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    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 Cut-off 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 cut-off bar (average)
    m
    Step 9 Force Required to Extract Flooded Condition
    Length from the discharge lip to the cut-off bar L m
    Height to the cut-off 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 3-4%)  
      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 Take-up 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
       
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