1

ABSTRACT

In Myanmar, belt conveyor systems are prevalent across various industrial

sectors such as mining and steel mill factories. There's a growing interest in adapting
these systems to enhance airport cargoing facilities. However, the existing conveyor
designs encounter a significant hurdle when it comes to efficiently managing the
transportation of rice bags for cargo aircraft. This challenge underscores the need for
innovation and optimization in conveyor systems to cater to the simultaneous handling
of rice bags, a crucial aspect of airport logistics. The primary objective of this research
is to develop a design for an inclined belt conveyor that prioritizes speed, accuracy,
customization, and efficiency, thereby reducing both time and labor costs. This paper
provides to design the conveyor system used for which includes the parameters are
finalizing the belt width and belt speed, motor selection, belt cross section, design of
drum, drum shaft, and drum shaft bearing and design of idler. In finalizing of belt width
and belt speed, the calculated results of belt width 0.4 m while belt speed is 0.6008 m/s.
Power needed to move belt conveyor is 0.766 kW, and the calculated results of drum
width is 0.5 m and drum shaft diameter is 0.038 m. In the design of idler, the diameter
of idler is 0.089 m and idler shaft diameter is 0.02 m. In the next step, Lead screw size,
lead screw efficiency, and power required based on the belt conveyor system. When the
lead screw's primary diameter is 36 mm, its efficiency is 65.2, and its power is 0.84
kW, the assembly is self-locking. Modeling of the belt conveyor system was done
according to the results obtained based on the input parameters calculations. Modeling
was done after installation of drum, idler, lead screw, belt conveyor frame, belt and
bearing included in the belt conveyor system. Modeling is done by using Solidwork
Software 2018. The height from the ground to driven drum is 1793.6 mm (5.976 ft)
meet the design requirement of Y8 cargo aircraft’ hatch. The minimum height is 4 ft
and the maximum height is 6 ft.

CHAPTER 1

INTRODUCTION

1.1. The Role of Belt Conveyor System

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Conveyor belts are no longer unfamiliar to people living in an age where

businesses are rapidly increasing. The problem of safely moving items across levels is
becoming more pressing as the need to safeguard human health grows. Conveyor belts
capable of delivering items to a particular height are increasingly becoming more
frequently used in a variety of developing nations, including moving commodities in
manufacturers, construction, and harbours. The initial illustration portrays a commonly
employed belt conveyor in the construction industry.

Figure1.1. Portable Conveyor

Conveyor belts are primarily used by conveyor shaft rollers, chain conveyors,
and conveyor systems in enterprises that use manufacturing and packing chains.
Airports, supermarkets, and small manufacturing facilities are also using more mobile
conveyors. These points demonstrate that the conveyor sector in particular and mobile
conveyors in general, are fast evolving.[1]
A Movable Conveyor Belt frequently referred as A Portable Belt Conveyor. A
portable conveyor is a sort of transportable conveyor that has supports that allow it to
move.
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This is a versatile equipment that is used in a variety of sectors, including the

light industry of food, medicine, textile, construction and so on. It is the primary method
of industrial production due to a number of benefits of short distance transportation.
The portable belt conveyor offers superior mobility as compared to standard belt
conveyors, thanks to the redirection system. With such a little gadget, the whole belt
conveyor seems to be alive, it can travel immediately to the material site and instantly
connect with both sides, it also eliminates the time that the belt conveyor must be fixed
at one location to transmit materials, which considerably reduces production costs.[3]
This thesis focuses on proving the versatility of the conveyor belt structure that
would be used for loading things from transport military trucks to Y8 Cargo Aircraft
and also Y8 to trucks as well as in limited locations such as a ware house, as well as
answering the issue of whether it is feasible to create a mobile conveyor. The second
issue that must be addressed is the procedures involved in creating a portable conveyor.
This article focuses on self-fabrication, the conveyor structure chosen is likely to be the
most basic.
1.2. History of Conveying Systems
The history of conveyors can be traced back to ancient times when the earliest
civilizations used simple conveyor systems to transport goods. In ancient Egypt, for
instance, laborers are believed to have used wooden rollers to move heavy stones during
the construction of the pyramids. Similarly, in ancient Greece, various forms of manual
conveyor systems were employed to move goods within mining operations and
construction sites.
The Industrial Revolution marked a significant turning point in the development
of conveyors during the 18th and 19th centuries. With the advent of steam power and
mechanization, conveyor systems evolved to become more sophisticated and efficient.
The first known conveyor belt system was introduced in the early 19th century,
consisting of leather belts running over wooden beds to move coal and ore in mining
operations. This laid the groundwork for the modern conveyor systems we see today.
In the 20th century, the conveyor technology continued to advance rapidly. The
introduction of synthetic materials like rubber for conveyor belts and the development
of powered conveyor systems further improved efficiency and versatility. The mid-20th
century saw the widespread adoption of conveyor systems in various industries,
including manufacturing, logistics, and transportation. Today, conveyors are integral to
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numerous industries, facilitating the smooth and automated movement of goods and
materials in diverse applications.[4]
1.3. Research in Global Conveyor Systems
The global belt conveyor market, valued at a substantial figure in 2023, is poised
for significant growth with a projected Compound Annual Growth Rate (CAGR) from
2024 to 2030. Major regions such as North America, the European Union, Asia-Pacific,
the Middle East and Africa, and Latin America drive demand, fueled by
industrialization and automation across sectors like automotive, food & beverage, and
mining. Despite growth drivers, challenges like high initial costs and environmental
concerns persist. Troughed Belt Conveyors (TBC), Roller Belt Conveyors (RBC), and
others cater to diverse material handling needs. Key players like ABB Ltd., Siemens
Mobility, and Hytrol Conveyor lead innovation, integrating technologies like IIoT and
AI for predictive maintenance and efficiency. Regulatory standards from OSHA, ISO,
and CE shape industry practices. Market strategies focus on innovation, partnerships,
and expansions, targeting emerging markets like BRICS and Southeast Asia for growth
and resilience.[5]

Figure 1.2. Annual Market Research in Global (2018-2032)

1.4. Domestic Market in Myanmar
In Myanmar, the domestic market for belt conveyors reflects the country's
growing industrial landscape and increasing emphasis on modernizing infrastructure.
As Myanmar undergoes economic development, industries such as manufacturing,
mining, and agriculture are witnessing a surge in demand for efficient material handling
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solutions. Belt conveyors play a crucial role in meeting these demands by providing a
reliable and cost-effective means of transporting goods within facilities.
The manufacturing sector in Myanmar, encompassing industries such as
textiles, food processing, and automotive assembly, is a key driver for the adoption of
belt conveyors. These systems enhance production efficiency, streamline logistics, and
contribute to overall operational optimization. Additionally, the mining industry, which
is a significant contributor to the country's economy, relies on belt conveyors for the
transportation of minerals and raw materials, contributing to the sector's growth. The
adaptability of belt conveyors to various industries aligns with Myanmar's evolving
industrial landscape, making them a preferred choice for domestic businesses looking
to enhance their material handling capabilities.
Moreover, Myanmar's focus on infrastructure development, including road and
building construction projects, further fuels the demand for belt conveyors in the
domestic market. As the country continues to modernize, the versatility and reliability
of belt conveyor systems position them as integral components in the local industrial
ecosystem. In summary, the domestic market for belt conveyors in Myanmar is
intricately linked to the nation's economic growth, with these systems serving as
indispensable tools for enhancing efficiency across diverse sectors.[5]

Figure 1.3. Market Research in Myanmar

1.5. Problem Statement
In Myanmar, belt conveyor systems are widely used in industrial, mining and
steel mill factory. The current design is to build conveyor prototypes that would help
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airport cargoing facilities. The existing belt conveyor system faces a challenge in
solving the demand of cargo aircraft efficiently handling the transportation of rice bags
simultaneously. The current design lacks optimization for the simultaneous conveyance
of rice bag, resulting in inefficiencies and increased labor requirements. Addressing this
problem is crucial to enhance the overall efficiency and productivity of the material
handling process in mining factory production and other product distribution.
1.6. Aim and Objectives
The aim of this research is to design of inclined belt conveyor, to produce quick,
accurate, customizable and reduce time and labor cost. This thesis will describe the
inclined belt conveyor design.
The objectives of this thesis are as follows:
(a) To finalize the belt width and belt speed
(b) To select Motor power and belt cross section
(c) To design of drum, drum-shaft and drum shaft bearing
(d) To design of idler and Lead screw selection
(e) Modeling of belt conveyor system
1.7. Scope of Thesis
The scope of thesis is to describe the design of belt conveyor system to transport
rice bags from military trucks to Y8 Cargo Aircraft and also Y8 to trucks. This conveyor
can produce quick, accurate, customizable, reduce time and labor cost and can be used
in another transportation or production line. In this thesis, design calculation of width
and speed of belt, motor power, drum, lead screw, and idler selection are described. And
also modeling of belt conveyor mechanism is described.
1.8. Outline of Thesis
In this thesis, five chapters can be presented. Chapter one is the introduction of
the belt conveyor system, market research, aim and objectives. Working principle,
components of this system and literature reviews are in Chapter two. This chapter
includes types of conveyor system, design specifications and concept selection. Chapter
three describes design theory of belt strength and width, belt tension, resistance of belt,
motor power, lead screw, drum and idler. Chapter four describes modeling and design
calculation of belt conveyor system. Discussions, conclusions and recommendation are
described in chapter five.
CHAPTER 2
LITERATURE REVIEW
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2.1. Historical Background

The evolution of belt conveyors, as an important type of continuous conveying
machinery, is examined here in a historical perspective. For this purpose, the selected
period is from the ancient time, i.e. occurrence of conveying equipment, and up to the
end of the nineteenth century. The basic postulation of a modern machine, including
conveyors, is often interlinked to that of its ancestor, which may be simple and
primitive. Ancient machines and principles of their work were the basis for later
improvements which also brought the inventions in engineering. For instance,
Archimedes lifted water to high altitude with a screw, which was regarded as the
ancestor of today’s screw conveyor and essentially his design has not changed since
then.
Bucket elevators also have their predecessors dating back to ancient times. In
the concrete case of belt conveyors, a first trace can be found in the beginning of the
seventeenth century, even classified as primitive example. During the Industrial
Revolutions, various machines, such conveyors, appeared. The first modern-like belt
conveyors are dedicated to the late eighteenth century due to the invention of Oliver
Evans in USA and to the nineteenth century, by Lyster in England, Lopatine in Russia
and Thomas Robins in USA. The technical solutions developed by the end of the
nineteenth century were forerunners of the today’s belt conveyors, while the key
operational principles have not changed.[6]

2.2. Literature Review

In 2023, Hau Tran (LAB University of Applied Sciences, Bachelor of
Engineering, Mechanical Engineering and Production Technology) designed a Movable
Inclined Conveyor with calculation of Flat Belt using roller and chain for rice
transportation. Final result of the conveyor at 5 degrees and 25 degrees, the conveyor
could carry with the smallest horizontal distance average of 7232 millimetres and the
maximum vertical lifting distance average of 4478 millimetres. In contrast to 25
degrees, at 5 degrees, the conveyor could achieve the highest transport
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distance at an average of 7951 millimetres and the minimum vertical lifting distance at
an average of 1919 millimetres.
In 2023, Captain Htein Lin (Degree of Master of Engineering, Department of
Mechanical Engineering, DSTA) wrote research paper is to design and fabricate of belt
conveyor, hydraulic cylinders and motors of semi-automatic block making machine.
The conveyor length of 8.95 m, inclination angle of 22 degrees, lift of material is 3.3 m
are design specification and calculation results of belt capacity are 72.65 ton/hr and
power motor is 1.1 kW.
In my research paper, conveyor length of 3m, capacity of 10 ton/hr, inclination
angle of 15 to 45 degree are design specifications to calculate the belt speed, width,
motor power and conveyor height.
2.3. Main Mechanical Components in a Conveyor
The following schematically shows the mechanical components of a typical belt
conveyor.

j m

k l

a b c d f g h i h b

Figure 2.1. Main Mechanical Components of a Conveyor System

(a) Tail pulley (in special case this can also be drive pulley with drive-unit
coupled to it)
(b) Snub pulley (at head-end and tall-end)
(c) Internal belt cleaner (internal belt scraper)
(d) Impact idlers (impact rollers)
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(e) Return idlers (return rollers)

(f) Belt (continuous loop of carrying run &return run)
(g) Bend pulleys
(h) lake-up pulley
(i) Take-up unit
(j) Carrying idlers (carrying rollers)
(k) Pulley cleaner (pulley scraper)
(l) External belt cleaner (external belt scraper)
(m) Head pulley (normally this is discharge pulley and also drive pulley.
Drive unit is coupled to this pulley when being drive pulley)
2.4. Working Principle
A belt conveyor operates by utilizing a continuous loop of material, typically a
rubber belt, which is supported by rollers or idlers throughout its path. This loop serves
to transport goods or materials from one point to another within a facility or across a
distance. The belt runs over a series of pulleys or drums, commonly referred to as drive
pulleys or head pulleys, which are connected to motors or drive mechanisms. The
rotational motion of these drive pulleys propels the belt forward, facilitating the
movement of the conveyed items along the conveyor line.
Loading of material onto the belt occurs at designated loading points, where
goods are placed manually or through the assistance of additional equipment like
chutes, hoppers, or feeders. Once loaded, the belt is kept under tension to ensure it
remains flat and taut, allowing for efficient transportation. Tension is typically
maintained by pulleys positioned at both ends of the conveyor, with one connected to a
drive mechanism such as an electric motor. This tensioning mechanism ensures the
proper functioning of the conveyor system and prevents slippage or sagging of the belt
during operation.
In addition to the driving and tensioning components, belt conveyors
incorporate support structures consisting of idler rollers or idler stations. These rollers
are strategically placed along the conveyor's length to minimize friction between the
belt and the support surface, enabling smooth and uninterrupted movement. The support
provided by these idlers ensures the stability and reliability of the conveyor system.
Overall, the belt conveyor system offers a versatile and dependable solution for the
transportation of various materials across industries such as mining, manufacturing,
logistics, and agriculture.
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2.5. Types of Conveyors

There are several types of belt conveyors designed to suit various applications
and operational requirements. Some common types of conveyor are:
(a) Flat Belt Conveyors
(b) Troughed Belt Conveyors
(c) Inclined Belt Conveyors
(d) Declined Belt Conveyors
(e) Pipe Belt Conveyors
(f) Curved Belt Conveyors
2.5.1. Flat Belt Conveyors
These are the most basic type of belt conveyor, consisting of a flat belt running
on pulleys at either end. Flat belt conveyors are versatile and suitable for conveying a
wide range of materials, including small parts, packages, and bulk materials. They are
commonly used in manufacturing, distribution, and warehousing facilities.

Figure 2.2. Flat Belt Conveyor

2.5.2. Troughed Belt Conveyors
Troughed belt conveyors feature a belt with raised edges (troughed) to contain
the material being conveyed. This design prevents spillage and allows for the efficient
transportation of bulk materials, such as grains, aggregates, and powders. Troughed belt
conveyors are commonly used in industries such as mining, agriculture, and
construction.

Figure 2.3. Troughed Belt Conveyor

2.5.3. Inclined Belt Conveyors
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Inclined belt conveyors are designed to transport materials at an angle, allowing

for vertical or steeply inclined conveying. They are used to overcome height differences
between different levels of a facility or to navigate terrain with varying elevations.
Inclined belt conveyors are often employed in industries such as food processing,
packaging, and manufacturing.

Figure 2.4. Inclined Belt Conveyor

2.5.4. Declined Belt Conveyors
Similar to inclined belt conveyors, declined belt conveyors transport materials
at an angle, but in the downward direction. They are used to facilitate the gravity-driven
movement of materials from higher to lower levels or to unload material from elevated
platforms. Declined belt conveyors are commonly found in shipping terminals,
distribution centers, and baggage handling systems.

Figure 2.5. Declined Belt Conveyor

2.5.5. Pipe Belt Conveyors
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Pipe belt conveyors feature a closed belt design, where the belt is formed into a
tubular shape using special idler rollers. This configuration allows for the efficient
transportation of bulk materials while containing dust and preventing spillage. Pipe belt
conveyors are particularly well-suited for conveying dusty or abrasive materials over
long distances and are used in industries such as mining, cement, and power generation.

Figure 2.6. Pipe Belt Conveyor

2.5.6. Curved Belt Conveyors
Curved belt conveyors are designed to navigate bends or curves in the conveyor
path while maintaining a continuous flow of material. They are used to optimize space
utilization in facilities with limited floor space or to accommodate complex layouts.
Curved belt conveyors are often used in airports, distribution centers, and
manufacturing facilities for sorting, merging, or diverting materials.

Figure 2.7. Curved Belt Conveyor

Each type of belt conveyor offers unique advantages and is selected based on
factors such as the type of material being conveyed, the required throughput capacity,
the layout of the facility, and specific operational requirements. By choosing the
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appropriate type of belt conveyor, businesses can optimize their material handling
processes and improve overall efficiency.
2.6. Customer Needs for Inclined Belt Conveyors
Price and usefulness of goods and services are two customer demands that might
inspire purchases. The product is focus on the functionality and basic construction of
the movable conveyor, the aims of the progress focus on development process in create
a basic model of Portable conveyor. Moreover, it should include some outstanding
advantages of this type of Belt Conveyor. Based on the market research, Medium-
Weight Conveyor Belt is the one that had more consumption than the rest, so the
movable belt conveyor size is chosen is estimated to have an average measurement.
It is common to see this kind of conveyor can be used to transport some powdery
or granular materials, such as grain, mineral powder particles and so on. Moreover,
portable belt conveyors may also be used to move bagged finished items. Loading, for
example, uses bagged grain in bags, which enhances loading efficiency and saves
human resources. In addition, its lightweight and adaptable wheels, the portable belt
conveyor may be trans- ported anywhere for better working conditions.
Furthermore, the ability of this kind of conveyor to adjust the elevator angle
enables it to function in a variety of scenarios, like the 2D drawing in figure below, used
for carrying products from a truck to a warehouse, traveling uphill, and so on.

Figure 2.8. Lifting Height of Conveyor

As a person from a developing nation, it is clear to notice that in the countryside,
human labor for transportation is still used, for example in fig. 2.9, either due to the tiny
size of the plant or the high cost of goods.
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Figure 2.9. Goods Transportation by Human Workers

For this reason, the final requirement that should be considered is the price of
the product. Because of its benefits, conveyors have been applied in many different
industries. They can also be used consecutively, especially in small space that does not
have enough area for fixed conveyor line; Fig. 2.10 depicts an instance of employing
multiple conveyors in a transport line.

Figure 2.10. Goods Transportation by Portable Belt Conveyor

Finally, the design is intended for those who want a Movable Belt Conveyor
capable of loading products onto transport vehicles or operating in confined spaces. It
is critical to maintain conveyor sizes on average, which is Medium-Weight Conveyor
might be used for a variety of functions. The pricing of the design is as low as feasible
while yet ensuring the quality of the conveyor. Bags or cartons weighing up to 50 kg
can be transported by the conveyor. The addition of wheels beneath the mechanism
allows the Conveyor to move more freely. To meet a range of operational requirements,
lifting and lowering are achieved utilizing a pulley and a motor.
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2.7. Design Specification for Prototyping

To be able to accomplish the requirement of the customer as best result as
possible, it is vital to determine relevant product parameters such as delivery volume,
conveyor angle, belt speed, conveyor length, and conveyor width. It is an essential
aspect of the design process since it gives an overview of the idea selection stage as
well as the initial data for the following calculating portions. To be able achieve this
requirement, Table (2.1) in identify section has been made.
Table 2.1. Specifications for Belt Conveyor

Sr. CONTENT SPECIFICATIONS DATA

Manufacturing, Post, Farms, Home

1. Application Industrial
Use, Construction, etc.
2. Condition Adaptable
3. Structure Portable Conveyor Belt

4. Core component Motor, Gearbox, Bearings

5. Power Source AC 220 V
6. Loading capacity Up to 50 kg
7. Delivery volume 10 ton/hour
8. Angle of conveyor 15 degrees to 45 degrees
9. Conveyor length 3 m, 3000 mm
10. Belt width ≥ 400 mm

2.8. Identifications
According to the need of customers, the movable inclined conveyor would be
used in an average area, which could be able to transport goods into different spaces.
The Portable Belt Conveyor that should be regularly used in the bag handling sectors
typically had a length that could be modified from 3000 to 12000 millimetres. Similarly,
for the fundamental design, there are various common sizes that can be easily obtained
in the market, such as 3 metres, 4 metres, 5 metres, 6 metres, 8 metres, 10 metres, and
12 metres. Conveyor angles in this application can be modified from 5 to 30 degrees.
Furthermore, the angle of the conveyor is determined at an average distance to
minimize slippage and keep the angle inclination from being too harsh.
The Y8 cargo aircraft currently in use by the Myanmar Army is essential for
good transportation and military operations. The Y8 cargo aircraft is also a main draw
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for delivering food such as rice, a staple food item essential for military personnel on
operational duty. Such logistics require fast delivery within a short period of time.
Loading food products onto the plane requires more labor effort because the plane's
hatch is 6 feet high.

6 feet

Figure 2.11. Height of Y8 Cargo Aircraft’ Hatch from Ground

2.9. Concept Selection for Belt Conveyor System
The needs of the client should be taken into consideration throughout the idea
selection step. The concept had been chosen based on Medium-Weight Conveyor Belt
type, and this product need to use the basic belt – rubber band. In addition to the fact
that this kind of belt is appropriate for the circumstance at hand, the decision to purchase
it was based on the reasonable cost of it.
The rubber conveyor belt demonstrated that it is a product with an affordable
price that satisfied all of the essential specifications for the moveable inclined conveyor
that is being designed. Because transported goods are already packaged in bags or
boxes, there is no need to use goods associated with food, such as a PVC Hygiene Belt
for the conveyor system.

Figure 2.12. Some Types of Belt Conveyor Idlers

Moreover, the concept had been comprehensively considered in many aspects.
There are two basic forms for idlers: a straight design and a V shape. In addition, the
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price of the conveyor is affected not only by its form but also by the number of idlers it
contains.
Furthermore, the thing that has to be taken into consideration is the frame of the
conveyor. In order to reduce the complexity of the final product, the decision was made
to make the frame out of a solid bar rather than a frame structure.
2.9.1. Concept One for Belt Conveyor System
Those concepts displayed below had gone through all the prerequisites when
carefully chosen to meet the end aim based on the analysis that had been given.
(a) The V-shape idlers of the conveyor included two rollers, and the flat idlers
was chosen.
(b) The rubber band is applied.
(c) To achieve the previously specified goal of simplifying the design and
lowering the price of the conveyor, the frame for concepts that should be
employed is a solid bar.
(d) The structure is kept as straightforward as possible.
(e) Perform competently in accordance with the necessity of transferring bags
or boxes.
The concept that had been shown in Fig. 2.12. was inspired by the most basic
portable conveyor, which used V-idlers (two idlers) and is also known as a Trough
Conveyor.

Figure 2.13. Concept One with a V-idler and a Conveyor Reference Model
The idlers from CEMA standards are shown in the picture as examples of how
the idler looks. V-Idlers, or conveyor belt support rollers, are built of materials such as
galvanised iron or stainless steel. Return idlers are Flat Idlers that are often made of
galvanised iron, 201 stainless steel, or 304 stainless steels.
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The driving and lifting motors had been separated and positioned in opposing
positions. The driving motor is at the tail pulley, while the lifting motor is near the head
pulley. The electrical control system works with a single-phase or three-phase power
source. The speed of the conveyor is intended to adjust depending on the purpose of
usage and is controlled automatically by the traction of the motor.
2.9.2 Concept Two for Belt Conveyor System
The second concept is another frequent sort of basic portable conveyor that may
be found un-der the Medium-Weight Conveyor Belt section, using a flat idler like the
one that is shown in Fig. 2.13.

Figure 2.14. Concept Two with Flat Idler with Reference Model of Conveyor
Another frequent sort of basic portable conveyor may be found under the
Medium-Weight Conveyor Belt section, using flat idler. The driving and lifting motors
are both located on the frame near the Head pulley in this conveyor type. Delivered and
return idlers of this conveyor are both flat, so the material of it could be galvanised iron,
201 stainless steel, or 304 stainless steels. CEMA standard idlers are provided as
samples of how the idler should appear. The speed of the conveyor is intended to adapt
based on the application and is regulated automatically by the traction of the motor.
2.9.3 Final Concept Selection
Table 2.2. Advantages and Disadvantages of Concept One and Two
Concept Advantages Disadvantages
➢ High capacity for heavy-duty ➢ More complex design.
applications. ➢ Higher initial cost.
Concept ➢ Better containment, reduced ➢ Material carryback along the
one spillage. return side.
➢ Suitable for inclines and long- ➢ Limited flexibility compared
distance conveying. to flat belt conveyors.
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Concept Advantages Disadvantages

➢ Simplicity: Easy installation ➢ Limited incline capability.
and maintenance. ➢ Tension maintenance
➢ Versatility: Suitable for required.
various materials and ➢ Limited containment,
applications. potential spillage.
Concept ➢ Cost-effective: Lower initial ➢ Prone to slippage in certain
two and operational costs. conditions.
➢ Smooth surface: Even
distribution, reduced spillage.
➢ Easy cleaning: Simple
maintenance, ideal for
hygiene-sensitive industries.

According to the comparison of concept one and two, concept two is simple to
use, easy to maintain and low initial cost. Concept two meets the design requirement.
So, we choose concept 2 for belt conveyor system.
CHAPTER 3
DESIGN THEORY OF BELT CONVEYOR AND POWER SCREW

3.1. System Design for Belt Conveyors

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In the previous chapter, it was already introduced the fundamentals of belt

conveyors and their applications. Now, let's get deeper into the design considerations
essential for the efficient and reliable operation of belt conveyors.

Figure 3.1. Proposed Research Plan

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Designing a belt conveyor involves a thorough understanding of various factors

such as material characteristics, operational requirements, and environmental
conditions. This chapter will outline key considerations in designing belt conveyors,
including belt selection, load characteristics, conveyor layout, and safety measures.
3.2. Belt Selection
Choosing the right belt is crucial for the performance and longevity of a
conveyor system. Several factors influence belt selection:
(a) It is the belt, which is actually conveying material.
(b) Belt is in contact with material and is taking all the punishment from
material, such as impact, abrasion, attrition etc.
(c) Often, belt is the costliest item, affecting capital investment.
(d) Belt is a wearing item. Improper design can result into fast wear and tear
of belt, resulting into higher running cost.
The designer should use standard belt widths as per international practice. The standard
belt widths in mm are 400, 500, 650, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2200,
2400, 2600, 2800, 3000 and 3200. The belt widths 450 mm, 600mm, 750 mm, 900 mm
and 1050 mm were also used in past and sometime one has to deal with these belt widths
as replacement requirement etc.
In USA belt width in inches are also in use which are 18, 24, 30, 36, 42, 48, 54,
60, 72, 84 and 96 inch size.

Figure 3.2. Belt Cross-section

3.3. Material Characteristics
The material behaviour on belt is an important issue which directly / indirectly
effects the load on idlers, tractive pull, belt tensions, belt life and overall performance
of conveyor. Through understanding of this behaviour is essential for proper
engineering judgement and correct design of the conveyor as a whole.
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3.3.1. Abrasiveness
Consider the abrasiveness of the conveyed material to select a belt with suitable
wear resistance. Abrasive materials such as sand, gravel, or ores require belts with high
abrasion resistance to prevent premature wear.
3.3.2. Temperature
For high-temperature materials, heat-resistant belts are necessary to prevent
premature degradation. Industries such as steelmaking, foundries, and cement plants
often require belts capable of withstanding extreme temperatures.
3.3.3. Moisture Content
Moisture-resistant belts are essential for materials prone to moisture absorption
or in humid environments. Agricultural products, such as grains or sugar, and waste
management facilities dealing with wet waste require belts that resist moisture
absorption and mold growth.
3.4. Belt Type
The type of belt used in conveyor system depends on various factors including
the specific application, the type of materials being transported, environmental
conditions, and operational requirements. Three basic types of belts are as follow flat
belts, troughed belts and chevron belts.

3.4.1. Flat Belts

Suitable for horizontal or slightly inclined conveying of lightweight materials.
Flat belts are commonly used in applications such as luggage handling at airports,
package handling in distribution centers, and food processing.

3.4.2. Troughed Belts

Ideal for conveying bulk materials over long distances and inclines, providing
better containment and stability. Troughed belts are commonly used in mining,
quarrying, and aggregate industries for transporting bulk materials such as coal, ore,
and aggregates.

3.4.3. Chevron Belts

Designed for handling materials with steep inclines or conveying materials up
slopes. Chevron belts feature V-shaped cleats on the surface to prevent material rollback
and improve conveying efficiency. They are commonly used in agricultural
applications, such as grain handling, and in construction for inclined conveying of bulk
materials.
 23

3.5. Belt Strength and Belt Width

Determine the required belt strength based on the maximum load and operating
conditions. Belt strength is typically expressed in terms of tensile strength and is
influenced by factors such as belt material, construction, and safety factors.
Empirical Formula,
B = x . a + 200 (3.1)
Where, x = 2.5 for graded material
x = 3.5 for ungraded material
Now, Let check the covering capacity of the “selected belt”
Q 12
Bmin =1.11[{ } + 0.05] (3.2)
ρCV
Where, Bmin= Minimum width of belt, m
Q = Conveyor capacity, tonnes/hr
v = Belt or chain velocity, m/s
C = Factor for the type of idler (From PSG 9.18)
= 240, for flat belt
= 460, for trough angle of 20
= 510, for trough angle of 25
= 545, for trough angle of 30
ρ = Density of rice, tonne/m3 (0.72 tonne/m3)
Table 3.1. Density of Commonly Conveyed Materials
Sr. Materials Density tonne/m3
1. Wheat 0.65 - 0.83
2. Slag, anthracite 0.6 - 0.9
3. Anthracite, fine, dry 0.8 - 0.95

Table 3.2. Standard Length of the Idlers

Belt width, B
Length
(mm) 400 500 650 800 1000 1200 1400 1600 1800 2000 2200 2400

L 500 600 750 950 1150 1400 1600 1800 2000 2200

L 250 315 380 465 600 670 750 900 1000 1150 1400 1400
 24

L 200 250 315 380 465 530 600 670 750 800 950

Table 3.3. Allowable Belt Conveyor Speed in m/s

Belt width, mm
Sr. Types of material conveyed
400 500 650 800 1000
1. Gravel, stone, coal, ash, ores 1.5 1.75 2 2.75 2.75
2. Coke, friable materials 1.25 1.5 1.5 1.75 2.0
Dry and wet sand, grains, and light
3. 2 3 3.5 4 4
materials
Abrasive materials, line coke, slag,
4. 1.25 2 2 2.5 2.5
crushed ore
Abrasive materials: in large lumps,
5. 1.75 1.75 2
slaggy rock, ores

(a) Resistance of belt on the top run, kgf

Wo = CfL [(Gg +G b ) cosδ + G ro ] ± H (Gg + G b ) (3.3)

Where, Wo = Resistance of the belt on the top run, kgf

C = Secondary resistance factor
f = Friction between idler and belt
L = Conveyor length, m
Gg = Weight of conveyed material/meter length, kgf/m
Gb = Weight of belt/meter length kgf/m
δ = Inclination of conveyor
Gro = Weight of troughing idlers on the top run/metre length kgf/m
H = Height through which material is conveyed, m
Table 3.4. Weight of Conveyor Belts, kgf/m
Sr. Belt width, mm 400 500 650 800 1000
1. Average weight per metre run, kgf 5 6.5 9 12 16

Table 3.5. Secondary Resistance Factor

Sr. Length, m Secondary Resistance factor, C
1. 3 9
2. 4 7.6
3. 5 6.6
 25

4. 6 5.9
5. 8 5.1
From PSG 9.22
Q
Gg = q = (3.4)
3.6v
Where, Gg = Weight of conveyed material/meter length, kgf/m,

q = Weight of load/ meter of conveyor, kgf/m

Q = Capacity of conveyor, tonne/hr
v = Belt or chain velocity, m/s
(b) Resistance of belt on the bottom run, kgf
Wu = CfL [( Gb cos δ + Gru)] – ( HGb ) (3.5)
Where, Gru = Weight of straight idlers on the bottom run/metre length kgf/m
Wr
Gru = ( 2 is bottom idler is larger space than top) (3.6)
2s
C = Secondary resistance factor, PSG 9.20
f = Friction between idler and belt
= 0.016 to 0.018 for non-portable conveyors with good idlers
= 0.02 for standard conveyors
= 0.023 to 0.027 for idlers in dusty environment
L = Conveyor length, m PSG 9.20
Table 3.6. Weight of Revolving Parts of Idlers in kgf/idler assembly
Belt Tube dia,
100 125 140 150
width,mm mm
Bearing
20 25 20 25 20 25 20 25
dia, mm
TROUGING IDLERS
400
13.6 14.1 16.4 20
500
650 17.9 21.6 24.4 24.6
800 19.4 23.1 26.2 27.4 34.7
1000 29.9 30.2 37.8
STRAIGHT IDLERS
400 7.6 7.8 9.5 10.7
 26

500
650 11 12.2 15.8 15.9
STRAIGHT IDLERS
800 12.65 13.7 18.2 18.8 22.5
1000 21.3 21.4 25.1
Belt Density of material conveyed, tonne/m3
width, Return
0.4 ~ 1.2 1.2 ~ 2 2 ~ 2.8
mm idler
400 1.6 1.5 1.4 3.0
500
650
800 1.5 1.3 1.2
1000

From PSG 9.18

WT = Wo + Wu
Where, WT = Total resistance of the belt, kgf
Wo = resistance of the belt on the top run, kgf
Wu = resistance of the belt on the bottom run, kgf
3.6. Load Characteristics
Understanding the characteristics of the material being conveyed is essential for
designing a conveyor system that can handle the load efficiently:
3.6.1. Bulk Density and Flow Properties
Determine the bulk density and flow properties (e.g., cohesive, free-flowing) of
the material to calculate the required conveyor capacity and select suitable belt speed
and inclination. Bulk density refers to the mass of material per unit volume and affects
the conveyor's load-carrying capacity. Flow properties, such as cohesion and angle of
repose, influence material flow behavior and conveyor performance.
3.6.2. Particle Size and Shape
Consider the particle size and shape to prevent material spillage, segregation, or
degradation during conveying. Particle size distribution and shape affect the material's
flowability, heap formation, and interaction with the conveyor belt surface. Irregularly
 27

shaped or oversized particles may cause belt tracking issues, chute blockages, and
excessive wear on conveyor components.
3.6.3. Impact and Abrasion
Assess the potential impact and abrasion on the belt and conveyor components
to implement appropriate wear protection measures. Impact loading occurs when
materials are dropped onto the conveyor belt from a height, causing localized stress and
potential belt damage. Abrasive materials or sharp-edged particles can cause wear and
tear on the belt surface, leading to reduced belt life and increased maintenance costs.
To mitigate impact and abrasion, conveyor design may incorporate features such as
impact beds, impact idlers, wear liners, and skirting systems.
3.7. Conveyor Layout
The layout of the conveyor system plays a significant role in optimizing material
flow, minimizing energy consumption, and ensuring operational efficiency: Determine
the layout configuration (e.g., straight, curved, inclined, declined) based on space
constraints, material flow requirements, and operational considerations. The conveyor
layout should facilitate efficient material handling, minimize transfer points, and
provide access for maintenance and inspection. Factors such as building layout,
equipment placement, and material flow paths influence conveyor configuration
decisions.
Design transfer points carefully to minimize material spillage, dust generation,
and belt wear. Transfer points are critical areas where material transitions between
conveyors, chutes, or other handling equipment. Proper design of transfer points
reduces material degradation, enhances dust control, and improves conveyor reliability.
Common transfer point design considerations include chute geometry, impact
protection, belt support, and sealing systems.
Drive arrangement (e.g., head drive, tail drive, center drive) based on the
conveyor layout and operational requirements. The drive arrangement determines how
power is transmitted to the conveyor belt and influences conveyor performance,
maintenance requirements, and belt tracking. Factors such as conveyor length, load
distribution, and space constraints dictate drive arrangement selection. Head drives are
commonly used for long, straight conveyors, while tail drives are suitable for reversible
conveyors or conveyors with limited space at the discharge end. Center drives are often
employed in applications requiring bidirectional operation or distributed drive power.
3.8. Maintenance Access
 28

Design the conveyor system with sufficient access points for maintenance and
inspection tasks, ensuring safe and efficient servicing of equipment. Maintenance
access facilitates routine inspection, lubrication, adjustment, and repair of conveyor
components, reducing downtime and prolonging equipment life. Access points should
be strategically located at key maintenance areas, such as drive assemblies, pulley
systems, belt splices, and idler frames. Safety considerations, such as fall protection,
lockout/tagout procedures, and confined space entry requirements, should be integrated
into maintenance access design.
In conclusion, the design of a belt conveyor requires careful consideration of
various factors, including belt selection, load characteristics, conveyor layout, and
safety measures. By addressing these considerations systematically, engineers can
design conveyor systems that meet operational requirements, enhance productivity, and
ensure safety in material handling operations. Through the integration of advanced
technologies, innovative design solutions, and best practices, conveyor designers can
optimize performance, reduce environmental impact, and achieve sustainable
development goals.
3.9. Motor Selection
The power required at the driving pulley just for driving the belt is given by the
formula,
From PSG 9.18
PV
Hp of drive, hp = (Assuming ηmech = 85%) (3.7)
75ηmech

Where, p = WT = Total resistance of the belt, kgf

But, the actual power requirements, taking into consideration the wrap
resistance between driving pulley and belt, and driving pulley bearings resistance. The
calculation of final motor power is dependent upon efficiency of the transmission
system applied including chain, belt drive, coupling and gear box etc.
Motor power = hp × 746 (3.8)
3.10. Maximum Tension in the Belt
The belt conveyor starts operating once the belt is set in motion. However,
various elements of belt conveyor, which are in contact with belt, impose resisting-
forces to the belt motion and conveyor would stop unless powered by external means.
The calculation of various resisting (opposing) forces to belt motion (conveyor
operation) has been described in follow.
 29

It is necessary to provide continuous tractive pull, equal to sum of all resisting-

forces, to ensure continuous operation of belt conveyor. This " tractive pull is applied
to belt by drive-pulley/s. The tractive pull results into specific pattern of belt tension to
belt by drive-pulley/s. The tractive pull results into specific pattern of belt tension along
conveyor axis.
This section is to find out
 eμα 
Maximum tension in the belt T1 = P  μα  (3.9)
 e - 1
Where, T1 = Maximum tension of belt or belt tension at tighter side, kgf
T2 = Belt tension at slack side
∝ = Angle of lap over pulley in radians or wrap angle in radian
µ = Coefficient of friction between pulley and belt, 0.1 to 0.45
Similarly, PSG 9.18,
Tension on slack side of belt, T2 = T1 – P (3.10)
3.11. Number of Plies
Some conveyor belting is manufactured with one ply of fabric. Fabric layer can
be coated with rubber, polymer, or elastomer. Most conveyor belting is manufactured
using two or more plies of fabric that are adhered to each other by using inner layers of
rubber, polymer, or elastomer.
T1
No of Plies (i) = (3.11)
BF
Where, B = width of standard belt, mm
f = working tension of belt for 1 mm width, kgf/mm
Table 3.7. Number of Plies of Belt
Density of material conveyed, t/m
Belt
over 0.4 0.85 1.25 1.75
Width
upto 0.85 1.25 1.75 2.5
No. of designation of belt fabric, oz
mm
Plies, i
2 3 2 3 3 4 3 3 4 4 3 3 4 4
8 2 8 2 6 2 2 6 2 8 2 6 2 8
min 3 3 3 3 4
400
max 5 4 5 4 4
min 3 3 4 4 3 4 4
500
max 6 5 6 5 5 5 5
 30

min 4 4 5 4 4 3 5 5 4 5 5 4
650
max 7 6 7 6 5 5 6 5 5 6 5 5
min 4 4 5 5 4 4 5 5 4 3 6 6 4 4
800
max 8 7 8 7 6 6 7 6 6 5 7 6 6 5
Table 3.8. Working Tension in Conveyor Belts
Designation 28 oz 32 oz 36 oz 42 oz 48 oz
Volcanised joint &
0.54 0.62 0.71 0.82 1.02
Working gravity take up
Tension, Mechanical joint &
kgf/mm width gravity take up or
0.48 0.57 0.66 0.77 0.98
per ply volcanised & screw
take up
3.12. Thickness of Belt
Light-weight conveyor belts are typically used in industries like food
processing, packing, and light manufacturing. They range in thickness from about 0.5
to 3 millimeters. Medium-duty conveyor belts are often used in industries like
agriculture, automotive and general manufacturing. They typically range in thickness
from 3 to 8 millimeters. Heavy-duty conveyor belts are used in industries like mining,
construction and heavy manufacturing. They tend to be thicker, ranging from 8 to 20
millimeters or more, depending on the application.

Figure 3.3. Belt Layers

The thickness of the belt, t = (I × 1mm) + Top cover thickness + Bottom cover
thickness + rubber impregnation
Permissible tensile stress for belt material, σt = 5 N/mm2
Young’s modulus of Elasticity, E = 100 N/mm2
 31

The belt for induced stresses,

T1 E t
[σ t ] = ( )+( ) (3.12)
B×t D
D = K1K 2i (3.13)

Where, D = Diameter of both driver and driven pulley, mm

K1 = 1.25 for fabric duct ply material
K2 = 100 for lap angle 240°
3.13. Drive Units
Conveyor includes one or more number of drive units to provide mechanical
power for operating the conveyor. The drive unit applies running torque to drive pulley,
which results into tractive pull for belt. Sometimes, decline conveyor will be
‘Regenerative’ i.e. it will have negative power demand in loaded condition. Such
conveyor will be continuously generating power, which is to be absorbed by drive unit
and electric power system. However, such conveyor will have positive power demand
when running empty. Thus, drive unit for regenerative conveyor is required to pull belt
during positive power mode, and to restrain belt during negative power mode.
The drive unit for a conveyor will generally comprise of electric motor, speed
reduction gearbox, couplings, holdback, brake, safety guards and base frames for
supporting above components in a single assembly. The drive unit for belt conveyor
always needs speed reduction ratio is selected such that its output rpm in combination
with pulley diameter results into required speed.
3.13.1. Design of Drum, Drum Shaft and Drum Shaft Bearing
A Head Drum also known as a Head Pulley or Drive Pulley are driven by
mechanical means to provide movement of the conveyor belt. A Tail Drum also known
as a Tail Pulley is located at the opposite end of the conveyor belt to the head drum.
They provide a direction of rotation for the conveyor belt and can also be used as a
tension device in some conveyor designs. These products find their applications in
various industrial sectors involving the use of a conveyor belt, especially in Quarrying
and Mining.
 32

Figure 3.3. Drum and Drum Shaft

A drum shaft also known as a roller shaft or conveyor roller shaft, is a
component used in conveyor systems. It refers to the cylindrical shaft that supports and
rotates the drum or roller of a conveyor belt. The drum shaft typically extends through
the center of the roller and connects to the conveyor frame or support structure. It
provides support and facilitates the rotation of the roller allowing the conveyor belt to
move smoothly along its path.

Figure 3.4. Roller Shaft Drum

A drum for a belt conveyor is a cylindrical component that serves as a pulley
for the conveyor belt. It is typically mounted at either end of the conveyor and is used
to support and drive the belt. The drum rotates, pulling the belt along its path and
facilitating the movement of materials or goods along the conveyor system. Drums for
belt conveyors come in various sizes and designs depending on the specific application
and requirements of the conveyor system. They are often made of durable materials
such as steel or rubber to withstand the rigors of continuous operation in industrial
settings.
 33

Figure 3.5. Each Components of Drum Parts

Width of drum, W = B + [ 2 × Edge clearance] (3.14)
Design of drum shaft,
Wds = T1 + T2 (3.15)
The formula for determining the maximum bending moment of a beam,
Wl
M= (3.16)
4
Where, M = Maximum bending moment, Nmm
W = applied load, N
L = length of the beam, mm
Power transmitted by the shaft,
 2πNT 
P = (3.17)
 60 

Where, T = Torque , Nmm

N = Rotational speed, rpm
Peripheral velocity is given by,
 πDN 
V = (3.18)
 60 
Equivalent twisting moment,

Teq = (k b × M)2 + (k T × T)2 (3.19)

Assuming material of shaft as C = 45, From PSG 1.9

σ yt
[σ t ]permissible = (3.20)
Factor of safety
π T τ 
Teq = ×d s 3×τ permi ,  =  (3.21)
16 J R
 34

3.13.2. Selection of Bearing

The rolls are fitted with antifriction bearing for connection between rotating
shell and stationary spindle. The antifriction bearing could be of taper roller type or
single row deep groove ball bearing type. The load acting on bearing has main
component in radial direction with secondary component in axial direction with
secondary component in axial direction. It has been found that both the aforesaid
bearings are suitable for load condition in roller.
Wds
(a) Radial Load = (Fr) = = 7.52 kN < 8 kN
2
(b) Axial Load = (Fa) = 0
Life in hours (Lh) = 20000 hrs (Assume)
Table 3.9. Service Factor for Bearing
Sr. Life time (Lh) Service factor (S)
1. 10000 1.35
2. 16000 1.16
3. 20000 1.08
4. 25000 1.00
5. 32000 0.93
6. 50000 0.79
7. 63000 0.73
8. 80000 0.68
9. 100000 0.63

Life in millions of revolutions,

60×N×Lh
Lmr = (3.22)
106
From PSG 4.2,
Equivalent load (PE ) = [(XVF r +YFa )×SK t ] (3.23)

Where, X = radial factor

Y = thrust factor
S = Service factor
For dynamic capacity, PSG 4.2
 35

K
C
L10 =   , K = 3 (For ball bearing) (3.24)
 PE 
3.14. Power Screw
Power screws, sometimes called lead screws, jack screws, or linear actuators,
are machine elements that transform rotary motion into translational motion, or amplify
a small tangential force moving (rotationally) through a large distance into a large axial
force moving through a small distance. Geometrically, a power screw is a threaded shaft
with an attached thrust collar at one end, engaged into a mating nut. With suitable
constraint, either the nut may be rotated to cause axial translation of the threaded screw,
or the screw may be rotated to cause axial translation of the nut. Common examples
include screw jacks for load lifting, C-clamps, vises, lead screws for precision lathes or
other machine tools, positive positioners for control rod drives in nuclear power
reactors, and compaction drives for home garbage compactors.

Figure 3.6. Basic Configuration of Load-raising Power Screw

The most useful thread forms that may be used for power screws are the square
thread, the modified square thread, the Acme thread, and the buttress thread, all
sketched in Fig. 3.4. The square thread provides the best strength and efficiency but is
difficult to manufacture. The 5° thread angle, θ, (10° included angle) of the modified
square thread improves its manufacturability. The Acme thread illustrated in Fig. 3.3,
with its 29° included angle (θ =14.5°) is easy to manufacture and allows the use of a
split nut that can be squeezed radially to adjust for wear. The buttress thread provides
greater strength for unidirectional loads [5].
 36

Figure 3.7. Common Thread Forms Used for Power Screw Applications
3.15. Power Screw Torque and Efficiency
The input torque required to operate a power screw when raising the load, as
illustrated in Fig. 3.5, may be estimated as the sum of the torque required to lift the
load, the torque required to overcome friction between the contacting threads of the
screw and the nut, and the torque required to overcome friction between the thrust collar
and the supporting frame [5].

Figure 3.8. Force Resolution at a Typical Point in the Thread Contact Zone when the
Load is being Raised
TR = TW + Ttf + Tcf (3.25)

ƩFx = 0, ƩFy = 0 and ƩMx = 0, ƩMy = 0

F z = W + Fn t sin  − Fn cos  n cos  = 0 (3.26)

 37

M z =TR − W c rc − rp Fn cos n sin  − rp Fn t cos  = 0 (3.27)

Torque required to raise the load,

 l cos  + 2 rp t 
TR = Wrp   + Wrc c (3.28)
 2 rp cos  − l t 
Torque required to lower the load,
 −l cos  + 2 rp t 
TL = Wrp   + Wrc c (3.29)
 2 rp cos  + l t 
Depending upon friction coefficients and thread geometry, the load being raised
may or may not back-drive the screw if the applied torque is removed. That is, axial
load may or may not be able lower itself by causing the screw to rotate in reverse. If
the screw cannot be rotated in reverse by any magnitude of axial load, the assembly is
said to be self-locking. If applying an axial load on the nut can cause the screw to rotate,
the assembly is said to be overhauling. If collar friction is negligibly small, the
condition that represents the boundary between self-locking and overhauling is that in
Equation 3.29. Since the denominator of the bracketed expression in equation 3.29
cannot be zero, for the screw to be self-locking,
l cos 
t  (3.30)
2 rp

and for the screw to be overhauling,

l cos 
t  (3.31)
2 rp

Efficiency of a power screw assembly, e, may be defined as the ratio of driving

torque (theoretical torque to raise the load if there were no friction in either collar or
thread contact zone) to (with collar and thread friction).
1
e= (3.32)
 cos  n + t cot   rc
 cos  −  tan   + c r cot 
 n t  p

One kilowatt (kw) equals 60,000 N-m/minute. If a constant torque

T is applied to a shaft rotating at constant angular velocity ω rad/min, the work
performed each minute is Tω, and the power transmitted is
T T (2 n) Tn
P= = = (3.33)
60000 60000 9549
CHAPTER 4
 38

DESIGN CALCULATION OF BELT CONVEYOR SYSTEM

4.1. Design Calculations of Belt Conveyor
When building the belt conveyor design, the necessary input data is as follow:-
Material to be conveyed - Rice Bag
Capacity - 10000 kg/h = 10 ton/h
Lump size - 0.01m = 10 mm
Length - 3m
Inclination angle - 15° - 45°
4.1.1. Finalizing the Belt Width and Belt Speed
As the first design calculations, the necessary data for the specifications
included in the belt section such as belt width and belt speed were calculated as
follows:-
From Empirical Formula,
The width of belt, B = x . a + 200
x = 2.5 for graded material
x = 3.5 for ungraded material
B = ( 2.5 × 10 ) + 200
B = 225 mm
Selecting Standard belt width from PSG 9.20, Table 3
B = 400 mm = 0.4 m
V= 2 m⁄s
Now, Let check the covering capacity of the “selected belt”
From PSG 9.19
Q 12
Bmin =1.11[{ } + 0.05]
ρCV
From PSG 9.22 (Table 6)
Density of Rice (ρ) = 0.72 tonne/m3
C= 240 (PSG 9.18)
V = 2 m/s (PSG 9.20 Table (3))
 39

Bmin= 0.4 m
1
Q
0.225=1.11[{ }]2 +0.05]
0.72×240×2
Q = 8.06 tonne/h < Qrequired =10 tonne/h

⸫ Selection fails.
Now, Selecting the next higher width from PSG 9.20.
Bmin= 400 mm or 0.4 m
V = 2 m/s
1
Q
0.4 = 1.11[{ }]2 +0.05]
0.72×240×2
Q = 33.3 tonne/h > Qrequired =10 tonne/h

Belt Conveyor Speed (m/s),

1
10
0.4=1.11[{ }]2 +0.05]
0.72×240×v
v = 0.6008 m/s < 2 m/s
[Bmin = 400 mm & v= 0.6008 m/s]
Hint (1) If lump size (a) is not given, then we cannot use the formula,
B = a × x +200.
(2) Use Trial and Error approach for the values of ‘B’ and ‘V’ from PSG
9.18 & compare Qcalculated from PSG 9.18 with Qrequired .

4.2. Motor Selection

From PSG 9.18
(a) Resistance of belt on the top run, kgf
Wo =CfL[(Gg +Gb ) cosδ+Gro ] ± H(Gg +Gb )

Wo =Resistance of the belt on the top run (kgf)

C = Secondary resistance factor
f = Friction between idler and belt (PSG-9.18)
L = Conveyor length (m)
Gg = Weight of conveyed material/meter length (kgf/m)
Gb = Weight of belt/meter length kgf/m (PSG-9.18, Table-1)
δ = inclination of conveyor
Gro = Weight of troughing idlers on the top run/metre length (kgf/m, Table-2)
 40

H = Height through which material is conveyed (m)

C = 9, F = 0.02 (for standard conveyor, PSG-9.18), L = 3 m
From PSG 9.23
Q
Gg = q =
3.6V
ton 1000kg 1hr
10 × ×
= h 1ton 3600s
m
3.6×0.6
s
Gg = 1.284 kgf/m
From PSG 9.19
Gb =5kgf/m (Table-1, Belt width 400mm)
Inclination angle, δ=15° (Given)
Wr
Gro=
s
kgf
7.6 idler
Gro = = = 4.75 kgf/m
1.6 m
idler
From the geometry of belt conveyor system
H
Sin δ =
L
H
H = sin δ × L
δ
= sin 15°× 3
= 0.7765 m
Iteration inclination angle = 15° to 45°

For inclination angle, δ = 20°

H20 = sin δ × L
= sin 20°× 3
= 1.026 m
For inclination angle, δ = 25°
H25 = sin δ × L
= sin 25°× 3
= 1.268 m
 41

For inclination angle, δ = 30°

H30 = sin δ × L
= sin 30°× 3
= 1.5 m
For inclination angle, δ = 35°
H35 = sin δ × L
= sin 35°× 3
= 1.721 m
For inclination angle, δ = 40°
H40 = sin δ × L
= sin 40°× 3
= 1.928 m
For inclination angle, δ = 45°
H45 = sin δ × L
= sin 45°× 3
= 2.121 m
Table 4.1. Height of Conveyor at Inclination Angle from 15° to 45°
Inclination angle 15° 20° 25° 30° 35° 40° 45°
Height(m) 0.7765 1.026 1.268 1.5 1.721 1.928 2.121

Wo = (9×0.02×3)[(1.286+5) cos 15°+ 4.75] +0.7765(1.286+5)]

Wo = 10.72 kgf
Similarly from PSG 9.18
(b) Resistance of belt on the bottom run, (kgf)
Wu = CfL [( Gb cos δ + Gru)] –(HGb)
Gru = Weight of straight idlers on the bottom run/metre length kgf/m
Wr
Gru = ( 2 is bottom idler is larger space than top)
2s
7.6
Gru = = 2.375 kgf/m
2 1.6
Wu = (9×0.02×3)[(5cos15°+2.375)]-(0.7765×5)
Wu = 7.999×10-3 kgf = 0.008 kgf
From PSG 9.18,
WT = Wo + Wu
 42

WT = 10.73+ 0.008
WT = 10.731 kgf (or) 107.31 N
From PSG 9.18,
WT V
Hp of drive, hp = (Assuming ηmech = 85% )
75ηmech

107.38  0.6
=
75  0.85
= 1.01 hp
Motor power = hp × 746
= 1.01 × 746
= 0.754 kW
4.3. Maximum Tension in the Belt
The maximum tension in a conveyor belt depends on several factors, including
the type of belt, the material being transported, the conveyor's length and width, the
conveyor's angle of incline or decline, and the speed of the conveyor. Additionally,
factors such as belt tensioning mechanisms, pulley diameters, and belt construction also
play a role. Typically, conveyor belt manufacturers provide specifications and
guidelines for the maximum tension that their belts can withstand. This maximum
tension is usually expressed in pounds per inch (lb/in) or Newtons per millimeter
(N/mm) of belt width.
It's essential to operate the conveyor within the recommended tension limits
provided by the manufacturer to ensure optimal performance, prevent belt damage, and
ensure safety. Regular maintenance and monitoring of tension levels are crucial to avoid
overloading the belt and its components.
From PSG 9.18,
 eμα 
Maximum tension in the belt, T1 =P  μα 
 e -1 

 e(0.25×4.19) 
T1 =107.38  (0.25×4.19) 
e -1 

T1 = 165.29 N (or) 0.165 kN

4.4. Tension on Slack Side of Belt
The tension on the slack side of a conveyor belt is typically lower than the
tension on the tight side. This is because the tension on the tight side is used to drive
 43

the belt and move the material being transported, while the slack side simply returns
the belt back to the drive pulley. The tension on the slack side is influenced by factors
such as the tensioning mechanism used, the length and width of the conveyor, the
weight of the belt itself, and any external forces acting on the belt.
Maintaining proper tension on the slack side is important to prevent belt
sagging, which can lead to mistracking, increased friction, and premature wear.
However, the tension on the slack side should not be too high, as this can cause
excessive stretching of the belt and increase the load on the conveyor components. The
tension on the slack side is typically adjusted using tensioning devices such as take-up
pulleys, gravity take-ups, or mechanical tensioners to ensure proper belt tracking and
performance.
Similarly, PSG 9.18,
Tension on slack side of belt,
T2 = T1- P
T2 = 165.5 - 107.38
T2 = 57.99 N (or) 0.058 kN
From PSG 9.18
T1
No. of Plies (i) =
BF
T1= max tension of belt, (kgf)
B = width of standard belt, (mm)
f = working tension of belt for 1mm width, (kgf/mm)
4.4.1. Number of Plies
The number of plies in a conveyor belt refers to the layers of fabric or other
material that make up the belt's carcass. Each ply is a separate layer, and multiple plies
are typically bonded together to form a stronger and more durable belt. Conveyor belts
can have different numbers of plies depending on the application and required strength.
Common configurations include:
(a) Single-ply belts
These belts consist of a single layer of fabric or other material. They are
often used for lightweight applications or where flexibility is important.
(b) Two-ply belts
These belts have two layers of fabric. They provide increased strength
and are suitable for medium-duty applications.
 44

(c) Three-ply belts

These belts have three layers of fabric. They offer even greater strength
and are commonly used in heavier-duty applications.
(d) Multi-ply belts
These belts have four or more layers of fabric. They provide the highest
level of strength and are used in heavy-duty applications such as mining,
construction, and aggregate handling.
The number of plies in a conveyor belt is determined based on factors such as
the weight and type of material being transported, the conveyor's operating conditions,
and safety requirements. It's essential to choose a belt with the appropriate number of
plies to ensure reliable performance and long service life.
From PSG 9.21,
f = 0.62
(165.5)
i=
(400  0.62)
ical = 0.667
From PSG 9.21,
imin = 3
imax = 4

4.4.2. Thickness of Belt

Conveyor Belt, Belt Thickness: 4 mm - 20 mm, thickness: 2 Ply to 8 Ply. Rubber
Conveyor Belts are manufactured in modern, fully automated plants, using the finest
raw material inputs, with strict quality controls.
The thickness of the belt, t = (I × 1mm) + Top cover thickness + Bottom cover
thickness + ruber impregnation
t = (3 × 1) + 2 mm + 1mm+ 2mm
t = 8 mm
Permissible tensile stress for belt material, [σ t ] = 5 N/mm2

Young’s modulus, E = 100 N/mm2

T1 E t
The belt for induced stresses, [σ t ] = ( )+( )
B×t D
D = Diameter of both driver and driven pulley (mm)
D = K1K 2i
 45

D = 1.25 × 100 × 3
D = 375 mm
From PSG 7.54
Selecting standard diameter pulley, D = 400 mm
165.5 100  8
[σ t ] = ( )+( )
400  8 400
[σ t ] = 2.0517 N/mm2 < [σ t ]permissible = 5 N/mm2

The belt is safe under tension.

Note : If the belt fails under tension, the select the next higher value of drum
size from PSG 7.54

4.5. Design of Drum, Drum Shaft and Drum Shaft Bearing

4.5.1. Cross Section of Drum
Width of drum, W = B + [2 × Edge clearance]
 50mm(B  650mm) 
Edge clearance = 75mm(650  B  1000mm) 

 
 100mm(B>1000mm) 

W = 400 + (2×50)
W = 500 mm
4.5.2. Design of Drum Shaft
Wds = T1 + T2 = (165.5) + (58.12)
Wds = 223.62N
Wds
= 111.81 N
2
The shaft is subjected to combined twisting and bending.
Assuming shaft as a simply supported beam with point load of the center.
Wl 223.62  500
M= = = 27.95×103 Nmm
4 4
 πDN 
Peripheral velocity is given by, V = 
 60 
 π  0.375  N 
0.6 =  
 60
N = 30.56 rpm
 2πNT 
Power transmitted by the shaft, P = 
 60 
 46

2π×30.56×T
754=
60
T = 235×103 Nm (or) 0.235×106 Nmm

Equivalent twisting moment, Teq = (k b ×M)2 +(k T ×T)2

Kb = 2, Kt = 1.5

Teq = (2×27.95 103 )2 +(1.5×0.235 106 )2

Teq =0.358×106 Nmm

Assuming material of shaft as C = 45, From PSG 1.9

σ yt = 36 kgf/mm2 = 360 N/mm2

Assuming factor of safety = 4

σ yt 360
[σ t ]permissible = = = 90 N/mm2
Factor of safety 4
[τ]permissible =0.5 [σt ]permissible = 0.5× 90 = 45 N/mm2

Considering the effect of key-way

[τ]permissible =0.75 [τ t ]permissible

[τ]permissible = 0.75 × 45 = 33.75 N/mm2

π T τ 
Teq = ×d s 3×τ permi ,  = 
16 J R
π
0.358 ×106 = ×ds3×33.75
16
ds= 37.79 mm (or) 38 mm (diameter of drum shaft)
Providing a stepping of 1.5 mm on each side,
Bearing shaft diameter = 38 – (2 × 1.5)
= 35 mm
4.6. Selection of Bearing
Wds
(i) Radial Load = (Fr) = = 111.6 N
2
(ii) Axial Load = (Fa) = 0
Life in hrs (Lh) = 20000 hrs (Assume)
60×N×Lh 60  30.56  20000
Life in millions of revolutions, Lmr = 6
=
10 106
= 36.672 mr
 47

Probability of survival = 90% (Assume)

L10 = 36.672 mr
From PSG 4.2,
Equivalent load (PE ) = [(XF r +YFa )×S]

= (1×111.6 + 0) ×1.3
PE = 145.13 N
Calculation of dynamic capacity, PSG 4.2
K
C
L10 =   , K = 3 (For ball bearing)
 PE 
3
 C 
77.36 =  
 145.35 
Dynamic capacity, C = 482.9 N (or) 49.3 kgf
Table 4.2. Bearing Size
Sr. Bearing No. Dynamic Load (kgf)
1. 6007 1250

Selecting a standard bearing SKF 6007

4.7. Design of Idler
Idler spacing on the carrying side of the conveyor, a o = 305 mm = 0.305 m
(Assume)
Idler spacing on the reverse side of the conveyor, au = 915 mm = 0.915 m
Q
(Assume) FTo =( +G)×a o ×10
3.6×v
10
FTo =( +5)×0.305×10
3.6×0.6
= 29.37 N

Table 4.3. Weight of Conveyor Belt, kgf/m

Sr. Belt width, mm 400 500 650 800 1000

Average weight permetre
1. 5 6.5 9 12 16
run, kgf

With idler spacing on the reverse side,

Q
FTu =( +G)×a u ×10
3.6×v
 48

10
FTu =( +5)×0.915×10
3.6×0.6
= 88.11 N
Determine the idler diameter
Table 4.4. Idler Diameter

V = 0.6 m/s

The idler speed n is 140 rpm and the diameter is 89 mm.

Table 4.5. Idler Length and Shaft Size

D=20 mm
140 rpm
1600 N
4400N

Based on the idler speed that had been chosen in diagram 1 then select the
appropriate diameter for it in case the shaft diameter is 20 mm, then the bearing load
rating could be seen in the diagram is an average of 4400 N. The work life of the bearing
with the life time is 20000 hours.
 49

Fr×k = 4400 × 1.08 = 4752 N

The coefficient k depends on the lifetime that had been chosen and could be
defined in the Roxon Conveyor Component Product catalogue.
According to the Roxon standard for idlers, the standard length of flat idlers
suited for a belt width of 400 mm is 500 mm.
In case shaft diameter is 20 millimeters, the shaft load rating is average 1600 N.
In conclusion, the idler chosen, with a diameter of 89 mm and a shaft diameter of 20
mm, meet the design requirement.
Product code for the idler TS89E-20B-500K

Roxon TS-E idler is a competitive standard idler for belt conveyors. TS-E idler
is used as carrying idler and also as a return idler for non-sticky materials. The steel
sealing casing and the weather seal form a reliable cover against the splashwater. The
multiple sealing labyrinth efficiently prevents the dirt from getting inside the idler. The
standard surface treatment is shot-blasting and epoxypowder coating RAL3000, red.
Special surface treatment is also available for sticky materials.
Idler total weight : w = 4.8 kg/m
Weight of rotating part : wr = 3.7 kg/m
Table 4.6. Idler weight (From Roxon Conveyor)
 50

Mass per meter of the revolving idler parts along the carrying side of the
conveyor,
wr 3.7
q Ro = = = 12.13 kg/m
a o 0.305
Mass per meter of the revolving idler parts along the return side of the conveyor,
wr 3.7
q Ru = = = 4.04 kg/m
a u 0.915
The idler bracket should be selected from the Roxon catalogue’s “Self-Aligning
idler bracket for the return belt,” since the idler utilized throughout the conveyor is flat.
[Link]. Design Calculation of Belt Conveyor System
3.2. In order to select the suitable belt conveyor system, the calculations of mass of
the design, finalizing the belt width and belt speed, motor selection, belt cross
section, design of drum, drum shaft, and drum shaft bearing and design of idler
are considered. Input data of belt conveyor system are,
Material to be conveyed - Rice Bag
Capacity - 10000 kg/h = 10 ton/h
Lump size - 0.01m = 10 mm
Length - 3m
Inclination angle - 15° to 45°
Factor for the type of idler (c)- 240
Ungraded material (x) - 2.5
Density of rice (ρ) - 0.72 Ton/m3
Secondary resistance factor (C)- 9
Friction between idler and belt (f)- 0.02
Mechanical Efficiency (ηmech)- 0.85
Yield stress of the material (σyt)- 360 N/mm2

Coefficient of friction between belt and pulley (μ)- 0.25

Permissible tensile stress for belt material (σtp)- 5 N/mm2

Young's Modulus of Elasticity (E)- 100 N/mm2
Life in hours (Lh) - 20000 hrs
Resistance factor (K) - 3
Table 4.7. Calculation Results of Belt Conveyor System for Inclination Angle 15°
 51

No. Descriptions Values Unit

1 Width of belt (B) 0.225 m
2 Standard belt width (B) 0.4 m
3 Velocity (v) 2 m/s
4 Belt conveyor speed (v) 0.6008 m/s

Motor Selection

5 Secondary resistance factor (C) 9

6 Friction between idler and belt (f) 0.02
7 Weight of conveyor material (Gg) 1.284314 kgf/m
8 Weight of belt (Gb) 5 kgf/m
9 Weight of revolving parts of idlers (Wr) 7.6 kgf/idler
10 Maximum spacing for idlers (s) 1.6 m
11 Weight of idler on the top run (Gro) 4.75 kgf/m
12 Inclination angle (δ) 15 °
13 Height through which material is conveyed (H) 0.776 m
14 Resistance of the belt on the top run (Wo) 10.72 kgf
15 Maximum tension in the belt (T1) 165.29
16 Tension on slack side of belt (T2) 57.99
17 Number of plies (i) 0.667
18 Motor Power (P) 0.754 kW
19 Safety Factor for Electrical Power (2) 1.508 kW
In the belt conveyor system, the height of the conveyor obtained at an
inclination angle of 15 degree is 0.776 m. At that inclination angle of 15 degree, the
resistance of the belt on the top run is 10.72 kgf. In that case, the motor power required
for the Belt Conveyor is 1.508 kW. The height of Belt Conveyor System obtained at
inclination angle 15 degree is 0.76 m (2.49 ft), which is not consistent with Y8 cargo
aircraft.
Table 4.8. Calculation Results of Belt Conveyor System for Inclination Angle 20°
No. Descriptions Values Unit
Finalizing the belt width and belt speed
1 Width of belt (B) 0.225 m
2 Standard belt width (B) 0.4 m
 52

No. Descriptions Values Unit

3 Velocity (v) 2 m/s
4 Belt conveyor speed (v) 0.6008 m/s
Motor Selection
5 Weight of conveyor material (Gg) 1.284 kgf/m
6 Weight of belt (Gb) 5 kgf/m
7 Weight of revolving parts of idlers (Wr) 7.6 kgf/idler
8 Maximum spacing for idlers (s) 1.6 m
9 Weight of idler on the top run (Gro) 4.75 kgf/m
10 Height through which material is conveyed (H) 1.026 m
11 Resistance of the belt on the top run (Wo) 12.2 kgf
12 Inclination angle (δ) 20 °
13 Weight of idler on the bottom run (Gru) 2.375 kgf/m
14 Resistance of the belt on the top run (Wu) -1.3106 kgf
15 Resistance of the belt (WT) 108.91 N
16 Motor Power (P) 0.766 kW
Belt cross-section
17 Maximum tension in the belt (T1) 167.77 N
18 Tension on slack side of belt (T2) 58.86 N
19 Working tension of belt (f) 0.62
20 Number of plies (i) 0.676
21 Minimum number of plies (imin) 3
22 Maximun number of plies (imax) 4
23 Thickness of belt (t) 8 mm
24 Selecting standard pulley diameter (D) 400 mm

25 Tensile stress for belt material (σt) 2.05 N/mm2

Design of drum, drum shaft and drum bearing
26 Width of drum (W) 500 mm
27 Resistance of the drum shaft (Wds) 226.62
28 Bending moment (M) 28328.07 Nmm
29 Periphreal velocity (N) 30.6 rpm
30 Twisting moment (T) 238968.6 Nmm
 53

No. Descriptions Values Unit

31 Equivalent twisting moment (Teq) 362902.7 Nmm
32 Permissible stress of the shaft (σt)permissible 90 N/mm2
33 Permissible strain of the shaft (key-way) (τ)per-key 33.75 N/mm2
34 Shaft diameter (ds) 37.97 mm
35 Bearing shaft diameter (dbs) 32.97 mm
36 Radial load (Fr) 113.3 N
37 Life in millions of revolutions (Lmr) 36.72 mr
38 Equivalent load (PE) 147.31 N
39 Basic dynamic capacity (C) 489.6 N

In the belt conveyor system, the height of the conveyor obtained at an

inclination angle of 20 degree is 1.026 m. At that inclination angle of 20 degree, the
resistance of the belt on the top run is 12.20 kgf. In that case, the motor power required
for the Belt Conveyor is 1.532 kW. The height of Belt Conveyor System obtained at
inclination angle 20 degree is 1.026 m (3.366 ft), which is consistent with Y8 cargo
aircraft. The requirement of height is achieved.

Table 4.9. Calculation Results of Belt Conveyor System for Inclination Angle 25°

No. Descriptions Values Unit

1 Width of belt (B) 0.225 m
2 Standard belt width (B) 0.4 m
3 Velocity (v) 2 m/s
4 Belt conveyor speed (v) 0.6008 m/s
Motor Selection
5 Secondary resistance factor (C) 9
6 Friction between idler and belt (f) 0.02
7 Weight of conveyor material (Gg) 1.284314 kgf/m
8 Weight of belt (Gb) 5 kgf/m
9 Weight of revolving parts of idlers (Wr) 7.6 kgf/idler
10 Maximum spacing for idlers (s) 1.6 m
11 Weight of idler on the top run (Gro) 4.75 kgf/m
12 Inclination angle (δ) 25 °
13 Height through which material is conveyed (H) 1.268 m
 54

No. Descriptions Values Unit

14 Resistance of the belt on the top run (Wo) 13.61 kgf
15 Maximum tension in the belt (T1) 169.42 N
16 Tension on slack side of belt (T2) 59.43 N
17 Number of plies (i) 0.683
18 Motor Power (P) 0.773 kW
19 Safety Factor for Electrical Power (2) 1.546 kW
In the belt conveyor system, the height of the conveyor obtained at an
inclination angle of 25 degree is 1.268 m. At that inclination angle of 25 degree, the
resistance of the belt on the top run is 13.61 kgf. In that case, the motor power required
for the Belt Conveyor is 1.546 kW. The height of Belt Conveyor System obtained at
inclination angle 25 degree is 1.268 m (4.16 ft), which is not consistent with Y8 cargo
aircraft.
Table 4.10. Calculation Results of Belt Conveyor System for Inclination Angle 30°
No. Descriptions Values Unit
1 Width of belt (B) 0.225 m
2 Standard belt width (B) 0.4 m
3 Velocity (v) 2 m/s
4 Belt conveyor speed (v) 0.6008 m/s
Motor Selection
5 Secondary resistance factor (C) 9
6 Friction between idler and belt (f) 0.02
7 Weight of conveyor material (Gg) 1.284314 kgf/m
8 Weight of belt (Gb) 5 kgf/m
9 Weight of revolving parts of idlers (Wr) 7.6 kgf/idler
10 Maximum spacing for idlers (s) 1.6 m
11 Weight of idler on the top run (Gro) 4.75 kgf/m
12 Inclination angle (δ) 30 °
13 Height through which material is conveyed (H) 1.500 m
14 Resistance of the belt on the top run (Wo) 14.93 kgf
15 Maximum tension in the belt (T1) 170.23 N
16 Tension on slack side of belt (T2) 59.72 N
17 Number of plies (i) 0.686
 55

No. Descriptions Values Unit

18 Motor Power (P) 0.777 kW
19 Safety Factor for Electrical Power (2) 1.554 kW

In the belt conveyor system, the height of the conveyor obtained at an

inclination angle of 30 degree is 1.5 m. At that inclination angle of 30 degree, the
resistance of the belt on the top run is 14.93 kgf. In that case, the motor power required
for the Belt Conveyor is 1.554 kW. The height of Belt Conveyor System obtained at
inclination angle 30 degree is 1.5 m (4.92 ft), which is not consistent with Y8 cargo
aircraft.
Table 4.11. Calculation Results of Belt Conveyor System for Inclination Angle 35°

No. Descriptions Values Unit

1 Width of belt (B) 0.225 m
2 Standard belt width (B) 0.4 m
3 Velocity (v) 2 m/s
4 Belt conveyor speed (v) 0.6008 m/s

Motor Selection

5 Secondary resistance factor (C) 9

6 Friction between idler and belt (f) 0.02
7 Weight of conveyor material (Gg) 1.284314 kgf/m
8 Weight of belt (Gb) 5 kgf/m
9 Weight of revolving parts of idlers (Wr) 7.6 kgf/idler
10 Maximum spacing for idlers (s) 1.6 m
11 Weight of idler on the top run (Gro) 4.75 kgf/m
12 Inclination angle (δ) 35 °
13 Height through which material is conveyed (H) 1.721 m
14 Resistance of the belt on the top run (Wo) 16.16 kgf
15 Maximum tension in the belt (T1) 170.20 N
16 Tension on slack side of belt (T2) 59.71 N
17 Number of plies (i) 0.686
18 Motor Power (P) 0.777 kW
19 Safety Factor for Electrical Power (2) 1.554 kW
 56

In the belt conveyor system, the height of the conveyor obtained at an

inclination angle of 35 degree is 1.721 m. At that inclination angle of 35 degree, the
resistance of the belt on the top run is 16.16 kgf. In that case, the motor power required
for the Belt Conveyor is 1.554 kW. The height of Belt Conveyor System obtained at
inclination angle 35 degree is 1.721 m (5.65 ft), which is not consistent with Y8 cargo
aircraft.

Table 4.12. Calculation Results of Belt Conveyor System for Inclination Angle 40°

No. Descriptions Values Unit

1 Width of belt (B) 0.225 m
2 Standard belt width (B) 0.4 m
3 Velocity (v) 2 m/s
4 Belt conveyor speed (v) 0.6008 m/s

Motor Selection

5 Secondary resistance factor (C) 9

6 Friction between idler and belt (f) 0.02
7 Weight of conveyor material (Gg) 1.284314 kgf/m
8 Weight of belt (Gb) 5 kgf/m
9 Weight of revolving parts of idlers (Wr) 7.6 kgf/idler
10 Maximum spacing for idlers (s) 1.6 m
11 Weight of idler on the top run (Gro) 4.75 kgf/m
12 Inclination angle (δ) 40 °
13 Height through which material is conveyed (H) 1.928 m
14 Resistance of the belt on the top run (Wo) 17.28 kgf
15 Maximum tension in the belt (T1) 169.32 N
16 Tension on slack side of belt (T2) 59.40 N
17 Number of plies (i) 0.683
18 Motor Power (P) 0.773 kW
19 Safety Factor for Electrical Power (2) 1.546 kW

In the belt conveyor system, the height of the conveyor obtained at an

inclination angle of 40 degree is 1.928 m. At that inclination angle of 40 degree, the
resistance of the belt on the top run is 17.28 kgf. In that case, the motor power required
for the Belt Conveyor is 1.546 kW. The height of Belt Conveyor System obtained at
 57

inclination angle 40 degree is 1.928 m (6.325 ft), which is consistent with Y8 cargo
aircraft. The requirement of height is achieved.

Table 4.13. Calculation Results of Belt Conveyor System for Inclination Angle 45°

No. Descriptions Values Unit

1 Width of belt (B) 0.225 m
2 Standard belt width (B) 0.4 m
3 Velocity (v) 2 m/s
4 Belt conveyor speed (v) 0.6008 m/s

Motor Selection

5 Secondary resistance factor (C) 9

6 Friction between idler and belt (f) 0.02
7 Weight of conveyor material (Gg) 1.284314 kgf/m
8 Weight of belt (Gb) 5 kgf/m
9 Weight of revolving parts of idlers (Wr) 7.6 kgf/idler
10 Maximum spacing for idlers (s) 1.6 m
11 Weight of idler on the top run (Gro) 4.75 kgf/m
12 Inclination angle (δ) 45 °
13 Height through which material is conveyed (H) 2.121 m
14 Resistance of the belt on the top run (Wo) 18.30 kgf
15 Maximum tension in the belt (T1) 167.61 N
16 Tension on slack side of belt (T2) 58.80 N
17 Number of plies (i) 0.676
18 Motor Power (P) 0.765 kW
19 Safety Factor for Electrical Power (2) 1.53 kW

In the belt conveyor system, the height of the conveyor obtained at an

inclination angle of 45 degree is 2.121 m. At that inclination angle of 45 degree, the
resistance of the belt on the top run is 18.3 kgf. In that case, the motor power required
for the Belt Conveyor is 1.53 kW. The height of Belt Conveyor System obtained at
inclination angle 45 degree is 2.121 m (6.95 ft), which is more than height of Y8 cargo
aircraft.
 58

Table 4.14. Calculation Results of Power and Height Based on Inclination angle

Power with
Inclination Height through which
Sr. Power (kW) Safety
angle (°) material is conveyed (m)
factor(kW)
1. 15 0.776 (2.49 ft) 0.754 1.508
2. 20 1.026 (3.36 ft) 0.766 1.532
3. 25 1.268 (4.16 ft) 0.773 1.546
4. 30 1.5 (4.92 ft) 0.777 1.554
5. 35 1.721 (5.65 ft) 0.777 1.554
6. 40 1.928 (6.32 ft) 0.773 1.546
7. 45 2.121 (6.95 ft ) 0.765 1.53

[Link]. Design Calculation of Lead Screw Mechanism for Up Down

Function
The lead screw size, lead screw efficiency, and power required when up down
conditions are shown in the table below based on the input data in the belt conveyor
system. Input data of lead screw mechanism for belt conveyor system are
Belt conveyor weight -300 kg
Moving length -1450 mm
Time -10 s
Static coefficient (μt-stc,μc-stc) -0.06
Sliding coefficient (μt-sld,μc-sld)-0.03
Table 4.15. List of Design Criteria for Lead Screw Mechanism

Sr. Description Values Unit

1. Major Diameter (D) 36 mm
2. Minor Diameter (Dr) 29.5 mm
3. Pitch Diameter (Dp) 32.75 mm
4. Pitch Radius (rp) 16.38 mm
5. Pitch (lead) (p) 6 mm
6. Collar Outer radius 39.6 mm
7. Collar Inner radius 19.8 mm
8. Thread angle (θ) 14.5 °
9. lead angle (α) 3.34 °
 59

Sr. Description Values Unit

10. Raise the load (TR)start 11.0624 Nm
11. Raise the load (TR)run 6.9337 Nm
12. Lower the load (TL)start 5.4201 Nm
13. Lower the load (TL)run 1.3075 Nm
14. Self-Locking 0.0565
15. Efficiency 0.405
16. Efficiency without collar friction 0.652
17. velocity (v) 145 mm/s
18. Rotational speed (N) 1450 rpm
19. Angular speed (ω) 151.8 rad/s
20. Power (P) 0.840 kW

The specifications obtained based on the major diameter of the lead screw are
shown in the table below.
Table 4.16. Efficiency, Power and Self-locking Achieved Based on Lead Screw Size
D Dr p e P lcosθ/2πrp
10 6.5 78.6 0.551 0.1121
3
12 8.5 74.8 0.623 0.0902
14 9.5 77.5 0.57 0.1049
16 11.5 74.7 0.624 0.0896
4
18 13.5 72.1 0.677 0.0783
20 15.5 69.7 0.731 0.0694
22 16.5 72.6 0.667 0.08
24 18.5 70.6 0.71 0.0725
5
26 20.5 68.7 0.753 0.0663
28 22.5 66.9 0.796 0.0610
30 23.5 69.6 0.732 0.0691
32 25.5 68.1 0.768 0.0643
6
34 27.5 66.6 0.804 0.0601
36 29.5 65.2 0.84 0.0565
38 30.5 67.6 0.779 0.0630
7
40 32.5 66.4 0.809 0.0595
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42 34.5 7 65.2 0.84 0.0564

44 36.5 64 0.871 0.0536
46 37.5 66.2 0.813 0.0591
48 39.5 65.1 0.84 0.0564
8
50 41.5 64.1 0.867 0.0539
52 43.5 63.1 0.894 0.0516
55 45.5 64.7 0.852 0.0552
58 48.5 63.3 0.888 0.0521
9
60 50.5 62.5 0.912 0.0502
62 52.5 61.7 0.936 0.0484

1
0.9
0.8
0.7
Power

0.6
0.5
0.4
0.3
0.2
0.1
0
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 55 58 60 62

Major Diameter

Figure 4.1. Power Needed to Drive the Lead Screw Mechanism

0.12
Coefficient of friction

0.1

0.08

0.06

0.04

0.02

0
10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 55 58 60 62

Major Diameter

Figure 4.2. Self-Locking and Overhauling of Lead Screw

The major diameter of the lead screw, ranging from 10 mm to 62 mm, is

evaluated to determine the appropriate lead screw size for the belt conveyor up down
function. This calculation considers various factors such as system requirements, load
capacity, and operational parameters to ensure optimal performance and reliability. The
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calculations concerning the lead screw size, lead screw efficiency, and power
requirements for belt conveyor are conducted based on the specific characteristics of
the conveyor intended for up down function. It is observed that when the lead screw's
primary diameter is 36 mm or larger, the assembly self-locks due to its size. This
characteristic justifies the selection of this particular size for the belt conveyor system,
ensuring stability and reliability during operation.
Furthermore, the lead screw assembly exhibits an efficiency rating of 65.2,
indicating its effectiveness in converting input power into mechanical work. The power
required to transport the rice bag is estimated at 0.84 kilowatts, reflecting the energy
consumption associated with the up down process. These findings offer valuable
insights into the design and operational considerations of the belt conveyor system,
contributing to its effective and efficient performance in fulfilling its intended function.

4.10. 3D Modeling of Belt Conveyor System

Modeling of the belt conveyor system was done according to the results
obtained based on the input parameters calculations. Modeling was done after
installation of drum, idler, lead screw, belt conveyor frame, belt and bearing included
in the belt conveyor system. Modeling is done by using Solidwork Software 2018.

Figure 4.3. Lead Screw Mechanism

Fig. 4.3 shows the lead screw modeled according to the results obtained from
the design calculation. lead screws are set at the front and back. The length of the front
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lead screw length is 600 mm and back length is 350 mm. The size of the lead screw is
36 mm, Efficiency is 0.405, power required based on the system is 0.840 kW.

Figure 4.4. Drum Set in a Belt Conveyor System

Fig. 4.4 shows the drum set modeled according to the results obtained from the
design calculation. The width of drum is 500 mm, drum diameter is 400 mm, shaft
diameter is 35 mm. Driver and driven drum are similar parameter at the head and tail
drum.

Figure 4.5. Idler Set

Fig. 4.5 shows the idler roller modeled according to the results obtained from
the design calculation. The width of idler is 500 mm, idler diameter is 89 mm and shaft
diameter is 20 mm. The carrying idler is 4 sets and return idler is 3 sets. Basic dynamic
capacity of bearing is 489.1 N. The number of carrying idler may be minimum 4 to
maximum 7 and return idler may be minimum 3 to maximum 6. The minimum carrying
idler spacing may be at least 1 ft.
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Figure 4.6. Modeling of Belt Conveyor System

Figure 4.7. Distance between Driven Drum and Ground Floor

 64

The height from the ground to driven drum is 1793.6 mm (5.976 ft) meet the
design requirement of Y8 cargo aircraft’ hatch. The minimum height is 4 ft and the
maximum height is 6 ft. The height may be changes depending on the frame design.

Figure 4.8. Distance between Drive Drum and Ground Floor

Fig. 4.8. describes the height from the ground to drive drum is 919.35 mm (3.06
ft). The minimum height is 3 ft and the maximum height is 4 ft. The height may be
changes depending on the frame design.
CHAPTER 5
DISCUSSIONS, CONCLUSION AND RECOMMENDATIONS
5.1. Discussions
The final 3D product is similar to the initial design idea. According to the
calculated designs of the conveyor at 15 degrees and 45 degrees, the conveyor could
carry with the smallest vertical distance average of 0.776 meters and the maximum
vertical lifting distance average of 2.121 meters. The lead screw is modeled according
to the results obtained from the design calculation. Lead screws are set at the front and
back. The length of the front lead screw length is 600 mm and back length is 350 mm.
The size of the lead screw is 36 mm, efficiency is 0.405 and power required based on
the system is 0.840 kW. The width of idler is 500 mm, idler diameter is 89 mm and
shaft diameter is 20 mm. The carrying idler is 4 sets and return idler is 3 sets. Basic
dynamic capacity of bearing is 489.1 N. The number of carrying idler may be minimum
 65

4 to maximum 7 and return idler may be minimum 3 to maximum 6. The minimum

carrying idler spacing may be at least 1 ft.
The drum set is modeled according to the results obtained from the design
calculation. The width of drum is 500 mm, drum diameter is 400 mm and shaft diameter
is 35 mm. Driver and driven drum are similar parameter at the head and tail drum. The
height from the ground to driven drum is 1793.6 mm (5.976 ft) meet the design
requirement of Y8 cargo aircraft’ hatch. The minimum height is 4 ft and the maximum
height is 6 ft . The height may be changes depending on the frame design. The height
from the ground to drive drum is 919.35 mm (3.06 ft). The minimum height is 3 ft and
the maximum height is 4 ft. The height may be changes depending on the frame design.
Considering it is still a 3D idea, further testing is required before establishing the
machine in operation. The final product cost is impossible to determine due to the price
of materials from several manufacturers varying or the lack of such information. The
assembled machine weighs roughly one ton.
5.2. Conclusion
In many different industries, the conveyor belt is a widely used device. Because
of this, manufacturers have made it easier for customers to purchase and
 66

install necessary components for their own conveyor. It is fascinating for individuals
with an interest in machinery as it can be built with a variety of materials and designs,
allowing for customization and creativity. Although selecting components and designs
is now simple and convenient, it still calls for certain mechanical processes like cutting,
welding, and grinding. Homemade construction is appropriate for small, low-capacity
devices. Large, powerful equipment nevertheless need technology, i.e., specialized
factories for manufacturing and testing. Overall, the conveyor belt is an example of
human ingenuity and has indirectly been a part of our everyday lives. Such devices are
not only practical for transporting goods but also a vital component in manufacturing.
5.3. Recommendations
In this thesis, belt conveyor and lead screw are mainly used to control the
process of carrying rice bags. However, the other type of conveyor, using of hydraulic
cylinders, changing idlers, using chain instead of drum, lead screw with power, various
set of frame design can be used, depending upon desired material to be loaded and eject.
Belt conveyor system is successfully developed and the one, who want to research
relating with this machine can be upgraded as fully automatic system to implement their
research and for that time, this thesis will be great benefit for their research.

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[7] [Link] Vijay S, [Link], “Design and Analyasis of Belt Conveyor System
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APPENDIX A