COOK ENGINEERING 1

Project: Project #: Rev.#:Item: Calculations by: cdk Date:

Checked by: Date:

BELT CONVEYOR AND BELT FEEDER DRIVE SIZING CALCULATIONS

BELT CAPACITYRequired Conveying Rate: 24.00 tph << input Material Conveyed: Sand << input Table 3-3

Material Density: 30.0 << input Table 3-3Angle of Repose: 45.0 deg << input Table 3-3Angle of Surcharge: 30.0 deg << input Table 3-1Belt Width: 36.0 in << input Figure 4-1Trough Angle (0 for flat belt): 0.0 deg << input

Maximum Load Cross Sectional Area: 1.1420 << input Tables 4-2 to 4-5

Maximum Belt Capacity: 6,857.00 << input Tables 4-2 to 4-5Maximum Lump Size: 0.2 in << input Belt Speed:

Design: 25.0 fpm << input Table 4-1Minimum to Handle Design Capacity: 23.3 fpm Should be less than design

Maximum Capacity at Design Speed: 25.714 TPH

Troughing Idler Info:Diameter 4.0 in << input Class (A-E) C << input Tables 5-8 to 5-12Load Rating 837.0 lb << input Tables 5-8 to 5-12

4.000 ft << input Table 5-2Return Idler Spacing: 10.0 ft << input Table 5-2

1.00 << input Table 5-41.15 << input Table 5-51.20 << input Table 5-60.85 << input Table 5-7

** 9.0 lb/ft << input Table 6-1

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

lb/ft3

ft2

ft3/hr/100fpm

IDLER DESIGN (Only Belt Weight W b req'd for Pan Belt Conveyors)

Si, Load Idler Spacing:

K1, Lump Adjustment Factor:K2, Environmental & Maintenance Factor:K3, Service Factor:K4, Belt Speed Factor:Wb, Belt Unit Weight:Wm, Material Unit Weight:

CALCULATIONSSUMMARY SHEET Engineer's Stamp

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

COOK ENGINEERING 2

Conveyor is Pan Type (Y or N): N << inputCoefficient of Dynamic Friction: 0.45 << input Pan Conveyor Only# of Plows: 0.0 << input # of Belt Cleaners (Scraper Type): 1.0 << input L, Length of Conveyor (3000 ft maximum): 40.0 ft << input H, Lift of Conveyor (Negative for Declining): 15.0 ft << input # of Tight Side Non-Driving Pulleys: 0.0 << input # of Slack Side Non-Driving Pulleys: 0.0 << input Belt Material (Fabric or Steel): Fabric << inputApproximate Tight Side Tension (Iterate): 29,040.0 lbs << input from belowApproximate Slack Side Tension (Iterate): 15,840.0 lbs << input from belowNumber of drive pulleys: 1.0 << input

8.0 ft << input

1.0 << input Fig 6-1

1.8 << input Page 76

0.48 lb/ft

0.028 << input Tables 6-2, 6-3Material velocity component in direction ofbelt travel as it is fed onto conveyor: 300.0 fpm << input Calculate

0.0095 << input Table 6-7Hopper used to regulate flow of material (Y or N)? N << inputw, Width of Hopper Outlet: 0.0 in << inputl, Length of Hopper Outlet: 0.0 in << input

0.0 lb

-1.9 lb

49.0 lb

0.0 lb << input Page 84

0.0 lb

180.0 lb Tension required to extract material from hopper (normal operation): 0.0 lb Tension from belt on slide (Pan Conveyor Only): 0.0 lb **** Manual entry for this conveyor ***

777.2 lb

BELT SELECTIONAngle of Wrap, Drive Pulley: 180.0 deg << input Wrap Factor Cw: (Lagged) 1.20 << input Table 6-8

with Dry Belt (higher for wet conditions): 932.6 lb Allowable percent sag of belt: 2.00 % << input Table 6-10

1,033.2 lb

1,709.8 lb << input Calc's p. 102-110Maximum Belt Tension per inch (operating): 47.5 lb/inMaximum Allowable Starting Tension: 330.0 lb/in << input Manufacturer

T e, EFFECTIVE TENSION

Lb, Length of Skirtboards (1 Side):

Kt, Temperature Factor:

Ai:

Kx:

Ky:

Cs, Skirtboard Friction Factor:

Tp, Tension From Non-Driving Pulleys:

Tam, Tension from Acceleration:

Tsb, Skirtboard Tension:

Ttr, Tripper Tension:

Tpl, Plow Tension:

Tbc, Belt Cleaner Tension:

Te, Effective Tension (Required for Operation):

T2, Slack-Side Tension Required to Prevent Slip

T0, Required Belt Tension to Reduce Sag:

T1, Operating Maximum Belt Tension:

COOK ENGINEERING 3

MOTOR SELECTION

0.6 hp Drive pulley friction loss horsepower: 0.13 hpSpeed Reduction Efficiency: 98.5 % << input ManufacturerMotor and Power Supply Efficiency: 99.0 % << inputOperating Motor Power Required: 0.7 hp

Effective Tension Required for Starts: 1,074.4 lbs Percentage Full Load Torque req'd for Starts: 138.2 %Breakaway Torque Required for Starting: 3.1 ft-lbs

Selected Motor Horsepower: 10.0 hp << inputSelected Motor RPM: 1,750.0 rpm << inputMotor Locked Rotor Torque (percentage ofrated full load torque. Use 140% max for VFDapplications, check with manufacturer): 250.0 % << input Table 13-1Motor Pull Up Torque (percentage of rated full load torque, check with manufacturer): 175.0 % << input Table 13-5Motor Rated Full Load Torque: 30.0 ft-lbsBreakaway Torque Available for Starting: 75.0 ft-lbsMinimum Pull Up Torque Available: 52.5 ft-lbs

Breakaway Torque Sufficient for Starting: YESPull Up Torque Sufficient for Acceleration: YESSelected Motor and Drive O.K.: YESReduced Torque Starting Required: YES

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 Page 16 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 119

PULLEY SELECTION (Based on Dodge PT-Components Engineering Catalog:)Selected Motor Horsepower: 10.0 hpPulley Face Width: 38 InchesDesign Bearing Center to Center: 51.00 Inches << inputBCMF: 13.00Te (Effective Tension): 13,200.0 lbsDrive Factor: (1.2 for bare manual, 0.8 for lagged) 1.2 << input Table 2 pg.13-52T2 (Slack Side Tension): 15,840.0 lbsT1 (Tight Side Tension): 29,040.0 lbsDesign PIW (Drive Side): 806.7 lbs per inchDesign PIW (Slack Side): 440.0 lbs per inchArc of Contact: 180.0 degreesTail Pulley Diameter: (Ext'g., Bare) 20.0 Inches << input Table 1 pg.13-12Drive Pulley Diameter: (Lagged, 1/4") 24.5 Inches << input Table 1 pg.13-12Check on Tail Pulley to Belt Tension 275 lbs per inch << input Manufacturer Check on Drive Pulley to Belt Tension 345 lbs per inch << input Manufacturer Selected Tail Pulley Size O.K.: NOSelected Drive Pulley Size O.K.: NO

SHAFT SELECTION (Based on Dodge PT-Components Engineering Catalog:)

Operating Shaft Power Required from Te:

COOK ENGINEERING 4

Resultant Pulley Load (Tail): 28,321.8 lbsResultant Pulley Load (Drive): 40,122.6 lbsDesign Drive Pulley Shaft Size: 2.9375 Inches << input Manufacturer Design Tail Pulley Shaft Size: 2.1875 Inches << input Manufacturer Check on Drive Shaft Load Rating: 3200 lbs << input Table 3 PT13-13Check on Tail Shaft Load Rating: 1100 lbs << input Table 3 PT13-13Design Steel Shafting Grade: (1045) 8,000 psi << input Manufacturer Valve N 6.5 Inches

8.25 Inches << input

2.50 << inputCheck on Drive Pulley Shaft from Torque: 6.5640 Inches

8.13 << input

1.50 << inputCheck on Tail Pulley Shaft from Torque: 4.7896 InchesSelected Drive Pulley Shaft O.K. for Load: NOSelected Drive Pulley Shaft O.K. for Torque: NOSelected Tail Pulley Shaft O.K. for Load: YESSelected Tail Pulley Shaft O.K. for Torque: NO

BELT SELECTIONSelect a belt with a MOR 1/4" X 1/8", Grooved PatternSELECTION: SCANDURA ROLYALON 3-330 BELT

SPEED REDUCER SELECTION (Based on Dodge Gearing Catalogue:)Dodge TDT SeriesConvert FPM to RPM: 3.9Determine Service Factor: 1 << input Table 2 pg.2-7Calculate Equivalent HP 10 HPApplication Class II << inputSelect Unit Size & Ratio TDT425 << input pg G1-21Unit ratio 24.38 Ratio << inputTherefore reuse existing 10 hp motor, new TDT425 reducer required

BELT DRIVE SELECTION (Based on Dodge PT-Components Engineering Catalog:)Determine Service Factor: 1.5 << input table 2 pg PT7-43Design HP: 15.0Determine Overall Ratio Required: 448.99 Motor rpm/belt rpm Determine Belt Drive Ratio: 18.42 Overall Ratio/reducer ratioSelected nearest ratio 1.31 << input Page B-168Driver Sheave OD 5.70 Inches << input Page B-168Driven Sheave OD 7.50 Inches << input Page B-168HP Per Belt 3VX series 15.64 << input Page B-168Minimum Number of belts required: 1.0 Belt Selection 5VX-500 << inputBelt Center to Center Distance 16.4 << input Page B-168Note: Designer can also use Dodge PT-Components Engineering Catalog pg. PT7-1

Adrive (use Table 4 to choose correct A calc.)

KB-drive (KB = 1.5 or KB = 2.5 for Overhung load)

Atail (use Table 4 to choose correct A calc.)

KB-tail (KB = 1.5 or KB = 2.5 for Overhung load)

RPM < Note: Manual add in lagging thickness

COOK ENGINEERING 5

Engineer's Stamp