higher values for K1.
K4 = Select the roll dia. as it is & higher belt speed to decide the value of K4.
If K1, K2, K3, K4 < 1, take it equal to 1.
If Adjusted load < Idler load, take Al= Il.

Some assumptions are made to decide the value of Ai :Pipe OD (mm)
Respective OD (inches) adjusted Duty type

as per CEMA
76.1
88.9
114.3
127
139.7
152.4
4
4
5
5
6
6
Ai
A, B , C
2.3
A, B , C ,D
1.8
C, D
1.5
165.1
7
E
2.4
168.3
7
Now with respect to belt width and troughing angle duty type is decided i.e. whether
idler rating is A, B, C, D or E. These values tabulated below are interpolated from
CEMA for belt widths available in India.
A type - Belt Width (mm)
400
500
600
650
750
800
900
B type - Belt Width (mm)
400
500
600
650
750
800
900
1000
1200
C type - Belt Width (mm)
400
20
300
300
300
300
300
294
278
Troughing
30
300
300
300
295
282
275
259
Angle
35
300
300
300
295
282
275
259
20
410
410
410
410
410
410
410
399
382
Troughing
30
410
410
410
410
410
410
410
384
355
Angle
35
410
410
410
410
410
410
410
384
355
20
900
Troughing Angle
30
35
900
900
5
45
297
297
290
284
270
265
251
45
410
410
410
410
410
407
398
371
344
45
900
Return Idler
150
143
127
119
102
94
78
Return Idler
220
212
192
184
167
163
156
147
132
Return Idler
475
500
600
650
750
800
900
1000
1200
1400
D type - Belt Width (mm)

650
750
800
900
1000
1200
1400
1600
1800
E type - Belt Width (mm)

900
1000
1200
1400
1600
1800
2000
900
900
900
900
900
900
872
807
741
900
900
900
900
885
843
812
750
690
900
900
900
900
885
843
812
750
690
20
1200
1200
1200
1200
1200
1200
1191
1125
1060
Troughing Angle
30
35
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1108
1108
1032
1032
986
986
20
1800
1800
1800
1800
1800
1800
1800
Troughing Angle
30
35
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1800
1730
1730
900
900
900
900
878
819
785
726
667
45
1200
1200
1200
1200
1200
1200
1056
1013
954
45
1800
1800
1800
1800
1800
1800
1699
433
330
306
256
238
205
172
129
Return Idler
600
600
600
600
544
435
358
249
167
Return Idler
1000
1000
1000
912
813
715
616
Now, we get Ai value, once we fix the combination of [Duty type - Roller dia]
A, B, C, D, E
7.
4, 5, 6, 7 inches
Kx = 0.00068 (Wb + Wm) + Ai

Si
Ky calculations :- For each portion of the profile, Ky is calculated seperately.

Ky selection is as per two tables in CEMA on pg. No. 78, 79.
(i)
Conveyor length
(ii) Wb + Wm
(iii)
Percent Slope
Lower value if it lies in between two points.

Interpolate
Lower side
With respect to this data, decide primary value of Ky. But this is for certain
specific spacing. These idler spacings are in ft (3,3.5,4,4.5,5). Converting it to
metres, gives the values, which are nearly equal to generally recommended idler
spacings.
Then corrected Ky values are decided from next table in CEMA on pg 80.
Here correct idler spacing is used for a range of (Wb + Wm).
All the basic parameters required for calculating effective tension are now available
at this stage.
Default roller diameter for carrying, return & impact idlers are also put in the
program with respect to belt width, which are as follows :(This information is picked up from one of the enquiries of Grasim cements where the
consultants were Holtec ltd.)
Belt Width (mm)

400
500
600
650
750
800
900
1000
1200
Roller dia for

C.I/SACl
R.I/SARI
88.9
76.1
88.9
76.1
114.3
89
114.3
89
114.3
89
139.7
114.3
139.7
114.3
139.7
114.3
139.7
114.3
7
Impact idler
Roller dia/Rubber ring OD
76.1/114.3
76.1/114.3
76.1/114.3
76.1/114.3
76.1/114.3
88.9/165
88.9/165
88.9/165
88.9/165
1400
1600
8.
152.4
152.4
139.7
139.7
114.3/190
114.3/190
Effective tension calculations :Idler friction, Tx = Kt[Kx carrying + Kx return] x L
Value calculated 0.015

above
always
developed = ___ ft
length (ft)
Resistance of belt dlexure as it moves over the idlers.

Tyb = Tyc + Tyr
for carrying & return sides
Tyc for profile nos (i) & (ii) = l x Ky x Wb x Kt = _______ lbs
Tyr for all profiles = l x 0.015 x Wb x Kt
fixed always
Resistance of material flexure as it rides the belt over the idler Tym for profile nos (i) & (ii) = L x Ky x Wm
= _______ lbs
(iii) & (iv) = [L1 x Ky1 + L2 x Ky2 + L3 x Ky3] x Wm

(v) & (vi) = [L1 x Ky1 + L2 x Ky2 + L3 x Ky3] x Wm
Force needed to lift the load For profiles (ii), (iii), (iv) & (v) Tm = Lift (ft) x Wm (lbs/ft)
= _______ lbs
Resistance of belt to flexure around pulleys & resistance of pulleys to rotate on their
bearings - (Tp)
Following databases are introduced to the program to ease calculations -
Screw
VGT
HGT
8
Head Pulley
Tail Pulley
Snub Pulley
Bend Pulley
Take up Pulley
Type of Pulley
Head/Drive
Tail/Take up
Snub/Bend
1
1
1
1
1
1
2
1
1
1
1
4
1
Value of Tp with respect to

take up will be W/o Tripper (Tp) lbs With Tripper (Tp)
Screw
450
-------- NA ------VGT
800
1100
Associated tension (lbs)

200
150
100
HGT
1000
1300
Force needed to accelerate the material as it is fed onto the belt Tam = Capacity (TPH) x 2204 x Belt speed (fpm) = _______ lbs
3600 x 32.2 x 60
Resistance due to belt cleaners = Resistance due to + Resistance due to
(Tbc)
external scrapper
internal scrapper
This factor is a constant as per CEMA = 5 x Belt Width (mm) x [2 +
25.4
2]
Force needed to overcome skirtboard friction

Tsb = length of skirtboard (ft) [Cs hs2 + 6] = _________ lbs
Cs = Power density (lbs/ft3) 1 - sin (angle of repose)
144
1 + sin(angle of repose)
hs = depth of material in skirtboard
= 10 % of belt width in inches - as per CEMA
Effective tension, Te=Ty + Tyb (Tyc + Tyr) + Tym + Tm + Tp + (Tbc + Tsb) + Tam = ___ lbs
Now calculate T1 as follows :T1 = (1 + Wrap factor) x Te = __________ lbs
Following database is introduced - CEMA
Wrap angle over head pulley
VGT / HGT
Bare
lagged
pulley
pulley
9
Screw take up
Bare
Lagged
pulley
pulley
1800
2000
2100
2200
2400
0.84
0.72
0.66
0.62
0.54
0.5
0.42
0.38
0.35
0.54
1.2
1
1
0.9
0.8
0.8
0.7
0.7
0.6
0.6
T1 (KN) = T1 (lbs) x 9.81

2.204 1000
Now following ratio is checked and it should be less than 80 %.
T1
< 80 %
Belt width (m) x Tmax
If it exceeds 80 %, the program displays a message & goes on the higher side to select
new rating. If belting is not available in that duty, then change the duty, appearing on
the screen in belting module. This procedure is continued, till safe belting is selected.
Now with the belt weight of this selected belting, again T e is calculated & checked
whether T1/Tmax is less than 80 %. Once the belting is finalised, then, depending on
the % value of T1/Tmax, pulley diameters are also decided in conjunction with carcass
thickness of selected belt as follows :-
Carcass thickness (mm)

from - upto & including
60 - 80 %
Head
(H)
2.8 - 3.5
3.6 - 4.4
4.5 - 5.5
5.6 - 7.0
7.1 - 8.8
8.9 - 11.1
323
400
500
630
800
1000
Tail/
Bend
(T)
273
323
400
500
630
800
0 - 60 %
Snub
(S)
219
273
323
400
500
630
323
400
500
630
800
273
323
400
500
630
219
273
323
400
500
Pulley diameters are decided only after Belting selection is finalised.
10
If wrap angles over head pulley & other pulleys also are not specified, then the
program will select the following tabulated valves -
Profile No
(v)
S V
H
(vi)
S V
H
<--------------------------------------------------------------------------------------------------------------------------->
<
--------------------------------------------------------------------------------------------------------------------------->
<----------------------------------------------------------30 0
by
-------------------------------------------------->
900 90
900+
900+
90 90
90 90
0
0
0
0
0
Angle
Angle
of
of
inclinati
inclinati
on
on
180 0
S
Head Pulley
a. without
snub
b. with
snub
Snub
Pulley
Bend
Pulley
(i)
V
(ii)
V
(iii)
V
(iv)
V
H
210 0
default
900+
Angle
of
inclinati
on
where, S - Screw, V - VGT, & H - HGT

Wrap angles for tail & take up pulleys will be always equal to 1800.
Motor selection Te (N) = Te (lbs) x 9.81 = __________ N
2.204
KW required at conveyor pulley shaft = Te (N) x Belt speed (m/sec)
1000
= _________ KW = _______ If this value
Let this value be
(X)
KW = -hp 30
GB= 0.75 (Worm)
>30
GB 0.925(Helical)
KW required at motor o/p shaft = X = ______ KW
GW
(Y)
Motor KW required = Y x Motor service factor (1.15 Default value. Option open
to change)
Adapt a motor of next higher rating (KW )
10. Gear Box Selection :To consider Peripheral speed of the belt, while selecting gear box Pulley dia = Base pulley dia (mm) +
2[lagging thk mm) +(top+bottom cover thk(mm)) + carcass thk (mm)]
11
= ___________ mm/1000 = ________________ m

Drive pulley rpm = 60 x belt speed (m/sec)
= ____________ rpm
x pulley dia (m) (value)
Gear box ratio =
1440 = ______________
Drive pulley rpm
Motor is selected, based on gear box efficiencies depending on whether KW required at
conveyor pulley shaft is less or greater than 30 KW. Now, if we want to change the
type of gear box, change it here only -
If gear box type is changed, accordingly efficiency will change & absorbed as
well as rated KW of motor will also change.
Once we specify the type of gear box, to arrive at proper size, the program follows the
following path Gear Box
Helical
Worm
Solid Shaft
Hollow Shaft
Bevel Helical
Solid Shaft
Hollow Shaft
NU
SBN/SCN
FSM It will go
Foot
Shaft KBN/KCN Foot
Shaft
downward while
mounted mounted
mounted mounted
selecting the correct
gear box size
SBH/SCH SBA/SCA
KBH/KCH KBA/KCA
The program will go from B to C i.e. from double to triple
reduction to select correct gear box size & ratio.
A separate gear box screen is introduced, which on getting the correct data selects
suitable gear box size Absorbed Power
Gear box selection based on
Rated Power
Default Option
Type of gear box
Worm
Helical
Bevel Helical
Shafting
Solid
Foot mounting
Hollow
Shaft mounting
Service factor
1.5 (Default value)
Now, if gear box type selected is -
option open to change
12
1.
Worm
Min. hp required for gear box = Absorbed/Rated motor x Gear box
hp
hp
service factor
= ___________ hp
Now the gear box ratio calculated, will not be always equal to or tally with the
standard ratios available.
Hence the program always selects the previous /lower gear box ratio.
Now with respect to this gear box ratio, & min. hp requirement, the program
selects the correct gear box size.
Due to reduction in gear box ratio, belt speed of conveyor will rise. Hence the
conveying capacity will increase for same belt width. There will also be a change in
motor power requirement, which increases from its original value.
(From previous page)

Hence gear box screen is continued with Required gear box ratio
Actually selected / std gear box ratio
Change in speed
Change in hp / New hp
Capacity increased/decreased
Hence, the program will always display the lower gear box ratio selected.
But if needed, we can select higher ratio & check whether capacity gets satisfied
or not. As we change ratio, corresponding charges will also be observed on the
screen. Only those ratios available in that particular series will get displayed.
2.
HELICAL/BEVEL HELICAL
Min. KW required for gear box = Absorbed/Rated motor KW x Gear box
service factor
Now with this KW and selected gear box ratio, program selects suitable size.
This portion is explained as follows :Required gear box ratio =
Selected ore
Drpurpm changed
=
=
Speed changed
1440
Drpurpm
___________ (Let it be X)
1440
X
x Dr.Dia x Drpurpm changed/60
13
KW changed (if any)
Te (N) x speed changed/1000
Capacity increased = Area x increased speed x 3600 x material bulk density x Kf.
11.
Coupling selection :Input coupling is selected, once motor & gear box are finalised selection
procedure for three types of couplings is introduced in the program. (Fluid, bin
& bush & geared).
If,
1.
Fluid Coupling
Check, whether the coupling is with or without delay chamber. See motor KW
selected. Select the coupling with rating equal to or greater than the above
motor KW at 1450 rpm.
2.
Pin & bush / Geared Coupling
Input coupling torque = 716 x Rated motor x cplg service factor x 9.81(NM)
1440
Select the greater value among motor shaft dia & gear box input shaft dia with respect
to this greater value, decide the keyway portion in hub, as per the following database Shaft dia (mm) [From - upto & including)
Keyway portion in hub (mm)
45 - 50
51 - 58
59 - 65
66 - 75
76 - 85
86 - 95
96 - 110
111 - 130
131 - 150
151 - 170
171 - 200
201 - 230
23 - 30
31 - 38
3.8
4.3
4.4
4.9
5.9
5.4
6.4
7.4
8.4
9.4
10.4
11.4
3.3
3.3
14
39 - 44
3.3
Following two conditions are checked Shaft dia of motor as well as I/p gear box should be min.bore of coupling
max.bore of coupling
Now, Keyway portion in + 10 mm + Greater value among

hub
the two shaft dias
Hub outside dia
This value is entered in

the coupling database
The program will select, the correct coupling size satisfying above three conditions of
torque, min & max bore & hub outside diameter criterion.
Output coupling selection :O/P Coupling torque = 716 x Rated motor x cplg service factor x 9.81(NM)
(1440/Gear box ratio)
Select the coupling with greater torque next to, calculated above & display the size.
Hold back torque at the
output shaft of gear box
= Head Pulley dia (m) Force needed to lift the load (m)
2
- (Idler friction (Tx) + Resistance
of belt flexure over idlers (Tyb)
+ Resistance of material flexure
over belt (Tym)/2)
= ___________ lbs/ft
= __________ x 0.4536 x 0.3048 = ____________ Kg.m
Considering 50 % safety margin

Hold back torque at Gear output shaft = __________ x 1.5 = __________ Kg.m
Equivalent mass of rotating parts of conveyor :Belt lengths for various types of take-ups is calculated as follows :1.
Screw take-up
15
Belt length = 2 x developed length (m) + 1 m + /2 [Head pulley dia + Tail

pulley dia]
2.
Should consider
bare pulley dia (m)
VGT
Belt length = 2 x developed length (m) + 1 m +
[ Head Pulley dia + Tail Pulley dia + Take up dia ]
2
2
+ 0.025 x developed length (m) x 2 = __________ m
3. HGT
Belt length = 2 x developed length (m) + 1 m +
[ Head Pulley dia + Tail Pulley dia + Take up dia ]
2
2
+ 0.025 x developed length (m) x 2 = __________ m
Equivalent mass of rotating = (i) + (ii) + (iii) + (iv) + (v)
parts of a conveyor
= ___________ lbs 2.204 = ______________ kgs
(a)
Now,
i. Belt weight = Total belt length (ft) x Wb (lbs/ft) = __________ lbs
ii. Weight of rotating parts = Weight of rotating parts of unit idler (lbs)
of carrying idler
x Total developed length (ft)
Carrying idler spacing (ft)
iii. Weight of rotating parts = Weight of rotating parts of unit idler
of return idler
x Total developed length (ft)
Return idler spacing (ft)
iv. Material weight = Developed length (ft) x Wm = ____________ lbs
v. Equivalent weight of = 2/3 Tail pulley wt + Snub pulley wt (lbs) +
non-driving pulleys
+ Take-up pulley wt (lbs) + No of bends pulleys
x bend pulley wt (lbs)
G92 value of conveyor, reterred =
a
to motor shaft
x motor rpm (1440) 2
belt speed (m/sec) x 60
= _____________ kg.m2 Total G92 of conveyor
without motor at motor
shaft
16
= (x + y)
Mass of rotating parts of conveyor without drive m1 = a
9.81
= _________ kg/m/sec2
= ________ x 2.204
3.28
= __________ lbs.sec2
G92 value of drive unit = G92 of motor
+ Gear Box
+ Input Coupling
+ Output Coupling
Mass of Drive unit reterred
to belt line
= b
x x motor rpm (1440)
9.81 belt speed (m/sec) x 60
= ___________ Kg/m/sec2 = ________ x 2.204
3.28
2
= ___________ lbs.sec /ft
Total equivalent mass of conveyor

referred to belt line
= A+B
= ________________ lbs.sec2/ft
Component (V) To find out weights of pulley
We, at this stage dont know the shaft diamters of pulleys.
following shaft diameters with respect to pulley diameters Pulley Dia
219
273
323
400
500
630
800
1000
Hence assume the
Shaft dia to be assumed to

be consider pulley weight
50
60
75
90
100
100
125
140
Let G- starting force produced, by drive unit considering average starting torque 160 %
of motor rated torque.
G = 1.6 x motor hp x Gear box x 75
Belt Speed (m/sec)
17
= _____________ Kg.f
= ________ x 2.204
= _______________ lbs
Acceleration = G - Te =
lbs
m
lbs.sec2/ft
= _________ ft/sec2
Effective force during starting,
Test = G x m1
= _________ lbs
T1st = e0 , = co-efficient of friction
T2st
= 0.25 -- for base head pulley
= 0.85 -- for lagged pulley
T1st = e . T2st
= Wrap angle over head pulley
But Test = T1st - T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T2st = Test/(e0 - 1)
T1st = Test + T2st
For calculating tensions of various points in the profile, it is assumed that snub
pulley is always present in the conveyor. Take up travel is considered 3% of
developed length in case of screw take-up & 2.5% in the case of VGT & HGT.
Separate calculations with respect to profile & type of take-up are introduced in
the program.
Profile No. 5 - (v) (Horizontal, inclined & horizontal), HGT (Elecon type)
T3st = T2st + 100 + x mass of snub pulley x 2.204 + Texternal scraper

18
32.2
= T2st + 100 + x mass of snub pulley x 2.204 + 5 x 2 x Belt width (mm)
32.2
25.4
= __________ lbs
T4st = T3st [0.015 x L4 (H) + 0.015 x L4(ft) x Wb (lbs/ft)] + x L4(ft) [Wb(lbs/ft) +
32.2
Wt. of rotating parts of unit return idler (lbs)]
= ___________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H5 (ft) x Wb(lbs/ft)
= ________ lbs
T6st = T5st + 100 + x mass of bend pulley x 2.204 = _________ lbs
32.2
T7st = T7st + 100 + x mass of take-up pulley x 2.204 = _________ lbs
32.2
T9st = T8st + 100 + x mass of bend pulley x 2.204 = __________ lbs
32.2
Considering four fall, wire rope arrangement, at take-up tower,
Min. counter weight = (T6st + T7st) x 2
= _____________ lbs/2.204 = ___________ Kgs.
(Make it a round figure, to ensure no slip)
From this calculated counter weight, fixed normal running full load belt tensions are
worked out as follows :T6 = Counter weight (lbs)/4 = ________ lbs = T7
T5 = T6 - 100
T4 = T5 - 100 + H5(ft) x Wb(lbs/ft) = ____________ lbs
T3 = T4 - [0.015 x L4(g) + 0.015 x L4 x Wb] = ________________ lbs
T2 = T3 - 100 = ______________ lbs
T1 = T2 + Te + 5 x 2 x Belt Width (mm) - H7 x Wb +
25.4
(0.015 x L10 + 0.015 x L10 x Wb(lbs/ft) = ______________ lbs
T11 = T10 + 100 = _______________ lbs
Profile No. 5 (v) VGT
Horizontal, Inclined & Horizontal

Test = G x m1
= _________ lbs
19

T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H5(ft) x Wb (lbs/ft)
32.2
= _______________ lbs
T6st = T5st + 100 + x mass of bend pulley x 2.204 = ___________ lbs
32.2
T7st = T6st + 150 + x mass of take-up pulley x 2.204 = ___________ lbs
32.2
32.2
Considering four fall, wire rope arrangement, at take-up tower,
Min. counter weight = (T6st + T7st) x 2
= _____________ lbs/2.204 = __________ kgs.
(Make it a round figure, to ensure no slip)
From this calculated counter-weight, fixed normal running full load belt tensions are
worked out as follows :T6
T5
T4
T3
T2
T1
=
=
=
=
=
=
Counter weight (lbs)/4 = _____________ lbs = T7

T6 - 100
T5 - 100 + H5(ft) x Wb (lbs/ft) = ____________ lbs
T4 - [0.015 x L4(g) + 0.015 x L4 x Wb] = _____________ lbs
T3 - 100 = ___________ lbs
T2 + Te + 5 x 2 x Belt Width (mm) = ___________ lbs
25.4
20
T8 = T7 + 100 = _____________ lbs

T9 = T8 + 100 + H6 x Wb = ____________ lbs
T10 = T9 + 5 + 2 x Belt Width (mm) - H7 x Wb +
25.4
(0.015 x L10 + 0.015 x L10 x Wb(lbs.ft)) = _________ lbs
T11 = T10 + 100 = ___________ lbs
Profile No. 5

Test = G x m1
= _________ lbs
T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = T3st [0.015 x L4 (H) + 0.015 x L4(ft) x Wb (lbs/ft)] + x L4(ft) [Wb(lbs/ft) +
32.2
Wt. of rotating parts of unit return idler (lbs)]
= ___________ lbs
T5st = T4st - (H5(ft) x Wb(lbs/ft) = _______ lbs
T6st = T5st + 150 + x mass of take up pulley x 2.284 = ________ lbs
32.2
T7st = T6st + (H5 x Wb) + 100 + + mass of bend pulley x 2.204
32.2
Min. counter weight = (T5st + T6st) = ________ lbs = ________ Kgs
21
2.204
Normal running full load belt tensions :T6 = Counter weight = ___________ lbs = T5
2
T4 = T5-100 + H5 x Wb = ____________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100 = _________ lbs
T1 = T2 + Te + 5 x 2 x Belt Width (mm)/25.4 = ________ lbs
T7 = T6 + (H5 x Wb) = ________ lbs + 100
T8 = T7 + 5 x 2 x Belt width (mm) - H7 x Wb + (0.015 x l10 + 0.015 x Wb)= _____ lbs
25.4
T9 = T8 + 100 = ___________ lbs
Profile No. (vi)
Test = G x m1
= _________ lbs
T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = T3st +[0.015 x l4 + 0.015 x l4 x Wb] + x l4 x [Wb + wt. of rotating parts of
32.2
unit return idler wt]
= -H5 x Wb = _____________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H6 x Wb = _________ lbs
32.2
22
T6st = T5st + 100 + x mass of bend pulley x 2.204 = ________ lbs

32.2
32.2
32.2
T9st = T8st + 100 + H7 x Wb = ___________ lbs
Assuming four full wire rope arrangement,
min. counter weight = T6st + T7st = __________ lbs
2
Normal running full load belt tension,
T6 = Counter weight = T7 = ___________ lbs
4
T5 = T6 - 100
T4 = T5 - 100 + (H6 x Wb) = ___________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] + H5 x Wb = __________ lbs
T2 = T3 - 100
T1 = Te + T2 + 5 x 2 x Belt Width (mm) = _______ lbs
25.4
T8 = T7 + 100
T9 = T8 + 100 + H7 x Wb
T10 = T9 + 5 x 2 x Belt Width (mm) - H8 x Wb + [0.015 x l10 + 0.015 x l10 x Wb]
25.4
= ___________ lbs
T11 = T10 + 100 = __________ lbs
Profile (vi) Inclined, horizontal & inclined
VGT
Test = G x m1
= _________ lbs
T2st
T1st = e . T2st

23
= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = T3st +[0.015 x l4 + 0.015 x l4 x Wb] + x l4 x [Wb + wt. of rotating parts of
32.2
unit return idler wt]
= -H5 x Wb = _____________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H6 x Wb = _________ lbs
32.2
32.2
32.2
T7 = T6 + 100 + H7 x Wb = ______________ lbs
T8 = T7 + 5 x 2 x Belt Width (mm) - H8 x Wb + [0.015 x l10 + 0.015 x l10 x Wb]
25.4
T9 = T8 + 100 = ___________ lbs
Profile No. (i) Horizontal - Screw take up
Test = G x m1
= _________ lbs
T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
24
32.2
32.2
25.4
= __________ lbs
Assuming tension at the at tail pulley is at least equal to min. tension T0, for % seq Options - 2%
T4 = 6.25 Si (ft) [Wb + Wm] = _________ lbs
T5 = T4 + 100
T3 = T4 -[0.015 x l4+0.015 x l4 x Wb] = __________ lbs
T2 = T3 - 100
T1 = Te + T2 + 5 x 2 x Belt Width (mm) = _________ lbs
25.4
Profile (i)
Horizontal VGT
Test = G x m1
= _________ lbs
T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
25
T4st = T3st + [0.015 x l4 + 0.015 x l4 x Wb] +

x l4 (ft) [Wb + Wt of rotating parts
32.2
of unit return idler]
T5st = T4st + 100 + + mass of the bend pulley x 2.204 - (H5 x Wb) = _________ lbs
32.2
T6st = T5st + 150 + + mass of take up pulley x 2.204
32.2
T7st = T6st + 100 + + mass of bend pulley x 2.204 + (H5 x Wb) = ________ lbs
32.2
Min. counterweight = (T5st + T6st) = ___________ lbs
2
T4 = T5 - 100 + (H5 x Wb) = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100
T1 = Te + T2 + 5 x x Belt width (mm) = _________ lbs
25.4
T7 = T6 + 100 + (H5 x Wb) = ___________ lbs
T8 = T7 + 5 x 2 x Belt Width (mm) + (0.015 x l8 + 2.015 x l8 x Wb(lbs/ft)= _____ lbs
25.4
T9 = T8 + 100 = _________ lbs
Profile (i)
Considering four full wire rope arrangement, at take up tower,

min. counter weight = (T8st + T7st) x 2 = __________ lbs
Normal running, full load belt tensions :T6 = Counter weight = __________ lbs = T7
4
T5 = T6 - 100
T4 = T5 - 100 + (H5 x Wb) = ________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = __________ lbs
T2 = T3 - 100 = _________ lbs
T1 = T2 + Te + 5 x 2 x Belt width (mm) + [0.015 x l10 + 0.015 x l10 x Wb]
25.4
T11 = T10 + 100 = ___________ lbs
Profile (ii) Inclined
Screw Take up
26
Test = G x m1
= _________ lbs
T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st

32.2
32.2
25.4
= __________ lbs
T4 = min. tension with respect to % seq.
T5
T3
T2
T1
=
=
=
=
T4 + 100 = ___________ lbs

T4 + H5 x Wb - 0.015 x l4 x Wb = __________ lbs
T3 + 100
T2 + Te + 5 x 2 x Belt width (mm) = _________ lbs
25.4
Profile (ii)
VGT
Test = G x m1
= _________ lbs
T2st
27
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = T3st + [0.015 x l4 + 0.015 x l4 x Wb] +
x l4 x [Wb + wt of rotating parts
32.2
- H5 x Wb = ___________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H6 x Wb = ___________ lbs
32.2
Min. counterweight = T5st + T6st
Normal running, full load belt tensions :T5 = T6 = Counter weight /2 = __________ lbs
T4 = T5 - 100 + H6 x Wb = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] + H5 x Wb = ___________ lbs
T2 = T3 - 100
T1 = Te + T2 + 5 x 2 x Belt Width (mm) - H8 x Wb + [0.015 x l10 + 0.015 x l10 x Wb]
25.4
= ______________ lbs
T7 = T6 + 100 + H7 x Wb
T8 = T7 + 5 x 2 x Belt Width (mm) - H8 x Wb + [0.015 x l10 + 0.015 x l10 x Wb] =
25.4
= ___________ lbs
T9 = T8 + 100 = ____________ lbs
Profile (ii)
HGT (Elecon type)
Test = G x m1
= _________ lbs
28
T2st

T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = T3st + [0.015 x l4 + 0.015 x l4 x Wb] +
x l4 x [Wb + wt of rotating parts
32.2
- H5 x Wb = ___________ lbs
T5st = T4st + 100 + x mass of bend pulley x 2.204 - H6 x Wb = ___________ lbs
32.2
T6st = T5st + 100 + x mass of bend pulley x 2.204 = _________ lbs
32.2
T7st = T6st + 150 + x mass of take up pulley x 2.204 = __________ lbs
32.2
T8st = T7st + 100 + x mass of bend pulley x 2.204 = ____________ lbs
32.2
32.2
+ H7 x Wb
Min. counterweight, assuming four fall wire rope arrangement = T6st + T7st
2
T6 = Counter weight/4 = T7 = ____________ lbs
T5 = T6 - 100 = ____________ lbs
T4 = T5 - 100 + [H6 x Wb] = _________ lbs
T3 = T4 + H5 x Wb - [0.015 x l4 + 0.015 x l4 x Wb] = ___________ lbs
T2 = T3 - 100,
T1 = T2 +Te + 5 x 2 x Belt Width (mm) = __________ lbs
25.4
T8 = T7 + 100
T9 = T8 + 100 + H7 x Wb = ______ lbs
29
T10 = T9 + 5 x 2 x Belt Width (mm)/25.4 - H8 x Wb

+ [ 0.015 x l10 + 0.015 x l10 x Wb] = _____________ lbs
T11 = T10 + 100 = ______________ lbs
Profile (iii)
Screw
Test = G x m1
= _________ lbs
T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st

32.2
32.2
25.4
= __________ lbs
T4st = min. tension with respect to % seq.
T5 = T4 + 100 = ______________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] + H5 x Wb = ________________ lbs
T2 = T3 + 100
T1 = T2 + Te + 5 x 2 x Belt width (mm) = _________ lbs
25.4
VGT :
30
Profile (i)
Horizontal VGT
Test = G x m1
= _________ lbs
T2st

T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = T3st + [0.015 x l4 + 0.015 x l4 x Wb] +
32.2
32.2
32.2
32.2
31
2
T4 = T5 - 100 + (H5 x Wb) = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100
25.4
T7 = T6 + 100 + (H5 x Wb) = ___________ lbs
25.4
T9 = T8 + 100 = _________ lbs
HGT :
T6 = Counter weight = ___________ lbs = T5

2
T4 = T5 - 100 + (H5 x Wb) = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100
25.4
T7 = T6 + 100 + (H5 x Wb) = ___________ lbs
25.4
T9 = T8 + 100 = _________ lbs
T10 = T9 + 5 x 2 x Belt Width (mm) + [0.015 x l10 + 0.015 x l10 x Wb] - H7 x Wb
= ___________ lbs
T11 = T10 + 100 = _____________ lbs
After calculating tensions at various points, with respect to profile, proceed with the
follwing :Rated belt tensions = ________________ (KN/m) width
= ________________ KN/belt width (m) (eg. 50 KN/m)
ex.
= 50 x 103
9.81
= _________ kgs x 2.204 = ___________ lbs (RBT)
Considering starting tensions is limited to 160 % of the rated belt tension :Then, allowable extra belt tension :32
Fa1 = 1.6 x (RBT) - T1

= _______________ lbs
Time for acceleration = M1 [Belt speed (fpm)]
60
Fa1
t
= ________________ secs
Max. permissible belt tension = 1.6 x RBT = ____________ lbs
Not to exceed, the max. permisible belt tensions, the time used for acceleration
should not be less than t.
- Known value calculated previously.
Starting time of equipment = Belt speed (fpm)
60 x
t1
= ____________ secs
t1 > t
Conveyor is safe to start fully loaded with the equipment selected.
Coasting time calculations :Mass of Conveyor system M = _______________ lbs.sec2 /ft
Kinetic energy of system = MW2
2
Retarding force = Effective tension = Te = _________ lbs
Total work performed during deceleration / retardation = Te x v(fpm) x t
2
2
= MV
2
Coasting time, t = MV
Te
= ______________ secs
Radius calculations (during starting conditions)-With material load upto point C :
Profile No. (v)
Resistance of the material, as it rides the belt over the idlers :Tym = l1 x ky1 x Wm = __________ lbs
Effective tension, here at point C,

Te = Tx + Tyb + Tym + Tp + Tam + Tac
= ____________ lbs
Material weight upto point C = l1 x Wm = ____________ lbs (A)
As calculated previously, Belt weight
= ___________ lbs
Carrying roller wt = ___________ lbs
Return roller wt = ___________ lbs
33
Let addition of
these be X.
Total mass of rotating parts = 1

(m1)
32.2
X = ___________ lbs
(X+A)
Total equivalent mass of conveyor system = m1 + m2

(M)
= _____________ lbs.sec2 / ft
Acceleration, = G - Te
M
= ___________ ft/sec2
T10st = T9st + (Kyreturn side + Kyreturn side x Wb)l1 - H7 x Wb + Tbc + l1 (Wb + Wm)
2
9
= T9st + (0.015 + 0.015 x Wb) x l1 only upto point C
- H7 x Wb + 5 x
i.e. the first
2
(ft)
horizontal portion
x Belt width (mm) x l1 (Wb + Wm)
25.4
32.2
= ____________ lbs
T11st
= T10st + 150 + x 2.204 x mass of tail pulley = ______________ lbs

32.2
Test
= T11st x l1 x [Wb + Wm + wt. of rotating parts of unit carrying idler (lbs)]

32.2
+ l1 [Kx + Ky1 (Wb + Wm)] + Tam + Tsb = ____________bs
Radius, Rst = 1.11 x Test

Wb
=
ft = _________m
3.28
Pulley Shaft diameter calculations :Profile No. (ii) Inclined
:- with VGT/SCREW/HGT,
SCREW
Test = G x m1
= _________ lbs
34

T2st
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = min. tension with respect to % seq.
T5 = T4 + 100 = ______________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] + H5 x Wb = ________________ lbs
T2 = T3 + 100
T1 = T2 + Te + 5 x 2 x Belt width (mm) = _________ lbs
25.4
VGT :
Profile (i)
Horizontal VGT
Test = G x m1
= _________ lbs
T2st
35
T1st = e . T2st

= T2st.eo - T2st
= T2st (e0 - 1)
T1st = Test + T2st
32.2
32.2
25.4
= __________ lbs
T4st = T3st + [0.015 x l4 + 0.015 x l4 x Wb] +
32.2
32.2
32.2
32.2
2
T4 = T5 - 100 + (H5 x Wb) = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100
25.4
T7 = T6 + 100 + (H5 x Wb) = ___________ lbs
25.4
T9 = T8 + 100 = _________ lbs
36
HGT :
T6 = Counter weight = ___________ lbs = T5

2
T4 = T5 - 100 + (H5 x Wb) = _________ lbs
T3 = T4 - [0.015 x l4 + 0.015 x l4 x Wb] = _________ lbs
T2 = T3 - 100
25.4
T7 = T6 + 100 + (H5 x Wb) = ___________ lbs
25.4
T9 = T8 + 100 = _________ lbs
T10 = T9 + 5 x 2 x Belt Width (mm) + [0.015 x l10 + 0.015 x l10 x Wb] - H7 x Wb
= ___________ lbs
T11 = T10 + 100 = _____________ lbs
After calculating tensions at various points, with respect to profile, proceed with the
follwing :Rated belt tensions = ________________ (KN/m) width
= ________________ KN/belt width (m) (eg. 50 KN/m)
ex.
= 50 x 103
9.81
= _________ kgs x 2.204 = ___________ lbs (RBT)
Considering starting tensions is limited to 160 % of the rated belt tension :Then, allowable extra belt tension :Fa1 = 1.6 x (RBT) - T1
= _______________ lbs
Time for acceleration = M1 [Belt speed (fpm)]
60
Fa1
t
= ________________ secs
Max. permissible belt tension = 1.6 x RBT = ____________ lbs
Not to exceed, the max. permisible belt tensions, the time used for acceleration
should not be less than t.
- Known value calculated previously.
37
Starting time of equipment = Belt speed (fpm)

60 x
t1
= ____________ secs
t1 > t
Conveyor is safe to start fully loaded with the equipment selected.
Coasting time calculations :Mass of Conveyor system M = _______________ lbs.sec2 /ft
Kinetic energy of system = MW2
2
Retarding force = Effective tension = Te = _________ lbs
Total work performed during deceleration / retardation = Te x v(fpm) x t

2
2
= MV
2
Coasting time, t = MV
Te
= ______________ secs
Radius calculations (during starting conditions)-With material load upto point C :
Profile No. (v)
Resistance of the material, as it rides the belt over the idlers :Tym = l1 x ky1 x Wm = __________ lbs
Effective tension, here at point C,
Te = Tx + Tyb + Tym + Tp + Tam + Tac
= ____________ lbs
Material weight upto point C = l1 x Wm = ____________ lbs (A)
As calculated previously, Belt weight
= ___________ lbs
Carrying roller wt = ___________ lbs
Return roller wt = ___________ lbs
Total mass of rotating parts = 1
(m1)
32.2
Let addition of
these be X.
X = ___________ lbs
(X+A)
Total equivalent mass of conveyor system = m1 + m2

(M)
= _____________ lbs.sec2 / ft
Acceleration, = G - Te
M
= ___________ ft/sec2
38
T10st = T9st + (Kyreturn side + Kyreturn side x Wb)l1 - H7 x Wb + Tbc + l1 (Wb + Wm)
2
9
= T9st + (0.015 + 0.015 x Wb) x l1 only upto point C
- H7 x Wb + 5 x
i.e. the first
2
(ft)
horizontal portion
x Belt width (mm) x l1 (Wb + Wm)
25.4
32.2
= ____________ lbs
T11st
= T10st + 150 + x 2.204 x mass of tail pulley = ______________ lbs

32.2
Test
= T11st x l1 x [Wb + Wm + wt. of rotating parts of unit carrying idler (lbs)]

+ l1 [Kx + Ky1 (Wb + Wm)] + Tam + Tsb = ____________bs
Radius, Rst = 1.11 x Test

Wb
=
ft = _________m
3.28
Drive Pulley Shaft :-
Tensions at drive pulley :- T1 = __________ N

(Converting it to Kgs, by dividing N by 9.81)
T2 = __________ Kgs
Resultant force acting on the head pulley :R1 =
[T1cos +T2cos(-180-)]2+[T1sin -T2 sin(-180-)+Drive pulley weight(kg)]2
= __________________ Kgs
39
where, is always equal to conveyor inclination angle

Bending moment, M = R x arm length (a) cm = ___________ Kg.cm
2
T = Torque at pulley shaft = T1 - T2 x pulley dia (cm) = __________ Kg. cm
2
Equivalent twisting moment, Tw =
(Kt x T)2 + (Kb x M)2 = ___________ Kg. cm
Kt = Service factor for torsion = 1.0 &

Kb = Service factor for bending = 1.5
Always
Equivalent bending moment, Me = b(M + Tu) = _____________ Kg. cm

Considering shaft material, as C45/EN8 or equivalent :Allowable bending stress = fb = 800 Kg/cm2
Allowable shear stress = fs = 650 Kg/cm2
Diameter due to bending moment = dm = 3 32 x Me/TT x bending stress
= _______________ cm
See, which value is greater & then decide the following :-
To consider key effect, increase shaft dia as follows :Greater value among the two shaft dia (let it be O) + O = __________ cm x 10
2
= ______________ mm
Adopted shaft dia at brg = (Next available brg in our database) = ________ mcm
at hub = This value + 10 = ________ mcm
Now, checking for deflection due to bending & torsion as well, as per following
procedure :Checking for bending deflection :Deflection at centre, c = M
[ 3lbr2 - 4a2]
24EI
40
= x (dia at hub)4 = ___________ cm4

64
E = 2.1 x 106 Kg/cm2
lbr = Brg centres __________ cm, a = arm length = __________ cm
Permissible deflection = lbr
= ___________
1200
c < permissible deflection (Display message safe/unsafe)
I
Checking for torsional deflection :Angular twist, = 584 x lbr x T

G x (dia at hub)4
G = 0.84 x 106 Kg/cm2
Permissible twist = 0.08 x 3.28 x lbr (m) (Take care, while putting into program,
lbr is in metres).
< permissible twist, - Dispaly message
Checking for bearing life :Brg type :- Display No. (brg + adapter sleeve)
[After displaying type of brg (always double row spherical roller brg)]
Basic dynamic capacity = C = ___________ Kgs
Bearing load = P = 1.2 x Radial load
= 1.2 x R = _________ Kgs
2
Bearing life in millions of revolutions = Lf = (C) 10/3
P
= _____________ mill. revolutions
Bearing life in hours = Lf x 106
60 x Pulley rpm
(Take value calculated during selection

of gear box ratio)
For Profile Nos. (I), (iv) & (v) - head pulley shaft - calculations
T1
T1 = __________
Kgs
T2
T2 = __________
W
R=
[T1+T2cos(-180)]2 + [-T2sin(-180)+Drive pulley wt (Kgs)]2 = _________ Kgs
Next, each & every step remains the same as explained above for the remaining
profiles.
41
Snub pulley shaft dia calculations :For profile Nos (ii), (iii) & (vi)
R=
[T3cos -T2cos(-180-)]2+[T3sin+T2sin(-180-)+snub pulley wt(kgs)]2
= ______________ Kgs
M = R x arm length (cm) = ______________ Kg.cm

2
Kb = 1.5
fb = 800 Kg/cm2
dm =
32 x M x 1.5/ x fb
= ______________ cm x 10 = ______________ mm
Adopt -----> next available brg, dia, = _____________ mm (at brg)

+ 10 mm = ______________ shaft dia at hub
Check for bending due to deflection only & calculate bearing life, as explained &
calculated on the previous pages.
For profile nos. (I), (iv) & (v)
R2 =
(T3 - T2 cos(-180)]2+[T2 sin(-180) + snub pulley wt (kg)]2
M = R x arm length (cm) = _______________ Kg. cm

2
Kb = 1.5
fb = 800 Kg/cm2`
dm =
32 x M x 1.5/ x fb
= _________ cm x 10 = ____________ mm
Adopt -------> next available brg dia = ____________ mm (at brg)

+ 10 mm = _____________ shaft dia at hub.
42
Check for bending due to deflection only and calculate bearing life, as explained and
calculated earlier.
For profile nos (I), (iv) & (v)
(-180) R =
(T3-T2cos(-180)]2+[T2sin(-180)+snub pulley wt(kg)]2
T2
W
VGT - There are two bend pulleys. In case of horizontal conveyors with Vgt, wrap
angle over both pulleys is same. But in case of inclined conveyors, wrap angle over
bend pulley nearer to snub pulley is less than, that over bend pulley nearer to tail
side. Hence in such cases, shaft dia is calculated, taking into consideration the
greater wrap angle and same is applicable to other bend pulley. Also in case of profile
nos (iii) and (iv) is assumed that, Vgt will always be placed in the inclined portion only,
near the head pulley.
For profiles (ii), (iii) & (iv)
T7
T6 = __________, T7 = __________ Kgs

R3 =
W T6
[(T7cos)]2 + [T7sin + T6 + Bend pulley wt (kg)]2

= ________________ Kgs
Remaining calculations same as those for snub pulley as done above.

For profiles (I), (iv) & (v)
R=
(T7)3 + [T6 + Bend Pulley wt (kg)]2 = _____________ Kgs
T6
Bend pulley shaft diameter if type of take up is HGT
For profiles (ii), (iii) & (vii)
Please note :- This angle is for profile nos (ii) & (iii) but it is
2 (i.e. inclination 2) for profile (vi) because, it
T9
contains two inclined portions.
W T8
R = (T9cos )2 + [T9sin + W(bend pulley wt kgs) + T8]2 ----> For profiles (ii) & (iii)
For profile (iv) replace by 2 (inclination of 2nd portion)
43
Profiles (I), (iv) & (v)

T9
R=
W
T8
(T9)2 + (T8 + Bend pulley wt)2
Rest is same.
Take up pulley shaft dia calculations :For VGT - and all profiles
T6
T5
R=
(-T5 - T6)2 + [Take up pulley weight (kgs)]2 = _________ Kgs
For HGT and all profiles

T7 R =
(-T6 - T7)2 + (Take up pulley wt (kgs))2 = __________ Kgs
T6
W
Rest of the procedure for calculation of shaft dia is same as explained and calculated
above.
Tail pulley shaft diameter calculations :For profiles (ii), (iv) & (vi)
T5 Profile (ii) & (iv) screw
T4 R =
(- T4 cos - T5 cos )2 + (weight of tail pulley (kgs) T4 sin - T5 sin)2
= ______________ kgs
W
In place of T4 and T5, use following tensions in case of

VGT
HGT
T4 = T8 & T5 T9
T4 = T10 & T5
T11
For profiles (i), (iii) & (iv)

44
T5 R =
(-T4-T5)2 + [Tail pulley wt (kgs)]2
T4
W
Use the following tensions in case of,
VGT
HGT
T4
T4
T8, T5
T10, T5
T9
T11
45
= ____________ kgs

Beltconv (1) - Cema

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Beltconv (1) - Cema

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Belt Conveyor Calculations as per CEMA

1. Following six profiles are introduced in the conveyor program me:

(iii) & (iv) c/c Horizontal length (m)

c/c Horizontal length (m)

Troughing angle is selected out of 4 alternatives (200,300,350,450).

These three parameters are interdependent. If two

Program will select

(i) Belt width, capacity

Min. belt speed (m/sec)

(ii) Belt width, Belt speed

Max. capacity (TPH)

(iii) Capacity, Belt speed

Min. belt width (mm)

angle are kept same as those for 450 troughing angle.

Belt width (mm) - Known value/ given by the client

for calculating belt weight

This information is provided by Mr.Nair of M/s Ashish

Loading cycle = 2 x conv. developed length (m)

Wb = constant factor x [top cover thk(mm) +Bottom cover thk(mm)]+Nominal

Weight of material is calculated as follows Wm =

Belt Width (mm)

Carrying Idler spacing (m) for

Return Idler spacing

Now, Idler load (Il) = (Wb + Wm)Si

If Adjusted load < Idler load, take Al= Il.

Respective OD (inches) adjusted Duty type

D type - Belt Width (mm)

E type - Belt Width (mm)

Kx = 0.00068 (Wb + Wm) + Ai

Ky calculations :- For each portion of the profile, Ky is calculated seperately.

Lower value if it lies in between two points.

Belt Width (mm)

Roller dia for

Effective tension calculations :Idler friction, Tx = Kt[Kx carrying + Kx return] x L

Value calculated 0.015

Resistance of belt dlexure as it moves over the idlers.

(iii) & (iv) = [L1 x Ky1 + L2 x Ky2 + L3 x Ky3] x Wm

Value of Tp with respect to

Associated tension (lbs)

Force needed to overcome skirtboard friction

T1 (KN) = T1 (lbs) x 9.81

Carcass thickness (mm)

Pulley diameters are decided only after Belting selection is finalised.

where, S - Screw, V - VGT, & H - HGT

= ___________ mm/1000 = ________________ m

1.5 (Default value)

Now, if gear box type selected is -

option open to change

(From previous page)

This portion is explained as follows :Required gear box ratio =

KW changed (if any)

Te (N) x speed changed/1000

Keyway portion in hub (mm)

Now, Keyway portion in + 10 mm + Greater value among

Hub outside dia

This value is entered in

Considering 50 % safety margin

Belt length = 2 x developed length (m) + 1 m + /2 [Head pulley dia + Tail

Total equivalent mass of conveyor

Hence assume the

Shaft dia to be assumed to

= Wrap angle over head pulley

But Test = T1st - T2st

= _ mm/1000 = ______ m