=power

power of rate of doing work

=parameter need to calculate to make a selection of speed for a belt conveyor

1 speed of the motor: rpm

2 torque of the motor: Nm

3 powers of motor: Hp

Power = torque * angular speed

Torque = power / angular speed

=In belt conveyor there are two perspective for calculation of belt conveyor

1 conveyor is a machine, which doing a work. Transferring the material from one end to another
end

For power consumption

Power is rate of doing work

Power consumption is equal to power generated by motor

-these perspective is regardless to roller diameter

Power is calculated on basis of load and linear speed , but in this method there is an limitation

2 directly calculate the capacity of motor, torque required to move the belt

Calculation according to 1st perspective

Parameter needs

Total length, width of belt conveyor (l = 5m, w =500mm)

Load over the conveyor belt

Total load on conveyor = total load = no of box * no of mass (20 no’s ,20 kg assumed)

Total load = 20 *20 = 400kg

Total mass of belt – according to belt material mass density (for mass density refer the below
table)
According to table we can understand that belt is not made of single material

Belt layers
Soft material
High strength material
Spring material

Mass of belt

Material selected; pvc., poly. canvas

Belt thickness 2.1 mm

Total mass of belt = total area * unit density

2 kg
5 m x 2.1 2
=11.5 kg
m
Area of belt: length of belt * width of belt
2
2 x 5 mm x 0 .5 mm=5 mm
Convert all units in si unit if not from USA

Length …… meter

Mass……. kg

Time………. sec.

Force……. newton

Angle……. radian

Speed of conveyor

20 meter
Linear speed: (assumed)(20 meter/minute –
60 sec
meter
Thus, linear speed of conveyor is 0.33
sec
If speed is given in Cycle time: (assumed) 15 sec.

Material to be transfer in 15 sec from one end to another end & length of conveyor is 5 meters.

5 meter meter
Material will transfer in 1 sec = = 0.33
15 sec sec
work displacement
Power is nothing but rate of doing work so power= (work done=force x )
time time
So power ( pull)=force x velocity

force required to pull the belt known as frictional force thus pull force – frictional force

frictional force = uN

frictional force – coefficient of friction x normal force (normal force(mg) = mass x canter of gravity)

frictional force=0.2 x 411.5 x 9.8 1=1614.7 newton

meter Nm Nm
Power = force x velocity = 1614.7 N x 0.33 =538.2 (1 =1 watt ) = 0.538.2 kw
sec sec sec
538.2
Converting kw into Hp (1Hp = 746 watt) so =0.72Hp
746
Fos = 1.5 thus required power = 1.5 x 0.72 = 1Hp

Rotational speed of motor: rpm

As we have linear speed of motor that can be converted into rotary speed

Considering roller diameter is 45 mm

Circumference of roller = π x D=3.14 x 45 mm=141.3 mm=0.1413 m

Means 0.141m = 1 revolution

1m = 1/0.141 rev.

20m = 20x1/0.141 rev = 141.5 rev.

As we know

Power of motor = torque x angular speed

2π
So converting power into rad./sec so
60
2π
Thus 141.5 rpm = 141.5 x = 14.8 rad./sec
60
Torque = power / angular speed = 538.2 watt/14.8 rad/sec = 36.33Nm

Now we have required motor power 1 HP & speed 141.5 rpm but required torque is 36.33Nm

Motor starting torque (cs) = motor torque (Cm) – Load torque (CL)

Motor starting torque (cs) = moment of inertia (j) x motor staring acc. (Ca)

2nd perspective

Directly calculate the capacity of motor torque required to move the belt.
Total required torque = belt pulling torque + MOI torque + rolling resistance torque

Belt pulling torque =pulling force x rotational radius

(roller Dia = 45 mm, Radius 44/2 = 22.5mm (0.0225m) driving roller = 36.33 Nm

Moment of inertia

1 2
Moi of rollers = mr
4
= 0.25 x 15 x (0.0225)2 x 2 = 0.0018 Kg-m 2

Mass of roller = 15kg, roller Dia = 0.225m (45/2mm), no of roller =2

Moment of inertia over load on conveyor belt

Moi of object in linear motion

M( A /2 π )2 (m mass = 411.5kg , a unit of movement roller circumference 0.141m

= 411.5 (0.141 /2∗3.14)2 = 0.208 kg m 2

Moment of inertia of motor & gearbox

Moi of motor = 28 x 10−4 kg m2= 0.0028 kg m 2

Moi of gear box = 6.3 x 10−4 kg m2= 0.00063 kg m 2s

Moment of inertia is an extensive property so Moi will be

Moi rollers + Moi load + Moi motor + Moi gearbox

0.0018 kg m 2 + 0.208 kg m 2+ 0.0028 kg m 2+ 0.00063 kg m 2 = 0.231 kg m 2

We know torque = Moi x angular acceleration

Acceleration time

Small size motor – (0-5 HP): acceleration time 0 - 2 sec

Medium motor - (1 - 100 HP): acceleration time 2 - 10 sec

Big size motor - (above=100 HP): acceleration time several min

Assuming acceleration velocity 2 sec

Motor acceleration = motor final velocity – motor initial velocity (0) / time taken (2 sec)

In belt conveyor an induction motor is used (3 phase induction motor)

Because speed of induction motor is = speed = 120 x frequency (50Hz)/no of pole

If the motor is of 2 poles than (120*50)/2 = 3000rpm

3000 rpm 2 pole high speed

1500 rpm 4 pole medium speed

1000 rpm 6 pole low speed

750 rpm 8 pole ultra-low speed

Selected motor

3 phase induction motor, 4 pole

Speed – 1450 …. 1430 rpm

Final speed (rated speed)

2π
Speed under load …1400rpm 1400 x =146.5 rad ./ sec
60
Motor acceleration = motor final velocity (146.5) – motor initial velocity (0)/ time taken (2 sec )

73.2 radian/ sec 2

Torque

Moi x angular acceleration

Starting torque: 15.65 Nm

Total torque = belt pulling torque + Moi torque + rolling resistance

36.33 Nm + 15.65Nm + consider Fos

Total required torque = 51.9 Nm = 52 Nm

Required speed fended above which is 141.5 rpm= 14.8 rad/sec

Required power of motor = torque x angular speed

= 52 x 14.8 = 769.6 watt = 1.03 Hp

Need to use gear box to reduce speed (generally used worm gear or helical worm gear)

Gear ratio = desired speed / selected motor speed = 141.5 rpm/ 1400rpm

1:10.1 - 1:10

By gear box the required load is decreased on motor by 10 times

Mean we need the motor which deliver 52/10 = 5.2Nm, speed: 1400 rpm

The gear box is only decreasing the output speed of motor but increasing torque of motor
Vfd (generally range: 0-60 Hz)

Example if a motor is driven at vfd frequency 40 Hz

Output speed = M. base speed (1430 rpm) VDF f (40 Hz) / m. base frequency 50 Hz = 1144 rpm