CALCULATIONS SUMMARY SHEET

Engineer's Stamp

Project: Item:

Project #: Calculations by: cdk Checked by:

Rev.#: Date: Date:

BELT CONVEYOR AND BELT FEEDER DRIVE SIZING CALCULATIONS

The reference material for this spreadsheet consists of CEMA's 4th Edition of Belt Conveyors for Bulk Materials from which all of the lookup values are obtained. CEMA 4th Edition Table or Figure or Page

BELT CAPACITY Required Conveying Rate: Material Conveyed: Material Density: Angle of Repose: Angle of Surcharge: Belt Width: Trough Angle (0 for flat belt): Maximum Load Cross Sectional Area: Maximum Belt Capacity: Maximum Lump Size: Belt Speed: Design: Minimum to Handle Design Capacity: Maximum Capacity at Design Speed:

24.00 Sand 30.0 45.0 30.0 36.0 0.0 1.1420 6,857.00 0.2

tph lb/ft deg deg in deg ft2 ft3/hr/100fpm in

3

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Table 3-3 Table 3-3 Table 3-3 Table 3-1 Figure 4-1 Tables 4-2 to 4-5 Tables 4-2 to 4-5

25.0 fpm 23.3 fpm 25.714 TPH

<< input Table 4-1 Should be less than design

IDLER DESIGN (Only Belt Weight Wb req'd for Pan Belt Conveyors) Troughing Idler Info: Diameter 4.0 in Class (A-E) C Load Rating 837.0 lb Si, Load Idler Spacing: 4.000 ft Return Idler Spacing: 10.0 ft K1, Lump Adjustment Factor: 1.00 K2, Environmental & Maintenance Factor: 1.15 K3, Service Factor: 1.20 K4, Belt Speed Factor: 0.85 W b, Belt Unit Weight: ** 9.0 lb/ft W m, Material Unit Weight: Max Material Weight 34.26 lb/ft Actual Material Weight 32.00 lb/ft Idler Load (Max material weight): 173.04 lb Adjusted Idler Load (Max material weight): 202.98 lb Suitability of Idler Selection: Selection is OK

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Tables 5-8 to 5-12 Tables 5-8 to 5-12 Table 5-2 Table 5-2 Table 5-4 Table 5-5 Table 5-6 Table 5-7 Table 6-1

COOK ENGINEERING

Te, EFFECTIVE TENSION Conveyor is Pan Type (Y or N): Coefficient of Dynamic Friction: # of Plows: # of Belt Cleaners (Scraper Type): L, Length of Conveyor (3000 ft maximum): H, Lift of Conveyor (Negative for Declining): # of Tight Side Non-Driving Pulleys: # of Slack Side Non-Driving Pulleys: Belt Material (Fabric or Steel): Approximate Tight Side Tension (Iterate): Approximate Slack Side Tension (Iterate): Number of drive pulleys: Lb, Length of Skirtboards (1 Side): Kt, Temperature Factor: Ai: Kx: Ky: Material velocity component in direction of belt travel as it is fed onto conveyor: Cs, Skirtboard Friction Factor: Hopper used to regulate flow of material (Y or N)? w, Width of Hopper Outlet: l, Length of Hopper Outlet: Tp, Tension From Non-Driving Pulleys: Tam, Tension from Acceleration: Tsb, Skirtboard Tension: Ttr, Tripper Tension: Tpl, Plow Tension: Tbc, Belt Cleaner Tension: Tension required to extract material from hopper (normal operation): Tension from belt on slide (Pan Conveyor Only): Te, Effective Tension (Required for Operation):

N 0.45 0.0 1.0 40.0 ft 15.0 ft 0.0 0.0 Fabric 29,040.0 lbs 15,840.0 lbs 1.0 8.0 ft 1.0 1.8 0.48 lb/ft 0.028 300.0 0.0095 N 0.0 0.0 0.0 fpm

<< input << input Pan Conveyor Only << input << input << input << input << input << input << input << input from below << input from below << input << input << input << input << input << input << input << input << input << input Fig 6-1 Page 76 Tables 6-2, 6-3 Calculate Table 6-7

in in lb

-1.9 lb 49.0 lb 0.0 lb 0.0 lb 180.0 lb 0.0 lb 0.0 lb 777.2 lb << input Page 84

**** Manual entry for this conveyor ***

BELT SELECTION Angle of Wrap, Drive Pulley: Wrap Factor Cw: (Lagged) T2, Slack-Side Tension Required to Prevent Slip with Dry Belt (higher for wet conditions): Allowable percent sag of belt: T0, Required Belt Tension to Reduce Sag: T1, Operating Maximum Belt Tension: Maximum Belt Tension per inch (operating): Maximum Allowable Starting Tension:

180.0 deg 1.20 932.6 lb 2.00 % 1,033.2 lb 1,709.8 lb 47.5 lb/in 330.0 lb/in

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Table 6-8

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Table 6-10 Calc's p. 102-110 Manufacturer

COOK ENGINEERING

MOTOR SELECTION Operating Shaft Power Required from Te: Drive pulley friction loss horsepower: Speed Reduction Efficiency: Motor and Power Supply Efficiency: Operating Motor Power Required: Effective Tension Required for Starts: Percentage Full Load Torque req'd for Starts: Breakaway Torque Required for Starting: Selected Motor Horsepower: Selected Motor RPM: Motor Locked Rotor Torque (percentage of rated full load torque. Use 140% max for VFD applications, check with manufacturer): Motor Pull Up Torque (percentage of rated full load torque, check with manufacturer): Motor Rated Full Load Torque: Breakaway Torque Available for Starting: Minimum Pull Up Torque Available: Breakaway Torque Sufficient for Starting: Pull Up Torque Sufficient for Acceleration: Selected Motor and Drive O.K.: Reduced Torque Starting Required: YES YES YES YES

0.6 0.13 98.5 99.0 0.7

hp hp % % hp

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Manufacturer

1,074.4 lbs 138.2 % 3.1 ft-lbs 10.0 hp 1,750.0 rpm << input << input

250.0 % 175.0 30.0 75.0 52.5 % ft-lbs ft-lbs ft-lbs

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Table 13-1 Table 13-5

Notes and Comments:

1. This design method does not cover conveyors of over 3000 feet length, horizontally curved conveyors, head and tail driven conveyors, high lift conveyors, large decline with braking requirements or conveyors with undulating geometrics. 2. This design method uses actual expected belt loading. It is worthwhile checking the horsepower requirements for a fully loaded belt in case of future higher capacity requirements. 3. Motor starting torque characteristics and conveyor acceleration should be checked in depth to ensure compatibility between motor and conveyor.

Page 16

Page 119

PULLEY SELECTION (Based on Dodge PT-Components Engineering Catalog:) Selected Motor Horsepower: 10.0 hp Pulley Face Width: 38 Inches Design Bearing Center to Center: 51.00 Inches BCMF: 13.00 Te (Effective Tension): 13,200.0 lbs Drive Factor: (1.2 for bare manual, 0.8 for lagged) 1.2 T2 (Slack Side Tension): 15,840.0 lbs T1 (Tight Side Tension): 29,040.0 lbs Design PIW (Drive Side): 806.7 lbs per inch Design PIW (Slack Side): 440.0 lbs per inch Arc of Contact: 180.0 degrees Tail Pulley Diameter: (Ext'g., Bare) 20.0 Inches Drive Pulley Diameter: (Lagged, 1/4") 24.5 Inches Check on Tail Pulley to Belt Tension 275 lbs per inch Check on Drive Pulley to Belt Tension 345 lbs per inch Selected Tail Pulley Size O.K.: NO Selected Drive Pulley Size O.K.: NO SHAFT SELECTION (Based on Dodge PT-Components Engineering Catalog:) Resultant Pulley Load (Tail): 28,321.8 lbs COOK ENGINEERING Resultant Pulley Load (Drive): 40,122.6 lbs Design Drive Pulley Shaft Size: 2.9375 Inches

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Table 2 pg.13-52

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Table 1 pg.13-12 Table 1 pg.13-12 Manufacturer Manufacturer

3 << input Manufacturer

Design Tail Pulley Shaft Size: Check on Drive Shaft Load Rating: Check on Tail Shaft Load Rating: Design Steel Shafting Grade: (1045) Valve N Adrive (use Table 4 to choose correct A calc.) KB-drive (KB = 1.5 or KB = 2.5 for Overhung load) Check on Drive Pulley Shaft from Torque: Atail (use Table 4 to choose correct A calc.) KB-tail (KB = 1.5 or KB = 2.5 for Overhung load) Check on Tail Pulley Shaft from Torque: Selected Drive Pulley Shaft O.K. for Load: Selected Drive Pulley Shaft O.K. for Torque: Selected Tail Pulley Shaft O.K. for Load: Selected Tail Pulley Shaft O.K. for Torque:

2.1875 3200 1100 8,000 6.5 8.25

Inches lbs lbs psi Inches Inches

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Manufacturer Table 3 PT13-13 Table 3 PT13-13 Manufacturer

2.50 6.5640 Inches 8.13 1.50 4.7896 Inches NO NO YES NO

BELT SELECTION Select a belt with a MOR 1/4" X 1/8", Grooved Pattern SELECTION: SCANDURA ROLYALON 3-330 BELT SPEED REDUCER SELECTION (Based on Dodge Gearing Catalogue:) Dodge TDT Series Convert FPM to RPM: 3.9 RPM Determine Service Factor: 1 Calculate Equivalent HP 10 HP Application Class II Select Unit Size & Ratio TDT425 Unit ratio 24.38 Ratio Therefore reuse existing 10 hp motor, new TDT425 reducer required

< Note: Manual add in lagging thickness << input Table 2 pg.2-7 << input << input << input

pg G1-21

BELT DRIVE SELECTION (Based on Dodge PT-Components Engineering Catalog:) Determine Service Factor: 1.5 Design HP: 15.0 Determine Overall Ratio Required: 448.99 Determine Belt Drive Ratio: 18.42 Selected nearest ratio 1.31 Driver Sheave OD 5.70 Inches Driven Sheave OD 7.50 Inches HP Per Belt 3VX series 15.64 Minimum Number of belts required: 1.0 Belt Selection 5VX-500 Belt Center to Center Distance 16.4 Note: Designer can also use Dodge PT-Components Engineering Catalog pg. PT7-1

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table 2 pg PT7-43

Motor rpm/belt rpm Overall Ratio/reducer ratio << input Page B-168 << input Page B-168 << input Page B-168 << input Page B-168 << input << input

Page B-168

COOK ENGINEERING

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n design

8 to 5-12 8 to 5-12

COOK ENGINEERING