













Step 1 Estimation of
Surcharge Angle










(Typically low angle
of repose will result in a lower surcharge angle and vice versa.)



Angle of repose



degrees









Material reduction allowance

[Km]


degrees










Slope / Velocity reduction allowance

[Kv]


degrees










Special reduction allowance

[Ks]


degrees















Step 2 Lump size
determining belt width













Lump Size (nominal product size)



minus mm

(allow 3 times
crusher manufacturers lump size)



Maximum anticipated lump size



mm



Minimum width b/w skirt liner plates



mm




Calculated required minimum belt width for lump size



mm









Step 3 Standard Burden
Edge Distance














[w]


mm

(An increase in belt
speed can reduce burden edge distance  not calculated here)













Step 4 Burden cross
sectional area from tables









mm




Idler angle

[Ia]


deg.







Nominal Surcharge angle  calculated



degrees

(Reduce belt velocity to reduce
[Kv] )






Surcharge Angle (see above for
reference)

[Sadeg]


deg.











Maximum Permissable Belt speed



m/s
















Step 5 Belt Speed by
Belt Dimensions













Tonnes per hour



tph










Material Density



kg/cu.m











Calculated belt speed required



m/s
















Step 6 Design Capacity














Material feed surge factor

[Kf]


[select] =>










(Equipment movement in addition to belt speed)



m/s

(e.g. long travel
machine movement with belt)








Calculated Design Capacity



tph















Step 7 Belt Deflection
Check for Troughability













Belt Thickness



mm














Step 8 Cutoff Bars
(minimum distance from chute)












Coefficient of friction b/w the belt and material













Angle of the conveyor at the loading point



deg.

(Check area of slot 4
times normal burden to allow feed)








Slot Width from feed point to cutoff bar (average)



m














Step 9 Force Required to
Extract Flooded Condition






Length from the discharge lip to the cutoff bar

L


m




Height to the cutoff bar

hc


m




Average width of the feed slot

wav


m




Calculated Vertical Force acting on the shear plane

Fvm


kN




Friction coefficient




(0.7 is for coal)



Calculated Horizontal Force acting

Fhm


kN




Length of skirts

Ls


m

(Min. 1.8m + 0.6m per
0.5m/s over 1.5m/s)



Height of material in contact with Skirts

hs


m









Coefficient of friction on skirt plate

Us

















Belt Tension Calculation






Step 10 Primary
Resistance & Slope Resistance Forces













Horizontal Length of conveyor (L)



m




Unit mass of belt (ub)



kg/m




Length of Impact Idlers



m










Trough idler dia.



mm

No data base connection to mass









Return Idler dia.



mm

No data base connection to mass









Impact Idler Spacing



mm










Trough Idler Spacing



mm











Return idlers spacing



mm










Impact Idler mass r/parts



kg










Trough Idler mass r/parts



kg










Return Idler mass r/parts



kg










Belt and idler friction factor



fx

(Length <100m =
0.02, for all others = 0.016)








Material burden friction factor (fy)




Range: 0.025 to 0.035









Vertical Lift of Loaded section (H)



m















Step 11 Secondary
Resistance Forces














Component of matrl
velocity in dirn of travel at loading point


m/s

(Eg. Travelling boom).



Skirt Length



m




No. Cleaners



No.










Pulley shaft diameter at bearing (d)

d


mm










Pulley diameter (D)

D


mm




Resultant Force on Pulley (Fr)

Fr


kN










Average belt tension at the pulley (Ta)



kN










Quantity of drive pulleys




















REUSLTS  Effective Tension







Calculated Effective
Tension (Sum of the tension forces)


kN









Step 12 Belt Selection













Conveyor belt type












Belt Rating (not belt width)













Bottom Cover Thickness



mm




Top cover thickness







Belt Steel cord diameter



mm

AS 1333 recommended



Calculated Minimum Pulley Diameter



mm









Step 13 Belt Velocity
Calculation by Pulley / Drive Dimensions









Full Load speed of the drive motor (n)

[n]


rev/min









Diameter of the drive pulley excluding lagging



mm









Drive pulley lagging thickness



mm




Diameter of the drive pulley over the lagging (D)

[D]


mm




Belt bottom cover thickness (bb)

[bb]


mm




Belt carcass thickness (bc)

[bc]


mm




Exact speed reducer ratio (Iex)

[lex]












Belt Speed Calculation Check:



m/s










RESULTS  Power Demand













Drive Pulley friction force



kN










Efficiency of the drive equipment (n)



%

(if fluid coupling  reducer
further 34%)



Calculated Power Demand



kW




Calculated power per drive pulley



kW











Summary of Inputs and Results














Lump Size (nominal product size)



minus mm




Required Capacity



tph



Design Capacity



tph




Material Bulk Density



kg/cu.m




Belt Width



mm




Belt Velocity



m/s



Trought Idler angle



degrees




Surcharge Angle



degrees




Burden CSA



mm






mm









Belt Type







Av. Carry side belt sag



%




Trough Idler Pitch



m




Material Velocity change



m/s




Quantity of impact idlers







Quantity of trough idlers







Quantity of return idlers







Impact Idler mass r/parts



kg




Trough Idler mass r/parts



kg




Return Idler mass r/parts



kg




Trough idler dia.



mm

No data base connection to mass



Return Idler dia.



mm

No data base connection to mass



Belt mass



kg/m




Horizontal centres



m




Load lift



m




Skirt Length



m




No. of Belt cleaners / ploughs







No. high tension N/D pulleys







Speed reducer loss



%




Fluid coupling loss


3

%











Material mass



kg/m











Conveyor empty friction factor






Material friction factor














Conveyor empty friction force



kN




Material friction force



kN




Material lift force



kN




Material acceleration force



kN




Miscellaneous friciton force



kN











Effective tension Te



kN




Total Power demand



kW




Power per Drive



kW










Step 15 Belt Sag
Requirement







Trough Idler Spacing



mm




Unit mass of material

um


kg/m




Unit mass of belt

ub


kg/m




Maximum belt sag criteria







Calculated minimum belt tension at end skirts



kN









Step 16 Takeup Tension
Requirement (minimum slack tension T2)












Conveyor power



kW

From Step 14



Full load motor torque











Drive efficiency



[Select]







Motor efficiency







Belt velocity



m/s

Go Back



Calculated minimum tension TeFLT



kN

To



Calculated minimum slack side tension T2FLT



kN

Step 12








Step 17 Pressure under
steel cords  Maximum steady state





Minimum pulley diameter

Dpc


mm

From Step 13



Belt cord diameter (carcass thickness)

dc


mm




Belt cord pitch

p


mm

From Steel Cored table



Allowable pressure under the cords

Pc

1.2

Mpa




Max steady state belt tension across pulley per m



kN/m width

Due to Steel Cords



Maximum steady state belt tension at the pulley



kN

Due to Steel Cords



Maximum steady state belt tension due to belt



kN/m width




Maximum steady state belt tension due to belt



kN









Step 18 Cover rubber
extension







Minimum pulley diameter



mm




Belt carcass thickness (cord diam)


15

mm




Maximum belt top cover thickness



mm








