b-13-1- pe0101_note de calcul mécanique convoyeur cl7'_mec31301_00_20151101

OCP:

00

CONFIDENTIAL – Any disclosure of this information is strictly forbidden without EMPI prior authorization

WBN

Name Date Name Date Name

30/11/2015 AFE 30/11/2015 WKT 30/11/2015

Note de Calcul Mécanique convoyeur CVL'

DLM

Ref.:B-13-1- PE0101_Note de Calcul Mécanique

Convoyeur CL7'_MEC31301_00_20151101

Rev. Author Checked Approved

Date

MEA EXPANSIONMEA EXTENSION: Alimentation de la 7ème ligne

EMPI DLMRoute 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 Sebâa - B.P. 2613

Casablanca MAROC

Phone : + 212(0) 5 22 66 96 00

Fax : + 212(0) 5 22 35 54 65

Bureau d'Etude: Contractant:

Consultant:Propriétaire:

OCP JACOBS Engineering

OCP GROUP

Web: www.ocpgroup.ma

Imm. 5 - Zénith Millenium - Lot. Attaoufik

Route Nouaceur - Sidi Mâarouf

Casablanca - 20270 Morocco

Tél: +212 (0)5 22 87 70 00 / +212 (0)5 22 87 71 50

1 PAGE DE GARDE

2 SOMMAIRE

3 1- OBJET

3 2- DOCUMENTS & NORMES DE REFERENCE

3 2-1- DOCUMENTS DE REFERENCE

3 2-2- NORMES DE REFERENCE

3 3- DONNEES DE CALCUL

3 3-1- GROUPE DE COMMANDE

3 3-2- PHILOSOPHIE DE CONCEPTION

4 4- CALCUL DE LA PUISSANCE DU MOTEUR

4 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 SYSTÈME 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

SOMMAIRE

OCP

MEA EXPANSION

Alimentation de la 7ème ligne


B-13-1- PE0101_Note de Calcul Mécanique Convoyeur CL7'_MEC31301_00_20151101

1- OBJET

L'objectif de cette note de calcul est la vérification des différents composants du transporteur à bande

RB2, à savoir:

- Vérification Puissance de Commande

- Vérification des Caractéristiques & de la Tension de Bande

- Vérification des Différents Tambours

- Vérification des Différents Paliers

- Vérification des Différentes 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 & Elévation_MEC31302_00_20151101

2-2- NORMES DE REFERENCE

ISO5048 (1989): Engins de manutention continue. Transporteurs à courroie munis de rouleaux porteurs -

Calcul de la puissance d'entraînement et des efforts de tension.

3- DONNEES DE CALCUL

3-1- GROUPE DE COMMANDE

Le groupe de commande sera considéré comme étant un système moto-réducteur avec un

accouplement Arbre plein avec frette de serrage pour la connection avec tambour de commande.

L'efficacité globale du groupe de commande est calculée comme suit:

- Efficacité Moteur:

- Efficacité Accouplement:

- Efficacité Réducteur:

- Efficacité Totale:

Couple de Démarrage Moteur:

3-2- PHILOSOPHIE DE CONCEPTION

La puissance minimale requise pour entrainer le système de convoyeur à bande est calculée en faisant

la somme des puissances suivantes:

- La charge de la bande et des stations de rouleau à vide

- La charge pour translation de la matière.

- La charge pour soulèvement de la matière.

- Les charges divers éléments de la bande (Points de décharge, Racleurs, etc.) intégrées dans

le facteur "C".

- L'efficacité du groupe de commande.

2.40 1.50

0.98

0.95

0.90

Avec Accouplement

Hydraulique

0.97

0.95

0.95

0.88

OCP

MEA EXPANSION



Sans Accouplement

Hydraulique

0.97


4-1- Power Calculation

Belt Design Summary

265.91 Required Motor Power Necessary to transmit to the belt

OK Check of Motor Power

6,022 Minimum Required Counterweight

0.819 Belt Slipping Coefficient

OK Check of Counterweight

OK Check of Belt Slipping

7,608 Start-up Minimum Required Counterweight

0.981 Start-up Belt Slipping Coefficient

OK Check of Counterweight @ Start-up

OK Check of Belt Slipping @ Start-up

2,489 Maximum Belt Elongation

784 Minimum Required Tensile Strength

OK Check of Belt Elongation Length

OK Check of Belt Tensile Strength

2,983 Start-up Maximum Belt Elongation

657 Start-up Minimum Required Tensile Strength

OK Check of Belt Elongation Length @ Start-up

OK Check of Belt Tensile Strength @ Start-up

Working Condition

Handled Material DefinitionPhosphate

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/s²)

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)

Medium Weight and Lump Size Material

dmax (mm)

CRm (N/mm)

P ≥ Pm

Wu ≥ CRmS

OCP Standard

Wu ≥ CRm

dmaxS (mm)

CRmS (N/mm)

Pm (kW)

FvminS (daN)

rS

Fv ≥ FvminS

rS ≤ 1

d ≥ 2 dmax

r ≤ 1

d ≥ 2 dmaxS


4- CALCUL DE LA PUISSANCE DU MOTEUR

OCP

MEA EXPANSION



Fvmin (daN)

r

Fv ≥ Fvmin



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/[m²xmm])

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. PulleyQu,n

(Ton/h)Lu,n (m) Hu,n (m)

bu,n

(Deg)Ncu,n Nru,n

1 D1 3600 2.480 0.000 0.00 3 0

2 NA 3600 175.657 0.000 0.00 140 0

3 NA 3600 3.479 0.030 0.50 3 0

4 NA 3600 3.479 0.103 1.70 3 0

5 NA 3600 3.479 0.152 2.50 2 0

6 NA 3600 3.479 0.213 3.50 3 0

7 NA 3600 3.479 0.274 4.50 3 0

8 NA 3600 3.479 0.335 5.50 3 0

9 NA 3600 3.479 0.396 6.50 3 0

10 NA 3600 3.479 0.458 7.50 2 0

11 NA 3600 44.777 6.293 8.00 36 0

12 NA 3600 1.783 0.251 8.00 7 0

13 D2 0 1.560 0.219 8.00 1 0

14 D5 0 0.877 -0.235 -15.00 0 0

15 NA 0 47.242 -6.639 -8.00 0 15

16 NA 0 3.479 -0.458 -7.50 0 2 <-Qu,n: Flight Capacity (Ton/h)

17 NA 0 3.479 -0.396 -6.50 0 1 <-Lu,n: Flight Length (m)

18 NA 0 3.479 -0.335 -5.50 0 1 <-Hu,n: Flight Height (m)

19 NA 0 3.479 -0.274 -4.50 0 1 <-bu,n: Flight Slop (Deg)

20 NA 0 3.479 -0.213 -3.50 0 1 <-Ncu,n: Carrying Idler Number Per Flight

21 NA 0 3.479 -0.152 -2.50 0 1 <-Nru,n: Return Idler Number Per Flight

22 NA 0 3.479 -0.103 -1.70 0 2

23 NA 0 3.479 -0.030 -0.50 0 1

24 D4-1 0 130.520 0.000 0.00 0 43

25 D4-3 0 0.000 4.581 90.00 0 0

26 D3 0 4.581 0.000 0.00 0 0

27

28

29

30



OCP

MEA EXPANSION



Lower Flight Definition

4 <-Nl: Lower Flight Number

No. PulleyQl,n

(Ton/h)Ll,n (m) Hl,n (m)

bl,n

(Deg)Ncl,n Nrl,n

1 D5 0 0.710 -0.125 -10.00 0 0

2 D4-2 0 46.385 0.000 0.00 0 15

3 D4-3 0 0.000 5.092 -90.00 0 0

4 D3 0 5.092 0.000 0.00 0 0

5

6

7

8

9

10

11

12

13

14

15

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

17 <-Ll,n: Flight Length (m)

18 <-Hl,n: Flight Height (m)

19 <-bl,n: Flight Slop (Deg)

20 <-Ncl,n: Carrying Idler Number Per Flight

21 <-Nrl,n: Return Idler Number Per Flight

22

23

24

25

26

27

28

29

30

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

j

T1

T2



OCP

MEA EXPANSION



Empty Belt & Idlers Weight Computation

6.5 <-qbc: Belt Carcass Weight for square Meter (Tab.13) (kg/m²)

18.5 <-q: Belt Weight per square Meter (kg/m²)

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)

bc r tc bcq q t tr



OCP

MEA EXPANSION



Forces Necessary for Movement of Belt

No.F1u,n

(kg)

F2u,n

(kg)

F3u,n

(kg)

F1l,n

(kg)

F2l,n

(kg)

F3l,n

(kg)

1 5.914 19.579 0 0.5517 0 -3.2425

2 322.55 1386.8 0 51.881 0 0

3 6.6902 27.466 8.776 0 0 131.88

4 6.6902 27.466 29.846 3.9565 0 0

5 5.3612 27.466 43.907 0 0 0

6 6.6902 27.466 61.507 0 0 0

7 6.6902 27.466 79.145 0 0 0

8 6.6902 27.466 96.831 0 0 0

9 6.6902 27.466 114.58 0 0 0

10 5.3612 27.466 132.39 0 0 0

11 82.636 353.5 1819 0 0 0

12 10.688 14.076 72.433 0 0 0

13 2.5411 0 5.6784 0 0 0

14 0.6814 0 -6.0863 0 0 0

15 52.547 0 -171.96 0 0 0

16 4.8152 0 -11.863 0 0 0

17 3.7592 0 -10.266 0 0 0

18 3.7592 0 -8.6762 0 0 0

19 3.7592 0 -7.0915 0 0 0

20 3.7592 0 -5.5111 0 0 0

21 3.7592 0 -3.9341 0 0 0

22 4.8152 0 -2.6743 0 0 0

23 3.7592 0 -0.7863 0 0 0

24 146.82 0 0 0 0 0

25 0 0 118.65 0 0 0

26 3.5594 0 0 0 0 0

27 0 0 0 0 0 0

28 0 0 0 0 0 0

29 0 0 0 0 0 0

30 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 <-F1: Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)

1,994 <-F2: Forces Necessary for Translation of the Load (kg)

2,483 <-F3: Forces Necessary for the Elevation of the Load (kg)

185 <-Ft,L: Tail Losses Between Take Up & Drive Pulley (kg)

1,000.87 <-FNS: Total Secondary & Special Resistance (daN)

Upper Flight Lower Flight

1, , ,1000

n n c c n r r n

BF f L q q N q N

2,

3.6

nn n

QF fL

v

3,3.6 1000

n nn n

Q H BF q H

v

NS N SF F F



OCP

MEA EXPANSION



Total Force and Motor Power Calculation

6,244 <-Fmin: Total Periphery Force Necessary to transmit to the belt (kg)

232.78 <-Pa: Theorical Motor Power Necessary to transmit to the belt (kW)

265.91 <-Pm: Required Motor Power Necessary to transmit to the belt (kW)

P ≥ Pm OK

Tension Calculation (During Operation)

7,257 <-F: Installed Periphery Force (daN)

0.384 <-K: Friction Factor

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

2,784 <-Tl,1n: Nominal Slack Side Tension (daN)

2,969 <-Tv1: Minimum Tension to Allow the Motion Transmission (daN)

3,011 <-Tsup: Minimum Tension For Max Sag of Carrying Idler (daN)

648 <-Tinf: Minimum Tension For Max Sag of Return Idler (daN)

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

931 <-Tv: Take-Up Over tension (daN)

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

3,715 <-Tl,1: Maximum Slack Side Tension (daN)

minaP gF v

am

PP

h

1

1K

emj

,1 1u nT F K

,1l nT FK

1 ,1 ,v l n t LT T F

sup

18 1000 3.6

ca qB QT

S v

inf

28 1000

ra qBT

S

min 1 sup inf2 ; ;v vF Max T T T

, ,12

vv t L l n

FT F T

PF

v

h

,1 ,1u u n vT T T

,1 ,1l l n vT T T

min 1 2 3 NSF F F F F



OCP

MEA EXPANSION



0.819 <-r: Belt Slipping Coefficient

Fv ≥ Fvmin OK

r ≤ 1 OK

Tension Calculation (During Start-up)

9,434 <-Fs: Installed Periphery Force at Starting (daN)

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

3,619 <-Tl,1nS: Start-up Nominal Slack Side Tension (daN)

3,804 <-Tv1S: Start-up Minimum Tension to Allow the Motion Transmission (daN)

7,608 <-FvminS: Start-up Minimum Required Counterweight (daN)

96 <-TvS: Start-up Take-Up Over tension (daN)

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

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

0.981 <-rS: Start-up Belt Slipping Coefficient

Fv ≥ FvminS OK

rS ≤ 1 OK

,1

,1

u

l

Tr

T emj

s

w PF

v

h

,1 1u nS sT F K

,1l nS sT F K

1 ,1 ,v S l nS t LT T F

min 1 sup inf2 ; ;v S v SF Max T T T

, ,12

vvS t L l nS

FT F T

,1 ,1u S u nS vST T T

,1 ,1l S l nS vST T T

,1

,1

u S

S

l S

Tr

T emj



OCP

MEA EXPANSION



Belt Tensile Strength Check (Operation Case)

No.DTu,n

(kg)

Tu,n

(kg)

DTl,n

(kg)

Tl,n

(kg)

1 25 10,972 -3 3,715

2 1,709 10946 52 3712.3

3 43 9237 132 3764.2

4 64 9194 4 3896

5 77 9130 0 3900

6 96 9053.3 0 0

7 113 8957.6 0 0

8 131 8844.3 0 0 Notes

9 149 8713.4 0 0 Tension will be Regulated via Material

10 165 8564.6 0 0 Trampling Losses Addition

11 2,255 8399.4 0 0 The Tension in Pulley Remains inchanged

12 97 6144.2 0 0

13 8 6047 0 0

14 -5 6038.8 0 0

15 -119 6044.2 0 0

16 -7 6163.6 0 0

17 -7 6170.7 0 0

18 -5 6177.2 0 0

19 -3 6182.1 0 0

20 -2 6185.4 0 0

21 0 6187.2 0 0

22 2 6187.4 0 0

23 3 6185.2 0 0

24 147 6182.2 0 0

25 119 6035.4 0 0

26 4 5916.8 0 0

27 0 5913.2 0 0

28 0 0 0 0

29 0 0 0 0

30 0 0 0 0

31 0 0

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

2,489 <-dmax: Maximum Belt Elongation (mm)

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


maxm s

TCR f

B

, 1 , 2 , 3 ,u n u n u n u nT F F FD

, 1 , 2 , 3 ,l n l n l n l nT F F FD

, 1 , ,u n u n u nT T T D

, 1 , ,l n l n l nT T T D

maxmax

10TL

B Wud



OCP

MEA EXPANSION



d ≥ 2 dmax OK

Wu ≥ CRm OK

Belt Tensile Strength Check (Start-up Case)

No. PulleyDTu,n

(kg)

Tu,nS

(kg)Pulley

DTl,n

(kg)

Tl,nS

(kg)

1 D1 25 13,149 D5 -3 3,715

2 NA 1,709 13123 D4-2 52 3712.3

3 NA 43 11414 D4-3 132 3764.2

4 NA 64 11371 D3 4 3896

5 NA 77 11307 0 0 3900

6 NA 96 11230 0 0 0

7 NA 113 11135 0 0 0

8 NA 131 11021 0 0 0 Notes

9 NA 149 10890 0 0 0 Tension will be Regulated via Material

10 NA 165 10742 0 0 0 Trampling Losses Addition

11 NA 2,255 10576 0 0 0 The Tension in Pulley Remains inchanged

12 NA 97 8321.3 0 0 0

13 D2 8 8224.1 0 0 0

14 D5 -5 8215.9 0 0 0

15 NA -119 8221.3 0 0 0

16 NA -7 8340.7 0 0 0

17 NA -7 8347.7 0 0 0

18 NA -5 8354.2 0 0 0

19 NA -3 8359.1 0 0 0

20 NA -2 8362.5 0 0 0

21 NA 0 8364.2 0 0 0

22 NA 2 8364.4 0 0 0

23 NA 3 8362.3 0 0 0

24 D4-1 147 8359.3 0 0 0

25 D4-3 119 8212.5 0 0 0

26 D3 4 8093.8 0 0 0

27 0 0 8090.3 0 0 0

28 0 0 0 0 0 0

29 0 0 0 0 0 0

30 0 0 0 0 0 0

31 0 0

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

2,983 <-dmaxS: Start-up Maximum Belt Elongation (mm)


, 1 , 2 , 3 ,u n u n u n u nT F F FD

, 1 , 2 , 3 ,l n l n l n l nT F F FD

, 1 , ,u n S u nS u nT T T D

, 1 , ,l n S l nS l nT T T D

maxmax

10SS

TL

B Wud



OCP

MEA EXPANSION



657 <-CRmS: Start-up Minimum Required Tensile Strength (N/mm)

d ≥ 2 dmaxS OK

Wu ≥ CRmS OK

Pulleys Tensions

No.Zx

(kg)

Zs

(kg)

1 13,149 3,715

2 8,224

3 3,896

4 3,712

5 3,712

6 3,715D5

Designation

D1

D2

D3

D4-1

D4-2

max SmS ss

TCR f

B

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/s²)


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/m²)

0.0315 <-A: Contact Area Between between belt cleaner and the belt (m²)

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. PulleyDi

(mm)

Ni

(kg)

Zxi

(kg)

Zsi

(kg)

d0i

(mm)

1 D1 630 16,077 13,149 3,715 180 <-D1: Drive Pulley

2 D2 500 16,461 8,224 0 160 <-D2: Tail/Return Pulley

3 D3 500 3,713 3,896 0 100 <-D3: Take up/Counter Weight Pulley

4 D4-1 400 3,713 3,712 0 100 <-D4: Bend/Deviation Pulley(s)

5 D4-2 400 3,713 3,712 0 100 <-D5: Snub Pulley(s)

6 D5 400 3,825 3,715 0 100

7

8

9

10

OCP

MEA EXPANSION





OCP

MEA EXPANSION





Special Resistance Calculations

263 <-qG: Mass per Meter of Material Handled (kg/m)

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

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

92.43 <-FgL: Resistance due to Friction between Material Handled and Skirtplates (daN)

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

492.11 <-Fs: Total Special Resistance (daN)

Secondary Resistance Calculations due Skirtplates, Inertial and Frictional Resistance

1.04 <-lb,min: Skirtplate Equivalent Length (m)

230 <-FbA: Inertial and Frictional Resistance at the Loading Point (daN)

66 <-Ff: Frictional Resistance between Handled material and the skirtplate in the acceleration Area (daN)

Secondary Resistance Calculations due Pulleys

No. PulleyFi

(N)

F1i

(daN)

FTi

(daN)

Fti

(daN)

1 D1 82,717 31

2 D2 80,678 38 16,148 26

3 D3 38,220 22 3,642 4

4 D4-1 36,417 26 3,642 5

5 D4-2 36,417 26 3,642 5

6 D5 36,444 26 3,753 5

7

8

9

10

3.6G

Qq

v

3.6v

QI

r

0 cos sinB GF C L q q ge e em d e

2

2

2 2

1

vgL

I glF

v b

m r

3rF Apm

s gL rF F F Fe

0bA vF I v vr

2 2

0,min

12b

v vl

gm

2

2 ,min

2

201

2

v b

f

I glF

v vb

m r

1 9 140 0.01 ii

i

F dF B

B D

Ti iF N g 00.005 iti Ti

i

dF F

D

OCP

MEA EXPANSION





<-Fi: Average Belt Tension at the Pulley (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)

Applicability of C Equivalent Method

1,000.87 <-FNS: Total Secondary & Special Resistance (daN)

1N bA f tF F F F F

NS N SF F F





No. Designation

Dp

(mm)

Tab.13

d

(mm)

N

(kg)

j

(Deg)

a

(Deg)

b

(Deg)

Zx

(kg)

Zs

(kg)

Fv

(kg)

q

(kg)

1 D1 630 180 16,077 210 0 13,149 3,715 0 1,063

2 D2 500 160 16,461 0 8,224 0 655

3 D3 500 100 3,713 3,896 7,800 414

4 D4-1 400 100 3,713 0 3,712 0 364

5 D4-2 400 100 3,713 0 3,712 0 364

6 D5 400 100 3,825 3 15 3,715 0 364

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)

5- CHARGES SUR TAMBOURS


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a

a

j

a

a

j

a

a

a

b

6-1- SPECIFICATIONS DU MOTEUR

Puissance installée (kW) 315

Standard de construction IEC60034

Facteur de puissance minimale cosj 80%

Facteur de service ≥ 1,5

Start-up/Nominal Absorbed Current Ratio (Is/In) 6.8

Tension d'alimentation 525V/3Ph

Vitesse de rotation (rpm) 1500

Fréquence 50Hz

Degrès de protection IP (IEC 60034-5) IP55

Classe d'isolation Class F

Température de design 50°C

Méthode de refroidissement selon IEC 60034-6 IC0A1

Protection thermique PT100

Environment de travail Poussièreux

Matériau de construction du stator Cast Iron

Matériau de construction Supports/oreilles de levage Fonte

Matériau de construction de la boite de jonction Fonte

Position boite de jonction au dessus du moteur

Type Cage d'écureuil

Poids approximatif (kg) 1500

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6- DIMENSIONNEMENT DU GROUPE DE COMMANDE


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6- DIMENSIONNEMENT DU GROUPE DE COMMANDE


6-2- SPECIFICATION DU REDUCTEUR

Standard de construction AGMA

Type

Diamètre du tambour (mm) 630

Vitesse de la bande (m/s) 3.8

Vitesse de rotation /petite vitesse (rpm) 115

Couple réducteur (Nm) 26,112

Puissance réducteur (kW) 315

Rapport de réduction 13

Température de design du réducteur 50°C

Nombre d'heure de service/jour (hr) 24H

Facteur de Service ≥ 1,5

Type d'arbre à grande vitesse Type 1

Type d'arbre à petite vitesse Type 1

Type 1: Arbre plein

Type 2: Arbre creux avec disque

Type 3: Arbre creux avec clavette

Peinture Intérieure & Extérieure

Sonde de température N/A

Indicateur de niveau d'huile oui

Trous de regards avec clapets Oui

Carcasse du réducteur

Antidévireur N/A

Orientation de l'arbre de sortie (droite/gauche) Droite


6-3- SPECIFICATION D'ACCOUPLEMENT

Type d'accouplement Hydraulique

Chambre de retardement Oui

Rapport (couple de démarrage transmissible/couple nominal) 1,5 à 1,6


6-4- SPECIFICATION SYSTÈME DE FREINAGE

Type de frein

Temps de freinage maximale (s) ≤ 5

6-5- SPECIFICATION CHASSIE GROUP DE COMMANDE

Peinture Intérieure & Extérieure

Matériaux Acier Carbone

Construction PRS


Les carters du réducteur en

deux parties moulées

Frein à sabot à commande

électromagnétique

Axes perpendiculaires, à Arbre

plein

Pulley Parameters Definition

No. DesignationDp

(mm)

d

(mm)

N

(kg)Type

Lp

(mm)

ts

(mm)

tf

(mm)

Lf

(mm)

th

(mm)

dho

(mm)

dhi

(mm)

Tab.23

WL

(kg)

Tab.23

PN

(N/mm²)

Tab.23

d1

(mm)

Tab.16

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)

1 D1 630 180 16,077 Type 1 1600 10 10 1400 20 310 235 8.15 110 220 1360 91 1920 210 175 175 172 787.5 170 962.5 115 315 26111.84 3024

2 D2 500 160 16,461 Type 2 1600 10 10 1400 20 300 210 5.5 145 190 1360 85 1920

3 D3 500 100 3,713 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

4 D4-1 400 100 3,713 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

5 D4-2 400 100 3,713 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

6 D5 400 100 3,825 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

7

8

9

10

<-Dp: Pulley Diameter (mm) <-tf : Pulley Flange Thickness (mm) <-PN: Pressure Applied From Locking Device to Hub (N/mm²) <-n: Gear Box Output Speed (r/min)

<-d: Shaft Diameter (mm) <-Lf : Distance Between Flange (mm) <-d1 :Shaft Inside Diameter (mm) <-P: Motor Nominal Power (kW)

<-N: Equivalent Load Applied From Belt Conveyor (kg) <-th: Hub Thickness (mm) <-Li: Shaft Inside Portion Length (mm) <-MTP: Moment Transmitted from Gear Box (Nm)

<-dho: Hub Outside Diameter (mm) <-k: Distance From Plummer Block Axis to Shaft End (mm) <-Wd: Approximatif Drive System Weight (kg)

<-Lp: Pulley Shell Length (mm) <-dhi: Hub Inside Diameter (mm) <-EA: Distance Between Plummer Blocks (mm)

<-ts: Pulley Shell Thickness (mm) <-WL: Locking Devices (kg) <-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)

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)

Pulley Shell Flange & Hub Parameters Driven Shaft Parameters Driving Shaft Parameters Gear Box & Motor Parameters


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7- VERIFICATION DES AXES & MOYEU TAMBOURS


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7- VERIFICATION DES AXES & MOYEU TAMBOURS

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

No. DesignationWp

(kg)Kb

Sf

(MPa)

MTT

(Nmm)

ag

(mm)

Mb

(Nmm)

dmin

(mm)

Stress

Checkrd

tan(a)/0

.005

Defl

Check

dho,min

(mm)

Hub

Stress

Check

1 D1 1062.8 0.6893 109.07 3E+07 260 4E+07 175.33 OK 0.974081 0.3302 OK 305.274 OK <-Wp: Pulley Weight (kg)

2 D2 654.84 0.7049 111.54 0 260 2E+07 142.2 OK 0.888777 0.5416 OK 298.285 OK <-Kb: Size Factor

3 D3 414.41 0.7708 121.96 0 260 5E+06 84.023 OK 0.840233 0.8006 OK 205.958 OK <-Sf: Allowable Bending Stress (MPa)

4 D4-1 364.35 0.7708 121.96 0 260 5E+06 84.023 OK 0.840233 0.8006 OK 205.958 OK <-MTT : Moment Transmitted to Pulley Taking into Consideration Drive System Efficiency & Starting Torque (Nmm)

5 D4-2 364.35 0.7708 121.96 0 260 5E+06 84.023 OK 0.840233 0.8006 OK 205.958 OK <-ag (mm)

6 D5 364.35 0.7708 121.96 0 260 5E+06 84.865 OK 0.848647 0.8249 OK 205.958 OK <-Mb: Bending Moment Applied to Shaft (Nmm)

7 <-dmin: Minimum Shaft Diameter Imposed by Stresses (mm)

8 <-rd: Minium Shaft Diameter to Nominal Shaft

9 <-tan(a): Shaft Deflection Ratio

10 <-dho,min: Minimum Hub Diameter (mm)

22

3min

f

32 3

4

b TT

ys

M MSFd

S S

22 22 2 2 22 2

11 1

27850 2 7850 2 7850 2 7850 7850 7850 7850 7850

4 4 4 4 4 4 4

p s ho qho hi m wp p p s f h L q m q w m

D t d Dd d D Dd dW D L t t t W L EA k b L L L L L L

0.19

25.4b

dK

2

usf a b c d e f g

SS k k k k k k k

1

0 2

TP

TT

M For TypeM w

For Typeh

2

f

g

EA La

2 2

db g w

WNM a b L

4

64tan

4

g g

s

Na EA a

E da

ho,min

yh N

hi

yh N

S Pd d

S P

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

No. Pulley Ref.Dp

(mm)

d

(mm)

N

(kg)

1 D1 630 180 16076.516

2 D2 500 160 16461.173

3 D3 500 100 3712.8286

4 D4-1 400 100 3712.8286

5 D4-2 400 100 3712.8286

6 D5 400 100 3825.4946

7

8

9

10

<-Dp: Pulley Diameter (mm)

<-d: Shaft Diameter (mm)

<-N: Equivalent Load Applied From Belt Conveyor (kg)


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8- VERIFICATION DES PALIERS

BND3236 22336 CCK/W33 D180

Plummer Block Designation

Tab. 14

BND3032 22232 CCK/W33 D160

BND2220 23232 CCK/W33 D100

BND2220 23232 CCK/W33 D100

BND2220 23232 CCK/W33 D100

BND2220 23232 CCK/W33 D100


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Bearing Rating Life Check

No.n

(rpm)

Pr

(N)

C

(N)

Tab.15

L10

(MR)

L10h

(h)

L10hE

(h)

L10hE ≥

L10M

1 115.20 118,283 2000000 12408 1795134 413,591 OK

2 145.15 121,113 2000000 11467 1316731 382,245 OK

3 145.15 27,317 1000000 162886 18703227 5,429,521 OK

4 181.44 27,317 475000 13621 1251176 454,018 OK

5 181.44 27,317 475000 13621 1251176 454,018 OK

6 181.44 28,146 475000 12328.75306 1132512.282 410958.4355 OK

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)

22336 CCK/W33

22336 CCK/W33

23232 CCK/W33

22232 CCK/W33

23232 CCK/W33

23232 CCK/W33

Bearing Designation

Tab.14

rP2

d

NC

10

3

10

rP

CL

6

10 10

10

60hL L

n 10 10

500hE h

nL L1000 60

p

v x xn

D

Idler Definition

No. Ref TypeIdlers

Type

l

(Deg)

d

(mm)

a

(m)Bearing

Hc

(m)

1 ID01 Impact Tern 35 159 0.3 6305-2RS1 1.4

2 ID02 Carrying Tern 35 159 1.25 6204-2RS1 0

3 ID03 Transition Tern 20 159 2 6305-2RS1 0

4 ID04 Return Couple 10 159 3 6204-2RS1 0

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 DefinitionOver 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/s²)

Belt Carcass Definition





6 <-ttc: Top Cover Thickness (mm)

4 <-tbc: Bottom Cover Thickness (mm)

1.2 <-rr: Rubber Average Weight (kg/[m²xmm])

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)

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9- VERIFICATION DES ROULEAUX


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9- VERIFICATION DES ROULEAUX


Belt Weight Computation

6.5 <-qbc: Belt Carcass Weight for square Meter (kg/m²)

25.9 <-qb: Belt Weight Per Linear Meter (kg/m)

263 <-qm: Material Weight Per Linear Meter (kg/m)

Idler Roller Speed Check

No. Refn

(rpm)Cs (N)

Fp

(Tab.21)Pi (N) Pr (N)

C (N)

(Tab.22)

L10

(MR)

L10h

(h)L10hE (h)

L10hE

≥

L10M

1 ID01 456 850 0.67 5,222 2,093 22,500 1,243 45,386 41,432 OK

2 ID02 456 3,543 0.67 0 1,431 12,700 699 25,525 23,301 OK

3 ID03 456 5,669 0.6 0 2,050 22,500 1,321 48,252 44,048 OK

4 ID04 456 762 0.5 0 230 12,700 169,138 6,175,919 5,637,927 OK

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)

1000 60v x xn

d

b bc r tc bcq q t t Br

3.6m

Qq

v

Reb

s

b m

aq g If turnC

a q q g Else

3

10

rP

CL

6

10 10

10

60hL L

n

10 10500

hE h

nL L

8

c

i

HP g Q

1 1

2 2r s d s m v p i pP C F F F F F PF

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)

####### <-Rminf: Minimum Belt Radius to Avoid Folding on the Belt egdes (m)

####### <-Rminc: Minimum Belt Radius to Avoid Over Stress at the Center (m)

####### <-Rmin: Minimum Belt Radius (m)

R ≥ Rmin #######

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10- VERIFICATION RAYON DE COURBURE CONCAVE


min

cos1000 3.6

cl

TR

B Qq

vs

min

sin

10 10004.5 4.4

u

f

W A BR

Tc

B

l

min

sin

1000109

u

c

u c

s

W A BR

W T

f B

l


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)

124.886 <-Rmine: Minimum Belt Radius to Avoid Over Stress at the edge (m)

124.886 <-Rmin: Minimum Belt Radius (m)

R ≥ Rmin OK

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11- VERIFICATION RAYON DE COURBURE CONVEX

1000

4.410

9

sinmin

B

B

T

AWR

c

uc

l

100010

9

sinmin

B

B

T

f

W

AWR

c

s

u

ue

l

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