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CONFIDENTIAL – Any disclosure of this information is strictly forbidden without EMPI prior authorization
WBN
Name Date Name Date Name
15/12/2015 AFE 15/12/2015 WKT 15/12/2015
Note de Calcul Mécanique convoyeur CVL'
DLM
Ref.:B-28-1- PE0101_Note de Calcul Mécanique
Convoyeur CVL'_MEC32801_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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
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
Note de Calcul Mécanique convoyeur CVL'
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-28-6- PE0101_Plan d'Ensemble Table de Réception Convoyeur CVL'_MEC32801_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 accouplement flexible 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
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
Sans Accouplement
Hydraulique
0.97
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4-1- Power Calculation
Belt Design Summary
311.29 Required Motor Power Necessary to transmit to the belt
OK Check of Motor Power
6,022 Minimum Required Counterweight
0.831 Belt Slipping Coefficient
OK Check of Counterweight
OK Check of Belt Slipping
6,971 Start-up Minimum Required Counterweight
0.997 Start-up Belt Slipping Coefficient
OK Check of Counterweight @ Start-up
OK Check of Belt Slipping @ Start-up
847 Maximum Belt Elongation
778 Minimum Required Tensile Strength
OK Check of Belt Elongation Length
OK Check of Belt Tensile Strength
1,017 Start-up Maximum Belt Elongation
653 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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
Fvmin (daN)
r
Fv ≥ Fvmin
CONVOYEUR CVL': D1:Ø630 / D2:Ø500
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
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 (%)
87.15 <-L: Belt Length Center-To-Center (m)
13.5 <-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
7 <-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 2.808 0.674 13.50 3 0
2 NA 3600 81.436 19.551 13.50 66 0
3 NA 3600 1.750 0.420 13.50 7 0
4 D2 0 1.156 0.278 13.50 0 0
5 D5 0 0.800 -0.214 -15.00 0 0
6 D4-1 0 41.644 -9.998 -13.50 0 14
7 D3 0 0.000 3.165 90.00 0 0
8
9
10
11
12
13
14
15
16 <-Qu,n: Flight Capacity (Ton/h)
17 <-Lu,n: Flight Length (m)
18 <-Hu,n: Flight Height (m)
19 <-bu,n: Flight Slop (Deg)
20 <-Ncu,n: Carrying Idler Number Per Flight
21 <-Nru,n: Return Idler Number Per Flight
22
23
24
25
26
27
28
29
30
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
Lower Flight Definition
3 <-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 0.790 0.000 0.00 0 0
2 D4-2 0 43.394 -10.418 -13.50 0 14
3 D3 0 0.000 3.366 -90.00 0 0
4
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)
2,100 <-d: Counterweight Elongation Course (mm)
7,000 <-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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
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 6.1688 22.168 194.87 0.6138 0 0
2 150.99 642.92 5651.4 48.501 0 -269.83
3 10.663 13.816 121.44 0 0 87.179
4 0.8982 0 7.1881 0 0 0
5 0.6216 0 -5.5519 0 0 0
6 47.141 0 -258.94 0 0 0
7 0 0 81.974 0 0 0
8 0 0 0 0 0 0
9 0 0 0 0 0 0
10 0 0 0 0 0 0
11 0 0 0 0 0 0
12 0 0 0 0 0 0
13 0 0 0 0 0 0
14 0 0 0 0 0 0
15 0 0 0 0 0 0
16 0 0 0 0 0 0
17 0 0 0 0 0 0
18 0 0 0 0 0 0
19 0 0 0 0 0 0
20 0 0 0 0 0 0
21 0 0 0 0 0 0
22 0 0 0 0 0 0
23 0 0 0 0 0 0
24 0 0 0 0 0 0
25 0 0 0 0 0 0
26 0 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)
266 <-F1: Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)
679 <-F2: Forces Necessary for Translation of the Load (kg)
5,610 <-F3: Forces Necessary for the Elevation of the Load (kg)
-134 <-Ft,L: Tail Losses Between Take Up & Drive Pulley (kg)
755.96 <-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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
Total Force and Motor Power Calculation
7,310 <-Fmin: Total Periphery Force Necessary to transmit to the belt (kg)
272.51 <-Pa: Theorical Motor Power Necessary to transmit to the belt (kW)
311.29 <-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)
2,650 <-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)
850 <-Tv: Take-Up Over tension (daN)
10,890 <-Tu,1: Maximum Tight Side Tension (daN)
3,634 <-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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
0.831 <-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)
3,485 <-Tv1S: Start-up Minimum Tension to Allow the Motion Transmission (daN)
6,971 <-FvminS: Start-up Minimum Required Counterweight (daN)
15 <-TvS: Start-up Take-Up Over tension (daN)
13,067 <-Tu,1S: Start-up Maximum Tight Side Tension (daN)
3,634 <-Tl,1S: Start-up Maximum Slack Side Tension (daN)
0.997 <-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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
Belt Tensile Strength Check (Operation Case)
No.DTu,n
(kg)
Tu,n
(kg)
DTl,n
(kg)
Tl,n
(kg)
1 223 10,890 1 3,634
2 6,445 10667 -221 3634.1
3 146 4221.8 87 3412.8
4 8 4075.9 0 3500
5 -5 4067.8 0 0
6 -212 4072.8 0 0
7 82 4284.6 0 0
8 0 4202.6 0 0 Notes
9 0 0 0 0 Tension will be Regulated via Material
10 0 0 0 0 Trampling Losses Addition
11 0 0 0 0 The Tension in Pulley Remains inchanged
12 0 0 0 0
13 0 0 0 0
14 0 0 0 0
15 0 0 0 0
16 0 0 0 0
17 0 0 0 0
18 0 0 0 0
19 0 0 0 0
20 0 0 0 0
21 0 0 0 0
22 0 0 0 0
23 0 0 0 0
24 0 0 0 0
25 0 0 0 0
26 0 0 0 0
27 0 0 0 0
28 0 0 0 0
29 0 0 0 0
30 0 0 0 0
31 0 0
10,890 <-Tmax: Maximum Belt Tension (daN)
847 <-dmax: Maximum Belt Elongation (mm)
778 <-CRm: Minimum Required Tensile Strength (N/mm)
Upper Flight Lower Flight
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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
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 223 13,067 D5 1 3,634
2 NA 6,445 12844 D4-2 -221 3634.1
3 NA 146 6398.9 D3 87 3412.8
4 D2 8 6253 0 0 3500
5 D5 -5 6244.9 0 0 0
6 D4-1 -212 6249.8 0 0 0
7 D3 82 6461.6 0 0 0
8 0 0 6379.6 0 0 0 Notes
9 0 0 0 0 0 0 Tension will be Regulated via Material
10 0 0 0 0 0 0 Trampling Losses Addition
11 0 0 0 0 0 0 The Tension in Pulley Remains inchanged
12 0 0 0 0 0 0
13 0 0 0 0 0 0
14 0 0 0 0 0 0
15 0 0 0 0 0 0
16 0 0 0 0 0 0
17 0 0 0 0 0 0
18 0 0 0 0 0 0
19 0 0 0 0 0 0
20 0 0 0 0 0 0
21 0 0 0 0 0 0
22 0 0 0 0 0 0
23 0 0 0 0 0 0
24 0 0 0 0 0 0
25 0 0 0 0 0 0
26 0 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
31 0 0
13,067 <-TmaxS: Start-up Maximum Belt Tension (daN)
1,017 <-dmaxS: Start-up Maximum Belt Elongation (mm)
Upper Flight Lower Flight
, 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
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
4- CALCUL DE LA PUISSANCE DU MOTEUR
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
653 <-CRmS: Start-up Minimum Required Tensile Strength (N/mm)
d ≥ 2 dmaxS OK
Wu ≥ CRmS OK
Pulleys Tensions
No.Zx
(kg)
Zs
(kg)
1 13,067 3,634
2 6,253
3 3,413
4 3,634
5 3,634
6 3,634D5
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
1200 <-r: Material Density (kg/m3)
9.81 <-g: Standard Gravity Acceleration (m/s²)
3600 <-Q: Maximum Belt Design Capacity (Ton/h)
3.8 <-v: Belt Speed (m/s)
1400 <-B: Belt Width (mm)
87.15 <-Le: Length of Installation Equiped with Tilted Idlers (m)
18.5 <-q: Belt Weight per square Meter (kg/m²)
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)
2.63 <-d: Medium Belt Inclination (Deg)
Pulleys Parameters
No. PulleyDi
(mm)
Ni
(kg)
Zxi
(kg)
Zsi
(kg)
d0i
(mm)
1 D1 630 15,962 13,067 3,634 170 <-D1: Drive Pulley
2 D2 500 12,519 6,253 0 140 <-D2: Tail/Return Pulley
3 D3 500 3,635 3,413 0 100 <-D3: Take up/Counter Weight Pulley
4 D4-1 400 3,635 3,634 0 100 <-D4: Bend/Deviation Pulley(s)
5 D4-2 400 3,635 3,634 0 100 <-D5: Snub Pulley(s)
6 D5 400 3,744 3,634 0 100
7
8
9
10
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
4- CALCUL DE LA PUISSANCE DU MOTEUR
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
OCP
MEA EXPANSION
Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
4- CALCUL DE LA PUISSANCE DU MOTEUR
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
Special Resistance Calculations
263 <-qG: Mass per Meter of Material Handled (kg/m)
0.83 <-Iv: Belt Capacity (m3/s)
117.53 <-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)
266.66 <-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 81,918 30
2 D2 61,342 31 12,281 17
3 D3 33,480 20 3,566 4
4 D4-1 35,651 26 3,566 4
5 D4-2 35,651 26 3,566 4
6 D5 35,645 26 3,673 5
7
8
9
10
3.6G
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
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Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
4- CALCUL DE LA PUISSANCE DU MOTEUR
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
<-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)
159 <-F1: Total Wrap Resistance between belt and Pulley (daN)
34 <-Ft: Total Pulley bearing resistance (daN)
489.30 <-FN: Total Secondary Resistance (daN)
Applicability of C Equivalent Method
755.96 <-FNS: Total Secondary & Special Resistance (daN)
1N bA f tF F F F F
NS N SF F F
Type 2 <-Type of Belt Conveyor
Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System
EP800/4 <-Carcass Style
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 630 170 15,962 210 0 13,067 3,634 0 942
2 D2 500 140 12,519 0 6,253 0 564
3 D3 500 100 3,635 3,413 7,000 414
4 D4-1 400 100 3,635 0 3,634 0 364
5 D4-2 400 100 3,635 0 3,634 0 364
6 D5 400 100 3,744 3 15 3,634 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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Note de Calcul Mécanique convoyeur CVL'
6- DIMENSIONNEMENT DU GROUPE DE COMMANDE
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6- DIMENSIONNEMENT DU GROUPE DE COMMANDE
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
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
Poids approximatif (kg) 790
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 630 170 15,962 Type 1 1600 10 10 1400 20 300 225 7.75 115 200 1360 88 1920 200 165 165 162 742.5 160 907.5 115 315 26111.84 2633.5
2 D2 500 140 12,519 Type 2 1600 10 10 1400 20 260 190 4.9 130 170 1360 79 1920
3 D3 500 100 3,635 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920
4 D4-1 400 100 3,635 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920
5 D4-2 400 100 3,635 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920
6 D5 400 100 3,744 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)
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Alimentation de la 7ème ligne
Note de Calcul Mécanique convoyeur CVL'
7- VERIFICATION DES AXES & MOYEU TAMBOURS
Pulley Shell Flange & Hub Parameters Driven Shaft Parameters Driving Shaft Parameters Gear Box & Motor Parameters
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Note de Calcul Mécanique convoyeur CVL'
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)
3.8 <-v: Belt Speed (Tab.4&5&6) (m/s)
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
Type 2 <-Type of Belt Conveyor
Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System
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 942.26 0.69684 110.262 3E+07 260 3.5E+07 169.774 OK 0.998672 0.4121 OK 295.955 OK <-Wp: Pulley Weight (kg)
2 D2 564.02 0.72303 114.405 0 260 1.6E+07 128.708 OK 0.9193425 0.70269 OK 259.589 OK <-Kb: Size Factor
3 D3 414.41 0.77076 121.958 0 260 4635327 83.4297 OK 0.8342972 0.78377 OK 205.958 OK <-Sf: Allowable Bending Stress (MPa)
4 D4-1 364.35 0.77076 121.958 0 260 4635327 83.4297 OK 0.8342972 0.78377 OK 205.958 OK <-MTT : Moment Transmitted to Pulley Taking into Consideration Drive System Efficiency & Starting Torque (Nmm)
5 D4-2 364.35 0.77076 121.958 0 260 4635327 83.4297 OK 0.8342972 0.78377 OK 205.958 OK <-ag (mm)
6 D5 364.35 0.77076 121.958 0 260 4775244 84.2608 OK 0.8426085 0.80743 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)
Type 2 <-Type of Belt Conveyor
Type 1: If Counter weight at Tail Position
Type 2: If Counter weight Near Drive System
Plummer Block Characteristics
No. Pulley Ref.Dp
(mm)
d
(mm)
N
(kg)
1 D1 630 170 15961.619
2 D2 500 140 12518.652
3 D3 500 100 3634.6952
4 D4-1 400 100 3634.6952
5 D4-2 400 100 3634.6952
6 D5 400 100 3744.4083
7
8
9
10
<-Dp: Pulley Diameter (mm)
<-d: Shaft Diameter (mm)
<-N: Equivalent Load Applied From Belt Conveyor (kg)
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
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Note de Calcul Mécanique convoyeur CVL'
8- VERIFICATION DES PALIERS
BND2234 22234 CCK/W33 D170
Plummer Block Designation
Tab. 14
BND3228 23228 CCK/W33 D140
BND2220 22220 EK D100
BND2220 22220 EK D100
BND2220 22220 EK D100
BND2220 22220 EK D100
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Note de Calcul Mécanique convoyeur CVL'
8- VERIFICATION DES PALIERS
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Note de Calcul Mécanique convoyeur CVL'
8- VERIFICATION DES PALIERS
Bearing Rating Life Check
No.n
(rpm)
Pr
(N)
C
(N)
Tab.15
L10
(MR)
L10h
(h)
L10hE
(h)
L10hE ≥
L10M
1 115.20 117,438 1120000 1840 266138 61,317 OK
2 145.15 92,106 915000 2108 241998 70,252 OK
3 145.15 26,742 425000 10092 1158784 336,394 OK
4 181.44 26,742 425000 10092 927028 336,394 OK
5 181.44 26,742 425000 10092 927028 336,394 OK
6 181.44 27,549 425000 9139.410579 839541.0857 304647.0193 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)
22234 CCK/W33
23228 CCK/W33
22220 EK
22220 EK
22220 EK
22220 EK
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
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
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)
1200 <-r: Material Density (kg/m3)
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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Note de Calcul Mécanique convoyeur CVL'
9- VERIFICATION DES ROULEAUX
B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101
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
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