beltstat v7.0 user manual.pdf
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BELTSTAT v7.0
User ManualDecember 2012
Revision 7.0.30
Conveyor Dynamics, Inc.
1111 West Holly, Street
Bellingham WA, 98225
(360) 671-2200
www.conveyor-dynamics.com
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1.0 INTRODUCTION ............................................................................................................................ 7
2.0 GETTING STARTED ...................................................................................................................... 8
3.0 THE USER INTERFACE ................................................................................................................ 9
3.1 OVERVIEW ...................................................................................................................................... 93.2 THE MAIN MENU &TOOLBAR........................................................................................................ 93.3 FILEMENU ....................................................................................................................................103.4 GENERAL-GENERAL PROJECT INFORMATION ............................................................................12
3.4.1 Client Information .................................................................................................................123.4.2 Job Number ........... ........... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......123.4.3 Designer ............. .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ...........123.4.4 Description .................. .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..123.4.5 Remarks .......... ........... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ....133.4.6 Input Units .......... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ...........133.4.7 Output Units ..........................................................................................................................133.4.8 Analysis Type ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .....133.4.9 Output Curve Report .............................................................................................................133.4.10 Itemized Loss Table ................. .......... ........... .......... ........... .......... .......... ........... .......... ...........13
3.5 MATERIALMATERIAL PROPERTIES ..........................................................................................143.5.1 Material Conveyed ........... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......143.5.2 Design Tonnage .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..143.5.3 Loading Multiplier .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... .........143.5.4 Allowed Cross Sectional Loading .......... .......... ........... .......... .......... ........... .......... ........... .......153.5.5 Bulk Density .......... .......... ........... .......... .......... ........... .......... ........... .......... ........... .......... .........153.5.6 Surcharge Angle ....................................................................................................................153.5.7 Maximum Lump Size .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .....153.5.8 Percent Lumps .......... ........... ........... .......... ........... .......... .......... ........... .......... ........... .......... ....153.5.9 Lump Shape Factor ........... ........... .......... ........... .......... ........... .......... ........... .......... ........... .....153.5.10 Chute Drop Distance .............................................................................................................153.5.11 Abrasive index .................. .......... ........... .......... ........... .......... .......... ........... .......... ........... .......15
3.5.12 Environmental Condition....... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..153.5.13 Maintenance Condition ........... .......... ........... .......... ........... .......... .......... ........... .......... ...........163.5.14 Hours in Service Per Day ......... ........... .......... ........... .......... ........... .......... ........... .......... .........163.5.15 Minimum Temperature ............... ........... .......... ........... .......... .......... ........... .......... .......... ........163.5.16 Maximum Temperature .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..16
3.6 BELTBELT PROPERTIES .............................................................................................................173.6.1 Belt Width .................. .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ....173.6.2 Belt Speed ........... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ...........173.6.3 Type of Carcass .....................................................................................................................173.6.4 Belt Rating .......... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ...........173.6.5 Belt Weight ........... .......... ........... .......... .......... ........... .......... ........... .......... ........... .......... .........183.6.6 Top Cover Thickness .............................................................................................................183.6.7 Bottom Cover Thickness .......... .......... ........... .......... ........... .......... .......... ........... .......... ...........18
3.6.8 Elasticity ......... ........... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ....183.6.9 Allowable Sag .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .....193.6.10 Edge Distance to Material .......... ........... .......... ........... .......... ........... .......... .......... ........... .......19
3.7 IDLERIDLER PROPERTIES ..........................................................................................................203.7.1 Carry Side Trough Angle .......................................................................................................203.7.2 Trough Angle - Return Side ...................................................................................................203.7.3 Number of Rolls .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..203.7.4 Idler Name / Series ................ .......... ........... .......... ........... .......... ........... .......... ........... .......... ..213.7.5 Roll Diameter .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .....213.7.6 Seal Friction ..........................................................................................................................21
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3.7.7 Coulomb Friction Coefficient (CFC) .......... .......... ........... .......... ........... .......... ........... .......... ..213.7.8 Rotating Weight ................... ........... .......... ........... .......... .......... ........... .......... ........... .......... ....213.7.9 Load Rating ................. .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..213.7.10 Trough Shape Multiplier - Carry Side ...................................................................................213.7.11 Trough Shape Multiplier - Return Side .......... ........... .......... ........... .......... ........... .......... .........223.7.12 Temperature Adjustment ........................................................................................................223.7.13 (KX/KY) Regenerative Correction .........................................................................................223.7.14 Skirtboard Friction Factor ....................................................................................................223.7.15 Skirtboard Width ....................................................................................................................233.7.16 Depth of Material Touching Skirtboard .......... ........... .......... .......... ........... .......... ........... .......233.7.17 Vertical Installation Tolerance ..............................................................................................233.7.18 Use Drift Tensions for Radii ..................................................................................................23
3.8 DRIVESCONVEYOR DRIVES/BRAKES &TAKE-UP PARAMETERS ...............................................243.8.1 Motor Nameplate ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... .........243.8.2 Power Ratio .......... .......... ........... .......... .......... ........... .......... ........... .......... ........... .......... .........243.8.3 Motor Synchronous Speed .......... ........... .......... ........... .......... ........... .......... .......... ........... .......253.8.4 Starting Torque Limit Percent ...............................................................................................253.8.5 Drive Inertia at Motor ................ ........... .......... ........... .......... .......... ........... .......... .......... ........253.8.6 Drive Efficiency .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..253.8.7 Drive Friction Factor (Running) ................... ........... .......... ........... .......... ........... .......... .........253.8.8 Drive Friction Factor (Accel/Decel) .......... .......... ........... .......... ........... .......... ........... .......... ..253.8.9 Brake Torque Ratio ........... ........... .......... ........... .......... ........... .......... ........... .......... ........... .....253.8.10 Acceleration Time ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... .........253.8.11 Braking Time ................ ........... .......... ........... .......... .......... ........... .......... ........... .......... ...........253.8.12 Total Brake Torque Ratio ......................................................................................................263.8.13 Drive Slip Percent .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... .........263.8.14 Counterweight Type ...............................................................................................................263.8.15 Gravity Take-up .....................................................................................................................263.8.16 Fixed Take-up .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .....263.8.17 Tension at Tension Device .....................................................................................................263.8.18 Take-up Extension .................................................................................................................26
3.9 PROFILECONVEYOR PROFILE INPUT .........................................................................................273.9.1 Flight .............. ........... .......... ........... .......... ........... .......... ........... .......... .......... ........... .......... ....28
3.9.2 Flight Number........ ........... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......283.9.3 Ground X (or Station) ............................................................................................................283.9.4 Ground Y (or Elevation) ........................................................................................................283.9.5 Flight Length .............. ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..283.9.6 Flight Height...... ........... ........... .......... ........... .......... .......... ........... .......... ........... .......... ...........283.9.7 Idler Spacing.......... ........... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......283.9.8 Flight ID .................. ........... .......... .......... ........... .......... ........... .......... ........... .......... ........... .....293.9.9 Load %......... .......... ........... .......... ........... .......... .......... ........... .......... ........... .......... ........... .......293.9.10 Conv. Load ............................................................................................................................293.9.11 Pulley Diameter .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ..293.9.12 Pulley Wrap .......... .......... ........... .......... .......... ........... .......... ........... .......... ........... .......... .........303.9.13 Vertical Curve Radius............................................................................................................303.9.14 Horizontal Curve Radius .......... ........... .......... ........... .......... ........... .......... ........... .......... .........30
3.9.15 Concentrated Weight Specification .......................................................................................303.9.16 Miscellaneous Drag Tension Specification .......... ........... .......... ........... .......... ........... .......... ..303.9.17 Notes .......... ........... .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... .........30
3.10QUICK START WINDOW ......................................................................................................................31
4.0 BELTSTAT OUTPUT FILE AND RESULTS WINDOW ..........................................................32
4.1 MATERIAL SPECIFICATIONS ...........................................................................................................334.2 BELT SPECIFICATIONS ....................................................................................................................344.3 IDLER AND ANCILLARY SPECIFICATIONS........................................................................................364.4 MOTOR /REDUCER /BRAKE SPECIFICATIONS ................................................................................38
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4.5 TENSIONSPECIFICATIONSAND "TENSION"WINDOW ............................................................404.6 "TENSION RATIO"DRIVE /BRAKE TENSION RATIOS ...................................................................424.7 "TAKE-UP"SPECIFICATIONS ...........................................................................................................434.8 FORCE /DRAG SUMMARY ..............................................................................................................474.9 CONVEYOR SUMMARY ...................................................................................................................474.10 THE RESULTS WINDOW WITH THE "PLOT"BUTTON SELECTED ......................................................484.11 THE RESULTS WINDOW WITH THE "MAIN"BUTTON SELECTED .....................................................49
4.11.1 "Summary" Window Selection Button ........... .......... ........... .......... .......... ........... .......... ...........494.11.2 "Tension" Window Selection Button ......................................................................................494.11.3 "Concave" Window Selection Buttons ...................................................................................504.11.4 "Convex" Window Selection Buttons .....................................................................................514.11.5 "Loss Table" Window Selection Buttons .......... ........... .......... .......... ........... .......... ........... .......52
4.12 VIEW BSOFILE ..............................................................................................................................53
5.0 PROFESSIONAL VERSION FEATURES ...................................................................................54
5.1 PROJECT FILES ...............................................................................................................................545.1.1 Project Files - Input Table .......... ........... .......... ........... .......... ........... .......... .......... ........... .......555.1.2 Project Files - Results Table ........... .......... ........... .......... .......... ........... .......... ........... .......... ....585.1.3 Project Files - Tension Table ....... .......... ........... .......... ........... .......... ........... .......... ........... .....59
5.3 SPLICE PATTERN ............................................................................................................................695.4 BELT TURNOVER CALCULATIONS ..................................................................................................735.5 TRANSITION LENGTHS ....................................................................................................................815.6 MATERIAL TRAJECTORY ................................................................................................................825.7BELT ROLL CALCULATIONS .................................................................................................................835.8MATERIAL LOADING PROFILE ..............................................................................................................845.9 BELT FEEDERS ...............................................................................................................................845.10 PULLEY DESIGN .............................................................................................................................855.11 IDLER MASS CALCULATIONS......................................................................................................895.12LOADING ON/OFF ...............................................................................................................................905.13 MULTIPLE DESIGN RUNS ................................................................................................................915.14 MICROSOFT WORK REPORTS......................................................................................................93
6.0 EXAMPLES .....................................................................................................................................95
6.1 EXAMPLE #1 ...................................................................................................................................966.2 EXAMPLE #2 .................................................................................................................................1086.3 EXAMPLE #3 .................................................................................................................................1206.4 EXAMPLE #4 .................................................................................................................................1316.5 EXAMPLE #5FIXED TAKE-UP ....................................................................................................141
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Foreword
ALL RIGHTS RESERVED. No part of this documentation may be reproduced in any form, by
any means, without the prior written permission of Conveyor Dynamics, Inc. (CDI) U.S.A.
CDI makes no representations or warranties with respect to the program material and specificallydisclaims any implied warranties, accuracy, merchantability or fitness for any particular purpose. Further,
CDI reserves the right to revise the program material and to make changes therein from time to time
without obligation to notify purchaser of any revisions or changes except specific errors determined to be
incorporated in the program material. It shall be the responsibility of CDI to correct any such errors in an
expeditious manner. In no event shall CDI be liable for any incidental, indirect, special or consequential
damages arising out of the purchasers use of program material.
Beltstat Minimum System Requirements
CPU Speed 200 Mhz
RAM 32 MB
Video Adapter VGA
Hard disk 20 MB
Operating System Windows 95 or Better
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1.0 INTRODUCTION
BELTSTAT is a computer program used in the design of troughed belt conveyors handling bulk materials.
BELTSTAT can analyze conveyors of any length and topography having up to twelve drive/brake stations,
without restriction as to location. The program can analyze downhill, regenerative conveyors, and belt
widths from 24 to 120 inches. Drives may be conventional head type, tail, and/or intermediate (TT-type)
drives of any combination. Both acceleration and braking action can be analyzed using either
independently controlled starting/stopping times or controlled acceleration/braking force. Starting and
stopping forces may be proportioned as desired among the multiple drives.
BELTSTAT is intended to be a design tool and computational aid to competent and experienced conveyor
design engineers. Correctly employing the program together with good engineering judgment and
conveyor design experience, users can quickly arrive at the following conveyor design data:
o Belt width and speed
o Belt tension rating
o Counterweight tension
o Horsepower rating of drive motors
o Drive motor starting characteristicso Idler specifications and spacing
o Pulley and shaft design
o Vertical curve radii and required special idler spacing
o Brake size (if required)
o Flywheel requirements (if applicable)
BELTSTAT has been verified against successfully operating conveyor systems. When used by an engineer
familiar with conveyor design methods, the program functions as a powerful design tool, providing
uniform, accurate, and rapid computations. The program allows the engineer to easily explore alternative
configurations, such as alternate counterweight and drive locations, which may result in a more economical
design.
The formulae and calculation methods of BELTSTAT are based upon the methods and data published bythe Conveyor Equipment Manufacturers Association (CEMA). Selected methods have been modified or
expanded to meet the requirements of high capacity, high speed, and overland systems.
Finally, BELTSTAT is designed to provide flexibility and convenience to the engineer. Where possible,
input parameters are optional. If the user does not specify these, the program will either use an appropriate
default value or make a selection based on the known variables.
BELTSTAT operates by reading an input file, analyzing the data, and then writing the final calculations to
an output file. The User Interface is a different program which allows the user to easily interact with
BELTSTAT. The User Interface allows you to input the conveyor geometry, and all the needed parameters
for the BELTSTAT input file. It will then write the input file for BELTSTAT, and allow you to run
BELTSTAT.
The manual consists of six chapters. Chapter 2 describes how to set up BELTSTAT on your computer, and
details the necessary files and equipment needed for the program to run. Chapter 3 presents the User
Interface that allows you to input the parameters needed for BELTSTAT. Then, Chapter 4 explains the
BELTSTAT results windows and output file. Chapter 5 discusses the advanced features found in the
professional version. Finally, Chapter 6 contains examples of conveyor designs made with BELTSTAT and
steps the user through each stage of the design. Many users may wish to skip directly to the example
section, and only reference the main body of the user manual as required.
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2.0 GETTING STARTED
Before proceeding be sure you have the following items.
1. BELTSTAT v7.0 CD-ROM2. Hardware key (dongel)3. BELTSTAT User Manual
The BELTSTAT CD-ROM contains the following directories:
1. INSTALL The installation directory with the BELTSTAT SETUP.EXE File2. SUPERPRO Directory containing software for the BELTSTAT hardware key.3. EXAMPLES A copy of the Examples files found in Chapter 6. This directory is also
copied onto your hard drive under the /BELTSTAT/EXAMPLES installation directory.
The User Interface requires Microsoft Windows 95, 98, ME, NT 4.0, or Windows 2000. It is also highly
recommended to use the default font types and a video resolution of 1024x768 or higher.
To install BELTSTAT on your computer insert the CD into your computers CR-ROM drive. If you haveautorun turned on the setup process be start automatically. Otherwise run the file:
X:/SETUP.EXE
WhereXis the drive letter of your CD-Rom. A setup window will appear and step you through the
installation process.
IMPORTANT: Be sure to enter the correct user name, company name, and correct serial number. The user
and company names will appear on all BELTSTAT output files. Your serial number was supplied to you at
the time of purchase and is also located on the front side of the hardware installation key. DEMO users
should leave the serial number blank.
Now follow the online instructions. You may be asked to re-boot your computer once the installation
process is finished.
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3.0 THE USER INTERFACE
3.1 Overview
The new BELTSTAT user interface is shown below. It contains various input and output windows. These
windows allow the user to quickly build, analyze, and optimize complex conveyor systems. Each window
will be briefly described in the following sections.
3.2 The Main Menu & Toolb ar
The Main Menu contains groups of pulldown lists. These lists give the user access to all the program
features. The pictures on the toolbar menu provide quick access to many of the most commonly used
items. Both the main menu and toolbar are shown below.
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3.3 FILE Menu
The File main menu list contains common file operation commands and output features found in most
windows based programs. The File menu pulldown list is shown below.
New File
Opens the "Conveyor Quick Start" window to begin working with a new BELTSTAT file.
Open FileOpens an existing file.
Save File
Saves the file using the current filename. The file is also automatically saved each time the
BELTSTAT calculations are run.
Save File As
Save the file under a different filename
Close File
Closes the current file. If the file has not been saved it will prompt the user to save the file.
Open / Save ProjectThese features are only available in the professional version of BELTSTAT. When designing a
conveyor the engineer must be aware of several different worst cases design scenarios. For
example, a conveyor with only the inclined, or declined sections loaded will behave very differently
and a separate BELTSTAT file should be created for each case. These multiple files can be saved as
a single "Project". The user can now automatically open ALL files in a project at once instead of
having to open each file one at a time. Furthermore, using the Project menu these files can all be
created automatically (this is discussed in detail in chapter 5). The Project file also contains the
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"Standard Cases" Input table parameters, thereby restoring any information used to create the
project.
Close All Files and Projects
Closes all opened files and projects. If a file has not been saved it will prompt the user to save the
file.
Print Current Window
Prints the currently selected window. This window maybe the BSO results window or any of the
Report windows (trajectory, flap, turnover, cases summary, etc.)
Print BSO File
Prints the results (*.BSO) file.
Print Conveyor Report
Allows the user to quickly print out specific information on all currently opened files.
Windows Options
Show ToolbarTurns the main toolbar on and off.
Close Input Window on ExitClose the current input window when another input window isselected.
Save Window Sizes and PositionsSave the current window sizes and the positions as the global
defaults for BELTSTAT.
Save & Close Current WindowSimple saves and closes the current input window.
Undo Changes to WindowUndoes any changes to the current window.
Opened WindowsShows a list of all opened windows.
Plotting Options
Set information pertaining to the BELTSTAT output plots.
Show Absolute Tension ValuesSets whether the tension values are plotted as absolute values (N
or LBS) or as belt rating values (N/mm or PIW).
Show Station NumbersTurns the station numbers on and off in the plot window.
Show Drive / Brake SymbolsTurns the drive /brake symbols on and off in the plot window.
Show 2ndPlot WindowShows a 2ndPlot window. This allows the user to view the BELTSTAT
plots and summary table at the same time.
Use User Default PlotsUses the user default plots.
Save Default PlotsSave the current plot configuration as the user default.
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RUN
Save the current file and runs the BELTSTAT calculations.
Recent Files List
List the last four files recently used. Selecting a file automatically opens the file.
Exit
Exits the BELTSTAT program
3.4 GENERAL - General Project Inform ation
The identification menu allows you to enter information about the conveyor, client, designer, etc. Each
option is limited to the space in the box, except for the conveyor description box which is longer than it
appears. The information placed in these boxes will be printed at the top of each page in the output file. It
is also used as the title blocks for the tension plots made in the plot menu.
The input units box controls how BELTSTAT interprets the data that you enter in the user interface. All
parameters must be entered in the same units. Also, if you change the unit type the user interface does not
change the values of the parameters which you have already entered. However, the unit labels do change
for each parameter. Be careful to enter the conveyor parameters in the correct units.
3.4.1 Client Information
Enter the clients name here (optional).
3.4.2 Job Number
Enter the job number here (optional).
3.4.3 Designer
Enter the name of the designer (optional). This field Defaults to the "User Name" specified when
installing the BELTSTAT program.
3.4.4 Description
Enter a description of the conveyor (optional). This information is also added to the bottom of each
of the conveyor output tension plots.
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3.4.5 Remarks
Enter any general remarks you feel relevant about the conveyor here (optional). This information is
also added to the bottom of each of the conveyor output tension plots.
3.4.6 Input Units
The input units box control how BELTSTAT interprets the data that you enter in the user interface.
All parameters must be entered in the same unit system. Also, if you change the unit type, the user
interface does not change the values of the parameters which you have already entered. However,
the unit labels do change for each parameter. Be careful to enter the conveyor parameters in the
correct units.
3.4.7 Output Units
The output units allows you to choose the whether the output file will be written in English or Metric
units. These units may differ from the input units.
3.4.8 Analysis Type
This field tells BELTSTAT how to calculate the KY values.
CEMAThe KY values will be calculated according to a modified CEMA KY formula.
Behren's and SchwartzThe KY values will be calculated according to KY calculations formulated by Behren's and
Schwartz. On large belts or belts with large idler spacing (greater than 6.0 feet), this analysis type
is suggested regardless of belt construction.
Rheological AnalysisThis analysis type is not currently marketed in BELTSTAT. Contact Conveyor Dynamics if you
are interested in more information about this analysis method.
3.4.9 Output Curve Report
Indicates whether or not a detailed curve report will be generated in the BELTSTAT output file.
3.4.10 Itemized Loss Table
When this box is selected a BELTSTAT itemized loss table is created showing where losses occur.
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3.5 MATERIAL Material Properties
The material menu allows you to enter the necessary information about the material being conveyed. The
TAB key moves between input lines (SHIFT-TAB moves back one line).
3.5.1 Material Conveyed
This field contains a description of the material being conveyed and has a pulldown submenu. Click
on the to see the available selections (coal, tar sand, copper ore, etc.). When a
material is chosen from the list its default properties will automatically be entered into the remaining
fields. The user is not limited to the default materials and may type in ANY material type and its
corresponding properties. Furthermore, by selecting, CREATE A NEW MATERIAL, or
DELETE A MATERIAL the user can add to, or remove, items from the default pulldown list.
3.5.2 Design Tonnage
Desired conveyor design capacity in tons per hour (metric) or short tons per hour (English), wet or
dry. Input value sets the belt size, speed, and material load on the belt. This field has no default, and
must be set by the user.
3.5.3 Loading Multiplier
The flight loading multiplier acts as a multiplying factor on each flight's loading. This is useful for
evaluating a partially loaded, overloaded, or empty conveyor. For example, a flight loading
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multiplier equal to zero will result in an empty-belt analysis. A multiplier of 0.5 will cause all flight
loading percentage to be reduced by half of their input value.
3.5.4 Allowed Cross Sectional Loading
Maximum allowable material cross-sectional loading, as defined by CEMA. The program will
select belt width, speed, and material edge clearance (unless these have been input) such that this
loading will not be exceeded. Default value is 85 percent.
3.5.5 Bulk Density
The bulk density of the material as defined by CEMA.
3.5.6 Surcharge Angle
Dynamic angle of repose as defined by CEMA. The default value is 20 degrees.
3.5.7 Maximum Lump Size
Maximum lump size is used to compute impact force at belt transfer and to indicate minimum
CEMA belt width when used in conjunction with percent lumps. Default value is 20 percent.
3.5.8 Percent Lumps
Percent lumps as defined by CEMA. Used in conjunction with maximum lump size and with
CEMA idler selection. Default value is 20 percent.
3.5.9 Lump Shape Factor
Although not described in CEMA, this factor can be found in the "Engineering Handbook -
Conveyor and Elevator Belting," by B. F. Goodrich Company. The factor is used to estimate lump
weight for calculation of loading station impact force. The factor describes the shape of the lump.
For a material with cubic shaped lumps, the factor would be equal to 1.0. With long Slabby lumps,
the factor would be 1.25. Default value is 1.4.
3.5.10 Chute Drop Distance
The height the material drops before contacting the belt at the loading station. This is used for
calculation of loading station impact force.
3.5.11 Abrasive index
Describes the abrasive characteristics of the material. This field has a submenu selection, which are:
Selection Meaning
1 none
2 light
3 moderate
4 very
5 extreme
The default selection is 4.
3.5.12 Environmental Condition
This variable indicates the cleanliness of the environment. The allowable input conditions are:
CLEAN, MODERATE, and DIRTY. This factor is used in idler selection and rating per CEMA.
Default value is DIRTY.
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3.5.13 Maintenance Condition
This variable describes the expected idler maintenance conditions. Allowable inputs are GOOD,
FAIR, or POOR. This factor is used in idler selection and idler rating per CEMA. The default value
is POOR.
3.5.14 Hours in Service Per Day
This factor is used in idler selection and rating per CEMA. Default value is 24 hours.
3.5.15 Minimum Temperature
This variable is the temperature used to evaluate the CEMA KT value, the ambient temperature
correction factor. Above 32 F, KT is equal to 1.0. The user is advised to input a temperature at 32
F or higher when executing a low-friction analysis. Default value is 30 F.
3.5.16 Maximum Temperature
This variable is used to obtain the total temperature change, and subsequently, the take-up travel due
to temperature change. Default value is 100 F.
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3.6 BELT Belt Properties
The belt menu contains the necessary information for the belt specification. The procedure for the belt
parameters is very much the same as those for the material parameters. The fields which have submenu
selections are belt width and type of carcass. The width of the belt can be from 18 inches to 120
inches. The belt carcass can be steel, polyester, nylon, or left blank. Those fields which are left blank will
be calculated by BELTSTAT. For example, if the belt width and strength are not specified thenBELTSTAT will determine the width and strength needed for the required tonnage, and conveyor profile.
However, there are some fields which require the input from the user. The Sag Allowable on Carry Side,
% must be entered by the user.
3.6.1 Belt Width
The user may specify the belt width or allow the program to select it. Any belt width from 18 inches
up to 120 inches, including nonstandard widths in this range, may be input by the user. If not input,
a selection will be made from the following values: 24, 30, 36, 42, 48, 54, 60, 66, 72, 84, 90, 96,
102, 108, 114, 120 (inches - for English units).
3.6.2 Belt Speed
The belt speed may be input or the user may allow the program to calculate it. The program
selection will be based on minimum edge distance, maximum allowable percentage loading, and belt
width. If neither belt width nor speed are input, the program will select the narrowest belt width for
which the required speed does not exceed 20 times the belt width in inches or 1200 FPM.
3.6.3 Type of Carcass
The user may specify POLYESTER, NYLON, or STEEL, or allow the program to select (leave
blank). If not input, the program will select polyester carcass unless the running stress exceeds 800
PIW, in which case the program will select steel cable.
3.6.4 Belt Rating
The user may specify or allow the program to select this parameter. Unless input, the program will
select a belt strength to meet the maximum "RUNNING" tension base on a factor of safety of 6.7
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(for steel cable belts). The selected PIW will be to the next higher 25 PIW increment for fabric and
100 PIW for steel cable belt.
3.6.5 Belt Weight
The user may specify or allow the program to select the belt weight. The program computes the
weights for polyester, nylon, and steel cable belting. Cover weights are calculated separately and
then added to the carcass weights to produce the total belt weight.
3.6.6 Top Cover Thickness
This variable refers to the thickness of gum rubber above the conveyor belt carcass. For steel cable
belts, the top cover thickness is interpreted as the thickness from the top of the steel cables to the top
surface of the belt cover.
The top cover thickness is used by the program in computing the belt weight when belt weight has
not been input.
If the user does not input the top cover thickness, the program will compute a suitable thickness
based on abrasiveness of the conveyed material, lump size, percentage of lumps, operating hours per
day, belt speed, and belt tape length. This formulation is based in part, on the Goodyear "red
handbook." Also, the following minimum thickness is maintained for load support and rubbersupport around high tension pulleys:
CARCASS MATERIAL PIW MIN. TOP COVER (IN.)
Fabric All 0.1875
Steel Cable Up to 2700 0.2500
Steel Cable 2701 to 3500 0.3125
Steel Cable Over 3500 0.3750
If any unusual conditions of abrasion are anticipated, the user is advised to input the appropriate
thickness, based on judgment and/or belt manufacturer's recommendations.
3.6.7 Bottom Cover Thickness
This variable refers to the thickness of gum rubber below the conveyor belt carcass. For steel cable
belts it is interpreted as the thickness from the bottom of the steel cables to the bottom surface of the
belt cover. As with the top cover thickness, the bottom cover thickness is used in the computation of
the belt weight when it has not been input.
If the user does not input a value, the program will select a value not less than one-third of the top
cover thickness, rounded to the nearest 1/32-inch. Also, the following minimums are applied for
steel cable belting:
PIW MIN. BOTTOM COVER (IN.)
Up to 3500 0.2500
Over 3500 0.3125
3.6.8 Elasticity
This input variable represents the elastic modulus of the conveyor belt and is used in curve
computations and in take-up travel computations. This is the TOTAL elasticity of the belt in LBS
and not PIW (N not N/mm).
If not input, the program will compute an approximate value based on the carcass material, carcass
rating, and belt width. Conveyor belt elasticity may vary considerably among different
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manufacturers, so the user is advised to input the manufacturers specified value, once a vendor
selection has been made.
3.6.9 Allowable Sag
The user may specify the maximum allowable Catenary sag between idlers. The value is computed
and set as a governing criterion for each geometric flight described later. Default value is 1.5
percent on carry side or absolute distance of 2/3 idler roll diameter of carry or return side.
3.6.10 Edge Distance to Material
The interpretation of the edge distance is according to CEMA, and refers to the minimum distance to
be maintained from the edge of the belt to the theoretical material cross-section when operating at
the rated tonnage. If this variable is not input, and no value is input for the cross-sectional design
loading, the program will select a minimum value based on lump size, surcharge angle, trough angle
and belt width.
In all cases where belt speed and/or width are input, these values are maintained. Therefore, if both
speed and width are input, the edge distance is fixed, and the value input for edge distance is
ignored.
When the cross-sectional design loading and edge distance are both input, both are used in selectingbelt width and speed (unless both are input). The program selection will meet both criteria.
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3.7 IDLER Idler Properties
The idler and ancillary specifications menu contains the necessary specifications for the idlers, and other
parameters. In this menu, only the trough angle and series number have submenu selections. If you
choose a standard idler from the series number submenu or leave this field blank then the input in fields
3A through 3E will be ignored by BELTSTAT. If you wish to enter customized values in the 3A through
3E fields, then you must enter a series number not available in the series number submenu. Those fieldwhich are left blank will be calculated from the known information. For example, the idler series number
will be calculated from then tension and other requirements in the belt, then the parameters which depend
on the series number (3A through 3E) will be calculated from the idler series number.
3.7.1 Carry Side Trough Angle
The user may input any desired trough angle, including nonstandard angles, or allow the program to
select. Only one trough angle may be specified for the full length of the conveyor. Default value is
35 degrees.
3.7.2 Trough Angle - Return Side
This variable refers to the angle of incline of the idler rolls on the V-return type idlers. If not input,
flat return idlers are assumed.
3.7.3 Number of Rolls
Number of rollers in the idler set.
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Suggestions:
A) When analyzing for the highest friction condition, allow the program to select a value.
However, when analyzing with ambient temperature below -10 degrees Fahrenheit, input a value
of 1.00.
B) When analyzing for the lowest friction condition (e.g. Regenerative conveyor), input a value of
1.00.
3.7.11 Trough Shape Multiplier - Return Side
CEMA return side friction factors make no allowance for the return idler incline angle (i.e. V-return
idlers). No representative field data has been compiled to evaluate the relationship between the
return idler angle and return side friction factors. Nevertheless, the program will compute a friction
factor multiplier for return idlers. The value will be 1.00 for flat idlers. Any input by the user will
override the program selection.
3.7.12 Temperature AdjustmentAmbient temperature correction factor (KT) is the idler rotational and flexing resistance increase of
the belt in cold weather operation. This is computed according to the CEMA data. The minimum
ambient temperature is used as the basis for computing this factor. Above 32 degrees F, the KT
factor is equal to 1.00.
3.7.13 (KX/KY) Regenerative Correction
CEMA recommends that when analyzing a regenerative (downhill; power-generating) conveyor or
when computing the longest expected drift time, a reduction factor be applied to KX and KY.
CEMA recommends that the KY and KX values be multiplied by 0.666 and that the idler bearing
seal friction, skirtboard rubber friction, and belt scraper friction be set to zero.
If the user desires this type of low-friction case, he should input a value of 0.666 (or other value
dictated by his judgment). The value input will be applied to the KY and KX factors. Also, if the
program detects an input value less than one, idler and pulley bearing seal friction, skirtboard rubber
friction, and scraper friction will be set to zero.
3.7.14 Skirtboard Friction Factor
Per CEMA, the program will accept input for the skirtboard coefficient of friction for the material
conveyed. The value is used per CEMA Fifth Edition. The default value is .06, which is the average
value for coal. The program internally adds 3 pounds per foot for the friction of the skirtboard
rubber. The skirt length is geometric input.
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Alumina, pulv. dry 0.1210 Coke, ground fine 0.0452 Limestone pulv., dry 0.1280
Ashes, coal, dry 0.0571 Coke, lumps and fines 0.0186 Magnesium chloride, dry 0.0278
Bauxfte, ground 0.1881 Copra, lumpy 0.0203 Oats 0.0219
Beans, navy, dry 0.0798 Cullet 0.0836 Phosphate rock, dry, broken 0.1086
Borax 0.0734 Flour, wheat 0.0265 Salt, common, dry, fine 0.0814
Bran, granular 0.0238 Grains, wheat, corn or rye 0.0433 Sand, dry, bank 0.1378
Cement Portland, dry 0.2120 Gravel, bank run 0.1145 Sawdust dry 0.0086
Cement clinker 0.1228 Gypsum, 1/2" screenings 0.0900 Soda ash, heavy 0.0705
Clay, ceramic, dry fines 0.0924 Iron ore, 200 lbs./cu ft 0.2760 Starch small lumps 0.0623
Coal, anthracite, sized 0.0538 Lime, burned, 1/8" 0.1166 Sugar, granulated dry 0.0349
Coal, bituminous, mined 0.0754 Lime hydrated 0.0490 Wood chips, hogged fuel 0.0095
3.7.15 Skirtboard Width
Per CEMA, the program will compute a skirtboard width of 2/3 the belt width. The designer mayinput other width selections. This value is used to calculate the depth of the material touching the
skirtboard and the resulting frictional forces.
3.7.16 Depth of Material Touching Skirtboard
The depth of the material touching the skirtboard (factor "Hs" in CEMA). If left blank, the program
will assume a material surcharge angle of zero and thus calculate the maximum possible depth of
material which can contact the skirtboard. This factor will override the depth calculated by the
above skirtboard width.
3.7.17 Vertical Installation Tolerance
The maximum possible vertical misalignment of the idlers from the ideal belt line elevation. The
tolerance is interpreted as a possible plus or minus value. This variable is used in sizing convexvertical curves and in determining the maximum load per idler on convex curves. To do this, an
idler on the curve is assumed to be elevated above its ideal position by the full value of the
installation tolerance, and the two adjacent idlers are assumed to be lowered by the same amount.
This is considered the worst case with respect to idler loading.
The program attempts to size the convex curve such that the idler capacity is not exceeded.
However under certain conditions, this is not possible and the program will show an overload
condition. If this occurs, the user must make the necessary corrections to the idler capacity,
installation tolerance, belt tension, or curve radius.
3.7.18 Use Drift Tensions for Radii
For certain conveyors, the drift tension condition may never occur. An example would be a
conveyor which is always started and/or stopped using controlled braking and driving forces. Forthese cases, the conveyor designer may specify that the drift tensions as calculated by the program
shall not be used in vertical curve radius selection. If the drift time and tensions are used, the
vertical curve selections will evaluate the minimum and maximum, carry and return side tensions for
vertical curve selection criteria.
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3.8 DRIVES Convey or Drives/Brakes & Take-up Parameters
The user may specify the motor nameplate horsepower at each station or allow the program to select a
motor size based on running horsepower. This variable represents the total nameplate horsepower at each
drive station, regardless of whether the drive pulley is driven by one or two motors. The program has a
motor selection range from 1 to 10,000 HP.
3.8.1 Motor Nameplate
The user may specify the motor nameplate horsepower at each station or allow the program to select
the motor sized based on running horsepower. The variable represents the total nameplate
horsepower at each drive station, regardless of whether the drive pulley is driven by one or two
motors. The program has a motor selection range from 1 to 10,000 HP (7457 kW).
3.8.2 Power Ratio
This variable represents the distribution of the total running brake horsepower among the drive
pulley stations. This factor is not applicable to conveyors with one drive station only. The ratios
may be input in any manner that describes the distribution, such as the following examples:
Examples
(a) 1:1 - Two drive pulleys with equal power.
(b) 0.5:0.5 - Same as (a) above.
(c) 1:1:1 - Three drive pulleys with equal power.
(d) 2:1 - Two drive pulleys with twice primary power with respect to secondary pulley.
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3.9 PROFILE Conveyo r Prof i le Inpu t
The program requires the user to input the conveyor configuration in an explicit manner, which will be
described below. See Example #2 for a quick tutorial on creating a complete conveyor profile. Certain
flights are necessary for any conveyor analysis. These are the head pulley location, drive/brake locations as
applicable, and take-up location consisting of entering belt, take-up pulley, and exiting belt.
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3.9.8 Flight ID
The flight ID tells the program what "type" of element the flight is. Valid Options are.
A " S" in this column indicates the existence of a skirtboard at the given flight. The skirtboard is
assumed to extend along the entire length of the flight.
A "D" indicates the location of a drive/brake station. The program interprets a drive station asoccurring across a single conveyor flight. The program will allow any location on the conveyor
exclusive of the Take-up. When entering the "D" the program will automatically assign a number
to the drive station, i.e. "D1" for the first drive station, "D2" for the second, and so on. Input
parameters for each drive station are found under the "Conveyor Drives/Brakes & Take-up
Parameters".
A "P" indicates a pulley location.
A "T" indicates the location of the counterweight.
A "To" indicates the location of a belt turnover.
A "Ret" indicates that the flight is the first flight on the "Return" side of the conveyor. If this isnot explicitly defined than the first flight with a negative (-) length will be chosen as the beginning
of the return side.
A "V" or a "V #" indicates the location of a vertical radius. This will cut the current flight into "6"
or "#" new flights with a vertical radius as specified in the "Vertical Radius" column. For
example, a "V8" will create 8 new flights to make a vertical radius between the current flight and
the next flight.
A "RS #" will generate a flight which ends at starting location of the "#" flight. For example, an
"RS 21" will generate a flight with a length and height which will terminate at the beginning of
flight 21. When entering the RS flight the user is also ask to enter the distance between the carry
and return side of the conveyor. Example #2 at the end of this manual discusses the RS flight in
detail.
A "R # #" will generate return side flights from the first flight "#" to the second flight "#". For
example, "R 20 13" will automatically create return side flights mirroring the carry side flights
from flight 20 down to flight 13.
3.9.9 Load %
The percentage of design tonnage conveyed on each flight of the conveyor. The range is 0% to
100% plus. One hundred percent corresponds to a loading in pounds of material per lineal foot
equivalent to the full design tonnage at the selected belt speed. A value of zero denotes an empty
flight. This value is independent of the cross-sectional design loading.
3.9.10 Conv. Load
This variable indicates that material is being fed onto the belt at the given flight on the conveyor.This is used to calculate the belt tension requirement to accelerate the material to full belt speed. The
location of a skirtboard (Flight ID "S") usually accompanies a loading flight. The conveyor load is
input in STPH or T/H. For a single loading point on the conveyor only ONE flight will have a load
value (the conveyor tonnage). Also other Conv Load flights will be zero.
3.9.11 Pulley Diameter
Indicates the diameter of a pulley located at a given flight. This value is ignored unless a wrap angle
is specified at the flight. If a wrap angle is specified and the pulley diameter is left blank at a given
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flight, the program will select a pulley diameter. (Note: If an accurate estimation of the gear ratio is
required, then the drive pulley diameter should reflect lagging and the belts bottom co ver thickness
consideration.)
3.9.12 Pulley Wrap
The wrap angle of a pulley located at the given flight. The pulley wrap angle is used to denote a
pulley location and to estimate the shaft size required from a resultant force dependent on the wrapangle. A positive value indicates that the belt will wrap around the pulley in a clockwise direction.
A negative value will indicate that the belt will wrap around the pulley in a counterclockwise
direction.
3.9.13 Vertical Curve Radius
The vertical curve radius at a given flight number. An N in this column tells BELTSTAT to NOT
calculate a vertical curve. If this column is blanked out ( ), the computer program will attempt to
evaluate the minimum required curve radius at flights where the slopes of adjacent flights are
different. Curve radii are selected based on edge and center tension requirements in accordance with
CEMA. In the case of convex curves, avoiding idler overload is also a factor. For concave curves,
lifting of the belt is considered.
If the tension is too high or low to allow a curve selection, the program will show a radius of 999999in the output file, indicating that the user must make some changes to the input specifications to
allow a proper radius selection.
The program will indicate edge and center tension, etc., for all valid radii for concave curves and
idler loading for convex curves.
3.9.14 Horizontal Curve Radius
The horizontal curve radius at a given flight.
3.9.15 Concentrated Weight Specification
This input variable can be used to place a discrete mass at a fixed flight on the conveyor profile.
This can be used to set the weight of the pulleys (referenced to the conveyor belt line) if theseweights are known by the user. If concentrated weight values are not input at pulley locations, the
program will estimate the belt-line weight.
3.9.16 Miscellaneous Drag Tension Specification
This input variable allows the user to include any frictional drag forces acting on the conveyor belt
which the program would not otherwise compute. Examples might be belt turnovers, additional
scrapers other than those accounted for by the program, and tripper drive pulleys, etc.
3.9.17 Notes
Allows the user to enter addition notes about each individual flight. The designer may want to make
a note of why miscellaneous drag terms were added or why a specific radius was specified. Only
one note is allowed for each unique conveyor flight and notes can not be input on flight IP lines orduplicate flight numbers.
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4.0 BELTSTAT OUTPUT FILE AND RESULTS WINDOW
There are two ways to view the results form a BELTSTAT calculation. The first is to use the "View
Results Window" and the second is to use the "View BSO File", both found under the "Results" main
menu.
The BELTSTAT output file (default extension is *.bso) may also be printed from the user interface. This is
simply a dos text file. This file can then be E-mailed to others and printed using the DOS EDIT
command.
The "Results Window" is composed of three "Data Window" buttons ("Data", "Plot", "Main") and five
"Selection Window" buttons which vary depending on the data window button selected. For example, if
the "Plot" data window button is clicked then the five selection window buttons become: "Profile,
"Running", "Empty", "Accelerating", "Drift", & "Brake".
Using the data window buttons, in conjunction with the selection window buttons, makes it very easy for
the user to quickly switch between any of the BELTSTAT results views. The user can switch from themotor power table, to the conveyor profile, to a braking tension plot all with a quick click of the mouse.
Any of the results windows can quickly be sent to the default printer by selecting "Print the Current Results
Window" found under the "Results" main menu.
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When the "Data" window button is selected the five selection window buttons become "Material", "Belt",
"Idler", "Motor", "TR", & "Take-up". By click the corresponding selection box the results from the
BELTSTAT calculations are shown (the "Material" window is shown above). These windows show the
detailed output window for each of the major conveyor components as follows.
4.1 Material Specif ication s
The picture below shows the output window for the material specifications. Each of the parameters isdescribed in Section 3.5. Material specifications are also printed in the BELTSTAT output file on the first
page.
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X-Sectional Area Used
This cross-sectional area is that of the material for the case being analyzed. This is based on the
design tonnage, the given bulk density, and the belt speed. The program also shows the cross-
sectional loading percentage. This represents the area defined as 100 percent of CEMA.
Impact Force from Lumps
This represents the energy that a lump imparts to the conveyor belt at the loading station. This is
computed from the lump size, bulk density, lump shape factor, and chute drop distance.
Tape Length (Not Incl. Splice Length)
Total length of the belt not including additional lengths created by the splices.
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4.3 Idler and Anci l lary Specif ication s
The picture below shows the output window for the idler specifications. Each of the input parameters is
described in Section 3.6. Belt specifications are also printed in the BELTSTAT output file on the first
page.
Idler Name / Series See Section 3.7.4
Idler Angle See Section 3.7.1 / 3.7.2
Diameter See Section 3.7.5
Load Rating See Section 3.7.9
Adjusted Load Capacity
The program computes this according to the method outlined by CEMA. The idler load rating is
adjusted by the following factors:
o Lump Adjustment Factor
o Environmental and Maintenance Factor
o Service Factoro Belt Speed Correction Factor
Applied Load At Max Spacing
This is the maximum applied load on the idler sets in any of the flights of the conveyor. This load
does not include belt tension loads in vertical convex curves.
Rotating Weight See Section 3.7.8
Seal Drag (Ai) See Section 3.7.6
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Number Of Idlers
This is an approximate count of the idlers sets required for the conveyor.
Number Of Rollers See Section 3.7.3
KXC , KXR
Coulomb friction factor for the carry and return idlers. See section 3.7.7
(KY) Trough Shape Multiplier See Section 3.7.10 / 3.7.11
(KY/KX) Correction (Regeneration) See Section 3.7.13
(KT) Temperature Adjustment (KY/KX) See Section 3.7.12
Idler Seal Correction (Regeneration)
The idler seal correction factor is related to the KY and KX regenerative correction (See sections
3.7.13). The idler seal correction factor will be set to 1 if the Ky and KX regenerative correction is
greater than or equal to 1, otherwise it will be equal to 0. For example for a regenerative conveyor
the Kx/Ky factor would be set to 0.666. In this case the Idler Seal Drag is automatically set to 0 and
the Idler Seal Correction output will be 0.
Skirtboard Friction Factor See Section 3.7.14Skirtboard Width See Section 3.7.15
Max Mat. Height
This is the height of material in contact with the skirtboard walls, when traveling at full belt speed. It
is used by the program to compute the friction of the material scraping on the skirtboard walls. If the
belt cross- sectional loading is low, a value of zero may result, indicating that the material does not
contact the skirtboards.
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Gearbox Ratio
The gearbox ratio is computed from the motor running RPM, the belt speed, and the drive pulley
diameter.
Brake Torque Lowspeed
This represents the brake torque that is to be applied to the pulley shaft.
Brake Energy Absorbed
This output variable indicates how much heat the brake must absorb during the stopping cycle from
full speed to zero speed. A negative value indicates that the brake would have to produce power to
obtain the desired stopping time.
Acceleration Time and Travel
The acceleration time shown is either the input or resulting time from the starting torque limit. The
travel represents the amount of distance the belt moves during the starting cycle.
Drift Time and Travel
The drift time is the time it will take the conveyor to stop from full speed with no braking action.
The travel is the distance the belt will move during this cycle. A negative drift time will result for
regenerative conveyors and the absolute value represents the time it would take the conveyor to
accelerate from zero to full speed with no driving or braking forces imposed upon it.
Braking Time and Travel
This is similar to the acceleration time and travel, but for the braking cycle.
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4.5 TENSION SPECIFICATIONS and " Tension " Wind ow
The Tension specifications in the BELTSTAT output file and the "Tension" window in the user interface
show similar information. The Tension window in the user interface combines information from the
Flight Profile Summary and the Tension Specification in the output file.
Flight No.
Number of the flight.
Station Item
This is a description of the flight. The possibilities for this column are:
TAIL: Tail Station
HEAD P: Head pulley
HEAD DR#: Head pulley and drive combination
DRIVE #: Drive
TAIL DR#: Tail pulley and drive combination
TAKE-UP: Take up
TAIL TU: Tail pulley and take up combination
BEND P: Bend pulley
SKIRTBDS: Skirtboard
LOAD/SKT: Load station with skirtboard
LOAD STN: Load station
CONCAV R: Vertical concave curve.
CONVEX R: Vertical convex curve.
Ground X &Length
Station and Length of the individual flight
Ground Y & Height
Elevation & Height of the individual flight
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Running Tension
Tension at the flight under normal running conditions.
Empty Tension
Tension at the flight when the belt in empty of all material.
Accelerating Tension
Tension in the belt during acceleration.
Brake Tension
Tension in the belt during the braking cycle.
Drift Tension
Tension in the belt during a drift cycle.
Sag Tension
Indicates the minimum allowable running tension that will comply with the previously defined sag
criteria. If the user does not specify the counterweight tension, the program selects one which will
meet the sag tension requirements of all the flights on the conveyor for the running case.
LoadingThe loading of the individual flight as a percentage of the actual conveyor "Loading"
Flap Mode
The flap mode column indicates when the forced vibration of the belt in that flight coincides with the
belt's natural frequency. This condition can result in dangerously large belt oscillations, or
resonance, and should be avoided. If the belt vibrations are near resonance then this column will
contain the mode of resonance. For example, a flap mode of 1.10 indicates that the belt is near the
first resonance mode. The flap mode is a function of the belt velocity, tension in the belt, weight of
the material, idler diameter, and the idler spacing. If the belt in a flight is near a flap mode it is
advisable to change one of the above parameters in order avoid resonance of the belt. Four stars
(****) mean that the belt is not near a resonance mode.
V-Curve RadiusVertical curve radius as specified in the "Element" Table. If the radius was left blank in the
"Element" Table the program will estimate an approximate radius.
H-Curve Radius
Horizontal radius as specified in the "Element" Table
KY
This column indicates the KY values. See section 6.3.1 for the method of computation.
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4.6 " Tension Ratio" Drive / Brake Tensio n Ratios
The picture below shows the output window of the Drive/Brake Tension Ratios.
The same information is found in the BELTSTAT output file after the flight tension table. Below is
an example of the TE and tension ratio summary in the BELTSTAT output.
TE
This shows the effective tension at each drive station for each tension case. This is simply thedifference of the incoming and outgoing tensions, minus any gravity and/or acceleration/
deceleration forces active between these two flights.
WR Factr
This window shows the tension ratios for the running, acceleration, and braking cases. The warp
angle, static coefficient of friction, and dynamics coefficient of friction are also shown.
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For each load case two values are shown. The first is the wrap factor. The wrap factor is the
maximum allowable tension ratio of the drive pulley before belt slip on the pulley will occur. The
wrap factor is calculated from the following formula.
feFactrWR
Where:WR Factr = Wrap factor
e = natural logarithm (2.71828)
= Wrap angle of the given drive pulley (radians)
f = Friction factor of the given drive
For the running case the static coefficient of friction is used, whereas for the acceleration and
braking cases the dynamic coefficient of friction is used.
The wrap factor is used to evaluate whether the drive pulley has adequate slack side tension to avoid
slippage. The wrap factor is shown for each tension cases because the friction factor varies between
the running case and the other tension cases.
T1/T2This value is the ratio between the greater and lesser of the tensions entering and leaving a drive
station. The values are shown for all drive stations on the conveyor. The T1/T2 ratios should be
compared with the corresponding wrap factor. If the T1/T2 ratio is less than the corresponding wrap
factor, the slip criteria have been met.
If the slip criteria are not met, the user must modify the design by increasing the counterweight
tension, increasing the acceleration or braking time, etc. The program should then be re-executed.
4.7 " Take-up" Speci f icat ions
General Discussion about Take-up Tension and Displacement
Take-up Datum Position
The take-up travel in BELTSTAT assumes a zero baseline or datum position for an initially applied
take-up force and typical installation slack. The datum is not reference to any physical item such as
a pulley. Input take-up tension, belt mass and elasticity, idler spacing, and conveyor geometry affect
the datum position. If these variables do not change, then the take-up position from various
BELTSTAT runs may be directly compared. However, if any of the above variables change then the
take-up datum position also changes.
Input take-up tension and actual take-up tension will be the same for a gravity take-up. However for
a fixed take-up, input take-up tension and actual take-up tension can (and usually) will be the
different.
For example, if all variables remain the same on a gravity take-up system except for take-up tensionthen the take-up travel from the two runs are not relative to one another. BELTSTAT will show that
the tension travel of the empty belt of both cases is approximately the same. Obviously, the belt
stretch of the case with the higher take-up tension is the greatest.
The take-up pulley on a gravity take-up will generally be near the datum position when the belt is
empty at 20 C. However, the absolute take-up displacement is not important, only the relative
position is important.
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Take-up travel direction
Increasing positive take-up displacement indicates stretching in the belt. Therefore in a vertical
gravity take-up, positive displacement means the take-up pulley moves downward.
Gravity Take-up
A gravity take-up has constant belt line tensions and variable displacement. The input take-up
extension (in the Drives window) is not meaningful for a gravity take-up.
Fixed Take-up
A fixed take-up is a conveyor belt tensioning device that does not allow movement of the take-up
pulley. Consequently, the belt tension at the take-up pulley varies during different loading or
starting and stopping conditions. Belt mass must be input for a fixed take-up.
Explanation of Output Variables
Take Up Flight and Type
This is the location and type of the take up.
Input Take-up Tension
The take-up tension input by the user.
Input Displacement
This is the input displacement of the take up. This field is only meaningful for a fixed take-up.
Output Tension
The tension values calculated and used by BELTSTAT.
Take-up Tension Differential
This value represents the change in the counterweight tension that would just satisfy the friction
criteria for all drive pulleys for all tension cases. The friction criterion is determined by the
minimum allowable coefficient of friction between the drive pulley and belt and the drive wrapangle. The friction criterion sets the minimum belt tension to prevent belt slip on the drive. Thus, if
the counterweight tension is too low to satisfy the friction criteria, the designer may choose to
increase it by the amount shown and re-execute the program. If the value shown is negative, this
indicates that the counterweight tension can be reduced and still meet the friction criteria. The
computation of this value does not consider sag criteria, which also must be met, and which may
govern the setting of the counterweight tension.
Governing Case
This field shows which case govern the Take-up differential.
Take-up Tension Differential SAG
This value represents the change in the counterweight tension that would just satisfy the belt SAG
criteria.
Load Case Summary
Figure 1 shows the take-up force and displacement summary in the user interface. For this particular
conveyor, the take-up pulley will be 30 mm from the datum when empty and 370 mm from the
datum when fully loaded. Maximum displacements occur during acceleration and braking. The
total take-up range is 510 mm. Figure 3 shows the relative position of the take-up pulley for various
load cases.
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Figure 1 Take-up Summary
In the BELTSTAT output file, the take-up summary (labeled COUNTERWEIGHT SPECIFICATIONS)
is located after the drive tension differential summary and before the profile summary. Figure 2
shows the take-up summary in the output file. The tension travel summary is the fourth line in the
left-hand box. It also shows the location of the take-up displacements for each load case.
Figure 2Take-up Summary in output file
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DATUM
60 mm (brake)
447 mm (acceleration)
510 mm
30 mm (empty)
370 mm (full)
Figure 3Relative position of take-up
Required Take-up Displacement
BELTSTAT gives an estimate for the required take-up travel, which is labeled TAKEUP DISPL. in
the BELTSTAT output file. This estimate is in the lower left-hand box of the summary. The
formula used to calculate the total required take-up displacement is:
TD = 1.05 * (TN+SP/2+PE+TR)+CL
Where:
TD= required take-up travel
TN= tension travel range from different load cases (running, empty, start, brake, and drift)SP= estimated splice length
PE= permanent elongation of belt
TR= thermal travel
CL= clearance (300 mm or 12 inches)
The take-up summary also shows the input take-up tension and the actual take-up tension. Below
the take-up tension is the take-up tension differential.
Length of Splice (SP)
This is an estimated value of how much extra conveyor belting should be ordered for each splice to
be made on the conveyor belt. This value may vary considerably, so the user should consult the
belting manufacturer to obtain the exact splice requirements.
Thermal Travel (TR)
The thermal travel is the total amount that the conveyor belt will lengthen from minimum to
maximum ambient temperature. The program computes a value for steel cable belting but not for
fabric belt, since there is no consistent method to predict this for fabric belting.
Permanent Elongation (PE)
This represents an inelastic stretching of the belt. The value is computed as a percentage of the tape
length. The percentage factor varies with the type of belt carcass.
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Tension Travel (TN)
This is the total length that the belt will stretch compared to the state at rest, when the conveyor is
not running. The computation of these values considers the elastic stretch and sag between idlers
along each flight of the conveyor. The tension travel is shown for the running, empty, acceleration,
brake, and drift tensions.
4.8 Force / Drag SummaryThis output is found at the end of the BELTSTAT *.BSO file.
Drive Pulley Drag
These are the drag tensions induced by the pulley bearings at each drive pulley. These drag forces
are separated by the program from other drag forces because these drag losses, like gear reducer
losses, are not driven through the drive pulley / belt interface.
Lift Force
This represents the net gravity force acting on the conveyor belt. If the flight heights sum to zero,the lift force equals the force required to lift the conveyed material. Since the lift force is the same
for all tension cases (running, acceleration, braking, and drift), only one value is shown.
Friction Force
This represents the sum of all frictional forces excluding miscellaneous drag forces. This friction
force applies to the running, acceleration, braking and drift tension cases.
Total Miscellaneous Force
This is the sum of all miscellaneous drag forces. Like the friction force, this value applies to the
running, acceleration, braking and drift tension cases.
4.9 Conveyor SummaryThis output is found at the end of the BELTSTAT *.BSO file.
Horizontal Length
Here the program shows the arithmetic sum of all straight-line flight lengths. This value does not
include any allowance for extra belt length needed to splice the belt.
Total Elevation
The total elevation change in the conveyor from the tail to the head of the conveyor.
Material Lift
The total height that the material must be raised.
Sum of Flight Heights
This is the sum of height of each flight (carry and return). It should sum to zero.
Total Mass
This is the sum of all the individual flight masses.
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Edge and Center Tensions
Here the theoretical stress at the edges and center of the belt are shown. These are computed from
the belt tension at the curve, the curve radius, belt elastic modulus, belt width, trough shape, and
idler angle.
Lift Radius
The program computes the radius at which belt lift would be impending, using the computed
tensions at the given flight. The lift radius is computed using the weight of the belt plus that of the
material on it. The lift radius is also computed using the weight of an empty belt, though the same
belt tension is used.
4.11.4 "Convex" Window Selection Buttons
Minimum Allowable Center Tension
This is the minimum tension at the center of the belt
Maximum Allowable Edge Tension
Idler Vertical Tolerance
This is the vertical tolerance which the installed idlers can have for the given calculations.
Idler Corrected Load Capacity
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Flight Number
The flight at which the calculations were made.
Selected Radius
This is the radius upon which the calculation were based.
Tension Case
This row indicates the which tension case is being reported.
Edge and Center Tension
This indicates the tension at the center and edge of the belt.
Recommended Idler Spacing
The program sets the spacing such that the idler adjusted load capacity will not be exceeded for the
running tension case.
Load per Idler
The load per idler is computed using the spacing, weight of belt, weight of material on the given
flight on the conveyor, the belt tension, and the idler vertical tolerance. In computing the load on the
idlers due to belt tension, a given idler is assumed to be elevated above its ideal position by the fullvalue of the installation tolerance, and the two adjacent idlers are assumed to be lowered by the same
amount. This is considered the worst case with respect to idler loading.
4.11.5 "Loss Table" Window Selection Buttons
Shows a detailed summary of the power calculations and where they occur.
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4.12 View BSO File
This window show the actual BELTSTAT output file (*.BSO file). This window contains the same
information shown the standard Results Window. It is identical to the "View" command in BELTSTAT
v5.0. This file is saved a DOS text file so it can be easily E-mailed to clients or other engineers. The text
file canbe printed by non BELTSTAT users by using the DOS EDIT command.
Number Keys (1,2,3,4)
These keys will jump to a specific output page (i.e. Page 1, Page 2, etc.).
Arrow Keys / Page Up / Page Down
The arrow and Page keys move the user around the output window.
End Key
Quickly moves the user the end of the file
Home Key
Move the users to the beginning of the file.
Esc Key
Closes the output window
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Skirtboard Loading (*) See "Conveyor Loading"
This value (0-1) will be multiplied by the current Skirtboard Loading (flights in the element table
that have an ID type of "S") flights in the "Master File".
Belt Weight (*) See "Belt Weight"
This is a multiplication factor to increase (or decrease) the belt weight. The design may want to
increase the belt weight (10-15%) to compensate for possible "manufacturing" tolerances in the belt.
For an inclined conveyor system this may represent a design parameter for the Maximum Power
consumed (or Maximum regeneration for a decline system). On the other hand the designer may
want to decrease the belt weight slightly thereby assuming a lower than expected belt weight or
determine the effect of possible weight loss do to belt wear.
Top & Bottom Cover Thickness (+) See "Top Cover Thickness"
As opposed to changing the actual belt weight (above) the top & bottom cover thickness may be
specified in the "Master File". If so the values entered in "Top Cover Thickness (+)" and "Bottom
Cover Thickness (+)" will be added (or subtracted) from the "Master Files" value and the program
will calculate a new belt weight.
Seal Friction - Carry (*) & Return (*) See "Seal Friction"
This multiplication factor will cause the seal friction to be increases or decreased. It is important to
remember that the seal drag is only relevant when using user-defined idlers. If standard idlers sets,"C6" for example, are used in the "Master File" then the seal friction is irrelevant.
Trough Shape Mult - Carry & Return See "Trough Shape Multiplier"
A specific Trough Shape Multiplier may be entered.
Kx
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