Job Code : 374E1D1

Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

TYPE : Three Equal Roll Throughing Idlers

A. CONVEYOR CAPACITY
Design Data :
Conveyor Capacity (Qt) : 2500.00 Ton / hour
Material to be transported : Raw Ore
Density (r) : 1.00 Ton / m3
1000.00 kg / m3
Surcharge angle (a) : 20.00 °
Belt Width (b) : 1200.00 mm
Speed (v) : 330.00 m / min
5.50 m / det
Throughing angle (b) : 30.00 °
Checking Capacity :
Trapezoidal Area (Ab) : 0.10 m2
Circular Area (As) : 0.01 m2
Calculated Qt : 2229.33 Ton / hour Qt =((Ab + As) . v . r )*60
Calculated Qt > 150, OK

B. POWER CALCULATION

Power Requirement :
Conveyor Length (l) : 83.50 m
Lift Height (h) : 5.60 m
Inclination (g) : 3.00 °
Idler friction (f) : 6.00
Adjustment Length (lo) : 0.60 m
Belt weight (W1) : 15.50 kg / m
Weight of moving part carrier (Wc) : 15.10 kg / m
Weight of moving part return (Wr) : 13.40 kg / m
Carrier Pitch (lc) : 1.20 m
Return Pitch (lr) : 2.40 m
Weight of moving parts (W) : 49.17 kg / m
Weight of material loaded (Wm) : 126.26 kg / m
Friction Coeff. Material & belt (u) : 0.40
Power Efficiency (h) : 0.85
Volume of load (Qm) : 2500.00 m3/h Qm = Qt / r
Length of skirt (lk) : 3.00 m * 1 skirt applied
Width of skirt (bs) : 800.00 mm
0.80 m
Horizontal no-load axle power (P1) : 22.29 KW P1 = f (l + lo) W.v / 6120
Horizontal axle power under load (P2) : 57.25 KW P2 = f (l + lo) Wm.v / 6120
Vertical axle power under load (P3) : 38.13 KW P3 = H.Wm.v / 6120

Page 1 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Additional Resistance from skirt (Fk) : 95.65 kg Fk = u.Qm2.lk. r / (36002 . v2 . b2)
Additional Power from skirt (Ps) : 5.16 KW Ps = Fk . V / 6120
Calculated Axle Power Drive (P') : 122.83 KW
Motor Safety factor (SFM) : 1.25
Power Drive (Power efficiency) (P) : 180.64 KW P = P' . SFM / h

C. TENSION

Friction Coefficient Belt & Pulley (u1) : 0.30

Designed wrap angle (q) : 210.00 °

Effective Tension (Fp) : 2278.00 Kg Fp = 6120.P' / v

Tight Side Tension (F1) : 3421.32 Kg F2 = Fp . (1 / (e u1 q -1))
Slack Side Tension (F2) : 1143.32 Kg Fp = F 1 - F2
Incline Tension (Up) (F3) : -7697.12 Kg F3 = W1 . L (Tan a - f)
Belt sagging : 1.00 %
Minimum Tension Carrier (F 4c) : 2126.44 Kg F4c = 12,5 . lc . (Wm+W1)
Minimum Tension Return (F4r) : 465.00 Kg F4r = 12,5 . lr . W1

Maximum Tension For Uphill Conveyor :

Fr : 10551.22 Kg Fr = f (l + lo)(W1 + Wr/lr) - (H . W1)
Case 1 : -6146.78 Kg Fmax = Fp + F4c - Fr
Case 2 : -7808.22 Kg Fmax = Fp + F4r - Fr
Case 3 : 3421.32 Kg Fmax = Fp + F2
Case 4 : 2743.00 Kg Fmax = Fp + F4r
Fmax : 3421.32 Kg

Belting Specification :
Acceleration Tension & Time :
Drive Factor (k) : 1.50 k = 1 + (1 / (e u1 q -1))
Acceleration Time (t) : 0.18 sec t = v (l + lo) (W + Wm) /
(588 PA . k [f (l +lo)(W + Wm) + Wm.h])
PA = 0.35 Fmax / Fmax
Time Cycle : 0.51 min Time Cycle : 2 . l / v
Multiply - Fabric Safety Factor (SFz) : 11.00
Required Belt TS multi ply (F.TS) : 321.66 kg/cm F.TS = Fmax . SFz / Effective BW
Minimum number of plies (load support) : 3.00 Effective BW = b - 30
Maximum number of plies (troughability) : 6.00
Number of plies taken : 4.00
Tensile Strength Of One Ply : 80.42 kg/cm Taken : 100.00 kg/cm
Carcas : Polyester
Grade Cover : Normal
Fabric thickness : 1.00 mm
Top cover thickness : 4.00 mm
Bottom cover thickness : 2.00 mm Belt Manufacturer Recommendation for following spec.:
Belt Thickness : 9.60 mm Belt : EP 100.00 x 4.00 Ply
Minimum recommended pulley diameter : 406.40 mm Dp : 16.00 in

D. RUNNING TENSION
Uphill conveyor at head drive :
Run tension carrier side(Fc) : 78672.21 kg Fc = (f (l + lo) (W1 + (Wc/lc) + Wm))+h(W1+Wm)
Run tension return side (Fr) : 10551.22 kg Fr = (f (l + lo) (W1 + (Wr/lr))) - hW1
Tension at tight side (Foc) : 77878.34 kg Foc = f (l + lo) (W1 + (Wc/lc) + Wm)
Tension at slack side (For) : 10638.02 kg For = f (l + lo) (W1 + (Wr/lr)
Pre - Tension Fp' : 89223.43 kg Fp' = Fc + Fr
T1 : 223228.03 kg T2 = F2 = Fp'. k
T2 : 134004.60 kg T1 = F1 = Fp' + F2
T3 : 144555.82 kg T3 = T4 = F2 + For - h.W1

Page 2 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

T4 : 144555.82 kg When T4<F4c or F4r
T4 Selection , T4 max : 144555.82 kg T3 = T4 = F4c
Summary - Tension T2 = T3 + h.W1 - For
T1 : 223228.03 kg T1 = T2 + Fp'
T2 : 134004.60 kg
T3 : 144555.82 kg
T4 : 144555.82 kg

Take Up - Tension
Near to Head
Height at take up point to drive (H') : 3.00 m
FT : 133958.10 kg FT = F2 - (W1.H')
Near to Tail
Height at take up point to tail (H'') : 2.70 m
FT : 144600.77 kg FT = F2 + For - (W1.H'')
FT : 133958.10 kg

Tension Subjected to pulley

Head Drive
(F1) : 223228.03 kg
(F2) : 134004.60 kg
Tail
(F1) : 144555.82 kg
(F2) : 144555.82 kg
Snub Drive
Height from tail : 5.40 m
Distance from drive : 0.80 m
(F1) : 134004.60 kg
(F2) : 133992.20 kg F2 = T2 - (W1.H'')
Take Up
Height from tail : 3.00 m
Distance from drive : 4.30 m
(F1) : 133958.10 kg
(F2) : 133958.10 kg
Take Up, snub to head
Height from tail : 4.70 m
Distance from drive : 3.80 m
(F1) : 133931.75 kg F2 = T2 - (W1.H'')
(F2) : 133958.10 kg
Take Up, snub to tail
Height from tail : 4.60 m
Distance from drive : 4.70 m
(F1) : 133958.10 kg
(F2) : 144571.32 kg F2 = T2 + For - (W1.H'')

E. PULLEY DESIGN

E.1. Head Drive Pulley

Recommended minimum dia.(Dp min) : 406.40 mm

Standard pulley dia. (Dp) : 624.00 mm
Face distance (Fdp) : 1350.00 mm
Bearing Distance (Bdp) : 2000.00 mm
End disc arm (Ad) : 170.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm

Page 3 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 346.78 kg
Design Wrap Angle (Wa) : 210.00 °
a1 : 0.00 °
a2 : 30.00 °
Rpm : 168.42 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 345766.74 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 150.00 mm

Drive Torque (Tq) : 104467.27 kg.cm Tq = 71620 .1,36 . P / Rpm
90692.05 in.lb
Moment on end disc (Md) : 1275736.97 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 1125650.26 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)
Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi
Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 149.37 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 143.28 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 58.71 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.01007 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.01007 < 0.0023 in / in (acceptable)

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 165.00 mm

Dia. at Bearing (Db) : 160.00 mm
Nearest bearing standard
Bearing Type : 22224EK
Housing Type : SNH 524
Basic dynamic load rating (C) : 552000.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.06 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p
Shaft Diameter & Bearing Used
Dia. used at end disc : - mm
Dia. used at Bearing : - mm
Housing Type : SNH 524

Page 4 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Bearing Type : 22224EK

E.2. Tail Pulley

Recommended minimum dia.(Dp min) : 345.44 mm Dp = 0.85 . Dp Drive Pulley

Standard pulley dia. (Dp) : 400.00 mm
Face distance (Fdp) : 1000.00 mm
Bearing Distance (Bdp) : 1300.00 mm
End disc arm (Ad) : 200.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm
Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 156.65 kg
Design Wrap Angle (Wa) : 180.00 °
a1 : 0.00 °
a2 : 0.00 °
Rpm : 262.74 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 289111.68 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 1254944.83 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 784340.52 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi
Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 269.84 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 230.71 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 625.25 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.00 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.00050 < 0.0023 in / in (acceptable)

Minimum shaft dia. to resist from deflection calculated as follows :

De : 184.65 mm

Page 5 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 255.00 mm

Dia. at Bearing (Db) : 250.00 mm

Nearest bearing standard

Bearing Type : 22317EK
Housing Type : SNH 617
Basic dynamic load rating (C) : 470000.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.04 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

Shaft Diameter & Bearing Used

Dia. used at end disc : 95.00 mm
Dia. used at Bearing : 75.00 mm
Housing Type : SNH 617
Bearing Type : 22317EK

E.3. Snub Pulley For Head Drive Pulley

Recommended minimum dia.(Dp min) : 284.48 mm Dp = 0.7 . Dp Drive Pulley

Standard pulley dia. (Dp) : 350.00 mm
Face distance (Fdp) : 1000.00 mm
Bearing Distance (Bdp) : 1300.00 mm
End disc arm (Ad) : 200.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm
Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 132.34 kg
Design Wrap Angle (Wa) : 40.00 °
a1 : 210.00 °
a2 : 355.00 °
Rpm : 300.27 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 80741.24 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 350472.87 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 219045.54 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi

Page 6 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 176.38 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 150.80 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 114.14 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.0008 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.00077 > 0.0023 in / in (not acceptable)

Minimum shaft dia. to resist for deflection calculated as follows :

De : 134.23 mm

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 165.00 mm

Dia. at Bearing (Db) : 160.00 mm
Nearest bearing standard
Bearing Type : 22213EK
Housing Type : SNH 513
Basic dynamic load rating (C) : 176000.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.10 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

Shaft Diameter & Bearing Used

Dia. used at end disc : 70.00 mm
Dia. used at Bearing : 60.00 mm
Housing Type : SNH 513
Bearing Type : 22213EK

E.4. Take - Up Pulley

Recommended minimum dia.(Dp min) : 345.44 mm Dp = 0.85 . Dp Drive Pulley

Standard pulley dia. (Dp) : 400.00 mm
Face distance (Fdp) : 1000.00 mm
Bearing Distance (Bdp) : 1300.00 mm
End disc arm (Ad) : 200.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm
Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 156.65 kg

Page 7 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Design Wrap Angle (Wa) : 180.00 °
a1 : 90.00 °
a2 : 90.00 °
Rpm : 262.74 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 267759.56 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 1162261.83 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 726413.64 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi
Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 263.03 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 224.88 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 564.45 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.0005 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.00052 < 0.0023 in / in (acceptable)

Minimum shaft dia. to resist from deflection calculated as follows :

De : 181.15 mm

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 245.00 mm

Dia. at Bearing (Db) : 240.00 mm
Nearest bearing standard
Bearing Type : 22316EK
Housing Type : SNH 616
Basic dynamic load rating (C) : 431000.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.04 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

Page 8 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Shaft Diameter & Bearing Used

Dia. used at end disc : 80.00 mm
Dia. used at Bearing : 70.00 mm
Housing Type : SNH 616
Bearing Type : 22316EK

E.5. Tension Take - Up Pulley to Head

Recommended minimum dia.(Dp min) : 284.48 mm Dp = 0.7 . Dp Drive Pulley

Standard pulley dia. (Dp) : 350.00 mm
Face distance (Fdp) : 1000.00 mm
Bearing Distance (Bdp) : 1300.00 mm
End disc arm (Ad) : 200.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm
Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 132.34 kg
Design Wrap Angle (Wa) : 85.00 °
a1 : 166.00 °
a2 : 270.00 °
Rpm : 300.27 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 165025.07 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 716323.04 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 447701.90 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi
Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 223.84 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 191.38 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 296.05 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.000608 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.000608 > 0.0023 in / in (not acceptable)

Minimum shaft dia. to resist from deflection calculated as follows :

Page 9 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

De : 160.50 mm

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 210.00 mm

Dia. at Bearing (Db) : 205.00 mm
Nearest bearing standard
Bearing Type : 22313EK
Housing Type : SNH 613
Basic dynamic load rating (C) : 299,000.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.05 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

Shaft Diameter & Bearing Used

Dia. used at end disc : 70.00 mm
Dia. used at Bearing : 60.00 mm
Housing Type : SNH 613
Bearing Type : 22313EK

E.6. Tension Take - Up Pulley to Tail

Recommended minimum dia.(Dp min) : 284.48 mm Dp = 0.7 . Dp Drive Pulley

Standard pulley dia. (Dp) : 350.00 mm
Face distance (Fdp) : 1000.00 mm
Bearing Distance (Bdp) : 1300.00 mm
End disc arm (Ad) : 200.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm
Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 132.34 kg
Design Wrap Angle (Wa) : 100.00 °
a1 : 270.00 °
a2 : 346.00 °
Rpm : 300.27 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 219691.65 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 953613.83 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 596008.64 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi

Page 10 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 246.24 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 210.53 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 433.56 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.00055 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.00055 < 0.0023 in / in (acceptable)

Minimum shaft dia. to resist from deflection calculated as follows :

De : 172.40 mm

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 225.00 mm

Dia. at Bearing (Db) : 220.00 mm
Nearest bearing standard
Bearing Type : 22313EK
Housing Type : SNH 613
Basic dynamic load rating (C) : 299,000.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.02 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

Shaft Diameter & Bearing Used

Dia. used at end disc : 70.00 mm
Dia. used at Bearing : 60.00 mm
Housing Type : SNH 613
Bearing Type : 22313EK

F. TAKE UP TENSION
Take up tension calculated as follow:
Nearly to head
Height to drive (Ht') : 0.00 m
FT : 134004.60 kg FT = F2 - (W1.Ht')
Nearly to tail
Height to tail (Ht'') : 8.20 m
FT : 144515.52 kg FT = F2 + For - (W1.Ht'')
Since take up pulley is nearly to head FT will be as follow :
FT : 134004.60 kg

Page 11 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Pulley & Structure Appx. Weight (FM) : 956.26 kg

CounterWeight (WT) : 266096.69 kg WT = 2 (FT ± FM)

F. TAKE UP STROKE

Elastic elongation (f1) : 0.50 %

Permanent elongation (f2) : 0.80 %
Deflection ratio between idlers (f3) : 0.10 %
Extra margin (em) : 0.42 m em = 0.5*l / 100

Take Up Stroke (S) : 1.59 m S = ((l (f1 + f2 + f3))/100)+em

G. SPLICING LENGTH
Step length (S1) : 350.00 mm
Length of spliced section (l1) : 1050.00 mm l1 = S1(n -1)
Margin for splicing angle (l3) : 496.80 mm l3 = 0.414BW

Total Splicing length (lt) : 1546.80 mm

H. THROUGHING TRANSITION DISTANCE

Max. allowed edge belt elongation (e) : 0.20 %

Throughing transition distance (Tcr) : 2,314.78 mm Tcr = (5BW/3)*SQRT ((2(1-Cosb))/e)

I. MINIMUM RECOMMENDED BELT LENGTH

Horizontal length portion (hl) : 153.00 m
Inclined length portion (hi) : 82.30 m
Vertical length portion (hv) : 2.59 m
Splicing number : 3.00
Spare to take up upper limit : 2.90 m
Min. Total Length (TL) : 484 m TL = (2*(hl+hi+Spare))+(lt*spn/1000)+(3.14*(Dp/1000)*1.5)

J. RADIUS DESIGN

CONVEX

Minimum Bending Radius (R c) : 25,198.32 mm Rc = 42BW.sinb

Curvaturve length (lcv) : 87,908.25 mm lcv = (p . Bw . Sinb .Rc)/(180*3)

Maximum allowed elongation of edge belt : 703266.04 mm Dl = 1.00*8lcv

Page 12 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

CONCAVE

UNLOADING CONDITION
Design Data :
Conveyor Capacity (Qt) : 0.00 Ton / hour
Material to be transported : Raw Ore
Density (r) : 1.00 Ton / m3
Surcharge angle (a) : 20.00 °
Belt Width (b) : 900.00 mm
Speed (v) : 60.00 m / min
Throughing angle (b) : 30.00 °

POWER CALCULATION (UNLOADING)

Power Requirement :
Conveyor Length (l) : 233.00 m
Lift Height (h) : 20.90 m
Inclination (g) : 13.60 °
Idler friction (f) : 0.03
Adjustment Length (lo) : 49.00 m
Belt weight (W1) : 15.50 kg / m
Weight of moving part carrier (Wc) : 15.10 kg / m
Weight of moving part return (Wr) : 13.40 kg / m
Carrier Pitch (lc) : 1.20 m
Return Pitch (lr) : 2.40 m
Weight of moving parts (W) : 49.17 kg / m
Weight of material loaded (Wm) : 0.00 kg / m
Friction Coeff. Material & belt (u) : 0.40
Power Efficiency (h) : 0.85
Volume of load (Qm) : 0.00 m3/h Qm = Qt / r
Length of skirt (lk) : 3.00 m * 4 skirt applied
Width of skirt (bs) : 600.00 mm
Calculated Axle Power Drive (P') : 122.83 KW

TENSION (UNLOADING)

Friction Coefficient Belt & Pulley (u1) : 0.30

Designed wrap angle (q) : 210.00 °

Effective Tension (Fp) : 12528.98 Kg Fp = 6120.P' / v

Tight Side Tension (F1) : 18817.27 Kg F2 = Fp . (1 / (e u1 q -1))
Slack Side Tension (F2) : 6288.29 Kg Fp = F 1 - F2
Incline Tension (Up) (F3) : 766.62 Kg F3 = W1 . L (Tan a - f)
Belt sagging : 1.00 %

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 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Minimum Tension Carrier (F 4c) : 232.50 Kg F4c = 12,5 . lc . (Wm+W1)
Minimum Tension Return (F4r) : 465.00 Kg F4r = 12,5 . lr . W1

Maximum Tension For Uphill Conveyor :

Fr : -145.59 Kg Fr = f (l + lo)(W1 + Wr/lr) - (H . W1)
Case 1 : 12907.07 Kg Fmax = Fp + F4c - Fr
Case 2 : 13139.57 Kg Fmax = Fp + F4r - Fr
Case 3 : 18817.27 Kg Fmax = Fp + F2
Case 4 : 12993.98 Kg Fmax = Fp + F4r
Fmax : 18817.27 Kg

Acceleration Tension & Time :

Drive Factor (k) : 1.50 k = 1 + (1 / (e u1 q -1))
Number of plies taken : 4.00
Minimum recommended pulley diameter : 460.00 mm

RUNNING TENSION (UNLOADING)

Uphill conveyor at head drive :
Run tension carrier side(Fc) : 561.54 kg Fc = (f (l +lo)(W1+(Wc/lc)+Wm))+h(W1+Wm)
Run tension return side (Fr) : -145.59 kg Fr = (f (l + lo) (W1 + (Wr/lr))) - hW1
Tension at tight side (Foc) : 237.59 kg Foc = f (l + lo) (W1 + (Wc/lc) + Wm)
Tension at slack side (For) : 178.37 kg For = f (l + lo) (W1 + (Wr/lr)
Pre - Tension Fp' : 415.95 kg Fp' = Fc + Fr
T1 : 1040.66 kg T2 = F2 = Fp'. k
T2 : 624.71 kg T1 = F1 = Fp' + F2
T3 : 479.13 kg T3 = T4 = F2 + For - h.W1
T4 : 479.13 kg When T4<F4c or F4r
T4 Selection , T4 max : 479.13 kg T3 = T4 = F4c
Summary - Tension T2 = T3 + h.W1 - For
T1 : 1040.66 kg T1 = T2 + Fp'
T2 : 624.71 kg
T3 : 479.13 kg
T4 : 479.13 kg

BENDING RADIUS CARRIER SIDE

BENDING RADIUS AGAINST BELT LIFTING:
LOADING CONDITION
Horizontal Position (lx) : 150.00 kg
Vertical Position (hx) : 0.00 kg
T4 : 144555.82 kg
Twcx : 0.00 kg Twcx = hx(W1+Wm)
Tfcx : 139467.01 kg Tcx = (f (lx + lo) (W1 + (Wc/lc) + Wm))+hx(W1+Wm)
(Tension at carrier side conv.point) Tcx : 284022.83 kg Tcx = T4 + Twcx + Tfcx
(Min. Bending Radius at loaded) R cv : 2708.45 m Rcv = 1.35Tcx /(W1 + Wm) Cos g

BENDING RADIUS AGAINST BELT LIFTING:

UNLOADED CONDITION
(Tension at carrier side conv.point) Tcx : 1177.18 kg Tcx = T1 + For - (h . W1)
(Min. Bending Radius at unloaded) RcvO : 102.67 m RcvO = 1.35Tcx /(W1) Cos g

Page 14 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

BENDING PULLEY AT CONVEX

Recommended minimum dia.(Dp min) : 284.48 mm Dp = 0.7 . Dp Drive Pulley
Standard pulley dia. (Dp) : 300.00 mm
Face distance (Fdp) : 1000.00 mm
Bearing Distance (Bdp) : 1300.00 mm
End disc arm (Ad) : 200.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm
Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 109.39 kg
Design Wrap Angle (Wa) : 28.00 °
a1 : 175.00 °
a2 : 346.00 °
Rpm : 350.32 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 21160.39 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 91850.74 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 57406.71 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi
Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 112.87 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 96.51 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Page 15 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Shaft Deflection Check

Eg : 29000000.00 psi
I: 19.14 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.0012 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.00121 > 0.0023 in / in (not acceptable)

Minimum shaft dia. to resist for deflection calculated as follows :

De : 96.04 mm

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 110.00 mm

Dia. at Bearing (Db) : 105.00 mm
Nearest bearing standard
Bearing Type : 22208EK
Housing Type : SNH 508
Basic dynamic load rating (C) : 89700.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.75 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

BENDING PULLEY AT CONCAVE

F1 : 135224.69 kg
F2 : 143728.22 kg
Recommended minimum dia.(Dp min) : 284.48 mm Dp = 0.7 . Dp Drive Pulley
Standard pulley dia. (Dp) : 300.00 mm
Face distance (Fdp) : 1000.00 mm
Bearing Distance (Bdp) : 1300.00 mm
End disc arm (Ad) : 200.00 mm
End disc Thickness (Td) : 16.00 mm
Intermediate disc Thickness (Id) : 12.00 mm
Drum Thickness (Dt) : 12.00 mm
Drum Weight (Wd) : 109.39 kg
Design Wrap Angle (Wa) : 39.00 °
a1 : 170.00 °
a2 : 356.00 °
Rpm : 350.32 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Pulley resultant tension (Fr) : 109.39 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 474.82 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 296.76 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50

Page 16 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi
Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Shaft Dimension
Dia. at end disc (De) : 19.52 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 16.69 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 0.02 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.0070 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.00697 > 0.0023 in / in (not acceptable)

Minimum shaft dia. to resist for deflection calculated as follows :

De : 25.75 mm

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 35.00 mm

Dia. at Bearing (Db) : 30.00 mm
Nearest bearing standard
Bearing Type : 1207EK
Housing Type : SNH 507
Basic dynamic load rating (C) : 19000.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 78,243.01 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

HOLD DOWN ROLLER

Page 17 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Since tension subjected to hold roller near head is bigger than near to tail, the tension will be use for calculation for all hold roller.
F1 : 146456.72 kg
F2 : 284022.83 kg
Hold down roller dia. (Dr) : 314.00 mm
Roller distance (Rdp) : 621.00 mm
Bearing Distance (Bdp) : 1000.00 mm
End disc arm (Ad) : 189.50 mm
End disc Thickness (Td) : 16.00 mm
Drum Weight (Wd) : 80.00 kg
Design Wrap Angle (Wa) : 20.00 °
a1 : 170.00 °
a2 : 355.00 °
Rpm : 334.70 Fr = Sqrt ((F1Sina1 + F2Sina2) - Wd)2+
Resultant tension (Fr) : 138705.46 kg (F1Cosa1 + F2Cosa2)2 )

Bearing arm (Ab) : 125.00 mm

Drive Torque (Tq) : 0.00 kg.cm Tq = 71620 .1,36 . P / Rpm
0.00 in.lb
Moment on end disc (Md) : 570468.62 in.lb Md = Fr . Ad / (25,4 . 0,4535 . 2 . 2)
Moment on Bearing (Mb) : 376298.56 in.lb Mb = Fr . Ab / (25,4 . 0,4535 . 2 . 2)

Cm : 1.50
Ct : 1.00

Mechanical Properties of Material

Material : JIS - S45C
Max. shear stress tmax (For Drive) : 6000.00 psi
Max. shear stress tmax (For non Drive) : 8000.00 psi
Syield : 45000.00 psi
tmax : (0.5 * Syield *75%)/Sf (Keyway profile affect, reduced down to 75%)
Sf : 0.5 * 45000 * 0.75 / 8000 = 2.1 (non-drive pulley)
0.5 * 45000 * 0.75 / 6000 = 2.8 (drive pulley)

Page 18 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

Shaft Dimension
Dia. at end roller (De) : 207.48 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4
Dia. at Bearing (Db) : 180.61 mm d = ((( 16 /(3.14*tmax))*SQRT((Cm*Md)2+(Ct*T)2))^(1/3))*25.4

Shaft Deflection Check

Eg : 29000000.00 psi
I: 218.54 in4 I = 0.049087 D4/(25.44)
Tan a1 : 0.0005 in/in Tan a1 = Fr 0.4535 (Ad/25.4) ((Bdp/25.4) - (2Ad/25.4)) / 4EgI
CEMA - Recommendation < 0.0023 in / in
0.00045 > 0.0023 in / in (not acceptable)

Minimum shaft dia. to resist for deflection calculated as follows :

De : 138.19 mm

Bearing Selection & Bearing Life Calculation

In order to suit calculated shafting design with standard bearing will be safe if the diameter taken to upper standard as follow:

Dia. at end disc (De) : 195.00 mm

Dia. at Bearing (Db) : 190.00 mm
Nearest bearing standard
Bearing Type : 22209EK
Housing Type : SNH 509
Basic dynamic load rating (C) : 93700.00 N
Exponent for life equation (p) : 3.00 for ball bearing
3.33 for roller bearing
P =XFr + YFa
Basic rating life (L10) 0.00 hours L10 = (1000000/60n)*(C/(P*9.81*3/2))p

K. DISCHARGE TRAJECTORY

Height of load cg from belt surface (a1) : 70.00 mm

Height of top load from belt surface (h) : 190.00 mm
Center gravity radius (Rcg) : 391.60 mm Rcg = (a1 + belt thickness + pulley radius)

Tangential Velocity (Vs) : 6.90 m/sec Vs = (2*p*(Rcg/1000)*rpm)/60

Trajectory Condition (Tco) : 12.40 < 1 Tco = Vs2/(g*Rcg/1000)

since Tco < 1 material will follow part way around the pulley for angular distance y as follow :

cos y : 12.40
Angular distance y : #NUM! °
spaces grid : 345.2 mm

Falling Distance (CEMA Recommendation) :

Time Falling Distance

Interval in mm
1/20th 0.50 12.70
2/20ths 1.94 49.21
3/20th 4.38 111.13

Page 19 of 20
 Job Code : 374E1D1
Item : 1105
Rev : R1

CONVEYOR NAME : LOGA Date : 21/02/2004

4/20ths 7.75 196.85
5/20th 12.06 306.39
6/20ths 17.38 441.33
7/20th 23.63 600.08
8/20ths 30.88 784.23

Page 20 of 20