Cema Design Book
Cema Design Book
Cema Design Book
P. Staples Pr.Eng BS . MSAIME Manag!ng D!re t"r C"n#e$"r %n"&le'ge an' In("r)at!"n Te *n"l"g$ +Pt$,Lt' +C%IT,
INDE-
1. 2. 3. 4.
INTRODUCTION JUSTIFICATION FOR A STANDARD PRESENT DESIGN STANDARDS PROPOSED STANDARD FORMAT 4.1 4.2 4.3 Se!e&%ion 4.4 4.* Dri+e S%andards Power P !!e" o$ and and (id%# Tension S#a$%s )e!o&i%" S%andards
'e!% Id!er
and
*.
CONC,USION
S.MMARY T#is -a-er #as .een -re-ared wi%# %#e in%en%ion o$ #i/#!i/#%in/ %#e -ro.!e0s $a&ed ." desi/n en/ineers w#o are $or&ed %o nder%a1e %#e desi/n o$ .e!% &on+e"or s"s%e0s sin/ a 0 !%i% de o$ desi/n s%andards w#i&# #a+e no% .een .ro /#% in%o !ine wi%# 0odern %e&#no!o/i&a! ad+an&e0en%s. To o+er&o0e so0e o$ %#ese -ro.!e0s2 a .asi& o %!ine o$ a ni+ersa! s%andard #as .een -ro-osed2 w#i&# &an easi!" .e ada-%ed %o s i% indi+id a! needs2 wi%#o % red &in/ %#e e$$i&ien&" o$ %#e desi/ner and #is %ea0. /. INTROD.CTION T#e desi/n o$ .e!% &on+e"or s"s%e0s #as .een one o$ %#e 0os% &o00on o&& rren&es in %#e So %# A$ri&an 0inin/ $ie!d $or o+er one # ndred "ears. Con+e"ors are seen on +ir% a!!" a!! 0inin/ ins%a!!a%ions2 and are %#e .i//es% -ro.!e0 $or %#e -!an% 0ain%enan&e en/ineer2 .ein/ %#e &a se o$ 0os% -!an% s# %downs. (#" do .e!% &on+e"ors &a se s &# -ro.!e0s3 I% 0 s% .e re0e0.ered %#a% 0inin/ #o ses s a!!" #a+e a se% o$ desi/n s%andards %o &on$or0 %o4 s%andards w#i&# are &!ai0ed #a+e .een de+e!o-ed o+er 0an" "ears %o s i% %#eir own needs in %#e 0a%eria!s #and!in/ $ie!d. 5owe+er2 as I &an nders%and %#e need $or so0e as-e&%s o$ a s%andard2 o%#ers &o0-!e%e!" .a$$!e 0e. I% a--ears %#a% #a+in/ s-en% a /rea% dea! o$ %i0e o+er &er%ain re6 ire0en%s o$ a desi/n s%andard2 0an" o$ %#e $ nda0en%a!s %o w#i&# I a0 re$errin/ are o$ &o rse %#e e$$e&%s o$ o+er-owerin/ on %#e w#o!e &on+e"or s"s%e0. A!so2 we 1now %#a% %o &on+e" 0a%eria! $ro0 one -oin% %o ano%#er re6 ires a s-e&i$i& a0o n% o$ -ower sin/ a .e!% desi/ned %o wi%#s%and a de$ini%e %ension2 so w#" is i% %#a% i$ a &on+e"or desi/n -ro.!e0 is se% %o a n 0.er o$ desi/ners2 %#e" wi!! &o0e - wi%# 0an" +aria%ions on a so! %ion2 e+en sin/ %#e sa0e desi/n s-e&i$i&a%ion. T#is o$ &o rse &o0es down %o %#e in%er-re%a%ion o$2 and %#e $a0i!iari%" wi%# %#e s%andard %o .e sed. 'asi&a!!" I a0 s //es%in/ %#a% %#e s%andards as a+ai!a.!e %o7da"2 !ea+e a !o% %o .e desired $ro0 %#e -oin% o$ +iew o$ &o0-!e%eness2 and ease o$ a--!i&a%ion.
0. 1.STI2ICATION 2OR A STANDARD Do we need a s%andard a% a!!3 and i$ so2 w#a% $or0 s#o !d i% %a1e3 To answer %#is 6 es%ion !e% s !oo1 a% a %"-i&a! desi/n o$$i&e se% -. On an" -ro8e&% %#ere are %#ree 1e" &a%e/ories o$ s%a$$2 %#e desi/ners2 #is dra /#%s0en and a /ro - o$ -eri-#era! s%a$$2 9-!anners2 . "ers2 s%r &% ra!2 &i+i! and e!e&%ri&a! en/ineers:. T# s we #a+e a se% - w#i&# !oo1s as $o!!ows;7 2!g3re /. T$p! al pr"4e t Eng!neer!ng 2l"& S*eets
T#e desi/ner is /i+en a .asi& s-e&i$i&a%ion w#i&# wi!! in&! de 0a%eria! %"-e and 6 an%i%" %o .e &on+e"ed $ro0 A %o '. T#is #e 0 s% %rans$or0 in%o drawin/s $or 0an $a&% re and $a.ri&a%ion2 desi/n da%a $or &i+i!2 e!e&%ri&a! and s%r &% ra! en/ineers2 .i!!s o$ 6 an%i%ies $or . "ers and a&%i+i%" ne%wor1s $or -!anners. (i%# %#e e<&e-%ion o$ %#e -!annin/ in$or0a%ion w#i&# is on!" rea!!" re!e+an% $or %#e &ons%r &%ion -#ase o$ %#e -ro8e&%2 %#e desi/ner #as a -ro.!e0 w#i&# #e wi!! $ind +er" di$$i& !% %o o+er&o0e2 and %#a% is %o s --!" a!! %#e ne&essar" in$or0a%ion %o ea&# dis&i-!ine on %#e -ro8e&% w#en %#e" re6 ire i%. T#ere$ore #a+in/ o.%ained a s&o-e o$ wor1 $ro0 %#e &!ien% in 6 es%ion2 %#e desi/ner #as %o 6 i&1!" -rod &e %#e desi/n da%a2 . % .e$ore #e is a.!e %o -ro&eed #e 0 s% o.%ain in$or0a%ion $ro0 #is drawin/ o$$i&e re!a%in/ %o %#e !a"o % o$ %#e &on+e"ors in %#e s"s%e0. Now %#e -ro.!e0s .e/in; Prior %o nder%a1in/ an" &a!& !a%ions w#a%soe+er %#e desi/ner 0 s% &#e&1 %#e s-e&i$i&a%ions %o w#i&# #e 0 s% &on$or0. As +ir% a!!" a!! &!ien%s #a+e %#eir own o-inion on %#e s .8e&% o$ &on+e"or desi/n2 we &an res% ass red %#ere wi!! .e so0e $or0 o$ &!ien% in- %2 w#e%#er i% .e a %wo +o! 0e 0an s&ri-% or si0-!" an2 =A!! dri+es s#a!! ........= do& 0en%. T#e desi/ner is &on$ron%ed wi%# &on$or0in/ %o %#e said s-e&i$i&a%ion2 . % 0 &# worse2 #e 0 s% ens re %#a% #is drawin/ o$$i&e s%a$$ are aware %#a% %#ere is a s-e&i$i&a%ion %o wor1 %o. Consider %#a% %#e -re+io s wee1 %#e" 0a" #a+e .een wor1in/ on ano%#er -ro8e&% and #ad %o &on$or0 %o a &o0-!e%e!" di$$eren% s-e&i$i&a%ion. (#a% does %#e desi/ner do3 Does #e &ir& !a%e 0 !%i-!e &o-ies %o #is drawin/ o$$i&e wi%# %#e ins%r &%ion %#a% i% 0 s% .e read -rior %o an" wor1 .ein/ s%ar%ed. I$ so2 #e wi!! -ossi.!" no% 0ee% #is dead!ine on %#e s --!" o$ da%a %o %#e -eri-#era! dis&i-!ines. Does #e %r" %o &#e&1 %#a% #is dra /#%s0en &on$or0 ." =!oo1in/ o+er %#eir s#o !ders= $ro0 %i0e %o %i0e 9w#i&# is %#e wa" 0is%a1es are / aran%eed %o o&& r:. A!%erna%i+e!" does #e ins%r &% #is drawin/ o$$i&e %#a% %#ere is a s-e&i$i&a%ion %o wor1 %o and %#a% i% is !"in/ aro nd so0ew#ere and %o =-!ease &#e&1 i% i$ "o are no% %o s re o$ #ow %o -ro&eed=. In a!! %#e o$$i&es in w#i&# I #a+e wor1ed2 %#e !as% %wo so! %ions #a+e .een a--!ied2 wi%# %#e res !% %#a%2 a!0os% wi%#o % e<&e-%ion2 %#e e<-erien&ed dra /#%s0en w#o 1now #ow %o 0a1e a s"s%e0 wor1 wi!! &on%in e wi%# +er" !i%%!e re$eren&e %o %#e said s-e&i$i&a%ion. T#e -ro.!e0 0a" .e %#a% on %#is -ro8e&% =%#e - !!e"s are 0 &# .i//er2 %#e %a1e7 - !en/%# 0 s% .e se!e&%ed sin/ an i!! de$ined $or0 !a and .asi&a!!" we don=% 1now #ow %o desi/n a &on+e"or an"0ore. I$ %#is -ro.!e0 is &a /#% ear!" eno /# we on!" #a+e %o &#an/e a 6 an%i%" o$ drawin/s and are %#en .a&1 on %#e ri/#% road. 5owe+er "o &an .e s re %#a% in -ra&%i&e i% wi!! .e %oo !a%e2 and %#e desi/ner #as %o /o %o %#e &!ien% and as1 $or a &on&ession .e&a se #e is no% a.!e %o &on$or0 %o %#e s-e&i$i&a%ion2 and %o 0a1e an" &#an/es %o %#e drawin/s now wi!! - % #i0 wa" .e#ind s&#ed !e. F r%#er0ore .e$ore %#e &!ien% wi!! a&&e-% de+ia%ions %o %#e -ro-osed $or0a%2 e+er" a+en e 0 s% .e e<-!ored2 and a re-or% on %#e de+ia%ion -re-ared. T#e desi/ner is now .e#ind w#e%#er #e !i1es i% or no% and %o 0a1e - %i0e #e 0 s% ne/!e&% %#e one $ n&%ion w#i&# &o0-!e%es %#e %o%a! &on+e"or desi/n2 %#a% o$ se&ondar" desi/n. '" se&ondar" desi/n2 I 0ean %#e desi/n w#i&# &o0es a$%er %#e &on&e-% a! or /enera! arran/e0en% !a"o %s are &o0-!e%e. T#is is %#e desi/n o$ %#e &# %es2 %#e !o&a%ion o$ .earin/s2 %#e .e!% &!eanin/ s"s%e0 %o .e e0-!o"ed and %#e a&&ess $or 0ain%enan&e. T#is is !e$% %o a dra /#%s0an wi%#o % an" en/ineerin/ s --or%. 5owe+er2 %#e se&ondar" desi/n s a!!" en&o0-asses %#e 0a8or -ro.!e0s o$ .e!% &on+e"or s"s%e0 desi/n. T#ese are areas wi%# +er" !i%%!e &o+era/e in s-e&i$i&a%ions2 wi%# &o00en%s s &# as2 =a!! &on+e"ors wi!! #a+e - !!e"s a% %er0ina! -oin%s=2 .ein/ %#e !i0i% %o s &# s-e&i$i&a%ions. I -ose %#e 6 es%ion a/ain2 do we need a desi/n s%andard3 T#ose w#o a/ree wi%# %#e s&enario I #a+e se% wi!! -ro.a.!" sa"2 =A!!ow %#e desi/ner %#e $reedo0 %o do %#e 8o.=. 5owe+er 1 $ee! %#a% a s%andard is essen%ia!. T#ere are +er" $ew s-e&ia!is% &on+e"or desi/ners and %# s so0e $or0 o$ / idan&e 0 s% .e /i+en. 5owe+er %#ere s#o !d
.e on!" one s%andard2 wi%# one .asi& se% o$ -ara0e%ers and w#i&# &an &a%er $or %#e needs o$ e+er" 0inin/ and -ro&ess -!an% a--!i&a%ion. (i%#o % !essenin/ %#e e$$i&ien&" o$ %#e desi/ner and #is %ea0 s &# a s%andard wi!! $a&i!i%a%e %#e e$$i&ien&" %#e o+er&o0in/ o$ %#e -ro.!e0s o&& rrin/ in se&ondar" desi/n. (e 1now %#is #as .een %ried re-ea%ed!" in %#e -as%2 . % a!wa"s in iso!a%ion $ro0 %#e 0ain s%rea0 o$ desi/n and s a!!" wi%# %#e s%a%e0en%2 =. % i% &a%ers $or o r own indi+id a! needs=2 as 8 s%i$i&a%ion. 5a+in/ .een &on$ron%ed wi%# &on+e"or desi/n s%andards $or a n 0.er o$ "ears2 I #a+e s%i!! %o $ind a %r e s-e&ia!is% need2 I 1now %#a% so0e &!ien%s re6 ire !ess &a-a&i%" on a .e!%2 o%#ers re6 ire !ar/er - !!e"s and %#i&1er .e!%s2 re6 irin/ %#e se o$ &o0-!i&a%ed $or0 !a %o arri+e a% a so! %ion2 . % %#is &an no% .e 8 s%i$i&a%ion $or de+isin/ &o0-!e%e!" indi+id a! s-e&i$i&a%ions2 w#i&# &o !d 0ore s i%a.!" .e &o+ered in a sin/!e -ara/ra-# o$ a &o0-re#ensi+e s-e&i$i&a%ion. 5. PRESENT DESIGN STANDARDS ,e% s !oo1 a% a% %#e Con+e"or desi/n s%andards a+ai!a.!e2 and in -ar%i& !ar %#e $o r 0os% &o00on!" sed2 C.E.M.A.2 GOOD >EAR2 ISCOR and A.A.C. I$ we &onsider %#e -ower and %ension +aria%ion -redi&%ed ." sin/ %#ese s"s%e0s2 as in Ta.!e 12 we see 6 i%e a wide ran/e o$ -ossi.i!i%ies. T#e reason $or %#is is in %#e se!e&%ion o$ %#e ro!!in/ resis%an&e $a&%or2 9&oe$$i&ien% o$ $ri&%ion2 resis%an&e %o $!e< re or o%#er &o00on!" sed %er0s: w#i&# +aries .e%ween ?2?1@ and ?2?3* as sed in %#e a.o+e s%andards. Ta6le / P"&er an' Tens!"n al 3lat!"ns. /+a, 6ase' "n 6elt apa !t$ "( 788t"ns per *"3r, 6elt &!'t* "( 988)) an' a 6elt #el" !t$ "( 0,0):se . Lengt* L!(t C.E.M.A. P"&er ) 3? 2?? 1??? 1??? ) ? @? ? 4? ;< @ 1?1 B1 132 Tesn ;N A @* 4? C2 GOOD YEAR P"&er ;< 1* AA BA 143 Tesn ;N 1@ @4 43 CC ISCOR P"&er ;< 1@ 1?4 113 1@C Tesn ;N 1A @@ *4 BB A.A.C. P"&er ;< 12 1?2 1?4 1*B Tesn ;N 1B @@ *? B4
/+6, 6ase' "n 6elt apa !t$ "( 0888t"ns per *"3r, 6elt &!'t* "( /788)) an' a 6elt #el" !t$ "( 5):se . Lengt* L!(t C.E.M.A. P"&er ) 3? 2?? 1??? 1??? ) ? @? ? 4? ;< 1B 3CB 221 43A Tesn ;N 22 1@C B4 1C4 GOOD YEAR P"&er ;< 3@ 3B? 2@2 4CA Tesn ;N 41 1@B AB 1BB ISCOR P"&er ;< 3B 4?3 34A *@C Tesn ;N 42 1C@ 12C 21C A.A.C. P"&er ;< 3C 3A1 31* *33 Tesn ;N 42 1C2 11@ 2?@
On %#e s#or%er s"s%e0s %#is di$$eren&e is 6 i%e insi/ni$i&an%2 e<&e-% %#a% %#e .e!% !en/%# $a&%or -!a"s an i0-or%an% -ar%. 5owe+er on %#e now &o00on !ar/e o+er!and %"-e s"s%e0s2 %#ese +aria%ions are nsa%is$a&%or" %o sa" %#e !eas%. Are we a.!e or -re-ared %o a&&e-% s &# +aria%ions3 A.!e2 I wi!! sa" "es2 -ro+ided we %a1e &o/nisan&e o$ %#e e$$e&%s o$ o+er-owerin/. 5owe+er I a0 no% &on+in&ed we s#o !d .e -re-ared %o a&&e-% %#ese +aria%ions2 a-ar% $ro0 %#e o+er-owerin/ $a&%or %#ere are - re!" e&ono0i& &onsidera%ions %o a&&o n% $or. T#is -oin% is +er" no%i&ea.!e w#en one .e&o0es in+o!+ed in e&ono0i& e+a! a%ions 9$easi.i!i%" s% dies: o$ +ario s a!%erna%i+e so! %ions %o a s-e&i$i& 0a%eria!s #and!in/ -ro.!e0. For ins%an&e2 #ow &o0-e%i%i+e wo !d a -ne 0a%i& &on+e"in/ s"s%e0 or &a.!e .e!% s"s%e0 .e i$ desi/ned %o si0i!ar se%s o$ s%andards as %#e &on+e"or. 5owe+er as %#ese s%andards are as "e%2 no%
a+ai!a.!e2 %#e 0an $a&% rer o$ &o0-e%i%i+e s"s%e0s #as $ar rea&#in/ ad+an%a/es o+er %#e &on+e"or 0an $a&% rers. I a0 no% $or one 0o0en% s //es%in/ %#a% %#e &o0-e%i%i+e s"s%e0s are is no% !i0i%ed %o desi/nin/ wi%#in a &onser+a%i+e s-e&i$i&a%ion. nder desi/ned2 si0-!" %#a% %#e desi/ner
Too o$%en we see e<a0-!es o$ &on+e"or s"s%e0s $eedin/ -ro&ess -!an%s2 w#ere %o &on$or0 %o s-e&i$i&a%ion %#e w#o!e &on+e"or ne%wor1 is desi/ned $or a !ar/e a0o n% o$ e<&ess &a-a&i%". 5owe+er2 %#is -#i!oso-#" is no% %rans$erred %o %#e re!a%ed e6 i-0en% in %#e res% o$ %#e -!an%. =. PROPOSED STANDARD 2ORMAT =./ P"&er an' Tens!"n (i%# -ower and %ension &a!& !a%ions %#ere e<is%s %#e -ossi.i!i%" $or a &o0.ina%ion o$ a!! $o r o$ %#e a.o+e s%andards ." %i!iDin/ a sin/!e $ri&%ion $a&%or $or %#e s#or%er .e!%s2 . % e!i0ina%in/ %#e .e!% !en/%# $a&%or w#i&# &an easi!" .e &o0-ensa%ed $or wi%# %#e o+erra%in/ $a&%or o$ %#e 0o%or. In -ro/ressin/ %o %#e !on/er &on+e"ors %#is $a&%or &o !d .e +aria.!e2 as ad+o&a%ed ." C.E.M.A.2 on!" now .e si0-!" a $ n&%ion o$ .e!% !en/%# and &a-a&i%". T#en we &o !d se a si0-!i$ied $or0 !a as $o!!ows;7 A.B1 < ,.)991FG1>9(0G(.:G2?1*(.:G 95.(0:: 1???
Power 91(: E
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, E 5oriDon%a! - !!e" &en%ers 90: 5 E )er%i&a! - !!e" &en%ers 90: ) E 'e!% +e!o&i%" 90Hse&.: (0 E Mass o$ 0a%eria! -er 0e%er r n 91/: (. E Mass o$ .e!% -er 0e%re r n 91/: ?2?1* E Re% rn .e!% resis%an&e 1F E 'e!% s!ide and Id!er ro%a%iona! resis%an&e and &an 1F E ?2???@B9(0G(.:G?2?229ro%a%in/ 0ass o$ %#e Id!er -er 0e%er: 91/H0: .e o.%ained $ro0;7
1> E Resis%an&e o$ %#e .e!% o$ $!e< re as i% 0o+es o+er %#e Id!ers2 and &an .e &onsidered %o .e %#e sa0e as %#e $ri&%ion $a&%ors /i+en in a!! %#e s-e&i$i&a%ions.
T"-i&a! +a! es o$ 1> are /i+en in %a.!e 2 .e!ow. Ta6le 0. Sele t!"n "( ;Y (a t"r 6ase' "n Belt lengt*, l!(t an' apa !t$. Lengt* ) 1?? 2?? 2?? 4?? 4?? B?? 1??? L!(t ) 2? 2? 4? 2? 4? 4? 4? ;Y 788t:*r. ?2?3* ?2?32 ?2?3? ?2?3? ?2?2@ ?2?22 ?2?2? ;Y /888t:*r. ?2?3? ?2?2@ ?2?22 ?2?22 ?2?2? ?2?2? ?2?2? ;Y 0888t:*r. ?2?2@ ?2?22 ?2?2? ?2?2? ?2?2? ?2?2? ?2?2? ;Y 5888t:*r. ?2?22 ?2?2? ?2?2? ?2?2? ?2?2? ?2?2? ?2?2?
To ena.!e %#e &!ien% %o 0ain%ain &on%ro! o$ %#e o %&o0e o$ %#e &a!& !a%ion2 i% is ne&essar" on!" %o s-e&i$" %#e 1> $a&%or %o .e sed in a si0-!e addend 0 %o %#e 0ain s-e&i$i&a%ion. 'e!% %ension &a!& !a%ion &an .e 1e-% s%rai/#%$orward2 -ro+ided %#e desi/ner s%ar%s ." &onsiderin/ %#e 0ini0 0 .e!% %ensions2 a% .o%# %#e dri+e and %ai! - !!e"s2 ." sin/ %#e $o!!owin/ $or0 !ae ;7
T0in E 422<A2B1H1??? si9(.G(0: 1N (#ere 422 E E Id!er s-a&in/20 Fa&%or .ased on a 3I .e!% sa/.
Si
and Ts!a&1 side E Te$$e&%i+e H e 71 (#ere T e$$e&%i+e is %#e ins%a!!ed dri+e e$$e&%i+e %ension and no% %#e e$$e&%i+e %ension &o0- %ed $ro0 %#e a.o+e -ower $or0 !a. T#e one -ro.!e0 %#a% is en&o n%ered is in %#e se!e&%ion o$ a &oe$$i&ien% o$ $ri&%ion $or %#e dri+e - !!e". A s%andard s &# as /i+en In Ta.!e 3 &o !d .e sed. Ta6le 5 C"e((! !ent "( 2r! t!"n ("r Dr!#e P3lle$s. T$pe "( Ta;e .p Plant Des r!pt!"n (e% Se0i7we% Dr" C"n#e$"r C"nstr3 t!"n Co+ered Un&o+ered Co+ered Un&o+ered Co+ered Un&o+ered A3t")at! Lagge' ?22* ?22? ?23? ?22* ?23* ?23? .nlagge' ?21? ?21? ?22? ?21* ?222 ?21B ?22? ?22? ?22* ?222 ?22* ?22* Man3al Lagge' .nlagge' ?21? ?21? ?21B ?213 ?22? ?21*
Ta.!e 3 #as .een &o0-i!ed $ro0 e0-iri&a! da%a s &# as %#a% /i+en in Ta.!e 4. I% s#o !d .e no%ed %#a% %#ese +a! es are %#e !i0i%in/ &ondi%ions 9w#en %#e .e!% is on %#e -oin% o$ s!i--in/:. T#e a&% a! &oe$$i&ien%s o$ $ri&%ion de+e!o-ed .e%ween s r$a&es are2 in -ra&%i&a!!" a!! &ases w#ere s!i--in/ does no% o&& r2 in e<&ess o$ %#ose !is%ed. T#ere$ore2 %#e &on+en%ion o$ sin/ %#ese +a! es does no% re$!e&% w#a% a&% a!!" o&& rs a% %#e dri+e - !!e". I$ one &onsiders a dri+e - !!e" nder o-era%in/ &ondi%ions %#en %#e #i/#er %ensioned .e!% se&%ion is s%re%&#ed 0ore %#an on %#e !ower %ensioned se&%ion2 %# s %#e .e!% en%erin/ %#e -osi%i+e dri+e wi!! .e %ra+e!in/ $as%er %#an w#en i% !ea+es i%. T#e e!as%i& re&o+er" o$ %#e .e!% o&& rs o+er on!" a -ar% o$ %#e %o%a! an/!e o$ &on%a&%2 and i% is a% %#is -oin%2 w#ere &ree- %a1es -!a&e2 %#a% %#e dri+in/ is done2 w#i!e 0a1in/ $ !! se o$ %#e &oe$$i&ien% o$ $ri&%ion. '" a--!"in/ %#e &!assi& %ension $or0 !a %o %#e w#o!e an/!e o$ wra- a $i&%i%io s &oe$$i&ien% o$ $ri&%ion is .ein/ sed Ta6le =. Re "))en'e' Dr!#e C"e((! !ent "( 2r! t!"n "( Var!"3s Stan'ar's. C"n'!t!"n 'are - !!e" ,a//ed Dr" ,a//ed (e% ,a//ed (e% J Dir%" C.E.M.A. ?22* ?23* ?23* ?23* ?23* STEVENS ADAMSON ?23* ?23* ?23* ?23* ?23* BRIDGESTONE ?22? 777 ?23* ?22* ?22? LINATE777 ?2@? ?2@? ?2B? ?24? REMA TIP TOP 777 ?24* ?24* ?23* ?22*
T#e ad+an%a/e o$ wor1in/ $ro0 0ini0 0 dri+e %ension .a&1 %o %#e 0a<i0 0 dri+e %ension2 &an .e .e%%er e<-!ained i$ one !oo1s a% %#e desi/n o$ - !!e"s and s#a$%s. O+er %#e "ears %#ere #as .een a !o% wri%%en a.o % %#e desi/n o$ a - !!e" s#a$%2 wi%# %#e ai0 o$ %r"in/ %o e!i0ina%e %#e #i/# $ai! re ra%e and %#e &os% asso&ia%ed wi%# s &# $ai! res. I $ee! %#a% %#ere are on!" %wo .asi& reasons $or - !!e" $ai! re2 $irs%!" %#e .ad 0an $a&% rin/ -ro&ed res2 and se&ond!"2 $ai! re owin/ %o an ina.i!i%" %o &a!& !a%e %#e 0ini0 0 dri+e %ension. T#e !a%%er &ase o$ in&orre&% desi/n
res !%s in %#e &o n%erwei/#% 0ass #a+in/ %o .e in&reased %o o+er&o0e dri+e s!i- on s%ar% -2 wi%# %#e res !% %#a% - !!e" s#a$%s are s .8e&%ed %o e<&essi+e !oads2 -rod &in/ e+en% a! $ai! re. '" &on%ras%2 i$ %#e 0ini0 0 dri+e %ension is sed as a desi/n .asis2 we &an o+er&o0e2 $ai! res in - !!e"s2 &a sed ." ina&& ra%e desi/n. T# s %#e 0a<i0 0 %ension wi!! .e o.%ained $ro0 ;7 T0a<i0
0
E T0ini0 0GTe$$e&%i+e
(#ere Te$$e&%i+e is &o0- %ed $ro0 s#a$% -ower and no% %#e ins%a!!ed -ower. No%e %#a% %#e $or0 !ae dis& ssed a.o+e are a--!i&a.!e %o A?I o$ %#e &on+e"or ins%a!!a%ions .ein/ desi/ned %o7 da". 5owe+er a !i%%!e 0ore ana!"sis is re6 ired $or so0e o+er!and and &o0-!e< s"s%e0s. =.0 P3lle$ an' S*a(t Stan'ar's T#ere are -resen%!" %wo 0a8or s%andards sed $or - !!e" and s#a$% se!e&%ion2 %#ese .ein/ %#e ISCOR and AAC s"s%e0s. I 1now 0 &# #as .een wri%%en a.o % %#e #i/# de/ree o$ o+ersiDin/ ado-%ed ." .o%# s%andards2 . % I $ee! %#a% as %#e - !!e" is one o$ %#e !eas% e<-ensi+e &o0-onen%s in a &on+e"or ins%a!!a%ion2 we s#o !d no% .e o+er &on&erned on %#e -oin%. E$$or%s s#o !d ra%#er .e dire&%ed a% red &in/ %#e a0o n% o$ +aria%ions %#ere are in %#e se!e&%ion o$ $a&e wid%# and .earin/ &en%ers. A% %#e 0o0en% .o%# ISCOR and AAC #a+e %wo siDes -er .e!% wid%#2 a!! di$$eren%. T#is s#o !d .e red &ed %o a sin/!e siDe -er .e!% wid%#2 and %#is siDe s#o !d .e as .i/ as -ossi.!e %o a!!ow eas" a&&ess and #en&e red &e %#e da0a/e %o &on+e"or .e!%s. A s%andard a!on/ %#e !ines o$ %a.!e * .ased on %#e ISCOR s-e&i$i&a%ion wo !d .e %#e 0os% a&&e-%a.!e. P !!e" and s#a$% dia0e%ers s#o !d .e 1e-% %o a 0ini0 0 o$ %wo -er &on+e"or2 wi%# as 0 &# s%andardiDa%ion as -ossi.!e .ein/ e0-!o"ed on %#e w#o!e &on+e"or s"s%e0. T#e se!e&%ion o$ - !!e"s and s#a$%s &o !d .e $ro0 a %a.!e si0i!ar %o %#a% s#own as Ta.!e @. Ta6le 7. P3lle$ 2a e <!'t* an' Bear!ng Centers Belt &!'t* )) 4*? @?? C*? A?? 1?*? 12?? 13*? 1*?? 1B?? 21?? =.5 Sele t!"n "( Belt <!'t* an' Vel" !t$ T#e se!e&%ion o$ .e!% wid%# and +e!o&i%" is -ro.a.!" %#e 0os% $r s%ra%in/ o$ -ro.!e0s $a&in/ %#e desi/ner. T#ere are a +arie%" o$ $a&%ors .ein/ sed2 $a&%ors s &# as ;7 %#e .e!% wid%# 0 s% .e %#ree %i0es %#e 0a<i0 0 ! 0- siDe2 %#e .e!% wid%# 0 s% .e s &# %#a% %#e s"s%e0 &an &a%er $or @@I e<&ess &a-a&i%"2 and i$ a %ri--er is sed %#e $a&%ors 0 s% .e in&reased ." a $ r%#er 3?I e%&. T#is %"-e o$ $a&%or $or0s %#e .asis $or 0os% s%andards in se %o7da"2 and %#ese &o !d %#ere$ore .e ra%iona!iDed in%o a sin/!e 0ore a&&e-%a.!e s%andard %o 0a1e %#e desi/ner=s %as1 easier. T#e $irs% ne&essar" s%e- is %#e re0o+a! o$ %#e a/e o!d .e!% s-eed res%ri&%ions2 a$%er a!! s-eeds in e<&ess o$ 40Hse& are now 6 i%e &o00on. 2a e &!'t* )) **? C?? A?? 1?*? 12?? 13*? 1*?? 1C?? 2??? 23?? Bear!ng enter )) BA? 114? 13C? 1*2? 1@C? 1B*? 2??? 23?? 2@3? 2A3?
I a0 no% ad+o&a%in/ %#a% %#e #i/#es% -ossi.!e .e!% s-eed .e sed $or a!! ins%a!!a%ions4 I si0-!" s //es% %#a% .e!% s-eeds s#o !d no% .e se!e&%ed on!" on %#e .asis o$ -as% e<-erien&e2 . % on %#e .asis o$ .e!% !en/%#2 %rans$er -oin% and e&ono0i& &onsidera%ions. I $ee! %#a% %o se %#e &ri%erion I #a+e se% o % wi!! a %o0a%i&a!!" res !% in %#e se!e&%ion o$ %#e 0os% s i%a.!e .e!% wid%# and s-eed. M" reasonin/ #ere is %#a%2 $or in-!an% ins%a!!a%ions .e!% wid%#s and s-eeds are a!0os% a!wa"s se!e&%ed on %#e .asis o$ s%andardiDa%ion and -ossi.!e %rans$er -oin% -ro.!e0s. '" &on%ras%2 %#e !ar/er o+er!and s"s%e0s are se!e&%ed on %#e .asis o$ &a-i%a! &os%s and %#e asso&ia%ed o-era%in/ and 0ain%enan&e &os%s2 .e&a se as .e!% s-eeds in&rease o-era%in/ and 0ain%enan&e &os%s s a!!" $o!!ow s i%. Consider %#e s //es%ed 0e%#ods o$ se!e&%in/ a .e!% wid%# and s-eed. Firs%!"2 %#e a0o n% o$ 0a%eria! on a .e!% 0 s% .e re!a%ed %o %#e e<-e&%ed %rans$er -oin% -ro.!e0s. A $!a% $eed -oin% $ed ." a &on%ro!!ed s"s%e0 wi!! .e $ar easier %o desi/n %#an an in&!ined $eed -oin% $ed $ro0 a &r s#er2 w#ere s r/es are +er" &o00on. T#ere$ore %o s //es% a si0i!ar s%andard $or .o%# a--!i&a%ions is no% -ra&%i&a!. (e o$%en are %o!d %#a% &on+e"ors s#o !d no% .e $ed a% an/!es o$ BK in&!ine $eed -oin%s and +er" %i/#% +er%i&a! & r+es2 wi%# %#e res !% %#a% %#e $eed -oin% s%a"s &!ean2 . % a% %#e & r+e %#e .e!% #as !i$%ed &a sin/ s-i!!a/e. I wo !d !i1e %o s //es% %#a% a .e!% &an .e easi!" $ed a% an/!es o$ - %o 1@K2 -ro+ided %#e .e!% wid%# and s-eed are &orre&%!" se!e&%ed. I% 0a" .e ne&essar" %o ins%a!! .e!%s wi%# %#i&1er &o+ers2 . % %#is &an $or0 %#e .asis $or a .e%%er desi/n. T# s %#e %"-e o$ s%andard %#a% &o !d .e sed is s#own in Ta.!e C. Ta6le > I)plant C"n#e$"r L"a' 2a t"rs L"a'!ng P"!nt T$pe 5oriDon%a! 5oriDon%a! In&!ine 5oriDon%a! Tri--er S# %%!e 2ee' T$pe Uni$or0 S r/e Uni$or0 S r/e ..... ..... O#erl"a' 2a t"r 122? 12*? 12*? 12C* 12C* 12*?
T#e o+er!oad $a&%or wo !d .e sed %o in&rease %#e desi/n %onna/e $or se!e&%ion - r-oses. For o+er!and &on+e"ors i% is &o00on %o se #oriDon%a! !oadin/ -oin%s2 and we are no% &on$ron%ed wi%# %#e sa0e -ro.!e0s. As 0en%ioned ear!ier i% is on!" ne&essar" %o &onsider %#e e&ono0i&s o$ %#e s"s%e02 wi%# %#e $o!!owin/ !i0i%a%ions as /i+en in Ta.!e B. Ta6le ?. O#erlan' C"n#e$"r M!n!)3) Belt <!'t*s an' Ma@!)3) Spee's Ter)!nal P3lle$ Centers +), 3?? %o *?? *?? %o 1??? o+er 1??? Belt <!'t* +)), @?? C*? A?? Belt Spee' +):se , 32*? 32*? C2??
T#e o+er!oad $a&%or sed s#o !d a!wa"s .e a 0ini0 0 o$ 122 %i0es %#e desi/n %onna/e. =.= I'ler Stan'ar's =.=./ Intr"'3 t!"n T#e in%rod &%ion o$ %#e SA'S Id!er s-e&i$i&a%ion wi!! ens re a 0ore ni$or0 se!e&%ion o$ id!ers. As a res !% %#e &#oi&e o$ %"-e and s-a&in/ $or Id!ers s#o !d .e on a 0ore s&ien%i$i& .asis. T#e %"-es o$ Id!er %o .e sed on &on+e"ors are4 %ransi%ion2 %ro /#in/2 i0-a&% and re% rn id!ers. A% %#is %i0e %#ere is no sa%is$a&%or" %rainin/ id!er a+ai!a.!e so %#e" s#o !d .e a+oided.
=.=.0 Tr"3g*!ng I'ler Spa !ng Two %"-es o$ %ro /#in/ id!er are sed $re6 en%!"2 $i<ed and s s-ended ro!!. T#ere is +er" !i%%!e di$$eren&e .e%ween %#e %wo2 e<&e-% %#e %rainin/ &#ara&%eris%i&s and -ossi.!e &os% sa+in/s asso&ia%ed wi%# %#e s s-ended ro!!. T#e 6 es%ion o$ id!er s-a&in/ needs .e &onsidered 0ore &are$ !!". T#e res%ri&%i+e s%andards as a--!ied %o7da" do 0ore #ar0 %#an /ood %o a &on+e"or s"s%e0. Id!ers are %#e #i/#es% 0ain%enan&e &os% i%e0 on a &on+e"or ins%a!!a%ion and %#e .i//es% &a se o$ .e!% da0a/e2 %#ere$ore =%#e $ewer %#e .e%%er. Id!er s-a&in/ 0 s% .e se!e&%ed on %#e /ro nds o$ a+ai!a.!e .e!% %ension2 $a%i/ e !i$e o$ %#e id!er .earin/s2 and s%r &% ra! &onsidera%ions. T#e --er s-a&in/ !i0i% s#o !d .e se% a% 22??00. A&&o n% s#o !d .e %a1en o$ $o r and $i+e ro!! se%s2 . % no si/ni$i&an&e &an .e a%%a&#ed %o %#e &!ai0 %#a% $o r and $i+e ro!! id!ers /i+e .e%%er .e!% !i$e. =.7 Dr!#e stan'ar's T#e s%andardiDa%ion o$ dri+es is %#e 1e" %o 0os% s &&ess$ ! &on+e"or s"s%e0s. T#e -ro.!e0 is #owe+er %#a% so0e dri+es #a+e %o .e dras%i&a!!" o+ersiDed %o o.%ain so0e de/ree o$ &on$or0i%". '" &onsiderin/ %#is -oin% a% an ear!" s%a/e in %#e desi/n -ro&ess. i% is s a!!" -ossi.!e %o o+er&o0e %#e -ro.!e02 %#ere$ore si0-!e &os% ana!"ses o$ a!! %#e -ossi.!e so! %ions &an 6 i&1!" de&ide on %#e dri+e siDes %o .e ado-%ed. A!so i% is a% %#is -oin% in %i0e w#en a $ina! se!e&%ion o$ .e!%s &an .e &arried o %2 .e&a se %#ere is o$%en s&o-e %o &#an/e .e!% s-eeds %o %#e re6 ired de/ree o$ s%andardiDa%ion2 and we s#o !d no% .e a$raid %o %o %#is. 7. C"n l3s!"n To &on&! de I wo !d !i1e %o rei%era%e %#e need $or a sin/!e desi/n s%andard2 w#i&# &o !d .e a--!ied %o an" &on+e"or ins%a!!a%ion. 5owe+er2 %#is s%andard 0 s% .e s &# %#a% i% a!!ows %#e &!ien% a s0a!! a0o n% o$ indi+id a!i%" and $!e<i.i!i%". T#e desi/n s"s%e0 as o %!ined in %#is -a-er &an o$$er %#is $!e<a.i!i%"2 ." a!!owin/ %#e &!ien% %#e $reedo0 %o se!e&% %#e 1> $a&%or2 %#e dri+e &oe$$i&ien% o$ $ri&%ion and %#e !oad $a&%or $or se!e&%in/ %#e .e!% wid%# and s-eed. Co -!ed wi%# %#is we &an #a+e a +er" e$$i&ien% s"s%e0 es-e&ia!!" i$ i% is ada-%ed %o &o0- %erised &a!& !a%ion %e&#ni6 es. I 1now %o7da" %#a% 0an" s &# desi/n -ro/ra0s are a+ai!a.!e2 . % .e&a se o$ %#e +aria%ions in s%andards %#a% 0 s% .e in&or-ora%ed2 %#eir &redi.i!i%" is n8 s%!" 0ade s s-e&%2 $or&in/ %#e desi/ner %o re+er% %o %#e !on/winded n 0.er &r n&#in/ e<er&ises w#i&# o.+io s!" red &e #is e$$e&%i+eness in %#e drawin/ o$$i&e. MA-IM.M SAA2T SAA2T BEARING SAA2T BEARING SAA2T BEARING PLY STEEL LOAD CLASS CORE <IDTA DIA.D DIA.' DIA.'/ DIA.' DIA.'/ DIA.' DIA.'/ ;N 4*? 3?? 4?? *?? @3? A? 1?? 12* 14? C* C* 1?? 11? C* C* 1?? 11? *? *? C* A? 7 7 C* A? 7 7 *? C* 2?? 2*? @3? B?? 1B 22 *@ C2 BELT P.LLEY AEAVY D.TY MEDI.M D.TY LIGAT D.TY BELT TYPE
@??
4?? *?? @3? C1? 4?? *?? @3? C1? B?? 4?? *?? @3? C1?
11? 12* 14? 1@? 12* 14? 1@? 1B? 2?? 14? 1@? 1B? 2??
A? 1?? 11? 12* 1?? 11? 12* 14? 1@? 11? 12* 14? 1@?
A? 1?? 11? 12* 1?? 12* 14? 1@? 1B? 11? 14? 1@? 1B?
2*? @3? B?? 12*? 2*? @3? B?? ST*?? 12*? ST@3? 12*? ST12*? 2*? @3? B?? 12*?
C*?
A??
ST*?? ST@3?
B??
22?
1B?
2??
1@?
1@?
12* IN PU,,E>
12*? ST12*?
34?
A!! DIMENSIONS MAFIMUM ,OAD FIGURE E PERMISSI',E ,OAD ON 5EA)> DUT> E 1??I MEDIUM DUT> E @?I ,IG5T DUT> E 3?I DENOTES RATING 'ASED UPON FOR A,,O(A',E ,OAD ON 'EARING SEE 'EARING RATING TA',ES
MI,,IMETRES E T(ICE 'E,T TENSION MAFIMUM ,OAD MAFIMUM ,OAD MAFIMUM ,OAD STEE, CORE 'E,T
BELT RATING CAART, Ta6le Ba BELT P.LLEY AEAVY D.TY MEDI.M D.TY LIGAT D.TY BELT TYPE MA-IM.M SAA2T LOAD ;N 13? 1C? 2@? 3A* *?* AB* 1*? 1A? 3?? 4*? *C* 113? 1C? 21* 34? *?* @*? 12C? 24? 3C* *@? C2? 14?? 1B?? 4*? @C? B@* 1C?? 21?? 2C?? *2* CA? 1?1? 1A?? 2*?? 31??
SAA2T BEARING SAA2T BEARING SAA2T BEARING PLY STEEL <IDTA DIA. D DIA. ' DIA. '/ DIA. ' DIA. '/ DIA. ' DIA. '/ CLASS CORE 1?*? *?? @3? C1? B?? 1??? 12*? *?? @3? C1? B?? 1??? 12*? *?? @3? C1? B?? 1??? 12*? @3? C1? B?? 1??? 12*? 14?? C1? B?? 1??? 12*? 14?? 1*?? C1? B?? 1??? 12*? 14?? 1*?? 1B? 2?? 22? 24? 2*? 3@? 1B? 2?? 22? 24? 2@? 3@? 2?? 22? 24? 2B? 3?? 3@? 24? 2B? 3?? 32? 3@? 4?? 3?? 32? 34? 3B? 41? 43? 3?? 32? 34? 3B? 41? 43? 14? 1@? 1B? 2?? 22? 34? 14? 1@? 1B? 2?? 22? 34? 1@? 1B? 2?? 24? 2@? 32? 2?? 24? 2@? 2B? 32? 3B? 2@? 2B? 3?? 34? 3B? 4?? 2@? 2B? 3?? 34? 3B? 4?? 14? 1@? 1B? 2?? 22? 2@? 14? 1@? 1B? 2?? 22? 3?? 1B? 2?? 22? 24? 2@? 3?? 2?? 22? 24? 2@? 2B? 32? 2@? 2B? 3?? 32? 34? 3@? 2@? 2B? 3?? 32? 34? 3B? 11? 12* 14? 1@? 1B? 22? 11? 12* 14? 1@? 1B? 2@? 14? 1@? 1B? 2?? 22? 2@? 1@? 1B? 2?? 22? 24? 2B? 22? 24? 2@? 2B? 3?? 32? 22? 24? 2@? 2B? 3?? 34? 11? 11? 12* 14? 1@? 1B? 11? 12* 14? 1@? 1B? 22? 14? 1@? 1B? 2?? 22? 24? 14? 1@? 1B? 2?? 22? 24? 1B? 2?? 24? 2@? 3B? 3?? 1B? 2?? 24? 2@? 2B? 3?? C* A? 1?? 11? 12* 14? A? 1?? 11? 12* 14? 1B? 11? 12* 14? 1@? 1B? 2?? 11? 12* 14? 1@? 1B? 2?? 1@? 1B? 2@? 22? 24? 2@? 1@? 1B? 2?? 22? 24? 2B? @3? B?? ST*?? 12*? ST@3? 12*? ST12*? 1@?? ST1@?? 2??? ST31*? @3? B?? ST*?? 12*? ST@3? 12*? ST12*? 1@?? ST1@?? 2??? ST31*? @3? B?? ST*?? 12*? ST@3? 12*? ST12*? 1@?? ST1@?? 2??? ST31*? B?? 12*? 12*? 1@?? 2??? 2*?? 12*? 12*? 1@?? 2??? 2*?? 12*? 12*? 1@?? 2??? 2*?? ST*?? ST@3? ST12*? ST1@?? ST31*? ST4??? ST@3? ST12*? ST1@?? ST31*? ST4??? ST*??? ST@3? ST12*? ST1@?? ST31*? ST4??? ST*???
12??
13*?
1*??
1B??
21??
1.A. Rall Pr.Eng., BS Eng., MSAIME Aansen Trans)!ss!"ns +Pt$, lt' P. Staples Pr.Eng BS , MSAIME Manag!ng D!re t"r C"n#e$"r %n"&le'ge an' In("r)at!"n Te *n"l"g$ +Pt$,Lt' +C%IT,
S3))ar$C T#is is a s#or% re+iew o$ -ar% o$ %#e !in1 .e%ween %#e e!e&%ri& -ower /rid and $!a% r ..er &o+ered .e!%s sed $or %rans-or%in/ !ar/e +o! 0es o$ /ran !ar 0a%eria!. I% is &on&erned wi%# #i/# +o! 0e 0a%eria! &on+e"in/ and no% wi%# s-e&ia! &ases s &# as $eed or 0e%erin/ &on+e"ors2 s%ee- in&!ined &on+e"ors e%&. I% &onsiders 0ain!" %#e s-eed red &er .e%ween 0o%or &o -!in/ and dri+e - !!e"2 ra%in/s2 .earin/ !i$e2 ser+i&e $a&%ors2 s%o--in/ and an%i7 r n.a&1 de+i&es. /. GeneralC T#e e+er in&reasin/ ra%e o$ &ons 0-%ion o$ ear%#=s raw 0a%eria!s #as .ro /#% wi%# i% a need $or $as%er 0o+e0en% o$ %#ese 0a%eria!s $ro0 %#e -oin% o$ e<%ra&%ion %o %#e -oin% o$ -ro&ess or sa/e and %rans-or%in/ %#ese 0a%eria!s %#ro /# %#e -ro&ess -!an% and dis-osin/ o$ %#e was%e in %#e s#or%es% -ossi.!e %i0e. Man" 0e%#ods o$ 0a%eria! #and!in/ are e0-!o"ed $ro0 w#ee! .arrows %o d 0- %r &1s or s# %%!e &ars2 %o -ne 0a%i& d &%s &arr"in/ - !+erised -ar%i&!es in an air s%rea0. In %#is !ine o$ 0o+e0en%2 .e!% &on+e"ors -!a" a +er" i0-or%an% -ar% in %#e re!ia.!e &arr"in/ o$ 0a%eria! o+er !on/ dis%an&es a% a &o0-e%i%i+e &os%. Ea&# 0e%#od o$ 0a%eria! &on+e"in/ #as i%s ad+an%a/es and disad+an%a/es. One o$ %#e -ro.!e0s wi%# .e!% &on+e"ors is %#a% so$% $ria.!e 0a%eria! &an .e de/raded2 -ar%i& !ar!" in !oadin/ and n!oadin/. I$ %#e 0ain%enan&e o$ ! 0- siDe is i0-or%an%2 %#is &an -resen% di$$i& !%ies on a &o0-!i&a%ed &on+e"or s"s%e0. Con+e"or s"s%e0s #a+e .e&o0e !ar/er and 0ore &o0-!e< and dri+e s"s%e0s #a+e a!so .een /oin/ %#ro /# a -ro&ess o$ e+o! %ion and wi!! &on%in e %o do so. 'i//er .e!%s re6 ire 0ore -ower and #as .ro /#% %#e need $or !ar/er indi+id a! dri+es as we!! as 0 !%i-!e dri+es s &# as 4 dri+es o$ 1??? 1( ea&# on one .e!%. S#a$% 0o n%in/ o$ %#e &o0-!e%e dri+e ni% is ano%#er &#an/e w#i&# #as .ro /#% wi%# i% %#e re6 ire0en% $or 0ore &o0-a&% and !i/#%er dri+e ni%s. T#is %ends %o $a+or a ri/#% an/!e dri+e &on$i/ ra%ion wi%# %#e 0o%or ne<% %o %#e .e!% and #ardened /ears %o red &e %#e di0ensions and 0ass o$ %#e dri+e. 0. Dr!#e Rat!" an' Belt spee'sC De-endin/ on %#e 6 an%i%"2 siDe2 dis%an&e and &#ara&%eris%i&s o$ %#e 0a%eria! %o .e &on+e"ed2 %#e a.sor.ed -ower2 wid%#2 %ensi!e re6 ire0en%s and %o- &o+er %#i&1ness o$ %#e .e!% wi!! .e de&ided. ,ar/e +o! 0e &on+e"or .e!%s r n in %#e ran/e o$ 2 %o @ 0e%reHse&ond and %#e a!!owa.!e .end radi s o$ %#e .e!% de%er0ines - !!e" dia0e%ers w#i&# $or !ar/e .e!%s is o$ %#e order o$ ?2B %o 12* 0 /i+in/ - !!e" s-eeds .e%ween *? and 12* r-0. Ass 0in/ %#a% 4 -o!e 0o%ors are sed2 %#is /i+es a red &%ion ra%io re6 ired .e%ween 12;1 and 3?;1. Mos% 0odern /ear 0an $a&% rers do no% se a #i/#er ra%io -er s%a/e %#an *;12 w#i&# 0eans %#a% s-eed red &ers wi!! .e ei%#er 2 or 3 s%a/e red &%ion. 9E<&e-% $or s0a!! -owers w#ere wor0 red &ers2 or %or6 e ar0s and ) .e!% dri+es 0a" .e sed:. T#ere is a 0is&on&e-%ion %#a% one &an red &e %#e &os% o$ %#e /ear7s-eed red &er ." sin/ a @ or B -o!e 0o%or2 . % e+en an B -o!e 0o%or on %#e #i/#er s-eeds wo !d re6 ire a red &%ion a.o+e @;1 and a 2 s%a/e ni% wo !d s%i!! .e re6 ired. T#e . !1 o$ %#e &os% o$ a /ear.o< is re!a%ed %o %#e !ow s-eed s#a$% %or6 e and %#ere$ore #a+in/ de%er0ined %#is2 %#ere is /enera!!" no e&ono0i& ad+an%a/e a% a!! in sin/ an"%#in/ . % a 4 -o!e 0o%or. T#e 0o%or 0an $a&% rers2 .e&a se o$ siDe and +o! 0e2 /enera!!" s --!" 4 -o!e 0o%ors a% %#e !owes% -ri&e2 and as a r !e %#ere$ore2 a 4 -o!e 0o%or is %#e .es% &#oi&e wi%# a /ear.o< o$ %#e a--ro-ria%e ra%io %o arri+e a% %#e desired &on+e"or s#a$% s-eed. (#ere .a!! and ro!!er .earin/s are s-eeds $or 0o%ors o+er 1??? 1(. sed in %#e e!e&%ri& 0o%ors so0e 0an $a&% rers -re$er @ -o!e or e+en B -o!e
5a+in/ &a!& !a%ed %#e -ower re6 ired %o dri+e %#e .e!% and #a+in/ &onsidered %#e .e!% %ension and an/!e o$ &on%a&%2 a de&ision &an .e %a1en on w#e%#er %#e .e!% s#o !d .e $i%%ed wi%# sin/!e or 0 !%i-!e dri+e. T#is de&ision is o$%en in$! en&ed ." o%#er e6 i-0en% ins%a!!ed in a -!an% and 0 !%i-!es o$ o%#er s0a!!er dri+es are o$%en sed. Dri+e siDe 0a" a!so .e de%er0ined ." %#e neares% s%andard 0o%or a+ai!a.!e. (#ere a dri+e -oin% is si% a%ed so0e &onsidera.!e dis%an&e $ro0 %#e 0ain -ower so r&e2 a !on/ &a.!e 0a" .e in+o!+ed %o s --!" e!e&%ri& -ower %o %#e dri+e. In %#is &ase2 %#e &a.!e siDe and &os% o$ %rans$or0ers 0a" -!a" an i0-or%an% -ar% in %#e se!e&%ion o$ n 0.er and siDe o$ 0o%ors sed. (i%# dire&% on !ine s%ar%in/2 %#e -ea1 & rren% %#e 0o%or wi!! draw is !i1e!" %o .e o$ %#e order o$ @ < $ !! !oad & rren% and %#e &o0.ina%ion o$ r nnin/ & rren% o$ a 0o%or or /ro - o$ 0o%ors wi%# %#e s%ar%in/ & rren% o$ %#e !as% 0o%or %o s%ar% wi!! #a+e a s%ron/ in$! en&e on %#e dri+e &#oi&e. 5.0 Met*"' "( L"& Spee' S*a(t C"nne t!"ns. Dri+e $ro0 %#e red &er %o %#e .e!% - !!e" s#a$% is ei%#er ." L$!e<i.!eL &o -!in/ $ro0 a dri+e -a&1 0o n%ed on a $o nda%ion ne<% %o %#e s%r &% re or ." s#a$% 0o n%ed dri+e ni% #an/in/ on %#e - !!e" s#a$%. (#en s#a$% 0o n%ed2 %#e dri+e ni% &an .e ei%#er #o!!ow s#a$%2 dri+in/ %#ro /# a $ri&%ion !o&1in/ e!e0en% or so!id s#a$% a%%a&#ed ." a ri/id &o -!in/ %o %#e &on+e"or s#a$%. So0e %"-i&a! a%%a�en%s are s#own in %#e s1e%&#es. 9See a--endi< A:. =./. C*"! e "( Start!ng )et*"', 'r!#e s!De an' Pr"te t!"nC D rin/ s%ar% - o$ &on+e"or .e!%s2 a &onsidera.!e 0ass is s a!!" in+o!+ed w#i&# re6 ires a&&e!era%ion2 and %o red &e %#e !en/%# o$ %i0e %#a% %#e 0o%or draws s%ar%in/ & rren%2 a Ls!i- &o -!in/L is $i%%ed .e%ween %#e dri+e 0o%or and s-eed red &er. A!%erna%i+e!"2 s!i- rin/ 0o%ors are sed %o a&#ie+e a 6 i&1 . % /en%!e s%ar% - wi%# &on%ro! o$ %#e -ea1 & rren%. On s0a!! .e!%s .e!ow 1?1( dire&% on !ine s%ar%in/ dire&%!" &o -!ed is 6 i%e nor0a! and on .e!%s2 sa" .e!ow 1?? 1( D.O.,. s%ar%in/ wi%# Ls!i-L &o -!in/s is 0os% &o00on2 and -ro.a.!" %#e si0-!es% and 0os% &os% e$$e&%i+e. On !ar/er dri+es wi%# -ower a% i%s -resen% &on%in o s!" in&reasin/ &os%2 s!i- rin/ 0o%ors 0a" .e a%%ra&%i+e2 d e %o %#e -re+en%ion o$ %#e -ea12 -ar%i& !ar!" w#ere 0a<i0 0 de0and -!a"s a -ar% in %#e e!e&%ri&i%" %ari$$. T#ere is a 0 !%i% de o$ s!i- &o -!in/s on %#e 0ar1e% $or se wi%# D.O.,. s%ar% 0o%ors2 . % $or !ar/er .e!%s %#e 0a8ori%" in se are !i6 id %"-e &o -!in/s2 ei%#er s%rai/#% %ra&%ion or %ra&%ion wi%# de!a"ed $i!! or &on%ro!!a.!e $i!! 9s&oo- %"-e:. A $! id &o -!in/ wi!! a!wa"s Ls!i-L a s0a!! a0o n% and wi!! #e!- 0 !%i-!e dri+es %o s#are !oad2 -ro+ided %#e &o -!in/ L$i!!L #as .een &are$ !!" ad8 s%ed. As a r !e2 ea&# &o -!in/ #as a s!i/#%!" di$$eren% &#ara&%eris%i& and i$ ad8 s%ed %o s#are !oad &orre&%!" nder $ !! !oad &ondi%ions wi!! 0ore %#an !i1e!" no% s#are -ro-er!" nder !i/#% !oad &ondi%ions. Mo%or &#ara&%eris%i&s a!so +ar" a !i%%!e and &an a!so &on%ri. %e %o -oor !oad s#arin/ on 0 !%i-!e dri+es. Dri+e s"s%e0s &o00on!" /o - %o 4 0o%ors -er .e!%2 . % rare!" 0ore. =.0 M"t"r Start!ngC +D.O.L. &!t* (l3!' "3pl!ng,. On 0 !%i-!e dri+es a&&e-%ed -ra&%i&e is %o s%ar% %#e 0o%or on %#e se&ondar" dri+e $irs% and sa" 37* se&onds !a%er one o$ %#e -ri0ar" dri+e 0o%ors and %#en %#e ne<% -ri0ar" 0o%or sa" *71? se&onds !a%er. In -ra&%i&e2 #owe+er2 %#e o.ser+ed s%ar%in/ -ro&ed res and de!a" %i0es +ar" a /rea% dea!. A +er" &o00on si/#% is %o see %#e se&ondar" dri+e 0o%or r nnin/ and d e %o &onser+a%i+e &o -!in/ se!e&%ion2 %#e s%ar%in/ & rren% dro-s so0ew#a%2 . % s%ar%s risin/ 6 i&1!" a/ain d e %o %#e de!a"ed $i!! &o -!in/ in&reasin/ i%=s s!i- %or6 e2 w#i!e %#e .e!% re0ains s%a%ionar". I$ a -ri0ar" dri+e is s%ar%ed a% %#e &orre&% %i0e .e$ore %#e &o -!in/ %or6 e #as in&reased %oo $ar2 %#e .e!% is .ro /#% in%o 0o%ion 0 &# 6 i&1er wi%# a !ower o+era!! & rren%. T#e re!a%i+e s!i- o$ %#e &o -!in/ a$$e&%s i%=s %or6 e and so %#e 0o%or & rren%2 and %#e sooner %#e .e!% &an .e 0o+ed2 %#e sooner %#e & rren% -ea1s wi!! dro-. In %#e &ase o$ s&oo- &on%ro!!ed $! id &o -!in/s a!! 0o%ors are s%ar%ed in 6 i&1 s &&ession and %#en a!! &o -!in/s $i!!ed s!ow!". A si0i!ar -ro&ed re is $o!!owed wi%# s!i- rin/ 0o%ors and %#ese %wo 0e%#ods are ndo .%ed!" %#e 1indes% %o %#e .e!%2 - !!e" and !a//in/ e%&. T#e &#oi&e o$ s&oo- %"-e $! id &o -!in/s or s!i- rin/ 0o%ors is !i1e!" %o !ead %o %#e sa$e%" and -ossi.!e sa+in/s on swi%&# /ear 0ain%enan&e. =.5 Ot*er Dr!#e Met*"'sC (#ere a +aria.!e &on+e"in/ ra%e is re6 ired2 D.C. dri+es &an .e sed as we!! as s6 irre! &a/e 0o%ors wi%# $re6 en&" &on%ro!. Ano%#er 0e%#od is ." #"dro7s%a%i& dri+e4 a/ain idea! $or +aria.!e s-eed2 . % o+era!! r nnin/ and 0ain%enan&e &os%s on .i/ -owers are !i1e!" %o .e #i/#er %#an a $! id &o -!in/ dri+e2 wi%# S.C. 0o%or or s!irin/ 0o%or. se o$ s0a!!er 0o%ors wi%#
=.= Belt Pr"te t!"nC 'e!% -ro%e&%ion a/ains% o+er!oad and s%a!!in/ is &o00on!" done ." a &en%ri$ /a! swi%&# dri+en ." a ro!!er on %#e nderside o$ %#e .e!%. T#is2 #owe+er2 is no% +er" sensi%i+e and 0ore so-#is%i&a%ed 0e%#ods are now sed. One 0e%#od &onsis%s o$ $i%%in/ a - !se /enera%or %o %#e dri+e /ear.o< !ow s-eed s#a$% and si0i!ar - !se /enera%or %o a ro!!er dri+en ." %#e .e!%. A 0oni%orin/ ni% &o0-ares %#e - !se $re6 en&ies &on%in o s!" and i$ %#e" /o o %side se% !i0i%s2 an a!ar0 is /i+en or %#e .e!% s%o--ed. On s%ar% -2 .e!% s!i- &an .e 1e-% %o a 0ini0 0 ." sin/ %#e 0oni%orin/ ni% %o &on%ro! %#e s%ar% - on s!i-rin/ 0o%ors. T#e 0oni%orin/ ni% &an &on%ro! %#e ro%or resis%an&e and so %#e s%ar%in/ %or6 e. A!%erna%i+e!"2 %#e L$i!!L o$ a +aria.!e $i!! $! id &o -!in/ &an .e &on%ro!!ed ." %#e &o0-ari%or. 7. St"pp!ng a Belt C"n#e$"r 7./ 2"r&ar' st"pp!ng. As a /enera! r !e2 $ri&%ion wi!! red &e %#e nor0a! $orward s-eed o$ %#e .e!% and !oad and .rin/ i% %o res% in a re!a%i+e!" s#or% %i0e. T#e a!!owa.!e %i0e $or s%o--in/ de-ends 0ain!" on %#e dis&#ar/e end &ondi%ions. (#ere one .e!% $eeds on%o ano%#er2 %ri--in/ &ondi%ions2 %rans$er . n1er siDe and .e!% !a"o % 0a" indi&a%e a need $or a .e!% %o .e s!owed down ." o%#er 0e%#ods %#an nor0a! $ri&%ion. On a down#i!! se&%ion o$ a &on+e"or dis&#ar/in/ on%o a !e+e! or -#i!! .e!% is /enera!!" %#e -!a&e w#ere .ra1in/ is re6 ired. I$ one .e!% r ns on !on/er %#an %#e res% o$ a s"s%e0 o$ &on+e"ors2 . n1ers or %rans$er &# %es &an .e o+er!oaded and 0a" e+en .e a #aDard2 . % %#is is /enera!!" a +er" rare &ondi%ion. Considerin/ a &on+e"or !a"o % as -er s1e%&# 9see a--endi< ': $i%%ed wi%# a .ra1e on %#e /ear.o< #i/# s-eed s#a$%2 i% &an .e seen %#a% w#en s%o--ed nder !oad %#e iner%ia o$ %#e !oad wo !d %end %o -i&1 - %#e /ra+i%" %ensioner and re!ease %#e %ension in %#e .e!% .e%ween dri+e and #ead - !!e" and 0a" e+en /o s!a&1 ." %#e %i0e %#e !oad &o0es %o res%. T#e !oad assis%ed ." %#e /ra+i%" %a1e - wo !d %#en a&&e!era%e %#e .e!% in %#e re% rn dire&%ion w#i!e %#e dri+es are s%a%ioner" wi%# .ra1es on. (#en %#e .e!% .e%ween dri+e and #ead - !!e" .e&o0es %i/#% i% #as %o re%ard %#e !oad in a $ra&%ion o$ %#e dis%an&e in w#i&# i% #ad .een a&&e!era%ed. Under %#is s dden s%o--in/ o$ %#e !oad %#e dri+e is s .8e&%ed %o #ea+" s#o&1. In %#is &ase2 a .ra1e is no% on!" nne&essar"2 . % #i/#!" ndesira.!e. A .ra1e $i%%ed on a down#i!! .e!% dri+e wo !d a/ain re!ease %ension .e%ween dri+e and #ead - !!e" and -i&1 - %#e %a1e -2 . % %#is wo !d %end %o re!ease %ension on %#e dri+in/ 9or s%o--in/: - !!e"s and a!!ow %#e .e!% %o s!i-. T#is &an da0a/e %#e .e!% and - !!e" !a//in/ and &an a!so .e dan/ero s. T#e -ro-er 0e%#od o$ s%o--in/ a .e!% !i1e %#is is on %#e %ai! - !!e" or o%#er - !!e" on %#e re% rn .e!% a$%er i% !ea+es %#e %a1e -. Ano%#er a--!i&a%ion w#ere .ra1es are so0e%i0es sed is on .e!%s r nnin/ %#ro /# a 0o.i!e s%a&1er2 %o red &e %#e ris1 o$ %#e .e!% sna//in/4 s#o !d %#e s%a&1er .e 0o+ed w#i!e %#e .e!% is s%a%ionar". 5ere a/ain a .ra1e wo !d .e $i%%ed %o %#e %ai! - !!e" and a #o!d.a&1 %o %#e dri+e or #ead. 7.0 Re#erse St"pp!ngC U-#i!! &on+e"ors nor0a!!" on!" need an an%i7r n.a&1 de+i&e. T#is &an .e $i%%ed %o %#e #ead - !!e" or on one o$ %#e dri+e - !!e"s or %o %#e /ear.o<. I$ $i%%ed %o %#e /ear.o<2 %#e %or6 e w#i&# %#e #o!d.a&1 is re6 ired %o resis% is red &ed ." %#e ra%io o$ %#e /ears .e%ween %#e #o!d.a&1 and dri+e - !!e". 9See a--endi< C:. Considera.!e sa+in/s &an %#ere$ore .e 0ade on %#e siDe o$ #o!d.a&1 $i%%ed %o %#e /ear.o< &o0-ared %o %#a% re6 ired on %#e #ead or dri+e - !!e". 5owe+er2 on 0 !%i-!e dri+es %#ere &an .e -ro.!e0s wi%# !oad s#arin/. On nor0a! r nnin/ and s%ar% -2 %#e dri+in/ !oad is s#ared .e%ween %#e +ario s dri+es ." ei%#er $! id &o -!in/s or s!i-7rin/ 0o%ors as -re+io s!" 0en%ioned. (#en .ein/ #e!d ." a #o!d.a&1 $i%%ed %o %#e /ear.o<2 %#e s"s%e0 is %orsiona!!" 0 &# 0ore ri/id %#an in %#e dri+e dire&%ion and i% is #i/#!" n!i1e!" %#a% 0ore %#an one /ear.o< H .a&1s%o- &o0.ina%ion wo !d #o!d %#e .e!% n!ess s-e&i$i& -ro+ision is 0ade $or !oad s#arin/. On a &on%in o s!" in&!ined .e!%2 9w#i&# is %#e wors%2: a% %#e 0o0en% o$ &o0in/ %o res%2 %#e $ri&%ion !oad &an .e &onsidered no% %o -!a" an" si/ni$i&an% -ar% in #o!din/ %#e .e!% .a&1 and %#e $ !! dri+in/ %or6 e #as %o .e &onsidered a&%in/ in %#e re+erse dire&%ion. On a 0 !%i-!e dri+e in %#is si% a%ion2 i$ %#e s%ren/%# o$ one /ear.o< is s $$i&ien% %o resis% %#e r n.a&1 %or6 e2 %#en a #o!d.a&1 on one /ear.o< wi!! .e ade6 a%e. A!%erna%i+e!"2 0ore %#an one /ear.o< #as %o .e $i%%ed wi%# a #o!d.a&1 and so0e 0eans o$ !oad s#arin/ -ro+ided. 9See a--endi< D $or #o!d.a&1 s1e%&#es:. In 0an" &ases .ra1es are $i%%ed %o/e%#er wi%# #o!d.a&1s. I$ .o%# %#e .ra1e and #o!d.a&1 #a+e ea&# .een se!e&%ed $or a %or6 e so0ew#ere near %#e dri+in/ %or6 e2 %#en &!ear!" on r n.a&1 &ondi%ion wi%# .ra1e and #o!d.a&1
wor1in/ %o/e%#er2 %#eir &o0.ined %or6 e is !i1e!" %o .e &onsidera.!" #i/#er %#an %#e /ear.o< ra%in/. Re% rnin/ %o %#e s1e%&# o$ %#e &on+e"or 8 s% dis& ssed2 %#e .ra1es wi!! .rin/ %#e dri+e - !!e"s and /ear.o<es %o res% !on/ .e$ore %#e !oad. Consider %#e /ear.o< #i/# s-eed s#a$% $i%%ed wi%# .ra1e dr 0 and #o!d.a&1 .o%# !o&1ed a/ains% re+erse 0o%ion. (#en %#e .e!% s dden!" a--!ies re+erse dri+e %o %#e - !!e"2 %#e #o!d.a&1 and .ra1in/ %or6 e #as %o .e o+er&o0e and %#e .ra1e dr 0 a&&e!era%ed %#ro /# %#e /ear.o< as s-eed in&reases. In %#is si% a%ion2 an in&redi.!e s%ress is -!a&ed on %#e dr 02 !ow s-eed &o -!in/ and /ear7%rain. B. Ser#! e 2a t"rsC 9See a--endi< E $or ser+i&e $a&%ors re&o00ended ." AGMA:. B./ Gear Rat!ngC T#e se o$ a ser+i&e $a&%or is o$%en re/arded as a $a&%or o$ i/noran&e ." %#e end i/noran&e o$ %#e dri+e s --!iers o$ %#e %r e &ondi%ions. ses. I% 0a" we!! re-resen% %#e
In .road %er0s2 /ears ra%ed a&&ordin/ %o %#e AGMA 0e%#od o$ &a!& !a%ion wi!! %rans0i% %#e ra%ed !oad &on%in o s!"2 wi%# a ris1 o$ %oo%# $ai! re o$ !ess %#an 1I d e %o s r$a&e d ra.i!i%" or s%ren/%# -ro+ided %#a% no s#o&1 !oads are a--!ied2 no .earin/s $ai!2 no 0a%eria! de$e&%s e<is%2 !oad .earin/ is -er$e&% and ! .ri&a%ion is -er$e&% e%&. In -ra&%i&e2 a s%ead" !oad is no% +er" &o00on2 nei%#er are .earin/s w#i&# do no% wear or a.so! %e!" ri/id #o sin/s2 s#a$%s e%&. A ser+i&e $a&%or s#o !d %#ere$ore .e se!e&%ed wi%# d e &onsidera%ion o$ %#e a&% a! &ondi%ions and no% in Li/noran&e $ro0 a %a.!eL B.0 L"a' C"n'!t!"ns "n Teet* an' "t*er C")p"nentsC T#e !oadin/ and s%ress on an" one /ear %oo%# wi!! +ar" $ro0 Dero %o 0a<i0 0 on&e -er re+o! %ion %ensi!e on one $!an1 and &o0-ressi+e on %#e o--osi%e as !on/ as i% r ns and dri+es in one dire&%ion. I$ %#is sa0e dri+e ni% is sed on a re+ersi.!e dri+e2 %#e +aria%ion o$ s%ress on a %oo%# is %#ere$ore in&reased as .o%# $!an1s o$ %#e %ee%# are s .8e&%ed %o %ensi!e and &o0-ressi+e s%ress and %#e ran/e $ro0 0a<i0 0 %o 0ini0 0 near!" do .!ed and %#e $a%i/ e !i$e o$ %#e %ee%# &onsidera.!" red &ed. E+en nder s%ead" !oad &ondi%ions in .o%# dire&%ions2 %#e 1I &#an&e o$ $ai! re wi!! no !on/er a--!". Ano%#er -o%en%ia! -ro.!e0 area on re+ersi.!e dri+es is 1e"s and 1e"wa"s. Me"s in+aria.!" #a+e a +er" s0a!! a0o n% o$ side &!earan&e w#i&# wi!! 0o+e $ro0 one side o$ %#e 1e" %o %#e o%#er on re+ersa!. T#e e$$e&% %#is #as wi!! 0ain!" de-end on %#e a0o n% o$ &!earan&e and %#e s#o&1 w#i&# is a--!ied. T#is is nor0a!!" a 0a<i0 0 nder s%ar% - w#en .a&1!as# .e%ween %#e %ee%#2 &o -!in/2 e!e0en%s e%&.2 are !i1e!" %o .e o-en -ar%i& !ar!" on %#e re+erse s%ar% - &ondi%ion. Re+ersa! o$ s%ress in dri+e &o0-onen%s &an a!so o&& r on .ra1es are $i%%ed %o s!ow %#e .e!% down. ni%s r nnin/ on!" in one dire&%ion2 $or ins%an&e2 w#ere
T#e a.o+e $or ins%an&e2 a--!ies e6 a!!" %o %#e !ow s-eed s#a$% &o -!in/s w#ere a s-rin/ e!e0en% on a re+ersin/ &on+e"or 0a" $ai! in $a%i/ e w#ere an iden%i&a! dri+e on a nidire&%iona! &on+e"or s#ows no si/n o$ $a%i/ e. T#e &#oi&e o$ .ra1es on &on+e"or dri+es a--ear %o .e se!e&%ed %o s i% %#e dri+e 0o%or %or6 e or 0ore. On a &rane2 %#is 0a" .e a +a!id s%ar%in/ -oin% $or .ra1e se!e&%ion2 . % on a &on+e"or w#i&# 0a" #a+e - as we!! as down#i!! se&%ions2 %#e 0o%or %or6 e is !i1e!" %o !ead %o %#e se!e&%ion o$ 0 &# %oo !ar/e a .ra1e. On %#e se o$ ser+i&e $a&%ors2 i% is &o00on -ra&%i&e %o se!e&% a /ear.o< wi%# a 0ini0 0 ser+i&e $a&%or &a!& !a%ed on ins%a!!ed 0o%or -ower. T#e 0o%or -ower is o$%en arri+ed a% ." doin/ +er" e<%ensi+e and &are$ ! &a!& !a%ions o$ %#e -ower re6 ired %o dri+e %#e .e!% w#i&# in si0-!e %er0s wi!! &onsis% o$ -ower %o o+er&o0e $ri&%ion -! s -ower %o !i$% %#e !oad. In .o%# &ases2 an a.so! %e 0a<i0 0 &an .e %a1en and %#en a &on%in/en&" $a&%or added. T#e e$$i&ien&" o$ %#e $! id &o -!in/ &an %#en .e es%i0a%ed2 %o .e e<%re0e!" !ow and so a!so %#e /ear.o< e$$i&ien&". A--!" a ser+i&e $a&%or on %o- o$ %#is2 %#en se!e&% %#e ne<% .i//er s%andard 0o%or and %#e dri+e 0o%or wi!! .e a.!e %o &o-e wi%# %#e 0os% ad+erse $rea1 &ondi%ion wi%# -ower %o s-are2 . % do a $air a0o n% o$ da0a/e %o %#e .e!%2 - !!e"s e%&. T#e !as% %#in/ one wan%s %o do is se!e&% a dri+e ni% %oo s0a!!2 . % i% is essen%ia! %o do a!! %#e &a!& !a%ions a&& ra%e!" and %#en a--!" a L&on%in/en&"L $a&%or on!" on&e. T#e &onse6 en&es o$ se!e&%in/ a /ear.o< or a !ow s-eed s#a$% &o -!in/ on dr 0 s#a$% %oo !ar/e wo !d -rod &e an ne&ono0i& so! %ion2 . % wo !d /i+e a +er" !on/ e<-e&%ed !i$e. 5owe+er2 se!e&%in/ %oo !ar/e a 0o%or wi!! #a+e 6 i%e %#e o--osi%e e$$e&% on %#e !i$e o$ a .e!%2
- !!e"s2 /ear.o<es e%&.2 o+er an e<%ended -eriod o$ %i0e. As an e<a0-!e2 &onsider a &on+e"or dri+e &a!& !a%ed %o re6 ire C? 1( %o dri+e i% and add a *?I &on%in/en&" $a&%or. indi&a%in/ an a.so! %e 0a<i0 0 1?* 1(. T#e ne<% .i//er siDe o$ 0o%or is sa" 132 1(. On s%ar% - %#e dri+e %rain 0a" .e s .8e&%ed %o a %or6 e e6 i+a!en% %o 2N < 132 Mw E 33? 1( w#i!e ori/ina!!" one se% o % on!" needin/ C? 1(. On s%ar% -2 %#e 0e&#ani&a! &o0-onen%s o$ %#is dri+e wi!! &er%ain!" re&ei+e a .ea%in/. Re% rnin/ %o %#e &a!& !a%ed ra%in/ o$ %#e dri+e ni%4 %o ens re %#a% one 0ain%ains %#e &#an&e o$ $ai! re a% %#e &orre&% !e+e!2 %#e o-era%in/ &ondi%ions #a+e %o .e ana!"sed and a S.F. se!e&%ed %o ens re %#a% s#o&1 and o%#er n$orseen &ondi%ions do no% /o o %side %#e $a&%ors %a1en in%o %#e &a!& !a%ion. I% is a&&e-%ed %#a% %#e &a!& !a%ed ra%in/ o$ a /ear &an .e e<&eeded $or s#or% -eriods wi%#o % da0a/e. For ins%an&e2 i% a!!ows $or a s%ar%in/ %or6 e o$ %wi&e %#e AGMA ra%in/ o$ %#e /ear wi%#o % i!! e$$e&%. B.5 Bear!ng L!(eC T#e nor0a! 0e%#ods o$ ra%in/ a .a!! or ro!!er .earin/ in a /ear.o< is %o ass 0e a '1? !i$e o$ *??? #o rs and &a!& !a%e %#e ra%ed -ower o$ %#e /ears $or %#is .earin/ !i$e w#i&# is %#en %a1en as %#e .earin/ ra%in/. T#e 1( ra%in/ $or .earin/s wi!! %#ere$ore nor0a!!" .e #i/#er %#an %#e ra%in/ o$ %#e /ears. T#e /enera!ised re!a%ions#i- .e%ween %#e !i$e o$ ro!!er .earin/2 %#e o-era%in/ !oad and ra%ed &a-a&i%" is e<-ressed as;7 ,i$e E Cons%an% O Ra%ed !oad &a-a&i%" P
323
O-era%in/ s-eed O A&% a! o-era%in/ !oad P (#en %#e .earin/ ra%in/ a% a s-e&i$i& s-eed is &a!& !a%ed as s%a%ed a.o+e in %er0s o$ 1( $or *??? #o rs '1? !i$e and %#e a+era/e a.sor.ed -ower o$ %#e dri+en 0a&#ine is 1nown2 %#en %#e e<-e&%ed '1? .earin/ !i$e wi!! .e;7 *??? Q O 1( ra%in/ o$ .earin/ P P
323
5o rs
S%a%is%i&a!!" 0ore %#an A?I o$ a!! .earin/s o-era%in/ nder %#ese &ondi%ions wi!! #a+e a !i$e a% !eas% e6 a! %o %#e &a!& !a%ed $i/ re or %#e &#an&e o$ $ai! re is !ess %#an 1?I in %#is -eriod o$ r nnin/ %i0e. T#is is a s%a%is%i&a! -ro.a.i!i%" .ased on %#e ass 0-%ion %#a% %#e a&% a! !i$e wi!! .e nor0a!!" dis%ri. %ed and %#e 1?I $ai! res in&! de %#e -ossi.i!i%" o$ a $ai! re in %#e $irs% 0in %e o$ o-era%ion. !i1ewise %#e A?I w#i&# wi!! e<&eed %#is &a!& !a%ed !i$e wi!! in&! de so0e w#i&# wi!! #a+e in$ini%e !i$e as %#e %ai!s o$ %#e nor0a! dis%ri. %ion & r+e s%re%&# $ro0 Dero %o in$ini%". For o%#er &#an&es o$ $ai! re2 %#e .earin/ 0an $a&% rers /i+e %#e $o!!owin/ $a&%ors wi%# w#i&# %o 0 !%i-!" %#e '1? !i$e %o &a!& !a%e %#e e<-e&%ed !i$e $or %#e &orres-ondin/ &#an&e o$ $ai! re. Pro.a.i!i%" o$ $ai! re 1?I *I Fa&%or 1 4I 3I 2I 1I
T#e &a%a!o/ e ra%in/ $or a /ear ni% is %#e ra%in/ in 1( o$ %#e wea1es% e!e0en% in %#e /ear ni%. Ass 0in/ %#e . "er re6 es%s a S.F. o$ 12* on %#e a.sor.ed -ower2 and %#a% a .earin/ is %#e wea1es% e!e0en%2 %#en %#e e<-e&%ed .earin/ !i$e wi!! .e a--ro<i0a%e!" 1A??? #o rs $or a 1?I &#an&e o$ $ai! re or 4??? #o rs $or 1I &#an&e o$ $ai! re. T#e re!a%ions#i- .e%ween !oad and !i$e is e<-onen%ia! and a s0a!! &#an/e in !oad wi!! #a+e a si/ni$i&an% in$! en&e on e<-e&%ed .earin/ !i$e2 %#ere$ore2 i% is essen%ia! %#a% %#e a+era/e a.sor.ed -ower o$ %#e .e!% .e &a!& !a%ed. >. C"n l3s!"nC To -ro+ide a $irs% &!ass so! %ion %o a 0a%eria!s &on+e"in/ -ro.!e0 an i0-or%an% -oin% is a /ood in%e/ra%ed .a!an&ed desi/n o$ w#i&# %#e dri+e is one e!e0en% w#i&# re6 ires &!ose and o-en &o!!a.ora%ion .e%ween %#e &on+e"or desi/ner and %#e dri+e s --!ier. To %#is end2 0a" we s //es% %#a% w#en -!a&in/ an en6 ir" $or &on+e"or dri+es o$ sa" o+er 1?? 1(2 %#a% %#e $o!!owin/ in$or0a%ion .e /i+en;7
1. 2.
3. 4. *. @. C.
A si0-!e s1e%&# o$ %#e &on+e"or !a"o %. Ca!& !a%ed a.sor.ed -ower in so0e de%ai! s &# as;7 a. Power %o o+er&o0e a!! $ri&%ion !osses. ........... ... 1( .. Power %o !i$% !oad. 9I$ !i$% is in+o!+ed:. ........... ... 1( &. Power %o 0o+e !oad on !e+e!. 9(#ere !e+e! and !i$% in+o!+ed:. RRRRRRRRRR1( d. a G . G & E Ca!& !a%ed nor0a! %o%a! a.sor.ed -ower. EEEEEEEE1( e. Con%in/en&" $or o+er!oad and $re6 en&" e<-e&%ed 9or &#an&e o$ o+er!oad in I:. ................1( $. To%a! 0a<i0 0 &a!& !a%ed a.sor.ed -ower. EEEEEEEE1( /. Addi%iona! %or6 e re6 ired %o a&&e!era%e !oad ............ .... N0 I$ %#is is 0ore %#an C*I o$ %#e e6 i+a!en% %or6 e O$ 9$:2 %#en i% needs &onsidera%ion in re!a%ion %o %#e 0o%or &#ara&%eris%i&s. #. For - r-oses o$ .earin/ !i$e &a!& !a%ion2 %#e e<-e&%ed a+era/e &on%in o s a.sor.ed -ower. Me%#od o$ s%ar%in/ and e<-e&%ed s%ar% - %i0e. Me%#od o$ -re+en%in/ r n.a&1. SiDe o$ 0o%or 9I$ no% !ess %#a% =$= reason $or &#oi&e:. E<-e&%ed ser+i&e $a&%or and reason $or &#oi&e o$ S.F. E<-e&%ed .earin/ !i$e and a&&e-%a.!e &#an&e o$ .earin/ $ai! re.
T#e end ser re6 ires !ar/er o %- %s $or a s-e&i$i& &a-i%a! &os%s &o -!ed %o !ow ener/" &ons 0-%ion2 !ow 0ain%enan&e &os%s and #i/# re!ia.i!i%" o+er a !on/ o-era%in/ !i$e. One o$ %#e Le!e0en%s in %#is L0i<L is %#e s-eed red &er $or w#i&# %#e o-%i0 0 &#oi&e is a% %#e -resen% 0o0en% &er%ain %o .e a #e!i&a! /ear ni% wi%# s#a$%s r nnin/ on .a!! or ro!!er .earin/ wi%# #ardened %ee%# dri+en ." an a--ro-ria%e L0i<L o$ e!e&%ri& 0o%or and &o -!in/ E@ternal S*r!n; D"36le Taper. Appen'!@ A/
N"r)al R3nn!ng
23ll l"a' tr!p Bra;es st"p 6elt an' l"a' arr!es "n p! ;!ng 3p gra#!t$ ta;e 3p a3s!ng sla ; 6elt. I( 6ra;es are reE3!re' F-F !s t*e pr"per pla e t" appl$ t*e). Gear6"@ Rat!" /BC/ T*en T"rE3e "n Ba ;st"p /:/Bt*. "( L.S.S. T"rE3e Appen'!@ C
L.S. Gearset Rat!" =C/ T"rE3e "n Ba ;st"p "n Inter)e'!ate S*a(t G "( L.S.S. T"rE3e
A H L" ;!ng D!re t!"n B H 2ree <*eel!ng D!re t!"n Ban' T$pe A"l'6a ;s Appen'!@ D5
APPENDI- E <ITA AC%NO<LEDGEMENT TO AGMA. AGMA STANDARD PRACTICE 2OR ENCLOSED SPEED RED.CERS OR INCREASERS .SING SP.R, AELICAL, AERRINGBONE AND SPIRAL BEVEL GEARS =. Ser#! e 2a t"rs 4.1 'e$ore a red &er &an .e se!e&%ed $or an" /i+en a--!i&a%ion2 %#e e6 i+a!en% #orse-ower is &o0- %ed ." 0 !%i-!"in/ %#e s-e&i$ied or a&% a! #orse-ower ." %#e ser+i&e $a&%or $or %#e -ar%i& !ar !oad &!assi$i&a%ion $or w#i&# %#e ni% is %o .e sed. I% is ne&essar" %#a% %#e ni% se!e&%ed #a+e a &a-a&i%" e6 a! %o or in e<&ess o$ %#is e6 i+a!en% #orse-ower. T#e re&o00ended ser+i&e $a&%ors $or +ario s !oad &!assi$i&a%ions and d ra%ion o$ ser+i&e are s#own $or se+era! %"-es o$ -ri0e 0o+ers in Ta.!e 1. 4.2 ,oad &!assi$i&a%ions $or +ario s a--!i&a%ions are /i+en in Ta.!e 2. T#e" are &!assi$ied in%o %#ree &o00on!" re&o/niDed !oad &!assi$i&a%ions ; Uni$or02 Modera%e S#o&12 and 5ea+" S#o&1. 4.3 Ser+i&e $a&%ors re-resen% %#e nor0a! re!a%ions#i- .e%ween /ear desi/n -ower ra%in/ and %#e &on%in o s -ower re6 ire0en%s. A--!i&a%ions in+o!+in/ n s a! or se+ere !oadin/ or re6 irin/ a #i/# de/ree o$ de-enda.i!i%" s#o !d .e &are$ !!" re+iewed wi%# %#e 0an $a&% rer .e$ore a ser+i&e $a&%or is a--!ied. 4.3.1 A--!i&a%ions wi%# #i/#7%or6 e 0o%ors and 0o%ors $or in%er0i%%en% o-era%ions and a--!i&a%ions w#ere e<%re0e re-e%i%i+e s#o&1 o&& rs or w#ere #i/#7ener/" !oads 0 s% .e a.sor.ed2 as w#en s%a!!in/2 re6 ire s-e&ia! &onsidera%ion and are no% &o+ered ." %#e ser+i&e $a&%ors /i+en in Ta.!e 1. Ta6le / Ser#! e 2a t"rs
Pr!)e M"#er
D3rat!"n "( Ser#! e O&&asiona! 1H2#r. -er da" In%er0i%%en% 3#rs. -er da" O+er 3#rs - %o and in&!. 1?#rs. -er da" O+er 1? #rs. -er da" O&&asiona! 1H2#r. -er da" In%er0i%%en% 3#rs. -er da" O+er 3#rs. - %o and in&!. 1?#rs. -er da" O+er 1?#rs. -er da" O&&asiona! 1H2#r. -er da" In%er0i%%en% 3#rs. -er da" O+er 3#rs. - %o and in&!. 1?#rs. -er da" O+er 1?#rs. -er da"
Dr!#en Ma *!ne L"a' Class!(! at!"n .n!("r) M"'erate S*" ; Aea#$ S*" ; ?.*? ?.B? 1.?? 1.2* ?.B? 1.?? 1.2* 1.*? 1.?? 1.2* 1.*? 1.C* ?.B? 1.?? 1.2* 1.*? 1.?? 1.2* 1.*? 1.C* 1.2* 1.*? 1.C* 2.?? 1.2* 1.*? 1.C* 2.?? 1.*? 1.C* 2.?? 2.2* 1.C* 2.?? 2.2* 2.*?
4.4 w#en dri+es are e6 i--ed wi%# .ra1es on %#e in- %2 and %#e %or6 e ra%in/ o$ %#e .ra1e e<&eeds %#e ra%in/ o$ %#e 0o%or2 %#e ra%in/ o$ %#e .ra1e di&%a%es %#e se!e&%ion o$ %#e /ear ni%. 4.* T#e re&o00ended ser+i&e $a&%ors $or Dr" Do&1 Crane a--!i&a%ions are /i+en in Ta.!e 3. D e %o %#e na% re o$ %#ese &rane dri+es2 %#e ser+i&e $a&%ors are %o .e sed $or an" d ra%ion o$ ser+i&e. 4.@ (#en a $! id &o -!in/ is sed .e%ween %#e -ri0e 0o+er and %#e /ear ni%2 %#e ser+i&e $a&%or /i+en in Ta.!e 1 $or 0odera%e or #ea+" s#o&1 0a" .e 0odi$ied .ased on %#e ni% 0an $a&% rer=s ana!"sis and re&o00enda%ion $or %#e a--!i&a%ion. 4.C T#e 0a<i0 0 0o0en%ar" or s%ar%in/ !oad 0 s% no% e<&eed 2?? -er &en% o$ ra%ed !oad 91 ?? -er &en% o+er!oad:. Ra%ed !oad is de$ined as %#e ni% ra%in/ wi%# a ser+i&e $a&%or o$ 1.?. 4.B T#e ser+i&e $a&%ors !is%ed $or -a-er 0i!! a--!i&a%ions are &onsis%en% wi%# %#ose s#own in TAPPI 9Te&#ni&a! Asso&ia%ion o$ %#e P !- and Pa-er Ind s%r": S%andard 4?@.?B2 LSer+i&e Fa&%ors $or Gears on Ma8or E6 i-0en% in %#e Pa-er and P 0- Ind s%r".L AGMA STANDARD PRACTICE 2OR ENCLOSED SPEED RED.CERS OR INCREASERS .SING SP.R, AELICAL, AERRINGBONE AND SPIRAL BEVEL GEARS Ta6le 0 Appl! at!"n Class!(! at!"n ("r En l"se' Spee' Re'3 ers Appl! at!"n AGITATORS P re ,i6 ids ,i6 ids and So!ids ,i6 ids7)aria.!e Densi%" L"a' Class!(! at!"n
',O(ERS Cen%ri$ /a! ,o.e )ane 'RE(ING AND DISTI,,ING 'o%%!in/ Ma&#iner" 'rew 1e%%!es2 Con%. D %"
Uni$or0
Uni$or0 Uni$or0 Coo1ers7Con%. D %" Mas# T .s7Con%. D %" S&a!e 5o--er2 Fre6 en% S%ar%s CAN FI,,ING MAC5INES CANE MNI)ES CAR DUMPERS CAR PU,,ERS C,ARIFIERS C,ASSIFIERS Uni$or0 Modera%e S#o&1 Uni$or0 SF E 1.*? 5ea+" S#o&1 Modera%e S#o&1 Uni$or0 Modera%e S#o&1
C,A> (ORMING MAC5INER> 'ri&1 Press 'ri6 e%%e Ma&#ine C!a" (or1in/ Ma&#iner" P / Mi!!
CON)E>ORS7UNIFORMA,,> ,OADED OR FED A-ron Asse0.!" 'e!% ' &1e% C#ain F!i/#% O+en S&rew
AGMA STANDARD PRACTICE 2OR ENCLOSED SPEED RED.CERS OR INCREASERS .SING SP.R, AELICAL, AERRINGBONE AND SPIRAL BEVEL GEARS Ta6le 0 Appl! at!"n Class!(! at!"n ("r En l"se' Spee' Re'3 ers + "nt!n3e', Appl! at!"n CON)E>ORS75EA)> DUT> NOT UNIFORM,> FED A-ron Asse0.!" 'e!% ' &1e% C#ain F!i/#% Q,i+e Ro!! O+en Re&i-ro&a%in/ S&rew L"a' Class!(! at!"n
Modera%e S#o&1 Modera%e S#o&1 Modera%e S#o&1 Modera%e S#o&1 Modera%e S#o&1 Modera%e S#o&1
CRANES 9See Ta.!e 3 $or Dr" Do&1 Cranes: Main 5ois%s Q'rid/e Tra+e! QTro!!e" Tra+e!
Uni$or0
Modera%e S#o&1 DREDGES Ca.!e Ree!s Con+e"ors C %%er 5ead Dri+es Ji/ Dri+es Mane +erin/ (in&#es P 0-s S&reen Dri+e S%a&1ers U%i!i%" (in&#es Modera%e S#o&1 5ea+" S#o&1 5ea+" S#o&1 Modera%e S#o&1 Modera%e S#o&1 5ea+" S#o&1 Modera%e S#o&1 Modera%e S#o&1 DR> DOCM CRANES See Ta.!e 3
Uni$or0 E,E)ATORS ' &1e%7Uni$or0 ,oad ' &1e%75ea+" ,oad ' &1e%7Con%. Cen%ri$ /a! Dis&#ar/e Es&a!a%ors Frei/#% Gra+i%" Dis&#ar/e QMan ,i$%s QPassen/er Modera%e S#o&1 Uni$or0 Uni$or0 Uni$or0 Modera%e S#o&1 Uni$or0
Uni$or0 Uni$or0 T .in/ '!ow Mo!ders Pre7-!as%i&iDers Uni$or0 Modera%e S#o&1 Modera%e S#o&1
QRe$er %o Fa&%or" QQTo .e se!e&%ed on .asis o$ 24#r ser+i&e on!". APPENDI- 2. Co0-arison o$ &a-i%a! &os% o$ s!i-rin/ 0o%or wi%# swi%&#/ear +ers s D.O.,. s%ar% S &a/e 0o%or wi%# s&oo- &o -!in/ and s"s%e0 !oses. For 323 Mw; 4*? Mw S!i-rin/ 1?B 3C* Mw 11B CI 22* Mw 1?A BI 2 Q $ !! !oad S%ar%in/ C rren%
D.O.,. s%ar%
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To%a! Es%i0a%ed ,osses BI %o 11I AI %o 12I 1?I %o 12I For *?? )o!%; S!i-rin/ 13? 11? CI 1?3 BI
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To%a! es%i0a%ed !osses AI %o 11I AI %o 12I 1?I %o 12I P!ease no%e on!" one 0an $a&% rers -ri&es were sed $or 0o%ors2 $! id &o -!in/s and swi%&#/ear. No a!!owan&e is 0ade $or s --!" &a.!e siDe %o &a%er $or s%ar%in/ & rren%.
Type and condition of the material to !e handled, including ma"imum particle si#e, and, if availa!le, the specific !ul$ density of the material to !e conveyed. %. &uantity of transported material, e"pressed in pounds or tons per hour. '. The distance for which the material is to !e conveyed.
In the ne"t sections is the necessary information for the selection of a screw conveyor system, presented in a series of five steps. These steps are arranged in logical order, and are divided into separate sections for simplicity. The five steps are: . Esta!lishing the characteristics of the material to !e conveyed. (ocating conveyor capacity )conveyor si#e and speed* on capacity ta!les. '. Selection of conveyor components. +. Calculation of re,uired horsepower. Chec$ing of component tor,ue capacities )including selection of shaft types and si#es*. %.
-.
.ll necessary calculations are e"pressed in graphic and e,uation form, and use of all charts, graphs, etc. will !e e"plained fully at the end of each section. Engineering data regarding the design of screw feeders and their selection, is presented in a separate section, immediately following the screw conveyor data. .ny unusual applications, or special designs, should !e referred to /0S 1fg2s. Engineering 3epartment.
Conveyor (oading
The recommended percentages of conveyor loading is a prime factor in determining the si#e of conveyor, and is !ased on the ma"imum depth at which materials will flow through the conveyor without causing undue wear. Considerations should !e made, for e"ample, for materials with a high a!rasiveness !ecause wear inde"es would normally !e higher due to a larger contact area with component parts.
8orsepower 4actor
The horsepower factor, representing the relative mo!ility of the material, is necessary for horsepower calculation.
7ote: Some materials, while they are not corrosive under 5normal5 conditions= may !ecome corrosive under certain other conditions, such as when heated or in the presence of moisture.
1aterials Ta!le
. C < C C C 36G C 86( C 16D C P69 C S C T6E Ta!les are in alpha!etical order. Clic$ a!ove to navigate to different sections. Ta!le $eys and e"planations are located in the 51aterial Characteristics5 Section.
Maximum Avera!e &.P. Component Abras' Corrosi' Flow' Particle Size "ei!#t Per $oa%in! Note Factor Series iveness veness ability (IN. Cu.Ft. F G% @:6A: ':< .? <+ II I II
Material .cetylenogen )Calcium Car!ide* .dipic .cid .lfalfa 1eal .lfalfa Seed .lmonds .lum .lum, lumpy .lumina .luminate Gell, dried .luminum Chips .luminum 8ydrate ).luminum 8ydro"ide* .luminum D"ide ).lumina* .luminum Dre )<au"ite* .luminum Silicate .luminum Sulfate ).lum* .mianthus ).s!estos * .mmonium Chloride, Crystalline .mmonium 7itrate .mmonium Sulfate .ndalusite ).luminum Silicate* .ntimony .pple Pomace, dry .rsenate of (ead )(ead .rsenate* .rsenic .rsenic D"ide ).rsenolite* .s!estos, Dre .s!estos, Shred
I II II II I I III II I I
II I I I I I I I I I
' .@ ? H H %
+H ':< ':.
.A .A :.A H .: :.A
C+ 3+ .% H <+ .%
III III I H II I
I I I H I I
I II II H III II
-,@,A
6 GA H 6 GA
+-6?% +:6-A +B
H H +-
H H :.A
H H .%
H H I
H H I
H III II
H .' H
H :..: H H .% .:
II II I H H III II
I I I H H I I
H @ %, HH-, @, A
.shes, Coal, dry .shes, Coal, dry .shes, Coal, wet .shes, Coal, wet .sphalt, Crushed
6 G% 6' 6 G% 6' 6 G%
'-6+'-6++-6-: +:6-: +-
<+ <+ 3+ 3+ .%
II II II II I
I I II II I
Conveyor Capacity
. capacity ta!le is provided on the ne"t section to aid you in calculation of proper conveyor si#e. To use this ta!le, find the capacity at ma"imum 9P1, opposite the recommended percentage of conveyor loading, which e,uals or e"ceeds the capacity of material re,uired per hour. The recommended conveyor diameter will then !e found in the appropriate column on the same line, as will the ma"imum particle si#e recommended for the screw diameter. If the ma"imum particle si#e you plan to convey is larger than the ma"imum recommended particle si#e for the conveyor you2ve chosen from the ta!le, you must then select a larger conveyor, ade,uate to handle the ma"imum particle si#e you intend to use.
E,uation Sym!ols
CS I Conveyor Speed C48 I Capacity in Cu!ic 4eet per 8our
E,uation Sym!ols
SC I Selection Capacity C48 I 9e,uired Capacity in Cu!ic 4eet per 8our C4 I Capacity 4actor
E"ample:
. conveyor is re,uired to transport : tons per hour of a material weighing ?% pounds per cu!ic foot and having a ma"imum particle si#e of :: mesh. To further complicate the pro!lem, we will re,uire that the material !e mi"ed in transit using cut and folded flights. Since the distance the material is to !e conveyed is relatively short, we want to use short pitch screws, to insure proper mi"ing of material. The materials ta!le recommends a loading percentage of ':L ..
4or proper calculation of si#e and speed, this volume must !e corrected, !y use of capacity factors, to compensate for cut and folded, and short )%G'* pitch flights. These capacity factors, ta$en from the preceding charts are: Cut and folded flights ':L loading I '.@Short pitch flights )%G' pitch* I .-: 0ith capacity factors included, capacity will now !e calculated: SC I '.@- J .-: J '%' SC I A @cu.ft. This selection capacity value will !e used in the capacity ta!le, for calculating correct si#e and speed. In the appropriate column, under ':L . loading, we find that a +5 conveyor, at the ma"imum recommended speed will convey % B+ cu. ft. per hr. or % . cu. ft. per revolution. To calculate actual conveyor speed, the following formula should !e used:
)7)8 cu. 4t. 5 #r. 2).) cu. 4t. 5 #r. at ) *PM ( 76.) *PM
This is the correct speed at which the +5 conveyor with cut and folded, and short pitch flights will convey the actual capacity of '%' cu. ft. per hour. Graphic selection of this conveyor could also !e accomplished !y use of the ':L . nomograph on page %% and the selection capacity of A @ cu. ft. per hour.
+ ? B : % + ? A %: %+ + ? B : % + ? A %: %+ + ? B : % + ? A %: %+
G% 'G+ 6 G% 6'G+ % %6 G% ' '6 G+ '6 G% + G% 'G+ 6 G% 6'G+ % %6 G% ' '6 G+ '6 G% + G% 'G+ 6 G% 6'G+ % %6 G% ' '6 G+ '6 G% +
-@ BA ?A' A+B ,+@? %, B+ ',:+? +,:A? -,:B% @,+%? %A BB '+@ +'% @@ , A% ,??+ %,%@: %,B B +,-A? ? + ' ,'?: ,@A% ',:': +,--A ?,-%+ A,?-B ,-B: @,-'-
.+ .-.? @.% '.' % . ' .+ +-.+ ?%. :B.% .+ .-.? @.% '.' % . ' .+ +-.+ ?%. :B.% .? %.%@ A.: :.A B.' ':.A +?.? ??. B-.: ?@.:
Conveyor loadings may sometime e"ceed the recommended L of (oading, listed in the materials ta!le. Considerations as to the material characteristics may Mustify up to B-L loading of tu!ular or shrouded con6 veyors. The following ta!le lists ma"imum speeds limited with regard to the percentage of loading normally recommended for the specific listed materials.
,BBB %,'?? %, %% %,-': %,A:+ ','%- %,BBB ',-A? ',@?% +,+-- ',B?: +,@-% +,- % -,'-A +,@B+ -,@A -,%%? ?,%' -,?%A ?,A'+ @,+'+ A,A-: A, +% B,B %
Paddle
.dMusta!le paddles provide complete mi"ing action, and controlled material flow.
3ischarge 1ethods
<elow are drawings of standard discharge components in a variety of designs. These configurations are listed for individual applications where the standard discharge spouts are not necessarily appropriate. Cautions are inserted when necessary for particular discharge components.
Plain Dpening
4actors Influencing 1aterials of Construction or Special 1echanical .rrangement of Screw Conveyor Components
Corrosive 1aterials
Corrosive materials, or materials which have a tendency to !ecome corrosive under certain conditions, may necessitate the use of corrosion6resistant alloys such as stainless steel.
.!rasive 1aterials
.!rasive materials which may cause e"cessive wear of components should !e conveyed at a nominal depth in the conveyor. It is often advisa!le to also specify /0S2s .!rasion69esistant Screw Conveyors or conveyors with flights formed of .9 steel plate. /0S2s .!rasion69esistant Screw Conveyors, which have a 9oc$well C hardness of ?A6@:, are covered in the Component Section. . ta!le listing the standard width of application of hard surfacing is included.
Contamina!le 1aterials
1aterials whose usefulness or value may !e altered !y contamination may re,uire the use of non6lu!ricated !earings, as well as a tightly sealed system.
8ygroscopic 1aterials
1aterials that readily a!sor! moisture re,uire a tightly sealed conveyor. It may !e necessary also to Mac$et the conveyor trough or housing with a circulating medium to maintain an elevated temperature. Purging the system with dry gas or air may !e necessary.
Interloc$ing 1aterials
1aterials which tend to mat or interloc$ are sometimes effectively conveyed !y using special devices to load the conveyor.
4luidi#ing 1aterials
Some materials tend to assume hydraulic properties when aerated or mechanically agitated. Such materials may 5flow5 in the conveyor much the same as a li,uid. These materials should !e referred to /0S2s engineering department for recommendations.
E"plosive 1aterials
3angerous e"plosive materials can !e handled !y sealing the system andGor the use of non6spar$ing components. It is also possi!le to utili#e e"haust systems for ha#ardous dust removal.
3egrada!le 1aterials
1aterials with particles that are easily !ro$en may !e effectively handled !y selection of a larger, slower conveyor.
Elevated Temperatures
1aterials handled at elevated temperatures may re,uire components manufactured of high6temperature alloys. If it is feasi!le to cool the material in transit, a Mac$eted trough used as a cooling device may also !e employed.
To"ic 1aterials
1aterials which emit harmful vapors or dusts re,uire tightly sealed systems. E"haust devices may also !e used to remove the vapors or dusts from the conveyor housing.
3escription of Components
Conveyor Screws
The recommended screws listed in the Component Series Ta!le are standard /0S helicoid and sectional screw conveyors. The use of helicoid or sectional conveyors is largely a matter of individual preference. It is advisa!le to use, whenever possi!le, standard conveyors in standard lengths. 0hen a special short length must !e used to ma$e up the total conveyor length, it is prefera!ly located at the discharge end.
Screw conveyors are structurally reinforced at the ends !y the use of end lugs which are welded to the non6 carrying side of the flights so that material flow will not !e o!structed. Screw conveyors which move material in a single direction should not !e turned end6for6end unless the direction of screw rotation is reversed. (i$ewise, the direction of rotation should not !e reversed unless the conveyor is turned end6for6end. 9e,uirements for reversi!le conveyors should !e referred to /0S2s Engineering 3epartment. 4lighting should !e omitted at the final discharge, so that material will not carry past the discharge point.
To assure proper material flow past hanger !earing points, flight ends should !e positioned to each other at A: degrees. The 5hand5 of a conveyor, in conMunction with the direction the conveyor is rotated, determines the direction of material flow. The diagram !elow illustrates flow direction for 5right6hand5 and 5left6hand5 conveyors when rotated cloc$wise or countercloc$wise. . right6hand screw conveyor pulls the material toward the end which is !eing rotated cloc$wise. The direction of flow is reversed when the direction of rotation is reversed. . left6hand conveyor pushes the material away from the end which is !eing rotated cloc$wise. .gain, the direction of material flow is reversed when the direction of rotation is reversed. To determine the hand of a conveyor, o!serve the slope of the near side of the flighting. If the slope is downward to the right, the conveyor is right6hand. If the slope is downward to the left, the conveyor is left6 hand. 9ight6hand conveyor is furnished unless otherwise specified.
Shafts
The primary consideration in determining the type and si#e of coupling and drive shafts is whether the shafts selected are ade,uate to transmit the horsepower re,uired, including any overload. 7ormally, cold6rolled shafts are ade,uate. 8owever, high6tensile shafts may !e re,uired due to tor,ue limitations. .lso, stainless steel shafts may !e necessary when corrosive or contamina!le materials are to !e handled. Conveyors e,uipped with non6lu!ricated iron hanger !earings re,uire hardened coupling shafts, and hard6surfaced hanger !earings re,uire hard6surfaced shafts. Specific shaft si#e determination is covered in the Tor,ue Capacities Section.
Shaft Seals
Several conveyor end seal types are availa!le to prevent contamination of the conveyed material or to prevent the escaped of material from the system.
<earings
8anger <earings 6 The purpose of hanger !earings is to provide intermediate support when multiple screw sections are used. 8anger !earings are designed primarily for radial loads. .de,uate clearance should !e allowed !etween the !earings and the conveyor pipe ends to prevent damage !y the thrust load which is transmitted through the conveyor pipe. The hanger !earing recommendations listed in the Component Series Ta!le are generally ade,uate for the material to !e handled. Dften, however, unusual characteristics of the material or the conditions under which the conveyor must operate ma$e it desira!le to use special !earing materials. . list of availa!le special !earing materials is provided in this section. 4or specific recommendations regarding the use of special !earing materials, consult /0S2s Engineering 3epartment.
End <earings 6 Several end !earing types are availa!le, and their selection depends on two !asic factors: 9adial load and thrust load. The relative values of these loads determines end !earing types.
9adial load is negligi!le at the conveyor tail shaft. 8owever, drive ends )unless integrated with the conveyor end plate* are su!Mect to radial loading due to overhung drive loads, such as chain sproc$ets or shaft6 mounted speed reducers. Thrust is the reaction, through the conveyor screw or screws, resulting from movement of the material. Therefore, the end !earing must prevent a"ial movement of the screw which would allow contact with hanger !earings or ends. Thrust !earings should !e located at the discharge end of the conveyor. This places the conveyor in tension, preventing deflection in the screws when the system is heavily loaded. The following diagrams illustrate discharge and inlet end positions of the thrust !earing.
Component Series
The recommended Component Series for the material to !e conveyed may !e found in the 1aterials Ta!le at the !eginning of the Engineering Section. The alpha!etical code relates to the general component series, and the numerical code refers to !earings and coupling shafts. The Component Series Ta!le follows on the ne"t page. <earing and coupling shaft recommendations are listed in the ta!le !elow. The Component Series Ta!le lists the screw conveyor num!ers for !oth helicoid and sectional screws and gives the trough and cover thic$nesses. The <earing and Coupling Shaft Ta!le lists the recommended materials of construction.
Series % ' + Couplin! S#a4t Standard or 8igh Tor,ue Standard or 8igh Tor,ue Standard or 8igh Tor,ue 8ardened or 8ard Surfaced :earin! Material <a!!itt 0ood <ron#e <a!!itt 0ood <ron#e <all <a!!itt 8ard Iron 8ard Surfaced
Graphite <ron#e Graphite6Impregnated Plastic 1achined 7ylon 1olded 7ylon Dil6Impregnated <ron#e Plastic, (aminated 4a!ric6<ase Teflon
Series .
Screw Number &elicoi% Sectional ?S':B BS':B BS+:B :S':B :S+:B %S+:B %S-:B %S?:B +S-:B +S?:B ?S? % AS? % AS@ % %:S? % %:S@ % %+S@ % +ube or +rou!# +#ic;ness ? Ga. ? + + % &elicoi% +8%:? ?8':A B8' % B8+ % :8':?J :8+ % %8+ % %8- % %8? + +8-:A +8? + ?8? +
Series <
Screw Number Sectional ?S':B BS':B BS+:B :-' % :S+ % %S+ % %S- % %S? % +S- % +S? % ?S? ? AS? ? AS@ ? %:S? ? %:S@ ? %+S@ ? +ube or +rou!# +#ic;ness + Ga. + : : 'G ?5
? Ga. ? ? ? +
+8%:+ ?8':+ B8':? B8+:? :8':? :8+ % %8+:A %8-:A %8? + +8-:A +8? + ?8? :
+ ? A %: %+
+ + + + %
% % % : :
Series C
Screw Number &elicoi% Sectional ?S' % BS' % BS+ % :S' % :S+ % %S+ ? %S- ? %S? ? +S-%+ +S?%+ ?S? ? AS?%+ AS@%+ +ube or +rou!# +#ic;ness + Ga. + : : 'G ?5 &elicoi% +8%:?J ?8' % B8' % B8+ + :8':?J :8+ %J %8+ %J %8- %J %8? + +8-:AJ +8? +J ?8? +J
Series 3
Screw Number Sectional ?S' ? BS' ? BS+ ? :S' ? :S+ ? %S+%+ %S-%+ %S?%+ +S-%+ +S?%+ ?S?%+ AS?%+ AS@%+ +ube or +rou!# +#ic;ness : 'G ?5 'G ?5 G+5
? Ga. ? ? ? +
+8%:? ?8' % B8' % B8+ + :8':?J :8+ % %8+ % %8- % %8? + +8-:AJ +8? + ?8? +
+ ? A
+ + +
%: %+
+ %
'G ?5 'G ?5
G+5 G+5
J8ard6Surfacing 9ecommended
8orsepower Calculation
Calculation !y E,uation
TS8P may also !e calculated !y e,uation using the following formulas:
D9
M&P ( CP x MF x $ )3///3///
7ote: If calculated 1aterial 8orsepower is less than - it should !e corrected for potential overload. The corrected horsepower value corresponding to the calculated 1aterial 8orsepower will !e found on the lower scale of the 1aterial. 8orsepower Dverload Correction Chart.
+S&P ( F&P < M&P9 JCorrected if !elow - 8P. 7ote: The actual motor horsepower re,uired to drive the loaded conveyor system is dependent on the method used to reduce the speed the motor to the re,uired speed of the conveyor. 3rive losses must !e ta$en into consideration when selecting the motor and drive e,uipment.
E,uation Sym!ols
+S&P F&P M&P $ S DF &:F CF& " CP MF Total Shaft 8.P. 4riction 8.P. )8.P. re,uired to drive the conveyor empty* 1aterial 8.P. )8.P. re,uired to move the material* Conveyor (ength Conveyor Speed Conveyor 3iameter 4actor 8anger <earing 4actor Conveyor Capacity 0eight per cu. ft. Capacity, l!s. per hr. 1aterial 8.P 4actor )4rom the 1aterials Ta!le*
3iameter 4actors
Diameter + ? B : % + ? A %: %+ Factor % A ' '@ -@A :? '?%'-
J7on6(u!ricated
J Std. paddles at +-; reverse pitch Total Shaft 8orsepower )TS8P* is calculated !y adding 1aterial 8orsepower, multiplied !y the appropriate modified flight factor or factors, to 4riction 8orsepower. 7ote: Conveyors which have deviation in pitch only do not re,uire special consideration, and their horsepower calculations are as descri!ed for standard conveyors.
E"ample
. :6inch conveyor '- feet long with a capacity of : tons per hour at +- 9P1 has !een selected. 4rom the 1aterials Ta!le, a 8orsepower 4actor of :.A is found for the material to !e conveyed. The ta!le also indicates Series + hanger !earings and shafts. 8ard iron !earings and hardened coupling shafts have !een selected to suit this re,uirement. 4riction 8orsepower, the horsepower re,uired to drive the conveyor empty, is calculated as follows: 3iameter 4actor I '@ 8anger <earing 4actor I +.+
1aterial 8orsepower, the horsepower re,uired to move the material, is calculated !y the following e,uation: Capacity )in l!s. per hr.* I %:,::: 8orsepower 4actor (ength 9P1 I +.+ (ength I '9P1 I +M&P ( 2/3/// x /.7 x ., )3///3/// ( /.,6/
Since the calculated 1aterial 8orsepower is less than -, it is necessary to find the corrected horsepower value corresponding to :.-? horsepower on the Dverload Correction Chart !elow. This value is found to !e .'%: horsepower. Total Shaft 8orsepower )TS8P* is the sum of 4riction horsepower and the corrected 1aterial 8orsepower. Thus TS8P is calculated as follows: +S&P ( /.2,6 < )..2/ ( ).,86 &.P. .ssuming a drive efficiency of A-L resulting in a total drive horsepower of .A-', a standard % horsepower motor would !e selected for the drive input. The horsepower re,uired for the a!ove conveyor may also !e determined graphically !y the use of the two horsepower nomographs. The first nomograph determines 4riction 8orsepower. The second determines 1aterial 8orsepower. Total Shaft 8orsepower is determined !y adding the two values.
Friction &orsepower
Material &orsepower
$en!t#
Spee%
Friction &.P.
$en!t#
Material &.P.
.nalysis of a specific conveyor system with regard to component tor,ue ade,uacy may !e conveniently and ,uic$ly made !y use of the two following nomographs.
7ote:8igh starting tor,ue motors must not !e used without design verification !y /0S2s Engineering 3epartment. E"ample: . %6inch car!on steel conveyor has !een selected with a re,uired shaft horsepower of A.B and a speed of ?+ 9P1. The drive to !e used has an efficiency of A-L, thus re,uiring a drive input of :.+? horsepower. Therefore, a - horsepower motor must !e used. This total motor horsepower could !e transmitted to the conveyor components if overloaded or stalled.
Three standard shaft si#es are availa!le for %6inch conveyors. They are %5, %6@G ?5 and '5. . straight edge is placed from - horsepower on the left scale to ?+ 9P1 on the center scale. ProMect the straight line to the left vertical line of the chart at the right. . hori#ontal line from this point will pass through component groups suita!le for the tor,ue. 4or the conveyor under consideration, it is found that standard components will !e ade,uate, with the e"ception of coupling !olts which must !e high tensile.
Spee%
Component Size9
S I standard car!on steel 8 I high6tensile steel +: I pipe schedule )standard* A: I pipe schedule )high capacity*
Spee%
Component Size9
JCoupling !olt si#es !ased on conveyor shaft diameters. Conveyor pipe listed as nominal pipe si#e.
7umerous com!inations and types of drives are availa!le for screw conveyor e,uipment. Some of the more fre,uently used drives and mechanical arrangements are descri!ed !elow:
. screw conveyor drive consists of a standard single or dou!le reduction shaft6mounted speed reducer, a steel motor mounting !rac$et, an adapter with CE1. drilling containing shaft seals, and a remova!le steel shaft, all mounted on a screw conveyor trough end. The motor !rac$et is rigidly mounted with clearance over the trough end for easy trough cover removal without disassem!ling any part of the drive. . variety of mounting arrangements ma$es it possi!le to locate the drive to avoid interference with other e,uipment. Correct O6!elt tension can !e easily maintained !y simple adMustment of the motor mounting plate. The drive assem!ly can !e ,uic$ly removed !y removing the !rac$et mounting !olts.
The helical gear shaft mount speed reducer uses the screw conveyor drive shaft as an 5output shaft,5 ma$ing a mounting !ase and low speed coupling unnecessary. <ecause it does not mount to the trough end it offers several advantages. It can !e used in limited, higher temperature applications where damaging heat can !e dissipated !efore it affects the reducer. Pou have a greater variety of seals and !earings to choose from. Pou can utili#e heavy duty !earing for higher than usual !earing loads. The reducer can !e rotated in any position around the shaft.
O6!elt tension is maintained in the same manner as the screw conveyor drive when using the adMusta!le motor mount. . tie6rod turn!uc$le loc$s the shaft6mounted reducer into position. )0e !elieve this is !est accomplished in the field, conse,uently we do not normally support the tie6rod from the conveyor.*
Com!ination 1otor69educer
Integral motor6reducer drives consist of a com!ination motor and speed reducer which may !e mounted directly to the conveyor cover with an adapter !ase. The motor6reducer may also !e mounted in other positions, depending on availa!le space and accessi!ility. The motor6reducer output shaft is connected to the conveyor drive shaft through roller chain and sproc$ets. Speed changes in the field are possi!le !y replacement of one or !oth sproc$ets. Suita!le conveyor drive end !earings are re,uired for the overhung sproc$et loads.
Dther 3rives
Dther drive e,uipment which may !e re,uired includes varia!le speed units which allow manual or automatic adMustment of conveyor capacity !y speed deviation. Such drives are especially useful for regulating the flow of material into a process.
7ote
4luid, pneumatic or resilient couplings may !e used for starting heavily loaded conveyors and to prevent drive component damage due to heavy intermittent overloads.
Dur !elt guards are custom designed to meet your specific re,uirements. They are D.S.8... approved and will accent the !est of drives. Dur two piece construction provides you with the !est availa!le features. The !ac$ panel is designed to !e securely supported. The front panel with sides is easily remova!le !y loosening a hand $no!. This permits complete access to sheaves, !ushing and O6!elts. Standard 4eatures:
Slotted for !elt adMustment ? ga. steel construction 4ully enclosed Safe 6 rounded ends
9 I 3river, N5 P.3. F%5 S8 I Shaft 3iameters N5 0 I (ongest 8u!F%5 )min +5* C3 I Center 3istance 9 I 3river, N5 P.3. F%5 S8 I Shaft 3iameterF 5
Screw 4eeders
'.
Inlet opening matches !in or hopper discharge. %. Shroud cover prevents material flooding. Twin tapered, varia!le pitch Screw Conveyor permits even draw off of material. +. Twin tapered trough. .lso availa!le with drop !ottom feature. -. 3ischarge opening. ?. Solid shafting transmits rotary motion to driving gears. @. 3riving gears synchroni#e the action of the screw conveyors.
7ormally short in length, Screw 4eeders are designed to regulate the volumetric rate of material flow from a hopper, !in or storage unit. The inlet is usually flooded with material ) ::L load capacity* !ut !y incorporating changes in the construction of the flighting )diameter, pitch, etc.* and the speed of the feeder screw, the material discharge can !e governed to the desired rate. 4eeders can !e !uilt with varia!le diameter or stepped pitch or !oth in units )com6posed of one, two or a multiple num!er of screws )i.e., (ive <ottom <in* depending on the application. Screw 4eeders are normally e,uipped with a shroud )curved* cover for a short distance !eyond the inlet opening. This prevents flooding of the conveyor with material. 0hen handling very freely flowing materials, e"tended shroud covers, tu!ular housing construction or short pitch flights are occasionally re,uired for positive control. Screw 4eeders with uniform diameter and pitch normally convey the material from the rear of the inlet opening first. To draw off material evenly across the full length of the inlet, a tapered screw or stepped pitch conveyor screw is re,uired. 0hile Screw 4eeders are availa!le in many designs to fit your particular re,uirements, several commonly used types are descri!ed !elow.
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In designing a Screw 4eeder, virtually every situation is uni,ue in one respect or another. 4or this reason, we recommend that you consult /0S Engineering 3epartment for proper recommendations concerning your particular needs.
@. A. B.
CA$CA$A+I?NS : Shaftless 1ass 4low 4actor, C Spcl. 4light Type 4actor, C4% I I
.:: .::
Flowrate (v
m 3ensity
+++.+
4tR'G8r
%.B'
4tR'G8rGrpm
*eBuire% Spee%3 N I
+++.+ %.B
4tR'G8r 4tR'G8rGrpm
'+.+
rpm