Conveyor and processing belts

Calculation methods
conveyor belts
Content

The formulae, figures and recommendations in this brochure are state of the art
and a result of our years of experience.
The calculation results can however differ
from our calculation programme B_Rex
(free download on the internet under
www.siegling.com).

These differences are a result of the

basically different approaches: whereas
B_Rex is based on empirical measurements
and requires a detailed description of the
machine, the calculation methods here are
based on general, simple physical formulae
and derivations backed up by factors (c2)
that include a safety margin. In the majority
of cases the safety margin used for calculation in this brochure will be larger than
for the corresponding B_Rex calculation.

Conveyor and power transmission belts

made of modern synthetics
Worldwide leaders in technology, quality and service

Terminology

Unit goods conveying systems

Take-up range for

load-dependent take-up systems

Bulk goods conveying systems

Calculation example
Unit goods conveying systems

12

Further information on machine design

can be found in our brochure no. 305
Recommendations for machine design.

Conveyor and processing belts

Unit

Force on each belt strand

Maximum belt pull (at drive drum)
Minimum belt pull (at drive drum)
Effective belt pull
Shaft load at drive drum
Shaft load at end drum
Motor power
Calculated power at drive drum
Belt pull at 1% elongation per unit of width
Drum/roller width
Belt width
Geometric belt length
Calculation constants
Drum/roller diameter
Drive drum diameter
Rolling resistance of support rollers
Difference in drum radii
Coefficient of friction with support rollers
Coefficient of friction with accumulated goods
Coefficient of friction with skid plate
Acceleration due to gravity
Production tolerance
Upper support roller pitch
Lower support roller pitch
Transition length
Mass of material conveyed
over whole conveying length (total load)
Mass of belt
Mass of all rotating drum/rollers, except drive drum
Mass of conveyed goods on upper side (total load)
Mass of conveyed goods on return side (total load)
Mass of conveyed goods per m of conveying length on upper side
Line load
Mass of conveyed goods per m of conveying length on return side
Line load
Tension take-up range
Total tension take-up range
Height of lift
Conveyor length
Belt speed
Belt sag
Drum deflection
Arc of contact at drive drum and idler
Opening angle at drive drum
Incline (+) or decline () angle of conveyor
Elongation at fitting
Drive efficiency
Density of material conveyed

Symbol

Designation

Terminology

F
F1
F2
FU
FWA
FWU
PM
PA
SD
b
b0
Lg
c..
d
dA
f
h
R
ST
T
g
Tol
lo
lu
ls

N
N
N
N
N
N
kW
kW
N/mm
mm
mm
mm

mm
mm

mm

9,81m/s2
%
mm
mm
mm

m
mB
mR
m1
m2
m'o

kg
kg
kg
kg
kg
kg/m

m'u
Z
X
hT
lT
v
yB
yTr

kg/m
mm
mm
m

m/s
mm
mm

kg/m3

Conveyor and processing belts

Unit goods conveying systems

Loading examples to determine
the effective pull FU [N]

m = lT . mass of conveyed material per m

FU = R . g . (m + mB + mR )

[N]

mB
mB
FU = T . g . ( m + ___ ) + R . g ( ___ + mR )
2
2

[N]

FU = T . g . (m1 + m2 + mB )

[N]

Coefficient of friction
of end drum was ignored

()
FU = R . g (m + mB + mR) + g . m . sin

[N]

() increasing
(+) decreasing

()
mB
mB
FU = T . g ( m + ___ ) + R . g ( ___ + mR )+ g . m . sin
2
2
[N]

mB
mB
FU = T . g ( m + ___ ) + R . g ( ___ + mR )+ ST . g . m [N]
2
2

FU = please inquire
FUges = FU1 + FU2 + FU3

[N]

FU =please inquire

[N]

Conveyor and processing belts

Coefficients of friction S
(guidelines)
T (skid plate)
R (rollers)
ST (*)

0, A0, E0,
T, U0, P

NOVO

U1, V1, VH

UH, V2H, U2H,

V5H, V10H

0.33
0.033
0.33

0.33
0.033
0.33

0.5
0.033
0.5

0.5
0.033
0.5

* accumulated goods

Maximum belt pull F1

F1 = FU . c1

[N]

Transilon
with underside of

V3, V5, U2,

A5, E3

Arc of contact

180

210

smooth steel drum

dry
wet

1.5
3.7

lagged drum
dry
wet

1.4
1.8

c2 constant
Counter-checking the type selection

[N]

If effective belt pull FU cannot be

calculated, maximum belt pull F1 can be
determined from the installed motor
power PM as per the given formula and
used to select a belt type.

With calculable effective pull FU.

c1 constant
(is valid for drive drum)

PM . . c1 . 1000
F1 = _______________
v

V1, U1, UH, U2H

V2H, V5H

0, U0, NOVO,
T, P

240

180

210

240

180

1.4
3.2

1.3
2.9

1.8
5.0

1.6
4.0

1.5
3.0

2.1
1.9 1.7
not recommendable

1.3
1.6

1.2
1.5

1.6
3.7

1.5
3.2

1.4
2.9

1.5
2.1

210 240

1.4
1.9

1.3
1.7

F
b0

If the value ___1 > c2,

F1
___
c2
b0

the next stronger type must be used.

Transilon
Type
E 2/1 E 3/2
Constant c2 2

10

E 2/2 E 4/2
E 3/1 E 5/2
E 4/1

E 6/1

NOVO E12/3
E 8/2 E12/2
E10/M E15/M E18/3 E20/M E30/3 E44/3

15

25

35

40

60

70

Note: With perforated belts the number

of holes reducing the cross-section must
be deducted from b0. In the case of
extreme temperatures c2 constants change.
Please enquire.

Conveyor and processing belts

Minimum drive drum diameter dA

FU . c3 . 180
dA = ___________
b .

[mm]

Transilon
with underside of

V3, V5, U2,

A5, E3

V1, U1, UH

0, U0, NOVO,
T, P

smooth steel drum

dry
wet

25
50

50
not recommendable

80
not recommendable

lagged drum
dry
wet

25
30

30
40

30
50

c3 constant
(is valid for drive drum)

Power PA at drive drum

FU . v
PA = _______
1000

[kW]

Motor power PM required

PA
PM = ____ [kW] = next largest standard motor is chosen

Conveyor and processing belts

Take-up range
for screw-operated take-up systems

The following factors must be taken into

account when determining the tension
take-up range:
1. The approximate amount of elongation
of the belt resulting from belt load.
For determination of see pages 7
and 8.

Tol

+Tol

2. The production length tolerances

of the belt (Tol).

3. Possible external influences, e.g.

temperature, stop-and-go operation,
which may necessitate a higher
elongation (tension) than normal
or justify the allowance of a tension
take-up reserve.

Guidelines for shaft load at rest

with force F

Generally, depending on the load, an

elongation at fitting in the range of approx.
0.1 1% is adequate; a tension take-up
range x of 1% of the belt length is therefore
sufficient.

Conveyor at rest

When assessing shaft loads please take

into account the differing belt pulls in
stationary and operational modes.

FW1 = FW2 = 2 . F

Guidelines for elongation at fitting

with head drives

F % . SD . b0

[N]

Head drive in operation

The minimum operational elongation at

the fitting for a head drive is

F /2 + 2 . F
2 . SD . b

U
2
___________

[%]

F2 = F1 FU

FWA = F1 + F2

Conveyor and processing belts

Guidelines for elongation at fitting

with tail drives

Tail drive in operation

The operational elongation at fitting for a

head drive is

F /2 + 2 . F + F
2 . SD . b

U
2
U
_______________

[%]

F2 = F1 FU

Guidelines for elongation at fitting

with return-side drives

The operational elongation at fitting for a

return-side drive is

FW3

F (c K)
SD . b

U 1
__________

FW6

[%]

Return side drive in operation

K with head drive

K with return-side drive
K with trail drive

Example drive drum = 180

FWA = F1 + F2

= 0.75
= 0.62
= 0.25

Guidelines for operational shaft load

Example snub roller = 15

___________________
FW3 = 2 . F12 2 . F12 . cos

[N]

Example snub roller = 25

___________________
FW6 = 2 . F22 2 . F22 . cos

[N]

Conveyor and processing belts

Take-up range for

load-dependent take-up systems
With gravity-operated take-up systems the
tensioning weight must generate the force
F2 in order to achieve satisfactory grip by
the belt on the drive drum (spring-loaded,
pneumatic and hydraulic take-up devices
operate in similar fashion).

Determination of FR

The take-up range is a function of the

effective pull, the required force F2, the belt
length Lg, its delivery tolerance Tol, the
tension reserve Z and the belt type.

The tensioning weight must be capable of

moving freely. The take-up unit can only
be installed after the drive unit. Such a
design cannot be used with a reversible
conveyor.

FR = 2 . F2 FTR

[N]

FU F1
F2
F2

Example for determining the tensioning

weight FR [N] with a 180 arc of contact.
FTR

FR = 2 F2 cos __ _ FTR
2

FR

[N]

FU F1
F2

Example for determining the tensioning

weight FR [N] with an angle as shown
below.
FTR = weight of tension roller [N]

F2

FTR

FR

Conveyor and processing belts

Bulk goods conveying systems

Bulk goods

(ca.)

Bulk goods

(ca.)

Ash, dry
Ash, wet
Earth, moist
Grain, except oats
Lime, lumps
Potatoes
Gypsum, pulverized
Gypsum, broken
Wood, chips
Fertilizer, artificial
Flour

16
18
18 20
14
15
12
23
18
22 24
12 15
15 18

Salt, fine
Salt, rock
Loam, moist
Sand, dry, wet
Peat
Sugar, refined
Sugar, raw
Cement

15 18
18 20
18 20
16 22
16
20
15
15 20

Goods

Bulk density [103 kg/m3]

Ash, cold, dry

Earth, moist
Grain, except oats
Wood, hard
Wood, soft
Wood, chips
Charcoal
Pulses
Lime, lumps
Fertilizer, artificial
Potatoes
Salt, fine
Salt, rock
Gypsum, pulverized
b0

0.7
1.5 1.9
0.7 0.85
0.6 1.2
0.4 0.6
0.35
0.2
0.85
1.0 1.4
0.9 1.2
0.75
1.2 1.3
2.1
0.95 1.0
mm

Bulk density [103 kg/m3]

Goods
Gypsum, broken
Flour
Clinker
Loam, dry
Loam, moist
Sand, dry
Sand, wet
Soap, flakes
Slurry
Peat
Sugar, refined
Sugar, raw
Sugarcane

Guidelines for maximum incline angles

for various bulk goods.
The values are determined by the particle
shape, size and mechanical properties of
the material conveyed, irrespective of the
surface material of the belt.

Density of certain bulk goods

1.35
0.5 0.6
1.2 1.5
1.5 1.6
1.8 2.0
1.3 1.4
1.4 1.9
0.15 0.35
1.0
0.4 0.6
0.8 0.9
0.9 1.1
0.2 0.3

400

500

650

800

1000

1200

1400

Angle of surcharge 0

25

32

42

52

66

80

94

Angle of surcharge 10

40

57

88

123

181

248

326

Longitudinal angle of incline

Volume flow for flat conveyors

The table shows the hourly volume flow

(m3/h) at a belt speed of v=1m/s for a flat,
horizontal conveyor belt with 20 mm high
T20 longitudinal profiles welded along
both edges of the top face.

Conveyor and processing belts

Volume flow for troughed conveyors

b0

mm

400

500

650

800

1000

1200

1400

21
36

36
60

67
110

105
172

173
281

253
412

355
572

30
44

51
74

95
135

149
211

246
345

360
505

504
703

20 troughed

Note: In practical operations the theoretical value established for the volume flow
is seldom obtained since it applies only
to belts running horizontally and loaded
evenly. Uneven distribution of the goods
plus changes in the nature of the goods
may reduce the volume carried by as much
as 30 %.

c6 constant

For belts on inclined conveyors the

theoretical quantity carried has to be
reduced by the c6 constant depending
on the angle of inclination .
Determination of the effective pull FU

() increasing
(+) decreasing

c4 constant

Angle of surcharge 0
Angle of surcharge 10
30 troughed
Angle of surcharge 0
Angle of surcharge 10

Angle of inclination []

10

12

c6 constant

1.0

0.99

0.98

0.97

0.95

0.93

Angle of inclination []

14

16

18

20

22

0.91

0.89

0.85

0.81

0.76

c6 constant

FU = g c4 . f ( m + mB + mR) g m . sin
plus peripheral forces from scrapers and cleaning devices

IT [m]
c4

Coefficient of rolling resistance f

for support rollers

[N]

25

50

75

100

150

200

1.9

1.8

1.7

1.5

1.3

f = 0.025 for roller bearings

f = 0.050 for plain bearings

For other calculations

please refer to unit goods

10

Conveyor and processing belts

Support roller pitch is a function of the

belts effective pull and the combined
masses of belt and goods. It is calculated
according to the following equation

lo =

yB . 800 . F
__________
m'o + m'B

lo
yB
F
m'o + m'B

11

[mm]

If a max. belt sag of 1% is permitted,

i.e. if yB = 0.01 lo is used, then
Recommendations

8.F
lo = ________
m'o + m'B

= upper support roller pitch in mm

= max. belt sag in mm
= effective pull at appropriate point in N
= weight of conveyed goods plus belt in kg/m

lo max 2b0
lu 2 3 lo max

[mm]

Support roller pitch

Conveyor and processing belts

Unit goods conveying systems

Conveyor belts are loaded with a wide
variety of goods (objects, containers)
which are then sent to the distribution
centre.
Horizontal configuration, skid plate
support, return side drive as shown above,
drive drum lagged, tension take-up,
14 support rollers.
Proposed belt type:
Transilon E8/2 U0/V5H black

End drums 1, 2, 6
Snub rollers 3, 7, 8
Drive drums 5
Support rollers 4, 9, et al.
Tension roller 6.

Effective pull FU [N]

Conveying length
Geom. belt length
Belt width
Total load
Arc of contact
v = ca. 0.8 m/s
Mass rollers

lT = 50 m
Lg = 105000 mm
b0 = 600 mm
m = 1200 kg
= 180
g = 9.81 m/s2
mR = 570 kg
(all drums
except drum 5)

mB
mB
FU = T . g (m + ___ ) +R . g ( ___ + mR )
2
2
_____ ) + 0.033 . 9.81 ( 157.5
_____ + 570)
FU = 0.33 . 9.81 (1200 + 157.5
2
2
FU 4340 N
m
R
T
mB

Maximum belt pull F1 [N]

= 1200 kg
= 0.033
= 0.33
= 157.5 kg (from 2.5 kg/m2 . 105 . 0.6)

FU = 4350 N
c1 = 1.6

F1 = FU . c1
F1 = 4350 . 1.6
F1 6960 N

Counter-checking the type selection

F1 = 6960 N
b0 = 600 mm

F1
c2 = ___
b0
6960
c2 = ____
600
c2 = 11.6 N/mm 15 N/mm for E 8/2
The selected belt type is correct.

12

Conveyor and processing belts

FU
c3
b
b0

= 4340 N
= 30
= 180
= 600 mm

FU. c3 . 180
dA = ___________
b0 .

[mm]

4340 . 30 . 180
dA = _______________
600 . 180

[mm]

Minimum drive drum diameter

dA = 218 mm
dA 250 mm selected

FU = 4350 N
= 0.8 m/s

FU .
PA = _______
1000

[kW]

Power PA at the drive drum

4350 . 0.8
PA = _________
1000
PA 3.5 kW

PA = 3.5 kW
= 0.8 (assumed)

PA
PM = ____

[kW]

3.5
PM = ____
0.8

[kW]

Motor power PM required

PM 4.4 kW
PM 5.5 kW and higher

FU
c1
K
SD
b0

= 4350 N
= 1.6
= 0.62
= 8 N/mm for E 8/2
= 600 mm

FU (c1 K)
= _________
SD . b0

[%]

4350 (1.6 0.62)

= _______________
8 . 600

[%]

0.9 %

13

Minimum elongation
at fitting for return-side drive

Conveyor and processing belts

Shaft load (in operation)

Drum 2 (end drum)

Simplified calculation
assuming = 180

FW2 = 2 . F1

F1 = 6960 N

FW2 = 2 . 6960 N
FW2 13920 N

Shaft load (in operation)

Drum 1 (end drum)

F2 = F1 FU
F2 = 6960 4350
F2 = 2610 N

FW1 = 2 . F2
FW1 = 2 . 2610 N
FW1 5220 N

Shaft load (in operation)

Drum 5 (drive drum)

F1
F2
F2
F2

= 6960 N
= F1 FU
= 6960 4350
= 2610 N

FW5 = F1 + F2
FW5 = 6960 + 2610
FW5 9570 N

Shaft load (in operation)

Drum 3 (snub roller)

The calculation of FW3 influenced by

belt pull F1 , proceeds as given in the
equation on page 7.

14

Conveyor and processing belts

When the conveyor is at rest, the forces

in the upper and return strands are
determined solely by the elongation at
fitting . The force F in each strand is
given by

F = [%] . SD . b0

[N]

Shaft load at rest

In order to compare the differences

between the stationary and operational
modes, please look at the variations in
shaft load at drum 1.

Example for a drum where the arc of

contact = 180

= 8640 N
FW1 at rest
FW1 operational = 5220 N

FW = 2 . F
FW = 2 . 0.9 . 8 . 600
FW 8640 N

(This force acts on drums 1, 5 and 6

because of their 180 arc of contact.)

Note: Both modes must be taken into

account when designing the conveyor.

Where =/ 180 the following applies

in determining FW

FW = F12 + F22 2 . F1 . F2 . cos

FW = [N]

(where F1 = F2 can be used when the

conveyor is at rest.)

Tension take-up range

_ 105 +105

473

200

210
883

Tol

Lg
z

= 0.2 %
= 0.9 %
= 105000 mm
= 200 mm

X=

. Tol . Lg
2
. Lg
_________
+ _____
100
100
_________________

X=

2 . 0,2 . 105000
0,9 . 105000
_______________
+ ___________
100
100
______________________________

X = 210 + 473 + 200

X 883 mm

15

+z

[mm]

+ 200

[mm]

[mm]

Ausgabe 01.07/2 UD
Printed in Germany.

304

Registered trademarks
Siegling
Extremultus
Transilon
ProLink

Reproduction of text or parts

thereof only with our approval.
Modifications reserved.

This paper was made from

non-chlorine-bleached
cellulose.

Ref. No.

Conveyor and processing belts

Because our products are used in so many

applications and because of the individual factors
involved, our operating instructions, details and
information on the suitability and use of the products
are only general guidelines and do not absolve the
ordering party from carrying out checks and tests
themselves. When we provide technical support on
the application, the ordering party bears the risk of
the machinery functioning properly.

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