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HIC Conveyor Idler Selection Guide for Moving Belt Conveying System Load

Follow simple steps for as to How to select conveyor idler to move material load through rollers on belt conveyor system:-

Step 1 of HIC Universal conveyor idler Selection:

Conveying Capacity of belt conveyor assessment- Cross-sectioned Area (A) multiplied by conveying speed (V) gives result of conveying capacity of belt conveyor, further multiplied by slope Correction factor ranging from 0.8 to 1.0 .

Qv (m3 /h) = A (m2) x V (m/s) x 3600 x (Slope Correction Factor)

Qm (TPH) = A (m2) x V (m/s) x 3.6 x Material Density (kg/m3) x (Slope Correction Factor)

Step 2 of HIC Universal conveyor idler Selection:

Troughing Angle of Idlers choice based on conveyed Material Class – Greater carrying capacity for a given belt width is achieved using idlers with end-roll sets at steeper troughing angles of 35o and 45o degree angles in place of normal 20o angle. Though, minimum transition distances (1.0 belt width to 9b as per trough depth and rated tension) for idler adjacent to terminal pulleys need to be followed if using steeper troughing angles and higher transverse flexibility fabric carcass design conveyor belting by opting very high tensile rating belt with lesser number of plies.

Step 3 of HIC Universal conveyor idler Selection:

Belt Width choice based on Lump size and Peak Load vis-à-vis- Belt Speed - Belt width between 500 mm (max lump size of 4”) to 2400 mm (max lump size of 18”) based on 20o angle of surcharge and surge or peak load (TPH) being 80% full cross-sectional load area of the belt and belt speed 100 FPM to 750 Feet Per Minute may be chosen. Belt width calculation method:-

i) Capacity conversion to cubic feet per hour from TPH :

FT3 / HR = TPH x 2000 LBS/TON

Material Density (LBS/ FT3) x 80 %

ii) Capacity Equivalent at a belt speed of 100 FPM :

Capacity equivalent = FT3 / HR = 100 FPM

Belt Speed FPM (chosen)

iii) Minimum or higher Belt Width selection based on correct surcharge and troughing angle.

iv) Design Belt Speed or final FPM:

design Speed FPM = FT3 / HR (Method i) x 100 FPM

selected BW Capacity FT3 /HR @ 100 FPM (Method iii)

Higher speeds above 350 FPM requires special chute design and tripper drive, thus idlers designing involves complex procedure.

Step 4 of HIC Universal conveyor idler Selection:

Adjusted Load of Idlers computation- Actual load and then Adjusted load of troughing carrying idler be calculated as stated:

Actual Idler Load, IL = Wb ( conveyor Belt weight, kg/m) + Wm ( material weight, kg/m)

x Si ( Idler Spacing, between 0.6 to 1.5 m )

Adjusted Load, AL = IL x K1 ( lump adjustment factor, bet. 1.0 to 1.4 ) x K2 ( maintenance factor, bet.1.0 to 1.15 ) x K3 ( service factor, bet. 0.8 to 1.2 ) x K4 (belt correction factor, bet. 0.8 to 1.05) + IML ( force due to idler height deviation )

Step 5 of HIC Universal conveyor idler Selection:

Pipe Series and Bearing Load Ratings of Idlers choice- Approximate Load ratings with rigid frame based on min. 30,000 operating hours at 500 RPM at trough angle of 20o with three equal length rolls of ‘B’ class Pipe series carrying roller idlers with ball bearings being 185 kgs up to 800 mm belt width, 160 kgs >800 up to 1000 mm BW, 150 kgs >1000 up to 1200 mm conveyor belt-width.

‘C’ series, ‘D’ series pipe rollers with tapered roller bearings for heavy duty and corrosive environments are selected for 60,000 operating hours or more trouble-free movement.

RPM = Belt Speed ( FPM ) x 12

Roll Diameter (inch) x 3.146 ( л )

Larger diameter roller sizes choice implies increased bearing life and idler-wear life. Similarly, larger shaft thickness choice also influences more load carrying capacity as higher capacity bearing size is used, thereby increases overall idlers running life.

Load Ratings for Idlers

The Following conveyor belt capacity charts show tons per hour (TPH) based on material weighing 100 lbs. per cubic foot, 20° material surcharge angle with three equal length rolls on troughing idlers.

Load Ratings for CEMA Idlers - Rigid Frame (Lbs)

Idler Class Belt Width (Inches) Single Roll Return Two Roll Vee
20° 35° 45°
CEMA B Idlers 18 410 410 220
24 410 410 190
30 410 410 165
36 410 410 155
42 390 363 140
48 380 353 125
Ratings Based on Min L10 of 30,000 Hours at 500 RPM
CEMA C Idlers 18 900 900 475
24 900 900 325
30 900 900 250
36 900 837 200
42 850 791 150
48 800 744 125
54 750 698 *
60 700 650 *
66 *
CEMA D Idlers 24 1,200 1,200 600
30 1,200 1,200 600
36 1,200 1,200 600
42 1,200 1,200 500
48 1,200 1,200 425
54 1,200 1,116 375
60 1,150 1,070 280
66 215
72 1,050 977 155
78 125
NOTES FOR TABLE:

1. TROUGHING IDLER LOAD
RATINGS ARE FOR THREE EQUAL LENGTH ROLLS.


2. LOAD RATINGS ALSO APPLY FOR IMPACT ROLLS.

3. TROUGHING IDLER LOAD
RATINGS ARE BASED ON A LOAD DISTRIBUTION OF 70% ON CENTER ROLL AND 15% ON EACH END ROLL FOR ALL TROUGH ANGLES.

Picking Idler Load Ratings (Lbs.)

Belt Width CEMA C CEMA D
24 475 600
30 475 600
36 325 600
42 250 600
48 200 530
54 150 440
60 125 400
72 280
84
96

Live Shaft Idler Load Capacities (Lbs.)

Belt Width CEMA C CEMA D
18 1,200
24 1,200 1,400
30 1,200 1,400
36 1,200 1,400
42 1,100 1,400
48 1,000 1,275
54 875 1,150
60 780 1,000
72 850
84

Conveyor Idler Bearing Load as per CEMA

Belt width mm load on center bearings kg* shaft dia. mm
S 500 S 1000 S 1500
450 11 23 34
600 20 40 60
750 31 63 94
900 45 90 135
20
1050 61 123 180
1200 80 160 240 25
1350 101 203 304
1500 125 250 375
1800 180 360 540 30
2100 245 490 735
2400 320 640 960
40


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