TaskJunction βš™οΈ Engineering Tools
Mechanical Design

Conveyor Design Calculator

Calculate belt tension, power requirements, capacity, and speed for flat belt conveyor systems. SI & Imperial unit support.

πŸ“ Belt Geometry
m
m
Β°
m/s
m
βš–οΈ Load & Material
kg/mΒ³
kg/m
kg/m
%
-
πŸ“Š Calculation Results
Drive Power
-
kW
Effective Tension
-
N
Belt Capacity
-
t/h
Tight-Side Tension
-
N
Slack-Side Tension
-
N
Total Load
-
kg
Gravity Component
-
N
Friction Force
-
N
Conveyor Schematic, Side Profile
Power Status
-
Inclination
-
Capacity Rating
-
πŸ“ Formula Reference
Friction Force
F_f = f Γ— L Γ— (m_b + m_l) Γ— g Γ— cos(ΞΈ)
Gravity Component
F_g = (m_b + m_l) Γ— g Γ— sin(ΞΈ) Γ— L
Effective Tension
T_e = F_f + F_g
Drive Power
P = (T_e Γ— v) / Ξ·
Belt Capacity
Q = m_l Γ— v Γ— 3.6 (t/h)
Tight-Side Tension
T₁ = Tβ‚‚ + T_e
πŸ“š Recommended Resource
πŸ“–
Amazon
R.S. Khurmi, Theory of Machines & Machine Design
The most trusted mechanical engineering reference book for Indian students & professionals. Covers gears, springs, shafts, belts, chains and more, everything this calculator is based on.
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Conveyor Calculator: Belt Conveyor Design & Power Calculation Guide

Belt conveyors are the most efficient method for bulk material handling. They are central to cement, coal, grain, fertiliser and packaging industries. Correct conveyor design, belt speed, capacity, drive power and tension calculation, determines system reliability and energy efficiency.

πŸ“‹ How to Use This Calculator

  1. Enter conveyor geometry, length (m), lift (m) and inclination angle (Β°).
  2. Specify belt width (mm) and belt speed (m/s).
  3. Enter material density (kg/mΒ³), surcharge angle and idler spacing.
  4. View required motor power, belt tensions (T₁, Tβ‚‚, T_eff), drive pulley torque and belt sag results.

πŸ“ Formula & Working Principle

Material capacity Q = 3600 Γ— A Γ— v Γ— ρ (tonnes/hr). Effective tension Te = Tx + Ty + Tz. Power P = Te Γ— v / 1000 (kW). Drive power = P Γ— service factor / transmission efficiency.

πŸ’‘ Worked Example

Horizontal conveyor, L=100 m, Belt width=800 mm, v=1.5 m/s, Material density=1000 kg/mΒ³. Cross-section area=0.07 mΒ². Q=3600Γ—0.07Γ—1.5Γ—1=378 T/hr. Teβ‰ˆ12 kN. Motor power=12Γ—1.5/1000=18 kW.

❓ Frequently Asked Questions (FAQ)

Q: What is the maximum conveyor inclination angle?

For most bulk materials, the maximum inclination is 18–20Β°. For fine dry materials (cement, sand), the maximum is 15Β°. Cleated belts allow up to 30–35Β°.

Q: What should the belt sag limit be?

Maximum belt sag = 0.5–1.5% of idler spacing. Excess sag causes material spillage and belt wear, increase belt tension.

Q: How is idler spacing decided?

Carry side: 1.2–1.5 m, return side: 2.5–3.0 m for general materials. For heavy materials, use 0.8–1.0 m on the carry side.

Q: What is the best practice for belt vulcanising joints?

Mechanical fasteners: temporary/low-tension belts. Cold bonding: medium duty. Hot vulcanising: highest strength, permanent joint, preferred for critical conveyors.

Q: How should conveyor starting torque be managed?

Use a soft starter or VFD, direct-on-line starting causes belt jerk that can damage joints and cause material spillage.