Date: January 26, 2023

Conveyor Design Report

BATCH PLANT COVEYOR SYSTEM

CV1 - RECEIVING CONVEYOR
---
WACOM - GMI MALI

PREPARED: RICHMOND YARRICK

______________________

Description:

Page 1 / 35
 System Information Number of idler sets 14 7
Calculation method..........................................CEMA 5th Roll diameter 102 102
Conveyor Length / Height..................................6 / 0.0 m Roll rpm 243 243
Material lift..............................................................0.0 m Total drag (N) 10.2 3.4
Ambient temperature...............................................10 °C Roll length 340 994
Shaft diameter (mm) 25.0 25.0
Rating (N) 3,723 890
Material Properties
Calc Idler Load (N) 693 154
Type........................................................Cement, Clinker L10 life1 (1000 hrs) 350.0 350.0
Design Tonnage.....................................................421 t/h
Density............................................................1360 kg/m3
Maximum lump size..............................................50 mm
Surcharge angle......................................................20 deg

Belt Properties
Type............................................................Fabric (2-Ply)
Width....................................................................900 mm
Rating...............................................................315 N/mm
Speed...................................................................1.30 m/s
Top / bottom cover thickness.......................7.5 x 2.0 mm
Total thickness.......................................................12 mm
Weight...............................................................12.7 kg/m
Modulus.........................................................3,851 kN/m
Tape length...........................................................12.60 m
Belt cycle time............................................................10 s

Tension Summary Running Momentary

Maximum tension
5.45 6.67
(kN)
Minimum safety factor 52.05 42.50
Minimum tension (kN) 3.70 3.48
Maximum belt sag (%) 0.96 1.12
Cross Sectional Loading
Material mass (wm)............................................90.0 kg/m
Combined mass (wm + wb)..............................102.7 kg/m
Edge distance (required / actual)...................72 / 115 mm
Cross sectional area............................................0.066 m²
Cross sectional loading (utility / total)..........76 % / 52 %
Bed depth.............................................................148 mm

Flooded belt tonnage..............................................814 t/h

Flooded (wm + wb)...........................................186.7 kg/m

Idler Set Data

Carry Return
Manufacture SANS-1313 SANS-1313
Series name C4 C4
Number of rolls 3 1
Trough angle (deg) 35 0
Type Inline Inline
Idler spacing (m) 0.37 1.10

Page 2 / 35
1
L10 life above which 95% of idlers exceed Start time.........................................................0.7 to 1.0 s
Emergency stop control.............................................Drift
Drive Station Emergency stop time.......................................0.8 to 0.9 s
Type.............................................................Not Specified Material buildup in chute........................................0.0 m³
Synchronous RPM...........................................1500 RPM
Motor quantity / rating...................................1 / 5.50 kW Tension Ratios
Total installed power...........................................5.50 kW Allowable (running)...................................................2.73
Empty / full power..................(75 / 83%) 4.15 / 4.56 kW Running tension ratio.................................................1.47
Frame Size.........................................................IEC 132S Allowable (dynamic)..................................................3.30
Motor Voltage.............................................Not Specified Starting tension ratio..................................................1.89
Efficiency................................................................95.5%
Maximum starting torque........................................150% Transition Lengths
Inertia - Motor...................................................0.1 kg·m²
Transition method...............................................CEMA 7
Pulley lagging type................................................Rubber
Tail transition length (inline)..................................1.70 m
Motor wrap angles......................................................180
Head transition length (inline)...............................1.70 m
Lagging friction factor (run / accel).................0.32 / 0.38
Estimated Splice Data
Take-up Data
Splice type..............................................................1-Step
Type.......................................................................Gravity
Splice step length.................................................200 mm
Location....................................................Tail / Pulley #2
22 degree bias angle.............................................365 mm
Required belt line tension.....................................3.73 kN
Total splice length................................................565 mm
Cable reeving ratio (trolley:counterweight).................1:1
Counterweight mass.........................................0.8 tonnes

Required pulley displacement................................0.62 m Take-Up Cable

        Dynamic displacement (incl thermal).............0.00 m Counterweight mass.........................................0.8 tonnes
        Permanent elongation......................................0.08 m Cable reeving ratio (trolley:counterweight).................1:1
        Splice length (1 included)...............................0.28 m Take-up cable tension.............................................7.5 kN
        Clearance.........................................................0.25 m Cable diameter......................................................8.0 mm
Cable breaking strength (1800 MPa)...................42.0 kN
Backstops Safety factor.................................................................5.6
Number of clips (crosby clamps)....................................3
Backstop type.............................................None installed
Turnback / free end length............................150 / 35 mm
Sheave Root Diam...............................................140 mm
Brakes
Brake type..................................................None installed
Other Information
Reducer Information Loaded beltline mass (excluding motors)...........1,468 kg
Manufacture................................................................N/A Total inertia (ref HS shaft)...............................0.10 kg·m2
Frame size...................................................................N/A
Reducer ratio..........................................................13.330 Demand Power (kW)
Catalog reducer ratio................................................0.000 Demand % Motor
RPM (High Speed)..........................................1500 RPM Case
power Nameplate
RPM (Low Speed)..........................................112.5 RPM Empty - NF 4.2 75.5
Configuration................................................Shaft Mount Full - NF 4.6 82.8
Number of stages............................................................3
Service factor...............................................................1.4 Din Factor and Total Equivalent Mass
Power rating...............................................................0.00 Belt line
Case Din factor
mass (kg)
Motor Torque Empty - NF 0.0602 1,773
100% Motor Torque - High Speed........................36 N·m Full - NF 0.0445 2,178
Motor Shaft Torque - Running (FN).....................29 N·m
Motor Shaft Torque - Starting (FN)......................53 N·m Maximum Belt Tensions (kN)
100% Motor Torque - Low Speed......................474 N·m Case Running Dynamic
Low Speed Shaft Torque - Running (FN)...........373 N·m Empty - NF 5.14 6.10
Low Speed Shaft Torque - Running (Max)........373 N·m Full - NF 5.45 6.67
Low Speed Shaft Torque - Starting (FN)............579 N·m
Low Speed Shaft Torque - Starting (Max)..........579 N·m Belt Safety Factor
Case Running Dynamic
Empty - NF 55.15 46.47
Starting and Stopping
Full - NF 52.05 42.50
Start control.............................................Constant torque

Page 3 / 35
 Splice Safety Factor
Case Running Dynamic
Empty - NF 27.57 23.24
Full - NF 26.02 21.25

Minimum Belt Tensions (kN)

Case Running Dynamic
Empty - NF 3.70 3.48
Full - NF 3.70 3.54

Maximum Belt Sag (%)

Case Running Dynamic
Empty - NF 0.46 0.48
Full - NF 0.96 1.12

Page 4 / 35
 Conveyor Profile
Overall length = 6 m - Overall height = 0.0 m - True Length = 5.5 m

Pulleys

Pulleys - Top View

Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)

Wrap Resultant Resultant

Pulley Type T1 T2 T1 T2
(deg) Force Force

5.45 3.70 9.14 6.67 3.91 10.6

Take-up Pulley 2-LT 180 3.734.81 8.54 3.735.43 9.16

Page 5 / 35
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

Pulley Shaft Results

Shaft Shaft Design Design

Bearing Pulley & Resultant Resultant Resultant Bending
Pulley Safety Slope at Deflection T1 T2
L10 Life Shaft Force Angle Torque Moment
# Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)

1 1.66 4.24 0.050 500 35.4 30.1 308 65.7 183 0.7 10.6

2 1.60 5.45 0.063 500 23.0 23.0 239 46.1 357 0.0 7.1
Design tensions for shaft fatigue are based on all design level 1 cases.    Running tensions have an added multiplier of 1.10 on high
tension pulleys, and a multiplier of 1.25 on all other pulleys.   

Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley

Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)

1 Rubber 200 10.0 220 1050 140 115 1550 526 23226 417

2 Rubber 200 10.0 220 1050 120 100 1550 522 23222 316

Pulley Shaft Information

Hub Bearing Overhung

Tensile Yield Fatigue Hub Fillet Overhung
Locking Shaft Center to Fillet Moment
Type Strength Strength Strength Diameter Radius Load
Device Material Distance Distance Arm
(MPa) (MPa) (MPa) (mm) (mm) (kN)
(mm) (mm) (mm)

1 XT-60 SAE 1018 400.0 220.0 200.0 140 905 100 38 0.0 0

2 XT-50 SAE 1018 400.0 220.0 200.0 120 930 93 30 0.0 0

Page 6 / 35
 Conveyor Load Cases
During the course of operation, the conveyor experiences different operating conditions at various frequencies.    Normal
operating conditions, such as steady state running, loading and unloading, and other common load cases are designated as
Design Level 1.    Unusual operating conditions, such as when all incline or decline section are simultaneously loaded,
are defined as Design Level 2.    These design levels allow easy summarization of the various possible loading conditions.

For this conveyor, there are two Design Level 1 loads, which are:

1.    Empty
2.    Fully Loaded

In the load case figures, the red line is the conveyor profile and the blue line indicates positions that are loaded.

Empty

Fully Loaded

Page 7 / 35
 Take-up Displacement Summary
1. Type...................................................................................................................................................Gravity
2. Location.................................................................................................................................Tail / Pulley #2
3. Belt line tension................................................................................................................................3.73 kN
4. Take-up pulley displacement range
a. Running...........................................................................................................................0.00 to 0.00 m
b. Momentary......................................................................................................................0.00 to 0.00 m

Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal).................................................................................................0.00 m
2. Permanent elongation.........................................................................................................................0.08 m
3. Splice length (1 included)...................................................................................................................0.28 m
4. Clearance............................................................................................................................................0.25 m
5. Required displacement.......................................................................................................................0.62 m

Counterweight Displacement Summary (1:1 Cable Reeving Ratio)

1. Dynamic displacement.......................................................................................................................0.00 m
2. Permanent elongation.........................................................................................................................0.08 m
3. Splice length (1 included)...................................................................................................................0.28 m
4. Clearance............................................................................................................................................0.25 m
5. Required displacement.......................................................................................................................0.62 m

Page 8 / 35
 Pulley Details
The following table lists recommended pulley design tensions. The first column lists belt tensions for bearing
L10 life and pulley fatigue stress calculations.    Belt tensions for the fatigue design criterion are based on all
design level 1 cases.    Running tensions have an added multiplier of 1.10 on high tension pulleys, and a
multiplier of 1.25 on all other pulleys.   

Pulleys are also to be design for the structural design tensions. For structural design tensions, the pulley
manufacturer is to ensure that the pulleys will be adequate to meet these worst case conditions.

Pulley Design Tensions (added safety factors as described above)

Fatigue Design Tensions (kN) Structural Design Tension (kN)

Wrap Resultant Resultant

Pulley Type T1 T2 T1 T2
(deg) Force Force

35.4 30.1 65.7 7.34 4.40 12.1

Take-up Pulley 2-LT 180 23.023.0 46.1 4.106.24 10.6

Required Pulley Diameter (Tension based on a safety factor of 10)

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)

Motor 1 Head (3) 1 - LT 180 200 200 19 24

Take-up Pulley Tail (8) 2 - LT 180 200 200 17 19

Pulley Shaft Stress Analysis (Individual Pulleys)

Hub Hub Fillet Fillet Fillet Von Hub Von Overhung

Shaft Slope
Pulley Safety Bending Torsion Bending Torsion Mises Mises Von Mises
Type at Hub
# Factor Stress Stress Stress Stress Stress Stress Stress
(min)
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)

1 1 1.66 4.24 39.3 1.3 29.1 2.4 39.4 29.4 0.0

2 2 1.60 5.45 42.1 0.0 29.1 0.0 42.1 29.1 0.0

Running Drive Tensions by Load Case (kN)

Motor 1

Resultant
T1 T2
Force
Load Case
5.14 3.70 8.84

5.45 3.70 9.14

Pulley Tension Summary - All Load Cases and Conditions

Page 9 / 35
 Load Case Running Starting O-Stop E-Stop
Pulley
T1 T2 T1 T2 T1 T2 T1 T2
ID Description
(kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN)

Motor 1 5.14 3.70 6.10 3.48 4.11 3.91 4.11 3.91

EM-N Empty - NF
Take-up Pulley 3.73 4.81 3.73 5.43 3.73 4.20 3.73 4.20

Motor 1 5.45 3.70 6.67 3.54 3.84 3.88 3.84 3.88

FL-N Full - NF
Take-up Pulley 3.73 4.81 3.73 5.27 3.73 4.28 3.73 4.28

Page 10 / 35
 #1 - Motor 1 36. Resultant Torque..................................0.71 kN·m
37. Estimated Pulley & Shaft Mass..................308 kg
Pulley Location and Geometry
38. Estimated Mass with Bearings...................417 kg
1. Name (Type-1)...........................................Motor 1
2. Pulley Diameter..........................................200 mm
3. Face Width...............................................1050 mm Shaft Stresses & Deflections
39. Shaft slope at hub....................................4.24 min
40. Shaft slope at bearing..............................5.92 min
Lagging
41. Shaft deflection at center.........................0.77 mm
4. Lagging Type...............................................Rubber
42. Shaft deflection at center (%).......................0.050
5. Lagging Thickness.......................................10 mm
43. Shaft Safety Factor (CEMA)..........................1.66
6. Diameter with lagging................................220 mm
44. Shaft Safety Factor (AS1403)........................2.29
45. Bending Stress.......................................39.3 MPa
Shaft Specification 46. Torsional Stress........................................1.3 MPa
7. Shaft Center Diameter................................140 mm
47. Von Mises Stress....................................39.4 MPa
8. Shaft Material.........................................SAE 1018
48. Fillet Von Mises Stress..........................29.4 MPa
9. Yield Strength........................................220.0 MPa
10. Fatigue Strength...................................200.0 MPa
Shell Dimension and Stresses
49. Shell thickness............................................22 mm
Locking Device 50. Sitzwohl reqd shell thickness1....................10 mm
11. Hub Center Distance................................905 mm
51. Sitzwohl shell stress...............................13.9 MPa
12. Shaft diameter at hub...............................140 mm
52. Shell stress at 180 wa.............................13.9 MPa
13. Turndown radius at hub................................0 mm 1
Assumes 180 deg wrap and allowable stress of 34.0 MPa
14. Locking Device...........................................XT-60
15. Size........................................................140 x 292 End Disk Dimension and Stresses
16. Hub width...................................................73 mm
53. End disk thickness......................................73 mm
17. Hub pressure........................................0.0 N/mm²
54. End disk stress.........................................9.0 MPa
18. Maximum torque.........................................0 N·m
19. Hub outer diameter...................................292 mm

Bearing Specifications
20. Bearing Center Distance........................1550 mm
21. Shaft diameter at bearing..........................115 mm
22. Bearing to Fillet Distance........................100 mm
23. Turndown radius at bearing........................38 mm
24. Bearing........................................................23226
25. SNL Plummer Block.......................................526
26. Dynamic Capacity.....................................780 kN
27. Bearing L10....................................500,000 hours

Design Tensions and Loads

28. Running T1 Tension.................................5.45 kN
29. Running T2 Tension.................................3.70 kN

30. Design T1 Tension....................................35.4 kN

31. Design T2 Tension....................................30.1 kN
32. Wrap angle................................................180 deg
33. Design Resultant Tension.........................65.7 kN
34. Resultant Angle........................................183 deg
35. Resultant Moment................................10.6 kN·m
Page 11 / 35
 #2 - Take-up Pulley 36. Resultant Torque..................................0.00 kN·m
37. Estimated Pulley & Shaft Mass..................239 kg
Pulley Location and Geometry
38. Estimated Mass with Bearings...................316 kg
1. Name (Type-2)................................Take-up Pulley
2. Pulley Diameter..........................................200 mm
3. Face Width...............................................1050 mm Shaft Stresses & Deflections
39. Shaft slope at hub....................................5.45 min
40. Shaft slope at bearing..............................7.44 min
Lagging
41. Shaft deflection at center.........................0.97 mm
4. Lagging Type...............................................Rubber
42. Shaft deflection at center (%).......................0.063
5. Lagging Thickness.......................................10 mm
43. Shaft Safety Factor (CEMA)..........................1.60
6. Diameter with lagging................................220 mm
44. Shaft Safety Factor (AS1403)........................2.17
45. Bending Stress.......................................42.1 MPa
Shaft Specification 46. Torsional Stress........................................0.0 MPa
7. Shaft Center Diameter................................120 mm
47. Von Mises Stress....................................42.1 MPa
8. Shaft Material.........................................SAE 1018
48. Fillet Von Mises Stress..........................29.1 MPa
9. Yield Strength........................................220.0 MPa
10. Fatigue Strength...................................200.0 MPa
Shell Dimension and Stresses
49. Shell thickness............................................18 mm
Locking Device 50. Sitzwohl reqd shell thickness1......................7 mm
11. Hub Center Distance................................930 mm
51. Sitzwohl shell stress...............................12.2 MPa
12. Shaft diameter at hub...............................120 mm
52. Shell stress at 180 wa.............................12.2 MPa
13. Turndown radius at hub................................0 mm 1
Assumes 180 deg wrap and allowable stress of 34.0 MPa
14. Locking Device...........................................XT-50
15. Size........................................................120 x 251 End Disk Dimension and Stresses
16. Hub width...................................................60 mm
53. End disk thickness......................................60 mm
17. Hub pressure........................................0.0 N/mm²
54. End disk stress.........................................8.5 MPa
18. Maximum torque.........................................0 N·m
19. Hub outer diameter...................................251 mm

Bearing Specifications
20. Bearing Center Distance........................1550 mm
21. Shaft diameter at bearing.........................100 mm
22. Bearing to Fillet Distance..........................93 mm
23. Turndown radius at bearing........................30 mm
24. Bearing........................................................23222
25. SNL Plummer Block.......................................522
26. Dynamic Capacity.....................................600 kN
27. Bearing L10....................................500,000 hours

Design Tensions and Loads

28. Running T1 Tension.................................3.73 kN
29. Running T2 Tension.................................4.81 kN

30. Design T1 Tension....................................23.0 kN

31. Design T2 Tension....................................23.0 kN
32. Wrap angle................................................180 deg
33. Design Resultant Tension.........................46.1 kN
34. Resultant Angle........................................357 deg
35. Resultant Moment................................7.15 kN·m

Page 12 / 35
 Belt Flap Summary
Belt flap may occur when the natural frequency of the belt matches the rotational frequency of the idlers.    If belt flap is
severe, it can destroy the idlers and increase the demand power of the conveyor. Belt flap should be avoided.

The belt flap ratio is defined as the rotational frequency of the idler divided by the natural frequency of the belt.    If this
ratio is equal to an integer (i.e. 1, 2, 3) then the idler may induce transverse vibrations at the natural frequency mode and
result in resonance.

The chart below shows the flap ratio along the length of the conveyor.    The solid green line shows flap mode of the
empty belt under the normal friction case.    The shaded pink areas should be avoided.

*
Belt flap resonance occurs at flap ratios 1, 2, 3, and 4

Page 13 / 35
 Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.

Material Trajectory

Page 14 / 35
 Belt Transition Length Requirements
The table below lists the required transition length at head and tail pulleys.    Transition lengths are based on the CEMA
7th Method.    The figure below shows the geometry of the inline transition and elevated pulley transition.

Geometry of inline and elevated pulley transition

Required transition lengths

Head pulley transition

Tail pulley transition (m)
(m)

Inline transition (L1) 1.62 1.62

Elevated pulley transition (L2) 1.08 1.08

Pulley elevation (h) 53.534 53.534

Page 15 / 35
 Material Loading Profiles

Material Properties
Type........................................................Cement, Clinker
Design Tonnage.....................................................421 t/h
Density............................................................1360 kg/m3
Maximum lump size..............................................50 mm
Surcharge angle......................................................20 deg

Tonnage..................................................................421 t/h
Belt speed............................................................1.30 m/s
Material mass....................................................90.0 kg/m
Edge distance (required / actual)...................72 / 115 mm
Cross sectional loading (utility / total)..........76 % / 52 %
Bed depth.............................................................148 mm

Page 16 / 35
 Idler Specifications

Idler Specifications

Equal Roll
Type Flat Idler
Trough

Number of rolls 3 1

Trough angle (deg) 35 0

Roll diameter (mm) 102 102

Roll length (mm) 340 994

Shaft diameter (mm) 25.0 25.0

Bearing series C4 C4

Maximum roll RPM 243 243

Min Life (1000 hrs) 350 350

95% life1 (1000 hrs) 350 350

Idler Load (N) 693.4 154.1

Mass (kg) 13.1 11.8

Rotating mass for set (kg) 10.7 9.6

Wk2 for set (kg·mm²) 23,119 21,070

Idler Spacing and Count Summary

General Carry Return

Idler spacing (m) 0.42 0.82

Number of idler sets 14 7

Number of rolls 42 7

Total drag (N) 10.2 3.4

Idler Life and Shaft Deflection Summary-Carry Side

Vertical Radius Idler Spacing Idler Calculated

# Station (m) Length (m) L Life (hours)
(m) (m) Type 10 Idler Load (N)

1 0.0 1.0 0.60 1 350,000 115

2 1.0 2.0 0.37 1 350,000 693

3 3.0 2.5 0.37 1 350,000 444

Page 17 / 35
Idler Life and Shaft Deflection Summary-Return Side

Vertical Radius Idler Spacing Idler Calculated

# Station (m) Length (m) L Life (hours)
(m) (m) Type 10 Idler Load (N)

5 5.5 1.0 0.64 2 350,000 109

6 4.5 1.5 0.90 2 350,000 133

7 3.0 2.0 1.10 2 350,000 154

8 1.0 1.0 0.60 2 350,000 106

Page 18 / 35
 Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures).    Additionally they must include any other external
loads (wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the
required live load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes
for the project.

The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and
other details. These forces must then be multiplied by the required dead load structural design safety factor requirements
(typically 1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together
to obtain the total structural design forces.

The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for
the high friction case with 0 t/h have also been included. This specific load case results in 107% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 150% for this case. The maximum tension values have
been multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum tensions
have been reduced by 10%. The resultant force values include the vertical weight of the pulley.

Structural Live Loads - Includes case with 0 t/h under steady state and dynamic conditions + 110% multiplier

Minimum Tensions (kN) Maximum Tensions (kN)

Shaft Shaft Shaft
Wrap Hub stress Center Resultant Resultant
Pulley Type T1 T2 T1 T2
(deg) Slope safety Def. Force Force
(min) factor (mm)
3.45 3.13 7.24 7.34 4.40 12.1

Take-up Pulley 2 180 1.25 1.60 0.22 3.363.78 7.51 4.106.24 10.6

Bearing Reaction Forces (excluding any overhung loads)

Bearing Horizontal Direction (kN) Bearing Vertical Direction (kN)

Structural Structural Structural Structural

Entry Exiting Pulley, FL-N FL-N
Min Max Min Max
Wrap Vector Vector Shaft & Case Case
Pulley Tension Tension Tension Tension
(deg) Angle Angle Bearings
(deg) (deg) Mass (kg)
-6.58 -9.14 -11.7 -4.09 -4.09 -4.09

7.14 8.54 10.3 -3.10 -3.10 -3.10

The idler stringer loading should be based on the flooded belt surge capacity of 814 t/h and 186.7 kg/m plus the idler and
frame masses.    Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.

Page 19 / 35
Page 20 / 35
Element Summary Details

Tension Summary

Power Summary

Page 21 / 35
 Element Summary Details
Summary of Conveyor Elements

Vertical Idler
Station Elevation Length Height Slope Idler
# Name Radius Spacing
(m) (m) (m) (m) (deg) Type
(m) (m)

1 0.0 0.00 1.0 0.00 0.00 0.60 1

2 Loading Point 1.0 0.00 2.0 0.00 0.00 0.37 1

3 3.0 0.00 2.5 0.00 0.00 0.37 1

4 Motor 1 5.5 0.00 0.8 -0.80 ---

5 5.5 -0.80 1.0 0.00 0.00 0.64 2

6 4.5 -0.80 1.5 0.05 1.91 0.90 2

7 3.0 -0.75 2.0 -0.05 -1.43 1.10 2

8 1.0 -0.80 1.0 0.00 0.00 0.60 2

9 Take-up Pulley 0.0 -0.80 0.8 0.80 ---

Page 22 / 35
 Min/Max Tension Summary per Element
Element Tension (kN)

Running Momentary

Maximum Minimum %Sag Maximum Minimum %Sag

4.81 4.81 0.19 5.43 4.20 0.22

4.83 4.83 0.96 5.50 4.17 1.09

5.30 5.07 0.88 6.12 4.17 1.12

# Name 5.45 5.14 0.00 6.67 3.84 0.00

3.70 3.70 0.27 3.91 3.48 0.29

3.70 3.70 0.38 3.87 3.53 0.40

3.72 3.72 0.46 3.83 3.60 0.48

3.72 3.72 0.25 3.77 3.68 0.25

3.73 3.73 0.00 3.73 3.73 0.00

Page 23 / 35
 Te Tension Summary per Load Cases
Belt Tension Summary per Load Case (N)

EM-N FL-N

Total (Beltline) 1,345 1,651

Total (Power) 3,193 3,504

Lift Force 0 0

Frictional Drag 1,345 1,651

Motor Pulley/Reducer Drag 1,848 1,853

Rolling Resistance 22 147

Material+Belt Flexure 0 0

Idler Bearing Drag 164 164

Idler Alignment 1 4

Pulleys & Accessories 982 982

Loading Point 175 353

Mechanical Losses 171 176

Motor Pulley Drag Components 1,677 1,677

Page 24 / 35
 Pulley Summary Table - All Cases
Pulley Geometry Details

Type 1 2

Lagging Type Rubber Rubber

Diameter (mm) 200 200

Lagging Thickness (mm) 10.0 10.0

Diameter with Lagging (mm) 220 220

Face Width (mm) 1050 1050

Shaft Center Diameter (mm) 140 120

Bearing Diameter (mm) 115 100

Bearing Center Distance (mm) 1550 1550

Plummer Block 526 522

Pulley & Shaft Mass (kg) 308 239

Locking Device XT-60 XT-50

Hub Center Distance (mm) 905 930

Hub Diameter (mm) 140 120

Bearing to Fillet Distance (mm) 100 93

Fillet Radius (mm) 38 30

Shaft Material SAE 1018 SAE 1018

Yield Strength (MPa) 220.0 220.0

Fatigue Strength (MPa) 200.0 200.0

Page 25 / 35
 Element Tension Details per Case

Element Tension Breakdown - (EM) Empty - Normal

Individual drag components per element

Running Element Pulley Feeder Extra

Running Wm+Wb Lift Force Belt Idler
# Ten Diff Tonnage Drag Pt. Force Accessory
Tension (N) (kg/m) (N) Force (N) Force (N)
(N) (t/h) Force (N) (N) Force (N)

1 4,812 19 12.7 2 17

2 4,831 235 12.7 4 55 175

3 5,066 75 12.7 5 69

4-M 5,141 -1,445 12.7 -100 890 788

5 3,696 7 12.7 2 5

6 3,704 15 12.7 6 3 6

7 3,718 4 12.7 -6 4 6

8 3,722 8 12.7 2 6

9-T 3,730 1,082 12.7 100 667 315

Element Tension Breakdown - (FL) Fully Loaded - Normal

Individual drag components per element

Running Element Pulley Feeder Extra

Running Wm+Wb Lift Force Belt Idler
# Ten Diff Tonnage Drag Pt. Force Accessory
Tension (N) (kg/m) (N) Force (N) Force (N)
(N) (t/h) Force (N) (N) Force (N)

1 4,812 19 12.7 2 17

2 4,831 470 421 102.7 60 57 353

3 5,302 145 421 102.7 74 71

4-M 5,447 -1,751 12.7 -100 890 788

5 3,696 7 12.7 2 5

6 3,704 15 12.7 6 3 6

7 3,718 4 12.7 -6 4 6

8 3,722 8 12.7 2 6

9-T 3,730 1,082 12.7 100 667 315

Page 26 / 35
 Equipment Tags and Commodity Codes
Table of major items with description, tags, and commodity codes.

Item Description Equipment Tag Commodity Code

Pulley Pulley 1

      Motor       Motor 1

      Reducer       Reducer 1

Pulley Pulley 2

Idlers Carry

Idlers Return

Belt -

Page 27 / 35
 Belt Supplier Data Sheet System Information
Type............................................................Fabric (2-Ply) Calculation method..........................................CEMA 5th
Width....................................................................900 mm Conveyor Length / Height..................................6 / 0.0 m
Rating...............................................................315 N/mm Ambient temperature...............................................10 °C
Speed...................................................................1.30 m/s
Top / bottom cover thickness.......................7.5 x 2.0 mm Material Properties
Total thickness.......................................................12 mm Type........................................................Cement, Clinker
Weight...............................................................12.7 kg/m Design Tonnage.....................................................421 t/h
Modulus.........................................................3,851 kN/m Density............................................................1360 kg/m3
Tape length...........................................................12.60 m Maximum lump size..............................................50 mm
Belt cycle time............................................................10 s Surcharge angle......................................................20 deg
Cross Sectional Loading Drive Station
Material mass (wm)............................................90.0 kg/m
Combined mass (wm + wb)..............................102.7 kg/m Type.............................................................Not Specified
Edge distance (required / actual)...................72 / 115 mm Synchronous RPM...........................................1500 RPM
Cross sectional area............................................0.066 m² Motor quantity / rating...................................1 / 5.50 kW
Cross sectional loading (utility / total)..........76 % / 52 % Total installed power...........................................5.50 kW
Bed depth.............................................................148 mm Empty / full power..................(75 / 83%) 4.15 / 4.56 kW
Maximum starting torque........................................150%
Pulley lagging type................................................Rubber
Motor wrap angles......................................................180

Idler Set Data

Carry Return
Series name C4 C4
Number of rolls 3 1
Trough angle (deg) 35 0
Type Inline Inline
Flooded belt tonnage..............................................814 t/h Idler spacing (m) 0.37 1.10
Flooded (wm + wb)...........................................186.7 kg/m

Pulley Details
Tension Summary Running Momentary Pulley diameter (Type 1)......................................200 mm
Maximum tension (kN) 5.45 6.67 Pulley diameter (Type 2)......................................200 mm
Minimum safety factor 52.05 42.50
Take-up Data
Estimated Splice Data Type.......................................................................Gravity
Location....................................................Tail / Pulley #2
Splice type..............................................................1-Step Required belt line tension.....................................3.73 kN
Splice step length.................................................200 mm Required pulley displacement................................0.62 m
22 degree bias angle.............................................365 mm
Total splice length................................................565 mm

Transition Lengths Idler Set Data

Transition method...............................................CEMA 7 Carry Return
Tail transition length (inline)..................................1.70 m Manufacture SANS-1313 SANS-1313
Head transition length (inline)...............................1.70 m Series name C4 C4
Number of rolls 3 1
Trough angle (deg) 35 0
Type Inline Inline
Idler spacing (m) 0.37 1.10
Roll diameter 102 102
Roll rpm 243 243
Total drag (N) 10.2 3.4
Roll length 340 994
Shaft diameter (mm) 25.0 25.0
Rating (N) 3,723 890
Calc Idler Load (N) 693 154
L10 life1 (1000 hrs) 350.0 350.0

Number of idler sets 14 7

Page 28 / 35
Number of rolls 42 7 System Information
Calculation method..........................................CEMA 5th
Conveyor Length / Height..................................6 / 0.0 m
Idler Set Data Ambient temperature...............................................10 °C
Impact Transition
Manufacture SANS-1313 SANS-1313 Material Properties
Series name
Type........................................................Cement, Clinker
Number of rolls 0 0
Design Tonnage.....................................................421 t/h
Trough angle (deg) 0 0
Density............................................................1360 kg/m3
Type
Maximum lump size..............................................50 mm
Idler spacing (m) 0.37 1.10
Surcharge angle......................................................20 deg
Roll diameter 0 0
Roll rpm 0 0
Total drag (N) 0.0 0.0 Cross Sectional Loading
Roll length 0 0 Material mass (wm)............................................90.0 kg/m
Shaft diameter (mm) 0.0 0.0 Combined mass (wm + wb)..............................102.7 kg/m
Rating (N) Edge distance (required / actual)...................72 / 115 mm
Calc Idler Load (N) Cross sectional area............................................0.066 m²
L10 life1 (1000 hrs) 0.0 0.0 Cross sectional loading (utility / total)..........76 % / 52 %
Bed depth.............................................................148 mm
Number of idler sets 0 0
Number of rolls 0 0
1
L10 life above which 95% of idlers exceed

Flooded belt tonnage..............................................814 t/h

Flooded (wm + wb)...........................................186.7 kg/m

Belt Supplier Data Sheet

Type............................................................Fabric (2-Ply)
Width....................................................................900 mm
Rating...............................................................315 N/mm
Speed...................................................................1.30 m/s
Top / bottom cover thickness.......................7.5 x 2.0 mm
Weight...............................................................12.7 kg/m

Tension Summary Running Momentary

Maximum tension (kN) 5.45 6.67
Minimum safety factor 52.05 42.50

Page 29 / 35
 System Information Roll diameter 102 102
Calculation method..........................................CEMA 5th Roll rpm 243 243
Conveyor Length / Height..................................6 / 0.0 m Total drag (N) 10.2 3.4
Material lift..............................................................0.0 m Roll length 340 994
Ambient temperature...............................................10 °C Shaft diameter (mm) 25.0 25.0
Rating (N) 3,723 890
Calc Idler Load (N) 693 154
Material Properties
L10 life1 (1000 hrs) 350.0 350.0
Type........................................................Cement, Clinker 1
L10 life above which 95% of idlers exceed
Design Tonnage.....................................................421 t/h
Density............................................................1360 kg/m3 Drive Station
Maximum lump size..............................................50 mm
Type.............................................................Not Specified
Surcharge angle......................................................20 deg
Synchronous RPM...........................................1500 RPM
Motor quantity / rating...................................1 / 5.50 kW
Belt Properties Total installed power...........................................5.50 kW
Type............................................................Fabric (2-Ply) Empty / full power..................(75 / 83%) 4.15 / 4.56 kW
Width....................................................................900 mm Frame Size.........................................................IEC 132S
Rating...............................................................315 N/mm Motor Voltage.............................................Not Specified
Speed...................................................................1.30 m/s Efficiency................................................................95.5%
Top / bottom cover thickness.......................7.5 x 2.0 mm Maximum starting torque........................................150%
Total thickness.......................................................12 mm Inertia - Motor...................................................0.1 kg·m²
Weight...............................................................12.7 kg/m Pulley lagging type................................................Rubber
Modulus.........................................................3,851 kN/m Motor wrap angles......................................................180
Tape length...........................................................12.60 m Lagging friction factor (run / accel).................0.32 / 0.38
Belt cycle time............................................................10 s
Take-up Data
Tension Summary Running Momentary
Type.......................................................................Gravity
Maximum tension (kN) 5.45 6.67
Location....................................................Tail / Pulley #2
Minimum safety factor 52.05 42.50
Required belt line tension.....................................3.73 kN
Minimum tension (kN) 3.70 3.48
Cable reeving ratio (trolley:counterweight).................1:1
Maximum belt sag (%) 0.96 1.12
Counterweight mass.........................................0.8 tonnes
Cross Sectional Loading
Material mass (wm)............................................90.0 kg/m Required pulley displacement................................0.62 m
Combined mass (wm + wb)..............................102.7 kg/m         Dynamic displacement (incl thermal).............0.00 m
Edge distance (required / actual)...................72 / 115 mm         Permanent elongation......................................0.08 m
Cross sectional area............................................0.066 m²         Splice length (1 included)...............................0.28 m
Cross sectional loading (utility / total)..........76 % / 52 %         Clearance.........................................................0.25 m
Bed depth.............................................................148 mm

Flooded belt tonnage..............................................814 t/h

Flooded (wm + wb)...........................................186.7 kg/m

Idler Set Data

Carry Return
Manufacture SANS-1313 SANS-1313
Series name C4 C4
Number of rolls 3 1
Trough angle (deg) 35 0
Type Inline Inline
Idler spacing (m) 0.37 1.10
Number of idler sets 14 7

Page 30 / 35
 Conveyor Profile
Overall length = 6 m - Overall height = 0.0 m - True Length = 5.5 m

Pulleys

Pulleys - Top View

Page 31 / 35
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)

Wrap Resultant Resultant

Pulley Type T1 T2 T1 T2
(deg) Force Force

5.45 3.70 9.14 6.67 3.91 10.6

Take-up Pulley 2-LT 180 3.734.81 8.54 3.735.43 9.16

T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

Pulley Shaft Results

Shaft Shaft Design Design

Bearing Pulley & Resultant Resultant Resultant Bending
Pulley Safety Slope at Deflection T1 T2
L10 Life Shaft Force Angle Torque Moment
# Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)

1 1.66 4.24 0.050 500 35.4 30.1 308 65.7 183 0.7 10.6

2 1.60 5.45 0.063 500 23.0 23.0 239 46.1 357 0.0 7.1
Design tensions for shaft fatigue are based on all design level 1 cases.    Running tensions have an added multiplier of 1.10 on high
tension pulleys, and a multiplier of 1.25 on all other pulleys.   

Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley

Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)

1 Rubber 200 10.0 220 1050 140 115 1550 526 23226 417

2 Rubber 200 10.0 220 1050 120 100 1550 522 23222 316

Pulley Shaft Information

Hub Bearing Overhung

Tensile Yield Fatigue Hub Fillet Overhung
Locking Shaft Center to Fillet Moment
Type Strength Strength Strength Diameter Radius Load
Device Material Distance Distance Arm
(MPa) (MPa) (MPa) (mm) (mm) (kN)
(mm) (mm) (mm)

1 XT-60 SAE 1018 400.0 220.0 200.0 140 905 100 38 0.0 0

2 XT-50 SAE 1018 400.0 220.0 200.0 120 930 93 30 0.0 0

Page 32 / 35
 #1 - Motor 1 36. Resultant Torque..................................0.71 kN·m
37. Estimated Pulley & Shaft Mass..................308 kg
Pulley Location and Geometry
38. Estimated Mass with Bearings...................417 kg
1. Name (Type-1)...........................................Motor 1
2. Pulley Diameter..........................................200 mm
3. Face Width...............................................1050 mm Shaft Stresses & Deflections
39. Shaft slope at hub....................................4.24 min
40. Shaft slope at bearing..............................5.92 min
Lagging
41. Shaft deflection at center.........................0.77 mm
4. Lagging Type...............................................Rubber
42. Shaft deflection at center (%).......................0.050
5. Lagging Thickness.......................................10 mm
43. Shaft Safety Factor (CEMA)..........................1.66
6. Diameter with lagging................................220 mm
44. Shaft Safety Factor (AS1403)........................2.29
45. Bending Stress.......................................39.3 MPa
Shaft Specification 46. Torsional Stress........................................1.3 MPa
7. Shaft Center Diameter................................140 mm
47. Von Mises Stress....................................39.4 MPa
8. Shaft Material.........................................SAE 1018
48. Fillet Von Mises Stress..........................29.4 MPa
9. Yield Strength........................................220.0 MPa
10. Fatigue Strength...................................200.0 MPa
Shell Dimension and Stresses
49. Shell thickness............................................22 mm
Locking Device 50. Sitzwohl reqd shell thickness1....................10 mm
11. Hub Center Distance................................905 mm
51. Sitzwohl shell stress...............................13.9 MPa
12. Shaft diameter at hub...............................140 mm
52. Shell stress at 180 wa.............................13.9 MPa
13. Turndown radius at hub................................0 mm 1
Assumes 180 deg wrap and allowable stress of 34.0 MPa
14. Locking Device...........................................XT-60
15. Size........................................................140 x 292 End Disk Dimension and Stresses
16. Hub width...................................................73 mm
53. End disk thickness......................................73 mm
17. Hub pressure........................................0.0 N/mm²
54. End disk stress.........................................9.0 MPa
18. Maximum torque.........................................0 N·m
19. Hub outer diameter...................................292 mm

Bearing Specifications
20. Bearing Center Distance........................1550 mm
21. Shaft diameter at bearing..........................115 mm
22. Bearing to Fillet Distance........................100 mm
23. Turndown radius at bearing........................38 mm
24. Bearing........................................................23226
25. SNL Plummer Block.......................................526
26. Dynamic Capacity.....................................780 kN
27. Bearing L10....................................500,000 hours

Design Tensions and Loads

28. Running T1 Tension.................................5.45 kN
29. Running T2 Tension.................................3.70 kN

30. Design T1 Tension....................................35.4 kN

31. Design T2 Tension....................................30.1 kN
32. Wrap angle................................................180 deg
33. Design Resultant Tension.........................65.7 kN
34. Resultant Angle........................................183 deg
35. Resultant Moment................................10.6 kN·m
Page 33 / 35
 #2 - Take-up Pulley 38. Estimated Mass with Bearings...................316 kg
Pulley Location and Geometry
1. Name (Type-2)................................Take-up Pulley Shaft Stresses & Deflections
2. Pulley Diameter..........................................200 mm 39. Shaft slope at hub....................................5.45 min
3. Face Width...............................................1050 mm 40. Shaft slope at bearing..............................7.44 min
41. Shaft deflection at center.........................0.97 mm
42. Shaft deflection at center (%).......................0.063
Lagging
43. Shaft Safety Factor (CEMA)..........................1.60
4. Lagging Type...............................................Rubber
44. Shaft Safety Factor (AS1403)........................2.17
5. Lagging Thickness.......................................10 mm
45. Bending Stress.......................................42.1 MPa
6. Diameter with lagging................................220 mm
46. Torsional Stress........................................0.0 MPa
47. Von Mises Stress....................................42.1 MPa
Shaft Specification 48. Fillet Von Mises Stress..........................29.1 MPa
7. Shaft Center Diameter................................120 mm
8. Shaft Material.........................................SAE 1018
9. Yield Strength........................................220.0 MPa
Shell Dimension and Stresses
49. Shell thickness............................................18 mm
10. Fatigue Strength...................................200.0 MPa
50. Sitzwohl reqd shell thickness1......................7 mm
51. Sitzwohl shell stress...............................12.2 MPa
Locking Device 52. Shell stress at 180 wa.............................12.2 MPa
11. Hub Center Distance................................930 mm 1
Assumes 180 deg wrap and allowable stress of 34.0 MPa
12. Shaft diameter at hub...............................120 mm
13. Turndown radius at hub................................0 mm End Disk Dimension and Stresses
14. Locking Device...........................................XT-50
53. End disk thickness......................................60 mm
15. Size........................................................120 x 251
54. End disk stress.........................................8.5 MPa
16. Hub width...................................................60 mm
17. Hub pressure........................................0.0 N/mm²
18. Maximum torque.........................................0 N·m
19. Hub outer diameter...................................251 mm

Bearing Specifications
20. Bearing Center Distance........................1550 mm
21. Shaft diameter at bearing.........................100 mm
22. Bearing to Fillet Distance..........................93 mm
23. Turndown radius at bearing........................30 mm
24. Bearing........................................................23222
25. SNL Plummer Block.......................................522
26. Dynamic Capacity.....................................600 kN
27. Bearing L10....................................500,000 hours

Design Tensions and Loads

28. Running T1 Tension.................................3.73 kN
29. Running T2 Tension.................................4.81 kN

30. Design T1 Tension....................................23.0 kN

31. Design T2 Tension....................................23.0 kN
32. Wrap angle................................................180 deg
33. Design Resultant Tension.........................46.1 kN
34. Resultant Angle........................................357 deg
35. Resultant Moment................................7.15 kN·m
36. Resultant Torque..................................0.00 kN·m
37. Estimated Pulley & Shaft Mass..................239 kg
Page 34 / 35
 Drive Station
Type.............................................................Not Specified
Synchronous RPM...........................................1500 RPM
Motor quantity / rating...................................1 / 5.50 kW
Total installed power...........................................5.50 kW
Empty / full power..................(75 / 83%) 4.15 / 4.56 kW
Frame Size.........................................................IEC 132S
Motor Voltage.............................................Not Specified
Efficiency................................................................95.5%
Maximum starting torque........................................150%
Inertia - Motor...................................................0.1 kg·m²
Pulley lagging type................................................Rubber
Motor wrap angles......................................................180
Lagging friction factor (run / accel).................0.32 / 0.38

Reducer Information
Manufacture................................................................N/A
Frame size...................................................................N/A
Reducer ratio..........................................................13.330
Catalog reducer ratio................................................0.000
RPM (High Speed)..........................................1500 RPM
RPM (Low Speed)..........................................112.5 RPM
Configuration................................................Shaft Mount
Number of stages............................................................3
Service factor...............................................................1.4
Power rating...............................................................0.00

Motor Torque
100% Motor Torque - High Speed........................36 N·m
Motor Shaft Torque - Running (FN).....................29 N·m
Motor Shaft Torque - Starting (FN)......................53 N·m
100% Motor Torque - Low Speed......................474 N·m
Low Speed Shaft Torque - Running (FN)...........373 N·m
Low Speed Shaft Torque - Running (Max)........373 N·m
Low Speed Shaft Torque - Starting (FN)............579 N·m
Low Speed Shaft Torque - Starting (Max)..........579 N·m

Starting and Stopping

Start control.............................................Constant torque
Start time.........................................................0.7 to 1.0 s
Emergency stop control.............................................Drift
Emergency stop time.......................................0.8 to 0.9 s
Material buildup in chute........................................0.0 m³

Demand Power (kW)

Demand % Motor
Case
power Nameplate
Empty - NF 4.2 75.5
Full - NF 4.6 82.8

Page 35 / 35