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Beltconveyor

9 Tensionscalculaon
9.1 Basicexplanaon
Therequiredpowerhavingbeencalculated,itisnowimportanttoknowthedriveforcetothedrivepulleyto
ensurethatthesystemworkswell.
ThisdrivingforceFUisdeterminedbythedierencebetweentheinputandoutputtensionsofthebelt
onthedrivepullet,whichdependsalsoonthefriconcoecientbetweenthebeltandthepulley.
FUisalsocalledeecvetensionTeofthebelt.
Naturally,foradisplacementtooccur,theremustbeadierencebetweentensions.
Thegraphicalrepresentaonofthisdistribuonisgivenbythegurebelow:

Thegreatesttensioniscalledghtsidetension,T1,andthesmallesttensioniscalledslacksidetension,T2.
Soifthereisnoslacksidetensiontopreventslippage,thebandcannottransmitmovement.
Thuswehavetheequaon:

or:

With:
FU=Peripheralforceoreecvetensionofthebeltinkg
T1=ghtsidetensioninkg
T2=slacksidetensioninkg
Fromthefeedsidetothedischargeside,thetensionT1becomesT2tensioninanexponenalway,asdened
bytheEulerEytelweinformula:

or:

With:
f=coecientoffriconbetweenthebeltandthedrivingpulley
=angleofwraporcontactwiththebeltonthepulley
The=signintheformuladenesthelimitcondionofadherenceofthebelt.
IftheT1/T2raoishigherthane,thebeltslipsonthedrivingpulleyandthemovementcannotbetransmi ed.
T1decreasesalongthewrapanglewithrespecttothevalueofT2inlogarithmicspiral.
Frombothformulasabove,wehave:
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And

With:
C1andC2=drivefactors
Thus,thecalculaonoftheminimumtensionvaluesofthebeltgivesthebeltadherencelimitonthepulley
andoneknowsifonemustaddatensionerposioneddownstreamofthedrivepulley.
Abelttensioningdevicecanbeusedifnecessarytoincreasetheadherenceofthebelttothedrivepulley.
Itwillbeusedtomaintainasucienttensionforallcondions.
Belowarethewrapanglevaluesencounteredintheindustry:

Friconfactorsfmaydierfromonemanufacturertoanotherbecausetheyaredeterminedbasedonthe
experiencegainedoverme.
Anyway,theyaredependentsofthesurfaceofthepulley,thepresenceofwater,dirtandalsooftemperature.
HerebelowthetablefromthebrochurecalledCONVEYORBELTTECHNIQUEDESIGNANDCALCULATION
fromDunlop:

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Fromtheanglevaluesandfriconfactorsabove,wecancalculatethecoecientC2,asinthetablebelow:

Below,anothertablewiththetransmissioncoecientvalues(source:DunlopConveyorBeltDesignManual):

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Asseen,thevaluesforsmoothorlaggedpulleywithatensionerbygravityarethesameforbothtables.
ForthecoecientC2,simplyaddtheunittothecorrespondingvalueofC1.
Thefriconcoecientandthewrapangleofthedrivingpulleyhaveafundamentalimpactontheselecon
ofcomponentsofabeltconveyor.
Theaddionofarubberlaggingonthepulleythatincreasesfriconwillgreatlyreducetensions.
9.2 Eecvetension
Inordertocalculatethemaximumtensionofthebeltandthereforetherequiredstrength,itisrstnecessary
tocalculatetheeecvetension.
Thisistheforcerequiredtomovetheconveyorandtheloadtobetransportedataconstantspeed.
Tocalculatetheeecvetension,oneproceedssimilarlytothecalculaonofpower,either:
*Necessarytensionfortheconveyorwithoutmaterial
*Tensionneededtotransportthematerial
*Necessarytensiontoraisethematerial
*Tensionforaccessories
Theformulasareasfollows:
Formulaofthetensionnecessaryfortheconveyoronly:

Formulaofthetensionneededtotransportthematerial:

Note:TheanglemustbeconvertedintoradianstobecalculatedinthecalculatorderivedfromExcel.
Formulaofthetensionrequiredtoraisethematerial:

Theformulaofthetensionfortheaccessoriesthatarereducedinnumberintheconguraonofthiscalculator
isthetensionderivedfromthepowerrequiredforthecleaners:

Eecvetension:

AllthesetensionsareinNewton.
With:
fb=friconfactorofequipments
Lh=horizontallengthoftheconveyorcentertocenterinm
lf=lengthcoecientinm
Mb=weightofthebeltinkgpermeter
=inclinaonangleoftheconveyorindegrees
mrs=weightofthesupportidlersinkg
drs=distancebetweencarryingidlersinm
mri=weightofthereturnidlersinkg
dri=distancebetweenreturnidlersinm
fm=friconfactorofmaterial
mm=weightofthematerialtransportedinkg/m
H=elevaondistanceinm
Pit=powerofaccessoriesinkW
v=beltspeedinm/sec

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9.3 Minimumtension
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Itisimportanttoknowtheminimumbelttensionsothatthesagbetweensupporngrollersdoesnotexceed
acertainvalue.
Thisvalueisnormally1%ofthedistancebetweenrollers.
Theminimumtensionisgivenbytheformula:

With:
Tmin=MinimumtensioninN
mm=weightofthematerialtransportedinkg/m
Mb=weightofthebeltinkgpermeter
drs=distancebetweencarryingidlersinm
g=9,81m/s2
f=saginm
9.4 TensionsT3andT4
T3andT4tensionsarethoselocatedonthesideofthereturnpulley.
Seediagrambelow:

T3andT4areusuallydierentbuttensionsareconsideredequal.

Seehereaboveforthesignicaonofsymbols
9.5 Tensioningdevicetension
Itisinthiscasethetensionofthecounterweightwhenlocatedonmotorpulleyside.
Seediagramabove.
Thistensioniscalculatedasfollows:

9.6 Unitworkingtension
Thistensioniscalculatedasfollows:

With:
TU=unitworkingtensioninN/mm
l=beltwidthinmm
9.7 Peripheralforceinnonsteadystate
Thisforceiscalculatedasfollows:

With:
ftc=torquefactordependingofthecommanddrivetype

9.8 Acceleraonofthebelt
Acceleraonisgivenbythefollowingformula:

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With:
Ab=acceleraoninm/s2
L=Conveyorlengthinm
Seeaboveforotheritems
9.9 Starngme
Thismeisgivenby:

9.10 Startupdistance
Thisdistanceisgivenby:

Forcompletetechnicalinformaon,consulttheliteratureandmanufacturers'brochures

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