Conveyor Dimentions

MINIMUM PULLEY DIAMETERS (mm)
DTr*	Rate of utilization of the maximum permissible belt breaking strength**
	over 60 to 100 %			over 30 to 60 %			up to 30 %
	Pulley group
	A	B	C	A	B	C	A	B	C
160	160	125	100	125	100		100	100
200	200	160	125	160	125	100	125	125	100
250	250	200	160	200	160	125	160	160	125
315	315	250	200	250	200	160	200	200	160
400	400	315	250	315	250	200	250	250	200
500	500	400	315	400	315	250	315	315	250
630	630	500	400	500	400	315	400	400	315
800	800	630	500	630	500	400	500	500	400
1000	1000	800	630	800	630	500	630	630	500
1250	1250	1000	800	1000	800	630	800	800	630
1400	1400	1250	1000	1250	1000	800	1000	1000	800
1600	1600	1400	1250	1400	1250	1000	1250	1250	1000
1800	1800	1600	1400	1600	1400	1250	1400	1400	1250
2000	2000	1800	1600	1800	1600	1400	1600	1600	1400
*							**

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VOLUME FLOW (m³/h)
Belt width	Idler length	Troughing angle of the belt
(mm)	(mm)	0°	20°	25°	30°	35°	40°	45°
500	200	39	72	79	85	90	94	97
650	250	69	132	145	155	164	171	176
800	315	108	207	226	243	257	268	276
1000	380	174	337	369	396	419	437	449
1200	465	256	493	540	580	614	640	658
1400	530	353	685	750	806	853	888	913
1600	600	466	907	993	1067	1128	1175	1208
1800	670	594	1160	1270	1365	1443	1502	1544
2000	740	739	1443	1581	1699	1795	1869	1920
2200	800	917	1802	1974	2121	2241	2332	2394
2400	870	1115	2196	2406	2585	2730	2840	2915
2600	940	1332	2628	2880	3094	3268	3399	3486
2800	1000	1568	3104	3402	3654	3859	4012	4113
3000	1070	1824	3615	3961	4255	4492	4670	4788
3200	1140	2099	4164	4563	4902	5174	5379	5513

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STEEL CORD CONVEYOR BELT WEIGHT AND THICKNESS (X grade covers)
Rating	Thickness (mm)	Weight (kg/m²)	*Please add 1,1 kg per square meter and 1 mm thickness of cover! For V self-extinguishing resp. FRAS grades, use 1,5 kg/m²/mm! For exact figures please consult the belt manufacturer!
St 1000	4,0	8,5
St 1250	4,0	10,5
St 1600	5,5	12,6
St 2000	5,5	13,6
St 2500	7,0	18,7
St 3150	8,0	21,2
St 4000	9,0	26,0
St 4500	9,5	28,5
St 5000	10,0	30,8
St 5400	10,5	31,8
St 6300	12,0	41,8
St 6800	13,5	43,4
St 7500	14,5	44,8
St 8500	15,0	46,6
St 10000	16,0

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TEXTILE BELT WEIGHT AND THICKNESS (X grade)
Rating (N/mm)	Thickness (mm)	Weight (kg/m²)*	*Please add 1,1 kg per square meter and 1 mm thickness of cover! Example: 1200 / EP 800/4 6+3: (5,5+(9x1,1))x1,2=18,5 kg/m For exact figures please consult the belt manufacturer!
EP 400/2	3,5	4,4
EP 630/2	4,5	5,4
EP 800/2	5,0	5,9
EP 400/3	3,0	3,4
EP 500/3	3,5	3,7
EP 630/3	4,0	4,3
EP 500/4	3,8	4,9
EP 630/4	4,1	5,2
EP 800/4	4,5	5,5
EP 800/5	5,0	6,3
EP 1000/5	5,5	7,1
EP 1250/5	7,0	8,9

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COEFFICIENTS OF FRICTION (µ)
Condition	Steel pulley	PU lagging	Rubber lagging	Ceramic lagging
dry	0.35 - 0.4	0.35 - 0.4	0.4 - 0.45	0.4 - 0.45
wet (water)	0.1	0.35	0.35	0.35 - 0.4
wet (soiled)	0.05 - 0.1	0.2	0.25 - 0.3	0.35

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BULK DENSITY (ρ)
Ash, dry	0.5 - 0.7
Ash, wet	0.9
Basalt	1.6
Bauxite, crushed	1.3
Cement	1.35
Clay, dry	1.8
Coal, r.o.m.	1.1 - 1.4
Coal, fine	0.7 - 0.9
Copper ore	2.15
Gravel	1.8 - 2.2
Gold ore	1.2
Lignite	0.65 - 0.85
Limestone	1.5 - 1.9
Iron ore	2.1
Mineral salt	1.0
Oil sand	1.5
Overburden	1.5 - 1.8
Phosphate	1.2 - 1.5
Potash	1.35
Rock debris	1.8
Salt	1.2 - 1.5
Sand, dry	1.6
Sand, wet	2.0

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MAXIMUM SLOPE ANGLES (°)
Cement										23
Coal, r.o.m.										17
Coal, fine										16
Ore										18
Gravel										15
Limestone										18
Salt										20
Sand, dry										16
Sand, wet										20
The coefficient  jSt as per DIN 22101 provides the relationship of the dynamical angle of inclination. For bulk materials with higher inner friction, the following guide values can be used:

Inclination	2°	4°	6°	8°	10°	12°	14°	16°	18°	20°
Coefficient (φSt)	1.0	0.99	0.98	0.97	0.95	0.93	0.91	0.89	0.85	0.81

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COEFFICIENT FOR THE DETERMINATION OF THE VOLUME FLOW (φSt)
Gradient angle	2°	4°	6°	8°	10°	12°	14°	16°	18°	20°
Coefficient (φSt)	1.0	0.99	0.97	0.97	0.95	0.93	0.91	0.89	0.85	0.81

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DISTANCE BETWEEN BELT EDGE AND DEEPEST POINT OF TROUGH (mm)
Belt width	Idler length	Belt width on	Belt troughing angle
(mm)	(mm)	side idlers (mm)	25°	30°	35°	37,5°	40°	45°
500	200	150	63	75	86	91	96	106
650	250	200	85	100	115	122	129	141
800	315	243	102	121	139	148	156	171
1000	380	310	131	155	178	189	199	219
1200	465	368	155	184	211	224	236	260
1400	530	435	184	218	250	265	280	308
1600	600	500	211	250	287	304	321	354
1800	670	565	239	283	324	344	363	400
2000	740	630	266	315	361	384	405	445
2200	800	700	296	350	402	426	450	495
2400	870	765	323	383	439	466	492	541
2600	940	830	351	415	476	505	534	587
2800	1000	900	380	450	516	548	579	636
3000	1070	965	408	483	554	587	620	682
3200	1140	1030	435	515	591	627	662	728

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MINIMUM BELT FORCES TO ENSURE TRANSMISSION OF PERIPHERAL PULLEY FORCES
Coeff. of friction	170°	175°	180°	185°	190°	195°	200°	205°	210°	215°	220°	225°	230°	235°	240°	245°
0.05	6.25	6.06	5.88	5.71	5.55	5.39	5.24	5.10	4.97	4.85	4.72	4.61	4.50	4.39	4.29	4.20
0.10	2.90	2.80	2.71	2.62	2.54	2.47	2.39	2.32	2.26	2.20	2.14	2.08	2.02	1.97	1.92	1.87
0.15	1.78	1.72	1.66	1.60	1.55	1.50	1.45	1.41	1.36	1.32	1.28	1.25	1.21	1.18	1.14	1.11
0.20	1.23	1.19	1.14	1.10	1.06	1.03	0.99	0.96	0.92	0.89	0.87	0.84	0.81	0.79	0.76	0.74
0.25	0.91	0.87	0.84	0.81	0.77	0.75	0.72	0.69	0.67	0.64	0.62	0.60	0.58	0.56	0.54	0.52
0.30	0.70	0.67	0.64	0.61	0.59	0.56	0.54	0.52	0.50	0.48	0.46	0.44	0.43	0.41	0.40	0.38
0.35	0.55	0.52	0.50	0.48	0.46	0.44	0.42	0.40	0.38	0.37	0.35	0.34	0.33	0.31	0.30	0.29
0.40	0.44	0.42	0.40	0.38	0.36	0.34	0.33	0.31	0.30	0.29	0.27	0.26	0.25	0.24	0.23	0.22
0.45	0.36	0.34	0.32	0.31	0.29	0.28	0.26	0.25	0.24	0.23	0.22	0.21	0.20	0.19	0.18	0.17

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REVOLVING MASS OF IDLERS (3-part idlers, kg/m)
Belt width (mm)	Idler diameter (mm)
	108	133	159	168
1000	17,0	24,5	26,5	35,0
1200	19,0	29,0	32,5	40,0
1400	21,0	31,5	35,5	45,0
1600	23,5	34,5	39,0	50,0
1800	25,5	35,0	42,5	54,0
2000	28,0	37,5	47,0	62,0

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f VALUES (artificial friction coefficient f), Examples
Installation	Conditions	f value
Horizontal, belt speed of 5 m/s, low rolling resistance belt	Favorable, easily rotating idlers, good tracking	0.012
Horizontal, belt speed of 5 m/s, X grade belt	As above	0.016
As above	"Normal"	0.020
As above	Unfavorable conditions, low temperature	0.026
Steep decline, belt speed 5 m/s	As a safety measure, downhill conveyors shall be calculated with a substantially lower f value than driven conveyors.	0.014
The f value is negatively influenced by higher troughing angles, higher belt speeds, smaller idler diameters, poorly aligned installations etc.

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COEFFICIENT C
Length (m)	80	200	300	500	800	1000	1500	2500	5000
C	1,92	1,45	1,31	1,2	1,17	1,09	1,05	1,04	1,03

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FACTOR c
Belt speed (m/s)	2	3	4	5	8
c	1,92	1,45	1,31	1,2	1,17

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MINIMUM CURVES FOR PIPE CONVEYOR BELTS (guide numbers)
Carcass	Diameter d (mm)	Curve radius
		up to 25°	25°- 50°	50° - 75°	75° - 100°
Polyamide (PP)	150 - 300	300 d	400 d	500 d	600 d
	350 - 500	400 d	500 d	600 d	700 d
Polyester/Polyamide (EP)	150 - 300	400 d	500 d	600 d	700 d
	350 - 500	500 d	600 d	700 d	800 d
Aramide (D)	150 - 300	500 d	600 d	700 d	800 d
	350 - 500	600 d	700 d	800 d	900 d
Steel cord (St)	150 - 300	700 d	800 d	900 d	1000 d
	350 - 500	800 d	900 d	1000 d	1100 d

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MINIMUM BELT TURNOVER LENGTH (guide values in m)
Max. belt width B (mm)	Type of turnover	Textile conveyor belts	Steel cord conveyor belts
1200	unguided	10 x B	-
1600	guided	12,5 x B	22 x B
2400	supported	10 x B	15 x B
3200

Care and maintenance of conveyor systems

Care and maintenance of conveyor systems

A conveyor system is often the lifeline to a company’s ability to effectively move its product in a timely fashion. The steps that a company can take to ensure that it performs at peak capacity, include regular inspections, close monitoring of motors and reducers, keeping key parts in stock, and proper training of personnel.
Increasing the service life of your conveyor system involves: choosing the right conveyor type, the right system design and paying attention to regular maintenance practices.
A conveyor system that is designed properly will last a long time with proper maintenance. Here are six of the biggest problems to watch for in overhead type conveyor systems including I-beam monorails, enclosed track conveyors and power and free conveyors.
Poor take-up adjustment: This is a simple adjustment on most systems yet it is often overlooked. The chain take-up device ensures that the chain is pulled tight as it leaves the drive unit. As wear occurs and the chain lengthens, the take-up extends under the force of its springs. As they extend, the spring force becomes less and the take-up has less effect. Simply compress the take-up springs and your problem goes away. Failure to do this can result in chain surging, jamming, and extreme wear on the track and chain. Take-up adjustment is also important for any conveyor using belts as a means to power rollers, or belts themselves being the mover. With poor-take up on belt-driven rollers, the belt may twist into the drive unit and cause damage, or at the least a noticeable decrease or complete loss of performance may occur. In the case of belt conveyors, a poor take-up may cause drive unit damage or may let the belt slip off of the side of the chassis.
Lack of lubrication: Chain bearings require lubrication in order to reduce friction. The chain pull that the drive experiences can double if the bearings are not lubricated. This can cause the system to overload by either its mechanical or electrical overload protection. On conveyors that go through hot ovens, lubricators can be left on constantly or set to turn on every few cycles.

Contamination: Paint, powder, acid or alkaline fluids, abrasives, glass bead, steel shot, etc. can all lead to rapid deterioration of track and chain. Ask any bearing company about the leading cause of bearing failure and they will point to contamination. Once a foreign substance lands on the raceway of a bearing or on the track, pitting of the surface will occur, and once the surface is compromised, wear will accelerate. Building shrouds around your conveyors can help prevent the ingress of contaminants. Or, pressurize the contained area using a simple fan and duct arrangement. Contamination can also apply to belts (causing slippage, or in the case of some materials premature wear), and of the motors themselves. Since the motors can generate a considerable amount of heat, keeping the surface clean is an almost-free maintenance procedure that can keep heat from getting trapped by dust and grime, which may lead to motor burnout.

Product Handling: In conveyor systems that may be suited for a wide variety of products, such as those in distribution centers, it is important that each new product be deemed acceptable for conveying before being run through the materials handling equipment. Boxes that are too small, too large, too heavy, too light, or too awkwardly shaped may not convey, or may cause many problems including jams, excess wear on conveying equipment, motor overloads, belt breakage, or other damage, and may also consume extra man-hours in terms of picking up cases that slipped between rollers, or damaged product that was not meant for materials handling. If a product such as this manages to make it through most of the system, the sortation system will most likely be the affected, causing jams and failing to properly place items where they are assigned. It should also be noted that any and all cartons handled on any conveyor should be in good shape or spills, jams, downtime, and possible accidents and injuries may result.

Drive Train: Notwithstanding the above, involving take-up adjustment, other parts of the drive train should be kept in proper shape. Broken O-rings on a Line shaft, pneumatic parts in disrepair, and motor reducers should also be inspected. Loss of power to even one or a few rollers on a conveyor can mean the difference between effective and timely delivery, and repetitive nuances that can continually cost downtime.

Bad Belt Tracking or Timing: In a system that uses precisely controlled belts, such as a sorter system, regular inspections should be made that all belts are traveling at the proper speeds at all times. While usually a computer controls this with Pulse Position Indicators, any belt not controlled must be monitored to ensure accuracy and reduce the likelihood of problems. Timing is also important for any equipment that is instructed to precisely meter out items, such as a merge where one box pulls from all lines at one time. If one were to be mistimed, product would collide and disrupt operation. Timing is also important wherever a conveyor must "keep track" of where a box is, or improper operation will result.
Since a conveyor system is a critical link in a company’s ability to move its products in a timely fashion, any disruption of its operation can be costly. Most “downtime” can be avoided by taking steps to ensure a system operates at peak performance, including regular inspections, close monitoring of motors and reducers, keeping key parts in stock, and proper training of personnel.