Conveyor Belt TENSION CALCULATIONS Full-Motor Method

Tension According to Belt Wizard Conveyor operating tension is a fundamental criterion for belt selection. Over the years, many formulation methods have been created and utilized for making such calculations. Most of us are familiar with FDAs Belt Wizard computer program. This customized program, based on the CEMA model, is a unique blending of various empirical formulas and field/operational data. Over the years, these formulations have been continually refined and updated making Belt Wizard one of the most sophisticated and successful steady-state tension models available today. Belt Wizard makes all its calculations including tension from the input of a wide range of possible operational and product data. In the days before the computer age, such complex tension calculations could be very time-consuming! Back then, we referred to any of these more detailed tension models as the long calculation method. Full-Motor Calculation an Alternative Method: To save time in those pre-digital days, we often opted to calculate tension using the Full-Motor method! This alternative tension approach had some obvious advantages among them, requiring only a few basic inputs, and just ONE simple calculation! It also had some limitations most noted was an inflated tension value. Sometimes referred to as the short tension calculation method, the Full-Motor calculation was typically represented as follows:
.

 where: PIW = lbs/in width (max operating tension) S = belt speed (ft/min) W = belt width (inches) HP = motor horsepower (nameplate)

and, Cw = drive wrap factor

Wrap Angle 1800 210
0

Automatic TU Bare 0.84 0.66 Lagge d 0.50 0.38

Manual TU Bare 1.2 1.0 Lagge d 0.8 0.7

Full-Motor Tension Realities: Basic Assumption This simple tension format is based on assuming that 100% of the motors nameplate horsepower will be delivered directly into the belt. That, of course, can never happen!! Actual belt tensionas calculated by any more detailed long methodwill surely reflect some lesser value. Such maximum tension calculations should only be used as an initial estimate. (Final belt selection still needs to be qualified by the other four carcass selection criterion.) Horsepower/Speed Relationships Horsepower and speed are critical inputs to the Full-Motor calculation. When motor nameplate values exceed 75 hp, and/or belt speeds drop below 300 feet/min, the calculated tension values can become unreasonably high. In such situations, I seldom would even bother with this calculation formula!! Cw (or Drive Wrap Factor) This input data is based on drive wrap angle, lagging, and takeup information. Checking belt speed From these inputs, several wrap factor combinations are indeed possible. On the previous page, I merely charted the Cw combinations that tended to be more common with lower motor horsepower applications. (For a more complete listing of wrap factor combinations, refer to p. 133 of the CEMA v6 manual.)

Frank Comment: In spite of todays sophistication and availability of computer programs like Belt Wizard, Ill still find myself using this Full-Motor calculation method and often on a daily basis! True, using it will ALWAYS generate HIGH tension values! Yet, in many applications, or field issues, belt tension is simply not a factor! Sometimes, I may not even be in a position to access my Belt Wizard program (traveling, etc). In these instances, that simple Full-Motor calculation will quickly help to guide me through the belt selection or the field problem-solving process.

Full-Motor candidates!!

If youre not already familiar with the Full-Motor calculation routine, you might want to get acquainted with it. Im betting that it can help assist you in a similar fashion!

George Big G Frank Manager, Application Engineering August 2005