Recommendations For Constructing and Calculating Conveyors: Plastic Modular Belting

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Plastic modular belting

Recommendations for
constructing and calculating
conveyors
Contents

Belt support 2
Shafts 3
Conventional conveyors 5
Reversible conveyors 6
Inclined conveyors 7
Curve variations 9
Spiral conveyors 10
Further information/
Effect of temperature 11
Calculation 12

You can obtain detailed information on


ProLink plastic modular belts in the over-
view of the range (ref. no. 223) and the
data sheets on the individual series.

Conveyor and power transmission belts


1 made of modern synthetics
Worldwide leaders in technology, quality and service
Plastic modular belting

Belt support

Skid plate ≥5 Belt width b0 at maximum temperature ≥5

The belt can be supported in the


following ways:
– Continuous plate support made of steel Figure 1 (“see the section Effect of temperature” p. 11)
or plastics such as PE 1000. We
recommend this for conveyors with
heavy loads.
– Straight parallel runners (figs. 1 + 2)
made of steel or plastics. This is an
inexpensive solution for applications
with minimal loads. The belt wear is
limited to the areas where the runners
support the belt. We recommend a
distance of approx. 120 – 150 mm
between the runners for the upper side
and approx. 200 mm for the return
side.
– The belt is supported over the entire Figure 2 Figure 3 Figure 4
width by a V-shaped arrangement of
the runners (figs. 3 + 4). This spreads
the wear and tear evenly and means X
heavy loads can be applied.
– Around the curves the belt is supported
by plastic guides at the sides, for
example PE 1000 or a plastic with
lubricating properties, on the inner
radius (see fig. 5).
Suitable plastic runners are available from
specialized dealers. The width should be
approx. 30 – 40 mm, whereby the thick-
ness depends on the height of the screw
heads. Figure 5 Figure 6

The permissible temperature ranges, as


given by the manufacturer, must also Thermal expansion and contraction must – Distance X ≤ 1.5 x module pitch
correspond to the expected operating also be taken into consideration when
– Place the snub roller on the return side
conditions. mounting the support. These effects can
so that the arc of contact on the drive
be eliminated by slots and appropriate
and idle shafts ≥ 180°. (This does not
distancing between the runners (see the
apply to conveyors with e ≤ 2 m. Rollers
section “Effect of temperature”).
on the return side are not necessary
here.)

Rollers are not generally used to support


Roller support the belt on the upper face. Unavoidable
belt sag between the rollers as well as the
chordal action of the drive unit (see page
11) mean the goods are tipped which can
cause problems. Sometimes rollers are
used for conveying bulk goods.

2
Plastic modular belting

Shafts

In general, we recommend the selection of Occasionally round shafts with feather keys Drive Shaft
a square shaft. The main advantage of this are also used for low-loaded, narrow belts.
design is that positive drive and tracking Specially designed sprockets with bore and
are possible without keys and keyways. keyway are available.
This saves on additional manufacturing
costs. In addition, this form facilitates the
lateral movement of the sprockets in the
case of temperature variations.

Shaft 40 x 40 mm
Fastening the sprocket with a retainer ring Fastening the sprockets
2,5
mm in accordance with DIN 471 (Seeger circlip
ring) d = 56 mm. Usually only 1 sprocket (as near as possible
mm
2,5
to the centre) must be fastened axially on
each idle or drive shaft. The design of this
sprocket enables positive tracking of the
40
mm
belt.
Examples of possible methods for fastening
a sprocket are shown on the left:

Figure 1

Self-locking plastic retainer rings that can


be supplied with the sprockets.
To prevent shifting to the side (e.g. due
to large lateral forces, fluctuation in
temperature, etc.), the retainer rings
should be secured with an additional
screw.

Figure 2

Fixation of the sprocket with retainer rings


in accordance with DIN 471 (Seeger circlip
ring).

Figure 3

3
Plastic modular belting

Deflection

Large belt widths and/or high tensile loads


can lead to excessive deflection, preventing
perfect belt-tooth engagement in the drive
area. This results in uneven stress on the
teeth of the sprocket, and it is possible
that the sprockets do not engage properly,
leading to “jumping” of the teeth when the
belt is loaded. The borderline value per-
mitted is the tooth engagement angle αz
and depends on the shape of the gear ring
and module. For the ProLink linear belts Figure 4
this is 1.2°.
If the borderline values are exceeded,
additional intermediate bearings must be
applied or a larger shaft selected.
The tooth engagement angle αz is The shaft deflection yW is calculated using
calculated using this formula: the following formulae

Fig. 5

FW . I3
yW = 0.156 _____ [mm]
d

yW E · d4
αz = arctan ( l
· 2)
Solid shaft

Fig. 6

80 · FW . I3
yW = ____________ [mm]
d

E . d4 . π . 96
Solid shaft

Fig. 7

80 . F . I3
yW = _________________
W [mm]
da
di

96 . E (da4 – di4) . π

Hollow shaft

FW = shaft load [N]


l = bearing centre distance [mm]
E = shaft’s modulus of elasticity [N/mm2] (e.g. for steel = 2.1 · 105 N/mm2)
d = length of side of square shaft [mm]
d, di, da = diameter of shaft [mm]
yW = shaft deflection

4
Plastic modular belting

Conventional conveyors

Belt sag/control of belt length

≤ 2000 mm There are various causes for changes in the


belt length, e.g.
– Elongation or contraction of the belt
due to temperature variation
– Wear of the connecting rods as well as
30 – 100 mm enlargement of the connecting rod holes
in the modules after a certain “break-in
time” (enlargement of holes, 0.5 mm
larger holes in a 50 mm module result
Figure 1 in an elongation of 1%).
Therefore we recommend not supporting
one (or several) sections on the return side
and using the resulting belt sag to
compensate for the increase in length. It is
important that perfect engagement
between belt and sprocket is ensured.
Following are several examples:
a) Short conveyor (fig. 1)
300 – 500 mm 30 – 100 mm 300 – 500 mm
b) Medium length conveyors, up to a
centre distance of approx. 4,000 mm
(fig. 2)

Figure 2 c) Long conveyors:


centre distance > 20,000 mm and
low speeds
centre distance < 15,000 mm and
high speeds
(fig. 3)
50 – 180 mm
Another effective method for
compensating for belt elongation is a load-
dependent take-up system (e.g. weighted
roller). This should be located as closely to
the drive shaft as possible since the take-up
300 – 500 mm 800 – 1200 mm 800 – 1200 mm system will ensure even tension on the re-
turn side and therefore perfect engagement
between sprocket and belt (fig. 4).
Figure 3 For series 1 and 3 we recommend a weighted
roller, 150 mm in diameter and a weight of
approx. 30 kg/m belt width.
For series 2 and 4 we recommend a weighted
roller, 100 mm in diameter and a weight of
50 – 150 mm
approx. 15 kg/m belt width.

300 – 500 mm 800 – 1200 mm 800 – 1200 mm


F

Figure 4

5
Plastic modular belting

Reversible conveyors

Two-motor design

Advantages: Low tension on the return


side, making smaller shaft loads possible
Disadvantage: Increased costs due to
additional motor and electronic control.
For larger conveyors with relatively heavy
loads, however, this system may still be the ≥ 600 mm ≥ 600 mm
most reasonably priced.

Figure 1

Centre drive

For reversing operation the drive shaft


must be located as close to the middle as
possible. To the right and the left of the
drive unit, areas with belt sag are to be
provided, since these are necessary for the
required belt tension. The 180° arc of
500 mm 1200 mm ca.
ca. 4 x Modulteilung
module pitch
contact on the drive shaft means belt and
sprocket engage perfectly making reliable
power transmission in both operational
directions possible.
Figure 2
The location of the drive unit causes more
stress on the shafts at the ends of the
conveyor as there is effective pull on both
the upper and return sides in the form of
belt tension.

Alternating tail-head drive


configuration

In the case of head drives the conveyor is


like a conventional conveyor. It is only
when conveying direction is reversed that
the conveyor become tail-driven and the
drive unit has to push the belt and its load. 10 – 35 mm
If the tension on the return side is not
greater than that on the upper side it will 400 – 550 mm ≤ 3000 mm 400 – 550 mm
jump sprockets.
An approximate value for the tension on
the return side is 1.2 – 1.3 x FU. This
Figure 3
automatically leads to a greater shaft load.
FW ≈ 2.2 – 2.3 x FU

6
Plastic modular belting

Inclined conveyors

Inclined conveying

We always recommend the following:


– Only operate with a head drive, i.e. use
A–A the upper shaft as the drive shaft.
m
0m
45
25
0– – There is always a screw-operated take-
A
up system or a load-dependent tension
take-up on the return side since tension
decreases with increasing inclination
A
(caused by the belt sag).
– If sprockets are used at upper inter-
mediate points, the centre sprockets
rmin = 150 mm may not be fastened axially.
– If rollers are used at upper intermediate
points, a minimum radius of approx.
Figure 1 – Belt with lateral profiles 80 mm is required.
– When shoe or runners are used, the
radius should be as large as possible
in order to keep wear to a minimum.
A–A
We recommend a minimum radius of
approx. 150 mm. The width of the shoe
250 – 450 mm
should not be smaller than 30 mm.
rmin = 150 mm
A – If the belt is more than 600 mm wide,
we recommend providing further
rmin = 150 mm
supports on the belt surface or on the
A profiles on the return side.

dmin = 80 mm

≤ 1000 mm

Figure 2 – Belt with lateral profiles

rmin = 150 mm

A–A

250 – 450 mm

rmin = 150 mm
A

rmin = 150 mm

dmin = 80 mm

≤ 1000 mm

Figure 3 – Belt with side guards

7
Plastic modular belting

Declined conveying

For this conveyor design, a tail drive unit is


possible if there is an active load-dependent rmin = 150 mm

tension take-up at the lower idle shaft (e.g.


gravity, spring or pneumatic). Otherwise
the general recommendations given above A–A 10 – 35 mm
apply here.
≤ 2000 mm 250 – 450 mm

Figure 4 – Belt with lateral profiles

8
Plastic modular belting

Curve variations

Meshing Belt tension

The teeth must mesh into the modular The three usual tensioning methods are
belting in the areas marked by the arrows. possible to create the correct belt tension:
(fig. 1)
– Screw-operated take-up system
– Gravity take-up system
Inner radius – Catenary sag on the return side
near the drive drum
ProLink inner radius rmin
for curved belts
Figure 1 rmin = 2 x b0

Geometries of curves

Please consult us if you cannot construct


the conveyor according to the drawings
because space is restricted.
r mi b 0
2
n
x

≥ 2 x b0
≥ 2 x b0

b0

Figure 2 – 180° Curve

Figure 4 – S-shaped curve ≥ 2 x b0


≥ 2 x b0
b0
r mi b 0
2
n
x
xb n
i
rm

0
2

≥ 2 x b0
≥ 2 x b0

r mi b 0
2
n
x

b0

≥ 2 x b0
Figure 3 – 90° Curve

9
Plastic modular belting

Spiral conveyors

Possible conveyor designs

Fig. 1:
Example of declined conveying to join two
production units with different heights. Figure 1

Fig. 2:
For inclined conveying, the drive unit must
be located at the end of the curve at the
top. Make sure that the arc of contact on
the drive shaft is approx. 180°. This type of
design (without driven inner cage) should
not have more than 2 – 3 tiers.

Figure 2

Fig. 3:
The main drive system is the driven inner
cage, which as a rule consists of vertical
rods. The curved belt is supported on the
inner radius by the cage and is moved by
traction between the belt and the cage. The
direction of rotation of the cage determines
whether the conveying is inclined or de-
clined.
The drive and tensioning unit depicted
in the sketch provides the necessary belt
tension. The speed of the motor must be
coordinated with the speed of the cage
drive.
It should be possible to move the tensioning
unit a distance corresponding to approx.
1% of the belt length.
The belt can be supported by runners as
described on page 2.

Figure 3

10
Plastic modular belting

Further information

Calculation of changes in length


Material Coefficient of thermal and width: Effect of temperature
expansion a [mm/m/°C] *
∆ l = l0 · (t2 - t1) · a Plastics can expand or contract significantly
Polyethylene PE 0.21
Polypropylene PP 0.16 ∆ b = b0 · (t2 - t1) · a when temperatures fluctuate. The construc-
Acetal POM 0.12 tion engineer must make allowances for
Polyamide PA 0.07 Calculation example: changes in belt lengths and widths if the
PE 500 0.16 operating temperature is not the same as
PE 1000 0.16 Ambient temperature 20° C, the belt is the ambient temperature. Essentially, this
used for the conveying of hot goods, re- affects the belt sag on the return side and
* Average values for the permissible sulting in an operating temperature of
temperature range the lateral clearance on the conveyor
90° C. Belt length 30 m, belt width 1 m, frame.
belt material polypropylene.

∆l = change in length in mm ∆ l = 30 · (90 - 20) · 0.16


+ = elongation
– = contraction ∆ l = 336 mm

l0 = belt length ∆ b = 1 · (90 - 20) · 0.12


at initial temperature in m ∆ b = 11.4 mm
b0 = belt width
at initial temperature in m The increase in belt length of 252 mm is
not insignificant which means that the re-
t2 = operating temperature °C turn side must be designed in such a way
t1 = initial temperature °C that the additional belt sag is absorbed. In
order to accommodate the increase in width,
a = coefficient of thermal the conveyor frame must have a wider
expansion mm/m/°C design.
When operating at temperatures below 0° C,
the length and width contract. This must
also be accomodated in the conveyor design.

Chordal Action
∆v
[%] What is known as chordal action is typical
14 for all sprocket-driven belts, chains etc.
12 The rise and fall of a module during the
10 slewing motion cause changes in the linear
8 speed of the belt.
6 The number of teeth on sprocket is the
4 decisive factor for these periodic fluctua-
2 tions in speed.
0
6 8 10 12 14 16 18 20 As the number of teeth increases, the
percentual change in speed decreases. In
practice this means that the largest number
Figure 1 – Number of teeth on sprocket
of teeth possible must be used if the goods
are not to tip or for other reasons an even
belt speed is required

11
Plastic modular belting

Calculation

Key to the symbols

Designation

Symbols

Unit
Effective belt pull FU N
Force determining belt selection FB N
Shaft load FW N
Calculated power at drive drum PA kW
Coefficient of friction with accumulated goods µST –
Coefficient of friction with skid plate µT –
Operational factor C1 –
Temperature factor C2 –
Stability factor C3 –
Acceleration due to gravity g 9.81 m/s2
Conveyor length lT m
Height of lift hT m
Mass of entire belt (see data sheet) mB kg
Total load m kg
Mass of drive drum mW kg
Angle of conveyor α °
Belt width b0 mm
Belt speed v m/min

12
Plastic modular belting

Loading examples
One of the three following formulae is used to calculate FU, to determine the effective pull FU

A depending on the design of the conveyor.

lT
FU = µT · g · ( m + mB ) [N]

(–) lT +
FU = µT · g ( m + mB ) + g · m · sin α [N] –
(+) inclined

hT
(–) declined α

FU = µT · g · ( m + mB ) + µST · g · m [N]
Mass of rotating parts on the return side was ignored.

Skid Belt material Coefficients of friction µT (guidelines)


plate PE PP POM between skid plate and belt
made of dry wet dry wet dry wet
The figures stated have been established
PE 500 not recommended 0.12 0.10 0.08 0.08 under ideal conditions. When operating
PE 1000 0.33 0.25 0.14 0.12 0.10 0.10
under other conditions we recommend
using higher friction coefficients
Steel or 0.15 0.15 0.25 0.25 0.18 0.18
stainlessl steel

Belt material Coefficients of friction µST (guidelines)


Container PE PP POM between belt surface and accumulated goods
material dry wet dry wet dry wet

Steel 0.15 0.15 0.25 0.25 0.18 0.18

Glass 0.15 0.12 0.12 0.10 0.12 0.11

Plastic 0.10 0.10 0.15 0.12 0.15 0.12

13
Plastic modular belting

Force determining belt selection FB


C1
B FB = FU · —–
C2
[N]

C1
Operational factor C1
Smooth operating conditions (smooth start) + 1.0
Start-Stop-operation (start when loaded) + 0.2
Tail drive (push configuration) + 0.2
Belt speed greater than 30 m/min + 0.2
Inclined or swan-neck conveyor + 0.4

⇒ Total C1 ____

Belt material
Temperature factor C2 Temperature [°C] PE PP POM

– 60 0.97 *– –
– 40 0.96 *– 0.98
– 20 0.92 *– 0.98
0 0.86 *– 0.97
+ 20 0.78 0.98 0.96
+ 40 0.70 0.95 0.96
+ 60 0.62 0.85 0.96
+ 80 – 0.65 0.75
+ 100 – 0.45 –
* below + 7 °C avoid jolts, ensure smooth start.

14
Plastic modular belting

Counter-checking the ProLink type selection


FB
C —– = C3 ≤ C3 max
b0

Material
Factor C3 max
PP PE POM
Type [N/mm] [N/mm] [N/mm]

S1 30 18 40
S2 5 3 7
S3 12 6 16
S4 4 2 6
S5 CM 25, linear/curved module 18/1000 N 10/– 25/1800 N
S5 CM 50, linear/curved module 22/1600 N 12/– 30/2800 N
S6– 20 30/36*
S7 18 40 60/80*

* depending on hinge pin and gear ring

from C3 max, the distance between Number of sprockets on the drive drum
(guidelines)
C3 ≤ 20 % the sprockets should then be
approx. 160 mm. Where centre distances are substantial, the
number of drive sprockets still depends on
from C3 max, the distance between the engagement ratio between teeth/module
C3 ≤ 40 % the sprockets should then be (i.e. on the belt length)
approx. 100 mm.

from C3 max, the distance between


C3 ≤ 60 % the sprockets should then be
approx. 80 mm.

from C3 max, the distance between


C3 ≤ 80 % the sprockets should then be
approx. 60 mm.

C3 > 80 % from C3 max, please inquire.

Shaft load FW

D FW ≈ FU · C1 + mw · g [N]

Power requirement at the drive drum PA

E PA =
FU · v
1000 · 60
v in m/min [kW]

15
Plastic modular belting

Printed in Germany.
Issue 5.06/2 – UD
Ref. No.
206
This paper was made from
non-chlorine-bleached
cellulose.
thereof only with our approval.
Reproduction of text or parts

Modifications reserved.
Registered trademarks

Extremultus
Transilon
Siegling

ProLink
Because our products are used in so many
applications and because of the individual factors
involved, our operating instructions, details and
information on the suitability and use of the products
are only general guidelines and do not absolve the
ordering party from carrying out checks and tests
themselves. When we provide technical support on
the application, the ordering party bears the risk of
the machinery functioning properly.

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