B-13-1 - PE0101 - Note de Calcul Mécanique Convoyeur CL7' - MEC31301 - 00 - 20151101

Propritaire:
Consultant:
OCP
JACOBS Engineering
OCP GROUP
Web: www.ocpgroup.ma
Imm. 5 - Znith Millenium - Lot. Attaoufik

Route Nouaceur - Sidi Marouf
Casablanca - 20270 Morocco
Tl: +212 (0)5 22 87 70 00 / +212 (0)5 22 87 71 50
Bureau d'Etude:
Contractant:
EMPI
DLM
Route El Ain Km 4
Immeuble RAWDHAN
Tel: (+216) 74 264 180 // (+216) 74 610 780
Web: www.empi.tn // www.group-ips.com
Route de Rabat - Km 9, Ain Seba - B.P. 2613

Casablanca MAROC
Phone : + 212(0) 5 22 66 96 00
Fax
: + 212(0) 5 22 35 54 65
MEA EXPANSION
MEA EXTENSION: Alimentation de la 7me ligne
Note de Calcul Mcanique convoyeur CVL'
DLM B-13-1- PE0101_Note de Calcul Mcanique

Ref.: Convoyeur CL7'_MEC31301_00_20151101
Rev.
00
Author
Date
30/11/2015
OCP:
Checked
Name
AFE
Date
30/11/2015
Approved
Name
WKT
Date
30/11/2015
CONFIDENTIAL Any disclosure of this information is strictly forbidden without EMPI prior authorization
Name
WBN
OCP
MEA EXPANSION
Alimentation de la 7me ligne
B-13-1- PE0101_Note de Calcul Mcanique Convoyeur CL7'_MEC31301_00_20151101
SOMMAIRE
1
PAGE DE GARDE
SOMMAIRE
1- OBJET
2- DOCUMENTS & NORMES DE REFERENCE
2-1- DOCUMENTS DE REFERENCE
2-2- NORMES DE REFERENCE
3
3
3
4
3- DONNEES DE CALCUL
3-1- GROUPE DE COMMANDE
3-2- PHILOSOPHIE DE CONCEPTION
4- CALCUL DE LA PUISSANCE DU MOTEUR
4-1- POWER CALCULATION
14
4-2- SECONDARY & SPECIAL RESISTANCE
17
5- CHARGES SUR TAMBOURS
18
6- DIMENSIONNEMENT DU GROUPE DE COMMANDE
18
6-1- CARACTERISTIQUES MOTEUR
19
6-2- CARACTERISTIQUES REDUCTEUR
19
6-3- SPECIFICATION D'ACCOUPLEMENT
19
6-4- SPECIFICATION SYSTME DE FREINAGE
19
6-5- SPECIFICATION CHASSIS
20
7- VERIFICATION DES AXES & MOYEU TAMBOURS
22
8- VERIFICATION DES PALIERS
24
9- VERIFICATION DES ROULEAUX
26
10- VERIFICATION RAYON DE COURBURE CONCAVE
27
11- VERIFICATION RAYON DE COURBURE CONVEX
OCP
MEA EXPANSION
1- OBJET
L'objectif de cette note de calcul est la vrification des diffrents composants du transporteur bande
RB2, savoir:
- Vrification Puissance de Commande
- Vrification des Caractristiques & de la Tension de Bande
- Vrification des Diffrents Tambours
- Vrification des Diffrents Paliers
- Vrification des Diffrentes Stations de Rouleau
2- DOCUMENTS & NORMES DE REFERENCE
2-1- DOCUMENTS DE REFERENCE
B-13-2- PE0101_Plan d'Ensemble Convoyeur CL7' - Vue en Plan & Elvation_MEC31302_00_20151101
2-2- NORMES DE REFERENCE

ISO5048 (1989): Engins de manutention continue. Transporteurs courroie munis de rouleaux porteurs Calcul de la puissance d'entranement et des efforts de tension.
3- DONNEES DE CALCUL
3-1- GROUPE DE COMMANDE
Le groupe de commande sera considr comme tant un systme moto-rducteur avec un
accouplement Arbre plein avec frette de serrage pour la connection avec tambour de commande.
L'efficacit globale du groupe de commande est calcule comme suit:
- Efficacit Moteur:
- Efficacit Accouplement:
- Efficacit Rducteur:
- Efficacit Totale:
Couple de Dmarrage Moteur:
Sans Accouplement
Hydraulique
Avec Accouplement
Hydraulique
0.97
0.98
0.95
0.90
0.97
0.95
0.95
0.88
2.40
1.50
3-2- PHILOSOPHIE DE CONCEPTION

La puissance minimale requise pour entrainer le systme de convoyeur bande est calcule en faisant
la somme des puissances suivantes:
- La charge de la bande et des stations de rouleau vide
- La charge pour translation de la matire.
- La charge pour soulvement de la matire.
- Les charges divers lments de la bande (Points de dcharge, Racleurs, etc.) intgres dans
le facteur "C".
- L'efficacit du groupe de commande.
OCP
MEA EXPANSION
4-1- Power Calculation
Belt Design Summary

Pm (kW)
P Pm
Fvmin (daN)
r
Fv Fvmin
r1
FvminS (daN)
rS
Fv FvminS
rS 1
dmax (mm)
CRm (N/mm)
d 2 dmax
Wu CRm
dmaxS (mm)
CRmS (N/mm)
d 2 dmaxS
Wu CRmS
265.91
OK
6,022
0.819
OK
OK
7,608
0.981
OK
OK
2,489
784
OK
OK
2,983
657
OK
OK
Required Motor Power Necessary to transmit to the belt

Check of Motor Power
Minimum Required Counterweight
Belt Slipping Coefficient
Check of Counterweight
Check of Belt Slipping
Start-up Minimum Required Counterweight
Start-up Belt Slipping Coefficient
Check of Counterweight @ Start-up
Check of Belt Slipping @ Start-up
Maximum Belt Elongation
Minimum Required Tensile Strength
Check of Belt Elongation Length
Check of Belt Tensile Strength
Start-up Maximum Belt Elongation
Start-up Minimum Required Tensile Strength
Check of Belt Elongation Length @ Start-up
Check of Belt Tensile Strength @ Start-up
Working Condition
OCP Standard
Medium Weight and Lump Size Material
Handled Material Definition
Phosphate
Brut
<-Material Designation
35 <-a: Material Angle of Repose (Deg)

15 <-q: Material Surcharge Angle (Deg)
1200 <-r: Material Density (kg/m3)
9.81 <-g: Standard Gravity Acceleration (m/s)
Belt Definition
3600 <-Q: Maximum Belt Design Capacity (Ton/h)
3.8 <-v: Belt Speed (Tab.4&5&6) (m/s)
1400 <-B: Belt Width (mm)
EP800/4 <-Carcass Style
800 <-Wu: Belt Resistance at Break (N/mm)
OCP
MEA EXPANSION
1 <-z: Maximum Belt Elongation During Service (Load = 10% of Belt Resistance at Break) (%)
10 <-fs: Belt Required Safety Factor
7 <-fss: Belt Required Safety Factor at Starting
6 <-ttc: Top Cover Thickness (mm)
4 <-tbc: Bottom Cover Thickness (mm)
1.2 <-rr: Rubber Average Weight (kg/[mxmm])
1.5 <-S1: Maximum Sag Along the Carrying Section (%)
1.5 <-S2: Maximum Sag Along the Return Section (%)
254.091 <-L: Belt Length Center-To-Center (m)
8 <-d: Maximum Belt Inclination (Deg)
Idlers Definition
159 <-dc: Carrying Idlers Diameter (mm)
Tern <-Carrying Idlers Type
35 <-l: Idlers Inclination Angle (Deg)
159 <-dr: Return Idlers Diameter (mm)
Couple <-Return Idlers Type
1.250 <-ac: Distance Between Carrying Idler (Tab.12) (m)
3.000 <-ar: Distance Between Return Idler (Tab.12) (m)
Upper Flight Definition
26 <-Nu: Upper Flight Number
No.
Pulley
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
D1
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
D2
D5
NA
NA
NA
NA
NA
NA
NA
NA
NA
D4-1
D4-3
D3
Qu,n
(Ton/h)
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
3600
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Lu,n (m) Hu,n (m)

2.480
175.657
3.479
3.479
3.479
3.479
3.479
3.479
3.479
3.479
44.777
1.783
1.560
0.877
47.242
3.479
3.479
3.479
3.479
3.479
3.479
3.479
3.479
130.520
0.000
4.581
0.000
0.000
0.030
0.103
0.152
0.213
0.274
0.335
0.396
0.458
6.293
0.251
0.219
-0.235
-6.639
-0.458
-0.396
-0.335
-0.274
-0.213
-0.152
-0.103
-0.030
0.000
4.581
0.000
b u,n
(Deg)
0.00
0.00
0.50
1.70
2.50
3.50
4.50
5.50
6.50
7.50
8.00
8.00
8.00
-15.00
-8.00
-7.50
-6.50
-5.50
-4.50
-3.50
-2.50
-1.70
-0.50
0.00
90.00
0.00
Ncu,n
Nru,n
3
140
3
3
2
3
3
3
3
2
36
7
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
15
2
1
1
1
1
1
2
1
43
0
0
<-Qu,n: Flight Capacity (Ton/h)

<-Lu,n: Flight Length (m)
<-Hu,n: Flight Height (m)
<-b u,n: Flight Slop (Deg)
<-Ncu,n: Carrying Idler Number Per Flight
<-Nru,n: Return Idler Number Per Flight
OCP
MEA EXPANSION
Lower Flight Definition
4 <-Nl: Lower Flight Number
No.
Pulley
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
D5
D4-2
D4-3
D3
Ql,n
b l,n
Ll,n (m) Hl,n (m)
(Ton/h)
(Deg)
0
0.710 -0.125 -10.00
0
46.385 0.000
0.00
0
0.000 5.092 -90.00
0
5.092 0.000
0.00
Ncl,n
Nrl,n
0
0
0
0
0
15
0
0
<-Ql,n: Flight Capacity (Ton/h)

<-Ll,n: Flight Length (m)
<-Hl,n: Flight Height (m)
<-b l,n: Flight Slop (Deg)
<-Ncl,n: Carrying Idler Number Per Flight
<-Nrl,n: Return Idler Number Per Flight
Pulley & Motor Definition

315 <-P: Installed Motor Power (kW)
6,000 <-d: Counterweight Elongation Course (mm)
7,800 <-Fv: Counterweight Value (daN)
210 <-j: Belt to Drive Pulley Contact Angle (Deg)
0.35 <-m: Friction Coefficient Between Belt & Pulley (Tab.10)
1.3 <-w: Starting Motor Coefficient
0.88 <-h: Mechanical Efficiency Coefficient for the Transmission (Tab.8)
Type 2 <-Type of Belt Conveyor
Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System
T1
j
T2
OCP
MEA EXPANSION
Empty Belt & Idlers Weight Computation
6.5 <-qbc: Belt Carcass Weight for square Meter (Tab.13) (kg/m)
18.5 <-q: Belt Weight per square Meter (kg/m)
q qbc rr ttc tbc
44.3 <-qc: Carrying Idler Unit Weight (Tab.11) (kg)

35.2 <-qr: Return Idler Unit Weight (Tab.11) (kg)
Friction & Length Coefficient
0.03 <-f: Idlers Friction Coefficient (Tab. 9)
OCP
MEA EXPANSION
Forces Necessary for Movement of Belt
F1,n f Ln q
qc N c ,n qr N r ,n
1000
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
F2,n fLn
Qn
3.6v
F3,n
Qn H n
B
q
Hn
3.6v
1000
Upper Flight
Lower Flight
F1u,n
F2u,n
F3u,n
F1l,n
F2l,n
F3l,n
(kg)
(kg)
(kg)
(kg)
(kg)
(kg)
5.914 19.579
0
0.5517
0
-3.2425
322.55 1386.8
0
51.881
0
0
6.6902 27.466 8.776
0
0
131.88
6.6902 27.466 29.846 3.9565
0
0
5.3612 27.466 43.907
0
0
0
6.6902 27.466 61.507
0
0
0
6.6902 27.466 79.145
0
0
0
6.6902 27.466 96.831
0
0
0
6.6902 27.466 114.58
0
0
0
5.3612 27.466 132.39
0
0
0
82.636 353.5
1819
0
0
0
10.688 14.076 72.433
0
0
0
2.5411
0
5.6784
0
0
0
0.6814
0
-6.0863
0
0
0
52.547
0
-171.96
0
0
0
4.8152
0
-11.863
0
0
0
3.7592
0
-10.266
0
0
0
3.7592
0
-8.6762
0
0
0
3.7592
0
-7.0915
0
0
0
3.7592
0
-5.5111
0
0
0
3.7592
0
-3.9341
0
0
0
4.8152
0
-2.6743
0
0
0
3.7592
0
-0.7863
0
0
0
146.82
0
0
0
0
0
0
0
118.65
0
0
0
3.5594
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
<-F1,n: Flight Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)
<-F2,n: Flight Forces Necessary for Translation of the Load (kg)
<-F3,n: Flight Forces Necessary for the Elevation of the Load (kg)
767
1,994
2,483
185
1,000.87
<-F1: Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)
<-F2: Forces Necessary for Translation of the Load (kg)
<-F3: Forces Necessary for the Elevation of the Load (kg)
<-Ft,L: Tail Losses Between Take Up & Drive Pulley (kg)
<-FNS: Total Secondary & Special Resistance (daN)
FNS FN FS
OCP
MEA EXPANSION
Total Force and Motor Power Calculation
6,244 <-Fmin: Total Periphery Force Necessary to transmit to the belt (kg)
Fmin F1 F2 F3 FNS
232.78 <-Pa: Theorical Motor Power Necessary to transmit to the belt (kW)
Pa gFmin v
265.91 <-Pm: Required Motor Power Necessary to transmit to the belt (kW)
Pa
Pm
P Pm
OK
Tension Calculation (During Operation)

7,257 <-F: Installed Periphery Force (daN)
hP
v
0.384 <-K: Friction Factor
1
e 1
mj
10,041 <-Tu,1n: Nominal Tight Side Tension (daN)
Tu ,1n F K 1
2,784 <-Tl,1n: Nominal Slack Side Tension (daN)
Tl ,1n FK
2,969 <-Tv1: Minimum Tension to Allow the Motion Transmission (daN)
Tv1 Tl ,1n Ft , L
3,011 <-Tsup: Minimum Tension For Max Sag of Carrying Idler (daN)
Tsup
ac qB
Q
8S1 1000 3.6v
648 <-Tinf: Minimum Tension For Max Sag of Return Idler (daN)
Tinf
ar qB
8S2 1000
6,022 <-Fvmin: Minimum Required Counterweight (daN)
Fv min 2Max Tv1 ; Tsup ; Tinf

931 <-Tv: Take-Up Over tension (daN)
Tv
Fv
Ft , L Tl ,1n
2
10,972 <-Tu,1: Maximum Tight Side Tension (daN)
Tu ,1 Tu ,1n Tv
3,715 <-Tl,1: Maximum Slack Side Tension (daN)
Tl ,1 Tl ,1n Tv
OCP
MEA EXPANSION
0.819 <-r: Belt Slipping Coefficient
Tu ,1
Tl ,1e mj
Fv Fvmin
OK
r1
OK
Tension Calculation (During Start-up)

9,434 <-Fs: Installed Periphery Force at Starting (daN)
Fs
wh P
v
13,053 <-Tu,1nS: Start-up Nominal Tight Side Tension (daN)
Tu ,1nS Fs K 1
3,619 <-Tl,1nS: Start-up Nominal Slack Side Tension (daN)
Tl ,1nS Fs K
3,804 <-Tv1S: Start-up Minimum Tension to Allow the Motion Transmission (daN)
Tv1S Tl ,1nS Ft , L
7,608 <-FvminS: Start-up Minimum Required Counterweight (daN)
Fv min S 2 Max Tv1S ; Tsup ; Tinf

96 <-TvS: Start-up Take-Up Over tension (daN)
TvS
Fv
Ft , L Tl ,1nS
2
13,149 <-Tu,1S: Start-up Maximum Tight Side Tension (daN)
Tu ,1S Tu ,1nS TvS

3,715 <-Tl,1S: Start-up Maximum Slack Side Tension (daN)
Tl ,1S Tl ,1nS TvS

0.981 <-rS: Start-up Belt Slipping Coefficient
rS
Tu ,1S
Tl ,1S e mj
Fv FvminS
OK
rS 1
OK
OCP
MEA EXPANSION
Belt Tensile Strength Check (Operation Case)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Upper Flight
Tu,n
DTu,n
(kg)
(kg)
25
10,972
1,709 10946
43
9237
64
9194
77
9130
96
9053.3
113
8957.6
131
8844.3
149
8713.4
165
8564.6
2,255 8399.4
97
6144.2
8
6047
-5
6038.8
-119
6044.2
-7
6163.6
-7
6170.7
-5
6177.2
-3
6182.1
-2
6185.4
0
6187.2
2
6187.4
3
6185.2
147
6182.2
119
6035.4
4
5916.8
0
5913.2
0
0
0
0
0
0
0
Lower Flight
Tl,n
DTl,n
(kg)
(kg)
-3
3,715
52
3712.3
132
3764.2
4
3896
0
3900
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
DTu ,n F1u ,n F2u ,n F3u ,n

DTl ,n F1l ,n F2l ,n F3l ,n
Tu ,n 1 Tu ,n DTu ,n
Tl ,n 1 Tl ,n DTl ,n
Notes
Tension will be Regulated via Material
Trampling Losses Addition
The Tension in Pulley Remains inchanged
10,972 <-Tmax: Maximum Belt Tension (daN)

2,489 <-dmax: Maximum Belt Elongation (mm)
d max L
Tmax 10
B Wu
784 <-CRm: Minimum Required Tensile Strength (N/mm)
CRm f s
Tmax
B
OCP
MEA EXPANSION
d 2 dmax
OK
Wu CRm
OK
Belt Tensile Strength Check (Start-up Case)
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Upper Flight
Lower Flight
Tu,nS
Tl,nS
DTu,n
DTl,n
Pulley
Pulley
(kg)
(kg)
(kg)
(kg)
D1
25
13,149
D5
-3
3,715
NA
1,709 13123 D4-2
52
3712.3
NA
43
11414 D4-3
132
3764.2
NA
64
11371
D3
4
3896
NA
77
11307
0
0
3900
NA
96
11230
0
0
0
NA
113
11135
0
0
0
NA
131
11021
0
0
0
NA
149
10890
0
0
0
NA
165
10742
0
0
0
NA
2,255 10576
0
0
0
NA
97
8321.3
0
0
0
D2
8
8224.1
0
0
0
D5
-5
8215.9
0
0
0
NA
-119
8221.3
0
0
0
NA
-7
8340.7
0
0
0
NA
-7
8347.7
0
0
0
NA
-5
8354.2
0
0
0
NA
-3
8359.1
0
0
0
NA
-2
8362.5
0
0
0
NA
0
8364.2
0
0
0
NA
2
8364.4
0
0
0
NA
3
8362.3
0
0
0
D4-1
147
8359.3
0
0
0
D4-3
119
8212.5
0
0
0
D3
4
8093.8
0
0
0
0
0
8090.3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
13,149 <-TmaxS: Start-up Maximum Belt Tension (daN)

2,983 <-dmaxS: Start-up Maximum Belt Elongation (mm)
d max S L
Tmax S 10
B Wu
DTu ,n F1u ,n F2u ,n F3u ,n

DTl ,n F1l ,n F2l ,n F3l ,n
Tu ,n 1S Tu ,nS DTu ,n
Tl ,n 1S Tl ,nS DTl ,n
Notes
Tension will be Regulated via Material
Trampling Losses Addition
The Tension in Pulley Remains inchanged
OCP
MEA EXPANSION
657 <-CRmS: Start-up Minimum Required Tensile Strength (N/mm)
CRmS f ss
Tmax S
B
d 2 dmaxS
OK
Wu CRmS
OK
Pulleys Tensions
No.
Designation
D1
Zx
(kg)
13,149
D2
8,224
D3
3,896
D4-1
3,712
D4-2
3,712
D5
3,715
Zs
(kg)
3,715
OCP
MEA EXPANSION
4-2- Secondary & Special Resistance
Loading Parameters Material Definition

2 <-e: Tilte Angle of Idler (Deg)
0.4 <-Ce: Trough Factor
0.35 <-m0: Friction Coefficient Between Belt & Carrying Idlers
0.6 <-m1: Friction Coefficient Between Belt & Material
0.6 <-m2: Friction Coefficient Between Belt & Skirtplate
0.6 <-m3: Friction Coefficient Between Belt & Belt Cleaner
9.81 <-g: Standard Gravity Acceleration (m/s)
3.8 <-v: Belt Speed (m/s)
254.091 <-Le: Length of Installation Equiped with Tilted Idlers (m)
30000 <-p: Pressure between belt cleaner and the belt (N/m)
0.0315 <-A: Contact Area Between between belt cleaner and the belt (m)
1.5 <-v0: Velocity Component of the Conveying speed of the material handled (m/s)
3 <-l: Length of Installation Equiped with Skirt Plate (m)
1.05 <-b1: Width Between Skirtplates (m)
21 <-d: Belt Thickness (mm)
0.90 <-d: Medium Belt Inclination (Deg)
Pulleys Parameters
No.
Pulley
Di
(mm)
Ni
(kg)
Zxi
(kg)
Zsi
(kg)
d0i
(mm)
D1
630
16,077
13,149
3,715
180
D2
500
16,461
8,224
160
D3
500
3,713
3,896
100
D4-1
400
3,713
3,712
100
D4-2
400
3,713
3,712
100
D5
400
3,825
3,715
100
7
8
9
10
<-D1: Drive Pulley

<-D2: Tail/Return Pulley
<-D3: Take up/Counter Weight Pulley
<-D4: Bend/Deviation Pulley(s)
<-D5: Snub Pulley(s)
OCP
MEA EXPANSION
Special Resistance Calculations 4- CALCUL DE LA PUISSANCE DU MOTEUR
263 <-qG: Mass per Meter of Material Handled (kg/m)
qG
Q
3.6v
0.83 <-Iv: Belt Capacity (m3/s)
Iv
Q
3.6 r
342.98 <-Fe: Resistance due to Idler tilting (daN)
Fe Ce m0 Le qB qG g cos d sin e
92.43 <-FgL: Resistance due to Friction between Material Handled and Skirtplates (daN)
FgL
m2 I v2 r gl
v 2b12
56.70 <-Fr: Friction Resistance due to Belt Cleaner (daN)
Fr Apm3
492.11 <-Fs: Total Special Resistance (daN)
Fs Fe FgL Fr
Secondary Resistance Calculations due Skirtplates, Inertial and Frictional Resistance
1.04 <-lb,min: Skirtplate Equivalent Length (m)
lb,min
v 2 v02
2 g m1
230 <-FbA: Inertial and Frictional Resistance at the Loading Point (daN)
FbA I v r v v0
66 <-Ff: Frictional Resistance between Handled material and the skirtplate in the acceleration Area (daN)
Ff
m2 I v2 r glb ,min
v v0 2
2 b1
Secondary Resistance Calculations due Pulleys
F d
F1i 9 B 140 0.01 i

B Di
No.
Pulley
Fi
(N)
F1i
(daN)
D1
82,717
31
D2
80,678
D3
38,220
D4-1
5
6
7
8
9
10
FTi Ni g
FTi
(daN)
Fti
(daN)
38
16,148
26
22
3,642
36,417
26
3,642
D4-2
36,417
26
3,642
D5
36,444
26
3,753
Fti 0.005
d 0i
FTi
Di
OCP
MEA EXPANSION
4- CALCUL
DE
LAPulley
PUISSANCE
DU MOTEUR
<-Fi: Average Belt
Tension at
the
(N)
<-F1i: Wrap Resistance between belt and Pulley (daN)
<-F1i: Wrap Resistance between belt and Pulley (daN)
<-FTi: Vectorial Sum of the Forces Applied to Pulley (daN)
<-Fti: Pulley bearing resistance (daN)
170 <-F1: Total Wrap Resistance between belt and Pulley (daN)
43 <-Ft: Total Pulley bearing resistance (daN)
508.75 <-FN: Total Secondary Resistance (daN)
FN FbA Ff F1 Ft
Applicability of C Equivalent Method
1,000.87 <-FNS: Total Secondary & Special Resistance (daN)
FNS FN FS
OCP
MEA EXPANSION
5- CHARGES SUR TAMBOURS
Type 2
<-Type of Belt Conveyor

D1
Dp
(mm)
Tab.13
630
180
16,077
D2
500
160
16,461
D3
500
100
3,713
D4-1
400
100
3,713
3,712
364
D4-2
400
100
3,713
3,712
364
D5
400
100
3,825
3,715
364
No.
Designation
d
(mm)
N
(kg)
j
(Deg)
a
(Deg)
210
7
8
9
10
<-D1: Drive Pulley

<-D2: Tail/Return Pulley
<-D3: Take up/Counter Weight Pulley
<-D4: Bend/Deviation Pulley(s)
<-D5: Snub Pulley(s)
b
(Deg)
Zx
(kg)
Zs
(kg)
Fv
(kg)
q
(kg)
13,149
3,715
1,063
8,224
655
3,896
7,800
414
15
OCP
MEA EXPANSION
6-1- SPECIFICATIONS DU MOTEUR

Puissance installe (kW)
Standard de construction
Facteur de puissance minimale cosj
Facteur de service
Start-up/Nominal Absorbed Current Ratio (Is/In)
Tension d'alimentation
Vitesse de rotation (rpm)
Frquence
Degrs de protection IP (IEC 60034-5)
Classe d'isolation
Temprature de design
Mthode de refroidissement selon IEC 60034-6
Protection thermique
Environment de travail
Matriau de construction du stator
Matriau de construction Supports/oreilles de levage
Matriau de construction de la boite de jonction
Position boite de jonction
Type
Poids approximatif (kg)
315
IEC60034
80%
1,5
6.8
525V/3Ph
1500
50Hz
IP55
Class F
50C
IC0A1
PT100
Poussireux
Cast Iron
Fonte
Fonte
au dessus du moteur
Cage d'cureuil
1500
OCP
MEA EXPANSION
6-2- SPECIFICATION DU REDUCTEUR
Standard de construction
Type
Diamtre du tambour (mm)
Vitesse de la bande (m/s)
Vitesse de rotation /petite vitesse (rpm)
Couple rducteur (Nm)
Puissance rducteur (kW)
Rapport de rduction
Temprature de design du rducteur
Nombre d'heure de service/jour (hr)
Facteur de Service
Type d'arbre grande vitesse
Type d'arbre petite vitesse
Type 1: Arbre plein
Type 2: Arbre creux avec disque
Type 3: Arbre creux avec clavette
Peinture
Sonde de temprature
Indicateur de niveau d'huile
Trous de regards avec clapets
Carcasse du rducteur
Antidvireur
Orientation de l'arbre de sortie (droite/gauche)
AGMA
Axes perpendiculaires, Arbre
plein
630
3.8
115
26,112
315
13
50C
24H
1,5
Type 1
Type 1
Intrieure & Extrieure

N/A
oui
Oui
Les carters du rducteur en
deux parties moules
N/A
Droite
1254
6-3- SPECIFICATION D'ACCOUPLEMENT

Type d'accouplement
Chambre de retardement
Rapport (couple de dmarrage transmissible/couple nominal)
Hydraulique
Oui
1,5 1,6
50
6-4- SPECIFICATION SYSTME DE FREINAGE
Type de frein
Temps de freinage maximale (s)
Frein sabot commande

lectromagntique
5
6-5- SPECIFICATION CHASSIE GROUP DE COMMANDE

Peinture
Matriaux
Construction
Intrieure & Extrieure

Acier Carbone
PRS
220
OCP
MEA EXPANSION
Pulley Parameters Definition

Pulley Shell
Flange & Hub Parameters
Driven Shaft Parameters
D1
630
180
16,077
Type 1
1600
10
10
1400
20
310
1360
91
1920
D2
500
160
16,461
Type 2
1600
10
10
1400
20
300
210
5.5
145
190
1360
85
1920
D3
500
100
3,713
Type 2
1600
10
10
1400
20
210
145
2.6
145
130
1360
57
1920
D4-1
400
100
3,713
Type 2
1600
10
10
1400
20
210
145
2.6
145
130
1360
57
1920
D4-2
400
100
3,713
Type 2
1600
10
10
1400
20
210
145
2.6
145
130
1360
57
1920
D5
400
100
3,825
Type 2
1600
10
10
1400
20
210
145
2.6
145
130
1360
57
1920
No.
Designation
Dp
(mm)
d
(mm)
N
(kg)
Type
Lp
(mm)
ts
(mm)
tf
(mm)
Lf
(mm)
th
(mm)
dho
(mm)
WL
(kg)
Tab.23
8.15
PN
(N/mm)
Tab.23
110
d1
(mm)
Tab.16
220
Driving Shaft Parameters
dhi
(mm)
Tab.23
235
Gear Box & Motor Parameters
Li
(mm)
k
(mm)
Tab.16
EA
(mm)
b
(mm)
Dq
(mm)
Lq
(mm)
Dm
(mm)
Lm
(mm)
Dw
(mm)
Lw
(mm)
n
(tr/min)
P
(kW)
MTP
(Nm)
Wd
(kg)
210
175
175
172
787.5
170
962.5
115
315
26111.84
3024
7
8
9
10
<-Dp: Pulley Diameter (mm)

<-d: Shaft Diameter (mm)
<-N: Equivalent Load Applied From Belt Conveyor (kg)
<-Lp: Pulley Shell Length (mm)
<-ts: Pulley Shell Thickness (mm)
Hub Material Parameters Definition

C45+QT <-Hub Material Designation (Per EN10083-2)
200,000 <-Eh: Hub Modulus of elasticity (MPa)
430 <-Syh: Hub Yield Strength (MPa)
650 <-Suh: Hub Ultimate Limit Strength (MPa)
<-tf : Pulley Flange Thickness (mm)

<-Lf : Distance Between Flange (mm)
<-th: Hub Thickness (mm)
<-dho: Hub Outside Diameter (mm)
<-dhi: Hub Inside Diameter (mm)
<-WL: Locking Devices (kg)
<-PN: Pressure Applied From Locking Device to Hub (N/mm)

<-d1 :Shaft Inside Diameter (mm)
<-Li: Shaft Inside Portion Length (mm)
<-k: Distance From Plummer Block Axis to Shaft End (mm)
<-EA: Distance Between Plummer Blocks (mm)
<-b: Distance From Plummer Block Axis to Gear Box (mm)
<-Dq: First Shrink Disc Diameter (mm)
<-Lq: First Shrink Disc Length (mm)
<-Dm: Second Shrink Disc Diameter (mm)
<-Lm: Second Shrink Disc Length (mm)
<-Dw: Third Shrink Disc Diameter (mm)
<-Lw: Third Shrink Disc Length (mm)
<-n: Gear Box Output Speed (r/min)

<-P: Motor Nominal Power (kW)
<-MTP: Moment Transmitted from Gear Box (Nm)
<-Wd: Approximatif Drive System Weight (kg)
OCP
MEA EXPANSION
Shaft Material Parameters Definition
C55+N <-Shaft Material Designation (Per EN10083-2)
200,000 <-Es: Shaft Modulus of elasticity (MPa)
420 <-Sys: Shaft Yield Strength (MPa)
700 <-Sus: Shaft Ultimate Limit Strength (MPa)
Design Parameters
1400 <-BW: Belt Width (mm)
1.5 <-SF: Factor of Safety
0.8 <-Ka: Surface factor
0.897 <-Kc: Reliability factor
1 <-Kd: Temperature factor
1 <-Ke: Duty cycle factor
0.63 <-Kf: Fatigue stress concentration factor
1 <-Kg: Miscellaneous factor
0.88 <-h: Mechanical Efficiency Coefficient for the Transmission
1.3 <-w: Starting Motor Coefficient
Pulley Parameters Definition
d
Kb
25.4
Wp
No.
0.19
S
S f ka kb kc kd ke k f k g us
2
D
D L t 7850 2
p
2ts d ho2
2
p s
Designation
Wp
(kg)
Kb
t f 7850 2
32 SF M b 3 M TT
Sf 4 S ys
2
d min 3
M TT
Sf
(MPa)
MTT
(Nmm)
ag
(mm)
Mb
(Nmm)
dmin
(mm)
Stress
Check
rd
Defl
tan(a)/0
Check
.005
dho,min
(mm)
Hub
Stress
Check
D1
1062.8 0.6893
109.07
3E+07
260
4E+07
175.33
OK
0.974081
0.3302
OK
305.274
OK
D2
654.84 0.7049
111.54
260
2E+07
142.2
OK
0.888777
0.5416
OK
298.285
OK
D3
414.41 0.7708
121.96
260
5E+06
84.023
OK
0.840233
0.8006
OK
205.958
OK
D4-1
364.35 0.7708
121.96
260
5E+06
84.023
OK
0.840233
0.8006
OK
205.958
OK
D4-2
364.35 0.7708
121.96
260
5E+06
84.023
OK
0.840233
0.8006
OK
205.958
OK
D5
364.35 0.7708
121.96
260
5E+06
84.865
OK
0.848647
0.8249
OK
205.958
OK
8
9
10
ag
EA L f
2
d ho,min d hi
Mb
W
N
ag d b Lw
2
2
S yh PN
tan a
64 Nag EA ag
4 Es d 4
S yh PN
Dq2
d ho2 d hi2
Dm2
Dw2
d2
d2
th 7850 2WL 1 L1 7850
EA
L
7850
L
7850
L
7850
Lw Lm 7850
m q
1
q
4
4
4
4
4
4
M For Type 1
wh TP
0 For Type 2
<-Wp: Pulley Weight (kg)

<-Kb: Size Factor
<-Sf: Allowable Bending Stress (MPa)
<-MTT : Moment Transmitted to Pulley Taking into Consideration Drive System Efficiency & Starting Torque (Nmm)
<-ag (mm)
<-Mb: Bending Moment Applied to Shaft (Nmm)
<-dmin: Minimum Shaft Diameter Imposed by Stresses (mm)
<-rd: Minium Shaft Diameter to Nominal Shaft
<-tan(a): Shaft Deflection Ratio
<-dho,min: Minimum Hub Diameter (mm)
OCP
MEA EXPANSION
Spherical Roller Bearing
Bearing Mounted on Smooth Shafts, Design Standard ISO113:1999 & Tapered Bore Bearing
Design Parameters Definition

3.8 <-v: Belt Velocity (m/s)
50 <-T: Maximum Design Temperature (C)
90 <-R: Bearing Degree of Reliability (%)
1.5 <-Cd: Dynamic Load Factor
50,000 <-L10M: Minimum Bearing Rating Life operating hours Based on 500rpm (h)
Plummer Block Characteristics
d
(mm)
N
(kg)
Plummer Block Designation

Tab. 14
D1
Dp
(mm)
630
180
16076.516
BND3236 22336 CCK/W33 D180
D2
500
160
16461.173
BND3032 22232 CCK/W33 D160
D3
500
100
3712.8286
BND2220 23232 CCK/W33 D100
D4-1
400
100
3712.8286
BND2220 23232 CCK/W33 D100
D4-2
400
100
3712.8286
BND2220 23232 CCK/W33 D100
D5
400
100
3825.4946
BND2220 23232 CCK/W33 D100
No.
Pulley Ref.
1
2
7
8
9
10
<-Dp: Pulley Diameter (mm)

<-d: Shaft Diameter (mm)
<-N: Equivalent Load Applied From Belt Conveyor (kg)
OCP
MEA EXPANSION
OCP
MEA EXPANSION
Bearing Rating Life Check
10
v x1000 x 60
n
Dp
N
Pr Cd
2
C 3
L10
Pr
L10 h
106
L10
60n
L10 hE
n
L10 h
500
L10
(MR)
L10h
(h)
L10hE
(h)
L10hE
L10M
22336 CCK/W33
C
(N)
Tab.15
2000000
12408
1795134
413,591
OK
121,113
22336 CCK/W33
2000000
11467
1316731
382,245
OK
145.15
27,317
22232 CCK/W33
1000000
162886
18703227
5,429,521
OK
181.44
27,317
23232 CCK/W33
475000
13621
1251176
454,018
OK
181.44
27,317
23232 CCK/W33
475000
13621
1251176
454,018
OK
181.44
28,146
23232 CCK/W33
475000 12328.75306 1132512.282 410958.4355
No.
n
(rpm)
Pr
(N)
Bearing Designation
Tab.14
115.20
118,283
145.15
7
8
9
10
<-n: Number of Revolutions per Minute of the Roller (rpm)

<-Pr: Dynamic Load Applied to Bearing (N)
<-C: Basic Dynamic Load Rating (N)
<-L10: Basic Rating Life (Million Revolution)
<-L10h: Basic Rating Life operating hours (h)
<-L10hE: Equivalent Bearing Rating Life operating hours Based on 500rpm (h)
OK
OCP
MEA EXPANSION
Idler Definition
Type
Idlers
Type
l
(Deg)
d
(mm)
ID01
Impact
Tern
35
ID02
Carrying
Tern
35
ID03
Transition
Tern
ID04
Return
Couple
No.
Ref
1
2
a
(m)
Bearing
159
0.3
6305-2RS1
Hc
(m)
1.4
159
1.25
6204-2RS1
20
159
6305-2RS1
10
159
6204-2RS1
5
6
7
8
9
10
<-l: Idlers Inclination Angle (Deg)

<-d: Idlers Diameter (mm)
<-a: Distance Between Idler (m)
<-Hc: Discharge Height (m)
Material & Design Condition Definition
Over 16
hours per
day
<-Service Life
Abrasive or
Corrosive
Material
<-Environment Factor
20,000 <-L10M: Minimum Bearing Rating Life operating hours Based on 500rpm (h)
9.81 <- g: Standard Gravity Acceleration (m/s)
Belt Carcass Definition
6 <-ttc: Top Cover Thickness (mm)
4 <-tbc: Bottom Cover Thickness (mm)
1.2 <-rr: Rubber Average Weight (kg/[mxmm])
150 <-dL: Maximum Material Lump Size (mm)
Load Factor Computation
1.0272 <-Fd: Impact Factor (Material Lump Size) (Tab. 17)
1.2 <-Fs: Service Factor (Tab. 18)
1 <-Fm: Environment Factor (Tab. 19)
0.978 <-Fv: Speed Factor (Tab. 20)
OCP
MEA EXPANSION
Belt Weight Computation
<-qbc: Belt Carcass Weight for square Meter (kg/m)
6.5
25.9 <-qb: Belt Weight Per Linear Meter (kg/m)
qb qbc r r ttc tbc B

263
<-qm: Material Weight Per Linear Meter (kg/m)
qm
Q
3.6v
Idler Roller Speed Check
v x 1000 x 60
d
Pi g Q
Hc
8
aqb g If Re turn
Cs
a qb qm g Else
1
1
Pr Cs Fd Fs Fm Fv Fp PF
i p
2
2
C
L10
Pr
L10 h
106
L10
60n
L10 hE
n
L10 h
500
Cs (N)
Fp
(Tab.21)
Pi (N)
Pr (N)
C (N)
(Tab.22)
L10
(MR)
L10h
(h)
L10hE (h)
456
850
0.67
5,222
2,093
22,500
1,243
45,386
41,432
L10hE
L10M
OK
456
3,543
0.67
1,431
12,700
699
25,525
23,301
OK
ID03
456
5,669
0.6
2,050
22,500
1,321
48,252
44,048
OK
ID04
456
762
0.5
230
12,700
169,138
6,175,919
5,637,927
OK
No.
Ref
n
(rpm)
ID01
ID02
3
4
5
6
7
8
9
10
<-n: Number of Revolutions per Minute of the Roller (r/min)

<-Cs: Static Load Applied to Troughing Set (N)
<-Fp: Participation Factor of Roller Under Greatest stress
<-Pi: Impact Load Due to Chute Applied to Troughing Set (N)
<-Pr: Dynamic Load Applied to Bearing (N)
<-C: Basic Dynamic Load Rating (N)
<-L10: Basic Rating Life (Million Revolution)
<-L10h: Basic Rating Life operating hours (h)
<-L10hE: Equivalent Bearing Rating Life operating hours Based on 500rpm (h)
OCP
MEA EXPANSION
10- VERIFICATION RAYON DE COURBURE CONCAVE
Geometric Parameters
0 <-s: Angle of the Curve (Deg)
NA <-R: Radius of Curvature (m)
Loadings Parameters
NA <-Tc: Tension at the Beginning of the Curve (daN)
3600 <-Q: Belt Capacity (Ton/h)
35 <-A: Unitary Elastic Modulus of the Belt (kN/m)
Minimum Radius Computation
####### <-Rminl: Minimum Belt Radius due to Weight (m)
Rmin l
Tc
B
Q
q
cos s
1000 3.6v
####### <-Rminf: Minimum Belt Radius to Avoid Folding on the Belt egdes (m)
Rmin f
sin l Wu A
B
10Tc
1000
4.5
4.4
B
####### <-Rminc: Minimum Belt Radius to Avoid Over Stress at the Center (m)
Rmin c
sin l Wu A
B
W 10Tc 1000
9 u
B
fs
####### <-Rmin: Minimum Belt Radius (m)

R Rmin
#######
OCP
MEA EXPANSION
11- VERIFICATION RAYON DE COURBURE CONVEX
Geometric Parameters
0 <-s: Angle of the Curve (Deg)
200 <-R: Radius of Curvature (m)
Loadings Parameters
8,399 <-Tc: Tension at the Beginning of the Curve (daN)
3600 <-Q: Belt Capacity (Ton/h)
35 <-A: Unitary Elastic Modulus of the Belt (kN/m)
Minimum Radius Computation
44.9359 <-Rminc: Minimum Belt Radius to Avoid Folding on the Belt Center (m)
R min c
sin l W u A
B
10 T c
1000
9
4 .4
B
124.886 <-Rmine: Minimum Belt Radius to Avoid Over Stress at the edge (m)
R min e
sin l W u A
W
10 T c
9 u
B
fs
B
1000
124.886 <-Rmin: Minimum Belt Radius (m)

R Rmin
OK

B-13-1 - PE0101 - Note de Calcul Mécanique Convoyeur CL7' - MEC31301 - 00 - 20151101

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Imm. 5 - Znith Millenium - Lot. Attaoufik

Route de Rabat - Km 9, Ain Seba - B.P. 2613

Note de Calcul Mcanique convoyeur CVL'

DLM B-13-1- PE0101_Note de Calcul Mcanique

2- DOCUMENTS & NORMES DE REFERENCE

2-1- DOCUMENTS DE REFERENCE

2-2- NORMES DE REFERENCE

4-1- POWER CALCULATION

4-2- SECONDARY & SPECIAL RESISTANCE

5- CHARGES SUR TAMBOURS

6- DIMENSIONNEMENT DU GROUPE DE COMMANDE

6-1- CARACTERISTIQUES MOTEUR

6-2- CARACTERISTIQUES REDUCTEUR

6-3- SPECIFICATION D'ACCOUPLEMENT

6-4- SPECIFICATION SYSTME DE FREINAGE

6-5- SPECIFICATION CHASSIS

7- VERIFICATION DES AXES & MOYEU TAMBOURS

8- VERIFICATION DES PALIERS

9- VERIFICATION DES ROULEAUX

10- VERIFICATION RAYON DE COURBURE CONCAVE

11- VERIFICATION RAYON DE COURBURE CONVEX

2-2- NORMES DE REFERENCE

Couple de Dmarrage Moteur:

3-2- PHILOSOPHIE DE CONCEPTION

Belt Design Summary

Required Motor Power Necessary to transmit to the belt

35 <-a: Material Angle of Repose (Deg)

Lu,n (m) Hu,n (m)

<-Qu,n: Flight Capacity (Ton/h)

<-Ql,n: Flight Capacity (Ton/h)

Pulley & Motor Definition

q qbc rr ttc tbc

44.3 <-qc: Carrying Idler Unit Weight (Tab.11) (kg)

Tension Calculation (During Operation)

0.384 <-K: Friction Factor

10,041 <-Tu,1n: Nominal Tight Side Tension (daN)

8S1 1000 3.6v

6,022 <-Fvmin: Minimum Required Counterweight (daN)

Fv min 2Max Tv1 ; Tsup ; Tinf

10,972 <-Tu,1: Maximum Tight Side Tension (daN)

Tension Calculation (During Start-up)

13,053 <-Tu,1nS: Start-up Nominal Tight Side Tension (daN)

Fv min S 2 Max Tv1S ; Tsup ; Tinf

13,149 <-Tu,1S: Start-up Maximum Tight Side Tension (daN)

Tu ,1S Tu ,1nS TvS

Tl ,1S Tl ,1nS TvS

DTu ,n F1u ,n F2u ,n F3u ,n

10,972 <-Tmax: Maximum Belt Tension (daN)

784 <-CRm: Minimum Required Tensile Strength (N/mm)

Belt Tensile Strength Check (Start-up Case)

13,149 <-TmaxS: Start-up Maximum Belt Tension (daN)

DTu ,n F1u ,n F2u ,n F3u ,n

Loading Parameters Material Definition

<-D1: Drive Pulley

0.83 <-Iv: Belt Capacity (m3/s)

342.98 <-Fe: Resistance due to Idler tilting (daN)

56.70 <-Fr: Friction Resistance due to Belt Cleaner (daN)

Secondary Resistance Calculations due Pulleys

F1i 9 B 140 0.01 i

5- CHARGES SUR TAMBOURS

<-Type of Belt Conveyor

EP800/4 <-Carcass Style