Belt Conveyor Power Calculation Program for Bulk Handling Applications

Rulmeca Corporation assists conveyor designers and technicians with bulk handling conveyor belt pull and power calculations in three ways:

We use a modified version of the Conveyor Equipment Manufacturers Association guidelines.  The primary equation for Effective Tension, Te, is as follows:

Te = LKt (Kx + KyWb + 0.015Wb) + Wm(LKy + H) + Tp + Tam + Tac

The Rulmeca Power Calculation Program will enable you to:

  • Calculate Belt Conveyor Power Requirements
  • Calculate Belt Tension Requirements
  • Plot Material Trajectory,
  • Plot Material Cross Section.

The program not only determines required power, but also displays all Motorized Pulleys available (for 60 Hz power supply), and plots dimensional information to scale.

Pertinent parameters from the Rulmeca Belt Conveyor Power Calculation Program are as follows:

Te = effective belt tension at drive.
ang = angle of belt wrap around drive pulley(s).
Cw = “wrap factor”, to determine slack side tension to prevent belt slippage on drive pulley.
T2 = estimated slack-side tension required to either keep belt from slipping on pulley surface or maintain trough at allowable sag percentage, whichever is greater.
T1 = Te + T2
T1 + T2 = Sum of belt forces on drive pulley.  NOTE: This is not a vector sum.
T_L = type of lagging specified for drive pulley(s).
Tatype = type of take-up specified to apply “slack-side tension”.
Beltype = type of belt carsass specified.
w = belt width
str = tensile strength of specified belt.
pstr = percentage of available belt tensile strength used.
btr = thickness range of specified belt
Ai = belt tension required to overcome frictional resistance and rotate idlers.
Cs = skirtboard friction factor.
H = vertical distance that material is lifted or lowered.
Kt = ambient temperature correction factor.
Kx = factor to calculate frictional resistance of the idlers and the sliding resistance between belt and idler rolls.
Ky = factor to calculate resistance of belt and resistance of load to flexure as they move over idlers.
L = length of conveyor.
Q = tons per hour conveyed.
Si = troughing idler spacing.
Tac = total of the tensions from conveyor accessories.
Tam = tension required to accelerate the material continuously as it is fed onto belt.
Tb = tension required to lift or lower the belt.
Tbc = tension required to overcome belt cleaner drag.
Te = effective belt tension at drive.
Tm = tension required to lift or lower conveyed material.
Tp = tension required to overcome resistance of belt to flexure around pulleys and resistance of pulleys to rotate on their bearings.
Tpl = tension required to overcome belt plow drag.
Tsb = tension required to overcome skirtboard drag.
Ttr = tension required to overcome special loading condition(s.)
Tx = tension required to overcome carrying and return idler friction.
Tyb = total of tensions due to resistance of belt to flexure as it rides over carrying and return idlers.
Tyc = tension due to resistance of belt to flexure as it rides over carrying idlers.
Tym = tension due to resistance of material to flexure as it rides over carrying idlers.
Tyr = tension due to resistance of belt to flexure as it rides over return idlers.
V = design belt speed.
Wb = weight of belt per unit of length of conveyor.
Wm = weight of material per unit of length of conveyor.
Sag = recommended maximum sag percentage to avoid spillage in troughed section of belt.
Ls = Length of conveyor from tail pulley to Drive snub (for return run drive only)
Hd = Height of conveyor from top of tail pulley to bottom of drive pulley (for return run drive only)