b-28-1- pe0101_note de calcul mécanique convoyeur cvl'_mec32801_00_20151101

OCP:

00

CONFIDENTIAL – Any disclosure of this information is strictly forbidden without EMPI prior authorization

WBN

Name Date Name Date Name

15/12/2015 AFE 15/12/2015 WKT 15/12/2015

Note de Calcul Mécanique convoyeur CVL'

DLM

Ref.:B-28-1- PE0101_Note de Calcul Mécanique

Convoyeur CVL'_MEC32801_00_20151101

Rev. Author Checked Approved

Date

MEA EXPANSIONMEA EXTENSION: Alimentation de la 7ème ligne

EMPI DLMRoute El Ain Km 4

Immeuble RAWDHAN

Tel: (+216) 74 264 180 // (+216) 74 610 780

Web: www.empi.tn // www.group-ips.com

Route de Rabat - Km 9, Ain Sebâa - B.P. 2613

Casablanca MAROC

Phone : + 212(0) 5 22 66 96 00

Fax : + 212(0) 5 22 35 54 65

Bureau d'Etude: Contractant:

Consultant:Propriétaire:

OCP JACOBS Engineering

OCP GROUP

Web: www.ocpgroup.ma

Imm. 5 - Zénith Millenium - Lot. Attaoufik

Route Nouaceur - Sidi Mâarouf

Casablanca - 20270 Morocco

Tél: +212 (0)5 22 87 70 00 / +212 (0)5 22 87 71 50

B-28-1- PE0101_Note de Calcul Mécanique Convoyeur CVL'_MEC32801_00_20151101

1 PAGE DE GARDE

2 SOMMAIRE

3 1- OBJET

3 2- DOCUMENTS & NORMES DE REFERENCE

3 2-1- DOCUMENTS DE REFERENCE

3 2-2- NORMES DE REFERENCE

3 3- DONNEES DE CALCUL

3 3-1- GROUPE DE COMMANDE

3 3-2- PHILOSOPHIE DE CONCEPTION

4 4- CALCUL DE LA PUISSANCE DU MOTEUR

4 4-1- POWER CALCULATION

14 4-2- SECONDARY & SPECIAL RESISTANCE

17 5- CHARGES SUR TAMBOURS

18 6- DIMENSIONNEMENT DU GROUPE DE COMMANDE

18 6-1- CARACTERISTIQUES MOTEUR

19 6-2- CARACTERISTIQUES REDUCTEUR

19 6-3- SPECIFICATION D'ACCOUPLEMENT

19 6-4- SPECIFICATION SYSTÈME DE FREINAGE

19 6-5- SPECIFICATION CHASSIS

20 7- VERIFICATION DES AXES & MOYEU TAMBOURS

22 8- VERIFICATION DES PALIERS

24 9- VERIFICATION DES ROULEAUX

26 10- VERIFICATION RAYON DE COURBURE CONCAVE

27 11- VERIFICATION RAYON DE COURBURE CONVEX

SOMMAIRE

OCP

MEA EXPANSION

Alimentation de la 7ème ligne


1- OBJET

L'objectif de cette note de calcul est la vérification des différents composants du transporteur à bande

RB2, à savoir:

- Vérification Puissance de Commande

- Vérification des Caractéristiques & de la Tension de Bande

- Vérification des Différents Tambours

- Vérification des Différents Paliers

- Vérification des Différentes Stations de Rouleau

2- DOCUMENTS & NORMES DE REFERENCE

2-1- DOCUMENTS DE REFERENCE

B-28-6- PE0101_Plan d'Ensemble Table de Réception Convoyeur CVL'_MEC32801_00_20151101

2-2- NORMES DE REFERENCE

ISO5048 (1989): Engins de manutention continue. Transporteurs à courroie munis de rouleaux porteurs -

Calcul de la puissance d'entraînement et des efforts de tension.

3- DONNEES DE CALCUL

3-1- GROUPE DE COMMANDE

Le groupe de commande sera considéré comme étant un système moto-réducteur avec un

accouplement Arbre plein avec accouplement flexible pour la connection avec tambour de commande.

L'efficacité globale du groupe de commande est calculée comme suit:

- Efficacité Moteur:

- Efficacité Accouplement:

- Efficacité Réducteur:

- Efficacité Totale:

Couple de Démarrage Moteur:

3-2- PHILOSOPHIE DE CONCEPTION

La puissance minimale requise pour entrainer le système de convoyeur à bande est calculée en faisant

la somme des puissances suivantes:

- La charge de la bande et des stations de rouleau à vide

- La charge pour translation de la matière.

- La charge pour soulèvement de la matière.

- Les charges divers éléments de la bande (Points de décharge, Racleurs, etc.) intégrées dans

le facteur "C".

- L'efficacité du groupe de commande.

2.40 1.50

0.98

0.95

0.90

Avec Accouplement

Hydraulique

0.97

0.95

0.95

0.88

OCP

MEA EXPANSION



Sans Accouplement

Hydraulique

0.97


4-1- Power Calculation

Belt Design Summary

311.29 Required Motor Power Necessary to transmit to the belt

OK Check of Motor Power

6,022 Minimum Required Counterweight

0.831 Belt Slipping Coefficient

OK Check of Counterweight

OK Check of Belt Slipping

6,971 Start-up Minimum Required Counterweight

0.997 Start-up Belt Slipping Coefficient

OK Check of Counterweight @ Start-up

OK Check of Belt Slipping @ Start-up

847 Maximum Belt Elongation

778 Minimum Required Tensile Strength

OK Check of Belt Elongation Length

OK Check of Belt Tensile Strength

1,017 Start-up Maximum Belt Elongation

653 Start-up Minimum Required Tensile Strength

OK Check of Belt Elongation Length @ Start-up

OK Check of Belt Tensile Strength @ Start-up

Working Condition

Handled Material DefinitionPhosphate

Brut<-Material Designation

35 <-a: Material Angle of Repose (Deg)

15 <-q: Material Surcharge Angle (Deg)

1200 <-r: Material Density (kg/m3)

9.81 <-g: Standard Gravity Acceleration (m/s²)

Belt Definition

3600 <-Q: Maximum Belt Design Capacity (Ton/h)

3.8 <-v: Belt Speed (Tab.4&5&6) (m/s)

1400 <-B: Belt Width (mm)

EP800/4 <-Carcass Style

800 <-Wu: Belt Resistance at Break (N/mm)

Medium Weight and Lump Size Material

dmax (mm)

CRm (N/mm)

P ≥ Pm

Wu ≥ CRmS

OCP Standard

Wu ≥ CRm

dmaxS (mm)

CRmS (N/mm)

Pm (kW)

FvminS (daN)

rS

Fv ≥ FvminS

rS ≤ 1

d ≥ 2 dmax

r ≤ 1

d ≥ 2 dmaxS


4- CALCUL DE LA PUISSANCE DU MOTEUR

OCP

MEA EXPANSION



Fvmin (daN)

r

Fv ≥ Fvmin

CONVOYEUR CVL': D1:Ø630 / D2:Ø500



OCP

MEA EXPANSION



1 <-z: Maximum Belt Elongation During Service (Load = 10% of Belt Resistance at Break) (%)

10 <-fs: Belt Required Safety Factor

7 <-fss: Belt Required Safety Factor at Starting

6 <-ttc: Top Cover Thickness (mm)

4 <-tbc: Bottom Cover Thickness (mm)

1.2 <-rr: Rubber Average Weight (kg/[m²xmm])

1.5 <-S1: Maximum Sag Along the Carrying Section (%)

1.5 <-S2: Maximum Sag Along the Return Section (%)

87.15 <-L: Belt Length Center-To-Center (m)

13.5 <-d: Maximum Belt Inclination (Deg)

Idlers Definition

159 <-dc: Carrying Idlers Diameter (mm)

Tern <-Carrying Idlers Type

35 <-l: Idlers Inclination Angle (Deg)

159 <-dr: Return Idlers Diameter (mm)

Couple <-Return Idlers Type

1.250 <-ac: Distance Between Carrying Idler (Tab.12) (m)

3.000 <-ar: Distance Between Return Idler (Tab.12) (m)

Upper Flight Definition

7 <-Nu: Upper Flight Number

No. PulleyQu,n

(Ton/h)Lu,n (m) Hu,n (m)

bu,n

(Deg)Ncu,n Nru,n

1 D1 3600 2.808 0.674 13.50 3 0

2 NA 3600 81.436 19.551 13.50 66 0

3 NA 3600 1.750 0.420 13.50 7 0

4 D2 0 1.156 0.278 13.50 0 0

5 D5 0 0.800 -0.214 -15.00 0 0

6 D4-1 0 41.644 -9.998 -13.50 0 14

7 D3 0 0.000 3.165 90.00 0 0

8

9

10

11

12

13

14

15

16 <-Qu,n: Flight Capacity (Ton/h)

17 <-Lu,n: Flight Length (m)

18 <-Hu,n: Flight Height (m)

19 <-bu,n: Flight Slop (Deg)

20 <-Ncu,n: Carrying Idler Number Per Flight

21 <-Nru,n: Return Idler Number Per Flight

22

23

24

25

26

27

28

29

30



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MEA EXPANSION



Lower Flight Definition

3 <-Nl: Lower Flight Number

No. PulleyQl,n

(Ton/h)Ll,n (m) Hl,n (m)

bl,n

(Deg)Ncl,n Nrl,n

1 D5 0 0.790 0.000 0.00 0 0

2 D4-2 0 43.394 -10.418 -13.50 0 14

3 D3 0 0.000 3.366 -90.00 0 0

4

5

6

7

8

9

10

11

12

13

14

15

16 <-Ql,n: Flight Capacity (Ton/h)

17 <-Ll,n: Flight Length (m)

18 <-Hl,n: Flight Height (m)

19 <-bl,n: Flight Slop (Deg)

20 <-Ncl,n: Carrying Idler Number Per Flight

21 <-Nrl,n: Return Idler Number Per Flight

22

23

24

25

26

27

28

29

30

Pulley & Motor Definition

315 <-P: Installed Motor Power (kW)

2,100 <-d: Counterweight Elongation Course (mm)

7,000 <-Fv: Counterweight Value (daN)

210 <-j: Belt to Drive Pulley Contact Angle (Deg)

0.35 <-m: Friction Coefficient Between Belt & Pulley (Tab.10)

1.3 <-w: Starting Motor Coefficient

0.88 <-h: Mechanical Efficiency Coefficient for the Transmission (Tab.8)

Type 2 <-Type of Belt Conveyor

Type 1: If Counter weight at Tail Position

Type 2: If Counter weight Near Drive System

j

T1

T2



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MEA EXPANSION



Empty Belt & Idlers Weight Computation

6.5 <-qbc: Belt Carcass Weight for square Meter (Tab.13) (kg/m²)

18.5 <-q: Belt Weight per square Meter (kg/m²)

44.3 <-qc: Carrying Idler Unit Weight (Tab.11) (kg)

35.2 <-qr: Return Idler Unit Weight (Tab.11) (kg)

Friction & Length Coefficient

0.03 <-f: Idlers Friction Coefficient (Tab. 9)

bc r tc bcq q t tr



OCP

MEA EXPANSION



Forces Necessary for Movement of Belt

No.F1u,n

(kg)

F2u,n

(kg)

F3u,n

(kg)

F1l,n

(kg)

F2l,n

(kg)

F3l,n

(kg)

1 6.1688 22.168 194.87 0.6138 0 0

2 150.99 642.92 5651.4 48.501 0 -269.83

3 10.663 13.816 121.44 0 0 87.179

4 0.8982 0 7.1881 0 0 0

5 0.6216 0 -5.5519 0 0 0

6 47.141 0 -258.94 0 0 0

7 0 0 81.974 0 0 0

8 0 0 0 0 0 0

9 0 0 0 0 0 0

10 0 0 0 0 0 0

11 0 0 0 0 0 0

12 0 0 0 0 0 0

13 0 0 0 0 0 0

14 0 0 0 0 0 0

15 0 0 0 0 0 0

16 0 0 0 0 0 0

17 0 0 0 0 0 0

18 0 0 0 0 0 0

19 0 0 0 0 0 0

20 0 0 0 0 0 0

21 0 0 0 0 0 0

22 0 0 0 0 0 0

23 0 0 0 0 0 0

24 0 0 0 0 0 0

25 0 0 0 0 0 0

26 0 0 0 0 0 0

27 0 0 0 0 0 0

28 0 0 0 0 0 0

29 0 0 0 0 0 0

30 0 0 0 0 0 0

<-F1,n: Flight Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)

<-F2,n: Flight Forces Necessary for Translation of the Load (kg)

<-F3,n: Flight Forces Necessary for the Elevation of the Load (kg)

266 <-F1: Forces Necessary for Movement of Empty Belt & Carrying Idlers (kg)

679 <-F2: Forces Necessary for Translation of the Load (kg)

5,610 <-F3: Forces Necessary for the Elevation of the Load (kg)

-134 <-Ft,L: Tail Losses Between Take Up & Drive Pulley (kg)

755.96 <-FNS: Total Secondary & Special Resistance (daN)

Upper Flight Lower Flight

1, , ,1000

n n c c n r r n

BF f L q q N q N

2,

3.6

nn n

QF fL

v

3,3.6 1000

n nn n

Q H BF q H

v

NS N SF F F



OCP

MEA EXPANSION



Total Force and Motor Power Calculation

7,310 <-Fmin: Total Periphery Force Necessary to transmit to the belt (kg)

272.51 <-Pa: Theorical Motor Power Necessary to transmit to the belt (kW)

311.29 <-Pm: Required Motor Power Necessary to transmit to the belt (kW)

P ≥ Pm OK

Tension Calculation (During Operation)

7,257 <-F: Installed Periphery Force (daN)

0.384 <-K: Friction Factor

10,041 <-Tu,1n: Nominal Tight Side Tension (daN)

2,784 <-Tl,1n: Nominal Slack Side Tension (daN)

2,650 <-Tv1: Minimum Tension to Allow the Motion Transmission (daN)

3,011 <-Tsup: Minimum Tension For Max Sag of Carrying Idler (daN)

648 <-Tinf: Minimum Tension For Max Sag of Return Idler (daN)

6,022 <-Fvmin: Minimum Required Counterweight (daN)

850 <-Tv: Take-Up Over tension (daN)

10,890 <-Tu,1: Maximum Tight Side Tension (daN)

3,634 <-Tl,1: Maximum Slack Side Tension (daN)

minaP gF v

am

PP

h

1

1K

emj

,1 1u nT F K

,1l nT FK

1 ,1 ,v l n t LT T F

sup

18 1000 3.6

ca qB QT

S v

inf

28 1000

ra qBT

S

min 1 sup inf2 ; ;v vF Max T T T

, ,12

vv t L l n

FT F T

PF

v

h

,1 ,1u u n vT T T

,1 ,1l l n vT T T

min 1 2 3 NSF F F F F



OCP

MEA EXPANSION



0.831 <-r: Belt Slipping Coefficient

Fv ≥ Fvmin OK

r ≤ 1 OK

Tension Calculation (During Start-up)

9,434 <-Fs: Installed Periphery Force at Starting (daN)

13,053 <-Tu,1nS: Start-up Nominal Tight Side Tension (daN)

3,619 <-Tl,1nS: Start-up Nominal Slack Side Tension (daN)

3,485 <-Tv1S: Start-up Minimum Tension to Allow the Motion Transmission (daN)

6,971 <-FvminS: Start-up Minimum Required Counterweight (daN)

15 <-TvS: Start-up Take-Up Over tension (daN)

13,067 <-Tu,1S: Start-up Maximum Tight Side Tension (daN)

3,634 <-Tl,1S: Start-up Maximum Slack Side Tension (daN)

0.997 <-rS: Start-up Belt Slipping Coefficient

Fv ≥ FvminS OK

rS ≤ 1 OK

,1

,1

u

l

Tr

T emj

s

w PF

v

h

,1 1u nS sT F K

,1l nS sT F K

1 ,1 ,v S l nS t LT T F

min 1 sup inf2 ; ;v S v SF Max T T T

, ,12

vvS t L l nS

FT F T

,1 ,1u S u nS vST T T

,1 ,1l S l nS vST T T

,1

,1

u S

S

l S

Tr

T emj



OCP

MEA EXPANSION



Belt Tensile Strength Check (Operation Case)

No.DTu,n

(kg)

Tu,n

(kg)

DTl,n

(kg)

Tl,n

(kg)

1 223 10,890 1 3,634

2 6,445 10667 -221 3634.1

3 146 4221.8 87 3412.8

4 8 4075.9 0 3500

5 -5 4067.8 0 0

6 -212 4072.8 0 0

7 82 4284.6 0 0

8 0 4202.6 0 0 Notes

9 0 0 0 0 Tension will be Regulated via Material

10 0 0 0 0 Trampling Losses Addition

11 0 0 0 0 The Tension in Pulley Remains inchanged

12 0 0 0 0

13 0 0 0 0

14 0 0 0 0

15 0 0 0 0

16 0 0 0 0

17 0 0 0 0

18 0 0 0 0

19 0 0 0 0

20 0 0 0 0

21 0 0 0 0

22 0 0 0 0

23 0 0 0 0

24 0 0 0 0

25 0 0 0 0

26 0 0 0 0

27 0 0 0 0

28 0 0 0 0

29 0 0 0 0

30 0 0 0 0

31 0 0

10,890 <-Tmax: Maximum Belt Tension (daN)

847 <-dmax: Maximum Belt Elongation (mm)

778 <-CRm: Minimum Required Tensile Strength (N/mm)


maxm s

TCR f

B

, 1 , 2 , 3 ,u n u n u n u nT F F FD

, 1 , 2 , 3 ,l n l n l n l nT F F FD

, 1 , ,u n u n u nT T T D

, 1 , ,l n l n l nT T T D

maxmax

10TL

B Wud



OCP

MEA EXPANSION



d ≥ 2 dmax OK

Wu ≥ CRm OK

Belt Tensile Strength Check (Start-up Case)

No. PulleyDTu,n

(kg)

Tu,nS

(kg)Pulley

DTl,n

(kg)

Tl,nS

(kg)

1 D1 223 13,067 D5 1 3,634

2 NA 6,445 12844 D4-2 -221 3634.1

3 NA 146 6398.9 D3 87 3412.8

4 D2 8 6253 0 0 3500

5 D5 -5 6244.9 0 0 0

6 D4-1 -212 6249.8 0 0 0

7 D3 82 6461.6 0 0 0

8 0 0 6379.6 0 0 0 Notes

9 0 0 0 0 0 0 Tension will be Regulated via Material

10 0 0 0 0 0 0 Trampling Losses Addition

11 0 0 0 0 0 0 The Tension in Pulley Remains inchanged

12 0 0 0 0 0 0

13 0 0 0 0 0 0

14 0 0 0 0 0 0

15 0 0 0 0 0 0

16 0 0 0 0 0 0

17 0 0 0 0 0 0

18 0 0 0 0 0 0

19 0 0 0 0 0 0

20 0 0 0 0 0 0

21 0 0 0 0 0 0

22 0 0 0 0 0 0

23 0 0 0 0 0 0

24 0 0 0 0 0 0

25 0 0 0 0 0 0

26 0 0 0 0 0 0

27 0 0 0 0 0 0

28 0 0 0 0 0 0

29 0 0 0 0 0 0

30 0 0 0 0 0 0

31 0 0

13,067 <-TmaxS: Start-up Maximum Belt Tension (daN)

1,017 <-dmaxS: Start-up Maximum Belt Elongation (mm)


, 1 , 2 , 3 ,u n u n u n u nT F F FD

, 1 , 2 , 3 ,l n l n l n l nT F F FD

, 1 , ,u n S u nS u nT T T D

, 1 , ,l n S l nS l nT T T D

maxmax

10SS

TL

B Wud



OCP

MEA EXPANSION



653 <-CRmS: Start-up Minimum Required Tensile Strength (N/mm)

d ≥ 2 dmaxS OK

Wu ≥ CRmS OK

Pulleys Tensions

No.Zx

(kg)

Zs

(kg)

1 13,067 3,634

2 6,253

3 3,413

4 3,634

5 3,634

6 3,634D5

Designation

D1

D2

D3

D4-1

D4-2

max SmS ss

TCR f

B

4-2- Secondary & Special Resistance

Loading Parameters Material Definition

2 <-e: Tilte Angle of Idler (Deg)

0.4 <-Ce: Trough Factor

0.35 <-m0: Friction Coefficient Between Belt & Carrying Idlers

0.6 <-m1: Friction Coefficient Between Belt & Material

0.6 <-m2: Friction Coefficient Between Belt & Skirtplate

0.6 <-m3: Friction Coefficient Between Belt & Belt Cleaner


9.81 <-g: Standard Gravity Acceleration (m/s²)


3.8 <-v: Belt Speed (m/s)


87.15 <-Le: Length of Installation Equiped with Tilted Idlers (m)

18.5 <-q: Belt Weight per square Meter (kg/m²)

30000 <-p: Pressure between belt cleaner and the belt (N/m²)

0.0315 <-A: Contact Area Between between belt cleaner and the belt (m²)

1.5 <-v0: Velocity Component of the Conveying speed of the material handled (m/s)

3 <-l: Length of Installation Equiped with Skirt Plate (m)

1.05 <-b1: Width Between Skirtplates (m)

21 <-d: Belt Thickness (mm)

2.63 <-d: Medium Belt Inclination (Deg)

Pulleys Parameters

No. PulleyDi

(mm)

Ni

(kg)

Zxi

(kg)

Zsi

(kg)

d0i

(mm)

1 D1 630 15,962 13,067 3,634 170 <-D1: Drive Pulley

2 D2 500 12,519 6,253 0 140 <-D2: Tail/Return Pulley

3 D3 500 3,635 3,413 0 100 <-D3: Take up/Counter Weight Pulley

4 D4-1 400 3,635 3,634 0 100 <-D4: Bend/Deviation Pulley(s)

5 D4-2 400 3,635 3,634 0 100 <-D5: Snub Pulley(s)

6 D5 400 3,744 3,634 0 100

7

8

9

10

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Special Resistance Calculations

263 <-qG: Mass per Meter of Material Handled (kg/m)

0.83 <-Iv: Belt Capacity (m3/s)

117.53 <-Fe: Resistance due to Idler tilting (daN)

92.43 <-FgL: Resistance due to Friction between Material Handled and Skirtplates (daN)

56.70 <-Fr: Friction Resistance due to Belt Cleaner (daN)

266.66 <-Fs: Total Special Resistance (daN)

Secondary Resistance Calculations due Skirtplates, Inertial and Frictional Resistance

1.04 <-lb,min: Skirtplate Equivalent Length (m)

230 <-FbA: Inertial and Frictional Resistance at the Loading Point (daN)

66 <-Ff: Frictional Resistance between Handled material and the skirtplate in the acceleration Area (daN)

Secondary Resistance Calculations due Pulleys

No. PulleyFi

(N)

F1i

(daN)

FTi

(daN)

Fti

(daN)

1 D1 81,918 30

2 D2 61,342 31 12,281 17

3 D3 33,480 20 3,566 4

4 D4-1 35,651 26 3,566 4

5 D4-2 35,651 26 3,566 4

6 D5 35,645 26 3,673 5

7

8

9

10

3.6G

Qq

v

3.6v

QI

r

0 cos sinB GF C L q q ge e em d e

2

2

2 2

1

vgL

I glF

v b

m r

3rF Apm

s gL rF F F Fe

0bA vF I v vr

2 2

0,min

12b

v vl

gm

2

2 ,min

2

201

2

v b

f

I glF

v vb

m r

1 9 140 0.01 ii

i

F dF B

B D

Ti iF N g 00.005 iti Ti

i

dF F

D

OCP

MEA EXPANSION





<-Fi: Average Belt Tension at the Pulley (N)

<-F1i: Wrap Resistance between belt and Pulley (daN)

<-F1i: Wrap Resistance between belt and Pulley (daN)

<-FTi: Vectorial Sum of the Forces Applied to Pulley (daN)

<-Fti: Pulley bearing resistance (daN)

159 <-F1: Total Wrap Resistance between belt and Pulley (daN)

34 <-Ft: Total Pulley bearing resistance (daN)

489.30 <-FN: Total Secondary Resistance (daN)

Applicability of C Equivalent Method

755.96 <-FNS: Total Secondary & Special Resistance (daN)

1N bA f tF F F F F

NS N SF F F





No. Designation

Dp

(mm)

Tab.13

d

(mm)

N

(kg)

j

(Deg)

a

(Deg)

b

(Deg)

Zx

(kg)

Zs

(kg)

Fv

(kg)

q

(kg)

1 D1 630 170 15,962 210 0 13,067 3,634 0 942

2 D2 500 140 12,519 0 6,253 0 564

3 D3 500 100 3,635 3,413 7,000 414

4 D4-1 400 100 3,635 0 3,634 0 364

5 D4-2 400 100 3,635 0 3,634 0 364

6 D5 400 100 3,744 3 15 3,634 0 364

7

8

9

10

<-D1: Drive Pulley

<-D2: Tail/Return Pulley

<-D3: Take up/Counter Weight Pulley

<-D4: Bend/Deviation Pulley(s)

<-D5: Snub Pulley(s)

5- CHARGES SUR TAMBOURS


OCP

MEA EXPANSION



a

a

j

a

a

j

a

a

a

b

6-1- SPECIFICATIONS DU MOTEUR

Puissance installée (kW) 315

Standard de construction IEC60034

Facteur de puissance minimale cosj 80%

Facteur de service ≥ 1,5

Start-up/Nominal Absorbed Current Ratio (Is/In) 6.8

Tension d'alimentation 525V/3Ph

Vitesse de rotation (rpm) 1500

Fréquence 50Hz

Degrès de protection IP (IEC 60034-5) IP55

Classe d'isolation Class F

Température de design 50°C

Méthode de refroidissement selon IEC 60034-6 IC0A1

Protection thermique PT100

Environment de travail Poussièreux

Matériau de construction du stator Cast Iron

Matériau de construction Supports/oreilles de levage Fonte

Matériau de construction de la boite de jonction Fonte

Position boite de jonction au dessus du moteur

Type Cage d'écureuil

Poids approximatif (kg) 1500

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MEA EXPANSION



6- DIMENSIONNEMENT DU GROUPE DE COMMANDE


OCP

MEA EXPANSION



6- DIMENSIONNEMENT DU GROUPE DE COMMANDE


6-2- SPECIFICATION DU REDUCTEUR

Standard de construction AGMA

Type

Diamètre du tambour (mm) 630

Vitesse de la bande (m/s) 3.8

Vitesse de rotation /petite vitesse (rpm) 115

Couple réducteur (Nm) 26,112

Puissance réducteur (kW) 315

Rapport de réduction 13

Température de design du réducteur 50°C

Nombre d'heure de service/jour (hr) 24H

Facteur de Service ≥ 1,5

Type d'arbre à grande vitesse Type 1

Type d'arbre à petite vitesse Type 1

Type 1: Arbre plein

Type 2: Arbre creux avec disque

Type 3: Arbre creux avec clavette

Peinture Intérieure & Extérieure

Sonde de température N/A

Indicateur de niveau d'huile oui

Trous de regards avec clapets Oui

Carcasse du réducteur

Antidévireur N/A

Orientation de l'arbre de sortie (droite/gauche) Droite

Poids approximatif (kg) 790

6-3- SPECIFICATION D'ACCOUPLEMENT

Type d'accouplement Hydraulique

Chambre de retardement Oui

Rapport (couple de démarrage transmissible/couple nominal) 1,5 à 1,6

6-4- SPECIFICATION SYSTÈME DE FREINAGE

Type de frein

Temps de freinage maximale (s) ≤ 5

6-5- SPECIFICATION CHASSIE GROUP DE COMMANDE

Peinture Intérieure & Extérieure

Matériaux Acier Carbone

Construction PRS

Les carters du réducteur en

deux parties moulées

Frein à sabot à commande

électromagnétique

Axes perpendiculaires, à Arbre

plein

Pulley Parameters Definition

No. DesignationDp

(mm)

d

(mm)

N

(kg)Type

Lp

(mm)

ts

(mm)

tf

(mm)

Lf

(mm)

th

(mm)

dho

(mm)

dhi

(mm)

Tab.23

WL

(kg)

Tab.23

PN

(N/mm²)

Tab.23

d1

(mm)

Tab.16

Li

(mm)

k

(mm)

Tab.16

EA

(mm)

b

(mm)

Dq

(mm)

Lq

(mm)

Dm

(mm)

Lm

(mm)

Dw

(mm)

Lw

(mm)

n

(tr/min)

P

(kW)

MTP

(Nm)

Wd

(kg)

1 D1 630 170 15,962 Type 1 1600 10 10 1400 20 300 225 7.75 115 200 1360 88 1920 200 165 165 162 742.5 160 907.5 115 315 26111.84 2633.5

2 D2 500 140 12,519 Type 2 1600 10 10 1400 20 260 190 4.9 130 170 1360 79 1920

3 D3 500 100 3,635 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

4 D4-1 400 100 3,635 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

5 D4-2 400 100 3,635 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

6 D5 400 100 3,744 Type 2 1600 10 10 1400 20 210 145 2.6 145 130 1360 57 1920

7

8

9

10

<-Dp: Pulley Diameter (mm) <-tf : Pulley Flange Thickness (mm) <-PN: Pressure Applied From Locking Device to Hub (N/mm²) <-n: Gear Box Output Speed (r/min)

<-d: Shaft Diameter (mm) <-Lf : Distance Between Flange (mm) <-d1 :Shaft Inside Diameter (mm) <-P: Motor Nominal Power (kW)

<-N: Equivalent Load Applied From Belt Conveyor (kg) <-th: Hub Thickness (mm) <-Li: Shaft Inside Portion Length (mm) <-MTP: Moment Transmitted from Gear Box (Nm)

<-dho: Hub Outside Diameter (mm) <-k: Distance From Plummer Block Axis to Shaft End (mm) <-Wd: Approximatif Drive System Weight (kg)

<-Lp: Pulley Shell Length (mm) <-dhi: Hub Inside Diameter (mm) <-EA: Distance Between Plummer Blocks (mm)

<-ts: Pulley Shell Thickness (mm) <-WL: Locking Devices (kg) <-b: Distance From Plummer Block Axis to Gear Box (mm)

<-Dq: First Shrink Disc Diameter (mm)

<-Lq: First Shrink Disc Length (mm)

<-Dm: Second Shrink Disc Diameter (mm)

<-Lm: Second Shrink Disc Length (mm)

<-Dw: Third Shrink Disc Diameter (mm)

<-Lw: Third Shrink Disc Length (mm)

Hub Material Parameters Definition

C45+QT <-Hub Material Designation (Per EN10083-2)

200,000 <-Eh: Hub Modulus of elasticity (MPa)

430 <-Syh: Hub Yield Strength (MPa)

650 <-Suh: Hub Ultimate Limit Strength (MPa)


OCP

MEA EXPANSION



7- VERIFICATION DES AXES & MOYEU TAMBOURS

Pulley Shell Flange & Hub Parameters Driven Shaft Parameters Driving Shaft Parameters Gear Box & Motor Parameters


OCP

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7- VERIFICATION DES AXES & MOYEU TAMBOURS

Shaft Material Parameters Definition

C55+N <-Shaft Material Designation (Per EN10083-2)

200,000 <-Es: Shaft Modulus of elasticity (MPa)

420 <-Sys: Shaft Yield Strength (MPa)

700 <-Sus: Shaft Ultimate Limit Strength (MPa)

Design Parameters

1400 <-BW: Belt Width (mm)


1.5 <-SF: Factor of Safety

0.8 <-Ka: Surface factor

0.897 <-Kc: Reliability factor

1 <-Kd: Temperature factor

1 <-Ke: Duty cycle factor

0.63 <-Kf: Fatigue stress concentration factor

1 <-Kg: Miscellaneous factor

0.88 <-h: Mechanical Efficiency Coefficient for the Transmission

1.3 <-w: Starting Motor Coefficient




Pulley Parameters Definition

No. DesignationWp

(kg)Kb

Sf

(MPa)

MTT

(Nmm)

ag

(mm)

Mb

(Nmm)

dmin

(mm)

Stress

Checkrd

tan(a)/0.

005

Defl

Check

dho,min

(mm)

Hub

Stress

Check

1 D1 942.26 0.69684 110.262 3E+07 260 3.5E+07 169.774 OK 0.998672 0.4121 OK 295.955 OK <-Wp: Pulley Weight (kg)

2 D2 564.02 0.72303 114.405 0 260 1.6E+07 128.708 OK 0.9193425 0.70269 OK 259.589 OK <-Kb: Size Factor

3 D3 414.41 0.77076 121.958 0 260 4635327 83.4297 OK 0.8342972 0.78377 OK 205.958 OK <-Sf: Allowable Bending Stress (MPa)

4 D4-1 364.35 0.77076 121.958 0 260 4635327 83.4297 OK 0.8342972 0.78377 OK 205.958 OK <-MTT : Moment Transmitted to Pulley Taking into Consideration Drive System Efficiency & Starting Torque (Nmm)

5 D4-2 364.35 0.77076 121.958 0 260 4635327 83.4297 OK 0.8342972 0.78377 OK 205.958 OK <-ag (mm)

6 D5 364.35 0.77076 121.958 0 260 4775244 84.2608 OK 0.8426085 0.80743 OK 205.958 OK <-Mb: Bending Moment Applied to Shaft (Nmm)

7 <-dmin: Minimum Shaft Diameter Imposed by Stresses (mm)

8 <-rd: Minium Shaft Diameter to Nominal Shaft

9 <-tan(a): Shaft Deflection Ratio

10 <-dho,min: Minimum Hub Diameter (mm)

22

3min

f

32 3

4

b TT

ys

M MSFd

S S

22 22 2 2 22 2

11 1

27850 2 7850 2 7850 2 7850 7850 7850 7850 7850

4 4 4 4 4 4 4

p s ho qho hi m wp p p s f h L q m q w m

D t d Dd d D Dd dW D L t t t W L EA k b L L L L L L

0.19

25.4b

dK

2

usf a b c d e f g

SS k k k k k k k

1

0 2

TP

TT

M For TypeM w

For Typeh

2

f

g

EA La

2 2

db g w

WNM a b L

4

64tan

4

g g

s

Na EA a

E da

ho,min

yh N

hi

yh N

S Pd d

S P

Spherical Roller Bearing

Bearing Mounted on Smooth Shafts, Design Standard ISO113:1999 & Tapered Bore Bearing

Design Parameters Definition

3.8 <-v: Belt Velocity (m/s)

50 <-T: Maximum Design Temperature (°C)

90 <-R: Bearing Degree of Reliability (%)

1.5 <-Cd: Dynamic Load Factor

50,000 <-L10M: Minimum Bearing Rating Life operating hours Based on 500rpm (h)




Plummer Block Characteristics

No. Pulley Ref.Dp

(mm)

d

(mm)

N

(kg)

1 D1 630 170 15961.619

2 D2 500 140 12518.652

3 D3 500 100 3634.6952

4 D4-1 400 100 3634.6952

5 D4-2 400 100 3634.6952

6 D5 400 100 3744.4083

7

8

9

10

<-Dp: Pulley Diameter (mm)

<-d: Shaft Diameter (mm)

<-N: Equivalent Load Applied From Belt Conveyor (kg)


OCP

MEA EXPANSION



8- VERIFICATION DES PALIERS

BND2234 22234 CCK/W33 D170

Plummer Block Designation

Tab. 14

BND3228 23228 CCK/W33 D140

BND2220 22220 EK D100

BND2220 22220 EK D100

BND2220 22220 EK D100

BND2220 22220 EK D100


OCP

MEA EXPANSION





OCP

MEA EXPANSION




Bearing Rating Life Check

No.n

(rpm)

Pr

(N)

C

(N)

Tab.15

L10

(MR)

L10h

(h)

L10hE

(h)

L10hE ≥

L10M

1 115.20 117,438 1120000 1840 266138 61,317 OK

2 145.15 92,106 915000 2108 241998 70,252 OK

3 145.15 26,742 425000 10092 1158784 336,394 OK

4 181.44 26,742 425000 10092 927028 336,394 OK

5 181.44 26,742 425000 10092 927028 336,394 OK

6 181.44 27,549 425000 9139.410579 839541.0857 304647.0193 OK

7

8

9

10

<-n: Number of Revolutions per Minute of the Roller (rpm)

<-Pr: Dynamic Load Applied to Bearing (N)

<-C: Basic Dynamic Load Rating (N)

<-L10: Basic Rating Life (Million Revolution)

<-L10h: Basic Rating Life operating hours (h)

<-L10hE: Equivalent Bearing Rating Life operating hours Based on 500rpm (h)

22234 CCK/W33

23228 CCK/W33

22220 EK

22220 EK

22220 EK

22220 EK

Bearing Designation

Tab.14

rP2

d

NC

10

3

10

rP

CL

6

10 10

10

60hL L

n 10 10

500hE h

nL L1000 60

p

v x xn

D

Idler Definition

No. Ref TypeIdlers

Type

l

(Deg)

d

(mm)

a

(m)Bearing

Hc

(m)

1 ID01 Impact Tern 35 159 0.3 6305-2RS1 1.4

2 ID02 Carrying Tern 35 159 1.25 6204-2RS1 0

3 ID03 Transition Tern 20 159 2 6305-2RS1 0

4 ID04 Return Couple 10 159 3 6204-2RS1 0

5

6

7

8

9

10

<-l: Idlers Inclination Angle (Deg)

<-d: Idlers Diameter (mm)

<-a: Distance Between Idler (m)

<-Hc: Discharge Height (m)

Material & Design Condition DefinitionOver 16

hours per

day

<-Service Life

Abrasive or

Corrosive

Material

<-Environment Factor

20,000 <-L10M: Minimum Bearing Rating Life operating hours Based on 500rpm (h)

9.81 <- g: Standard Gravity Acceleration (m/s²)

Belt Carcass Definition





6 <-ttc: Top Cover Thickness (mm)

4 <-tbc: Bottom Cover Thickness (mm)

1.2 <-rr: Rubber Average Weight (kg/[m²xmm])

150 <-dL: Maximum Material Lump Size (mm)


Load Factor Computation

1.0272 <-Fd: Impact Factor (Material Lump Size) (Tab. 17)

1.2 <-Fs: Service Factor (Tab. 18)

1 <-Fm: Environment Factor (Tab. 19)

0.978 <-Fv: Speed Factor (Tab. 20)

OCP

MEA EXPANSION



9- VERIFICATION DES ROULEAUX


OCP

MEA EXPANSION



9- VERIFICATION DES ROULEAUX


Belt Weight Computation

6.5 <-qbc: Belt Carcass Weight for square Meter (kg/m²)

25.9 <-qb: Belt Weight Per Linear Meter (kg/m)

263 <-qm: Material Weight Per Linear Meter (kg/m)

Idler Roller Speed Check

No. Refn

(rpm)Cs (N)

Fp

(Tab.21)Pi (N) Pr (N)

C (N)

(Tab.22)

L10

(MR)

L10h

(h)L10hE (h)

L10hE

≥

L10M

1 ID01 456 850 0.67 5,222 2,093 22,500 1,243 45,386 41,432 OK

2 ID02 456 3,543 0.67 0 1,431 12,700 699 25,525 23,301 OK

3 ID03 456 5,669 0.6 0 2,050 22,500 1,321 48,252 44,048 OK

4 ID04 456 762 0.5 0 230 12,700 169,138 6,175,919 5,637,927 OK

5

6

7

8

9

10

<-n: Number of Revolutions per Minute of the Roller (r/min)

<-Cs: Static Load Applied to Troughing Set (N)

<-Fp: Participation Factor of Roller Under Greatest stress

<-Pi: Impact Load Due to Chute Applied to Troughing Set (N)

<-Pr: Dynamic Load Applied to Bearing (N)

<-C: Basic Dynamic Load Rating (N)

<-L10: Basic Rating Life (Million Revolution)

<-L10h: Basic Rating Life operating hours (h)

<-L10hE: Equivalent Bearing Rating Life operating hours Based on 500rpm (h)

1000 60v x xn

d

b bc r tc bcq q t t Br

3.6m

Qq

v

Reb

s

b m

aq g If turnC

a q q g Else

3

10

rP

CL

6

10 10

10

60hL L

n

10 10500

hE h

nL L

8

c

i

HP g Q

1 1

2 2r s d s m v p i pP C F F F F F PF

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