Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016 Description Tripper Conveyor Example Sidewinder v6.06 - Conveyor Design Software Advanced Conveyor Technologies, Inc. Page 1 / 33 System Information Calculation method ........................................... DIN / ISO Conveyor Length / Height ........................... 2116 / 17.8 ft Material lift ............................................................. 27.9 ft Ambient temperature range .............................32 to 95 °F Kt factor at minimum temperature ............................. 1.02 Material Properties Type ............................................................ Rock, crushed Design Tonnage .................................................. 8818 tph Density ................................................................125 lb/ft 3 Maximum lump size ................................................ 3.3 in Surcharge angle ...................................................... 20 deg Belt Properties Manufacture ................................................ Fabric 2000/5 Type ............................................................ Fabric (5-Ply) Width ..................................................................... 63.0 in Rating................................................................ 1142 PIW Speed ................................................................... 787 fpm Top / bottom cover thickness ...................... 0.39 x 0.12 in Total thickness ......................................................... 1.0 in Weight (new / worn) ................................. 29.7 / 24.5 lb/ft Modulus ......................................................... 89,490 PIW Tape length ........................................................... 4,290 ft Belt cycle time ...................................................... 5.4 min Tension Summary Running Momentary Maximum tension (kip) 54.2 57.8 Minimum safety factor 13.27 12.44 Minimum tension (kip) 16.0 16.0 Maximum belt sag (%) 0.89 0.89 Cross Sectional Loading Material mass (w m ) ........................................... 373.3 lb/ft Combined mass (w m + w b ) ................................ 403.0 lb/ft Edge distance (required / actual)...................... 4.1 / 5.1 in Cross sectional area ............................................. 2.990 ft² Cross sectional loading (utility / total) ........... 91 % / 65 % Bed depth ............................................................... 13.1 in Flooded belt tonnage........................................ 13,481 tph Flooded (w m + w b ) ............................................ 600.4 lb/ft Idler Set Data Carry Return Series name Series 25 Series 25 Bearing 6305 6305 Number of rolls 5 2 Trough angle (deg) 45 10 Type Inline Inline Idler spacing (ft) 3.28 6.56 Number of idler sets 670 322 Roll diameter 6.0 6.0 Roll rpm 503 503 Total drag (lbf) 3.3 1.3 Roll length 14.1 34.0 Shaft diameter (in) 0.98 0.98 Dynamic capacity (kip) 23.4 23.4 L10 life 1 (1000 hrs) 139.8 / 101.0 350.0 Shaft deflection (min) 3.96 / 6.26 4.08 1 L 10 life above which 95% of idlers exceed Drive Station Type .......................................................... Variable speed Synchronous RPM ........................................... 1500 RPM Motor quantity / rating ...................................... 2 / 536 hp Total installed power ............................................ 1073 hp Nominal empty / full power ........ (13 / 77%) 140 / 830 hp Min / max demand power.......... (13 / 98%) 140 / 1048 hp Frame Size.................................................... NEMA 585T Motor Voltage ............................................. Not Specified Efficiency .................................................... 91.5 to 95.5% Maximum starting torque ......................................... 136% Inertia - Motor ................................................. 211.2 lb·ft² Pulley lagging type ...............................................Ceramic Motor wrap angles....................................................... 204 Lagging friction factor (run / accel) ................. 0.35 / 0.40 Take-up Data Type ...................................................................... Gravity Location ................................................... Tail / Pulley #5 Required belt line tension..................................... 18.0 kip Cable reeving ratio (trolley:counterweight) ................. 4:4 Counterweight mass ........................................... 18.0 tons Required pulley displacement ............................... 41.60 ft Dynamic displacement (incl thermal) ...............3.68 ft Permanent elongation ..................................... 27.89 ft Splice length (2 included) .................................8.04 ft Clearance ..........................................................2.00 ft Backstops
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Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
Sidewinder v6.06 - Conveyor Design Software Advanced Conveyor Technologies, Inc.
Page 1 / 33
System Information Calculation method ........................................... DIN / ISO Conveyor Length / Height ........................... 2116 / 17.8 ft Material lift ............................................................. 27.9 ft Ambient temperature range ............................. 32 to 95 °F Kt factor at minimum temperature ............................. 1.02
Material Properties Type ............................................................ Rock, crushed Design Tonnage .................................................. 8818 tph Density ................................................................125 lb/ft3 Maximum lump size ................................................ 3.3 in Surcharge angle ...................................................... 20 deg
Belt Properties Manufacture ................................................ Fabric 2000/5 Type ............................................................ Fabric (5-Ply) Width ..................................................................... 63.0 in Rating................................................................ 1142 PIW Speed ................................................................... 787 fpm Top / bottom cover thickness ...................... 0.39 x 0.12 in Total thickness ......................................................... 1.0 in Weight (new / worn) ................................. 29.7 / 24.5 lb/ft Modulus ......................................................... 89,490 PIW Tape length ........................................................... 4,290 ft Belt cycle time ...................................................... 5.4 min
Tension Summary Running Momentary Maximum tension (kip) 54.2 57.8 Minimum safety factor 13.27 12.44 Minimum tension (kip) 16.0 16.0 Maximum belt sag (%) 0.89 0.89
Cross Sectional Loading Material mass (wm) ........................................... 373.3 lb/ft Combined mass (wm + wb) ................................ 403.0 lb/ft Edge distance (required / actual)...................... 4.1 / 5.1 in Cross sectional area ............................................. 2.990 ft² Cross sectional loading (utility / total) ........... 91 % / 65 % Bed depth ............................................................... 13.1 in
Flooded belt tonnage ........................................ 13,481 tph
Idler Set Data Carry Return Series name Series 25 Series 25 Bearing 6305 6305 Number of rolls 5 2 Trough angle (deg) 45 10 Type Inline Inline Idler spacing (ft) 3.28 6.56 Number of idler sets 670 322 Roll diameter 6.0 6.0 Roll rpm 503 503 Total drag (lbf) 3.3 1.3 Roll length 14.1 34.0 Shaft diameter (in) 0.98 0.98 Dynamic capacity (kip) 23.4 23.4 L10 life1 (1000 hrs) 139.8 / 101.0 350.0 Shaft deflection (min) 3.96 / 6.26 4.08
1 L10 life above which 95% of idlers exceed
Drive Station Type .......................................................... Variable speed Synchronous RPM ........................................... 1500 RPM Motor quantity / rating ...................................... 2 / 536 hp Total installed power ............................................ 1073 hp Nominal empty / full power ........ (13 / 77%) 140 / 830 hp Min / max demand power.......... (13 / 98%) 140 / 1048 hp Frame Size .................................................... NEMA 585T Motor Voltage ............................................. Not Specified Efficiency .................................................... 91.5 to 95.5% Maximum starting torque ......................................... 136% Inertia - Motor ................................................. 211.2 lb·ft² Pulley lagging type ............................................... Ceramic Motor wrap angles....................................................... 204 Lagging friction factor (run / accel) ................. 0.35 / 0.40
Take-up Data Type ...................................................................... Gravity Location ................................................... Tail / Pulley #5 Required belt line tension ..................................... 18.0 kip Cable reeving ratio (trolley:counterweight) ................. 4:4 Counterweight mass ........................................... 18.0 tons Required pulley displacement ............................... 41.60 ft Dynamic displacement (incl thermal) ............... 3.68 ft Permanent elongation ..................................... 27.89 ft Splice length (2 included) ................................. 8.04 ft Clearance .......................................................... 2.00 ft
Backstops
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Location ............................................... Head on Pulley #3 Backstop (quantity x type) ........................ 2 x High speed Torque rating at high speed shaft .............. 2 x 2,950 lbf·ft Torque rating at low speed shaft ............. 2 x 59,684 lbf·ft Reducer Ratio ..................................................... 20.230:1 Total Installed Power Multiplier ................................ 1.36 Pulley diameter ...................................................... 41.2 in
Brakes Brake type .................................................. None installed
Reducer Information Manufacture ................................................................ N/A Frame size ................................................................... N/A Reducer ratio .......................................................... 20.230 Catalog reducer ratio ................................................ 0.000 RPM (High Speed) .......................................... 1500 RPM RPM (Low Speed) ............................................ 74.1 RPM Configuration ................................................ Shaft Mount Number of stages ............................................................ 3 Service factor ............................................................... 1.4 Power rating .................................................................... 0
Starting and Stopping Start control ..................................................... Controlled Start time .................................................................... 0.0 s Operational stop control................................... Fixed time Operational stop time ................................................. 0.0 s O-Stop distance ............................................................ 0 ft Emergency stop control ............................................. Drift Emergency stop time ................................................. 0.0 s Material buildup in chute ..................................... 160.0 ft³
Tension Ratios Allowable (running) ................................................... 3.48 Running tension ratio ................................................. 3.40 Allowable (dynamic) ................................................. 4.20 Starting tension ratio .................................................. 0.00
Transition Lengths
Transition method ........................................... DIN 22101 Tail transition length (inline) ................................... 9.00 ft Head transition length (elevated 4.25 in) ................ 6.50 ft
Estimated Splice Data Splice type ............................................................... 4-Step Splice step length ................................................... 17.7 in 22 degree bias angle ............................................... 25.6 in Total splice length .................................................. 96.5 in
Take-Up Cable Counterweight mass ........................................... 18.0 tons Cable reeving ratio (trolley:counterweight) ................. 4:4 Take-up cable tension ............................................ 9.0 kip Cable diameter ....................................................... 0.63 in Cable breaking strength (261 MPa)...................... 38.7 kip Safety factor ................................................................. 4.3 Number of clips (crosby clamps) .................................... 3 Turnback / free end length ......................... 310.0 / 65.0 in Sheave Root Diam.................................................. 11.0 in
Other Information Loaded beltline mass (excluding motors)......... 987,413 lb Total inertia (ref HS shaft) .............................. 7,104 lb·ft2
Demand Power (hp) Case Demand
power % Motor
Nameplate Empty - Normal Frict. 140 13.0 Full - Normal Frict. 830 77.4 Full - Low Frict. 658 61.4 Full - High Frict. 1028 95.8 Full - With Pullout - Normal Frict. 1048 97.7
Din Factor and Total Equivalent Mass Case Din factor Belt line
mass (lb) Empty - Normal Frict. 0.0200 262,433 Full - Normal Frict. 0.0200 1,046,119 Full - Low Frict. 0.0150 1,023,978 Full - High Frict. 0.0250 1,051,655 Full - With Pullout - Normal Frict. 0.0200 1,046,119
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Maximum Belt Tensions (kip) Case Running Dynamic
Empty - Normal Frict. 21.2 21.2 Full - Normal Frict. 48.8 48.8 Full - Low Frict. 42.7 42.7 Full - High Frict. 54.2 54.2 Full - With Pullout - Normal Frict. 57.8 57.8
Belt Safety Factor Case Running Dynamic
Empty - Normal Frict. 33.94 33.94 Full - Normal Frict. 14.74 14.74 Full - Low Frict. 16.85 16.85 Full - High Frict. 13.27 13.27 Full - With Pullout - Normal Frict. 12.44 12.44
Splice Safety Factor Case Running Dynamic
Empty - Normal Frict. 27.15 27.15 Full - Normal Frict. 11.79 11.79 Full - Low Frict. 13.48 13.48 Full - High Frict. 10.61 10.61 Full - With Pullout - Normal Frict. 9.96 9.96
Minimum Belt Tensions (kip) Case Running Dynamic
Empty - Normal Frict. 16.7 0.00 Full - Normal Frict. 16.6 0.00 Full - Low Frict. 17.1 0.00 Full - High Frict. 16.0 0.00 Full - With Pullout - Normal Frict. 16.6 0.00
Maximum Belt Sag (%) Case Running Dynamic
Empty - Normal Frict. 0.15 0.15 Full - Normal Frict. 0.87 0.87 Full - Low Frict. 0.89 0.89 Full - High Frict. 0.86 0.86 Full - With Pullout - Normal Frict. 0.59 0.59
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Conveyor Profile Overall length = 2116 ft - Overall height = 17.8 ft - True Length = 2168.2 ft
Tail Arrangement Head Arrangement
Middle Arrangement
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
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Maximum Pulley Tensions (without any additional safety factors)
Pulley Type Wrap (deg)
Steady State Tensions (kip) Momentary Tensions (kip)
Take-up Pulley 2-MT 180 18.0 36.5 18.0 36.5 T1 & T2 values may not be from the same load cases. Therefore the max resultant force is not the vector sum of these values.
Design tensions for shaft fatigue are based on all design level 1 cases. Running tensions have an added pulley multiplier of 1.10. Pulley Geometry Details (Pulley Types)
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
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Description Tripper Conveyor Example
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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 two Design Level 1 loads, which are: 1. Empty 2. Fully Loaded 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 = 27.9 ft) There are one Design Level 2 loads, which are: 1. Fully Loaded - With Pullout
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Fully Loaded - With Pullout
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Take-up Displacement Summary 1. Type ................................................................................................................................................... Gravity 2. Location ................................................................................................................................ Tail / Pulley #5 3. Belt line tension ................................................................................................................................ 18.0 kip 4. Take-up pulley displacement range
a. Running .......................................................................................................................... -2.41 to 0.00 ft b. Momentary ..................................................................................................................... -3.68 to 0.00 ft
Take-up Pulley Displacement Summary 1. Dynamic displacement (incl thermal) ................................................................................................. 3.68 ft 2. Permanent elongation ....................................................................................................................... 27.89 ft 3. Splice length (2 included) ................................................................................................................... 8.04 ft 4. Clearance ............................................................................................................................................ 2.00 ft 5. Required displacement ..................................................................................................................... 41.60 ft Counterweight Displacement Summary (4:4 Cable Reeving Ratio) 1. Dynamic displacement ....................................................................................................................... 3.68 ft 2. Permanent elongation ......................................................................................................................... 4.18 ft 3. Splice length (2 included) ................................................................................................................... 0.00 ft 4. Clearance ............................................................................................................................................ 2.00 ft 5. Required displacement ....................................................................................................................... 9.86 ft *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).
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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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 and dynamic conditions. Running tensions have an added pulley multiplier of 1.10. 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)
Empty - Normal Frict. 21.2 16.8 37.1 Full - Normal Frict. 48.8 16.6 64.3 Full - Low Frict. 42.7 17.3 58.9 Full - High Frict. 54.2 16.0 69.1 Full - With Pullout - Normal Frict. 57.8 16.6 73.2
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Pulley Tension Summary - All Load Cases and Conditions
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
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Description Tripper Conveyor Example
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#1 - Pulley 1 Pulley Location and Geometry 1. Name (Type-1) ............................................ Pulley 1 2. Pulley Diameter ............................................ 39.4 in 3. Face Width .................................................... 69.0 in Lagging 4. Lagging Type ............................................. Ceramic 5. Lagging Thickness .......................................... 0.8 in 6. Diameter with lagging .................................. 40.9 in Shaft Specification 7. Shaft Center Diameter .................................... 9.0 in 8. Shaft Material ......................................... SAE 1018 9. Yield Strength ............................................. 31.9 ksi 10. Fatigue Strength ........................................ 29.0 ksi Locking Device 11. Hub Center Distance ................................... 62.0 in 12. Shaft diameter at hub .................................... 9.0 in 13. Turndown radius at hub ................................ 0.0 in 14. Locking Device ......................................... XT-100 15. Size .................................................... 9.00 x 17.50 16. Hub width ..................................................... 4.1 in 17. Hub pressure .................................................. 0 psi 18. Maximum torque ........................................ 0 lbf·ft 19. Hub outer diameter ..................................... 17.5 in Bearing Specifications 20. Bearing Center Distance ............................. 88.0 in 21. Shaft diameter at bearing .............................. 7.5 in 22. Bearing to Fillet Distance ............................. 5.7 in 23. Turndown radius at bearing .......................... 2.3 in 24. Bearing ......................................................... 23044 25. SNL Plummer Block ...................................... 3044 26. Dynamic Capacity ..................................... 274 kip 27. Bearing L10 ...................................... 91,232 hours
Design Tensions and Loads 28. Running T1 Tension ................................. 36.9 kip 29. Running T2 Tension ................................. 37.1 kip 30. Design T1 Tension ................................... 44.8 kip 31. Design T2 Tension ................................... 45.1 kip 32. Wrap angle ................................................186 deg 33. Design Resultant Tension ......................... 90.9 kip 34. Resultant Angle .........................................195 deg 35. Resultant Moment ................................ 49.2 kip·ft 36. Resultant Torque .................................. 0.59 kip·ft 37. Estimated Pulley & Shaft Mass ................ 5,027 lb 38. Estimated Mass with Bearings ................. 5,699 lb Shaft Stresses & Deflections 39. Shaft slope at hub ............................... 0.0019 in/in 40. Shaft slope at bearing ......................... 0.0024 in/in 41. Shaft deflection at center .......................... 0.058 in 42. Shaft deflection at center (%) ....................... 0.066 43. Shaft Safety Factor (CEMA) .......................... 1.66 44. Shaft Safety Factor (AS1403) ........................ 1.54 45. Bending Stress ............................................. 8.3 ksi 46. Torsional Stress ........................................... 0.0 ksi 47. Von Mises Stress ......................................... 8.3 ksi 48. Fillet Von Mises Stress ............................... 8.4 ksi Shell Dimension and Stresses 49. Shell thickness .............................................. 1.0 in 50. Sitzwohl reqd shell thickness1 ...................... 0.9 in 51. Sitzwohl shell stress .................................... 4.6 ksi 52. Shell stress at 180 wa .................................. 4.0 ksi 1 Assumes 180 deg wrap and allowable stress of 4.9 ksi End Disk Dimension and Stresses 53. End disk thickness ........................................ 1.5 in 54. End disk stress ........................................... 14.4 ksi
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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#2 - Pulley 2 Pulley Location and Geometry 1. Name (Type-1) ............................................ Pulley 2 2. Pulley Diameter ............................................ 39.4 in 3. Face Width .................................................... 69.0 in Lagging 4. Lagging Type ............................................. Ceramic 5. Lagging Thickness .......................................... 0.8 in 6. Diameter with lagging .................................. 40.9 in Shaft Specification 7. Shaft Center Diameter .................................... 9.0 in 8. Shaft Material ......................................... SAE 1018 9. Yield Strength ............................................. 31.9 ksi 10. Fatigue Strength ........................................ 29.0 ksi Locking Device 11. Hub Center Distance ................................... 62.0 in 12. Shaft diameter at hub .................................... 9.0 in 13. Turndown radius at hub ................................ 0.0 in 14. Locking Device ......................................... XT-100 15. Size .................................................... 9.00 x 17.50 16. Hub width ..................................................... 4.1 in 17. Hub pressure .................................................. 0 psi 18. Maximum torque ........................................ 0 lbf·ft 19. Hub outer diameter ..................................... 17.5 in Bearing Specifications 20. Bearing Center Distance ............................. 88.0 in 21. Shaft diameter at bearing .............................. 7.5 in 22. Bearing to Fillet Distance ............................. 5.7 in 23. Turndown radius at bearing .......................... 2.3 in 24. Bearing ......................................................... 23044 25. SNL Plummer Block ...................................... 3044 26. Dynamic Capacity ..................................... 274 kip 27. Bearing L10 ...................................... 94,737 hours
Design Tensions and Loads 28. Running T1 Tension ................................. 37.0 kip 29. Running T2 Tension ................................. 37.2 kip 30. Design T1 Tension ................................... 45.0 kip 31. Design T2 Tension ................................... 45.4 kip 32. Wrap angle ................................................171 deg 33. Design Resultant Tension ......................... 89.9 kip 34. Resultant Angle .............................................1 deg 35. Resultant Moment ................................ 48.7 kip·ft 36. Resultant Torque .................................. 0.59 kip·ft 37. Estimated Pulley & Shaft Mass ................ 5,027 lb 38. Estimated Mass with Bearings ................. 5,699 lb Shaft Stresses & Deflections 39. Shaft slope at hub ............................... 0.0019 in/in 40. Shaft slope at bearing ......................... 0.0024 in/in 41. Shaft deflection at center .......................... 0.057 in 42. Shaft deflection at center (%) ....................... 0.065 43. Shaft Safety Factor (CEMA) .......................... 1.68 44. Shaft Safety Factor (AS1403) ........................ 1.56 45. Bending Stress ............................................. 8.2 ksi 46. Torsional Stress ........................................... 0.0 ksi 47. Von Mises Stress ......................................... 8.2 ksi 48. Fillet Von Mises Stress ............................... 8.3 ksi Shell Dimension and Stresses 49. Shell thickness .............................................. 1.0 in 50. Sitzwohl reqd shell thickness1 ...................... 0.9 in 51. Sitzwohl shell stress .................................... 4.9 ksi 52. Shell stress at 180 wa .................................. 4.0 ksi 1 Assumes 180 deg wrap and allowable stress of 4.9 ksi End Disk Dimension and Stresses 53. End disk thickness ........................................ 1.5 in 54. End disk stress ........................................... 14.2 ksi
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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#3 - Motors 1/2 - Backstops 1/2 Pulley Location and Geometry 1. Name (Type-1) ............. Motors 1/2 - Backstops 1/2 2. Pulley Diameter ............................................ 39.4 in 3. Face Width .................................................... 69.0 in Lagging 4. Lagging Type ............................................. Ceramic 5. Lagging Thickness .......................................... 0.8 in 6. Diameter with lagging .................................. 40.9 in Shaft Specification 7. Shaft Center Diameter .................................... 9.0 in 8. Shaft Material ......................................... SAE 1018 9. Yield Strength ............................................. 31.9 ksi 10. Fatigue Strength ........................................ 29.0 ksi Locking Device 11. Hub Center Distance ................................... 62.0 in 12. Shaft diameter at hub .................................... 9.0 in 13. Turndown radius at hub ................................ 0.0 in 14. Locking Device ......................................... XT-100 15. Size .................................................... 9.00 x 17.50 16. Hub width ..................................................... 4.1 in 17. Hub pressure .................................................. 0 psi 18. Maximum torque ........................................ 0 lbf·ft 19. Hub outer diameter ..................................... 17.5 in Bearing Specifications 20. Bearing Center Distance ............................. 88.0 in 21. Shaft diameter at bearing .............................. 7.5 in 22. Bearing to Fillet Distance ............................. 5.7 in 23. Turndown radius at bearing .......................... 2.3 in 24. Bearing ......................................................... 23044 25. SNL Plummer Block ...................................... 3044 26. Dynamic Capacity ..................................... 274 kip 27. Bearing L10 .................................... 166,197 hours
Design Tensions and Loads 28. Running T1 Tension ................................. 48.8 kip 29. Running T2 Tension ................................. 16.6 kip 30. Design T1 Tension ................................... 59.7 kip 31. Design T2 Tension ................................... 17.6 kip 32. Wrap angle ................................................204 deg 33. Design Resultant Tension ......................... 75.9 kip 34. Resultant Angle .........................................181 deg 35. Resultant Moment ................................ 41.1 kip·ft 36. Resultant Torque .................................. 36.1 kip·ft 37. Estimated Pulley & Shaft Mass ................ 5,027 lb 38. Estimated Mass with Bearings ................. 5,699 lb Shaft Stresses & Deflections 39. Shaft slope at hub ............................... 0.0016 in/in 40. Shaft slope at bearing ......................... 0.0020 in/in 41. Shaft deflection at center .......................... 0.048 in 42. Shaft deflection at center (%) ....................... 0.055 43. Shaft Safety Factor (CEMA) .......................... 1.76 44. Shaft Safety Factor (AS1403) ........................ 1.47 45. Bending Stress ............................................. 6.9 ksi 46. Torsional Stress ........................................... 3.0 ksi 47. Von Mises Stress ......................................... 8.7 ksi 48. Fillet Von Mises Stress ............................. 11.5 ksi Shell Dimension and Stresses 49. Shell thickness .............................................. 1.0 in 50. Sitzwohl reqd shell thickness1 ...................... 0.8 in 51. Sitzwohl shell stress .................................... 5.9 ksi 52. Shell stress at 180 wa .................................. 3.4 ksi 1 Assumes 180 deg wrap and allowable stress of 4.9 ksi End Disk Dimension and Stresses 53. End disk thickness ........................................ 1.5 in 54. End disk stress ........................................... 12.0 ksi
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
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#4 - Pulley 4 Pulley Location and Geometry 1. Name (Type-3) ............................................ Pulley 4 2. Pulley Diameter ............................................ 24.8 in 3. Face Width .................................................... 69.0 in Lagging 4. Lagging Type ............................................... Rubber 5. Lagging Thickness .......................................... 0.8 in 6. Diameter with lagging .................................. 26.4 in Shaft Specification 7. Shaft Center Diameter .................................... 4.4 in 8. Shaft Material ......................................... SAE 1018 9. Yield Strength ............................................. 31.9 ksi 10. Fatigue Strength ........................................ 29.0 ksi Locking Device 11. Hub Center Distance ................................... 64.0 in 12. Shaft diameter at hub .................................... 4.4 in 13. Turndown radius at hub ................................ 0.0 in 14. Locking Device ........................................... XT-45 15. Size ................................................... 4 7/16 x 8.00 16. Hub width ..................................................... 2.1 in 17. Hub pressure .................................................. 0 psi 18. Maximum torque ........................................ 0 lbf·ft 19. Hub outer diameter ....................................... 8.0 in Bearing Specifications 20. Bearing Center Distance ............................. 80.0 in 21. Shaft diameter at bearing .............................. 3.9 in 22. Bearing to Fillet Distance ............................. 3.6 in 23. Turndown radius at bearing .......................... 0.8 in 24. Bearing ......................................................... 23222 25. SNL Plummer Block ........................................ 522 26. Dynamic Capacity ..................................... 135 kip 27. Bearing L10 .................................... 500,000 hours
Design Tensions and Loads 28. Running T1 Tension ................................. 16.6 kip 29. Running T2 Tension ................................. 16.9 kip 30. Design T1 Tension ................................... 19.0 kip 31. Design T2 Tension ................................... 19.1 kip 32. Wrap angle ..................................................24 deg 33. Design Resultant Tension ......................... 9.66 kip 34. Resultant Angle .........................................262 deg 35. Resultant Moment ................................ 3.22 kip·ft 36. Resultant Torque .................................. 0.06 kip·ft 37. Estimated Pulley & Shaft Mass ................ 1,671 lb 38. Estimated Mass with Bearings ................. 1,768 lb Shaft Stresses & Deflections 39. Shaft slope at hub ............................... 0.0022 in/in 40. Shaft slope at bearing ......................... 0.0025 in/in 41. Shaft deflection at center .......................... 0.054 in 42. Shaft deflection at center (%) ....................... 0.067 43. Shaft Safety Factor (CEMA) .......................... 3.48 44. Shaft Safety Factor (AS1403) ........................ 2.97 45. Bending Stress ............................................. 4.5 ksi 46. Torsional Stress ........................................... 0.0 ksi 47. Von Mises Stress ......................................... 4.5 ksi 48. Fillet Von Mises Stress ............................... 4.1 ksi Shell Dimension and Stresses 49. Shell thickness .............................................. 0.7 in 50. Sitzwohl reqd shell thickness1 ...................... 0.5 in 51. Sitzwohl shell stress .................................... 3.8 ksi 52. Shell stress at 180 wa .................................. 2.7 ksi 1 Assumes 180 deg wrap and allowable stress of 4.9 ksi End Disk Dimension and Stresses 53. End disk thickness ........................................ 1.1 in 54. End disk stress ............................................. 6.1 ksi
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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#5 - Take-up Pulley Pulley Location and Geometry 1. Name (Type-2) ................................ Take-up Pulley 2. Pulley Diameter ............................................ 31.5 in 3. Face Width .................................................... 69.0 in Lagging 4. Lagging Type ............................................... Rubber 5. Lagging Thickness .......................................... 0.8 in 6. Diameter with lagging .................................. 33.1 in Shaft Specification 7. Shaft Center Diameter .................................... 7.0 in 8. Shaft Material ......................................... SAE 1018 9. Yield Strength ............................................. 31.9 ksi 10. Fatigue Strength ........................................ 29.0 ksi Locking Device 11. Hub Center Distance ................................... 62.5 in 12. Shaft diameter at hub .................................... 7.0 in 13. Turndown radius at hub ................................ 0.0 in 14. Locking Device ........................................... XT-80 15. Size .................................................... 7.00 x 14.75 16. Hub width ..................................................... 3.6 in 17. Hub pressure .................................................. 0 psi 18. Maximum torque ........................................ 0 lbf·ft 19. Hub outer diameter ..................................... 14.8 in Bearing Specifications 20. Bearing Center Distance ............................. 84.0 in 21. Shaft diameter at bearing .............................. 6.0 in 22. Bearing to Fillet Distance ............................. 4.7 in 23. Turndown radius at bearing .......................... 1.5 in 24. Bearing ......................................................... 23036 25. SNL Plummer Block ...................................... 3036 26. Dynamic Capacity ..................................... 187 kip 27. Bearing L10 .................................... 309,084 hours
Design Tensions and Loads 28. Running T1 Tension ................................. 18.0 kip 29. Running T2 Tension ................................. 18.3 kip 30. Design T1 Tension ................................... 19.8 kip 31. Design T2 Tension ................................... 20.3 kip 32. Wrap angle ................................................180 deg 33. Design Resultant Tension ......................... 40.2 kip 34. Resultant Angle .........................................355 deg 35. Resultant Moment ................................ 18.0 kip·ft 36. Resultant Torque .................................. 0.77 kip·ft 37. Estimated Pulley & Shaft Mass ................ 3,208 lb 38. Estimated Mass with Bearings ................. 3,552 lb Shaft Stresses & Deflections 39. Shaft slope at hub ............................... 0.0019 in/in 40. Shaft slope at bearing ......................... 0.0023 in/in 41. Shaft deflection at center .......................... 0.053 in 42. Shaft deflection at center (%) ....................... 0.063 43. Shaft Safety Factor (CEMA) .......................... 2.24 44. Shaft Safety Factor (AS1403) ........................ 2.00 45. Bending Stress ............................................. 6.4 ksi 46. Torsional Stress ........................................... 0.1 ksi 47. Von Mises Stress ......................................... 6.4 ksi 48. Fillet Von Mises Stress ............................... 6.1 ksi Shell Dimension and Stresses 49. Shell thickness .............................................. 0.9 in 50. Sitzwohl reqd shell thickness1 ...................... 0.5 in 51. Sitzwohl shell stress .................................... 2.1 ksi 52. Shell stress at 180 wa .................................. 2.1 ksi 1 Assumes 180 deg wrap and allowable stress of 4.9 ksi End Disk Dimension and Stresses 53. End disk thickness ........................................ 1.3 in 54. End disk stress ............................................. 9.4 ksi
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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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
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Belt Transition Length Requirements DIN 22101 Transition Lengths
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Material Loading Profiles
Material Properties Type ............................................................ Rock, crushed Design Tonnage .................................................. 8818 tph Density ................................................................125 lb/ft3 Maximum lump size ................................................ 3.3 in Surcharge angle ...................................................... 20 deg
Tonnage .............................................................. 8818 tph Belt speed ............................................................ 787 fpm Material mass .................................................... 373.3 lb/ft Edge distance (required / actual)...................... 4.1 / 5.1 in Cross sectional loading (utility / total) ........... 91 % / 65 % Bed depth ............................................................... 13.1 in
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Idler Specifications Idler Specifications
Type 5 Equal Rolls VEE
Number of rolls 5 2 Trough angle (deg) 45 10 Roll diameter (in) 6.0 6.0 Roll length (in) 14.1 34.0 Shaft diameter (in) 0.98 0.98 Bearing series 6305 6305 Maximum roll RPM 503 503 Min Life (1000 hrs) 101 350 95% life1 (1000 hrs) 101 350 Shaft deflection (min) 6.26 4.08 Mass per Roll (lb) 15.9 34.2 Rotating mass for set (lb) 79.3 68.4 Wk2 for set (lb·in²) 613 555 Idler Spacing and Count Summary General Carry Return Idler spacing (ft) 3.28 6.56 Number of idler sets 670 322 Number of rolls 3,350 644 Total drag (lbf) Nominal friction 3.3 1.3 High friction 3.3 1.3 Low friction 0.0 0.0
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Idler Life and Shaft Deflection Summary-Carry Side
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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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 10,299 tph have also been included. This specific load case results in 100% 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 10,299 tph under steady state and dynamic conditions + 110% multiplier
The idler stringer loading should be based on the flooded belt surge capacity of 13,481 tph and 600.4 lb/ft plus the idler and frame masses. Additionally, all other loads (hood covers, wind loads, etc.) must also be taken into consideration.
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Element Summary Details
Tension Summary
Power Summary
Client Name Sidewider Demo Designer AC-Tek Project Name Tripper Example Company AC-Tek
Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Vertical Curve Summary Summary of Vertical Curve on Carry Strand
Elements Station (ft) Type Radius (ft) Running Tension Momentary Tension
Req'd Radius (ft) Reason Req'd Radius
(ft) Reason
8-10 1,510 - 1,573 concave -246 -1315 Lift Off -1537 Lift Off 18-20 1,726 - 1,849 concave -2461 -1487 Lift Off -1692 Lift Off
Summary of Vertical Curve on Return Strand
Elements Station (ft) Type Radius (ft) Running Tension Momentary Tension
Req'd Radius (ft) Reason Req'd Radius
(ft) Reason
26-28 1,726 - 1,849 concave -2461 -699 Lift Off -699 Lift Off
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Conveyor Name Tripper 1 Filename Tripper Conveyor Location Date February 16, 2016
Description Tripper Conveyor Example
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Element Summary Details Summary of Conveyor Elements