System Information Idler Set Data

Client Name EUROCHEM Designer HAK
Project Name 221526 Company Birikim Mühendislik End.

Conveyor Name M-5 Filename M-5
Location KOVDORSKIY GOK Date Mart 1, 2023
Description:
System Information
Calculation method DIN / ISO Idler Set Data
Conveyor Length / Height 1560 / -0,7 m Carry Return
Material lift 10,0 m Series name Series 50 Series 30
Ambient temperature range -40 to 35 °C Bearing 6310 6206
Kt factor at minimum temperature 3,01 Number of rolls 3 2
Trough angle (deg) 45 10
Material Properties Type Inline Inline
Type rock Idler spacing (m) 1,50 3,00
Design Tonnage 9000 t/h Number of ıdler sets 1.048 527
Density 2070 kg/m3 Roll diameter 194 159
Maximum lump size 300 mm Roll rpm 512 625
Surcharge angle 22 deg Total drag (N) --- ---
Roll length 750 1150
Shaft diameter (mm) 50,0 30,0
Belt Properties
Dynamic capacity (kN) 65,0 20,3
Type Steel cord L10 life1 (1000 hrs) 350,0 / 51,1 313,4
Width 1600 mm Shaft deflection (min) 0,64 / 3,21 6,17
Rating 2500 N/mm 1
L10 life above which 95% of idlers exceed
Speed 5,20 m/s
Top / bottom cover thickness 10,0 x 4,0 mm Drive Station
Total thickness 21 mm
Weight (new / worn) 55,3 / 43,5 kg/m Type Variable speed
Modulus 180.000 kN/m Synchronous RPM 1500 RPM
Tape length 3.155 m Motor quantity / rating 4 / 630 kW
Belt cycle time 10,1 min Total ınstalled power 2520 kW
Nominal empty / full power (25 / 82%) 636 / 2074 kW
Tension Summary Running Momentary Min / max demand power (16 / 96%) 408 / 2414 kW
Maximum tension (kN) 500 517 Frame Size IEC 400J
Minimum safety factor 8,00 7,73 Motor Voltage 400 V
Minimum tension (kN) 112 95,2 Efficiency 94,5 to 97,5%
Maximum belt sag (%) 0,68 0,76 Maximum starting torque 104%
Inertia - Motor 14,0 kg·m²
Cross Sectional Loading Pulley lagging type Ceramic
Material mass (wm) 480,8 kg/m Motor wrap angles 196 / 196
Combined mass (wm + wb) 536,1 kg/m Lagging friction factor (run / accel) 0,36 / 0,45
Edge distance (required / actual) 105 / 187 mm
Cross sectional area 0,232 m² Take-up Data
Cross sectional loading (utility / total) 73 % / 53 %
Bed depth 277 mm Type Hydraulic cylinder
Location Head / Pulley #3
Steady state tension 498 to 498 kN
Momentary tension 314 to 515 kN
Required pulley displacement 6,97 m

Dynamic displacement (incl thermal) 2,46 m
Permanent elongation 1,58 m
Splice length (2 included) 1,94 m
Clearance 1,00 m
Backstops
Flooded belt tonnage 16.841 t/h
Flooded (wm + wb) 954,9 kg/m Backstop type None installed
Sidewinder - v7.22 - Conveyor Design Software

Advanced Conveyor Technologies, Inc.
Page 1 / 48
Description:
Cable diameter 6,5 mm

Brakes Number of cables 103
Brake type None installed Cable pitch / cable gap in splice 14,94 / 3,39 mm
Reducer Information
Other Information
Manufacture N/A
Frame size N/A Loaded beltline mass (excluding motors) 990.581 kg
Reducer ratio 19,070 Total inertia (ref HS shaft) 1.119 kg·m2
Catalog reducer ratio 0,000
RPM (High Speed) 1500 RPM Demand Power (kW)
RPM (Low Speed) 78,7 RPM Demand % Motor
Case
Configuration Shaft Mount power Nameplate
Number of stages 3 Empty - NF 636 25,2
Service factor 1,4 Full - NF 2074 82,3
Power rating 0 Empty - LF 408 16,2
Empty - HF 809 32,1
Motor Torque Full - LF 1673 66,4
Full - HF 2414 95,8
100% Motor Torque - High Speed 4.072 N·m
Motor Shaft Torque - Running (FN) 3.351 N·m Din Factor and Total Equivalent Mass
Motor Shaft Torque - Starting (FN) 3.693 N·m Belt line
100% Motor Torque - Low Speed 77.649 N·m Case Din factor
mass (kg)
Low Speed Shaft Torque - Running (FN) 60.675 N·m Empty - NF 0,0300 315.206
Low Speed Shaft Torque - Running (Max) 70.279 N·m Full - NF 0,0300 1.040.201
Low Speed Shaft Torque - Starting (FN) 66.774 N·m Empty - LF 0,0255 277.851
Low Speed Shaft Torque - Starting (Max) 76.415 N·m Empty - HF 0,0345 321.263
Full - LF 0,0255 1.002.846
Starting and Stopping Full - HF 0,0345 1.046.258
Start control Fixed time
Start time 135,0 s Maximum Belt Tensions (kN)
Emergency stop control Drift Case Running Dynamic
Emergency stop time 11,0 to 18,6 s Empty - NF 500 501
Material buildup in chute 10,2 m³ Full - NF 500 515
Empty - LF 500 502
Tension Ratios (Motor Station 1/2) Empty - HF 500 504
Full - LF 500 516
Allowable (running) 3,43 / 3,43 Full - HF 500 517
Running tension ratio 1,75 / 2,93
Allowable (dynamic) 4,66 / 4,68 Belt Safety Factor
Starting tension ratio 1,83 / 3,46 Case Running Dynamic
Empty - NF 8,01 7,98
Transition Lengths Full - NF 8,01 7,76
Transition method CEMA 7 Empty - LF 8,01 7,98
Tail transition length (inline) 10,30 m Empty - HF 8,00 7,94
Head transition length (inline) 10,30 m Full - LF 8,01 7,75
Full - HF 8,00 7,73
Estimated Splice Data
Splice type 2-Step
Splice step length 495 mm
Transition length (each side) 150 mm
22 degree bias angle 650 mm
Total splice length 1940 mm
Page 2 / 48
Description:
Minimum Belt Tensions (kN) Maximum Belt Sag (%)

Case Running Dynamic Case Running Dynamic
Empty - NF 435 431 Empty - NF 0,05 0,05
Full - NF 161 143 Full - NF 0,52 0,58
Empty - LF 456 453 Empty - LF 0,03 0,03
Empty - HF 418 415 Empty - HF 0,05 0,05
Full - LF 214 198 Full - LF 0,41 0,44
Full - HF 112 95,2 Full - HF 0,68 0,76

Page 3 / 48
Description:
Conveyor Profile
Overall length = 1560 m - Overall height = -0,7 m - True Length = 1592,4 m
Tail Arrangement Head Arrangement
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Pulley 1 1-HT 180 498500 997 514516 1.030
Pulley 2 2-MT 79 499500 633 515517 654
Take-up Pulley 2-MT 78 498500 631 515517 653
Motors 1/2 3-HT 196 500 465 954 517 476 967
Pulley 5 4-SN 16 465466 129 476477 133
Pulley 6 4-SN 16 488489 139 490491 140
Motors 3/4 3-HT 196 489 456 935 490 473 954
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.

Page 4 / 48
Description:
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Safety Slope at Deflection T1 T2
Pulley # 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 2,50 4,51 0,048 127 547 550 4797 1.107 194 1,4 221,4
2 2,83 4,08 0,040 90 623 624 3166 811 319 0,7 121,6
3 2,98 3,88 0,038 108 622 625 3166 770 37 1,1 115,4
4 2,46 4,06 0,040 91 548 511 4794 1.044 175 11,9 156,6
5 4,65 4,55 0,045 236 581 582 1746 179 262 0,4 26,8
6 4,35 4,87 0,048 188 610 611 1746 191 277 0,4 28,7
7 2,51 3,98 0,039 97 538 502 4794 1.023 6 11,6 153,4
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)
Rubber
1 1250 12,0 1274 1800 340 300 2400 3164 23164 6.262
Plain
Rubber
2 1000 12,0 1024 1800 300 260 2200 3156 23156 4.150
Plain
3 Ceramic 1250 12,0 1274 1800 320 280 2200 3160 23160 6.005
Rubber
4 800 12,0 824 1800 200 160 2200 3036 23036 2.008
Plain
Pulley Shaft Information

Overhun
Hub Bearing
Tensile Yield Fatigue Hub Fillet Overhun g
Locking Shaft Center to Fillet
Type Strength Strength Strength Diameter Radius g Load Moment
Device Material Distance Distance
(MPa) (MPa) (MPa) (mm) (mm) (kN) Arm
(mm) (mm)
(mm)
1 B-LOC 115 SAE 4140 655,0 417,0 327,5 340 1600 190 60 0,0 0
2 B-LOC 115 SAE 4140 655,0 417,0 327,5 300 1600 165 60 0,0 0
3 B-LOC 115 SAE 4140 655,0 417,0 327,5 320 1600 180 60 0,0 0
4 B-LOC 115 SAE 4140 655,0 417,0 327,5 200 1600 120 60 0,0 0

Page 5 / 48
Description:
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 (Material Lift = 10,0 m)

Page 6 / 48
Description:
Take-up Displacement Summary

1. Type Hydraulic Cylinder
2. Location Head / Pulley #3
3. Belt line tension 498 kN
4. Momentary tension 314 to 515 kN
5. Take-up pulley displacement range
a. Running -1,52 to 0,93 m
b. Momentary -1,52 to 0,93 m
Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) 2,46 m
2. Permanent elongation 1,58 m
3. Splice length (2 included) 1,94 m
4. Clearance 1,00 m
5. Required displacement 6,97 m

Page 7 / 48
Description:
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
(deg) T1 T2 T1 T2
Force Force
Pulley 1 1-HT 180 547550 1.107 668676 1.355
Pulley 2 2-MT 79 623624 811 675678 878
Take-up Pulley 2-MT 78 622625 770 676678 837
Motors 1/2 3-HT 196 548 511 1.044 680 524 1.187
Pulley 5 4-SN 16 581582 179 524525 163
Pulley 6 4-SN 16 610611 191 539540 171
Motors 3/4 3-HT 196 538 502 1.023 539 521 1.044
Required Pulley Diameter (Tension based on a safety factor of 6,67)

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Pulley 1 Head (7) 1 - HT 180 1250 1000 83 86
Pulley 2 Head (9) 2 - MT 79 1000 800 83 86
Take-up Pulley Head (11) 2 - MT 78 1000 800 83 86
Motors 1/2 Head (14) 3 - HT 196 1250 1000 83 86
Pulley 5 Head (16) 4 - SN 16 800 630 78 80
Pulley 6 Tail (21) 4 - SN 16 800 630 82 82
Motors 3/4 Tail (23) 3 - HT 196 1250 1000 82 82
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 2,50 4,51 57,4 0,2 55,4 0,3 57,4 55,4 0,0
2 2 2,83 4,08 45,9 0,1 53,4 0,2 45,9 53,4 0,0
3 2 2,98 3,88 43,5 0,2 50,6 0,3 43,6 50,7 0,0
4 3 2,46 4,06 48,7 1,9 60,4 2,8 48,8 60,6 0,0
5 4 4,65 4,55 34,1 0,3 34,7 0,5 34,1 34,8 0,0
6 4 4,35 4,87 36,5 0,3 37,2 0,5 36,5 37,2 0,0
7 3 2,51 3,98 47,7 1,8 59,2 2,7 47,8 59,4 0,0

Page 8 / 48
Description:
Running Drive Tensions by Load Case (kN)

Motors 1/2 Motors 3/4
Load Case Resultant Resultant
T1 T2 T1 T2
Force Force
Empty - NF 499 449 939 484 435 910
Full - NF 499 313 804 347 161 504
Empty - LF 498 465 954 489 456 935
Empty - HF 500 437 928 480 418 888
Full - LF 498 344 834 368 214 576
Full - HF 500 285 778 327 112 435

Page 9 / 48
Description:
Pulley Tension Summary - All Load Cases and Conditions

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)
Pulley 1 495 499 497 501 470 474 470 474
Pulley 2 498 500 500 501 472 473 472 473
Take-up Pulley 498 499 500 501 471 472 471 472
EM-N Empty - NF Motors 1 / 2 499 449 501 446 470 469 470 469
Pulley 5 449 451 446 448 469 470 469 470
Pulley 6 483 484 484 486 462 463 462 463
Motors 3 / 4 484 435 485 431 463 463 463 463
Pulley 1 495 499 511 515 338 341 338 341
Pulley 2 498 500 514 515 340 340 340 340
Take-up Pulley 498 499 514 515 338 339 338 339
FL-N Full - NF Motors 1 / 2 499 313 515 310 337 336 337 336
Pulley 5 313 314 310 311 337 337 337 337
Pulley 6 346 347 347 349 330 331 330 331
Motors 3 / 4 347 161 348 143 331 330 331 330
Pulley 1 498 500 499 502 481 483 481 483
Pulley 2 499 499 501 501 482 482 482 482
Take-up Pulley 498 498 500 501 480 480 480 480
EM-L Empty - LF Motors 1 / 2 498 465 501 463 479 476 479 476
Pulley 5 465 466 463 464 476 477 476 477
Pulley 6 488 489 490 491 475 476 475 476
Motors 3 / 4 489 456 490 453 475 473 475 473
Pulley 1 492 499 495 502 461 467 461 467
Pulley 2 498 500 501 503 465 466 465 466
Take-up Pulley 498 500 501 503 465 466 465 466
EM-H Empty - HF Motors 1 / 2 500 437 504 435 463 463 463 463
Pulley 5 437 439 436 438 463 465 463 465
Pulley 6 478 480 480 483 452 454 452 454
Motors 3 / 4 480 418 483 415 453 454 453 454
Pulley 1 498 500 514 516 369 370 369 370
Pulley 2 499 499 515 516 369 369 369 369
Take-up Pulley 498 498 515 515 367 367 367 367
FL-L Full - LF Motors 1 / 2 498 344 515 343 366 362 366 362
Pulley 5 344 345 343 344 362 363 362 363
Pulley 6 367 368 370 370 358 358 358 358
Motors 3 / 4 368 214 370 198 358 355 358 355
Pulley 1 492 499 509 516 310 316 310 316
Pulley 2 498 500 515 517 314 315 314 315
Take-up Pulley 498 500 515 517 314 315 314 315
FL-H Full - HF Motors 1 / 2 500 285 517 283 313 313 313 313
Pulley 5 285 287 284 285 314 315 314 315
Pulley 6 325 327 328 330 306 308 306 308
Motors 3 / 4 327 112 329 95,2 307 308 307 308

Page 10 / 48
Description:
28. Bearing L10 126.571 hours

#1 - Pulley 1
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-1) Pulley 1 29. Running T1 Tension 495 kN
2. Pulley Diameter 1250 mm 30. Running T2 Tension 499 kN
3. Face Width 1800 mm 31. Design T1 Tension 547 kN
32. Design T2 Tension 550 kN
33. Wrap angle 180 deg
Lagging
34. Design Resultant Tension 1.107 kN
4. Lagging Type Rubber
35. Resultant Angle 194 deg
5. Lagging Pattern Plain
36. Resultant Moment 221 kN·m
6. Lagging Thickness 12 mm
37. Resultant Torque 1,39 kN·m
7. Diameter with lagging 1274 mm
38. Estimated Pulley & Shaft Mass 4.797 kg
39. Estimated Mass with Bearings 6.262 kg
Shaft Specification
8. Shaft Center Diameter 340 mm
Shaft Stresses & Deflections
9. Shaft Material SAE 4140
40. Shaft slope at hub 4,51 min
10. Yield Strength 417,0 MPa
41. Shaft slope at bearing 5,80 min
11. Fatigue Strength 327,5 MPa
42. Shaft deflection at center 1,14 mm
43. Shaft deflection at center (%) 0,048
Locking Device 44. Shaft Safety Factor (CEMA) 2,50
12. Hub Center Distance 1600 mm 45. Shaft Safety Factor (AS1403) 2,48
13. Shaft diameter at hub 340 mm 46. Bending Stress 57,4 MPa
14. Turndown radius at hub 0 mm 47. Torsional Stress 0,2 MPa
15. Locking Device B-LOC 115 48. Von Mises Stress 57,4 MPa
16. Size 340 x 425 49. Fillet Von Mises Stress 55,4 MPa
17. Hub width 155 mm
18. Hub pressure 143,0 N/mm²
Shell Dimension and Stresses
19. Maximum torque 374.887 N·m
50. Shell thickness 35 mm
20. Hub outer diameter 756 mm
51. Sitzwohl reqd shell thickness1 43 mm
52. Sitzwohl shell stress 47,2 MPa
Bearing Specifications 53. Shell stress at 180 wa 47,2 MPa
21. Bearing Center Distance 2400 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
22. Shaft diameter at bearing 300 mm
23. Bearing to Fillet Distance 190 mm End Disk Dimension and Stresses
24. Turndown radius at bearing 60 mm 54. End disk thickness 54 mm
25. Bearing 23164 55. End disk stress 80,3 MPa
26. SNL Plummer Block 3164
27. Dynamic Capacity 3.750 kN

Page 11 / 48
Description:

#2 - Pulley 2
Lagging
34. Design Resultant Tension 811 kN
Shaft Specification

Page 12 / 48
Description:

#3 - Take-up Pulley
1. Name (Type-2) Take-up Pulley 29. Running T1 Tension 498 kN
Lagging
Shaft Specification

Page 13 / 48
Description:
#4 - Motors 1/2 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 499 kN
1. Name (Type-3) Motors 1/2 29. Running T2 Tension 313 kN
2. Pulley Diameter 1250 mm 30. Design T1 Tension 548 kN
Lagging
4. Lagging Type Ceramic
Shaft Specification

Page 14 / 48
Description:

#5 - Pulley 5
Lagging
36. Resultant Moment 26,8 kN·m
Shaft Specification
27. Dynamic Capacity 830 kN

Page 15 / 48
Description:

#6 - Pulley 6
Lagging
Shaft Specification

Page 16 / 48
Description:

#7 - Motors 3/4
Lagging
Shaft Specification 38. Estimated Mass with Bearings 6.005 kg
Locking Device 42. Shaft deflection at center (%) 0,039
11. Hub Center Distance 1600 mm 43. Shaft Safety Factor (CEMA) 2,51
12. Shaft diameter at hub 320 mm 44. Shaft Safety Factor (AS1403) 2,98
13. Turndown radius at hub 0 mm 45. Bending Stress 47,7 MPa
14. Locking Device B-LOC 115 46. Torsional Stress 1,8 MPa
15. Size 320 x 405 47. Von Mises Stress 47,8 MPa
16. Hub width 155 mm 48. Fillet Von Mises Stress 59,4 MPa
Bearing Specifications 51. Sitzwohl shell stress 66,3 MPa
20. Bearing Center Distance 2200 mm 52. Shell stress at 180 wa 44,7 MPa
21. Shaft diameter at bearing 280 mm 1
22. Bearing to Fillet Distance 180 mm
23. Turndown radius at bearing 60 mm End Disk Dimension and Stresses
24. Bearing 23160 53. End disk thickness 54 mm
25. SNL Plummer Block 3160 54. End disk stress 59,2 MPa

Page 17 / 48
Description:
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 18 / 48
Description:
Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.
Material Trajectory

Page 19 / 48
Description:
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) 10,24 10,24
Elevated pulley transition (L2) 6,88 6,88
Pulley elevation (h) 100,174 100,174

Page 20 / 48
Description:
Material Loading Profiles
Material Properties Material 1 on Idler Set 1

Type rock
Design Tonnage 9000 t/h
Density 2070 kg/m3
Maximum lump size 300 mm
Surcharge angle 22 deg
Material 1 on Idler Set 3
Tonnage 9000 t/h

Belt speed 5,20 m/s
Material mass 480,8 kg/m
Bed depth 277 mm
Tonnage 9000 t/h
Belt speed 5,20 m/s
Material mass 480,8 kg/m
Empty Idler Set 2
Bed depth 277 mm

Page 21 / 48
Description:
Idler Specifications
Idler Specifications
Equal Roll Equal Roll
Type VEE
Trough Trough
Number of rolls 3 2 3
Trough angle (deg) 45 10 45
Roll diameter (mm) 194 159 194
Roll length (mm) 750 1150 750
Shaft diameter (mm) 50,0 30,0 50,0
Bearing series 6310 6206 6310
Maximum roll RPM 512 625 512
Min Life (1000 hrs) 350 / 51 235 350 / 61
95% life1 (1000 hrs) 350 / 51 313 350 / 61
Shaft deflection (min) 0,64 / 3,21 6,17 0,60 / 4,11
Mass per Roll (kg) 19,9 21,3 19,9
Rotating mass for set (kg) 59,8 42,5 59,8
Wk2 for set (kg·mm²) 504.541 245.957 504.541
Idler Spacing and Count Summary

General Carry Return Impact
Idler spacing (m) 1,50 2,98 0,30
Number of ıdler sets 1.048 527 7
Number of rolls 3.144 1.054 21
Total drag (N)
Nominal friction 13,9 7,9 13,9
High friction 13,9 7,9 13,9
Low friction 0,0 0,0 0,0
Idler Life and Shaft Deflection Summary-Carry Side

Center
Idler Wing L10 Center L10 Wing Shaft
Vertical Idler Shaft
# Station (m) Length (m) Spacing Life Life Deflection
Radius (m) Type Deflection
(m) (hours) (hours) (min)
(min)
1 0,0 3,0 1,50 1 350.000 350.000 0,18 0,38
2 3,0 2,0 0,30 3 350.000 60.706 0,60 4,11
3 5,0 5,0 1,50 1 350.000 55.156 0,58 3,09
4-7 10,0 1.501,0 1,50 1 350.000 51.086 0,64 3,21
9 1.510,3 13,1 1,50 2 234.897 6,17
13-14 1.497,4 63,0 1,50 1 350.000 350.000 0,28 0,61
Idler Life and Shaft Deflection Summary-Return Side

Center
Idler Wing L10 Center L10 Wing Shaft
Vertical Idler Shaft
# Station (m) Length (m) Spacing Life Life Deflection
Radius (m) Type Deflection
(m) (hours) (hours) (min)
(min)
18-21 1.557,9 1.556,0 3,00 2 313.375 5,63

Page 22 / 48
Description:
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 10.317 t/h have also been included. This specific load case results in 100% 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 10.317 t/h under steady state and dynamic conditions + 110% multiplier
Shaft Shaft Shaft Minimum Tensions (kN) Maximum Tensions (kN)
Wrap Hub stress Center
(deg) Slope safety Def. T1 T2 T1 T2
Force Force
(min) factor (mm)
Pulley 1 1 180 5,51 2,50 1,39 264269 544 668676 1.355
Pulley 2 2 79 4,42 2,83 0,95 268269 360 675678 878
Take-up Pulley 2 78 4,22 2,98 0,90 267268 320 676678 837
Motors 1/2 3 196 4,62 2,45 0,99 266 236 494 680 524 1.187
Pulley 5 4 16 4,15 4,65 0,89 237238 82,9 524525 163
Pulley 6 4 16 4,35 4,35 0,93 255256 89,8 539540 171
Motors 3/4 3 196 4,06 2,51 0,87 255 -21,1 225 539 521 1.044
Bearing Reaction Forces (excluding any overhung loads)

Entry Exiting Pulley, Bearing Horizontal Direction (kN) Bearing Vertical Direction (kN)
Wrap Vector Vector Shaft & Structural Structural Structural Structural
Pulley FL-N FL-N
(deg) Angle Angle Bearings Min Max Min Max
Case Case
(deg) (deg) Mass (kg) Tension Tension Tension Tension
Pulley 1 180 191 191 6.262 -522 -975 -1.318 -166 -256 -325
Pulley 2 79 11 270 4.150 262 489 662 -257 -442 -586
Take-up Pulley 78 90 348 4.150 263 489 665 173 357 500
Motors 1/2 196 180 164 6.005 -493 -800 -1.183 6,24 27,2 85,5
Pulley 5 16 344 180 2.008 -10,5 -13,2 -20,9 -84,8 -106 -164
Pulley 6 16 360 196 2.008 9,28 12,9 20,9 -91,9 -118 -172
Motors 3/4 196 16 0 6.005 224 494 1.038 13,1 38,9 93,1
The idler stringer loading should be based on the flooded belt surge capacity of 16.841 t/h and 954,9 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
Description:
Element Summary Details
Tension Summary
Power Summary

Page 24 / 48
Description:
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 3,0 0,00 0,00 1,50 1
2 Loading Point 3,0 0,00 2,0 0,00 0,00 0,30 3
3 Skirtboards Only 5,0 0,00 5,0 0,00 0,00 1,50 1
4 10,0 0,00 483,3 0,00 0,00 1,50 1
5 493,3 0,00 483,3 0,00 0,00 1,50 1
6 976,7 0,00 483,3 0,00 0,00 1,50 1
7 1.460,0 0,00 51,0 10,00 11,31 1,50 1
8 Pulley 1 1.510,0 10,00 1,3 -1,25 ---
9 1.510,3 8,75 13,1 -2,57 -11,31 1,50 2
10 Pulley 2 1.497,4 6,18 0,6 -0,50 ---
11 1.497,0 5,68 2,8 -2,77 -90,00
12 Take-up Pulley 1.497,0 2,91 0,6 -0,50 ---
13 1.497,4 2,41 15,5 -3,09 -11,54 1,50 1
14 1.512,6 -0,68 47,5 0,00 0,00 1,50 1
15 Motors 1/2 1.560,1 -0,68 1,3 -1,25 ---
16 1.559,9 -1,93 2,0 0,56 16,00
17 Pulley 5 1.558,0 -1,37 0,1 0,02 ---
18 1.557,9 -1,36 389,0 0,15 0,02 3,00 2
19 1.168,9 -1,21 389,0 0,15 0,02 3,00 2
20 779,9 -1,07 389,0 0,15 0,02 3,00 2
21 390,9 -0,92 389,0 0,15 0,02 3,00 2
22 Pulley 6 1,9 -0,77 0,1 -0,02 ---
23 1,7 -0,79 1,6 -0,46 -16,37
24 Motors 3/4 0,2 -1,25 1,3 1,25 ---

Page 25 / 48
Description:
Min/Max Tension Summary per Element

Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 456 112 0,09 473 95,2 0,11
2 Loading Point 456 112 0,18 473 95,3 0,21
3 Skirtboards Only 463 146 0,68 480 130 0,76
4 464 148 0,67 481 132 0,75
5 473 242 0,41 479 236 0,42
6 483 336 0,29 483 285 0,35
7 492 430 0,23 494 260 0,38
8 Pulley 1 498 492 0,00 514 310 0,00
9 500 499 0,02 516 316 0,03
10 Pulley 2 499 498 0,00 515 314 0,00
11 500 499 0,00 517 315 0,00
12 Take-up Pulley 498 498 0,00 515 314 0,00
13 500 498 0,02 517 315 0,03
14 499 497 0,02 516 313 0,03
15 Motors 1/2 500 498 0,00 517 313 0,00
16 465 285 0,00 476 283 0,00
17 Pulley 5 465 285 0,00 476 284 0,00
18 466 287 0,07 477 285 0,07
19 471 296 0,07 476 296 0,07
20 477 307 0,07 477 307 0,07
21 483 316 0,07 483 309 0,07
22 Pulley 6 488 325 0,00 490 306 0,00
23 489 327 0,00 491 308 0,00
24 Motors 3/4 489 327 0,00 490 307 0,00

Page 26 / 48
Description:
Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N)
EM-N FL-N EM-L EM-H FL-L FL-H
Total (Beltline) 99.720 372.742 66.651 125.458 308.107 429.946
Total (Power) 122.351 398.767 78.555 155.496 321.726 464.322
Lift Force 0 47.147 0 0 47.147 47.147

Frictional Drag 99.720 325.595 66.651 125.458 260.960 382.798
Motor Pulley/Reducer Drag 22.631 26.025 11.904 30.038 13.619 34.376
Rolling Resistance 73.848 287.002 53.459 86.969 234.639 332.095

Material+Belt Flexure 0 0 0 0 0 0
Idler Bearing Drag 0 0 0 0 0 0
Idler Alignment 0 0 0 0 0 0
Pulleys & Accessories 25.258 24.375 12.667 37.789 12.276 36.311
Loading Point 613 14.219 525 701 14.045 14.393
Mechanical Losses 15.850 20.136 8.487 19.932 10.596 25.765

Motor Pulley Drag Components 6.781 5.888 3.417 10.106 3.023 8.611

Page 27 / 48
Description:
Pulley Summary Table - All Cases

Pulley Geometry Details
Type 1 2 3 4
Lagging Type Rubber Rubber Ceramic Rubber
Diameter (mm) 1250 1000 1250 800
Lagging Thickness (mm) 12,0 12,0 12,0 12,0
Diameter with Lagging (mm) 1274 1024 1274 824
Face Width (mm) 1800 1800 1800 1800
Shaft Center Diameter (mm) 340 300 320 200
Bearing Diameter (mm) 300 260 280 160
Bearing Center Distance (mm) 2400 2200 2200 2200
Plummer Block 3164 3156 3160 3036
Pulley & Shaft Mass (kg) 4.797 3.166 4.794 1.746
Locking Device B-LOC 115 B-LOC 115 B-LOC 115 B-LOC 115
Hub Center Distance (mm) 1600 1600 1600 1600
Hub Diameter (mm) 340 300 320 200
Bearing to Fillet Distance (mm) 190 165 180 120
Fillet Radius (mm) 60 60 60 60
Shaft Material SAE 4140 SAE 4140 SAE 4140 SAE 4140
Yield Strength (MPa) 417,0 417,0 417,0 417,0
Fatigue Strength (MPa) 327,5 327,5 327,5 327,5

Page 28 / 48
Description:
Element Tension Details per Case
Element Tension Breakdown - (EM) Empty - Normal

Individual drag components per element
Running Running Element Pulley Feeder Extra
Wm+Wb Lift Belt Idler
# Tension Ten Diff Tonnage Drag Pt. Force Accessory
(kg/m) Force (N) Force (N) Force (N)
(N) (N) (t/h) Force (N) (N) Force (N)
1 434.875 80 55,3 80
2 434.956 13.813 55,3 138 175 13.500
3 448.769 772 55,3 134 438 200
4 449.540 12.948 55,3 12.948
5 462.488 12.948 55,3 12.948
6 475.436 12.948 55,3 12.948
7 488.383 6.773 55,3 5.424 1.350
8-P 495.157 4.328 55,3 -678 2.205 2.800
9 499.484 -1.084 55,3 -1.392 309
10 - P 498.401 1.103 55,3 -272 1.375
11 499.503 -1.503 55,3 -1.503
12 - T 498.000 1.098 55,3 -272 1.370
13 499.098 -1.268 55,3 -1.677 409
14 497.830 1.273 55,3 1.273
15 - M 499.104 -50.366 55,3 -678 2.161 1.400
16 448.738 335 55,3 304 32
17 - P 449.073 1.556 55,3 9 1.547
18 450.629 7.993 55,3 79 7.814 100
19 458.622 8.393 55,3 79 7.814 500
20 467.015 7.893 55,3 79 7.814
21 474.908 7.893 55,3 79 7.814
22 - P 482.801 1.651 55,3 -9 1.660
23 484.452 -224 55,3 -250 25
24 - M 484.228 -49.353 55,3 677 2.100 1.120

Page 29 / 48
Description:
Element Tension Breakdown - (FL) Fully Loaded - Normal

1 160.969 80 55,3 80
2 161.049 27.269 9.000 536,1 421 13.348 13.500
3 188.318 1.912 9.000 536,1 841 871 200
4 190.230 81.311 9.000 536,1 81.311
5 271.541 81.311 9.000 536,1 81.311
6 352.852 81.311 9.000 536,1 81.311
7 434.164 60.993 9.000 536,1 52.571 8.422
8-P 495.156 4.328 55,3 -678 2.205 2.800
9 499.484 -1.084 55,3 -1.392 309
10 - P 498.400 1.103 55,3 -272 1.375
11 499.503 -1.503 55,3 -1.503
12 - T 498.000 1.099 55,3 -272 1.370
13 499.098 -1.268 55,3 -1.677 409
14 497.830 1.273 55,3 1.273
15 - M 499.104 -186.582 55,3 -678 2.010 1.400
16 312.522 335 55,3 304 32
17 - P 312.857 1.115 55,3 9 1.107
18 313.973 7.993 55,3 79 7.814 100
19 321.966 8.393 55,3 79 7.814 500
20 330.359 7.893 55,3 79 7.814
21 338.252 7.893 55,3 79 7.814
22 - P 346.145 1.208 55,3 -9 1.217
23 347.353 -224 55,3 -250 25
24 - M 347.129 -186.160 55,3 677 1.358 1.120

Page 30 / 48
Description:
Element Tension Breakdown - (EM) Empty - Low

1 455.974 59 43,5 59
2 456.033 6.949 43,5 111 88 6.750
3 462.982 637 43,5 99 438 100
4 463.619 9.574 43,5 9.574
5 473.193 9.574 43,5 9.574
6 482.768 9.574 43,5 9.574
7 492.342 5.262 43,5 4.262 999
8-P 497.604 1.974 43,5 -532 1.106 1.400
9 499.578 -870 43,5 -1.094 224
10 - P 498.708 474 43,5 -214 688
11 499.182 -1.182 43,5 -1.182
12 - T 498.000 471 43,5 -214 685
13 498.471 -1.015 43,5 -1.318 303
14 497.456 942 43,5 942
15 - M 498.397 -33.778 43,5 -533 1.088 700
16 464.620 260 43,5 239 21
17 - P 464.879 806 43,5 7 799
18 465.685 5.602 43,5 62 5.490 50
19 471.288 5.802 43,5 62 5.490 250
20 477.090 5.552 43,5 62 5.490
21 482.642 5.552 43,5 62 5.490
22 - P 488.194 832 43,5 -7 839
23 489.026 -179 43,5 -196 17
24 - M 488.847 -32.873 43,5 532 1.069 560

Page 31 / 48
Description:
Element Tension Breakdown - (EM) Empty - High

1 417.593 94 57,2 94
2 417.687 20.672 57,2 160 263 20.250
3 438.360 895 57,2 157 438 300
4 439.255 15.204 57,2 15.204
5 454.458 15.204 57,2 15.204
6 469.662 15.204 57,2 15.204
7 484.866 7.197 57,2 5.612 1.585
8-P 492.062 6.791 57,2 -701 3.292 4.200
9 498.853 -1.077 57,2 -1.441 363
10 - P 497.776 1.779 57,2 -282 2.061
11 499.556 -1.556 57,2 -1.556
12 - T 498.000 1.775 57,2 -282 2.057
13 499.775 -1.255 57,2 -1.735 480
14 498.520 1.495 57,2 1.495
15 - M 500.015 -63.156 57,2 -701 3.226 2.100
16 436.859 352 57,2 314 38
17 - P 437.211 2.273 57,2 9 2.264
18 439.484 9.471 57,2 82 9.239 150
19 448.954 10.071 57,2 82 9.239 750
20 459.025 9.321 57,2 82 9.239
21 468.345 9.321 57,2 82 9.239
22 - P 477.666 2.456 57,2 -9 2.465
23 480.122 -228 57,2 -258 30
24 - M 479.894 -62.301 57,2 700 3.100 1.680

Page 32 / 48
Description:
Element Tension Breakdown - (FL) Fully Loaded - Low

1 214.127 59 43,5 59
2 214.187 20.276 9.000 524,2 352 13.174 6.750
3 234.462 1.671 9.000 524,2 700 871 100
4 236.133 67.683 9.000 524,2 67.683
5 303.816 67.683 9.000 524,2 67.683
6 371.500 67.683 9.000 524,2 67.683
7 439.183 58.420 9.000 524,2 51.410 7.011
8-P 497.604 1.974 43,5 -532 1.106 1.400
9 499.578 -870 43,5 -1.094 224
10 - P 498.708 474 43,5 -214 688
11 499.182 -1.182 43,5 -1.182
12 - T 498.000 471 43,5 -214 685
13 498.471 -1.015 43,5 -1.318 303
14 497.456 942 43,5 942
15 - M 498.397 -154.376 43,5 -533 1.021 700
16 344.022 260 43,5 239 21
17 - P 344.282 611 43,5 7 604
18 344.893 5.602 43,5 62 5.490 50
19 350.495 5.802 43,5 62 5.490 250
20 356.297 5.552 43,5 62 5.490
21 361.849 5.552 43,5 62 5.490
22 - P 367.402 636 43,5 -7 643
23 368.037 -179 43,5 -196 17
24 - M 367.858 -153.731 43,5 532 741 560

Page 33 / 48
Description:
Element Tension Breakdown - (FL) Fully Loaded - High

1 111.627 94 57,2 94
2 111.721 34.257 9.000 538,0 485 13.522 20.250
3 145.978 2.141 9.000 538,0 971 871 300
4 148.120 93.822 9.000 538,0 93.822
5 241.941 93.822 9.000 538,0 93.822
6 335.763 93.822 9.000 538,0 93.822
7 429.585 62.477 9.000 538,0 52.759 9.718
8-P 492.062 6.791 57,2 -701 3.292 4.200
9 498.853 -1.077 57,2 -1.441 363
10 - P 497.776 1.779 57,2 -282 2.061
11 499.555 -1.556 57,2 -1.556
12 - T 498.000 1.775 57,2 -282 2.057
13 499.775 -1.255 57,2 -1.735 480
14 498.520 1.495 57,2 1.495
15 - M 500.015 -214.905 57,2 -701 2.975 2.100
16 285.111 352 57,2 314 38
17 - P 285.463 1.536 57,2 9 1.527
18 286.999 9.471 57,2 82 9.239 150
19 296.469 10.071 57,2 82 9.239 750
20 306.540 9.321 57,2 82 9.239
21 315.861 9.321 57,2 82 9.239
22 - P 325.181 1.714 57,2 -9 1.724
23 326.895 -228 57,2 -258 30
24 - M 326.667 -215.041 57,2 700 1.857 1.680

Page 34 / 48
Description:
Equipment Tags and Commodity Codes

Table of major items with description, tags, and commodity codes.
Item Description Equipment Tag Commodity Code
Pulley Pulley 1
Pulley Pulley 2
Pulley Pulley 3
Pulley Pulley 4
Motor Motor 1
Reducer Reducer 1
Motor Motor 2
Reducer Reducer 2
Pulley Pulley 5
Pulley Pulley 6
Pulley Pulley 7
Motor Motor 3
Reducer Reducer 3
Motor Motor 4
Reducer Reducer 4
Idlers Carry
Idlers Return
Idlers 6310
Belt -
Take-up -

Page 35 / 48
Description:
Belt Supplier Data Sheet System Information

Type Steel cord Calculation method DIN / ISO
Width 1600 mm Conveyor Length / Height 1560 / -0,7 m
Rating 2500 N/mm Ambient temperature range -40 to 35 °C
Speed 5,20 m/s Kt factor at minimum temperature 3,01
Top / bottom cover thickness 10,0 x 4,0 mm
Total thickness 21 mm Material Properties
Weight (new / worn) 55,3 / 43,5 kg/m Type rock
Modulus 180.000 kN/m Design Tonnage 9000 t/h
Tape length 3.155 m Density 2070 kg/m3
Belt cycle time 10,1 min Maximum lump size 300 mm
Cross Sectional Loading Surcharge angle 22 deg
Material mass (wm) 480,8 kg/m
Combined mass (wm + wb) 536,1 kg/m Drive Station
Edge distance (required / actual) 105 / 187 mm Type Variable speed
Cross sectional area 0,232 m² Synchronous RPM 1500 RPM
Cross sectional loading (utility / total) 73 % / 53 % Motor quantity / rating 4 / 630 kW
Bed depth 277 mm Total ınstalled power 2520 kW
Nominal empty / full power (25 / 82%) 636 / 2074 kW
Min / max demand power (16 / 96%) 408 / 2414 kW
Maximum starting torque 104%
Pulley lagging type Ceramic
Motor wrap angles 196 / 196
Idler Set Data

Carry Return
Series name Series 50 Series 30
Bearing 6310 6206
Flooded belt tonnage 16.841 t/h Number of rolls 3 2
Flooded (wm + wb) 954,9 kg/m Trough angle (deg) 45 10
Type Inline Inline
Tension Summary Running Momentary Idler spacing (m) 1,50 3,00
Maximum tension (kN) 500 517
Minimum safety factor 8,00 7,73
Pulley Details
Estimated Splice Data Pulley diameter (Type 1) 1250 mm
Pulley diameter (Type 2) 1000 mm
Splice type 2-Step Pulley diameter (Type 3) 1250 mm
Splice step length 495 mm Pulley diameter (Type 4) 800 mm
Transition length (each side) 150 mm
22 degree bias angle 650 mm
Take-up Data
Total splice length 1940 mm
Cable diameter 6,5 mm Type Hydraulic cylinder
Number of cables 103 Location Head / Pulley #3
Cable pitch / cable gap in splice 14,94 / 3,39 mm Steady state tension 498 to 498 kN
Transition Lengths Required pulley displacement 6,97 m
Transition method CEMA 7
Tail transition length (inline) 10,30 m
Head transition length (inline) 10,30 m

Page 36 / 48
Description:
System Information
Idler Set Data Calculation method DIN / ISO
Carry Return Conveyor Length / Height 1560 / -0,7 m
Series name Series 50 Series 30 Ambient temperature range -40 to 35 °C
Bearing 6310 6206 Kt factor at minimum temperature 3,01
Number of rolls 3 2
Trough angle (deg) 45 10 Material Properties
Type Inline Inline Type rock
Idler spacing (m) 1,50 3,00 Design Tonnage 9000 t/h
Roll diameter 194 159 Density 2070 kg/m3
Roll rpm 512 625 Maximum lump size 300 mm
Total drag (N) --- --- Surcharge angle 22 deg
Shaft diameter (mm) 50,0 30,0 Cross Sectional Loading
Dynamic capacity (kN) 65,0 20,3 Material mass (wm) 480,8 kg/m
L10 life1 (1000 hrs) 350,0 / 51,1 313,4 Combined mass (wm + wb) 536,1 kg/m
Shaft deflection (min) 0,64 / 3,21 6,17 Edge distance (required / actual) 105 / 187 mm
Cross sectional area 0,232 m²
Number of ıdler sets 1.048 527 Cross sectional loading (utility / total) 73 % / 53 %
Number of rolls 3.144 1.054 Bed depth 277 mm
Idler Set Data

Impact Transition
Series name Series 50
Bearing 6310
Number of rolls 3 0
Trough angle (deg) 45 0
Type Inline
Idler spacing (m) 1,50 3,00
Roll diameter 194 0 Flooded belt tonnage 16.841 t/h
Roll rpm 512 0 Flooded (wm + wb) 954,9 kg/m
Total drag (N) --- --- Belt Supplier Data Sheet
Roll length 750 0
Type Steel cord
Shaft diameter (mm) 50,0 0,0
Width 1600 mm
Dynamic capacity (kN) 65,0 0,0
Rating 2500 N/mm
L10 life1 (1000 hrs) 350,0 / 60,7 0,0 / 0,0
Speed 5,20 m/s
Shaft deflection (min) 0,60 / 4,11 0,00
Top / bottom cover thickness 10,0 x 4,0 mm
Weight (new / worn) 55,3 / 43,5 kg/m
Number of ıdler sets 7 0
Number of rolls 21 0 Tension Summary Running Momentary
Maximum tension (kN) 500 517
1
L10 life above which 95% of idlers exceed Minimum safety factor 8,00 7,73

Page 37 / 48
Description:
System Information Flooded belt tonnage 16.841 t/h

Calculation method DIN / ISO Flooded (wm + wb) 954,9 kg/m
Conveyor Length / Height 1560 / -0,7 m
Material lift 10,0 m Idler Set Data
Ambient temperature range -40 to 35 °C Carry Return
Kt factor at minimum temperature 3,01 Series name Series 50 Series 30
Bearing 6310 6206
Material Properties Number of rolls 3 2
Type rock Trough angle (deg) 45 10
Design Tonnage 9000 t/h Type Inline Inline
Density 2070 kg/m3 Idler spacing (m) 1,50 3,00
Maximum lump size 300 mm Number of ıdler sets 1.048 527
Surcharge angle 22 deg Roll diameter 194 159
Roll rpm 512 625
Total drag (N) --- ---
Belt Properties
Type Steel cord Shaft diameter (mm) 50,0 30,0
Width 1600 mm Dynamic capacity (kN) 65,0 20,3
Rating 2500 N/mm L10 life1 (1000 hrs) 350,0 / 51,1 313,4
Speed 5,20 m/s Shaft deflection (min) 0,64 / 3,21 6,17
Top / bottom cover thickness 10,0 x 4,0 mm 1
L10 life above which 95% of idlers exceed
Total thickness 21 mm
Weight (new / worn) 55,3 / 43,5 kg/m Drive Station
Modulus 180.000 kN/m
Tape length 3.155 m Type Variable speed
Belt cycle time 10,1 min Synchronous RPM 1500 RPM
Motor quantity / rating 4 / 630 kW
Tension Summary Running Momentary Total ınstalled power 2520 kW
Maximum tension (kN) 500 517 Nominal empty / full power (25 / 82%) 636 / 2074 kW
Minimum safety factor 8,00 7,73 Min / max demand power (16 / 96%) 408 / 2414 kW
Minimum tension (kN) 112 95,2 Frame Size IEC 400J
Maximum belt sag (%) 0,68 0,76 Motor Voltage 400 V
Efficiency 94,5 to 97,5%
Cross Sectional Loading Maximum starting torque 104%
Material mass (wm) 480,8 kg/m Inertia - Motor 14,0 kg·m²
Combined mass (wm + wb) 536,1 kg/m Pulley lagging type Ceramic
Edge distance (required / actual) 105 / 187 mm Motor wrap angles 196 / 196
Cross sectional area 0,232 m² Lagging friction factor (run / accel) 0,36 / 0,45
Bed depth 277 mm Take-up Data
Type Hydraulic cylinder
Location Head / Pulley #3
Steady state tension 498 to 498 kN
Required pulley displacement 6,97 m

Dynamic displacement (incl thermal) 2,46 m
Permanent elongation 1,58 m
Splice length (2 included) 1,94 m
Clearance 1,00 m

Page 38 / 48
Description:
Conveyor Profile
Overall length = 1560 m - Overall height = -0,7 m - True Length = 1592,4 m
Tail Arrangement Head Arrangement

Page 39 / 48
Description:
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Pulley 1 1-HT 180 498500 997 514516 1.030
Pulley 2 2-MT 79 499500 633 515517 654
Take-up Pulley 2-MT 78 498500 631 515517 653
Motors 1/2 3-HT 196 500 465 954 517 476 967
Pulley 5 4-SN 16 465466 129 476477 133
Pulley 6 4-SN 16 488489 139 490491 140
Motors 3/4 3-HT 196 489 456 935 490 473 954
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
Safety Slope at Deflection T1 T2
Pulley # 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 2,50 4,51 0,048 127 547 550 4797 1.107 194 1,4 221,4
2 2,83 4,08 0,040 90 623 624 3166 811 319 0,7 121,6
3 2,98 3,88 0,038 108 622 625 3166 770 37 1,1 115,4
4 2,46 4,06 0,040 91 548 511 4794 1.044 175 11,9 156,6
5 4,65 4,55 0,045 236 581 582 1746 179 262 0,4 26,8
6 4,35 4,87 0,048 188 610 611 1746 191 277 0,4 28,7
7 2,51 3,98 0,039 97 538 502 4794 1.023 6 11,6 153,4
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)
Rubber
1 1250 12,0 1274 1800 340 300 2400 3164 23164 6.262
Plain
Rubber
2 1000 12,0 1024 1800 300 260 2200 3156 23156 4.150
Plain
3 Ceramic 1250 12,0 1274 1800 320 280 2200 3160 23160 6.005
Rubber
4 800 12,0 824 1800 200 160 2200 3036 23036 2.008
Plain
Pulley Shaft Information

Overhun
Hub Bearing
Tensile Yield Fatigue Hub Fillet Overhun g
Locking Shaft Center to Fillet
Type Strength Strength Strength Diameter Radius g Load Moment
Device Material Distance Distance
(MPa) (MPa) (MPa) (mm) (mm) (kN) Arm
(mm) (mm)
(mm)
1 B-LOC 115 SAE 4140 655,0 417,0 327,5 340 1600 190 60 0,0 0
2 B-LOC 115 SAE 4140 655,0 417,0 327,5 300 1600 165 60 0,0 0
3 B-LOC 115 SAE 4140 655,0 417,0 327,5 320 1600 180 60 0,0 0
4 B-LOC 115 SAE 4140 655,0 417,0 327,5 200 1600 120 60 0,0 0

Page 40 / 48
Description:

#1 - Pulley 1
Lagging
Shaft Specification

Page 41 / 48
Description:

#2 - Pulley 2
Lagging
Shaft Specification

Page 42 / 48
Description:

#3 - Take-up Pulley
1. Name (Type-2) Take-up Pulley 29. Running T1 Tension 498 kN
Lagging
Shaft Specification

Page 43 / 48
Description:

Lagging
Shaft Specification

Page 44 / 48
Description:

#5 - Pulley 5
Lagging
Shaft Specification

Page 45 / 48
Description:

#6 - Pulley 6
Lagging
Shaft Specification

Page 46 / 48
Description:

Lagging
Shaft Specification

Page 47 / 48
Description:
Demand Power (kW)

Drive Station Case
Demand % Motor
Type Variable speed power Nameplate
Synchronous RPM 1500 RPM Empty - NF 636 25,2
Motor quantity / rating 4 / 630 kW Full - NF 2074 82,3
Total ınstalled power 2520 kW Empty - LF 408 16,2
Nominal empty / full power (25 / 82%) 636 / 2074 kW Empty - HF 809 32,1
Min / max demand power (16 / 96%) 408 / 2414 kW Full - LF 1673 66,4
Frame Size IEC 400J Full - HF 2414 95,8
Motor Voltage 400 V
Efficiency 94,5 to 97,5%
Maximum starting torque 104%
Inertia - Motor 14,0 kg·m²
Pulley lagging type Ceramic
Motor wrap angles 196 / 196
Lagging friction factor (run / accel) 0,36 / 0,45
Reducer Information
Manufacture N/A
Frame size N/A
Reducer ratio 19,070
Catalog reducer ratio 0,000
RPM (High Speed) 1500 RPM
RPM (Low Speed) 78,7 RPM
Configuration Shaft Mount
Number of stages 3
Service factor 1,4
Power rating 0
Motor Torque
100% Motor Torque - High Speed 4.072 N·m
Motor Shaft Torque - Running (FN) 3.351 N·m
Motor Shaft Torque - Starting (FN) 3.693 N·m
100% Motor Torque - Low Speed 77.649 N·m
Low Speed Shaft Torque - Running (FN) 60.675 N·m
Low Speed Shaft Torque - Running (Max) 70.279 N·m
Low Speed Shaft Torque - Starting (FN) 66.774 N·m
Low Speed Shaft Torque - Starting (Max) 76.415 N·m
Starting and Stopping

Start control Fixed time
Start time 135,0 s
Emergency stop control Drift
Emergency stop time 11,0 to 18,6 s
Material buildup in chute 10,2 m³

Page 48 / 48

System Information Idler Set Data

Uploaded by

Copyright:

Available Formats

System Information Idler Set Data

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

System Information Idler Set Data

Uploaded by

Copyright:

Available Formats

Client Name EUROCHEM Designer HAK

Project Name 221526 Company Birikim Mühendislik End.

Required pulley displacement 6,97 m

Sidewinder - v7.22 - Conveyor Design Software

Cable diameter 6,5 mm

Minimum Belt Tensions (kN) Maximum Belt Sag (%)

Sidewinder - v7.22 - Conveyor Design Software

Tail Arrangement Head Arrangement

Maximum Pulley Tensions (without any additional safety factors)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Shaft Results

Pulley Geometry Details (Pulley Types)

Pulley Shaft Information

Sidewinder - v7.22 - Conveyor Design Software

Conveyor Load Cases

Fully Loaded (Material Lift = 10,0 m)

Sidewinder - v7.22 - Conveyor Design Software

Take-up Displacement Summary

Take-up Pulley Displacement Summary

Sidewinder - v7.22 - Conveyor Design Software

Pulley Design Tensions (added safety factors as described above)

Required Pulley Diameter (Tension based on a safety factor of 6,67)

Pulley Shaft Stress Analysis (Individual Pulleys)

Sidewinder - v7.22 - Conveyor Design Software

Running Drive Tensions by Load Case (kN)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Tension Summary - All Load Cases and Conditions

Sidewinder - v7.22 - Conveyor Design Software

28. Bearing L10 126.571 hours

Sidewinder - v7.22 - Conveyor Design Software

28. Bearing L10 90.413 hours

Sidewinder - v7.22 - Conveyor Design Software

28. Bearing L10 107.626 hours

Sidewinder - v7.22 - Conveyor Design Software

#4 - Motors 1/2 Design Tensions and Loads

Sidewinder - v7.22 - Conveyor Design Software

28. Bearing L10 235.567 hours

Sidewinder - v7.22 - Conveyor Design Software

28. Bearing L10 187.952 hours

Sidewinder - v7.22 - Conveyor Design Software

27. Bearing L10 97.115 hours

Sidewinder - v7.22 - Conveyor Design Software

Belt Flap Summary

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Belt Transition Length Requirements

Geometry of inline and elevated pulley transition

Required transition lengths

Sidewinder - v7.22 - Conveyor Design Software

Material Loading Profiles

Material Properties Material 1 on Idler Set 1

Tonnage 9000 t/h

Sidewinder - v7.22 - Conveyor Design Software

Idler Spacing and Count Summary

Idler Life and Shaft Deflection Summary-Carry Side

Idler Life and Shaft Deflection Summary-Return Side

Sidewinder - v7.22 - Conveyor Design Software

Bearing Reaction Forces (excluding any overhung loads)

Element Summary Details