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The following design equations are used across the industry for calculating the different design parameters of the flat idlers: Spacing of the idlers S = (8*T1*H)/ (mb+ml)*g..1.1 Where, S is in meters T1= Belt tension near the idlers as shown in the picture (N) H=Belt sag (m) mb = weight of the belt (kg/m) ml =Weight of the conveyed material (kg/m) g =Acceleration due to gravity The weight of the conveyed material can be further calculated as ml= (10*W)/ (36*V)1.2 Where, mb is in kg/m. W = Capacity of the conveyor (tons per hour) V = Belt speed (m/sec) Idler speed N = (60*V)/ (*D)1.3 Where, N is in RPM. V = Belt speed (m/sec) D = Diameter of the idlers Loads on each idlers F= (10*W*S*g)/ (36*V)1.4 Where, F is in Newtons g = Acceleration due to gravity W = Capacity of the conveyor (tones per hour)
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S = Spacing between the two idlers. V = Belt speed (m/sec) Maximum bending stress on the idlers b= (8*F*L)/ (3**D3)..1.5 Where, b is in Newtons per square meter F = loads on each idlers (Newton) L = length of the idlers (Meter) D = diameter of the idlers (meter)
Conclusion
There are three types of idlers used in the conveyor industry, out of which only the flat belt conveyor idler design calculations are discussed here theoretically. We have not used the factor of safety in the design calculations here, or in other words the factor of safety is considered as one through out the calculations. The theoretical calculations are ideal for the preliminary design. FEA tools like Ansys or Pro Mechanica should be used for the final virtual validation of the design. References Limberoller Belt Conveyor Idlers Bridgestone Conveyor Belt Design Manual
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