Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.

24
Material Cross Section Plotter
0
0
0
0

11/21/15
Date

0
Phone

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com

Fax

Copyright - Rulmeca Corp.

Reference Name
Conveyor Number

Return to Specifier

0
0

Cross Section at Troughing Idler:

Narrow Belt (scale: inches)

System Design Parameters:

Tonnage Rate (tph)
Belt Speed (fpm)
Bulk Density (lbs/cu ft)
Material Surcharge Angle

1000
1.5
1,440
25 degrees

Belt Width

36 in.

Idler Angle

35 degrees

15
12
9
6

Plot Wide Belt

Material Geometry in Troughing Idler:

CEMA Max. Allow. Cross Section

1.1 sq ft

Calculated Cross Section

1.4 sq ft

15

12

#DIV/0!

Cross Section at Pulley Face:

Narrow Belt (scale: inches)

15.4 sq ft

Material Height at Centerline

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

Warning: Specified Material Cross Section Exceeds CEMA Max. Allowable.

Material Geometry at Pulley Discharge:

Calculated Cross Section

9.5 in

-3

0.6 in

Calc'd Material Height at Centerline

-6

2.9 in

Calculated Edge Distance

-9

CEMA Standard Edge Distance

-3

-12

135%

-15

Calc'd Xsec/CEMA Xsec

Height of Center of Gravity (A1)

#DIV/0!

Assumed Edge Distance

0.32 in

Calculated Surcharge Angle

0 deg

CEMA Max. Allow height at center

CEMA Max Height of C.O.G.
CEMA Standard Edge Distance

6.6 in.
2.7 in.
1.44 in

2.7

0
-3

18

15

12

-3

-6

-9

-12

-15

-18

Note:
This program calculates height of actual C.O.G.*
by assuming that actual edge distance at pulley
face equals 1/2 of actual edge distance in troughed
section. Height of C.O.G.* for CEMA maximum
allowable cross section pulley face is given for
reference only.

Legend: Solid Line is CEMA Max. Allowable; Red Line is Calculated.

* C.O.G. = center of gravity of material

file:///var/www/apps/conversion/tmp/scratch_2/295751749.xls, Page 1 of 9

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Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

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

40
1000
1.5
6
-10
80
0
1
0
4
75
1
0

Elevation (Km above sea level)

1.0
Type of Material
Limestone, pulv., dry
Belt Width (mm)
1000
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 =

15944 N

29.8 kW
1050 mm
RECOMMENDED DRUM MOTOR
30 kW
1.6 m/s
JOKI Model(s):
630, 800
$0

ALTERNATE DUAL DRIVE OPTION

18.5 kW/ea
1.6 m/s
JOKI Model(s):
500
$0
0

RECOMMENDED OPTIONS:
1. Mechanical Backstop
2. Class H Motor Winding.
SPECIAL NOTES:
Exceeds recommended temp. Consult Rulmeca.

Engineering Design Data:

Ai
Cs
H
Kt
Kx
Ky
L
Q
Si
Tac
Tam
Tb
Tbc
Te

8.0064 N
0.128
6m
1.06
0.82kg/m
0.035
40 m
1000 mtph
1.2 m
1291 N
416 N
867 N
876 N
15944 N

295751749.xls 11/21/2015 09:27:54

Tm
Tp
Tpl
Tsb
Ttr
Tx
Tyb
Tyc
Tym
Tyr
V
Wb
Wm

10895 N
156 N
0N
415 N
0N
338 N
305 N
214 N
2542 N
92 N
2 m/s
15 kg/m
185 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

23.92
0.36
24.28
0.78
25.06
0.00
29.83

(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: 8206 Kw-Hrs/Yr, 1 shift/day or 24619 Kw-Hrs/Y

Save: 714 /Yr, 1 shift/day or 2142 /Yr, 3 shifts/day

kW
kW
kW
kW
kW
kW
kW

n 50 Hz power.)

eek/yr operation

V-belt drive)

or 24619 Kw-Hrs/Yr, 3 shifts/day

/Yr, 3 shifts/day @ 0.087 /Kw-Hr
295751749.xls 11/21/2015 09:27:54

Specifier

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Specifier Sheet and Recommendation Summary
11/21/15
Date
www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group
Head

Telephone

Telefax

e-mail

Head

Go to Design Parameters

Return Run
Tail

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

40
1000
1.5
6.0
-10
80
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):

29.8 kW
Force (N)
15,944
0
0
0
15,944

###

Limestone, pul

Ashes, coal, dr

Bauxite, groun

4
75
1

Elevation Above Sea Level

1.0 Km

RECOMMENDED OPTIONS:
1. Mechanical Backstop
2. Class H Motor Winding.

Cement, Portla

SPECIAL NOTES (if any):

Coke,
ground f
Cullet (broken

Cement clinke

Clay,
Coal, ceramic,
bitum. m

Material, fric coeff

Limestone, pulv.,dry,

0.128

Minimum allowable belt width for lump size is 450 mm

Grains,wheat,c

Bulk Density (Kg/m3)

Limestone, crushed,

1,440

Minimum Acceptable Diameter is 255 mm *

Gravel, bank ru

Size Consist

90% fines, 10% max lump size

Exceeds recommended temp. Consult Rulmeca.

Iron Ore,

100

*A smaller pulley diameter may cause belt carcass or fastener damage.

Limestone, pul

25 deg.

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:

Phosphate roc

Max. Lump Size (mm)

Material Surcharge Angle
Belt Width

1000 mm

Belt Carcass Type

Salt, dry fine,

Fabric

Idler Roll diameter

30 kW

Models Available:

Belt Speed:

1.6 m/s

630, 800

Face Width:

1050 mm

133 mm

Troughing Idler Angle

35

Troughing Idler Spacing

1.2 meters

Angle of Wrap**

180 degrees

Type of Lagging

Full Lagging

Type of Take-up

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY:

Power:
18.5 kW/ea
Models Available:

Manual

Belt Speed:

1.6 m/s

2 ply, 225 piw

Head

Face Width:

1050 mm

Elevating or Horizontal
well maintained

Type of Dual Drive (if any)

none

500

Power savings - 1 shift and 3 shift per day:

(Motorized Pulley compared to exposed conveyor belt drives)

nest on return si

Save: 8206 Kw-Hrs/Yr, 1 shift/day or 24619 Kw-Hrs/Yr, 3 shifts/day

Save: 714 /Yr, 1 shift/day or 2142 /Yr, 3 shifts/day @ 0.087 /Kw-Hr

** This parameter is for either single or dual drive arrangement.

Special Loading Conditions:

Go to Design Parameters

1. For hopper feeder specify opening dimensions below.

2. For slider bed, specify bed length & type of 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

Sand, dry, ban

Wood chips,

CEMA Type

Type of Belt
Drive Location
Material Flow
Condition of Idlers & Pulleys

Power:

None

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

295751749.xls, Specifier, Page 4 of 9

Ashes, coal, w

Ashes, coal, w
Bagasse, 10
11/21/2015 09:27:54

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Model Selector
0
0
0

11/21/15
Date
www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group

0
Telephone

0
Telefax

0
e-mail

0
Project Name
REQUIRED POWER:

0
Conveyor Reference
29.8 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)
15,944
0
0
0
15,944

Select Model

400M
Check Radial Load (to prevent internal
damage to pulley)
Force (N)
Maximum Allowable Radial Load
40,500
Estimated Maximum Radial Load
9,320
Selected model is appropriate for estimated radial load.
0

RECOMMENDED OPTIONS (if any):

1. Mechanical Backstop
2. Class H Motor Winding.
SPECIAL NOTES (if any):
Exceeds recommended temp. Consult Rulmeca.

Go to Design Parameters

RECOMMENDED "SINGLE DRIVE" MOTORIZED PULLEY:

Power:
Belt Speed:
Face Width:
Models Available:

30 kW
1.6 m/s
1050 mm
630, 800

Check Pulley Diameter

(to prevent belt damage.)
Minimum Acceptable Diameter is 255 mm *
Selected Diameter is 400 mm
Selected diameter is appropriate for specified belt.
(This calculation does not check pulley/belt traction.)
0

Check Belt Tension

Maximum Belt Tension (T1)
Allowable Belt Tension

Force (N)
6,452
39,685

Belt Tension Calculation Summary

Te, effective belt tension
T2, to prevent belt/pulley slippage
T2, to limit belt sag to 2 %
T1, maximum belt tension

Force (N)
3,585
2,868
1,829
6452

**Measured at Drive A in Dual Drive, if applicable.

Calculation for "Dual Drive on Carry Side" is under construction.

RECOMMENDED "DUAL DRIVE" MOTORIZED PULLEY:

Power:
Belt Speed:
Face Width:
Models Available:

18.5 kW/ea
1.6 m/s
1050 mm
500

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Design Parameter Summary
0
0
0

11/21/15
Date
www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group

0
Telephone

0
Telefax

0
e-mail

0
Project Name

0
Conveyor Reference

Power Calculation Summary

Return to Specifier Sheet

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

15944 N
180 degrees
0.8
12755 N
28699 N
41454 N
Full Lagging
Manual
2 ply
1000 mm
8858 N
73 %
5 to 11 mm
8.0064 N
0.128
6m
1.06
0.82kg/m

Ky
L
Q
Si
Tac
Tam
Tb
Tbc
Te
Tm
Tp

0.04
40 m
1000 mtph
1.2 m
1291 N
416 N
867 N
876 N
15944 N
10895 N
156 N

Tpl
Tsb
Ttr
Tx
Tyb
Tyc
Tym
Tyr
V
Wb
Wm
Sag
Ls
Hd

0N
415 N
0N
338 N
305 N
214 N
2542 N
92 N
2 m/s
15 kg/m
185 kg/m
#NAME?
0
0

23.9
0.4
24.3
0.8
25.1
0.0
4.8
29.8

kW
kW
kW
kW
kW
kW
kW
kW

Definition of Terms

Return to Specifier Sheet

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.
Sag = recommended maximum sag percentage to avoid spillage in troughed section of belt.
Ls = Length of conveyor from tail pulley to Drive snub (for return run drive only)
Hd = Height of conveyor from top of tail pulley to bottom of drive pulley (for return run drive only)
295751749.xls, Design Parameters, Page 6 of 9

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Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Conveyor Height Calculator
Inclined conveyor length (m)
Angle of inclination (degrees)
Material lift height (m)

0.0

www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group

Return to Specifier Sheet

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Bulk Handling Belt Conveyor Terminology

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Bulk Handling Belt Conveyor Terminology*

Bulk Handling Belt Conveyor Terminology*

6508-B Windmill Way
Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com

www.rulmecacorp.com
Return to Specifier Sheet

Copyright - Rulmeca Group

Return to Specifier

Print This Sheet

Return to Specifier

Print This Sheet

Copyright - Rulmeca Corp.

Return to Specifier

Belt Conveyor with Tripper

Return to Specifier

Tail Pulley Drive

Conveyor Cross Section in Skirt Zone

Initial Velocity of Material

Head Pulley Drive

Return to Specifier

Return to Specifier

Drive on Return Run

Conveyor Profile

* All sketches taken from CEMA Manual Fifth Edition, Chapter 6.

Hopper Feeder Conveyor

Lowering without Regenerative Load

Lowering with Regenerative Load

Horizontal or Elevating
Nested Drive - Carry Side
Nested Drive - Return Side
Head and Tail Drive

Horizontal or Elevating

Return to Specifier

Print This Sheet

* All sketches modified from CEMA Manual Fifth Edition.

6508-B Windmill Way

Wilmington, NC 28405
Ph 910-794-9294
Fax 910-794-9296
www.rulmecacorp.com
Copyright - Rulmeca Corp.

Return to Specifier
Print This Sheet

Return to Specifier

Cleated Belt with Sidewalls

Return to Specifier

Belt Conveyor with Two Diverter(s)

"CEMA" Idler Type Definitions

Return to Specifier

(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

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.

30

40+

Irregular, stringy, fibrous, interlocking material, such as wood chips, bagasse, and tempered
foundry sand.

295751749.xls, Terminology, Page 8 of 9

11/21/2015 09:27:55

Rulmeca Motorized Pulley Power Calculation Program - Metric Version 7.24

Bulk Handling Trajectory Calculator and Plotter
(based on CEMA 5th Edition)
0
0
0

0
Phone
Project Name
Conveyor Ref.

www.rulmecacorp.com
www.rulmeca.com
Copyright - Rulmeca Group

0
Fax

Return to Specifier

0
0

System Design Parameters:

Belt Width

Material Trajectory:
Small Pulley (scale: 75 mm/increment)

1000 mm

Belt Wid

Troughing Idler Angle

35

Pulley La

Diameter Pulley (mm)

330
mm
320

Lagging

Lagging Thickness (MM)

5 mm
5

Belt Speed

1.65 m/s

Surcharge Angle (degrees)

25 deg.

Tonnage Rate (MTPH)

1,000

Material Density (Kg/m3)

1,440

Belt Thickness (mm)

Actual B

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

Calculated Results:
Calc'd mat'l height at centerline
Calc'd actual height of C.O.G.*

187 mm
76 mm

Calc'd actual mat'l cross section

11.7 sq m

CEMA Max Allow. height at center

198 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

79 mm
13.7 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

295751749.xls, Page 9 of 9

11/21/2015 09:27:55