simple flat belt convoyor design calculation sample

Designing a simple flat belt conveyor for a crushing and sand-making production line requires careful consideration of several factors to ensure efficiency, durability, and safety. Below is a sample calculation to guide the design process for a conveyor system used in the aggregate and sand industry.

1. Determine Conveyor Parameters: First, identify the required belt width, speed, and capacity. For instance, if the conveyor needs to handle 100 tons per hour (TPH) of crushed stone with a bulk density of 1.6 t/m³, the belt speed can be calculated using the formula: Q = A × V × ρ, where Q is capacity (TPH), A is cross-sectional area (m²), V is belt speed (m/s), and ρ is bulk density (t/m³). Assuming a belt width of 800 mm and a trough angle of 20°, the cross-sectional area can be approximated as 0.07 m². Rearranging the formula, V = Q / (A × ρ) = 100 / (0.07 × 1.6) ≈ 0.89 m/s.

2. Calculate Belt Tension and Power: The tension required to move the load depends on the conveyor length, incline, and friction. For a horizontal conveyor of 50 meters with a friction coefficient of 0.03, the total tension (T) can be estimated as T = (m × g × L × μ) + (m × g × H), where m is mass per unit length (kg/m), g is gravity (9.81 m/s²), L is conveyor length (m), μ is friction coefficient, and H is vertical lift (m). If the mass per unit length is 30 kg/m and H = 0, T ≈ 30 × 9.81 × 50 × 0.03 ≈ 441 N. The motor power (P) can then be calculated as P = (T × V) / η, where η is efficiency (e.g., 0.85). Thus, P ≈ (441 × 0.89) / 0.85 ≈ 460 W.

3. Select Belt and Pulley Specifications: Choose a belt material suitable for abrasive materials like crushed stone, such as rubber with nylon reinforcement. The pulley diameter should be at least 125 times the belt thickness to minimize bending stress. For