Rulmeca Motorized Pulley Power Calculation Program - Metric Version 6.25 This is a worksheet only. It is to be hidden from view.
Customer Name Conveyor Number Conveyor Length (m) Load (T/hour) Belt Speed (m/s) Material Lift Height (m) Ambient temperature (deg C) Min Ambient temperature (deg C) Max Initial Velocity of Material (m/s) Number of Belt Cleaners Number of Belt Ploughs Length of Skirt Zone (m) Depth of Mat'l in skirt zone (mm) Number of Non-driven Pulleys 0 Kg/m
100 500 2 0 -10 40 0 1 0 0 0 1 0
Elevation (Km above sea level) 1.0 Type of Material Limestone, pulv., dry Belt Width (mm) 1200 Belt Carcass Type Fabric Idler Roll diam (mm) 133 CEMA Type (A,B,C,D,E) C Troughing (carrying) Idler Spacing (m) 1.2 Required Belt Pull, Te =
5034 N
11 kW 1250 mm RECOMMENDED DRUM MOTOR 11 kW 2 m/s JOKI Model(s): 400, 500, 630 $0
ALTERNATE DUAL DRIVE OPTION 7.5 kW/ea 2 m/s JOKI Model(s): 320, 400, 500, 630 $0 0
RECOMMENDED OPTIONS:
SPECIAL NOTES:
Engineering Design Data: Ai Cs H Kt Kx Ky L Q Si Tac Tam Tb Tbc Te
8.0064 N 0.128 0m 1.06 0.74kg/m 0.031 100 m 500 mtph 1.2 m 1051 N 278 N 0N 1051 N 5034 N
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Tm Tp Tpl Tsb Ttr Tx Tyb Tyc Tym Tyr V Wb Wm
0N 96 N 0N 0N 0N 765 N 720 N 486 N 2125 N 234 N 2 m/s 15 kg/m 69 kg/m
Calculated power to drive conveyor Drive pulley bearing friction: Power at motor: Gear loss in motorized pulley: Calculated power for JOKI Derate for high elevation Required Power for motorized pulle
10.07 0.25 10.32 0.66 10.97 0.00 10.97
(Note: JOKI models above are based on 50 Hz power.)
Power savings for 3 shift/day, 50 week/yr operation (JOKI pulley compared to gearmotor & V-belt drive)
Save: 2523 Kw-Hrs/Yr, 1 shift/day or 7568 Kw-Hrs/Yr, 3 s Save: 219 €/Yr, 1 shift/day or 658 €/Yr, 3 shifts/day @ 0.
kW kW kW kW kW kW kW
n 50 Hz power.)
eek/yr operation
V-belt drive)
or 7568 Kw-Hrs/Yr, 3 sh /Yr, 3 shifts/day @ 0. 295749015.xls 11/21/2015 08:58:22
Specifier
Rulmeca Motorized Pulley Power Calculation Program - Metric Version 6.25 Specifier Sheet and Recommendation Summary 11/21/15 Date www.rulmecacorp.com www.rulmeca.com © Copyright - Rulmeca Group Telephone
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Project Name
Conveyor Reference
Go to Trajectory Sheet
Standard Loading Conditions: Conveyor Length (m) Tonnage Rate (metric tons/hour) Belt Speed (m/s) Material Lift Height (m) Ambient temperature (°C) Min Ambient temperature (°C) Max Initial Velocity of Material (m/s) Number of Belt Cleaners Number of Return Belt Scrapers Length of Skirt Zone (m) Depth of Mat'l in skirt zone (mm) Number of Non-driven Pulleys
100 500 2 0.0 -10 40 0 1
REQUIRED POWER: BELT PULL SUMMARY: Standard Loading Belt Pull Extra pull for Hopper (if any) Extra pull for Slider Bed (if any) Extra pull for Diverter or Tripper (if any) TOTAL Required Belt Pull (Te):
11 kW Force (N) 5,034 0 0 0 5,034
###
Limestone, pul
Ashes, coal, dr
Bauxite, groun
0 0 1
Elevation Above Sea Level
RECOMMENDED OPTIONS:
Cement, Portla
Cement clinke
Clay, Coal, ceramic, bitum. m
SPECIAL NOTES (if any):
1.0 Km Limestone, pulv.,dry, 0.128 Belt Width Go to Design Parameters 1200 mm Belt Carcass Type RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY: Fabric Idler Roll diameter Power: 11 kW Models Available: 133 mm CEMA Type Belt Speed: 2 m/s 400, 500, 630 C Troughing Idler Spacing Face Width: 1250 mm 1.2 meters Angle of Wrap** RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY: 180 degrees Type of Lagging Power: 7.5 kW/ea Models Available: Full Lagging Type of Take-up Belt Speed: 2 m/s 320, 400, 500, 630 Automatic Type of Belt Face Width: 1250 mm 2 ply, 225 piw Material, fric coeff
Bulk Density (Kg/m3) Limestone, crushed, Condition of Idlers & Pulleys
1,440
well maintained
** This parameter is for either single or dual drive arrangement.
Coke, ground f Cullet (broken
Grains,wheat,c Gravel, bank ru
Iron Ore, pul Limestone,
Phosphate roc Salt, dry fine,
Sand, dry, ban Wood chips,
Power savings - 1 shift and 3 shift per day: (Motorized Pulley compared to exposed conveyor belt drives)
Condition of Idlers &
Save: 2523 Kw-Hrs/Yr, 1 shift/day or 7568 Kw-Hrs/Yr, 3 shifts/day Save: 219 €/Yr, 1 shift/day or 658 €/Yr, 3 shifts/day @ 0.087 €/Kw-Hr Minimum Acceptable Diameter is 255 mm *A smaller pulley diameter may cause belt carcass or fastener damage. This calculation does not check pulley/belt traction.
Special Loading Conditions:
Belt Strength (lb
Go to Design Parameters
1. For hopper feeder specify opening dimensions below. 2. For slider bed, specify bed length and type of bed material below.
3. If belt has cleats and/or sidewalls show dimensions below. 4. If conveyor has a tripper, define tripper below. 5. If conveyor has diverter(s), define below.
1. Hopper Feeder Design Parameters Hopper opening width (mm) Hopper opening length (mm) Number of Hopper Openings
0 0 0
2. Slider Bed Design Parameters Slider Bed Length (m) Type of Slider Bed Material Slider Bed Frictional Coefficient
Theoretical Be
0
None
0
3. Sidewall & Cleated Belt Parameters: Sidewall & cleat height (mm) Thickness of sidewall (mm) Distance between cleats (mm) Thickness of cleats (mm) Extra Sidewall & Cleat Wt (incl above)
Belt Width= piw =
0 0 0 0 0 Kg/m
Belt Strength= ### 180 degrees 180 degrees 200 degrees 210 degrees
4. Tripper Design Parameters Tripper length (m) Material lift height on tripper (m) No. of belt cleaners on tripper Length of tripper skirt zone (m) Depth of material in skirt zone (mm) No. of non-driven pulleys on tripper Estimated belt tension, Te (N) Estimated factor, Ky
220 degrees
0 0 0 0
240 degrees
360 degrees (d
420 degrees (d
0 0 0 0.03
Bulk Density C
5. Material Diverter (Belt Plough) No. of diverters that work simultaneously
295749015.xls, Specifier, Page 3 of 8
Ashes, coal, w
0
Ashes, coal, w Bagasse, 10
11/21/2015 08:58:22
Rulmeca Motorized Pulley Power Calculation Program - Metric Version 6.25 Model Selector 0 0 0
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REQUIRED POWER:
11 kW
BELT PULL SUMMARY: Standard Loading Belt Pull Extra pull for Hopper (if any) Extra pull for Slider Bed (if any) Extra pull for Diverter or Tripper (if any) TOTAL Required Belt Pull (Te):
Force (N) 5,034 0 0 0 5,034
Select Model
800M Check Radial Load (to prevent internal damage to pulley) Force (N) Maximum Allowable Radial Load 73,600 Estimated Maximum Radial Load 10,068 Selected model is appropriate for estimated radial load. 0
Check Pulley Diameter (to prevent belt damage.) Minimum Acceptable Diameter is 255 mm Selected Diameter is 800 mm Selected diameter is appropriate for specified belt.
RECOMMENDED OPTIONS (if any):
SPECIAL NOTES (if any):
(This calculation does not check pulley/belt traction.) 0
Go to Design Parameters
RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY: Power: 11 kW Models Available: Belt Speed:
2 m/s
Face Width:
1250 mm
400, 500, 630
RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY: Power: 7.5 kW/ea Models Available: Belt Speed:
2 m/s
Face Width:
1250 mm
320, 400, 500, 630
Check Belt Tension Maximum Belt Tension (T1) Allowable Belt Tension 0
Force (N) 7,551 47,622
Rulmeca Motorized Pulley Power Calculation Program - Metric Version 6.25 Design Parameter Summary 0 0 0
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Power Calculation Summary
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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 T1 T1 + T2 T_L Tatype Beltype w str pstr btr Ai Cs H Kt Kx
5034 N 180 degrees 0.5 2517 N 7551 N 10068 N Full Lagging Automatic 2 ply 1200 mm 10630 N 16 % 5 to 11 mm 8.0064 N 0.128 0m 1.06 0.74kg/m
Ky L Q Si Tac Tam Tb Tbc Te Tm Tp
0.03 100 m 500 mtph 1.2 m 1051 N 278 N 0N 1051 N 5034 N 0N 96 N
Tpl Tsb Ttr Tx Tyb Tyc Tym Tyr V Wb Wm
0N 0N 0N 765 N 720 N 486 N 2125 N 234 N 2 m/s 15 kg/m 69 kg/m
10.1 0.2 10.3 0.7 11.0 0.0 0.0 11.0
kW kW kW kW kW kW kW kW
Definition of Terms
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Te = effective belt tension at drive. ang = angle of belt wrap around drive pulley(s). T2 = estimated "slack-side tension" required to keep belt from slipping on pulley surface. T1 = Te + T2 T1 + T2 = Sum of belt forces on drive pulley. NOTE: This is not a vector sum. T_L = type of lagging specified for drive pulley(s). Tatype = type of take-up specified to apply "slack-side tension". Beltype = type of belt carsass specified. w = belt width str = tensile strength of specified belt. pstr = percentage of available belt tensile strength used. btr = thickness range of specified belt Ai = belt tension required to overcome frictional resistance and rotate idlers. Cs = skirtboard friction factor. H = vertical distance that material is lifted or lowered. Kt = ambient temperature correction factor. Kx = factor to calculate frictional resistance of the idlers and the sliding resistance between belt and idler rolls. Ky = factor to calculate resistance of belt and resistance of load to flexure as they move over idlers. L = length of conveyor. Q = tons per hour conveyed. Return to Specifier Sheet Si = troughing idler spacing. Tac = total of the tensions from conveyor accessories. Tam = tension required to accelerate the material continuously as it is fed onto belt. Tb = tension required to lift or lower the belt. Tbc = tension required to overcome belt cleaner drag. Te = effective belt tension at drive. Tm = tension required to lift or lower conveyed material. Tp = tension required to overcome resistance of belt to flexure around pulleys and resistance of pulleys to rotate on their bearings. Tpl = tension required to overcome belt plow drag. Tsb = tension required to overcome skirtboard drag. Ttr = tension required to overcome special loading condition(s.) Tx = tension required to overcome carrying and return idler friction. Tyb = total of tensions due to resistance of belt to flexure as it rides over carrying and return idlers. Tyc = tension due to resistance of belt to flexure as it rides over carrying idlers. Tym = tension due to resistance of material to flexure as it rides over carrying idlers. Tyr = tension due to resistance of belt to flexure as it rides over return idlers. V = design belt speed. Wb = weight of belt per unit of length of conveyor. Return to Specifier Sheet Wm = weight of material per unit of length of conveyor.
295749015.xls, Design Parameters, Page 5 of 8
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Rulmeca Motorized Pulley Power Calculation Program - Metric Version 6.25 Conveyor Height Calculator Inclined conveyor length (m) Angle of inclination (degrees) Material lift height (m)
9 18 2.8
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Rulmeca Motorized Pulley Power Calculation Program - Metric Version 6.25 Bulk Handling Belt Conveyor Terminology www.rulmeca.com
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Conveyor Profile
© Copyright - Rulmeca Group
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Conveyor Cross Section in Skirt Zone
Initial Velocity of Material
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Belt Conveyor with Tripper
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Return to Specifier
Hopper Feeder Conveyor
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Cleated Belt with Sidewalls
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Belt Conveyor with Two Diverter(s)
"CEMA" Idler Type Definitions
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(Based on Conveyor Equipment Manufacurters Association Manual)
Belt Width Idler Type > Idler (deg) > 460 610 760 915 1070 1220 1370 1525 1830 2130 2440
A 35 136 136 127 116 -
20 136 136 136 125 -
45 136 131 122 112 -
20 186 186 186 186 177 172 -
B 35 186 186 186 186 165 160 -
45 186 186 186 180 159 155 -
Idler Load Ratings* (kg) C 20 35 45 408 408 408 408 408 408 408 408 408 408 380 367 386 359 347 363 337 327 340 317 306 318 295 286 -
20 544 544 544 544 544 544 522 476 -
D 35 544 544 544 544 544 506 485 443 -
45 544 544 544 544 544 490 469 429 -
20 816 816 816 816 816 816 816 816 816 794
E 35 816 816 816 816 816 816 816 816 759 738
45 816 816 816 816 816 816 816 816 735 714
*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.
Return to Specifier Return to Trajectory Sheet
Material Surcharge Angle Guide (Based on Conveyor Equipment Manufacurters Association Manual)
Surcharge Angle
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 weight, 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, and tempered foundry sand.
30
295749015.xls, Terminology, Page 7 of 8
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Rulmeca Motorized Pulley Power Calculation Program - Metric Version 6.25 Bulk Handling Trajectory Calculator and Plotter (based on CEMA 5th Edition) 0 0 0
0 Phone Project Name Conveyor Ref.
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System Design Parameters: Belt Width
Material Trajectory: Small Pulley (scale: 75 mm/increment)
1200 mm
Belt Wid
Troughing Idler Angle
35° 35°
Pulley La
Diameter Pulley (mm)
516 mm 500
Lagging
Lagging Thickness (MM)
8 mm 8
Belt Speed
2.06 m/s
Surcharge Angle (degrees)
25 25 deg.
Tonnage Rate (MTPH)
Actual B
500 1,440
Material Density (Kg/m3) Belt Thickness (mm)
8
Distance to Chute Plate (mm)
700
Angle of Conv. Inclination (deg) Alternate Belt Speed (m/s)
Surcharge angle (deg Tonnage Rate (metric tp Belt Speed (fpm) Material Density (kg/cu Area A (sq ft)
0 1.4
Print This Sheet
Go to Large Pulley Sheet
Design Trajectory - solid red line; Alternate speed - dotted blue.
Go to Overview Sheet
0
Calculated Results: Calc'd mat'l height at centerline Calc'd actual height of C.O.G.*
119 mm 48 mm
Calc'd actual mat'l cross section
4.7 sq m
CEMA Max Allow. height at center
231 mm
CEMA Max Height of C.O.G.* CEMA Max Allow. cross section
Mat'l Cross Section at Pulley Face: Small Pulley (scale: 75 mm/increment)
Pulley Diam Lagged ( Pulley radius Lagged ( Belt Thickness (in) Radius to Belt Top (in
94 mm 18.1 sq m
Note: This program uses actual C.O.G.* height above top of belt (based on actual cross section) to plot trajectory. Height of C.O.G. for CEMA max. allow. cross section is given for ref. only.
Design Cross Section - dotted red line; CEMA max allow. - solid black line. *C.O.G. = center of gravity of material, shown as ∆ and ∆
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