System Information Idler Set Data

Client Name Designer HAK
Project Name 230013 Company Birikim Mühendislik

Conveyor Name 61-CV-11A Filename 61-CV-11A B=1200
Location GREECE Date Eylül 19, 2023
Description:
System Information
Calculation method CEMA 7th (type 1) Idler Set Data
Conveyor Length / Height 235 / 0,5 m Carry Return
Material lift 0,7 m Series name C5 C5
Ambient temperature range -16 to 39 °C Number of rolls 3 2
Kt factor at minimum temperature 1,23 Trough angle (deg) 45 10
Type Inline Inline
Material Properties Idler spacing (m) 1,20 3,00
Type tailing Number of ıdler sets 202 78
Operating / Design Tonnage 1170 / 1463 t/h Roll diameter 127 127
Density 1640 kg/m3 Roll rpm 278 278
Maximum lump size 1 mm Total drag (N) 8,0 5,3
Surcharge angle 6 deg Drag range (N) 4,9 - 38,7 3,1 - 24,9
Roll length 434 648
Shaft diameter (mm) 25,0 25,0
Belt Properties
Rating (N) 3.203 2.224
Type Fabric (4-Ply) Calc Idler Load (N) 3.239 616
Cover Grade DIN-X L10 life1 (1000 hrs) 52,2 350,0
Width 1200 mm 1
L10 life above which 95% of idlers exceed
Rating 630 N/mm
Speed 1,9 m/s Drive Station
Top / bottom cover thickness 6,0 x 3,0 mm
Total thickness 15 mm Type Fluid coupling
Weight (new / worn) 18,9 / 13,5 kg/m Synchronous RPM 1500 RPM
Modulus 6.061 kN/m Motor quantity / rating 1 / 90,0 kW
Tape length 482,2 m Total ınstalled power 90,0 kW
Belt cycle time 261 s Nominal empty / full power (29 / 47%) 26,3 / 42,0 kW
Min / max demand power (-2 / 84%) -1,7 / 75,3 kW
Tension Summary Running Momentary Frame Size IEC 280M
Maximum tension (kN) 67,0 88,0 Motor Voltage 400 V
Minimum safety factor 11,28 8,59 Efficiency 90,5 to 94,5%
Minimum tension (kN) 29,2 11,5 Maximum starting torque 140%
Maximum belt sag (%) 1,17 2,97 Inertia - Motor 2,0 kg·m²
Inertia - Fluid Coupling 0,1 kg·m²
Cross Sectional Loading BrakeInertia 2,62 kg·m2
Material mass (wm) 220,2 kg/m Pulley lagging type Ceramic
Combined mass (wm + wb) 239,1 kg/m Motor wrap angles 180
Edge distance (required / actual) 89 / 107 mm Lagging friction factor (run / accel) 0,35 / 0,45
Cross sectional area 0,134 m²
Cross sectional loading (utility / total) 91 % / 65 % Take-up Data
Bed depth 218 mm
Type Gravity
Location Head / Pulley #4
Required belt line tension 34,2 kN
Cable reeving ratio (trolley:counterweight) 1:2
Counterweight mass 13,9 tonnes
Required pulley displacement 4,94 m

Dynamic displacement (incl thermal) 0,91 m
Permanent elongation 3,13 m
Splice length (1 included) 0,54 m
Clearance 0,35 m
Flooded belt tonnage 2.254 t/h
Flooded (wm + wb) 358,2 kg/m
Sidewinder - v7.22 - Conveyor Design Software
Advanced Conveyor Technologies, Inc.
Page 1 / 98
Description:
100% Motor Torque - High Speed 582 N·m

Backstops Motor Shaft Torque - Running (FN) 273 N·m
Location Head on Pulley #1 Motor Shaft Torque - Starting (FN) 686 N·m
Backstop (quantity x type) 1 x High speed 100% Motor Torque - Low Speed 15.996 N·m
Pulley diameter 660 mm Low Speed Shaft Torque - Running (FN) 6.560 N·m
Load Share Factor % 100 Low Speed Shaft Torque - Running (Max) 12.304 N·m
Service Factor - Material Lift 1,50 Low Speed Shaft Torque - Starting (FN) 15.145 N·m
Service Factor - Motor Rating 1,30 Low Speed Shaft Torque - Starting (Max) 19.340 N·m
Material Lift Criteria 175 N·m
Motor Torque Criteria 756 N·m Starting and Stopping
Torque rating at high speed shaft 756 N·m Start control Constant torque
Torque rating at low speed shaft 20.795 N·m Start time 1,7 to 8,5 s
Reducer Ratio 27,500:1 Emergency stop control Brake
Emergency stop time 1,8 to 4,9 s
Brakes Material buildup in chute 0,6 m³
Type High speed - Constant Torque
Location Head / Pulley #1 Tension Ratios
Number of Disks 1 Allowable (running) 3,00
Torque rating at high speed shaft1 350 N·m Running tension ratio 2,02
Torque rating at low speed shaft 9.625 N·m Allowable (dynamic) 4,11
Reducer Ratio 27,500:1 Starting tension ratio 2,68
Pulley diameter 630 mm Allowable (brake) 4,11
Brake model N/S Emergency stop tension ratio 2,26
Number of calipers 1
Clamping force 1.823 N Transition Lengths
Brake disk size 580 x 30 mm Transition method CEMA 7
Tail transition length (inline) 2,90 m
Brake Torque Design Range Head transition length (elevated 90 mm) 3,00 m
Min Clamping force (at 2,5 mm pad wear) 1.367 N
Maximum clamping force 2.188 N
Disk to Pad COF (min/max) 0.35 / 0.45
Estimated Splice Data
Minimum brake torque 230 N·m Splice type 3-Step
Maximum brake torque 473 N·m Splice step length 200 mm
22 degree bias angle 485 mm
1
This is the nominal expected brake torque. The supplied brake Total splice length 1085 mm
must operate within the minimum and maximum brake torques.
The brake disk size must also be checked for thermal and other
design requirements by the supplier. Take-Up Cable
Counterweight mass 13,9 tonnes
Reducer Information
Cable reeving ratio (trolley:counterweight) 1:2
Manufacture N/A Take-up cable tension 68,4 kN
Frame size N/A Cable diameter 22,0 mm
Reducer ratio 27,500 Cable breaking strength (1800 MPa) 327,0 kN
Catalog reducer ratio 0,000 Safety factor 4,8
RPM (High Speed) 1500 RPM Number of clips (crosby clamps) 4
RPM (Low Speed) 54,5 RPM Turnback / free end length 660 / 100 mm
Configuration Shaft Mount Sheave Root Diam 385 mm
Number of stages 3
Service factor 1,4
Power rating 0,0
Motor Torque
Page 2 / 98
Description:
Maximum Belt Tensions (kN)

Other Information Case Running Dynamic
Loaded beltline mass (excluding motors) 85.136 kg Empty - NF 43,1 57,8
Total inertia (ref HS shaft) 12,3 kg·m2 Full - NF 51,5 76,9
Full - LF 45,2 73,2
Demand Power (kW) Full - HF 61,0 82,4
Demand % Motor Operating Tonnage - LF 43,2 70,5
Case Operating Tonnage - NF 49,1 74,1
power Nameplate
Empty - NF 26,3 29,2 Operating Tonnage - HF 58,2 79,5
Full - NF 42,0 46,7 PLUGGED CHUTE - HF 66,7 88,0
Full - LF 26,1 29,0 Inclines - LF 53,0 73,8
Full - HF 64,4 71,5 Inclines - NF 58,4 77,6
Operating Tonnage - LF 22,4 24,8 Inclines - HF 67,0 83,1
Operating Tonnage - NF 37,5 41,7 Declines - LF 37,3 58,9
Operating Tonnage - HF 59,2 65,8 Declines - NF 40,1 62,4
PLUGGED CHUTE - HF 74,8 83,1 Declines - HF 44,6 68,0
Inclines - LF 40,7 45,2
Belt Safety Factor
Inclines - NF 54,8 60,9
Case Running Dynamic
Inclines - HF 75,3 83,7
Empty - NF 17,54 13,08
Declines - LF -1,7 -1,9
Full - NF 14,69 9,84
Declines - NF 12,8 14,2
Full - LF 16,74 10,33
Declines - HF 33,9 37,6
Full - HF 12,39 9,17
Din Factor and Total Equivalent Mass Operating Tonnage - LF 17,51 10,73
Belt line Operating Tonnage - NF 15,41 10,21
Case Din factor Operating Tonnage - HF 12,99 9,50
mass (kg)
Empty - NF 0,0328 48.017 PLUGGED CHUTE - HF 11,33 8,59
Full - NF 0,0165 99.040 Inclines - LF 14,26 10,24
Full - LF 0,0098 96.001 Inclines - NF 12,95 9,75
Full - HF 0,0286 100.315 Inclines - HF 11,28 9,09
Operating Tonnage - LF 0,0088 85.783 Declines - LF 20,25 12,84
Operating Tonnage - NF 0,0161 88.726 Declines - NF 18,86 12,12
Operating Tonnage - HF 0,0298 89.867 Declines - HF 16,94 11,12
PLUGGED CHUTE - HF 0,0283 100.595
Splice Safety Factor
Inclines - LF 0,0105 66.265
Case Running Dynamic
Inclines - NF 0,0201 69.052
Empty - NF 13,16 9,81
Inclines - HF 0,0398 69.968
Full - NF 11,02 7,38
Declines - LF 0,0102 72.103
Full - LF 12,55 7,75
Declines - NF 0,0189 74.929
Full - HF 9,30 6,88
Declines - HF 0,0363 75.904
Operating Tonnage - LF 13,13 8,05
Operating Tonnage - NF 11,56 7,66
Operating Tonnage - HF 9,75 7,13
PLUGGED CHUTE - HF 8,50 6,44
Inclines - LF 10,70 7,68
Inclines - NF 9,71 7,31
Inclines - HF 8,46 6,82
Declines - LF 15,19 9,63
Declines - NF 14,14 9,09
Declines - HF 12,71 8,34

Page 3 / 98
Description:
Minimum Belt Tensions (kN) Maximum Belt Sag (%)

Case Running Dynamic Case Running Dynamic
Empty - NF 33,8 30,5 Empty - NF 0,21 0,22
Full - NF 33,4 11,9 Full - NF 1,05 2,96
Full - LF 29,2 11,5 Full - LF 1,17 2,97
Full - HF 33,1 13,5 Full - HF 0,90 2,66
Operating Tonnage - LF 30,5 14,3 Operating Tonnage - LF 0,91 1,92
Operating Tonnage - NF 33,8 14,8 Operating Tonnage - NF 0,83 1,93
Operating Tonnage - HF 33,1 16,6 Operating Tonnage - HF 0,71 1,75
PLUGGED CHUTE - HF 33,1 14,9 PLUGGED CHUTE - HF 0,79 2,41
Inclines - LF 34,2 28,2 Inclines - LF 0,92 1,20
Inclines - NF 33,8 28,8 Inclines - NF 0,87 1,20
Inclines - HF 33,1 31,4 Inclines - HF 0,77 1,09
Declines - LF 29,3 15,0 Declines - LF 1,13 2,00
Declines - NF 33,5 15,2 Declines - NF 1,02 2,03
Declines - HF 33,1 16,0 Declines - HF 0,88 1,95

Page 4 / 98
Description:
Conveyor Profile
Overall length = 235 m - Overall height = 0,5 m - True Length = 235,3 m
Tail Arrangement Head Arrangement
Maximum Pulley Tensions (without any additional safety factors)

Steady State Tensions (kN) Momentary Tensions (kN)
Wrap
Pulley Type Resultant Resultant
(deg) T1 T2 T1 T2
Force Force
Mtr 1 - Brk 1 - Bstp 1 1-HT 180 67,0 34,2 100 88,0 35,0 122
Pulley 2 2-LT 86 34,434,5 47,0 34,934,8 47,5
Pulley 3 2-LT 90 34,234,2 48,4 34,434,3 48,5
Take-up Pulley 3-LT 180 34,234,4 68,6 34,234,6 68,8
Pulley 5 4-LT 90 34,434,6 48,8 34,635,1 49,3
Pulley 6 4-LT 94 35,035,3 51,4 35,536,0 52,3
Tail Pulley 5-MT 180 37,939,6 77,4 42,544,0 86,5
T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Pulley Shaft Results

Shaft Shaft Design Design
Bearing Pulley & Resultant Resultant Resultant Bending
Safety Slope at Deflection T1 T2
Pulley # L10 Life Shaft Force Angle Torque Moment
Factor Hub at Center Tension Tension
1000 hrs Mass (kg) (kN) (deg) (kN·m) (kN·m)
(min) (% span) (kN) (kN)
1 2,84 6,64 0,065 500 73,7 36,5 880 111 188 12,3 12,5
2 4,41 6,16 0,059 500 43,0 43,1 571 62,7 313 0,0 6,3
3 4,88 5,57 0,053 500 42,7 42,8 571 56,6 41 0,0 5,7
4 3,94 6,14 0,059 500 42,7 43,0 617 86,0 184 0,1 8,6
5 4,83 5,62 0,054 500 43,0 43,3 571 57,2 41 0,1 5,7
6 4,03 6,74 0,064 500 43,8 44,1 571 68,5 230 0,1 6,8
7 3,48 6,94 0,066 500 47,3 49,5 617 97,2 354 0,6 9,7
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added multiplier of 1,10 on high tension
pulleys, and a multiplier of 1,25 on all other pulleys.

Page 5 / 98
Description:
Pulley Geometry Details (Pulley Types)

Diameter Shaft Bearing Pulley
Lagging Face Bearing
Lagging Diameter with Center Center Plummer Bearing Shaft
Type Thickness Width Diameter
Type (mm) Lagging Diameter Distance Block Series Bearing
(mm) (mm) (mm)
(mm) (mm) (mm) Mass (kg)
1 Ceramic 630 12,0 654 1400 140 115 1650 526 23226 990
Rubber
2 505 12,0 529 1400 120 100 1600 522 23222 647
Plain
Rubber
3 505 12,0 529 1400 130 110 1600 524 23224 715
Plain
Rubber
4 505 12,0 529 1400 120 100 1600 522 23222 647
Plain
Rubber
5 505 12,0 529 1400 130 110 1600 524 23224 715
Plain
Pulley Shaft Information

Overhun
Hub Bearing
Tensile Yield Fatigue Hub Fillet Overhun g
Locking Shaft Center to Fillet
Type Strength Strength Strength Diameter Radius g Load Moment
Device Material Distance Distance
(MPa) (MPa) (MPa) (mm) (mm) (kN) Arm
(mm) (mm)
(mm)
1 XT-60 C45 630,0 360,0 315,0 140 1200 100 38 0,0 0
2 XT-50 C45 630,0 360,0 315,0 120 1200 93 30 0,0 0
3 XT-60 C45 630,0 360,0 315,0 130 1200 98 30 0,0 0
4 XT-50 C45 630,0 360,0 315,0 120 1200 93 30 0,0 0
5 XT-60 C45 630,0 360,0 315,0 130 1200 98 30 0,0 0

Page 6 / 98
Description:
Conveyor Load Cases

During the course of operation, the conveyor experiences different operating conditions at various frequencies. Normal
operating conditions, such as steady state running, loading and unloading, and other common load cases are designated as
Design Level 1. Unusual operating conditions, such as when all incline or decline section are simultaneously loaded, are
defined as Design Level 2. These design levels allow easy summarization of the various possible loading conditions.
For this conveyor, there are six Design Level 1 loads, which are:
1. Empty
2. Fully Loaded
3. Operating Tonnage
4. PLUGGED CHUTE
5. Inclines Only
6. Declines Only
In the load case figures, the red line is the conveyor profile and the blue line indicates positions that are loaded.
Empty
Fully Loaded (Material Lift = 0,7 m)

Page 7 / 98
Description:
Operating Tonnage (Material Lift = 0,7 m)
PLUGGED CHUTE (Material Lift = 0,7 m)
Inclines Only (Material Lift = 5,9 m)
Declines Only (Material Lift = -5,2 m)

Page 8 / 98
Description:
Take-up Displacement Summary

1. Type Gravity
2. Location Head / Pulley #4
3. Belt line tension 34,2 kN
4. Take-up pulley displacement range
a. Running -0,15 to 0,17 m
b. Momentary -0,40 to 0,51 m
Take-up Pulley Displacement Summary

1. Dynamic displacement (incl thermal) 0,91 m
2. Permanent elongation 3,13 m
3. Splice length (1 included) 0,54 m
4. Clearance 0,35 m
5. Required displacement 4,94 m
Counterweight Displacement Summary (1:2 Cable Reeving Ratio)

1. Dynamic displacement 0,46 m
2. Permanent elongation 0,24 m
3. Splice length (1 included) 0,00 m
4. Clearance 0,35 m
5. Required displacement 1,04 m
*Counterweight displacements assume a winch is installed to adjust the counterweight position. As such the splice
length requirement and most of the permanent elongation can be removed from the total displacement (assuming the
counterweight location is repositioned periodically).

Page 9 / 98
Description:
Pulley Details
The following table lists recommended pulley design tensions. The first column lists belt tensions for bearing L10
life and pulley fatigue stress calculations. Belt tensions for the fatigue design criterion are based on all design
level 1 cases. Running tensions have an added multiplier of 1,10 on high tension pulleys, and a multiplier of 1,25
on all other pulleys.
Pulleys are also to be design for the structural design tensions. For structural design tensions, the pulley
manufacturer is to ensure that the pulleys will be adequate to meet these worst case conditions.
Pulley Design Tensions (added safety factors as described above)

Fatigue Design Tensions (kN) Structural Design Tension (kN)
Wrap
(deg) T1 T2 T1 T2
Force Force
Motor 1 - Brake 1 -
1-HT 180 73,7 36,5 111 108 38,5 148
Backstop 1
Pulley 2 2-LT 86 43,043,1 62,7 38,438,2 56,2
Pulley 3 2-LT 90 42,742,8 56,6 37,837,7 49,6
Take-up Pulley 3-LT 180 42,743,0 86,0 37,638,0 75,9
Pulley 5 4-LT 90 43,043,3 57,2 38,138,6 50,4
Pulley 6 4-LT 94 43,844,1 68,5 39,139,6 61,7
Tail Pulley 5-MT 180 47,349,5 97,2 46,848,3 95,6
Required Pulley Diameter (Tension based on a safety factor of 10)

Required
%
Pulley Wrap Diameter Pulley % Running
Pulley Location Momentary
Type (deg) (mm) Diameter Tension
tension
(mm)
Motor 1 - Brake 1 -
Head (11) 1 - HT 180 630 630 89 116
Backstop 1
Pulley 2 Head (13) 2 - LT 86 505 400 46 46
Pulley 3 Head (15) 2 - LT 90 505 400 45 46
Take-up Pulley Head (17) 3 - LT 180 505 400 45 46
Pulley 5 Head (19) 4 - LT 90 505 400 46 46
Pulley 6 Head (21) 4 - LT 94 505 400 47 48
Tail Pulley Tail (29) 5 - MT 180 505 500 52 58
Pulley Shaft Stress Analysis (Individual Pulleys)

Hub Hub Fillet Fillet Fillet Von Hub Von Overhung
Shaft Slope
Pulley Safety Bending Torsion Bending Torsion Mises Mises Von Mises
Type at Hub
# Factor Stress Stress Stress Stress Stress Stress Stress
(min)
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)
1 1 2,84 6,64 46,4 22,8 49,3 41,2 61,0 86,7 0,0
2 2 4,41 6,16 36,9 0,1 39,5 0,1 36,9 39,5 0,0
3 2 4,88 5,57 33,4 0,0 35,7 0,0 33,4 35,7 0,0
4 3 3,94 6,14 39,9 0,2 43,4 0,3 39,9 43,4 0,0
5 4 4,83 5,62 33,7 0,2 36,0 0,4 33,7 36,1 0,0
6 4 4,03 6,74 40,4 0,2 43,2 0,4 40,4 43,2 0,0
7 5 3,48 6,94 45,1 1,3 49,1 2,2 45,1 49,2 0,0

Page 10 / 98
Description:
Running Drive Tensions by Load Case (kN)

Motor 1 - Brake 1 - Backstop 1
Load Case Resultant
T1 T2
Force
Empty - NF 43,1 33,8 76,9
Full - NF 51,5 33,8 85,2
Full - LF 45,2 34,2 79,3
Full - HF 61,0 33,1 94,1
Operating Tonnage - LF 43,2 34,2 77,3
Operating Tonnage - NF 49,1 33,8 82,8
Operating Tonnage - HF 58,2 33,1 91,3
PLUGGED CHUTE - HF 66,7 33,1 99,9
Inclines - LF 53,0 34,2 87,2
Inclines - NF 58,4 33,8 92,2
Inclines - HF 67,0 33,1 100
Declines - LF 30,6 34,2 64,7
Declines - NF 36,0 33,8 69,8
Declines - HF 44,6 33,1 77,8

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Description:
Pulley Tension Summary - All Load Cases and Conditions

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Description:
Load Case Pulley Running Starting O-Stop E-Stop

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Description:
T1 T2 T1 T2 T1 T2 T1 T2
ID Description
(kN) (kN) (kN) (kN) (kN) (kN) (kN) (kN)

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Description:
EM-N Empty - NF Mtr 1 - Brk 1 - Bstp 1 43,1 33,8 57,8 32,5 30,5 34,9 30,5 34,9

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Description:
Pulley 2 34,4 34,5 33,8 34,1 34,9 34,8 34,9 34,8

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Description:
Pulley 3 34,1 34,2 33,8 34,1 34,4 34,2 34,4 34,2

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Description:
Take-up Pulley 34,2 34,3 34,2 34,6 34,2 34,1 34,2 34,1

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Description:
Pulley 5 34,3 34,5 34,6 35,1 34,0 34,0 34,0 34,0

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Description:
Pulley 6 34,9 35,0 35,5 36,0 34,3 34,3 34,3 34,3

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Description:
Tail Pulley 36,3 37,5 42,5 44,0 31,2 32,1 31,2 32,1

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Description:
FL-N Full - NF Mtr 1 - Brk 1 - Bstp 1 51,5 33,8 76,9 33,3 17,6 34,4 17,6 34,4

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Description:
Pulley 2 34,4 34,5 34,2 34,3 34,7 34,6 34,7 34,6

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Description:
Pulley 3 34,1 34,2 34,0 34,2 34,3 34,2 34,3 34,2

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Description:
Take-up Pulley 34,2 34,3 34,2 34,4 34,2 34,2 34,2 34,2

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Description:
Pulley 5 34,3 34,5 34,4 34,7 34,1 34,2 34,1 34,2

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Description:
Pulley 6 34,9 35,0 35,1 35,4 34,6 34,6 34,6 34,6

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Description:
Tail Pulley 36,3 37,5 38,6 39,8 33,4 34,4 33,4 34,4

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Description:
FL-L Full - LF Mtr 1 - Brk 1 - Bstp 1 45,2 34,2 73,2 33,7 17,2 34,6 17,2 34,6

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Description:
Pulley 2 34,4 34,4 34,1 34,3 34,6 34,5 34,6 34,5

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Description:
Pulley 3 34,2 34,2 34,0 34,2 34,3 34,2 34,3 34,2

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Description:
Take-up Pulley 34,2 34,2 34,2 34,3 34,2 34,1 34,2 34,1

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Description:
Pulley 5 34,2 34,3 34,4 34,6 34,1 34,1 34,1 34,1

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Description:
Pulley 6 34,6 34,7 34,9 35,1 34,4 34,3 34,4 34,3

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Description:
Tail Pulley 35,3 35,9 37,4 38,1 33,2 33,7 33,2 33,7

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Description:
FL-H Full - HF Mtr 1 - Brk 1 - Bstp 1 61,0 33,1 82,4 32,7 19,0 33,9 19,0 33,9

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Description:
Pulley 2 34,3 34,4 34,1 34,3 34,7 34,6 34,7 34,6

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Description:
Pulley 3 34,1 34,2 34,0 34,2 34,3 34,2 34,3 34,2

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Description:
Take-up Pulley 34,2 34,4 34,2 34,5 34,2 34,2 34,2 34,2

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Description:
Pulley 5 34,4 34,6 34,5 34,8 34,2 34,3 34,2 34,3

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Description:
Pulley 6 35,0 35,3 35,3 35,6 34,7 34,7 34,7 34,7

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Description:
Tail Pulley 37,9 39,5 39,8 41,6 34,1 35,6 34,1 35,6

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Description:
Operating
OT-L Tonnage - Mtr 1 - Brk 1 - Bstp 1 43,2 34,2 70,5 33,6 18,2 34,7 18,2 34,7
LF

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Description:
Pulley 2 34,4 34,4 34,1 34,2 34,7 34,6 34,7 34,6

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Description:
Pulley 3 34,2 34,2 34,0 34,2 34,3 34,2 34,3 34,2

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Description:
Take-up Pulley 34,2 34,2 34,2 34,4 34,2 34,1 34,2 34,1

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Description:
Pulley 5 34,2 34,3 34,4 34,6 34,1 34,1 34,1 34,1

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Description:
Pulley 6 34,6 34,7 34,9 35,1 34,3 34,3 34,3 34,3

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Description:
Tail Pulley 35,3 35,9 37,7 38,4 33,1 33,6 33,1 33,6

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Description:
Operating
OT-N Tonnage - Mtr 1 - Brk 1 - Bstp 1 49,1 33,8 74,1 33,2 18,7 34,4 18,7 34,4
NF

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Description:
Pulley 2 34,4 34,5 34,1 34,3 34,7 34,6 34,7 34,6

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Description:
Pulley 3 34,1 34,2 34,0 34,2 34,3 34,2 34,3 34,2

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Description:
Take-up Pulley 34,2 34,3 34,2 34,4 34,2 34,2 34,2 34,2

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Description:
Pulley 5 34,3 34,5 34,4 34,7 34,1 34,2 34,1 34,2

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Description:
Pulley 6 34,9 35,0 35,1 35,4 34,5 34,6 34,5 34,6

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Description:
Tail Pulley 36,3 37,5 39,0 40,2 33,2 34,2 33,2 34,2

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Description:
Operating
OT-H Tonnage - Mtr 1 - Brk 1 - Bstp 1 58,2 33,1 79,5 32,6 20,5 34,0 20,5 34,0
HF

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Description:
Pulley 2 34,3 34,4 34,1 34,3 34,7 34,7 34,7 34,7

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Description:
Pulley 3 34,1 34,2 34,0 34,2 34,3 34,2 34,3 34,2

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Description:
Take-up Pulley 34,2 34,4 34,2 34,5 34,2 34,2 34,2 34,2

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Description:
Pulley 5 34,4 34,6 34,5 34,8 34,2 34,2 34,2 34,2

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Description:
Pulley 6 35,0 35,3 35,3 35,6 34,6 34,7 34,6 34,7

Tail Pulley 37,9 39,5 40,2 42,0 33,8 35,3 33,8 35,3
Mtr 1 - Brk 1 - Bstp 1 66,7 33,1 88,0 32,9 19,9 34,0 19,9 34,0
Pulley 2 34,3 34,4 34,2 34,4 34,7 34,7 34,7 34,7
PLUGGED Pulley 3 34,1 34,2 34,0 34,2 34,3 34,2 34,3 34,2
FL-H CHUTE - Take-up Pulley 34,2 34,4 34,2 34,5 34,2 34,2 34,2 34,2
HF Pulley 5 34,4 34,6 34,5 34,7 34,2 34,2 34,2 34,2
Pulley 6 35,0 35,3 35,2 35,5 34,6 34,7 34,6 34,7
Tail Pulley 37,8 39,5 39,1 40,9 33,9 35,4 33,9 35,4
Mtr 1 - Brk 1 - Bstp 1 53,0 34,2 73,8 33,5 28,2 35,0 28,2 35,0
Pulley 2 34,4 34,4 34,0 34,2 34,8 34,6 34,8 34,6
Pulley 3 34,2 34,2 34,0 34,2 34,4 34,2 34,4 34,2
Inclines -
IO-L Take-up Pulley 34,2 34,2 34,2 34,4 34,2 34,0 34,2 34,0
LF
Pulley 5 34,2 34,3 34,4 34,7 34,0 33,9 34,0 33,9
Pulley 6 34,6 34,7 35,0 35,2 34,2 34,1 34,2 34,1
Tail Pulley 35,3 35,9 38,3 39,0 31,8 32,2 31,8 32,2
Mtr 1 - Brk 1 - Bstp 1 58,4 33,8 77,6 33,1 28,8 34,8 28,8 34,8
Pulley 2 34,4 34,5 34,1 34,3 34,9 34,7 34,9 34,7
Pulley 3 34,1 34,2 34,0 34,2 34,4 34,2 34,4 34,2
Inclines -
IO-N Take-up Pulley 34,2 34,3 34,2 34,4 34,2 34,1 34,2 34,1
NF
Pulley 5 34,3 34,5 34,5 34,8 34,0 34,0 34,0 34,0
Pulley 6 34,9 35,0 35,2 35,5 34,4 34,3 34,4 34,3
Tail Pulley 36,3 37,5 39,5 40,8 31,5 32,4 31,5 32,4
Mtr 1 - Brk 1 - Bstp 1 67,0 33,1 83,1 32,6 31,4 34,4 31,4 34,4
Pulley 2 34,3 34,4 34,0 34,3 34,9 34,8 34,9 34,8
Pulley 3 34,1 34,2 33,9 34,2 34,4 34,3 34,4 34,3
Inclines -
IO-H Take-up Pulley 34,2 34,4 34,2 34,5 34,2 34,1 34,2 34,1
HF
Pulley 5 34,4 34,6 34,5 34,9 34,1 34,0 34,1 34,0
Pulley 6 35,0 35,3 35,3 35,7 34,4 34,4 34,4 34,4
Tail Pulley 37,8 39,5 40,6 42,4 31,9 33,3 31,9 33,3
Mtr 1 - Brk 1 - Bstp 1 30,6 34,2 58,9 33,4 15,3 34,6 15,3 34,6
Pulley 2 34,4 34,4 34,0 34,2 34,6 34,5 34,6 34,5
Pulley 3 34,2 34,2 34,0 34,2 34,3 34,2 34,3 34,2
Declines -
DO-L Take-up Pulley 34,2 34,2 34,2 34,4 34,2 34,1 34,2 34,1
LF
Pulley 5 34,2 34,3 34,5 34,7 34,1 34,1 34,1 34,1
Pulley 6 34,6 34,7 35,0 35,3 34,4 34,4 34,4 34,4
Tail Pulley 35,3 35,9 38,7 39,5 33,5 34,0 33,5 34,0
Mtr 1 - Brk 1 - Bstp 1 36,0 33,8 62,4 33,0 16,1 34,4 16,1 34,4
Pulley 2 34,4 34,5 34,0 34,2 34,7 34,6 34,7 34,6
Pulley 3 34,1 34,2 33,9 34,2 34,3 34,2 34,3 34,2
Declines -
DO-N Take-up Pulley 34,2 34,3 34,2 34,5 34,2 34,2 34,2 34,2
NF
Pulley 5 34,3 34,5 34,5 34,8 34,2 34,2 34,2 34,2
Pulley 6 34,9 35,0 35,3 35,6 34,6 34,6 34,6 34,6
Tail Pulley 36,3 37,5 40,1 41,4 33,6 34,7 33,6 34,7
Mtr 1 - Brk 1 - Bstp 1 44,6 33,1 68,0 32,4 18,5 33,9 18,5 33,9
Pulley 2 34,3 34,4 34,0 34,2 34,7 34,6 34,7 34,6
Pulley 3 34,1 34,2 33,9 34,2 34,3 34,2 34,3 34,2
Declines -
DO-H Take-up Pulley 34,2 34,4 34,2 34,5 34,2 34,2 34,2 34,2
HF
Pulley 5 34,4 34,6 34,6 34,9 34,2 34,3 34,2 34,3
Pulley 6 35,0 35,3 35,4 35,8 34,7 34,7 34,7 34,7
Tail Pulley 37,9 39,6 41,3 43,1 34,2 35,7 34,2 35,7

Page 62 / 98
Description:
#1 - Motor 1 - Brake 1 - Backstop 1 Design Tensions and Loads

Pulley Location and Geometry 28. Running T1 Tension 51,5 kN
1. Name (Type-1) Motor 1 - Brake 1 - Backstop 1 29. Running T2 Tension 33,8 kN
2. Pulley Diameter 630 mm 30. Design T1 Tension 73,7 kN
3. Face Width 1400 mm 31. Design T2 Tension 36,5 kN
32. Wrap angle 180 deg
33. Design Resultant Tension 111 kN
Lagging
34. Resultant Angle 188 deg
4. Lagging Type Ceramic
35. Resultant Moment 12,5 kN·m
5. Lagging Thickness 12 mm
36. Resultant Torque 12,3 kN·m
6. Diameter with lagging 654 mm
37. Estimated Pulley & Shaft Mass 880 kg
38. Estimated Mass with Bearings 990 kg
Shaft Specification
7. Shaft Center Diameter 140 mm
Shaft Stresses & Deflections
8. Shaft Material C45
39. Shaft slope at hub 6,64 min
9. Yield Strength 360,0 MPa
40. Shaft slope at bearing 8,18 min
10. Fatigue Strength 315,0 MPa
41. Shaft deflection at center 1,07 mm
42. Shaft deflection at center (%) 0,065
Locking Device 43. Shaft Safety Factor (CEMA) 2,84
11. Hub Center Distance 1200 mm 44. Shaft Safety Factor (AS1403) 2,33
12. Shaft diameter at hub 140 mm 45. Bending Stress 46,4 MPa
13. Turndown radius at hub 0 mm 46. Torsional Stress 22,8 MPa
14. Locking Device XT-60 47. Von Mises Stress 61,0 MPa
15. Size 140 x 292 48. Fillet Von Mises Stress 86,7 MPa
16. Hub width 73 mm
17. Hub pressure 0,0 N/mm²
Shell Dimension and Stresses
18. Maximum torque 0 N·m
49. Shell thickness 22 mm
19. Hub outer diameter 292 mm
50. Sitzwohl reqd shell thickness1 10 mm
51. Sitzwohl shell stress 10,1 MPa
Bearing Specifications 52. Shell stress at 180 wa 10,1 MPa
20. Bearing Center Distance 1650 mm 1
Assumes 180 deg wrap and allowable stress of 34,0 MPa
21. Shaft diameter at bearing 115 mm
22. Bearing to Fillet Distance 100 mm End Disk Dimension and Stresses
23. Turndown radius at bearing 38 mm 53. End disk thickness 33 mm
24. Bearing 23226 54. End disk stress 46,6 MPa
25. SNL Plummer Block 526
26. Dynamic Capacity 780 kN
27. Bearing L10 500.000 hours

Page 63 / 98
Description:

#2 - Pulley 2
Pulley Location and Geometry Design Tensions and Loads
1. Name (Type-2) Pulley 2 29. Running T1 Tension 34,4 kN
2. Pulley Diameter 505 mm 30. Running T2 Tension 34,5 kN
32. Design T2 Tension 43,1 kN
Lagging
34. Design Resultant Tension 62,7 kN
4. Lagging Type Rubber
5. Lagging Pattern Plain
Shaft Specification
17. Hub width 60 mm

Page 64 / 98
Description:

#3 - Pulley 3
Lagging
Shaft Specification
17. Hub width 60 mm

Page 65 / 98
Description:

#4 - Take-up Pulley
1. Name (Type-3) Take-up Pulley 29. Running T1 Tension 34,2 kN
Lagging
Shaft Specification
17. Hub width 73 mm

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Description:

#5 - Pulley 5
Lagging
Shaft Specification
17. Hub width 60 mm

Page 67 / 98
Description:

#6 - Pulley 6
Lagging
Shaft Specification
17. Hub width 60 mm

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Description:

#7 - Tail Pulley 28. Bearing L10 500.000 hours
Pulley Location and Geometry
1. Name (Type-5) Tail Pulley Design Tensions and Loads
3. Face Width 1400 mm 30. Running T2 Tension 37,5 kN
Lagging
Shaft Specification 39. Estimated Mass with Bearings 715 kg
Locking Device 43. Shaft deflection at center (%) 0,066
12. Hub Center Distance 1200 mm 44. Shaft Safety Factor (CEMA) 3,48
13. Shaft diameter at hub 130 mm 45. Shaft Safety Factor (AS1403) 3,17
14. Turndown radius at hub 0 mm 46. Bending Stress 45,1 MPa
15. Locking Device XT-60 47. Torsional Stress 1,3 MPa
16. Size 130 x 292 48. Von Mises Stress 45,1 MPa
17. Hub width 73 mm 49. Fillet Von Mises Stress 49,2 MPa
Bearing Specifications 52. Sitzwohl shell stress 12,2 MPa
21. Bearing Center Distance 1600 mm 53. Shell stress at 180 wa 12,1 MPa
22. Shaft diameter at bearing 110 mm 1
23. Bearing to Fillet Distance 98 mm
24. Turndown radius at bearing 30 mm End Disk Dimension and Stresses
25. Bearing 23224 54. End disk thickness 27 mm
26. SNL Plummer Block 524 55. End disk stress 44,7 MPa

Page 69 / 98
Description:
Belt Flap Summary

Belt flap may occur when the natural frequency of the belt matches the rotational frequency of the idlers. If belt flap is
severe, it can destroy the idlers and increase the demand power of the conveyor. Belt flap should be avoided.
The belt flap ratio is defined as the rotational frequency of the idler divided by the natural frequency of the belt. If this ratio
is equal to an integer (i.e. 1, 2, 3) then the idler may induce transverse vibrations at the natural frequency mode and result in
resonance.
The chart below shows the flap ratio along the length of the conveyor. The solid green line shows flap mode of the empty
belt under the normal friction case. The shaded pink areas should be avoided.
*
Belt flap resonance occurs at flap ratios 1, 2, 3, and 4

Page 70 / 98
Description:
Material Trajectory
The image below shows the material trajectory for the fully loaded normal friction case.
Material Trajectory

Page 71 / 98
Description:
Belt Transition Length Requirements

The table below lists the required transition length at head and tail pulleys. Transition lengths are based on the CEMA 7th
Method. The figure below shows the geometry of the inline transition and elevated pulley transition.
Geometry of inline and elevated pulley transition
Required transition lengths

Head pulley transition
Tail pulley transition (m)
(m)
Inline transition (L1) 2,88 3,84
Elevated pulley transition (L2) 1,92 2,40
Pulley elevation (h) 90,309 90,309

Page 72 / 98
Description:
Material 1 on Idler Set 3

Material Loading Profiles
Material Properties
Type tailing
Operating / Design Tonnage 1170 / 1463 t/h
Density 1640 kg/m3
Maximum lump size 1 mm
Surcharge angle 6 deg Tonnage 1170 t/h
Material 1 on Idler Set 3 Belt speed 1,86 m/s
Material mass 174,4 kg/m
Edge distance (required / actual) 89 / 154 mm
Cross sectional loading (utility / total) 73 % / 51 %
Bed depth 184 mm
Tonnage 1463 t/h

Material 1 on Idler Set 1
Belt speed 1,85 m/s
Bed depth 218 mm
Tonnage 1170 t/h

Material 1 on Idler Set 1 Belt speed 1,86 m/s
Bed depth 184 mm
Tonnage 1463 t/h

Empty Idler Set 2
Belt speed 1,85 m/s
Bed depth 218 mm

Page 73 / 98
Description:
Idler Specifications
Idler Specifications
Equal Roll Equal Roll
Type VEE
Trough Trough
Number of rolls 3 2 3
Trough angle (deg) 45 10 45
Roll diameter (mm) 127 127 127
Roll length (mm) 434 648 434
Shaft diameter (mm) 25,0 25,0 25,0
Bearing series C5 C5 C5
Maximum roll RPM 278 278 278
Min Life (1000 hrs) 52 350 149
95% life1 (1000 hrs) 52 350 149
Idler Load (N) 3239,4 616,1 2283,4
Mass (kg) 21,9 20,1 21,9
Rotating mass for set (kg) 17,8 16,4 17,8
Wk2 for set (kg·mm²) 60.576 57.357 60.576
Idler Spacing and Count Summary

General Carry Return Impact
Idler spacing (m) 1,15 3,00 0,35
Number of ıdler sets 202 78 10
Number of rolls 606 156 30
Total drag (N)
Nominal friction 8,0 5,3 8,0
High friction 38,7 24,9 37,3
Low friction 4,9 3,1 4,5
Idler Life and Shaft Deflection Summary-Carry Side

Vertical Radius Idler Spacing Idler Calculated Idler
# Station (m) Length (m) L Life (hours)
(m) (m) Type 10 Load (N)
1 0,0 3,5 1,20 1 350.000 379
2 3,5 1,5 0,35 3 149.144 2.283
3 5,0 7,5 0,50 1 350.000 1.672
4 12,5 2,0 0,35 3 350.000 1.466
5-6 14,5 100,3 1,20 1 52.232 3.239
7-10 114,7 51,0 -450 1,20 1 58.165 3.125
11 165,7 69,4 1,20 1 52.773 3.228
Idler Life and Shaft Deflection Summary-Return Side

Vertical Radius Idler Spacing Idler Calculated Idler
# Station (m) Length (m) L Life (hours)
(m) (m) Type 10 Load (N)
13 235,0 27,0 3,00 2 350.000 613
23 207,0 41,2 3,00 2 350.000 615
24-27 165,9 51,4 -450 3,00 2 350.000 384
28-29 114,5 114,7 3,00 2 350.000 616

Page 74 / 98
Description:
Structural Loads
The live load structural design tensions should be based on the maximum dynamic tensions plus 10% (to account for
misalignment and abnormalities in the belt, pulleys, and structures). Additionally they must include any other external loads
(wind & snow loads, seismic, etc.) that the system will encounter. These forces must then be multiplied by the required live
load structural design safety factor requirements (typically 1.6) to meet the specific structural design codes for the project.
The dead load structural design loads must be calculated from the masses of the pulleys, drives, reducers, and other
components. These loads are not included in this report as they will depend on the specific manufacture selection and other
details. These forces must then be multiplied by the required dead load structural design safety factor requirements (typically
1.2) to meet the specific structural design codes for the project. The live and dead loads are then added together to obtain the
total structural design forces.
The table below includes the belt tensions from all current load cases. Additionally, steady state and dynamic tensions for the
high friction case with 2.582 t/h have also been included. This specific load case results in 97% nameplate motor power,
excluding any reducer losses. The starting torque has been set to 150% for this case. The maximum tension values have been
multiplied by 110% and the pulley shaft calculations shown in the table reflect these values. The minimum tensions have
been reduced by 10%. The resultant force values include the vertical weight of the pulley.
Structural Live Loads - Includes case with 2.582 t/h under steady state and dynamic conditions + 110% multiplier
Shaft Shaft Shaft Minimum Tensions (kN) Maximum Tensions (kN)
Wrap Hub stress Center
(deg) Slope safety Def. T1 T2 T1 T2
Force Force
(min) factor (mm)
Motor 1 - Brake
1 180 8,82 2,12 1,42 13,7 29,2 44,4 108 38,5 148
1 - Backstop 1
Pulley 2 2 86 5,53 4,41 0,84 30,430,7 45,7 38,438,2 56,2
Pulley 3 2 90 4,88 4,88 0,74 30,430,7 39,5 37,837,7 49,6
Take-up Pulley 3 180 5,42 3,94 0,82 30,830,6 61,7 37,638,0 75,9
Pulley 5 4 90 4,96 4,83 0,75 30,630,5 39,5 38,138,6 50,4
Pulley 6 4 94 6,07 4,03 0,92 30,730,7 49,2 39,139,6 61,7
Tail Pulley 5 180 6,83 3,49 1,04 28,128,9 57,6 46,848,3 95,6
Bearing Reaction Forces (excluding any overhung loads)

Entry Exiting Pulley, Bearing Horizontal Direction (kN) Bearing Vertical Direction (kN)
Wrap Vector Vector Shaft & Structural Structural Structural Structural
Pulley FL-N FL-N
(deg) Angle Angle Bearings Min Max Min Max
Case Case
(deg) (deg) Mass (kg) Tension Tension Tension Tension
Motor 1 - Brake
180 184 184 990 -42,8 -85,0 -146 -12,7 -15,6 -19,9
1 - Backstop 1
Pulley 2 86 4 270 647 30,3 34,3 38,3 -34,9 -38,4 -41,9
Pulley 3 90 90 0 647 30,7 34,2 37,7 24,1 27,8 31,5
Take-up Pulley 180 180 180 715 -61,4 -68,5 -75,7 -7,01 -7,01 -7,01
Pulley 5 90 0 90 647 30,6 34,3 38,1 24,2 28,1 32,2
Pulley 6 94 270 184 647 -30,6 -34,9 -39,5 -39,2 -43,7 -48,2
Tail Pulley 180 357 358 715 56,9 73,7 95,0 -9,52 -10,3 -11,2
The idler stringer loading should be based on the flooded belt surge capacity of 2.254 t/h and 358,2 kg/m plus the idler and
frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
Description:
12. Hopper Shape Factor 1,0

Load Case # 8 - Loading Point # 1
Calculation Method Arnold / McLean Bin - Area Above Hopper
13. Material Height in Bin 0,00 m
14. Bin Shape Factor 1,0
15. Material Surcharge Height in Bin 0,00 m
16. Surcharge Shape Factor 1,0
Other Forces
17. Drag Forces - Slot 2.053 N
18. Drag Forces - External 44 N
19. Sliderbed Drag Forces 0N
20. Material Acceleration 738 N
Pullout Forces
21. Surcharge Factor (qf) 0,24
22. Vertical Load 1.982 N
Total Drag 23. Material Shear Force 1.019 N
1. Steady State 3.854 N
2. Starting 7.404 N Startup Forces
24. Surcharge Factor (qi) 1,08
Dimensions 25. qi/qf 4,48
3. Slot Length 1,20 m 26. Vertical Load 8.884 N
4. Slot Width at Front 0,80 m 27. Material Shear Force 4.569 N
5. Slot Width at Rear 0,80 m
6. Exit Length 0,30 m Calculation Data
7. Material Depth on Skirtboards 0 mm 28. Shear Coefficient (u) 0,514
29. hc 0,00 m
Hopper 30. Qc/Ac 0 Pa
8. Hopper Width 1,60 m
9. Hopper Length 1,20 m
10. Hopper Half Angle 20,0 deg
11. Hopper Wall Friction Angle 30,0 deg
31. Beta 40,5 deg

32. X - Factor 13,93 deg
33. Y - Factor 3,56 deg

Page 76 / 98
Description:
12. Hopper Shape Factor 1,0

Load Case # 8 - Loading Point # 2
Calculation Method Arnold / McLean Bin - Area Above Hopper
13. Material Height in Bin 0,00 m
14. Bin Shape Factor 1,0
15. Material Surcharge Height in Bin 0,00 m
16. Surcharge Shape Factor 1,0
Other Forces
17. Drag Forces - Slot 2.053 N
18. Drag Forces - External 117 N
19. Sliderbed Drag Forces 0N
20. Material Acceleration 0N
Pullout Forces
21. Surcharge Factor (qf) 0,24
22. Vertical Load 1.982 N
Total Drag 23. Material Shear Force 1.019 N
1. Steady State 3.190 N
2. Starting 6.739 N Startup Forces
24. Surcharge Factor (qi) 1,08
Dimensions 25. qi/qf 4,48
3. Slot Length 1,20 m 26. Vertical Load 8.884 N
4. Slot Width at Front 0,80 m 27. Material Shear Force 4.569 N
5. Slot Width at Rear 0,80 m
6. Exit Length 0,80 m Calculation Data
7. Material Depth on Skirtboards 0 mm 28. Shear Coefficient (u) 0,514
29. hc 0,00 m
Hopper 30. Qc/Ac 0 Pa
8. Hopper Width 1,60 m
9. Hopper Length 1,20 m
10. Hopper Half Angle 20,0 deg
11. Hopper Wall Friction Angle 30,0 deg
31. Beta 40,5 deg

32. X - Factor 13,93 deg
33. Y - Factor 3,56 deg

Page 77 / 98
Description:
Element Summary Details
Tension Summary
Power Summary

Page 78 / 98
Description:
Vertical Curve Summary

Summary of Vertical Curve on Carry Strand
Running Tension Momentary Tension
Elements Station (m) Type Radius (m) Req'd Radius Req'd Radius
Reason Reason
(m) (m)
7-11 115 - 166 concave -450 -282 Lift Off -408 Lift Off
Summary of Vertical Curve on Return Strand

Running Tension Momentary Tension
Elements Station (m) Type Radius (m) Req'd Radius Req'd Radius
Reason Reason
(m) (m)
24-28 115 - 166 concave -450 -260 Lift Off -269 Lift Off

Page 79 / 98
Description:
Element Summary Details

Summary of Conveyor Elements
Vertical Idler
Station Elevation Length Height Slope Idler
# Name Radius Spacing
(m) (m) (m) (m) (deg) Type
(m) (m)
1 0,0 0,00 3,5 -0,15 -2,50 1,20 1
2 Loading Point 3,5 -0,15 1,5 -0,07 -2,50 0,35 3
3 Skirtboards Only 5,0 -0,22 7,5 -0,33 -2,50 0,50 1
4 Loading Point 12,5 -0,54 2,0 -0,09 -2,50 0,35 3
5 14,5 -0,63 50,2 -2,18 -2,50 1,20 1
6 64,6 -2,82 50,2 -2,18 -2,50 1,20 1
7 114,7 -5,00 12,8 -0,37 -1,68 -450 1,20 1
8 127,5 -5,38 12,8 -0,01 -0,06 -450 1,20 1
9 140,2 -5,39 12,8 0,35 1,56 -450 1,20 1
10 153,0 -5,04 12,8 0,71 3,19 -450 1,20 1
11 165,7 -4,33 69,4 4,84 4,00 1,20 1
Motor 1 - Brake 1 -
12 235,0 0,51 0,7 -0,65 ---
Backstop 1
13 235,0 -0,14 27,0 -1,88 -3,99 3,00 2
14 Pulley 2 208,1 -2,03 0,4 -0,26 ---
15 207,8 -2,29 1,7 -1,72 -90,00
16 Pulley 3 207,8 -4,01 0,4 -0,26 ---
17 208,1 -4,28 2,5 0,00 0,00
18 Take-up Pulley 210,6 -4,28 0,5 -0,53 ---
19 210,6 -4,80 3,0 0,00 0,00
20 Pulley 5 207,6 -4,80 0,4 0,26 ---
21 207,3 -4,54 2,2 2,16 90,00
22 Pulley 6 207,3 -2,38 0,4 0,26 ---
23 207,0 -2,12 41,2 -2,87 -3,99 3,00 2
24 165,9 -4,99 12,8 -0,71 -3,17 -450 3,00 2
25 153,1 -5,70 12,8 -0,34 -1,54 -450 3,00 2
26 140,2 -6,04 12,8 0,02 0,10 -450 3,00 2
27 127,4 -6,02 12,8 0,39 1,73 -450 3,00 2
28 114,5 -5,63 57,3 2,55 2,55 3,00 2
29 57,3 -3,08 57,3 2,55 2,55 3,00 2
30 Tail Pulley 0,0 -0,53 0,5 0,53 ---

Page 80 / 98
Description:
Min/Max Tension Summary per Element

Element Tension (kN)
Running Momentary
# Name
Maximum Minimum %Sag Maximum Minimum %Sag
1 39,6 35,9 0,08 44,0 32,1 0,09
2 Loading Point 40,9 36,3 0,27 44,9 32,5 0,29
3 Skirtboards Only 44,9 36,4 0,38 49,9 32,5 0,41
4 Loading Point 46,1 37,3 0,27 51,6 32,8 0,30
5 49,5 37,3 0,91 58,6 32,9 1,03
6 47,6 33,5 1,02 59,5 23,9 1,43
7 46,0 29,8 1,15 60,3 14,7 2,31
8 46,3 29,2 1,17 61,4 12,8 2,66
9 46,7 29,4 1,16 62,5 11,7 2,91
10 48,4 29,5 1,11 64,8 11,5 2,97
11 50,9 29,6 1,05 68,1 12,0 2,84
Motor 1 - Brake 1
12 67,0 30,6 0,00 88,0 15,3 0,00
- Backstop 1
13 34,2 33,1 0,23 35,0 32,4 0,23
14 Pulley 2 34,4 34,3 0,00 34,9 33,8 0,00
15 34,5 34,4 0,00 34,8 34,1 0,00
16 Pulley 3 34,2 34,1 0,00 34,4 33,8 0,00
17 34,2 34,2 0,00 34,3 34,1 0,00
18 Take-up Pulley 34,2 34,2 0,00 34,2 34,2 0,00
19 34,4 34,2 0,00 34,6 34,0 0,00
20 Pulley 5 34,4 34,2 0,00 34,6 34,0 0,00
21 34,6 34,3 0,00 35,1 33,9 0,00
22 Pulley 6 35,0 34,6 0,00 35,5 34,2 0,00
23 35,3 34,7 0,21 36,0 34,1 0,22
24 35,2 34,4 0,21 36,7 33,1 0,23
25 35,2 34,3 0,21 36,9 32,7 0,23
26 35,2 34,3 0,21 37,3 32,4 0,23
27 35,4 34,3 0,21 37,7 32,2 0,23
28 35,6 34,4 0,21 38,1 32,1 0,23
29 36,7 34,8 0,20 40,3 31,7 0,23
30 Tail Pulley 37,9 35,3 0,00 42,5 31,2 0,00

Page 81 / 98
Description:
Te Tension Summary per Load Cases

Belt Tension Summary per Load Case (N) - Part 1 / 3
EM-N FL-N FL-L FL-H OT-L OT-N
Total (Beltline) 9.194 17.562 10.908 27.723 8.925 15.162
Total (Power) 14.151 22.763 14.022 35.270 11.997 20.293
Lift Force 0 1.427 1.416 1.444 1.130 1.139

Frictional Drag 9.194 16.135 9.492 26.280 7.794 14.023
Motor Pulley/Reducer Drag 4.956 5.201 3.114 7.547 3.073 5.131
Rolling Resistance 465 4.053 2.215 6.004 1.707 3.163

Material+Belt Flexure 0 1.905 1.931 1.829 1.049 1.036
Idler Bearing Drag 3.747 4.023 1.362 10.120 1.334 3.968
Idler Alignment 59 400 380 408 312 331
Pulleys & Accessories 3.959 3.959 1.976 5.952 1.976 3.959
Loading Point 964 1.796 1.629 1.967 1.417 1.565
Mechanical Losses 2.665 2.885 1.965 4.032 1.927 2.822

Motor Pulley Drag Components 2.292 2.316 1.149 3.515 1.146 2.309

OT-H FL-H IO-L IO-N IO-H DO-L
Total (Beltline) 24.906 33.466 18.748 24.486 33.743 -3.696
Total (Power) 32.347 41.230 22.025 29.889 41.517 -885
Lift Force 1.151 1.451 12.726 12.817 12.952 -11.032

Frictional Drag 23.754 32.014 6.022 11.669 20.791 7.336
Motor Pulley/Reducer Drag 7.441 7.764 3.277 5.404 7.775 2.811
Rolling Resistance 4.717 6.038 1.036 1.967 2.973 1.239

Material+Belt Flexure 991 1.740 744 738 708 970
Idler Bearing Drag 10.043 10.098 1.273 3.841 9.836 1.302
Idler Alignment 338 410 181 200 206 220
Pulleys & Accessories 5.952 5.952 1.976 3.959 5.952 1.976
Loading Point 1.712 7.776 811 964 1.117 1.628
Mechanical Losses 3.938 4.224 2.116 3.067 4.233 1.683

Motor Pulley Drag Components 3.503 3.541 1.161 2.336 3.542 1.128

Page 82 / 98
Description:

DO-N DO-H
Total (Beltline) 2.083 11.347
Total (Power) 6.831 18.275
Lift Force -11.109 -11.225

Frictional Drag 13.192 22.572
Motor Pulley/Reducer Drag 4.748 6.928
Rolling Resistance 2.327 3.497

Material+Belt Flexure 963 934
Idler Bearing Drag 3.912 9.984
Idler Alignment 239 245
Pulleys & Accessories 3.959 5.952
Loading Point 1.792 1.960
Mechanical Losses 2.477 3.485

Motor Pulley Drag Components 2.271 3.443

Page 83 / 98
Description:
Pulley Summary Table - All Cases

Pulley Geometry Details
Type 1 2 3 4 5
Lagging Type Ceramic Rubber Rubber Rubber Rubber
Diameter (mm) 630 505 505 505 505
Lagging Thickness (mm) 12,0 12,0 12,0 12,0 12,0
Diameter with Lagging (mm) 654 529 529 529 529
Face Width (mm) 1400 1400 1400 1400 1400
Shaft Center Diameter (mm) 140 120 130 120 130
Bearing Diameter (mm) 115 100 110 100 110
Bearing Center Distance (mm) 1650 1600 1600 1600 1600
Plummer Block 526 522 524 522 524
Pulley & Shaft Mass (kg) 880 571 617 571 617
Locking Device XT-60 XT-50 XT-60 XT-50 XT-60
Hub Center Distance (mm) 1200 1200 1200 1200 1200
Hub Diameter (mm) 140 120 130 120 130
Bearing to Fillet Distance (mm) 100 93 98 93 98
Fillet Radius (mm) 38 30 30 30 30
Shaft Material C45 C45 C45 C45 C45
Yield Strength (MPa) 360,0 360,0 360,0 360,0 360,0
Fatigue Strength (MPa) 315,0 315,0 315,0 315,0 315,0

Page 84 / 98
Description:
Element Tension Details per Case
Element Tension Breakdown - (EM) Empty - Normal

Individual drag components per element
Running Running Element Pulley Feeder Extra
Wm+Wb Lift Belt Idler
# Tension Ten Diff Tonnage Drag Pt. Force Accessory
(kg/m) Force (N) Force (N) Force (N)
(N) (N) (t/h) Force (N) (N) Force (N)
1 37.468 855 18,9 -28 2 42 840
2 38.323 255 18,9 -12 1 60 131 75
3 38.578 1.212 18,9 -61 3 212 657 400
4 39.790 340 18,9 -16 1 81 175 100
5 40.130 220 18,9 -406 28 597
6 40.350 220 18,9 -406 28 597
7 40.570 89 18,9 -70 7 152
8 40.660 156 18,9 -2 7 152
9 40.816 224 18,9 65 7 152
10 41.040 291 18,9 132 7 152
11 41.330 1.764 18,9 899 39 826
12 - M 43.094 -9.315 18,9 -121 192 2.100
13 33.779 620 18,9 -349 39 90 840
14 - P 34.399 59 18,9 -49 108
15 34.457 -320 18,9 -320
16 - P 34.138 62 18,9 -49 112
17 34.200 0 18,9
18 - T 34.200 104 18,9 -98 202
19 34.304 0 18,9
20 - P 34.304 161 18,9 49 112
21 34.465 400 18,9 400
22 - P 34.865 167 18,9 49 118
23 35.032 -336 18,9 -533 59 138
24 34.697 -71 18,9 -132 18 43
25 34.626 -3 18,9 -64 18 43
26 34.623 65 18,9 4 18 43
27 34.689 133 18,9 72 18 43
28 34.822 747 18,9 474 82 192
29 35.569 747 18,9 474 82 192
30 - P 36.316 1.151 18,9 98 213 840

Page 85 / 98
Description:
Element Tension Breakdown - (FL) Fully Loaded - Normal

1 37.465 855 18,9 -28 2 42 840
2 38.320 895 1.463 239,1 -153 16 64 892 75
3 39.215 670 1.463 239,1 -766 92 232 713 400
4 39.885 192 1.463 239,1 -204 21 86 190 100
5 40.078 -3.142 1.463 239,1 -5.122 1.248 731
6 36.935 -3.125 1.463 239,1 -5.122 1.266 731
7 33.811 -368 1.463 239,1 -879 324 186
8 33.442 479 1.463 239,1 -32 324 186
9 33.921 1.324 1.463 239,1 816 323 186
10 35.245 2.168 1.463 239,1 1.662 320 186
11 37.414 14.049 1.463 239,1 11.351 1.686 1.012
12 - M 51.462 -17.683 18,9 -121 216 2.100
13 33.779 619 18,9 -349 39 90 840
14 - P 34.399 59 18,9 -49 108
15 34.457 -320 18,9 -320
16 - P 34.138 62 18,9 -49 112
17 34.200 0 18,9
18 - T 34.200 104 18,9 -98 202
19 34.304 0 18,9
20 - P 34.304 161 18,9 49 112
21 34.465 400 18,9 400
22 - P 34.865 167 18,9 49 118
23 35.032 -336 18,9 -533 59 137
24 34.696 -71 18,9 -132 18 43
25 34.625 -3 18,9 -64 18 43
26 34.622 65 18,9 4 18 43
27 34.688 133 18,9 72 18 43
28 34.821 747 18,9 474 82 191
29 35.567 747 18,9 474 82 191
30 - P 36.314 1.151 18,9 98 213 840

Page 86 / 98
Description:
Element Tension Breakdown - (FL) Fully Loaded - Low

1 35.860 414 13,5 -20 1 14 420
2 36.275 747 1.463 231,9 -149 9 23 827 38
3 37.022 302 1.463 231,9 -743 53 85 707 200
4 37.324 -12 1.463 231,9 -198 12 30 94 50
5 37.312 -3.780 1.463 231,9 -4.967 887 301
6 33.532 -3.757 1.463 231,9 -4.967 910 301
7 29.775 -541 1.463 231,9 -852 235 76
8 29.235 281 1.463 231,9 -31 235 76
9 29.515 1.101 1.463 231,9 791 234 76
10 30.617 1.920 1.463 231,9 1.612 231 76
11 32.537 12.627 1.463 231,9 11.009 1.202 416
12 - M 45.163 -10.994 13,5 -86 99 1.050
13 34.169 218 13,5 -248 16 31 420
14 - P 34.387 19 13,5 -35 54
15 34.406 -227 13,5 -227
16 - P 34.179 21 13,5 -35 56
17 34.200 0 13,5
18 - T 34.200 31 13,5 -70 101
19 34.231 0 13,5
20 - P 34.231 91 13,5 35 56
21 34.322 285 13,5 285
22 - P 34.607 93 13,5 35 59
23 34.700 -308 13,5 -379 24 47
24 34.393 -72 13,5 -94 7 15
25 34.321 -23 13,5 -45 7 15
26 34.297 25 13,5 3 7 15
27 34.322 73 13,5 51 7 15
28 34.396 435 13,5 337 33 65
29 34.831 435 13,5 337 33 65
30 - P 35.267 594 13,5 70 104 420

Page 87 / 98
Description:
Element Tension Breakdown - (FL) Fully Loaded - High

1 39.547 1.340 20,4 -30 3 107 1.260
2 40.887 1.100 1.463 243,0 -156 23 162 958 113
3 41.987 1.250 1.463 243,0 -779 134 574 721 600
4 43.237 477 1.463 243,0 -208 31 215 288 150
5 43.714 -1.886 1.463 243,0 -5.206 1.615 1.705
6 41.828 -1.877 1.463 243,0 -5.206 1.624 1.705
7 39.951 -45 1.463 243,0 -893 414 433
8 39.906 815 1.463 243,0 -32 414 433
9 40.721 1.674 1.463 243,0 829 412 433
10 42.395 2.532 1.463 243,0 1.689 409 433
11 44.927 16.069 1.463 243,0 11.538 2.171 2.360
12 - M 60.997 -27.854 20,4 -130 365 3.150
13 33.143 1.178 20,4 -376 67 227 1.260
14 - P 34.321 109 20,4 -53 161
15 34.430 -344 20,4 -344
16 - P 34.086 114 20,4 -53 167
17 34.200 0 20,4
18 - T 34.200 198 20,4 -106 303
19 34.398 0 20,4
20 - P 34.398 221 20,4 53 168
21 34.619 431 20,4 431
22 - P 35.050 231 20,4 53 178
23 35.280 -125 20,4 -573 102 346
24 35.155 -2 20,4 -142 32 108
25 35.153 71 20,4 -69 32 108
26 35.224 144 20,4 4 32 108
27 35.368 217 20,4 78 32 108
28 35.585 1.133 20,4 510 142 481
29 36.718 1.133 20,4 510 142 481
30 - P 37.851 1.697 20,4 106 331 1.260

Page 88 / 98
Description:
Element Tension Breakdown - (OT) Operating Tonnage - Low

1 35.860 414 13,5 -20 1 14 420
2 36.275 618 1.170 187,8 -120 7 22 672 38
3 36.892 376 1.170 187,8 -602 39 82 657 200
4 37.269 16 1.170 187,8 -161 9 30 88 50
5 37.284 -3.165 1.170 187,8 -4.023 579 280
6 34.120 -3.153 1.170 187,8 -4.023 590 280
7 30.966 -467 1.170 187,8 -690 152 71
8 30.499 198 1.170 187,8 -25 152 71
9 30.697 863 1.170 187,8 641 151 71
10 31.560 1.527 1.170 187,8 1.305 150 71
11 33.087 10.092 1.170 187,8 8.916 790 387
12 - M 43.180 -9.011 13,5 -86 96 1.050
13 34.169 218 13,5 -248 16 31 420
14 - P 34.387 19 13,5 -35 54
15 34.406 -227 13,5 -227
16 - P 34.179 21 13,5 -35 56
17 34.200 0 13,5
18 - T 34.200 31 13,5 -70 101
19 34.231 0 13,5
20 - P 34.231 91 13,5 35 56
21 34.322 285 13,5 285
22 - P 34.607 93 13,5 35 59
23 34.700 -308 13,5 -379 24 47
24 34.393 -72 13,5 -94 7 15
25 34.321 -23 13,5 -45 7 15
26 34.298 25 13,5 3 7 15
27 34.323 73 13,5 51 7 15
28 34.396 436 13,5 337 33 65
29 34.831 436 13,5 337 33 65
30 - P 35.267 594 13,5 70 104 420

Page 89 / 98
Description:
Element Tension Breakdown - (OT) Operating Tonnage - Normal

1 37.466 855 18,9 -28 2 42 840
2 38.321 759 1.170 194,6 -125 12 64 733 75
3 39.080 731 1.170 194,6 -624 70 228 657 400
4 39.810 210 1.170 194,6 -166 16 85 175 100
5 40.020 -2.609 1.170 194,6 -4.168 856 704
6 37.412 -2.600 1.170 194,6 -4.168 864 704
7 34.812 -315 1.170 194,6 -715 221 179
8 34.497 374 1.170 194,6 -26 221 179
9 34.871 1.063 1.170 194,6 664 220 179
10 35.934 1.751 1.170 194,6 1.353 219 179
11 37.685 11.377 1.170 194,6 9.238 1.164 975
12 - M 49.062 -15.283 18,9 -121 209 2.100
13 33.779 620 18,9 -349 39 90 840
14 - P 34.399 59 18,9 -49 108
15 34.457 -320 18,9 -320
16 - P 34.138 62 18,9 -49 112
17 34.200 0 18,9
18 - T 34.200 104 18,9 -98 202
19 34.304 0 18,9
20 - P 34.304 161 18,9 49 112
21 34.465 400 18,9 400
22 - P 34.865 167 18,9 49 118
23 35.032 -336 18,9 -533 59 138
24 34.696 -71 18,9 -132 18 43
25 34.625 -3 18,9 -64 18 43
26 34.623 65 18,9 4 18 43
27 34.688 133 18,9 72 18 43
28 34.821 747 18,9 474 82 191
29 35.568 747 18,9 474 82 191
30 - P 36.315 1.151 18,9 98 213 840

Page 90 / 98
Description:
Element Tension Breakdown - (OT) Operating Tonnage - High

1 39.550 1.340 20,4 -30 3 107 1.260
2 40.890 956 1.170 197,9 -127 18 161 792 113
3 41.846 1.294 1.170 197,9 -635 102 569 657 600
4 43.140 482 1.170 197,9 -169 24 214 263 150
5 43.621 -1.430 1.170 197,9 -4.241 1.138 1.673
6 42.191 -1.426 1.170 197,9 -4.241 1.142 1.673
7 40.765 -11 1.170 197,9 -727 291 425
8 40.754 690 1.170 197,9 -26 291 425
9 41.444 1.390 1.170 197,9 675 290 425
10 42.834 2.090 1.170 197,9 1.376 288 425
11 44.924 13.255 1.170 197,9 9.398 1.542 2.315
12 - M 58.179 -25.036 20,4 -130 353 3.150
13 33.143 1.178 20,4 -376 67 227 1.260
14 - P 34.321 109 20,4 -53 161
15 34.430 -344 20,4 -344
16 - P 34.086 114 20,4 -53 167
17 34.200 0 20,4
18 - T 34.200 198 20,4 -106 303
19 34.398 0 20,4
20 - P 34.398 221 20,4 53 168
21 34.619 431 20,4 431
22 - P 35.050 231 20,4 53 178
23 35.280 -125 20,4 -573 102 346
24 35.156 -2 20,4 -142 32 108
25 35.154 71 20,4 -69 32 108
26 35.224 144 20,4 4 32 108
27 35.368 217 20,4 78 32 108
28 35.586 1.133 20,4 510 142 482
29 36.719 1.133 20,4 510 142 482
30 - P 37.853 1.697 20,4 106 331 1.260

Page 91 / 98
Description:
Element Tension Breakdown - (FL) PLUGGED CHUTE - High

1 39.543 1.340 20,4 -30 3 107 1.260
2 40.883 3.995 1.463 244,2 -157 24 161 3.854 113
3 44.878 1.257 1.463 244,2 -783 135 572 732 600
4 46.134 3.377 1.463 244,2 -209 31 215 3.190 150
5 49.511 -1.929 1.463 244,2 -5.232 1.601 1.702
6 47.583 -1.920 1.463 244,2 -5.232 1.610 1.702
7 45.662 -54 1.463 244,2 -898 410 433
8 45.608 810 1.463 244,2 -32 410 433
9 46.418 1.674 1.463 244,2 833 408 433
10 48.093 2.537 1.463 244,2 1.698 406 433
11 50.629 16.111 1.463 244,2 11.595 2.160 2.356
12 - M 66.740 -33.596 20,4 -130 391 3.150
13 33.144 1.177 20,4 -376 67 226 1.260
14 - P 34.321 109 20,4 -53 161
15 34.430 -344 20,4 -344
16 - P 34.086 114 20,4 -53 167
17 34.200 0 20,4
18 - T 34.200 198 20,4 -106 303
19 34.398 0 20,4
20 - P 34.398 221 20,4 53 168
21 34.619 431 20,4 431
22 - P 35.050 231 20,4 53 178
23 35.280 -126 20,4 -573 102 345
24 35.155 -3 20,4 -142 32 107
25 35.152 70 20,4 -69 32 107
26 35.222 144 20,4 4 32 107
27 35.366 217 20,4 78 32 107
28 35.583 1.132 20,4 510 142 480
29 36.715 1.132 20,4 510 142 480
30 - P 37.846 1.697 20,4 106 331 1.260

Page 92 / 98
Description:
Element Tension Breakdown - (IO) Inclines Only - Low

1 35.860 414 13,5 -20 1 14 420
2 36.274 114 13,5 -9 0 20 66 38
3 36.388 884 13,5 -43 1 69 657 200
4 37.272 153 13,5 -12 0 26 88 50
5 37.425 -82 13,5 -288 10 196
6 37.343 -82 13,5 -288 10 196
7 37.261 3 13,5 -49 3 50
8 37.264 51 13,5 -2 3 50
9 37.314 1.098 1.463 233,5 796 225 76
10 38.413 1.923 1.463 233,5 1.623 223 76
11 40.335 12.668 1.463 233,5 11.085 1.167 416
12 - M 53.003 -18.834 13,5 -86 111 1.050
13 34.169 218 13,5 -248 16 31 420
14 - P 34.387 19 13,5 -35 54
15 34.406 -227 13,5 -227
16 - P 34.179 21 13,5 -35 56
17 34.200 0 13,5
18 - T 34.200 31 13,5 -70 101
19 34.231 0 13,5
20 - P 34.231 91 13,5 35 56
21 34.322 285 13,5 285
22 - P 34.607 93 13,5 35 59
23 34.700 -308 13,5 -379 24 47
24 34.392 -72 13,5 -94 7 15
25 34.321 -23 13,5 -45 7 15
26 34.297 25 13,5 3 7 15
27 34.322 73 13,5 51 7 15
28 34.395 435 13,5 337 33 65
29 34.831 435 13,5 337 33 65
30 - P 35.266 594 13,5 70 104 420

Page 93 / 98
Description:
Element Tension Breakdown - (IO) Inclines Only - Normal

1 37.463 855 18,9 -28 2 41 840
2 38.318 255 18,9 -12 1 60 131 75
3 38.573 1.210 18,9 -61 3 211 657 400
4 39.783 340 18,9 -16 1 80 175 100
5 40.123 216 18,9 -406 28 593
6 40.339 216 18,9 -406 28 593
7 40.555 88 18,9 -70 7 151
8 40.643 155 18,9 -2 7 151
9 40.799 1.323 1.463 240,5 820 317 186
10 42.122 2.172 1.463 240,5 1.672 315 186
11 44.294 14.092 1.463 240,5 11.419 1.663 1.011
12 - M 58.386 -24.607 18,9 -121 236 2.100
13 33.779 619 18,9 -349 38 90 840
14 - P 34.399 59 18,9 -49 108
15 34.457 -320 18,9 -320
16 - P 34.138 62 18,9 -49 112
17 34.200 0 18,9
18 - T 34.200 104 18,9 -98 202
19 34.304 0 18,9
20 - P 34.304 161 18,9 49 112
21 34.465 400 18,9 400
22 - P 34.865 167 18,9 49 118
23 35.032 -337 18,9 -533 59 137
24 34.696 -71 18,9 -132 18 43
25 34.625 -3 18,9 -64 18 43
26 34.622 65 18,9 4 18 43
27 34.687 133 18,9 72 18 43
28 34.820 746 18,9 474 82 191
29 35.566 746 18,9 474 82 191
30 - P 36.312 1.151 18,9 98 213 840

Page 94 / 98
Description:
Element Tension Breakdown - (IO) Inclines Only - High

1 39.543 1.340 20,4 -30 3 107 1.260
2 40.883 454 20,4 -13 1 156 197 113
3 41.336 1.744 20,4 -65 5 547 657 600
4 43.080 605 20,4 -17 1 208 263 150
5 43.685 1.141 20,4 -436 46 1.531
6 44.826 1.141 20,4 -436 46 1.531
7 45.967 326 20,4 -75 12 389
8 46.294 398 20,4 -3 12 389
9 46.692 1.674 1.463 244,3 833 408 433
10 48.366 2.537 1.463 244,3 1.698 406 433
11 50.903 16.113 1.463 244,3 11.598 2.159 2.356
12 - M 67.017 -33.873 20,4 -130 392 3.150
13 33.144 1.177 20,4 -376 67 226 1.260
14 - P 34.321 109 20,4 -53 161
15 34.430 -344 20,4 -344
16 - P 34.086 114 20,4 -53 167
17 34.200 0 20,4
18 - T 34.200 198 20,4 -106 303
19 34.398 0 20,4
20 - P 34.398 221 20,4 53 168
21 34.619 431 20,4 431
22 - P 35.050 231 20,4 53 178
23 35.280 -126 20,4 -573 102 345
24 35.154 -3 20,4 -142 32 107
25 35.152 70 20,4 -69 32 107
26 35.222 144 20,4 4 32 107
27 35.366 217 20,4 78 32 107
28 35.583 1.132 20,4 510 142 480
29 36.714 1.132 20,4 510 142 480
30 - P 37.846 1.697 20,4 106 331 1.260

Page 95 / 98
Description:
Element Tension Breakdown - (DO) Declines Only - Low

1 35.862 414 13,5 -20 1 14 420
2 36.276 759 1.463 228,8 -147 9 23 837 38
3 37.035 302 1.463 228,8 -734 52 85 699 200
4 37.337 -10 1.463 228,8 -196 12 31 93 50
5 37.327 -3.738 1.463 228,8 -4.902 863 300
6 33.589 -3.717 1.463 228,8 -4.902 885 300
7 29.872 -536 1.463 228,8 -841 228 76
8 29.336 51 13,5 -2 3 50
9 29.387 99 13,5 46 3 50
10 29.486 146 13,5 94 3 50
11 29.632 927 13,5 639 14 274
12 - M 30.559 3.610 13,5 -86 78 1.050
13 34.169 218 13,5 -248 16 31 420
14 - P 34.387 19 13,5 -35 54
15 34.406 -227 13,5 -227
16 - P 34.179 21 13,5 -35 56
17 34.200 0 13,5
18 - T 34.200 31 13,5 -70 101
19 34.231 0 13,5
20 - P 34.231 91 13,5 35 56
21 34.322 285 13,5 285
22 - P 34.607 93 13,5 35 59
23 34.700 -307 13,5 -379 24 47
24 34.393 -72 13,5 -94 7 15
25 34.321 -23 13,5 -45 7 15
26 34.298 25 13,5 3 7 15
27 34.323 73 13,5 51 7 15
28 34.396 436 13,5 337 33 66
29 34.832 436 13,5 337 33 66
30 - P 35.268 594 13,5 70 104 420

Page 96 / 98
Description:
Element Tension Breakdown - (DO) Declines Only - Normal

1 37.470 855 18,9 -28 2 42 840
2 38.325 906 1.463 235,8 -151 16 65 902 75
3 39.231 670 1.463 235,8 -756 91 233 703 400
4 39.902 193 1.463 235,8 -202 21 86 187 100
5 40.094 -3.102 1.463 235,8 -5.052 1.217 733
6 36.993 -3.085 1.463 235,8 -5.052 1.233 733
7 33.908 -364 1.463 235,8 -867 316 186
8 33.544 157 18,9 -2 7 152
9 33.701 224 18,9 65 7 152
10 33.925 291 18,9 132 7 152
11 34.216 1.767 18,9 899 39 829
12 - M 35.982 -2.204 18,9 -121 171 2.100
13 33.779 620 18,9 -349 39 91 840
14 - P 34.399 59 18,9 -49 108
15 34.457 -320 18,9 -320
16 - P 34.138 62 18,9 -49 112
17 34.200 0 18,9
18 - T 34.200 104 18,9 -98 202
19 34.304 0 18,9
20 - P 34.304 161 18,9 49 112
21 34.465 400 18,9 400
22 - P 34.865 167 18,9 49 118
23 35.032 -335 18,9 -533 59 138
24 34.697 -71 18,9 -132 18 43
25 34.627 -3 18,9 -64 18 43
26 34.624 65 18,9 4 18 43
27 34.689 134 18,9 72 18 43
28 34.823 748 18,9 474 82 192
29 35.571 748 18,9 474 82 192
30 - P 36.319 1.151 18,9 98 213 840

Page 97 / 98
Description:
Element Tension Breakdown - (DO) Declines Only - High

1 39.560 1.341 20,4 -30 3 108 1.260
2 40.901 1.111 1.463 239,5 -154 23 163 967 113
3 42.012 1.251 1.463 239,5 -768 132 577 710 600
4 43.263 476 1.463 239,5 -205 31 217 284 150
5 43.739 -1.842 1.463 239,5 -5.131 1.575 1.714
6 41.897 -1.833 1.463 239,5 -5.131 1.584 1.714
7 40.064 -41 1.463 239,5 -880 404 436
8 40.023 402 20,4 -3 12 393
9 40.426 474 20,4 69 12 393
10 40.900 547 20,4 142 12 393
11 41.447 3.172 20,4 967 64 2.141
12 - M 44.619 -11.477 20,4 -130 293 3.150
13 33.141 1.180 20,4 -376 67 228 1.260
14 - P 34.321 109 20,4 -53 161
15 34.430 -344 20,4 -344
16 - P 34.086 114 20,4 -53 167
17 34.200 0 20,4
18 - T 34.200 198 20,4 -106 303
19 34.398 0 20,4
20 - P 34.398 221 20,4 53 168
21 34.619 431 20,4 431
22 - P 35.050 231 20,4 53 178
23 35.280 -123 20,4 -573 102 348
24 35.158 -2 20,4 -142 32 109
25 35.156 72 20,4 -69 32 109
26 35.228 145 20,4 4 32 109
27 35.373 218 20,4 78 32 109
28 35.591 1.136 20,4 510 142 485
29 36.727 1.136 20,4 510 142 485
30 - P 37.863 1.697 20,4 106 331 1.260

Page 98 / 98

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Client Name Designer HAK

Project Name 230013 Company Birikim Mühendislik

Required pulley displacement 4,94 m

100% Motor Torque - High Speed 582 N·m

Maximum Belt Tensions (kN)

Sidewinder - v7.22 - Conveyor Design Software

Minimum Belt Tensions (kN) Maximum Belt Sag (%)

Sidewinder - v7.22 - Conveyor Design Software

Tail Arrangement Head Arrangement

Maximum Pulley Tensions (without any additional safety factors)

Pulley Shaft Results

Sidewinder - v7.22 - Conveyor Design Software

Pulley Geometry Details (Pulley Types)

Pulley Shaft Information

Sidewinder - v7.22 - Conveyor Design Software

Conveyor Load Cases

Fully Loaded (Material Lift = 0,7 m)

Sidewinder - v7.22 - Conveyor Design Software

Operating Tonnage (Material Lift = 0,7 m)

PLUGGED CHUTE (Material Lift = 0,7 m)

Inclines Only (Material Lift = 5,9 m)

Declines Only (Material Lift = -5,2 m)

Sidewinder - v7.22 - Conveyor Design Software

Take-up Displacement Summary

Take-up Pulley Displacement Summary

Counterweight Displacement Summary (1:2 Cable Reeving Ratio)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Design Tensions (added safety factors as described above)

Required Pulley Diameter (Tension based on a safety factor of 10)

Pulley Shaft Stress Analysis (Individual Pulleys)

Sidewinder - v7.22 - Conveyor Design Software

Running Drive Tensions by Load Case (kN)

Sidewinder - v7.22 - Conveyor Design Software

Pulley Tension Summary - All Load Cases and Conditions

Sidewinder - v7.22 - Conveyor Design Software

Load Case Pulley Running Starting O-Stop E-Stop

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Pulley 2 34,4 34,5 33,8 34,1 34,9 34,8 34,9 34,8

Sidewinder - v7.22 - Conveyor Design Software

Pulley 3 34,1 34,2 33,8 34,1 34,4 34,2 34,4 34,2

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Pulley 5 34,3 34,5 34,6 35,1 34,0 34,0 34,0 34,0

Sidewinder - v7.22 - Conveyor Design Software

Pulley 6 34,9 35,0 35,5 36,0 34,3 34,3 34,3 34,3

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Pulley 2 34,4 34,5 34,2 34,3 34,7 34,6 34,7 34,6

Sidewinder - v7.22 - Conveyor Design Software

Pulley 3 34,1 34,2 34,0 34,2 34,3 34,2 34,3 34,2

Sidewinder - v7.22 - Conveyor Design Software

Sidewinder - v7.22 - Conveyor Design Software

Pulley 5 34,3 34,5 34,4 34,7 34,1 34,2 34,1 34,2

Sidewinder - v7.22 - Conveyor Design Software

Pulley 6 34,9 35,0 35,1 35,4 34,6 34,6 34,6 34,6