BELTSTAT v7.0 User Manual.pdf

7/25/2019 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

Documents

BELTSTAT v7.0 User Manual.pdf