Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Specifier Sheet and Recommendation Summary 01/07/15
Date
Telephone
Telefax
e-mail
6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com © Copyright Copyright - Rulmeca Corp.
Project Name
Conveyor Reference
Standard Loading Conditions: Conveyor Length (ft) Tonnage Rate (tons/hour) Belt Speed (fpm) Material Lift Height (ft) Ambient temperature (°F) Min Ambient temperature (°F) Max Initial Velocity of Material (fpm) Number of Belt Cleaners Number of Return Belt Scrapers Length of Skirt Zone (ft) Depth of Mat'l in skirt zone (in) Number of Non-driven Pulleys
1000 800 300 -10 100 1 12 3 4
Elev. Above Sea Level (ft) Mat'l, friction coeff
3300 ft
Coal, bitum. mined,
Bulk Density (pcf) Size Consist
0.075
Coal, lignite, 45 pcf
REQUIRED POWER: BELT PULL SUMMARY: Standard Loading Belt Pull Extra pull for Hopper (if any) Extra pull for Slider Bed (if any) any) Extra pull for Diverter or Tripper (if any) TOTAL Required Belt Pull (Te):
44.9 HP Force (lbs) 4,714
4,714
RECOMMENDED OPTIONS:
SPECIAL NOTES: M i n i m u m a l l o w a b l e b e lt lt w i d t h f o r l u m p s i z e i s 1 2 in in M i n i m u m A c c e p t a b l e D i am am e t e r i s 1 4 i n . *
Avg is 50% Max Lump Size
Max. Lump Size (in)
2
Material Surcharge Angle Belt Width
25 deg.
Belt Carcass Type
Fabric
Idler Roll diameter
5 in
42 in
Troughing Idler Spacing
50HP
Models Available:
Belt Speed:
300 FPM
630
Face Width:
43.31 in.
4 ft
Angle of Wrap**
180 degrees
Type of Lagging
Partial (2/3)
RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY: Power:
25 HP/each
Models Available: 500
Automatic
Belt Speed:
300 FPM
2 ply, 225 piw Head
Face Width:
43.31 in.
Type of Take-up Drive Location
Power:
C
CEMA Type
Type of Belt
*A smaller pulley diameter diameter may cause belt carcass or fastener fastener damage.
RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:
Elevating or Horizontal Material Flow well maintained Condition of Idlers & Pulleys
(Motorized Pulley comp ared to exposed mot or, gearbox, V-belt V-belt conveyor drives)
Type of Dual Drive, if any
Save:
9135 Kw -Hrs/Yr, 1 shif t/day or 27404 27404 Kw -Hrs/Yr, 3 shift s/day
Save:
$731 /Yr, 1 shift/day or $2192 /Yr, 3 shifts /day @ $0.08/Kw-Hr $0.08/Kw-Hr
none
** This parameter is for either single or dual drive arrangement.
Power savings - 1 shift and 3 shift per day:
Special Loading Conditions: 1. For hopper feeder specify opening opening dimensions below. 2. For slider bed, specify bed length & type of bed mat'l below. below. 3. If belt is driven on return run, specify drive pulley location.
4. If belt has cleats and/or sidewalls show s how dimensions below. 5. If conveyor has a tripper, tripper, define tripper below. 6. If conveyor has diverter(s), define below.
1. Hopper Feeder Design Parameters Hopper opening width (in) Hopper opening length (in)
5. Tripper Design Parameters Tripper length (ft) Material lift height on tripper (ft) (ft) No. of belt cleaners on tripper Length of tripper skirt zone (ft)
2. Slider Bed Design Parameters Slider Bed Length (ft) Type of Slider Bed Material Slider Bed Frictional Coefficient
4. Sidewall & Cleated Belt Parameters: Sidewall & cleat height (in) Thickness of sidewall (in) Distance between cleats (in) Thickness of cleats (in) Extra Sidewall & Cleat Wt (incl above)
None
3. Drive Pulley Location ("return run" drive only) Conveyor Length, tail to drive snub (ft) Height, top of tail to bottom of drive (ft)
\\vboxsrv\conv ersion_tmp\scratch_2\256611390.xls.ms_office, Specifier, Page 1 of 8
Depth of material in skirt zone (in) No. of non-driven pulleys on tripper Estimated belt tension, Te (lbs) Estimated factor, Ky
0.03
6. Material Diverter (Belt Plow) No. of diverters that work simultaneously
1/7/2015 12:42 PM
Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Model Selector 01/07/15
Date
Telephone
Telefax
e-mail
Project Name
Conveyor Conveyor Reference
6508-B Windmill Way Wilmington, Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com © Copyright - Rulmeca Corp.
REQUIRED POWER:
44.9 HP Select Model
BELT PULL SUMMARY: Standard Loading Loading Belt Pull Extra pull for Hopper Hopper (if any) any) Extra pull for Slider Slider Bed (if any) any) Extra pull for Diverter Diverter or Tripper (if any) TOTAL Required Belt Pull (Te): (Te):
Force (lbs) 4,714
4,714
320H Check Radial Load (to prevent internal damage to pulley) Maximum Allowable Radial Load Estimated Maximum Radial Load**
Force (lbs) 7,868 10,466
Error: Selected mod el is incorrect. Choos e stronger or larger model to handle estimated radial load.
RECOMMENDED OPTIONS (if a ny):
Check Pulley Diameter (to prevent belt damage.) Minimum Acceptable Diameter is 14 in. Selected Diameter is 12.64 in Error: selected diameter is incorrect.
SPECIAL NOTES (if any):
Choos e larger diameter to prevent belt or fastener fastener damage.
Minimu m allowable belt width for lum p size is 12 12 in Minimu m Ac ceptable Diameter is 14 in. *
Check Maximum Belt Tension prevent belt damage) Maximum Belt Tension (T1) Allowable Fabric Belt Tension
*A smaller pulley diameter may cause belt carcass or fastener damage.
(to Force (lbs) 7,590 9,450
RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY: Power: Belt Speed: Face Width: Models Available:
50HP 300 FPM 43.31 in. 630
Belt Tension Calculation Summary Te, effective belt tension T2, to prevent belt/pulley slippage T2, to limit belt sag to 2 % T1, maximum belt tension
Force (lbs) 4,714 2,876 2,808 7,590
**Measured **Measured at Drive A in Dual Drive, if applicable. C a l c u l at at i o n f o r " D u a l D r i v e o n C ar ar r y S i d e " i s u n d e r c o n s t r u c t i o n .
RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY: Power: Belt Speed: Face Width: Models Available:
25 HP/each 300 FPM 43.31 in. 500
Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Bulk Handling Trajectory Calculator and Plotter (based on CEMA 5th Edition)
1/7/15
Date
Phone
6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com
Fax
© Copyright - Rulmeca Corp.
Project Name Conveyor Ref.
System Design Parameters: Belt Width Troughing Idler Angle Diameter Pulley (in) Lagging Thickness (in)
35° 13.26 in 0.31 in
Belt Speed
300 fpm
Surcharge Angle
25 deg.
Tonnage Rate (TPH)
800
Material Density (pcf)
45
Belt Thickness (in) Distance to Chute Plate (in)
0.75 24
Angle of Conv. Conv. Inclination Inclination (deg) (deg) Alternate Belt Speed (fpm)
Material Trajectory:
42 in
350
Small Pulley (scale: inches) 18 15 12 9 6 3 0 -3 -6 -9 -12 -15 -18 -21 -24
2 7
2 4
2 1
1 8
1 5
1 2
9
6
3
0
3
6
9
1 1 2 5
1 8
2 1
2 4
2 7
3 0
3 3
3 6
3 9
Design Trajectory - red red line; line; Alternate speed - blue blue.. WARNING: Material cross section exceeds CEMA allowable maximum.
Calculated Results: Calc'd mat'l height at centerline
9 in
Calc'd actual height of C.O.G.* C.O.G.*
4 in
Calc'd actual mat'l cross section
271.1 sq ft
CEMA Max Allow. height at center
8 in
CEMA Max Height of C.O.G.*
3 in
CEMA Max Allow. Allow. cross section
211.8 sq ft
Mat'l Cross Section at Pulley Face: Small Pulley (scale: inches) 9 6 3 0
Note: This program uses actual C.O.G.* height above top of belt (based on actual actual cross section) section) to plot
-3
1 8
1 5
1 2
9
6
3
0
3
6
9
1 2
1 5
1 8
trajectory. trajectory. Height of C.O.G. for CEMA max. allow. cross cross section is given for ref. only. only.
Design Cross Section - red red line; line; CEMA max allow. - b lack line. *C.O.G. = center center of gravity of material, material, shown as
\\vboxsrv\conversion_tmp\scratch_2\256611390.xls.ms_office, trajectory, Page 3 of 8
and
1/7/2015 12:42 PM
Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Material Cross Section Plotter 1/7/15
Date
6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com
Fax
Phone
© Copyright - Rulmeca Corp.
Reference Name Conveyor Number
Cross Section at Troughing Idler: Narrow Belt (scale: inches)
System Design Parameters: Tonnage Rate (tph) Belt Speed (fpm) Bulk Density (lbs/cu ft) Material Surcharge Angle
800 300 45 25 degrees
Belt Width
42 in.
Idler Angle
35 degrees
15 12 9 6 3
Material Geometry Geometry in Troughing Idler: CEMA Max. Allow. Cross Section
1.5 sq ft
Calculated Cross Section
1.9 sq ft
0 -3
1 5
1 2
9
6
3
0
3
6
9
1 2
Calc'd Xsec/CEMA Xsec
131%
CEMA Standard Edge Distance
3.2 in
Calculated Edge Distance
0.8 in
Legend: Solid Line is CEMA Max. Allowable; Red Red Line Line is Calculated.
Calc Calc'd 'd Mat Material rial Heig Height ht at Cent Center erlline ine
11 in
Warning: Specified Specified Material Cross Cross Section Exceeds Exceeds CEMA Max. Allowable. Allowable.
Material Geometry Geometry at Pulley Discharge: Calculated Cross Section
2 sq ft
Material Height at Centerline
#DIV/0!
Height of Center of Gravity (A1)
#DIV/0!
Assumed Edge Distance
0.41 in
Calculated Surcharge Angle
0 deg
CEMA Max. Allow height at center CEMA Max Height of C.O.G. CEMA Standard Edge Distance
7.8 in. 3.1 in. 1.61 in
Note: This program calculates calculates height of actual actual C.O.G.* by assuming assuming that actual edge distance at at pulley face equals 1/2 1/2 of actual edge distance distance in trough section. Height of C.O.G.* for CEMA maximum allowable cross section section pulley face is given for reference only.
1 5
Cross Section at Pulley Face: Narrow Belt (scale: inches) 9 6 SSX 3.1
3 0.00 0 -3
1 8
1 5
1 2
9
6
3
0
3
6
9
1 2
1 5
1 8
Legend: Solid Line is CEMA Max. Allowable; Red Red Line Line is Calculated.
* C.O.G. = center of gravity of material
\\vboxsrv\conversion_tmp\scratch_2\256611390.xls.ms_office, Page 4 of 8
1/7/2015 12:42 PM
Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Material Cross Section Plotter 1/7/15
Date
6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com
Fax
Phone
© Copyright - Rulmeca Corp.
Reference Name Conveyor Number
System Design Parameters: Tonnage Rate (tph) Belt Speed (fpm) Bulk Density (lbs/cu ft) Material Surcharge Angle
800 300 45 25 degrees
Belt Width
42 in.
Idler Angle
35 degrees
Cross Section at Troughing Idler: Wide Belt (scale: inches) 42 36 30 24 18 12 6
Material Geometry Geometry in Troughing Idler: CEMA Max. Allow. Cross Section
1.5 sq ft
Calculated Cross Section
1.9 sq ft
0 -6
4 2
3 6
3 0
2 4
1 8
1 2
6
0
6
1 2
1 8
2 4
3 0
3 6
4 2
Calc'd Xsec/CEMA Xsec
131%
CEMA Standard Edge Distance
3.2 in
Calculated Edge Distance
0.8 in
Legend: Solid Line is CEMA Max. Allowable; Red Red Line Line is Calculated.
Calc Calc'd 'd Mat Material rial Heig Height ht at Cent Center erlline ine
11 in
Warning: Specified Specified Material Cross Section Exceeds CEMA Max. Allowable. Allowable.
Cross Section at Pulley Face: Wide Belt (scale: inches)
Material Geometry Geometry at Pulley Discharge: Calculated Cross Section
2 sq ft
Material Height at Centerline
#DIV/0!
Height of Center of Gravity (A1)
#DIV/0!
Assumed Edge Distance
0.41 in
Calculated Surcharge Angle
0 deg
CEMA Max. Allow height at center CEMA Max Height of C.O.G. CEMA Standard Edge Distance
7.8 in. 3.1 in. 1.61 in
Note: This program calculates calculates height of actual actual C.O.G.* by assuming assuming that actual edge distance at at pulley face equals 1/2 1/2 of actual edge distance distance in trough section. Height of C.O.G.* for CEMA maximum allowable cross section section pulley face is given for reference only.
18 12 6
-6
3.1
0.00
0
4 8
4 2
3 6
3 0
2 4
1 8
1 2
6
0
6
1 2
1 8
2 4
3 0
3 6
4 2
4 8
Legend: Solid Line is CEMA Max. Allowable; Red Red Line Line is Calculated.
* C.O.G. = center of gravity of material
\\vboxsrv\conversion_tmp\scratch_2\256611390.xls.ms_office, Page 5 of 8
1/7/2015 12:42 PM
Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Design Parameter Summary 01/07/15
Date
Telephone
Telefax
e-mail
6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com © Copyright - Rulmeca Corp.
Project Name
Conveyor Reference
Power Calculation Summary Calculated power to drive conveyor belt : Drive pulley bearing friction: Power at motor: Gear loss in motorized pulley: Calculated power Derate for high elevation Derate for high temperature Required Power for motorized pulley:
Symbol
Value
Te ang Cw T2
4714 lbs 180 degrees 0.61 2876 lbs.
T1 T1 + T2 T_L Tatype Bel ty type w str pstr btr Ai Cs H Kt Kx Ky L Q Si Tac Tam Tb Tbc Te Tm Tp Tpl Tsb Ttr Tx Tyb Tyc Tym Tyr V Wb Wm Sag Ls Hd
42.9 HP 0.6 HP HP 43.5 HP 1.4 HP HP 44.9 HP HP HP 44.9 HP
Definition of Terms
Te = effective belt tension at drive. ang = angle of belt wrap around drive pulley(s). Cw = "wrap factor", to determine slack side tension to prevent belt slippage on drive pulley. T2 = estimated slack-side tension required to either keep belt from sli pping on pulley surface or maintain trough at allowable sag percentage, whichever is greater. 7590 lbs T1 = Te + T2 10466 lbs T1 + T2 = Sum of belt forces on drive pulley. NOTE: This is not a vector sum. Partial (2/3) T_L = type of lagging specified for drive pulley(s). Automatic Tatype = type of take-up specified to apply "slack-side tension". 2 ply, 225 piw Beltype = type of belt carsass specified. 42 in. w = belt width 9450 lbs. str = tensile strength of specified belt. 80 % pstr = percentage of available belt tensile strength used. 3/16 to 7/16 in. btr = thickness range of specified belt 1.8 lbs Ai = belt tension required to overcome frictional resistance and rotate idlers. 0.0754 Cs = skirtboard friction factor. 0 ft H = vertical distance that material is lifted or lowered. 1.59 Kt = ambient temperature correction factor. Kx = factor to calculate frictional resistance of the idlers and the sliding resistance between 0.52 lbs/ft belt and idler rolls. 0.03 Ky = factor to calculate resistance of belt and resistance of load to flexure as they move over idlers. 1000 ft L = length of conveyor. 800 tph Q = tons per hour conveyed. 4 ft Si = troughing idler spacing. 290 lbs Tac = total of the tensions from conveyor accessories. 69 lbs Tam = tension required to accelerate the material c ontinuously as it is f ed onto belt. 0 l bs Tb = tension required to lift or lower the belt. 210 lbs Tbc = tension required to overcome belt cleaner drag. 4714 lbs Te = effective belt tension at drive. 0 l bs Tm = tension required to lift or lower conveyed material. Tp = tension required to overcome resistance of belt to flexure around pulleys and resistance 160 lbs of pulleys to rotate on their bearings. 0 l bs Tpl = tension required to overcome belt plow drag. 80 lbs Tsb = tension required to overcome skirtboard drag. 0 l bs Ttr = tension required to overcome special loading condition(s.) 824 lbs Tx = tension required to overcome carrying and return idler friction. 831 lbs Tyb = total of tensions due to resistance of belt to flexure as it rides over carrying and return idlers. 545 lbs Tyc = tension due to resistance of belt to flexure as it rides over carrying idlers. 2541 lbs Tym = tension due to resistance of material to flexure as it rides over carrying idlers. 286 lbs Tyr = tension due to resistance of belt to flexure as it rides over return idlers. 300 fpm V = design belt speed. 12 lbs/ft Wb = weight of belt per unit of length of conveyor. 89 lbs/ft Wm = weight of material per unit of length of conveyor. 2.0% Sag = recommended maximum sag percentage to avoid spillage in troughed section of belt. Ls = Length of conveyor from tail pulley to Drive snub (for return run drive only) Hd = Height of conveyor from top of tail pulley to bottom of driv e pulley (for return run drive only)
\\v boxsrv \conv ersion_tmp\scratch_2\256611390.xls.ms_office, Design Parameters, Page 6 of 8
1/7/2015 12:42 PM
Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Bulk Handling Belt Conveyor Terminology
6508-B Windmill Way Wilmi ngton, NC 28405 Ph 910-794-9294 Fax 910-794-9296 www.rulmecacorp.com © Copyright - Rulmeca Corp.
Conveyor Profile Initial Velocity of Material
Conveyor Cross Section in Skirt Zone
Belt Conveyor with Tripper
Hopper Feeder Conveyor
Cleated Belt with Sidewalls
Belt Conveyor with Two Diverter(s)
"CEMA" Idler Type Definitions (Based on Conveyor Equipment Manufacturers Association Manual)
Belt Width Idler Type > Idler (deg) > 18 24 30 36 42 48 54 60 72 84 96
20 300 300 300 275 -
A 35 300 300 280 256 -
45 300 289 270 248 -
20 410 410 410 410 390 380 -
B 35 410 410 410 410 363 353 -
Idler Load Ratings* (lbs) C 45 20 35 45 20 410 900 900 900 410 900 900 900 1200 410 900 900 900 1200 396 900 837 810 1200 351 850 791 765 1200 342 800 744 720 1200 750 698 675 1200 700 650 630 1150 1050 -
D 35 1200 1200 1200 1200 1200 1116 1070 977 -
45 1200 1200 1200 1200 1200 1080 1035 945 -
20 1800 1800 1800 1800 1800 1800 1800 1800 1800 1750
E 35 1800 1800 1800 1800 1800 1800 1800 1800 1674 1628
45 1800 1800 1800 1800 1800 1800 1800 1800 1620 1575
*These ratings are for three-equal-roll idlers and are based on a 30,000 hour minimum BU bearing life at 500 RPM. BU bearing life represents the statistical point in hours where a minimum of 90% of the bearings will still be functional with no increase in torque or noise.
Material Surcharge Angle Guide (Based on Conveyor Equipment Manufacurters Association Manual)
Angle of Repose
Description of Material
5
0 to 19
Uniform size, very small rounded particles, either very wet or very dry; such as dry silica sand, cement, and wet concrete.
10
20 to 29
Rounded, dry polished particles, of medium weight, such as whole grain and beans.
20
30 to 34
Irregular, granular or lumpy materials of medium w eight, such as anthracite coal, cottonseed meal, and clay.
25
35 to 39
Typical common materials such as bituminous coal, stone, and most ores.
40+
Irregular, stringy, fibrous, interlocking material, such as wood chips, bagasse, bagasse, and tempered foundry sand.
Surcharge An le
30
\\vboxsrv\conversion_tmp\scratch_2\256611390.xls.ms_office, Terminology, Page 7 of 8
1/7/2015 12:42 PM
Rulmeca Motorized Pulley Power Calculation Program - Standard Version 6.03 Conveyor Height Calculator
Inclined conveyor length (ft) Angle of inclination (degrees) Material lift height (ft)
6508-B Windmill Way Wilmington, NC 28405 Ph 910-794-9294
Fax 910-794-9296 www.rulmecacorp.com © Copyright - Rulmeca Corp.
\\vboxsrv\conversion_tmp\scratch_2\256611390.xls.ms_office, Lift Height, Page 8 of 8
1/7/2015 12:42 PM
