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Conveyor system
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"Conveyor" redirects here. For other uses, see Conveyor (disambiguation).
This article is about conveyor systems. For information on conveyor belts, see conveyor
belts. For information on overhead conveyors, see overhead conveyors.

An overhead chain conveyor conveys cars at Mercedes in Germany

A conveyor system is a common piece of mechanical handling equipment that moves materials
from one location to another. Conveyors are especially useful in applications involving the
transportation of heavy or bulky materials. Conveyor systems allow quick and efficient
transportation for a wide variety of materials, which make them very popular in the material
handling and packaging industries. Many kinds of conveying systems are available, and are used
according to the various needs of different industries.

Contents
[hide]
• 1 Industries That Use Conveyor Systems
• 2 Care and Maintenance of Conveyor Systems
• 3 Types of Conveyor Systems
○ 3.1 Pneumatic Conveyor Systems
○ 3.2 Vibrating Conveyor Systems
○ 3.3 Flexible Conveyor Systems
• 4 See also
• 5 References

[edit] Industries That Use Conveyor Systems

A lineshaft roller conveyor conveys boxed produce at a distribution center

A Conveyor belt conveys papers at a newspaper print plant

Roller conveyor for carton transport in the apparel industry

Conveyor systems are used widespread across a range of industries due to the numerous benefits
they provide.
• Conveyors are able to safely transport materials from one level to another, which when
done by human labor would be strenuous and expensive.
• They can be installed almost anywhere, and are much safer than using a forklift or other
machine to move materials.
• They can move loads of all shapes, sizes and weights. Also, many have advanced safety
features that help prevent accidents.
• There are a variety of options available for running conveying systems, including the
hydraulic, mechanical and fully automated systems, which are equipped to fit individual
needs.
Conveyor systems are commonly used in many industries, including the automotive, agricultural,
computer, electronic, food processing, aerospace, pharmaceutical, chemical, bottling and
canning, print finishing and packaging. Although a wide variety of materials can be conveyed,
some of the most common include food items such as beans and nuts, bottles and cans,
automotive components, scrap metal, pills and powders, wood and furniture and grain and
animal feed. Many factors are important in the accurate selection of a conveyor system. It is
important to know how the conveyor system will be used beforehand. Some individual areas that
are helpful to consider are the required conveyor operations, such as transportation, accumulation
and sorting, the material sizes, weights and shapes and where the loading and pickup points need
to be.
[edit] Care and Maintenance of Conveyor Systems
A conveyor system is often the lifeline to a company’s ability to effectively move its product in a
timely fashion. The steps that a company can take to ensure that it performs at peak capacity,
include regular inspections, close monitoring of motors and reducers, keeping key parts in stock,
and proper training of personnel.
Increasing the service life of your conveyor system involves: choosing the right conveyor type,
the right system design and paying attention to regular maintenance practices.
A conveyor system that is designed properly will last a long time with proper maintenance. Here
are six of the biggest problems to watch for in overhead type conveyor systems including I-beam
monorails, enclosed track conveyors and power and free conveyors.
Poor take-up adjustment: This is a simple adjustment on most systems yet it is often it is
overlooked. The chain take-up device ensures that the chain is pulled tight as it leaves the drive
unit. As wear occurs and the chain lengthens, the take-up extends under the force of its springs.
As they extend, the spring force becomes less and the take-up has less effect. Simply compress
the take-up springs and your problem goes away. Failure to do this can result in chain surging,
jamming, and extreme wear on the track and chain. Take-up adjustment is also important for any
conveyor using belts as a means to power rollers, or belts themselves being the mover. With
poor-take up on belt-driven rollers, the belt may twist into the drive unit and cause damage, or at
the least a noticeable decrease or complete loss of performance may occur. In the case of belt
conveyors, a poor take-up may cause drive unit damage or may let the belt slip off of the side of
the chassis.
Lack of lubrication: Chain bearings require lubrication in order to reduce friction. The chain
pull that the drive experiences can double if the bearings are not lubricated. This can cause the
system to overload by either its mechanical or electrical overload protection. On conveyors that
go through hot ovens, lubricators can be left on constantly or set to turn on every few cycles.
Contamination: Paint, powder, acid or alkaline fluids, abrasives, glass bead, steel shot, etc. can
all lead to rapid deterioration of track and chain. Ask any bearing company about the leading
cause of bearing failure and they will point to contamination. Once a foreign substance lands on
the raceway of a bearing or on the track, pitting of the surface will occur, and once the surface is
compromised, wear will accelerate. Building shrouds around your conveyors can help prevent
the ingress of contaminants. Or, pressurize the contained area using a simple fan and duct
arrangement. Contamination can also apply to belts (causing slippage, or in the case of some
materials premature wear), and of the motors themselves. Since the motors can generate a
considerable amount of heat, keeping the surface clean is an almost-free maintenance procedure
that can keep heat from getting trapped by dust and grime, which may lead to motor burnout.
Product Handling: In conveyor systems that may be suited for a wide variety of products, such
as those in distribution centers, it is important that each new product be deemed acceptable for
conveying before being run through the materials handling equipment. Boxes that are too small,
too large, too heavy, too light, or too awkwardly shaped may not convey, or may cause many
problems including jams, excess wear on conveying equipment, motor overloads, belt breakage,
or other damage, and may also consume extra man-hours in terms of picking up cases that
slipped between rollers, or damaged product that was not meant for materials handling. If a
product such as this manages to make it through most of the system, the sortation system will
most likely be the affected, causing jams and failing to properly place items where they are
assigned. It should also be noted that any and all cartons handled on any conveyor should be in
good shape or spills, jams, downtime, and possible accidents and injuries may result.
Drive Train: Notwithstanding the above, involving take-up adjustment, other parts of the drive
train should be kept in proper shape. Broken O-rings on a Lineshaft, pneumatic parts in disrepair,
and motor reducers should also be inspected. Loss of power to even one or a few rollers on a
conveyor can mean the difference between effective and timely delivery, and repetitive nuances
that can continually cost downtime.
Bad Belt Tracking or Timing: In a system that uses precisely controlled belts, such as a sorter
system, regular inspections should be made that all belts are traveling at the proper speeds at all
times. While usually a computer controls this with Pulse Position Indicators, any belt not
controlled must be monitored to ensure accuracy and reduce the likelihood of problems. Timing
is also important for any equipment that is instructed to precisely meter out items, such as a
merge where one box pulls from all lines at one time. If one were to be mistimed, product would
collide and disrupt operation. Timing is also important wherever a conveyor must "keep track" of
where a box is, or improper operation will result.
Since a conveyor system is a critical link in a company’s ability to move its products in a timely
fashion, any disruption of its operation can be costly. Most “downtime” can be avoided by taking
steps to ensure a system operates at peak performance, including regular inspections, close
monitoring of motors and reducers, keeping key parts in stock, and proper training of personnel.
[edit] Types of Conveyor Systems

Belt driven roller conveyor for cartons and totes.

• Gravity roller conveyor
• Gravity skatewheel conveyor
• Belt conveyor
• Wire mesh
 • Plastic belt
• Belt Driven Live Roller
• Lineshaft roller conveyor
• Chain conveyor
• Screw conveyor
• Chain driven live roller conveyor
• Overhead conveyors
[edit] Pneumatic Conveyor Systems
Every pneumatic system, makes use of pipes or ducts called transportation lines that carry
mixture of materials and a stream of air. These materials are such as dry pulverised or free
flowing or light powdery materials like cement, fly ash etc. These materials can be transported
conveniently to various destinations by means of a stream of high velocity air through pipe lines.
Products are moved through various tubes via air pressure, allowing for extra vertical versatility.
Pneumatic conveyors are either carrier systems or dilute-phase systems; carrier systems simply
push items from one entry point to one exit point, such as the money exchanging tubes used at a
bank drive-thru window. Dillute-phase systems use push/pull pressure to guide materials through
various entry and/or exit points. Three basic systems that are used to generate high velocity air
stream: 1. Suction or Vacuum systems: utilizing a vacuum created in the pipeline to draw the
material with the surrounding air.The system operated at a low pressure, which is practically 0.4-
0.5 atm below atmosphere, and is utilized mainly in conveying light free flowing materials. 2.
Pressure Type systems: in which a positive pressure is used to push material from one point to
the next. The system is ideal for conveying material from one loading point to a number of
unloading points. It operates at a pressure of 6 atm and upwards. 3. Combination systems: in
which a suction system is used to convey material from a number of loading points and a
pressure system is employed to deliver it to a number of unloading points.

[edit] Vibrating Conveyor Systems

A Vibrating Conveyor is a machine with a solid conveying surface which is turned up on the side
to form a trough. They are used extensively in food grade applications where sanitation,
washdown, and low maintenance are essential. Vibrating conveyors are also suitable for harsh,
very hot, dirty, or corrosive environments. They can be used to convey newly cast metal parts
which may reach upwards of 1,500 °F (820 °C). Due to the fixed nature of the conveying pans
vibrating conveyors can also perform tasks such as sorting, screening, classifying and orienting
parts. Vibrating conveyors have been built to convey material at angles exceeding 45° from
horizontal using special pan shapes. Flat pans will convey most materials at a 5° Incline from
horizontal line.
[edit] Flexible Conveyor Systems
Flexible conveyor
The flexible conveyor is based on a conveyor beam in aluminium or stainless steel, with low
friction slide rails guiding a plastic multi-flexing chain. Products to be conveyed travel directly
on the conveyor, or on pallets/carriers.
[edit] See also
• Manufacturing
• Moving bed heat exchanger
[edit] References
Retrieved from "http://en.wikipedia.org/wiki/Conveyor_system"
Categories: Commercial item transport and distribution | Packaging machinery
References
1. ^ http://www.provisioneronline.com/CDA/Articles/Feature_Article/BNP_GUID_9-5-
2006_A_10000000000000421648
2. ^ Conveyor Maintenance - Increase the Service Life of Conveyor Systems Including Enclosed
Track Conveyors
3. ^ http://www.provisioneronline.com/CDA/Articles/Feature_Article/BNP_GUID_9-5-
2006_A_10000000000000421648
4. ^ Spec: Process Engineers Who Build
Retrieved from "http://en.wikipedia.org/wiki/Conveyor_system"

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Design procedure
The Conveyor Design Procedure can be used to design a conveyor. Contact Quick Conveyor if you need assistance.

1. Determine product rate (products/min).

2. Determine product length (inches).

3. Determine product weight (lbs).

4. Calculate chain speed (feet/min):

Product length (inches) x 1 ft/12 inches x product rate (bottles/min) x 1.5 = ft/min.
Above formula gives speed with 1/2 product length space between each product.
5. Sketch path conveyor needs to follow.

6. Start with idle end of conveyor. You have three choices:

 a. Q123 24" Idle.
b. Q144 30" Flush Left Idle.
c. Q198 30" Flush Right Idle.
If you want to transfer product from a machine to conveyor, select either Q144 or Q198. If conveyor is free
standing, select Q123. Flush side idles are free of bearings and bolt heads on the flush side.
7. Select straights required to get to first curve or drive. You have five choices:
a. Q134 12" Straight.
b. Q191 24" Straight.
c. Q120 48" Straight.
d. Q199 72" Straight.
e. Q130 96" Straight.
If you need length that is not an even multiple of 1 foot, then any straight can be cut to length desired.
8. Curves are available in two designs.
Curve Design # 1: 18" radius friction curves.

Friction curves cost less but limit conveyor length.

a. Q168 15 Degree 18" Radius.
b. Q190 30 Degree 18" Radius.
c. Q185 45 Degree 18" Radius.
d. Q124 60 Degree 18" Radius.
e. Q140 90 Degree 18" Radius.
The total of these curves should not exceed 180 degrees (i.e. two 90 degree curves or four 45 degree
curves, etc.) If you need to exceed the 180 degree limitation, then a transfer needs to be used to break
conveyor path into two conveyors. You have two choices:
a. Q187 30" Right to Left Transfer.
b. Q195 30" Left to Right Transfer.
Curve Design # 2: 8" radius non-friction curves.

Non-friction curves cost more but do not have drag. Do not count these curves when determining the 180
degree curve limitation. A conveyor with a Disk Curve is considered a straight conveyor.

You have three choices:

a. Q157 90 Degree 8" Radius Disk Curve.
b. Q167 135 Degree 8" Radius Disk Curve.
c. Q197 180 Degree 8" Radius Disk Curve.
9. Continue to select curves and straights until you complete your conveyor path.

10. Complete conveyor with a drive. You have three choices:

a. Q158 24" Drive.
b. Q192 30" Flush Left Drive.
c. Q117 30" Flush Right Drive.
Again, if you want to transfer product from a conveyor to a machine, select either Q192 or Q117. If conveyor
is free standing, select Q158. Flush side drives are free of bearings and bolt heads on the flush side.
11. Now that you have completed the path and selected conveyor modules, you need to check if each
conveyor is within design limits.
a. To accurately determine chain pull, dowanload Rexnord's Calculation Software for Rex Tabletop
Chains. Use the Tabletop Conveyor Analyzer. Select Sideflexing Conveyor Analysis.
b. Ideally, each conveyor should have less than 180 degrees of friction curves.
c. For additional help, contact Quick Conveyor.
If you exceed the recommended length for your configuration, revise conveyor by shortening conveyor,
reducing number of 18" radius friction curves, replacing 18" radius friction curves with 8" radius disk curves
or adding transfers.
12. Select gear motor based on speed required.
a. Q161 1/2 HP, 45 to 228 FPM. (FPM=Feet/Minute)
b. Q162 1/4 HP, 11.5 to 32.5 FPM.
See product information pages for details. All gear motors have 230/460 three phase motors. If 115 volt
single phase input is required, purchase a variable frequency controller product Q121 that has 115 volt input
and 230 volt 3 phase output. If variable speed is desired, again you will need to purchase a variable
frequency controller.
13. Select legs as required. Legs must be used on end of idles and drives, (two legs on transfers) and at
least every 8' of conveyor. If flush drives or idles are securely bolted to a machine, those legs can be
eliminated. Legs adjust in height for top of chain elevations between 36" and 41". Shorter legs can be made
by cutting standard pipe support as required. Longer legs can be made by purchasing 1.5" schd. 10
stainless steel pipe and cutting to desired length. You have six choices for legs:
a. Q107 Disk Curve Leg.
b. Q118 Double Conveyor Leg.
c. Q126 Drive/Idle Return Shoe Leg supports Q123 or Q158 20 1/2" from end of conveyor.
d. Q154 installs on straight conveyor.
e. Q155 18" Radius Curve Leg used on Q140.
f. Q194 installs on drives, idles and transfers.
14. Order chain Q137 for conveyor. Chain is sold in 120" lengths. 2' of chain is required for every 1' of
conveyor length.
15. Order wearstrip Q113 for straight conveyors. 4' of wearstrip is required for each 1' of conveyor length.
Only straights require wearstrips to be installed by customer. Drives, idles, transfers and curves have
wearstrip installed by Quick Conveyor. Wearstrip is sold in 240" lengths.
16. Order guide rail materials. You have two choices of molded plastic top guide rail brackets and one
stainless steel top bracket:
a. Q116 Short Top Guide Rail Bracket.
b. Q119 Tall Top Guide Rail Bracket.
c. Q128 Single Rail Top Guide Rail Bracket.
Modules are supplied with bottom guide rail brackets but without top guide rail brackets. Bottom brackets are
slotted vertically so they can be installed high or low. High position allows top bracket to extend over the top
of chain. Low position allows product to overhang the edge of chain and not hit the bottom bracket. Guide
rail Q178 has 1/2 round UHMW plastic insert. Q179 has a 1.25" flat UHMW plastic insert. They are sold in
96" lengths. With two guide rails on each side of conveyor, order 4' of guide rail for every 1' of conveyor. At
each attachment point of the guide rail to the top guide rail bracket, you will require a Guide Rail Clip Kit
Q100. Each top guide rail bracket requires a Carriage Bolt and Ratchet Handle Q106 to bolt top guide rail
bracket to bottom guide rail bracket or carriage bolt and not Q136. The following additional parts are
available if required:
a. Q101 18" Radius Curve Guide Rail Kit.
b. Q110 Guide Rail Splice Plate Kit.
c. Q111 Guide Rail Splice Sleeve is used if you need to join two guide rails.
d. Q115 Bottom Guide Rail Kit is used if you need to add additional bottom brackets.
e. Q151 90 Degree Disk Curve Guide Rail Kit.
f. Q152 135 Degree Disk Curve Guide Rail Kit.
g. Q153 180 Degree Disk Curve Guide Rail Kit.
17. Order other accessories if required:
a. Q108 Machine Interface provides parts to bolt Quick Conveyor to a machine.
b. Q135 Roller Deadplate Kit - 3 1/4 Chain.
c. Q164 Straight Connector Kit is used to connect two straights.
18. We also have 6' Handpack Stations Q148 and Q149.
19. We also have 42" Dia. feed and pack disks Q172, Q173, Q174, and Q175.
Comments on this procedure are welcome.
 1. INTRODUCTION
2. JUSTIFICATION FOR A STANDARD
3. PRESENT DESIGN STANDARDS
4. PROPOSED STANDARD FORMAT
4.1 Power and Tension
4.2 Pulley and Shafts
4.3 Selection of Belt Width and Velocity
4.4 Idler Standards
4.5 Drive Standards
5. CONCLUSION
SUMMARY
This paper has been prepared with the intention of highlighting the problems faced by design engineers who are forced to
undertake the design of belt conveyor systems using a multitude of design standards which have not been brought into
line with modern technological advancements.
To overcome some of these problems, a basic outline of a universal standard has been proposed, which can easily be
adapted to suit individual needs, without reducing the efficiency of the designer and his team.
1. INTRODUCTION
The design of belt conveyor systems has been one of the most common occurrences in the South African mining field for
over one hundred years. Conveyors are seen on virtually all mining installations, and are the biggest problem for the plant
maintenance engineer, being the cause of most plant shutdowns.
Why do belt conveyors cause such problems? It must be remembered that mining houses usually have a set of design
standards to conform to; standards which are claimed have been developed over many years to suit their own needs in the
materials handling field.
However, as I can understand the need for some aspects of a standard, others completely baffle me. It appears that
having spent a great deal of time over certain requirements of a design standard, many of the fundamentals to which I am
referring are of course the effects of overpowering on the whole conveyor system. Also, we know that to convey material
from one point to another requires a specific amount of power using a belt designed to withstand a definite tension, so why
is it that if a conveyor design problem is set to a number of designers, they will come up with many variations on a
solution, even using the same design specification.
This of course comes down to the interpretation of, and the familiarity with the standard to be used. Basically I am
suggesting that the standards as available to-day, leave a lot to be desired from the point of view of completeness, and
ease of application.
2. JUSTIFICATION FOR A STANDARD
Do we need a standard at all? and if so, what form should it take?
To answer this question let us look at a typical design office set up. On any project there are three key categories of staff,
the designers, his draughtsmen and a group of peripheral staff, (planners, buyers, structural, civil and electrical
engineers). Thus we have a set up which looks as follows:-
Figure 1. Typical project Engineering Flow Sheets

The designer is given a basic specification which will include material type and quantity to be conveyed from A to B. This
he must transform into drawings for manufacture and fabrication, design data for civil, electrical and structural engineers,
bills of quantities for buyers and activity networks for planners. With the exception of the planning information which is
only really relevant for the construction phase of the project, the designer has a problem which he will find very difficult to
overcome, and that is to supply all the necessary information to each discipline on the project when they require it.
Therefore having obtained a scope of work from the client in question, the designer has to quickly produce the design data,
but before he is able to proceed he must obtain information from his drawing office relating to the layout of the conveyors
in the system. Now the problems begin: Prior to undertaking any calculations whatsoever the designer must check the
specifications to which he must conform.
As virtually all clients have their own opinion on the subject of conveyor design, we can rest assured there will be some
form of client input, whether it be a two volume manuscript or simply an, 'All drives shall ........' document.
The designer is confronted with conforming to the said specification, but much worse, he must ensure that his drawing
office staff are aware that there is a specification to work to. Consider that the previous week they may have been working
on another project and had to conform to a completely different specification.
What does the designer do? Does he circulate multiple copies to his drawing office with the instruction that it must be read
prior to any work being started. If so, he will possibly not meet his deadline on the supply of data to the peripheral
disciplines.
Does he try to check that his draughtsmen conform by 'looking over their shoulders' from time to time (which is the way
mistakes are guaranteed to occur). Alternatively does he instruct his drawing office that there is a specification to work to
and that it is lying around somewhere and to 'please check it if you are not to sure of how to proceed'.
In all the offices in which I have worked, the last two solutions have been applied, with the result that, almost without
exception, the experienced draughtsmen who know how to make a system work will continue with very little reference to
the said specification.
The problem may be that on this project 'the pulleys are much bigger, the take-up length must be selected using an ill
defined formula and basically we don't know how to design a conveyor anymore. If this problem is caught early enough we
only have to change a quantity of drawings and are then back on the right road. However you can be sure that in practice
it will be too late, and the designer has to go to the client and ask for a concession because he is not able to conform to
the specification, and to make any changes to the drawings now will put him way behind schedule. Furthermore before the
client will accept deviations to the proposed format, every avenue must be explored, and a report on the deviation
prepared.
The designer is now behind whether he likes it or not and to make up time he must neglect the one function which
completes the total conveyor design, that of secondary design. By secondary design, I mean the design which comes after
the conceptual or general arrangement layouts are complete. This is the design of the chutes, the location of bearings, the
belt cleaning system to be employed and the access for maintenance. This is left to a draughtsman without any
engineering support. However, the secondary design usually encompasses the major problems of belt conveyor system
design. These are areas with very little coverage in specifications, with comments such as, 'all conveyors will have pulleys
at terminal points', being the limit to such specifications.
I pose the question again, do we need a design standard? Those who agree with the scenario I have set will probably say,
'Allow the designer the freedom to do the job'. However 1 feel that a standard is essential. There are very few specialist
conveyor designers and thus some form of guidance must be given. However there should be only one standard, with one
basic set of parameters and which can cater for the needs of every mining and process plant application. Without lessening
the efficiency of the designer and his team such a standard will facilitate the efficiency the overcoming of the problems
occurring in secondary design.
We know this has been tried repeatedly in the past, but always in isolation from the main stream of design and usually
with the statement, 'but it caters for our own individual needs', as justification.
Having been confronted with conveyor design standards for a number of years, I have still to find a true specialist need, I
know that some clients require less capacity on a belt, others require larger pulleys and thicker belts, requiring the use of
complicated formula to arrive at a solution, but this can not be justification for devising completely individual
specifications, which could more suitably be covered in a single paragraph of a comprehensive specification.
3. PRESENT DESIGN STANDARDS
Let us look at at the Conveyor design standards available, and in particular
the four most commonly used, C.E.M.A., GOOD YEAR, ISCOR and A.A.C. If we consider the power and tension variation
predicted by using these systems, as in Table 1, we see quite a wide range of possibilities. The reason for this is in the
selection of the rolling resistance factor, (coefficient of friction, resistance to flexure or other commonly used terms) which
varies between 0,016 and 0,035 as used in the above standards.
Table 1 Power and Tension calculations.
1(a) based on belt capacity of 500tons per hour, belt width of 900mm and a
belt velocity of 2,2m/sec.

Length Lift C.E.M.A. GOOD YEAR ISCOR A.A.C.

Power Tesn Power Tesn Power Tesn Power Tesn
m m kW kN kW kN kW kN kW kN
30 0 6 9 15 16 16 19 12 18
200 60 101 65 99 64 104 66 102 66
1000 0 81 40 89 43 113 54 104 50
1000 40 132 72 143 77 167 88 158 84

1(b) based on belt capacity of 2000tons per hour, belt width of 1500mm
and a belt velocity of 3m/sec.

Length Lift C.E.M.A. GOOD YEAR ISCOR A.A.C.

Power Tesn Power Tesn Power Tesn Power Tesn
m m kW kN kW kN kW kN kW kN
 30 0 18 22 36 41 38 42 37 42
200 60 378 167 380 168 403 176 391 172
1000 0 221 84 262 98 349 127 315 116
1000 40 439 174 479 188 567 217 533 206

On the shorter systems this difference is quite insignificant, except that the belt length factor plays an important part.
However on the now common large overland type systems, these variations are unsatisfactory to say the least.
Are we able or prepared to accept such variations? Able, I will say yes, provided we take cognisance of the effects of
overpowering. However I am not convinced we should be prepared to accept these variations, apart from the overpowering
factor there are purely economic considerations to account for. This point is very noticeable when one becomes involved in
economic evaluations (feasibility studies) of various alternative solutions to a specific materials handling problem. For
instance, how competitive would a pneumatic conveying system or cable belt system be if designed to similar sets of
standards as the conveyor. However as these standards are as yet, not available, the manufacturer of competitive systems
has far reaching advantages over the conveyor manufacturers.
I am not for one moment suggesting that the competitive systems are under designed, simply that the designer is not
limited to designing within a conservative specification.
Too often we see examples of conveyor systems feeding process plants, where to conform to specification the whole
conveyor network is designed for a large amount of excess capacity. However, this philosophy is not transferred to the
related equipment in the rest of the plant.
4. PROPOSED STANDARD FORMAT
4.1 Power and Tension
With power and tension calculations there exists the possibility for a combination of all four of the above standards by
utilizing a single friction factor for the shorter belts, but eliminating the belt length factor which can easily be compensated
for with the overrating factor of the motor. In progressing to the longer conveyors this factor could be variable, as
advocated by C.E.M.A., only now be simply a function of belt length and capacity. Then we could use a simplified formula
as follows:-
9.81
Power (kW) = x L.V((kX+kY(Wm+Wb)+,015Wb)+ (H.Wm))
1000
Where
1. L = Horizontal pulley centers (m)
2. H = Vertical pulley centers (m)
3. V = Belt velocity (m/sec.)
4. Wm = Mass of material per meter run (kg)
5. Wb = Mass of belt per metre run (kg)
6. 0,015 = Return belt resistance

7. kX = Belt slide and Idler rotational resistance and can be obtained from:-
kX = 0,00068(Wm+Wb)+0,022(rotating mass of the Idler per meter) (kg/m)

8. kY = Resistance of the belt of flexure as it

moves over the Idlers, and can be considered to be the same as the friction factors given in
all the specifications.
Typical values of kY are given in table 2 below.
Table 2. Selection of kY factor based on Belt length, lift and capacity.

Length Lift kY kY kY kY
m m 500t/hr. 1000t/hr. 2000t/hr. 3000t/hr.
100 20 0,035 0,030 0,026 0,022
200 20 0,032 0,026 0,022 0,020
200 40 0,030 0,022 0,020 0,020
400 20 0,030 0,022 0,020 0,020
400 40 0,026 0,020 0,020 0,020
800 40 0,022 0,020 0,020 0,020
1000 40 0,020 0,020 0,020 0,020

To enable the client to maintain control of the outcome of the calculation, it is necessary only to specify the kY factor to be
used in a simple addendum to the main specification.
Belt tension calculation can be kept straightforward, provided the designer starts by considering the minimum belt
tensions, at both the drive and tail pulleys, by using the following formulae :-
Tmin = 4,2x9,81/1000 si(Wb+Wm) kN
Where 4,2 = Factor based on a 3% belt sag.
Si = Idler spacing,m
and
Tslack side = Teffective / e -1
Where T effective is the installed drive effective tension and not the effective tension computed from the above power
formula.
The one problem that is encountered is in the selection of a coefficient of friction for the drive pulley. A standard such as
given In Table 3 could be used.
Table 3 Coefficient of Friction for Drive Pulleys.

Type of Take Up
Plant Conveyor Automatic Manual
Description Construction Lagged Unlagged Lagged Unlagged
Covered 0,25 0,10 0,20 0,10
Wet
Uncovered 0,20 0,10 0,20 0,10
Covered 0,30 0,20 0,25 0,18
Semi-wet
Uncovered 0,25 0,15 0,22 0,13
Covered 0,35 0,22 0,25 0,20
Dry
Uncovered 0,30 0,18 0,25 0,15

Table 3 has been compiled from empirical data such as that given in Table 4. It should be noted that these values are the
limiting conditions (when the belt is on the point of slipping). The actual coefficients of friction developed between surfaces
are, in practically all cases where slipping does not occur, in excess of those listed.
Therefore, the convention of using these values does not reflect what actually occurs at the drive pulley.
If one considers a drive pulley under operating conditions then the higher tensioned belt section is stretched more than on
the lower tensioned section, thus the belt entering the positive drive will be traveling faster than when it leaves it. The
elastic recovery of the belt occurs over only a part of the total angle of contact, and it is at this point, where creep takes
place, that the driving is done, while making full use of the coefficient of friction.
By applying the classic tension formula to the whole angle of wrap a fictitious coefficient of friction is being used
Table 4. Recommended Drive Coefficient of Friction of Various Standards.

Condition C.E.M.A. STEVENS BRIDGESTONE LINATEX REMA

ADAMSON TIP TOP
Bare pulley 0,25 0,35 0,20 --- ---
Lagged 0,35 0,35 --- 0,60 0,45
Dry Lagged 0,35 0,35 0,35 0,60 0,45
Wet Lagged 0,35 0,35 0,25 0,80 0,35
Wet & Dirty 0,35 0,35 0,20 0,40 0,25

The advantage of working from minimum drive tension back to the maximum drive tension, can be better explained if one
looks at the design of pulleys and shafts. Over the years there has been a lot written about the design of a pulley shaft,
with the aim of trying to eliminate the high failure rate and the cost associated with such failures.
I feel that there are only two basic reasons for pulley failure, firstly the bad manufacturing procedures, and secondly,
failure owing to an inability to calculate the minimum drive tension. The latter case of incorrect design results in the
counterweight mass having to be increased to overcome drive slip on startup, with the result that pulley shafts are
subjected to excessive loads, producing eventual failure.
By contrast, if the minimum drive tension is used as a design basis, we can overcome, failures in pulleys, caused by
inaccurate design. Thus the maximum tension will be obtained from :-
Tmaximum = Tminimum+Teffective
Where Teffective is computed from shaft power and not the installed power.
Note that the formulae discussed above are applicable to 90% of the conveyor installations being designed to-day.
However a little more analysis is required for some overland and complex systems.
4.2 Pulley and Shaft Standards
There are presently two major standards used for pulley and shaft selection, these being the ISCOR and AAC systems. I
know much has been written about the high degree of oversizing adopted by both standards, but I feel that as the pulley is
one of the least expensive components in a conveyor installation, we should not be over concerned on the point.
Efforts should rather be directed at reducing the amount of variations there are in the selection of face width and bearing
centers. At the moment both ISCOR and AAC have two sizes per belt width, all different. This should be reduced to a single
size per belt width, and this size should be as big as possible to allow easy access and hence reduce the damage to
conveyor belts. A standard along the lines of table 5 based on the ISCOR specification would be the most acceptable.
Pulley and shaft diameters should be kept to a minimum of two per conveyor, with as much standardization as possible
being employed on the whole conveyor system. The selection of pulleys and shafts could be from a table similar to that
shown as Table 6.
Table 5. Pulley Face Width and Bearing Centers

Belt width mm Face width mm Bearing center mm

450 550 890
600 700 1140
750 900 1370
900 1050 1520
1050 1200 1670
1200 1350 1850
1350 1500 2000
1500 1700 2300
1800 2000 2630
2100 2300 2930

4.3 Selection of Belt Width and Velocity

The selection of belt width and velocity is probably the most frustrating of problems facing the designer. There are a
variety of factors being used, factors such as :- the belt width must be three times the maximum lump size, the belt width
must be such that the system can cater for 66% excess capacity, and if a tripper is used the factors must be increased by
a further 30% etc.
This type of factor forms the basis for most standards in use to-day, and these could therefore be rationalized into a single
more acceptable standard to make the designer's task easier.
The first necessary step is the removal of the age old belt speed restrictions, after all speeds in excess of 4m/sec are now
quite common.
I am not advocating that the highest possible belt speed be used for all installations; I simply suggest that belt speeds
should not be selected only on the basis of past experience, but on the basis of belt length, transfer point and economic
considerations.
I feel that to use the criterion I have set out will automatically result in the selection of the most suitable belt width and
speed. My reasoning here is that, for inplant installations belt widths and speeds are almost always selected on the basis of
standardization and possible transfer point problems. By contrast, the larger overland systems are selected on the basis of
capital costs and the associated operating and maintenance costs, because as belt speeds increase operating and
maintenance costs usually follow suit.
Consider the suggested methods of selecting a belt width and speed. Firstly, the amount of material on a belt must be
related to the expected transfer point problems. A flat feed point fed by a controlled system will be far easier to design
than an inclined feed point fed from a crusher, where surges are very common. Therefore to suggest a similar standard for
both applications is not practical.
We often are told that conveyors should not be fed at angles of 8° incline feed points and very tight vertical curves, with
the result that the feed point stays clean, but at the curve the belt has lifted causing spillage.
I would like to suggest that a belt can be easily fed at angles of up to 16°, provided the belt width and speed are correctly
selected. It may be necessary to install belts with thicker covers, but this can form the basis for a better design.
Thus the type of standard that could be used is shown in Table 7.
Table 7 Implant Conveyor Load Factors

Loading Point Feed Overload

Type Type Factor
Horizontal Uniform 1,20
Horizontal Surge 1,50
Incline Uniform 1,50
Horizontal Surge 1,75
Tripper ..... 1,75
Shuttle ..... 1,50

The overload factor would be used to increase the design tonnage for selection purposes.
For overland conveyors it is common to use horizontal loading points, and we are not confronted with the same problems.
As mentioned earlier it is only necessary to consider the economics of the system, with the following limitations as given in
Table 8.
Table 8. Overland Conveyor Minimum Belt Widths and Maximum Speeds
 Terminal Pulley Belt Belt
Centers (m) Width (mm) Speed (m/sec)
300 to 500 600 3,50
500 to 1000 750 3,50
over 1000 900 7,00

The overload factor used should always be a minimum of 1,2 times the design tonnage.
4.4 Idler Standards
4.4.1 Introduction
The introduction of the SABS Idler specification will ensure a more uniform selection of idlers. As a result the choice of type
and spacing for Idlers should be on a more scientific basis. The types of Idler to be used on conveyors are; transition,
troughing, impact and return idlers. At this time there is no satisfactory training idler available so they should be avoided.
4.4.2 Troughing Idler Spacing
Two types of troughing idler are used frequently, fixed and suspended roll. There is very little difference between the two,
except the training characteristics and possible cost savings associated with the suspended roll.
The question of idler spacing needs be considered more carefully. The restrictive standards as applied to-day do more
harm than good to a conveyor system. Idlers are the highest maintenance cost item on a conveyor installation and the
biggest cause of belt damage, therefore 'the fewer the better.
Idler spacing must be selected on the grounds of available belt tension, fatigue life of the idler bearings, and structural
considerations. The upper spacing limit should be set at 2200mm. Account should be taken of four and five roll sets, but
no significance can be attached to the claim that four and five roll idlers give better belt life.
4.5 Drive standards
The standardization of drives is the key to most successful conveyor systems. The problem is however that some drives
have to be drastically oversized to obtain some degree of conformity.
By considering this point at an early stage in the design process. it is usually possible to overcome the problem, therefore
simple cost analyses of all the possible solutions can quickly decide on the drive sizes to be adopted. Also it is at this point
in time when a final selection of belts can be carried out, because there is often scope to change belt speeds to the
required degree of standardization, and we should not be afraid to to this.
5. Conclusion
To conclude I would like to reiterate the need for a single design standard, which could be applied to any conveyor
installation. However, this standard must be such that it allows the client a small amount of individuality and flexibility.
The design system as outlined in this paper can offer this flexability, by allowing the client the freedom to select the kY
factor, the drive coefficient of friction and the load factor for selecting the belt width and speed. Coupled with this we can
have a very efficient system especially if it is adapted to computerised calculation techniques. I know to-day that many
such design programs are available, but because of the variations in standards that must be incorporated, their credibility
is unjustly made suspect, forcing the designer to revert to the longwinded number crunching exercises which obviously
reduce his effectiveness in the drawing office.

BELT PULLEY HEAVY DUTY MEDIUM DUTY LIGHT DUTY BELT TYPE MAXIMUM
SHAFT
SHAFT BEARING SHAFT BEARING SHAFT BEARING PLY STEEL LOAD
CLASS CORE
WIDTH DIA.D DIA.d DIA.d1 DIA.d DIA.d1 DIA.d DIA.d1 kN

450 300 90 75 75 50 - - 200 18

400 100 75 75 50 - - 250 22
500 125 100 100 75 75 50 630 56
630 140 110 110 90 90 75 800 72

600 400 110 90 90 75 75 50 250 30

500 125 100 100 75 90 75 630 75
630 140 110 110 90 100 90 800 95
710 160 125 125 100 110 90 1250 150

750 400 125 100 100 75 75 50 250 35

500 140 110 125 100 90 75 630 95
630 160 125 140 110 110 90 800 ST500 120
710 180 140 160 125 125 100 1250 ST630 190
800 200 160 180 140 140 110 1250 ST1250 280
900 400 140 110 110 110 90 90 250 45
500 160 125 140 140 110 110 630 110
 630 180 140 160 125 125 100 800 ST500 145
710 200 160 180 140 140 110 1250 ST630 225
All DIMENSIONS IN MILLIMETRES
MAXIMUM LOAD FIGURE = PERMISSIBLE LOAD ON PULLEY = TWICE BELT TENSION
HEAVY DUTY = 100% MAXIMUM LOAD
MEDIUM DUTY = 60% MAXIMUM LOAD
LIGHT DUTY = 30% MAXIMUM LOAD
DENOTES RATING BASED UPON STEEL CORE BELT
FOR ALLOWABLE LOAD ON BEARING SEE BEARING RATING TABLES
BELT RATING CHART, Table 6a

BELT PULLEY HEAVY DUTY MEDIUM DUTY LIGHT DUTY BELT TYPE MAXIMUM
SHAFT
SHAFT BEARING SHAFT BEARING SHAFT BEARING PLY STEEL
LOAD
WIDTH DIA. D DIA. d DIA. d1 DIA. d DIA. d1 DIA. d DIA. d1 CLASS CORE
kN
1050 500 180 140 140 110 110 75 630 130
630 200 160 160 125 110 90 800 ST500 170
710 220 180 180 140 125 100 1250 ST630 260
800 240 200 200 160 140 110 1250 ST1250 395
1000 250 220 220 180 160 125 1600 ST1600 505
1250 360 340 260 220 180 140 2000 ST3150 985
1200 500 180 140 140 110 110 90 630 150
630 200 160 160 125 125 100 800 ST500 190
710 220 180 180 140 140 110 1250 ST630 300
800 240 200 200 160 160 125 1250 ST1250 450
1000 260 220 220 180 180 140 1600 ST1600 575
1250 360 340 300 260 220 180 2000 ST3150 1130
1350 500 200 160 180 140 140 110 630 170
630 220 180 200 160 160 125 800 ST500 215
710 240 200 220 180 180 140 1250 ST630 340
800 280 240 240 200 200 160 1250 ST1250 505
1000 300 260 260 220 220 180 1600 ST1600 650
1250 360 320 300 260 240 200 2000 ST3150 1270
1500 630 240 200 200 160 140 110 800 ST500 240
710 280 240 220 180 160 125 1250 ST630 375
800 300 260 240 200 180 140 1250 ST1250 560
1000 320 280 260 220 200 160 1600 ST1600 720
1250 360 320 280 240 220 180 2000 ST3150 1400
1400 400 380 320 280 240 200 2500 ST4000 1800
1800 710 300 260 260 220 180 160 1250 ST630 450
800 320 280 280 240 200 180 1250 ST1250 670
1000 340 300 300 260 240 260 1600 ST1600 865
1250 380 340 320 280 260 220 2000 ST3150 1700
1400 410 380 340 300 380 240 2500 ST4000 2100
1500 430 400 360 320 300 260 ST5000 2700
2100 710 300 260 260 220 180 160 1250 ST630 525
800 320 280 280 240 200 180 1250 ST1250 790
1000 340 300 300 260 240 200 1600 ST1600 1010
1250 380 340 320 280 260 220 2000 ST3150 1900
1400 410 380 340 300 280 240 2500 ST4000 2500
1500 430 400 380 340 300 280 ST5000 3100

SEE GENERAL NOTES ON SHEET 1

BELT RATING CHART, Table 6b