Lesson 14: Components

Idlers and Pulleys

In this lesson you will learn:
How to select idler class. How to determine the
desired drive pulley RPM. The effect of belt wrap
on belt tension and pulley selection. How to select
proper pulley diameter.
Idlers
Types -
Carry or Trough
Return



Purpose -
Shape load
Support the belt




Idlers
Return Idlers
Troughing or Carry
Idlers
Transition
Idlers
Impact Idlers
Idlers
CEMA Classifications

B

C

D

E

F

typical
aggregate sizes
Idlers
CEMA Idler Classification
Idlers
Common idler roll diameters -

4
5
6
7
8
typical aggregate sizes
Idlers
Carry Idlers


Idlers
Trough Angle -

20 degree

35 degree most widely used

45 degree




Idlers
Return Idlers - different profiles

Flat
Rubber disc
V
Idlers
Trough Training Idlers

Helps train the belt

Typically spaced every 100 -150

Training idlers - approximately taller than
standard idler to help create aligning effect
Idlers
Return Training Idlers

Helps train the belt on
return side

Typically spaced every 100 -150

Good contact with belt is critical

Idlers

Off-center loading cannot be corrected
by training idlers


Training idlers work more effectively at
low belt tensions

Idlers

Training idlers are especially effective in low
tension reversible conveyors


Belts greater than 48 wide are not generally
effected by training idlers belt weight provides
greater training force
Idlers
Rule of thumb

the greater the belt tension,
the less effective training idlers are!
Idlers
Idler selection
CEMA has a nice idler selection guide
Step-by-step method to select idlers
Step 1: Troughing Idler series selection
Calculated Idler load (CIL):
Idler selection
( ) ( ) ( ) IML S K W W CIL
i m b
+ - - + =
1
Where:
Wb = Belt Weight (lb/ft)
Wm = Material Weight (lb/ft)
Si = Idler spacing (ft)
K1 = Lump adjustment factor (see table on next slide)
IML = Idler misalignment load (lbs) (see slide after next)
Idler selection
K
1
Lump adjustment factor
Maximum Lump size (in)
Material Weight (lb/ft
3
)
50 75 100 125 150 175 200
4 1 1 1 1 1.1 1.1 1.1
6 1 1 1 1.1 1.1 1.1 1.1
8 1 1 1.1 1.1 1.2 1.2 1.2
10 1 1.1 1.1 1.1 1.2 1.2 1.2
12 1 1.1 1.1 1.2 1.2 1.2 1.3
14 1.1 1.1 1.1 1.2 1.2 1.3 1.3
16 1.1 1.1 1.2 1.2 1.3 1.3 1.3
18 1.1 1.1 1.2 1.2 1.3 1.3 1.4
Idler selection
Idler Misalignment Load (IML)

( )
( )
|
|
.
|

\
|
-
-
=
i
S
T D
IML
6
Where:
D = Misalignment (in)
T = Belt Tension (lbs)
S
i
= Idler spacing (ft)
Troughing series idler selection
Use CIL to select the idler series from the load rating
tables in the idler catalog
Idler selection
Step 2: Return idler series selection




Pick a return idler series based on the load rating
tables in the idler catalog
Idler selection
( ) IML S W CIL
i B R
+ - =
Steps 3-7:
Impact idler selection and L10 calculations
Read CEMA Idler standards for an overview
Will not be covered in this class
Rules of thumb for diameter
More than 500RPM decreases L10 life
Try to stay below 500RPM, but 4 is really going away
4dia @500RPM = 524FPM **only use 4 in economy situations
5dia @500RPM = 654FPM
6dia @500RPM = 785FPM
Etc.
Idler selection
Pulleys
End Disc
Rim Shaft
Hub
Bushing
Pulleys
Types -
Drum
Wing

Purpose -
Transmit power to the belt
Change belt direction
Pulleys
Tail
Pulley
Snub
Pulley
Take-up
Pulley
Bend Pulley
Bend Pulley
Head or Drive
Pulley
Pulleys
CEMA DUTY -

Load, dimensions and crown
defined by ANSI B105.1

Used on fabric belt


Pulleys
MINE DUTY

Not governed by ANSI

Standard size drums and wings

Manufacture specified designs

Pulleys

ENGINEERED CLASS -

Designed to meet load requirements
at a specific location on a conveyor

Primary used on steel cord belts

Belt tensions and loads exceed
CEMA B105.1 and 501.1
> 800 PIW
> 80,000 modulus PIW
Pulleys
Pulley Lagging a smooth or embossed
covering or coating applied to a pulley
Increases belt traction

Minimizes wear due to abrasion

Promotes cleaning action
Pulleys
Grooved lagging used on drive pulley to
shed water & improve traction

Chevron - grooves meet at center

Herringbone - offset at center by spacing


** Apex should be in direction of belt travel
Pulleys
Pulleys
Pulleys
Ceramic
Increased coefficient of friction


Excellent abrasion resistance


High tension & HP applications
Pulleys
Pulleys
Wing Pulleys
- help protect the conveyor belt from the damaging effects
of fugitive material trapped between pulley and belt.
Pulleys
Bent wings
Pulleys
Pulleys
Pulley selection is based heavily on belt tensions
So to start were going to look at belt tensions at
locations where pulleys are commonly installed
Pulley Selection
Belt Tensions
T
e
is calculated from the application
T
e
is used in an equation:


In order to find T
1
, we must first solve T
2
2 1
T T T
e
=
2 1
T T T
e
+ =
Belt Tensions
There are two equations that calculate T
2
Whichever T
2
is higher governs
T
2
based on 2% sag:
.long arduous equation I will spare you
from.
T
2
based on drive slip:
( )
w e
C T slip T - =
2
Belt Tensions
Once we have T2, we can solve the equation:


..to find T1
2 1
T T T
e
+ =
Belt Tensions
After T
2
, very little changes to belt tension down
to T
T
.
Some change due to return roller friction
Some change due to non-drive pulley friction
Example 100 conveyor
Head/drive tension (T
1
) = 6612.5lbs
Snub tension (T
2
) = 2527.9lbs
Bend pulley tensions (T
takeup
) = 2479.8lbs
Takeup pulley tension (T
takeup
) = 2479.8lbs
Tail pulley tension (T
T
) = 2287.6lbs
Pulley Selection
Turn tensions into PIW (pounds per inch of belt
width)


36BW:
T
1
= 6612.5lbs = 184PIW
T
2
= 2527.9lbs = 70PIW
T
takeup
= 2479.8lbs = 69PIW
T
T
= 2287.6lbs = 64PIW
Pulley Selection
) (
) (
in BeltWidth
lb n BeltTensio
PIW =
Select pulley diameter based on:
Wrap angle of the pulley
PIW at the pulley
Pulley catalog PIW chart
Note: Wing pulleys only rated at 180 wrap
Pulley Selection
Many programs can be used to select idlers and
pulleys
Here is an example of how they work:
Idler & Pulley Selection
Questions???