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BELT TRANSITIONS ANALYSIS BY FINITE ELEMENT ANALYSIS
Ryan Lemmon


Figure 1. In-line or full trough transition


Figure 2. Elevated pulley transition


Idler Trough Angle
% Rated Belt
Tension
Recommended Transition
Distance = Factor x Belt Width (BW)
Fabric Belts Steel Cord Belts
20
> 90% 0.9 2.0
60% to 90% 0.8 1.6
< 60% 0.6 1.0
35
> 90% 1.6 3.4
60% to 90% 1.3 2.6
< 60% 1.0 1.8
45
> 90% 2.0 4.0
60% to 90% 1.6 3.2
< 60% 1.3 2.3
Table 1. Table 7.26 of CEMA 6th edition half trough transition


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Idler Trough Angle
% Rated Belt
Tension
Recommended Transition
Distance = Factor x Belt Width (BW)
Fabric Belts Steel Cord Belts
20
> 90%
60% to 90% 1.6 3.2
< 60% 1.2 2.8
35
> 90% 3.2 6.8
60% to 90% 2.4 5.2
< 60% 1.8 3.6
45
> 90% 4.0 8.0
60% to 90% 3.2 6.4
< 60% 2.4 4.4
Table 2. Table 7.28 of CEMA 6th edition full trough (in-line) transition


Figure 3. Finite element model (final deformed shape) of 1600 mm belt (symmetric about
centreline)

Figure 4. Full belt width
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Figure 5. Finite element model (belt in final deformed state)


Figure 6. Elevated pulley transition


Figure 7. Boundary condition of the transition


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Figure 8. Material loading on the belt


Figure 9. Displacement of deformed belt in transition

Model
Required
Length (m)
Belt Length = 13.0 m
Edge SF
Edge Stress
(N/mm)
Centre Stress
(N/mm)
CEMA 12.8 NA NA NA
ISO 13.1 5.79 432 350
DIN 13.1 5.79 432 350
Beckley 13.1 5.79 432 348
FEA 13.1 5.77 433 357
Table 3. Results of in-line transition. Tension = 600 kN
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Figure 10. Stress contour plot of 13.0 m in-line transition. Tension = 600 kN


Figure 11. Stress distribution across width of belt. Tension = 600 kN

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Figure 12. Linear transition of wing roll trough angle in the in-line transition

Force on wing rolls
(Total force on roll is shown)
Force on centre rolls
(Total force on roll is twice shown)


Figure 13. Force on wing and centre rolls





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Figure 14. Beckley's recommended trough angle in transition
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Figure 15. Beckley geometry for the 13 m full trough transition




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Force on wing rolls
(Total force on roll is shown)
Force on centre rolls
(Total force on roll is twice shown)


Figure 16. Force on wing and centre rolls


Figure 17. Beckley transition of wing roll trough angle full trough transition

Model
Required
Length (m)
Belt Length = 12.1 m
Edge SF
Edge Stress
(N/mm)
Centre Stress
(N/mm)
CEMA 7.04 NA NA NA
ISO 12.1 26.5 94 0
DIN 12.1 26.5 94 0
Beckley 12.1 26.5 94 0
FEA 12.1 26.7 94 2

Table 4. Results of in-line transition. Tension = 48 kN, belt is empty
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Figure 18. Stresses in 12.1 m in-line transition. Tension = 48 kN

Model
Belt Length = 7.0 m (CEMA min Length)
Edge SF Edge Stress (N/mm)
Centre Stress
(N/mm)
ISO/DIN/Beckley 11.3 222 -60
FEA 12.1 206 -38
Table 5. Results of in-line tension. Tension = 48 kN

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Figure 19. Stresses in 7.0 m in-line transition. Tension = 48 kN

Model
Required
Length (m)
Pulley
Elevation
(mm)
Edge SF
Edge Stress
(N/mm)
Centre
Stress
(N/mm)
Beckley 5.2 212 5.80 436 255
CEMA 6.4 181 NA NA NA
ISO 8.7 121 5.81 436 349
DIN 9.4 121 5.80 436 349
Table 6. Results of elevated pulley transition. Tension = 600 kN

Model Length (m)
Pulley
Elevation
(mm)
Edge SF
Edge Stress
(N/mm)
Centre
Stress
(N/mm)
FEA 5.2 212, Linear 3.55 704 258
FEA 5.2 212, Beckley 2.43 1030 167
FEA 6.4 181 4.05 617 279
FEA 8.7 121 4.87 513 324
FEA 9.4 121 5.06 494 326
Table 7. Results of elevated pulley transition. Tension = 600 kN


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Figure 20. Recommended packing height and trough angle per Beckley for an elevated pulley
transition
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Figure 21. Elevated pulley transition, L=5.2 m, pulley elevation=212 mm, linear transition of idlers




Figure 22. Elevated pulley transition, L=5.2 m, pulley elevation=212 mm, recommended Beckley
transition of idlers

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Model Length (m)
Pulley
Elevation
(mm)
Edge SF
Edge Stress
(N/mm)
Centre
Stress
(N/mm)
FEA 13 0 5.77 433 347
FEA 13 121 5.71 438 334
FEA 13 181 5.68 440 304
FEA 13 212 5.66 442 290

Table 8. Results of 13 m transition. Tension = 600 kN










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Figure 23. Stresses in 13 m transition at different pulley elevations. Tension=600 kN

CENTRE ROLL WING ROLL









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Figure 24. Load on idler rolls in 13 m transition at different pulley elevations.Tension = 600 kN

Model
Required
Length (m)
Pulley
Elevation
(mm)
Edge SF
Edge Stress
(N/mm)
Centre
Stress
(N/mm)
CEMA 3.7 181 NA NA NA
ISO 8.1 121 26.67 94 0
DIN 8.8 121 26.63 94 0
Beckley 10.4 212 56.60 44 0
Table 9. Results of elevated pulley transition. Tension = 48 kN

Model Length (m)
Pulley
Elevation
(mm)
Edge SF
Edge Stress
(N/mm)
Centre
Stress
(N/mm)
FEA 3.7 181 6.23 401 -99
FEA 8.1 121 14.7 164 -11
FEA 8.8 121 16.7 150 -10
FEA 10.4 212, Linear 20.7 118 -11
FEA 10.4 212, Beckley 10.2 246 -38
Table 10. Results of elevated pulley transition. Tension = 48 kN, belt is empty

Model Length (m)
Pulley
Elevation
(mm)
Edge SF
Edge Stress
(N/mm)
Centre
Stress
(N/mm)
FEA 3.7 181 6.0 416 -127
FEA 8.1 121 14.7 170 -64
FEA 8.8 121 16.7 150 -65
FEA 10.4 212, Linear 20.7 121 -40
FEA 10.4 212, Beckley 10.4 240 -76
Table 11. Results of elevated pulley transition. Tension = 48 kN, belt is fully loaded
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Empty Belt

Fully Loaded Belt

Figure 25. Elevated pulley transition, L=10.4 m, pulley elevation=212 mm, linear transition of idlers
Empty Belt

Fully Loaded Belt

Figure 26. Elevated pulley transition, L=5.4 m, pulley elevation=212 mm, recommended Beckley
transition of idlers
Model Length (m)
Pulley
Elevation (mm) Edge SF
Max Stress
(N/mm)
Min
Stress
(N/mm)
FEA 12.1 0 26.6 94 2
FEA 12.1 121 26.6 94 8
FEA 12.1 181 26.5 98 -1
FEA 12.1 212 26.5 97 -16
Table 12. Results of 12.1 m transition. Tension = 48 kN, empty belt

Model Length (m)
Pulley
Elevation (mm) Edge SF
Max Stress
(N/mm)
Min
Stress
(N/mm)
FEA 12.1 0 28.4 88 -18
FEA 12.1 121 26.6 93 -20
FEA 12.1 181 26.6 96 -20
FEA 12.1 212 26.5 97 -22
Table 13. Results of 12.1 m transition. Tension = 48 kN, fully loaded belt
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Empty Belt Fully Loaded Belt










Figure 27. Stresses in 12.1 m transition at different pulley elevations. Tension = 48 kN
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Figure 28. Stress at belt edge and centre in 12.1 m elevated pulley transition, fully loaded belt

Figure 29. Stress at belt edge and centre in 12.1 m elevated pulley transition, fully loaded belt




12.1 m Elevated Pulley Transition
Pulley Elevation = 212 mm, Fully Loaded
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Longitudinal Location (m)
S
t
r
e
s
s

(
N
/
m
m
)
Stress at Belt Edge
Stress at Belt Center
B
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o
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T
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P
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L
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12.1 m Elevated Pulley Transition
Pulley Elevation = 212 mm, Empty Belt
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Longitudinal Location (m)
S
t
r
e
s
s

(
N
/
m
m
)
Stress at Belt Edge
Stress at Belt Center
B
e
g
i
n
n
i
n
g

o
f

T
r
a
n
s
i
t
i
o
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P
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e
y

L
o
c
a
t
i
o
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Figure 30. Stress across belt width in elevated pulley transition


CENTRE ROLL - Empty Belt CENTRE ROLL - Fully Loaded Belt






Stresses Across Belt Width
12.1 m Transition, Pulley Elevation = 212 mm
-20
0
20
40
60
80
100
120
0 100 200 300 400 500 600 700 800
Location Across Belt Width (mm)
S
t
r
e
s
s

(
N
/
m
m
)
Stress at Beginning of Transition
Stress at Trasition Mid Point
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Figure 31. Load on idler rolls in 12.1 m transition at different pulley elevations.
Tension = 48 kN