Y

The Technical Dimensioning of the Conveyor Chain

-/ Calculation Parameters

Designation Symbol Unit Designation Symbol Unit

Total tensile force of chain F N Filling ratio q

Circumferential tensile force F" N Coefficient of friction fr:

of chain, total between bush and roller

Circumferential tensile force Fi Sagging of

of chain, per chain strand slack strand

Supporting tensile force of FS Coefficient of friction lLt

chain(depending on sagging) (conveyed material to steel)

Centrifugal tensile force of Ff Distance of unit load

chain

Pretension force of chain FV N Coefficient of rolling resistance Fz

Breaking load of chain F,

'o N Chain velocity V MiS

Number of chain strands i Coefficient of sliding friction !Lr

Conveying height H Articulation surface of chain AK cm2

Conveying length, horizontal B m Slack distance 3'6m

Distance between axes a m Safety factor k ----

Angle of inclination of Ct Chain length of slack strand to fll

conveyor (degrees)

Mass of chain per m MK kg/m Articulation surface pressure, Per N/mm'

of chain effective

Mass of materials to be MF kg/m Articulation surface pressu re, Pzul Nimm'

conveyed per m of chain admissible

Conveyor capacity (pieces) QS SVh Chain pitch p m

Conveyor capacity (mass) QM Vh Angular velocity 0) s-r

Trough width of conveyer n m Number of teeth z

Trough height of conveyor n m Pitch diameter do m

Cross-sectional area of Ap4 m' Motor output P KW

conveyor of drive

Mass of bulk material to be v Um3 Efficiency of drive n

conveyed

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5.2 Types of Conveyor

The conveyors are subdivided in two main categories:

. Sliding conveyor chains

. Rolling conveyor chains

They are furthermore classified according to the following arrangement criteria:

. Horizontal conveyance
. Oblique conveyance
. Vertical conveyance
. Combined convevance

5.3 Total Mass of the Material to be conveyed

This is the total mass of the material to be conveyed, which is resting and is to be moved on the
conveyor chains or on possibly existing supporting elements (plates, transverse bars, cross-rails, slat
bands, etc.).

According to the load distribution on the conveyor chain, a difference is to be made between point,
individual and linear loading. lf the load is concentrated on a reduced area, the chain pins and rollers
have to be recalculated concerning deflexion and pressure, respectively, when dimensioning the
conveyor chain.

5.4 Load Carrying Capacity of the Rollers

The load carrying capacity of the rollers depends on the roller material, the type of bearing, the chain
velocity, the temperature, and the lubrication. For surface-hardened steel rollers, with a low chain
velocity (< 0,25mls) and a sufficient surface pressure, up to 800 N/cm'?are admissible.

lfrollers are made of quenched and tempered or of unhardened steel, of grey cast iron or of
synthetic material, lower bearing contact pressures are admissible (compare the following tables).

Advantages of synthetic rollers are:

. No maintenance
. Lightweight construction
. Silent run
. High chemical resistance

It is furthermore possible to improve ihe sliding properties of the rollers by means of bearing bushes.
A suitable bearing material is lead tin bronze (surface pressures up to 300 N/cm'), but also special
bearing materials are appropriate for a low-maintenance operation.

The following tables 3a and b show admissible roller loads for conveyor chains according to DIN 8165
and DIN 8167, which have to be multiplied by the corresponding correction factors from tables 4 to 8,
using the formulae indicated:

Admissible load of the roller = table value .\ f2 f3.f 4 fs

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 Mating of material
IW*H Mating of material
Chain according to Bush / Roller Chain according to Bush / Roller
DtN 8165 c15E / C15E DIN 8167 c15E / C15E
C15E | 9SMn28E C15E / 9SMn28E

FVT 40 2000 MT 20 1 050

FVT 63 3000 MT 28 1 350
FVT 90 3800 MT 40 '1900
FVT 112 51 00 MT 56 2750
FVT 140 7050 MT 80 3850
FVT 180 '10550 MT 112 5200
FVT 250 1 5550 MT 160 7200
FVT 315 21500 MT 224 '10050
FVT 4OO 23900 MT 3,15 3500
1

FVT 5OO 31200 MT 450 8450

1

FVT 630 39400 MT 630 26000

MT 9OO 36450

Tab. 3: Loadability of rollers (N/Roller)for carrying roller chains according to DIN 8165 and DIN 8'167

Roller type fl Roller material (bush of case-hardened +

t2
steel, hardened)
Roller 1,0 Case-hardened steel, hardened 1,00
Flanged roller 0,9 Stainless steel, hardened 0,60
Stainless steel, unhardened 0,30
Standard steel, unhardened 0,20
Grey cast iron 0,12

Tab. 4: Factor f1 : Roller type Tab 5: Factor f2 : Roller material

Lubricating conditions r3

Sufficient lubrication, no dirt or rough operating conditions 1,0

Insufficient lubrication, no dirt or rough operating conditions 0,4 - 0,6
Without lubrication, with much dirt and rough operating conditions 0,2 - 0,35
Tab. 6: Factor f3 : Lubrication

a
Chain velocity in m/s t4 Temperature in "C lS

0,10 1,15 20 - 200 1,00

0,25 1,00 200 - 260 0,50
0,50 0,85 260 - 285 0,25
1,00 0,50 285 - 300 n'i^
Tab.7: Factor fa : Chain velocity Tab 8: Factor f5 : Temperature

Mating of material Max. soecific

bearing contact pressure
Roller Bush in N/cm'

Case-hardened steel, hardened Case-hardened steel, hardened 800

Quenched and temoered steel n il 300
Unhardened steel il il
tou
Grey cast iron 100
Bronze 300
Polyamide 6 " '' 50

Tab. 9: Admissible maximum values of specific pressing

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 yruqqHr"H
5.5 Coefficients of Friction

5.5.1 Sliding Friction of Chains on a Base in Continuous Operarron

Fr
Material of slide rail lnsufficient Good
lubrication lubrication
Steel 0,35 0,25
Synthetic material 0,20 0,15
Hardwood 0,30 0,25
Tab. 10: Coefficient of sliding friction p1

5.5.2 Rolling Friction of Chains on Steel Guides

2.c + p3.d3
Coefficient of rolling resistance p2= Pz= 0,08".0,12'.-0,18
d5

.l-
v3 bush diameter lmml
ds= roller diameter lmml
experimental coefficient,
depending on material and the surface roughness of the areas of contact

Conditions of guide c

0,5 Steel roller on steel guide with smooth surface

0.6 Mean value
1,0 Steel roller on steel guide with rough surface

Tab. 11: Coefficient c in dependence on material and contact surface

P3
Mating of material Roller / bush Insufficient Good
lubrication lubrication
Steel roller on steel bush 0,30 0,20
Roller with bronze bush on steel bush 0,15
PA6 roller on steel bush 0,15 0,10
Roller with rolling bearing on steel bush 0,03 0,015 ... 0,005
Tab. 12: Coefficient of friction between roller and bush u"

5.5.3 Coefficient of Friction between Material to be conveyed and Steel ;.r., Bulk Weight y
and Filling Ratio q
Type of material Coefficient Bulk weight Filling ratio
to be conveyed of friction pa y in Vm" q
Ash 0,85 0,50 0,70
Ore 1,20 2,25 0,60
Cereals 0,50 nA6 0,80
Wood chips 0,80 0,25 n7Ä
Gravel 1,00 I -rtr
0,65
Coal 0,90 0,80 0,50
Coke 1,00 0,45 0,60
Loam n -rE 1,25 0,70
Flour 0,50 0,60 0,70
Sand 0,80 1,55 0,60
Broken stone 0,65 1,80 0,65
Peat 0,70 0,40 0,80
Cement 0,05 1,20 0,70

Tab. 13: Coefficient of friction - material to be conveyed / steel, bulk weight and filling ratio

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 Y
5.6 Calculation of the Total Tensile Force of Chain F

The total tensile force of a chain F results from the sum of the total circumferential tensile
force Fn, the supporting tensile force of chain F", and the centrifugal tensile force of chain F1.

F=Fn+F.+F1

5.6.1 Chain Supporting Tensile Force F"

The supporting tensile force of the chain is produced when the chain is freely sagging and
depends on the dead weight of the chain and the chain length of the sagging slack strand.

tr- M* '9,81 .aa2

?
ö.7 ä6-

Sag f results from the following equation:

ao.(lo-ao) (f selected should be = 10oÄ of ao )

5.6.2 Chain Centrifugal Tensile Force F1

The centrifugal tensile force of the chain is a tensile force depending on the chain velocity v and
the chain wheel diameter, which, as a component of the total tensile force of the chain, is to be
considered above all in the case of higher chain velocities'

Ft =Mrv2

O6
where v-(l).-: o = 2 .p . n (n = number of revolutions of the chain wheel in s-1)
2

5.6.3 Chain Circumferential Tensile Force F"

The circumferential tensile force (effective power) results from the operating load dependent torque of
the chain drive to be transmitted. In the following you will find some formulae for the calculation of the
total circumferential tensile force Fn in dependence of the conveyor type. lf the conveyor includes
various chain strands, the chain circumferential tensile force per strand F' results from the relation:

F^v
E_
' i-T

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 Sliding Friction

'1,1 .a . pr. 9,81.(2.M^+ M, )

3600 v
Fo = QS
ls

io
Fs=1,1. a. 9,81 [(rvo*Mr)' (p.,'coso+sinu) +Mx' (plcoso(-sinu)]
if (p,,. cos cx, - sin a) < 0 :

Fs = 1,'1 a 9,81 ' (M^* Mr ) (p.r'cos tx, + sin u)

Fu=2,2'F" if H/B> P,
Fu=2,2.[r"+s,at M^ (B.r,r-H)] if H/B<p1

Rolling Friction

Fs= 1,1 . a . *2.9,81 . (2' M*+ M, ) o. = !gf-f

Fu= 2,2 ' (F" + a .pr2 '9,81 'M6 )

Fs= 1,1'a' 9,81 [('v^*M-)' (plcosü+ sincr)*M^' (plcosü-sina)

if (pz.cos s - sin u)< 0 :

Fs= 1,1'a '9,81 ' (M^* Mr ) (p,' cos cx, + sin a)

Fu=2,2'F" tf HIB> pz
Fu=2,2.[r.+s,at M* (B pz-H) if HIB <1t,

Trough Chain Conveyor

a o,er Mx.lrr .
Fs=1,1
IZ #i" u- )
Fu=2,2'(F.+a'p, . 9,8'1 .MK )

.r r | | | r r \- Fn
-
--
---;--;---------
.:ü/
' Fg=1'1' a .e,81
t^ (p1 'cos a + sin
"). a:t'
(po'cos c' + tin o) *l
f
- _L_ _
L ttl^. (pr. cos ü - sin a) I

if (tr r .cos cx, - sin u)< 0 :

Fs=1'1' a. e,B1 (p,.cosa+ sin"l.ft' (po.coso*rino)]

[t^
Fr=2,2'F, if H/B> p1

Fu= 2,2 ' [r, + 9,41 'M* (e p,-Fl) if H/B < p.,

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 INBL"Y."T"H
5.7 Calculation of the Chain Breaking Load Fo required

Fo= k 'F,

Safetyfactork k=5...2 .12

The safety factor k depends mainly on the operational conditions and the number of teeth of the
chain wheel. Generallv, k is about 6 to 7.

5.8 Calculation of the Driving Power P

P= il-
1000 ''q
; where rt = 0,75...0,8...0,9

5.9 Calculation of the Articulation Surface Pressure P"n

tr
P"o =
Ä?

Diagram for Pru,

N
E Jvvv
LJ "nnn
z
?enn
-I 4VVv
-N
2600
-
L

fr zrco
L

9l
x tzvv
!
a
2000

. 1800
II
I
I

| 1600

0,3 0/. 0,5 12 3

....-..+ Chain velocity v lm/sl

Fig. 7: Adiculation surface pressure

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5.10 Examples of Calculation

Example 1: Trough conveyor, horizontal

Material to be conveyed Wood chips

Conveying length 40m
Conveyor capacity 25 lh
Trough width of conveyor 400 mm
Trough height of conveyor 300 mm
Number of chain strands 1

Number of teeth of chain wheel 8

a) Calculation of the chain velocity

Qrrrr = 3600 .v 'Anr 'T Av = b'h'tP Qu=25/n

en,r AH,r = 0,4'0,3 '0,75
v=- \ = 0,25 (see section 4.5.3)
3600.Av .y Av = 0,09 m2 g = 0,75 (see section 4.5.3)
b=0,4m
25
3600 .0.09 .0,25
=031{. h = 0,3m

b) Galculation of the chain tensile force

a=40m
F^ =1,1.a e,81 -f\ u.) ./
[2.Mx.u, Mo
'' =B*s/
/m
=1,1.40 e,81 os) Fr = 0,35 (see section 4.5.1)
F^
(2.8.0,35.--?!- p+ = 0,8 (see section 4.5.3)
F^ =10150N i=1
k=7
F^ 10150
ri --l- = P (F" and F negligible)
I

Fb = k.F = 7 .10150 = 71050 N

= 1. assumption: Selection of the trough conveyor chain TF 90 according to table on page 50

Standard pitch: P = 125 mm

c) Recalculation of chain considering articulation surface pressure

F F = 10150 N
Per =;- < Pzrt
ÄK Ax = 5 cm2 (see table on page 50)
(.."
Prul = 2500
/" , section 4.9)
p"n = !P = 2o3o
Y. ,
.2soo y 2

Chain size TF90 selected correctly!

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 Yreq.Y"TH
Example 1: Trough conveyor, horizontal - continuation

d) Calculation of chain pretensioning force

F, = 2,2.(Fs + a 'Fr . 9,81 MK ) F, = 0 (as slack strand is supported)

a=40m
Fu = 2,2. (o + 4o . 0,35 9,81 8)
Mn
'- =Brn/
/m
Fu = 2420 l,l ltr = 0,35 (see section 4.5.1)

e) Driving power required

P= F'v F = 10150 N
1000.q
v = O,g1%
n 10150 .0,31
l- = ----- = 3.9 kw
1000 , 0.8 I=0,8

Example 2: Conveyance of pallets

Material to be conveyed Pallets

Conveying length 30m
Pallet size Length: 1200 mm, width: 800 mm
Total mass per pallet 600 ks
Number of chain strands 2
Chain velocity 0,2 m/s
Number of teeth of chain wheel 10
Max. number of pallets 20
Chain type selected Carrying roller chain according to DIN 8165

a) Calculation of the chain tensile force

Fs = .a.Fz .9,81 .(2.M^ + M.

1,1 a=30m
)
Fn = 1,1'30 .0,12 9,81 (2 . 11 + a00) Fz = 0,12 (estimated, see section 4.5.2)
Fn = 16409 I
Mx =2 u5%=,,r/^
Fi =?= ry=82ogx
20 St. 600 k/.
/ ptece
Mr=
Fb = k.Fi 30t
tr
Vir = a00 k/,.
rb =7.8200 =57400 N
k=7

= Selection of the chain type FW 63, with a minimum breaking load of 63 kN (see table on page
44)

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 VJUrygqL"V.T"H
Example 2: Conveyance of pallets 'continuation

b) Recalculation of chain considering articulation surface pressure

Fi = 8200 N
P"o =*<P.u,
Ar = 3,7 cm2 (see tables on pages 44 and 45)

Pzur =2780 / , lseesection 4.9)

r"n = 93P =2220
Y"^r=2780
y ,

c) Recalculation of roller load

Number of carrying rollers : 4

Chain pitch : 100 mm
Pallet mass : 600 kg

600 '9'81
Existing roller load - 4 =1472 V .. = lsoo V
____JJ9!et _-----/--!9tte!
.,

Admissible roller load : see section 4.4

Carrying roller chain FVT 63 : 3ooo V t, f2.\.'14 fs

,/ rollel

- Roller f1 : 1,0
- Case-hardened steel, hardened f2: 1,0
- Insufficient lubrication, no dirt or rough operating conditions f3 : 0,4...0,6
- Chain velocity = 0,2 m/s fn:1.0
- Ambient temperature 10 - 25 "C f5 : 1,0

+ Admissible roller load = 3000 Yor.,.1,0'1,0 .0,4.1,0 .1,0 =1200 /o,,.,

+ Existing roller load = 1500 Yot",, 1200 Yo,,",

In dependence of the chain lubrication (factor f3), the admissible roller load may be exceeded. lt is
therefore more reasonable to select the next chain in size. + FVT 90

d) Driving power required

F^ .v Fs = 16400 N
P- 1000.n
"
v =0,2*
16400 0'2
P_ = 4,1 kW I=0,8
.
1000 0,8

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