Manufacturers of quality engineered components for Industry using the latest CNC machining technology

TEFCO ENGINEERING PTY LIMITED ABN 35 054 554 611

CONVEYOR PULLEY CAPABILITY

DESIGN

Tefco uses a number of design philosophies for the various elements that make up a modern live shaft pulley, dependent on type of pulley and the loads it operates under. Tefco has in house staff capable of designing conveyor pulleys, sheaves, bearing housings, winches, couplings and locking assemblies of every type and description and also employs Mechanical Engineers with solid modelling, CAD and Finite Element Analysis capability to assist with component design.

Shaft:We use AS1403 for shaft design which has been found to be a safe conservative tool for shaft design. We use the recommended Fs value of 1.2. Our K factor used is based on the calculated interference developed by the locking assembly which is dependent on the surface pressure induced by the tightening torque. The K factor is also significantly influenced by the UTS of the shaft material used and we use K1045 as standard with a stress limit of 270Mpa under all load conditions (45% of 600Mpa UTS). The use of other higher tensile materials such as 4140 does not generally give an advantage despite the higher allowable stress limit of 360Mpa (45% OF 800Mpa UTS) because the resultant higher K factor often produces a worse outcome for the same size. Generally we try to reduce the tightening toque to the equivalent of a grade 8.8 bolt despite using grade 12.9 bolts, which minimises the induced stress. Drive pulley locking assemblies are sized to ensure minimum transmitted torque capability of 2 x motor FLT. The shaft deflection is limited to less than 5 minutes under ALL load conditions.

Locking Assemblies: We generally use TAS or equivalent such as MAV or Bikon locking assemblies made in Europe. The series used depends on the loads and torque requirements, but as a rule we use the T3006 self centring series unless toque or bending moment requirements need a higher capacity where we will use the wider T3015 self centring series. For both these series we limit the allowable running bending moment thru the joint to 35% of the catalogue rating on drives and 45% for non drives.

Bearings & Housings: Once a shaft diameter has been determined we use ISO 281 to check the bearings theoretical B10 life. Housing type used is a function of diameter and client preference, but as a rule we use SNG500 series up to 90 diameter shaft, T or FSSNG500 series for 100 thru 140 diam and SD3100 series thru to 300 diameter and either CSD series or AW solid housings above that. We propose Taconite sealing for all pulley applications.

Shell:Our shell thickness calculation uses the thesis of Sitzwohl from Germany who investigated many failures of pulleys with belt wrap angles above and below 180 degrees and developed his now well proven theory which incorporates a correction factor (K1) dependent on the angle of belt wrap, where 180 degrees incurs the lowest K1 factor of 0.033 to a high of 0.13 which is incurred for a 70 degree wrap angle. We limit shell stress to less than 55Mpa at worst case run loads.

End Discs: For most pulleys we use standard flat plate theory based on the transmitted bending moment. We limit end disc stress to less than 55Mpa at worst case run loads. For highly stressed pulleys where the diameter permits we use the Schmoltzi flexible “T” disc design. The larger diameters are required for this style end disc or the resultant stiffness basically results in a rigid end disc design. A sample of this design is attached.

Couplings: Our coupling designs are based on the SKF oil injected method and we recommend tapered joints for better maintenance procedures. See sample attached.

DBCT Pulley design check.xls P92 Run Date: 18/11/2006

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Design PJB

Checked

PROJECT DBCT 7X Coal Terminal upgrade RUN DATE: 18-Nov-06

TEFCO REF: DBCT 7X Pulley Job 7313CONVEYOR REF: Feeders BF5 & BF11PULLEY REF: DRIVE P92 with installed power 1 X 110Kw Using Tefco Design

Belt Tension T1: Start. 300.0 kN Pulley Resolved load: Max 489.0 kN

Belt Tension T1: RUN 300.0 kN Pulley Resolved load: Run 489.0 kN

Belt Entry Angle A1 0 deg Belt Wrap Angle 200 Deg

Belt Tension T2: Start. 200.0 kN

Belt Tension T2: RUN 200.0 kN Pulley Speed

Belt Exit Angle A2 20 deg 15.3 R.P.M.

Belt Width 2400 mm

Belt speed 1.00 m/s

Pulley Shell Diameter 1226 mm Lagging Thickness 12mm Pulley Diam over lagging: 1250mm

Pulley Face Width 2650 mm Lagging Type - Razer Ceramic Grade

Bearing Housing Centres 3500 mm Qty Drive Ends 1Installed Power 110 Kw Legth.CL Brg/CL Drive -TBC 1450 mm

Motor Speed 1480 R.P.M. Drive Mount -Cplg or Shaft Cplg with shaft drive ext'n 340 Diam x 442Long

Overhung load 90 kN Motor FLT @ Pulley 68750 Nm Shaft lgth CL Hsg to end756

Brakes or Holdbacks Fitted Yes

Locking Assembly Type T3015 Bending Moment (M) 156830 Nm At Start Load

Locking Assembly Size 380 x 475 B/ Moment transferred 153474 Nm At Start Load

Hub centres 2420 mm B/ Moment transferred 153474 Nm At Run Load

Published Torque Rating (Mt) 524000 Nm B/ Moment Ratio % 29% At Start Load

B/ Moment Ratio % 29% At Run Load

Published Bolt Torque (Ma) 930 Nm Bolt Torque to be used 550 Nm

Published Hub Pressure (Pn) 113 Mpa Hub Pressure Used (pn) 67 Mpa

Published Shaft Pressure (Pw) 175 Mpa Resultant Shaft Pressure (pw) 103 Mpa Effective interference 0.456mm

L/Assy Torque Service Factor 451 % Actual Transmissable Torque 309892 Nm Stress raiser K@L/Assy 3.33

Bearing Life Required 60000 Hours Actual B10 Bearing Life 15433201 Hours At Run Load

Required Dynamic Capacity 814 kN Bearing Dynamic Rating 4300 kN

Bearing Size Select Spherical 23172 Brg Housing Designation SDD3172 Tac

SHAFT DESIGN TO AS1403 - using 4140 Grade Material with min UTS 800Mpa

Allowable Shaft Defl'n L/2000 1.75 mm Actual Deflection @ Ctr 0.84 mm At Start Load

Allowable Defl'n @ Hub 5.0 mins Actual Deflection @ Hub 2.8 mins At Run Load

Allowable Defl'n @ Hub 5.0 mins Actual Deflection @ Hub 2.8 mins At Start Load

Allowable Stress @ Hub 360 Mpa Actual Shaft Stress @ Hub 214 Mpa At Run Load

Allowable Stress @ Hub 360 Mpa Actual Shaft Stress @ Hub 214 Mpa At Start Load

Allowable Stress @ Brg 360 Mpa Actual Shaft Stress @ Brg 98 Mpa At Run Load

Allowable Stress @ Brg 360 Mpa Actual Shaft Stress @ Brg 98 Mpa At Start Load

Allowable Stress @ Cplg 360 Mpa Actual Shaft Stress @ Drive 108 Mpa At Run Load

Design Load "P" Max 244.5 KN Safety Factor used (Fs) 1.2Design Load "P" Run 244.5 KN Shaft O/All Lgth 4386 mm

Estimated Plly Assy. Mass 10226 kg

Mass moment of inertia 1442.6 kgm2

Shaft dia D5 D4 D3 D2 D1

390 380 380 340 340

Shaft Step Length E D C B A

1120 90 236 40 264

Allowable Shell Stress - Run 55 Mpa Actual Shell Stress 22.5 Mpa At Run Load

Allowable Shell Stress - Start 69 Mpa Actual Shell Stress 22.5 Mpa At Start Load

Min. Shell thickness - Run 20.4 mm Selected Shell Thickness 32 mm in Ctr 32 mm at Edge

Allowable End Disc Run Stress 55 Mpa Actual End Disk Stress 19.6 Mpa At Run Load

End Disc thickness 150 mm Actual End Disk Stress 19.6 Mpa At Start Load

SHELL DESIGN using SITZWOHL's THEORY

END DISC DESIGN using FLAT PLATE THEORY

TEFCO PULLEYS

Liveshaft Pulley "Design Sheet"

BEARING SELECTION to ISO 281

LOCKING ASSEMBLY SELECTION

D4D5 D3 D2 D1

E ABCD

C/L BRGC/L HUBC

L

ANGLE A1

T1

T2

ANGLE A2 ( - )

Tefco Schmoltzi Pulley Design.XLS Smoltzi Drive Run Date: 18/11/2006

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"T" Type End Disc Liveshaft Pulley "Design Verification Sheet" Designer PJBChecked

PROJECT Luan Wangzhuang Conveyor Project Run Date: 18-Nov-06

TEFCO REF: ACT Luan Wangzhuang Pulley quote 270105

CONVEYOR REF: Drift

PULLEY REF: Dual DRIVE 2 x 500 Kw with installed power 2 X 500Kw

Belt Tension T1: Maximum 441.0 kN Pulley Resolved load: Max 677.3 kN

Belt Tension T1: RUN 415.0 kN Pulley Resolved load: Run 651.3 kN

Belt Entry Angle A1 0 degrees Belt Wrap Angle 200 Deg

Belt Tension T2: Maximum 251.0 kN

Belt Tension T2: RUN 251.0 kN Pulley Speed

Belt Exit Angle A2 20 degrees 61.2 R.P.M.

Belt Width 1200 mm

Belt speed 5.20 m/s

Pulley Shell Diameter 1600 mm Lagging Thickness 12mm Pulley Diam. over Lagging 1624mm

Pulley Face Width 1400 mm Lagging Type - Razer Ceramic Grade

Bearing Centres 1850 mm Number of Drive Ends 2Installed Power 1000 Kw Length.C/L Brg to C/L Drive 1420 mm

Motor Speed 1480 R.P.M. Drive Mount - Cplg or Shaft CPLG with shaft drive ext'n 280 Diam x 420Long

Overhung load 20 kN Motor FLT @ Pulley 78077 Nm

Brakes or Holdbacks Fitted Yes

LOCKING ASSEMBLY SELECTIONLocking Assembly Type T3006 Bending Moment (M) 88459 Nm At Maximum Load

Locking Assembly Size 340 B/ Moment transferred 76431 Nm At Maximum Load

Hub & L/Assembly centres 1330 mm B/ Moment transferred 73526 Nm At Run Load

Published Torque Rating (Mt) 218000 Nm B/ Moment Ratio % 35% At Maximum Load

B/ Moment Ratio % 34% At Run Load

Published Bolt Torque (Ma) 690 Nm Bolt Torque to be used 500 Nm

Published Hub Pressure (Pn) 109 Mpa Hub Pressure Used (pn) 79 Mpa

Published Shaft Pressure (Pw) 136 Mpa Resultant Shaft Pressure (pw) 99 Mpa Effective interference 0.319mm

L/Assy Torque Service Factor 202 % Actual Transmissable Torque 157971 Nm Stress raiser K@L/Assy 2.37

"T" TYPE END DISC DESIGN using SCHMOLTZI's THEORYEnd Disc thickness (W2) 29 mm

End Disk thickness (W1) 60 mm

End Disk Hub Width (L2) 80 mm

L/Assy contact width (L1) 74 mm

Bore Diameter of Hub 425 mm

Radius Disc/Shell 20 mm

Radius Disc/Hub 25 mm

Diameter outside Hub (Ri) 700 mm

Diameter inside shell (Ra) 1518 mm

Allowable End Disc Run Stress 55 Mpa

Actual Disk Stress Running Full 38 Mpa

Actual Disk Stress Starting Full 39 Mpa

END DISC HOOP STRESS CHECK using THICK WALL THEORYAt Hub inner Diameter 129 Mpa Effective Hub OD 870 mm

At Hub outer Diameter 50 Mpa Von Mises stress 181 Mpa When Starting Full

BEARING SELECTION to ISO 281 Bearing Life Required 60000 Hours Actual B10 Bearing Life 553982 Hours At Run Full Load

Required Dynamic Capacity 1643 kN Bearing Dynamic Rating 3200 kN

Bearing Size Selected Spherical 23160 Bearing Housing Designation SD3160 TACSHAFT DESIGN TO AS1403 - using 1045 Grade Material with min UTS 600Mpa

Allowable Shaft Deflection L/2000 0.93 mm Actual Deflection @ Centre 0.26 mm At Maximum Load

Allowable Defl'n @ Hub 5.0 mins Actual Deflection @ Hub 1.6 mins At Run Load

Allowable Defl'n @ Hub 5.0 mins Actual Deflection @ Hub 1.7 mins At Maximum Load

Allowable Stress @ Hub 270 Mpa Actual Shaft Stress @ Hub 140 Mpa At Run Full Load

Allowable Stress @ Hub 270 Mpa Actual Shaft Stress @ Hub 153 Mpa When Starting Full

Allowable Stress @ Brg 270 Mpa Actual Shaft Stress @ Brg 139 Mpa At Run Full Load

Allowable Stress @ Brg 270 Mpa Actual Shaft Stress @ Brg 152 Mpa When Starting Full

Allowable Stress @ Cplg 270 Mpa Actual Shaft Stress @ Cplg 201 Mpa At Run Load

Design Load "P" Max 338.6 Kn Safety Factor used (Fs) 1.2Design Load "P" Run 325.6 Kn Estimated Shaft O/All Length 3012 mm

Estimated Plly Assembly Mass 6397 kg

Mass moment of inertia 2130 kgm2

Shaft dia D5 D4 D3 D2 D1350 340 340 280 280

Shaft Step Length E D C B A615 50 -5 50 215

SHELL DESIGN using SITZWOHL's THEORYAllowable Shell Stress - Run 55 Mpa Actual Shell Stress 47.6 Mpa At Run Full Load

Allowable Shell Stress - Start 69 Mpa Actual Shell Stress 49.4 Mpa When Starting Full

Minimum Run Shell thickness 38.1 mm Selected Shell Thickness 41 mm In Pulley Centre

TEFCO PULLEYS

D4D5 D3 D2 D1

E ABCD

C/L BRGC/L HUBC

L

ANGLE A1

T1

ANGLE A2 (-)

T2

L1

W1

W2

L2

Shell I.D.

Hub O.D.

Bore Diam

T2

Rigid Coupling Taper Design Rev2.xls CPLG Run Date: 4/10/2006

TEFCO ENGINEERING PTY.LTD. Page: of

COUPLING DESIGN CHECK SHEET USING SKF METHOD

DESIGNER PJB

COUPLING STYLE OIL INJECTED TAPERED BORE CHECKED

DATE 4-Oct-06

PROJECT NAME: Ashton Maingate

TEFCO JOB or QUOTE No.: 7195

CONVEYOR REF: Maingate 1

INSTALLED POWER 400 kW TORQUE ( @ START ) 65258 Nm

GEARBOX OUTPUT SPEED 78.1 RPM BENDING MOMENT (Mb) 22500 Nm

START UP FACTOR 1.3 REQUIRED CONTACT PRESSURE 43.8 MPa

OVERHUNG LOAD 30 Kn REQUIRED INTERFERENCE 0.165 mm

G/BOX C/L TO COUPLING C/L 750 mm CHOSEN INTERFERENCE 0.203 mm

BORE DIA ( NOMINAL) 220 mm RESULTING CONTACT PRESSURE 53.8 MPa

HUB OUTSIDE DIAMETER 330 mm MIN RESULTING FIT SAFETY FACTOR 2.46 At Start

CONTACT WIDTH 280 mm

FLANGE DIAM 490 mm BORE & SHAFT MACHINING TOLERANCESFLANGE THICKNESS 42 mm Based on U6 bore / h7 shaft interference relationship

BOLT DIAMETER ( Grade 10.9 ) M30 mm Upper Limit Lower Limit

BOLT QUANTITY 20 SHAFT DIAM - Large End (mm) 220.000 219.954

COUPLING HALF MASS 141 Kg SHAFT DIAM - Small End (mm) 210.667 210.621Upper Limit Lower Limit

COUPLING BORE - Large End (mm) 219.751 219.722

INPUT DATA FROM DIAGRAM 17 COUPLING BORE - Small End (mm) 210.418 210.389

FRICTION ZONE (nL) 0.7 SHAFT TAPER LENGTH 280 mm

m 0.4 DRIVE UP LENGTH (min and max) 6.1mm 8.3mm

BENDING ZONE RATIO ( Z ) 4.35 EQUIVALENT STRESS @ MINIMUM INTERFERENCE

NOTE: Z Preferably to exceed 3.0 MINIMUM INTERFERENCE 0.203 mm

OUTER HUB 173 MPa

CALCULATED VALUES FOR DIAGRAM 17 INNER HUB 194 MPa

BENDING MOMENT FRICTION 0.28 MINIMUM PRESSURE 54 MPa

Ce 0.67

nd 2.39 EQUIVALENT STRESS @ MAXIMUM INTERFERENCE

MAXIMUM INTERFERENCE 0.278 mm

MATERIAL INFORMATION OUTER HUB 237 MPa

COUPLING MATERIAL GRADE 1045 INNER HUB 265 MPa

MATERIAL YIELD MINIMUM 600 MPa MAXIMUM PRESSURE 74 MPa

REQUIRED SAFETY FACTOR @ START 2.0 MIN. MATERIAL YEILD REQUIRED 264 MPa

YOUNGS MODULUS (E) 210000 Pa

FRICTION COEFFICIENT 0.14 ACTUAL TORQUE RANGE

SURFACE FINISH 0.005 mm MINIMUM TORQUE CAPABILITY 160414 Nm

MAXIMUM TORQUE CAPABILITY 219680 Nm

SHRINK FITTING TEMPERATURE

BORE DIAM 220 mm RESULTS DUE TO BENDING MOMENT

BASE TEMPERATURE 25 deg C CHANGE OF PRESSURE 3.01 MPa

HEAT COUPLING TO TEMPERATURE 180 deg C FRICTION ZONE WIDTH (L) 64.32

BORE GROWTH 0.399 mm

MAXIMUM INTERFERENCE 0.278 mm BOLTED FLANGE TRANSMISSIBLE TORQUE-10.9 BOLT TF

FITTING CLEARANCE (MIN 0.1mm) 0.121 mm TORQUE CAPABILITY 187336 Nm

FRICTION COEFFICIENT USED 0.25

RESULTING SAFETY FACTOR 2.87 At Start

280

10 42

98

110

430 Bolt PCD

R12

1/4"BSP

490 Flange Dia

310(H6/h6)Spigot Dia 330 Hub Diam

210.418 Bore Diam 219.751 Bore Diam

INPUT DATA OUTPUT DATA