KWS Manufacturing

Drag Conveyor Horsepower Calculation

The KWS Dragon-Flite conveyor is an efficient, high performance alternative to conventional means of material handling. Because the material is moved En-Masse, horsepower requirements can be as much as half of that of alternative means of conveyance.

The Horsepower (HP) requirements of a Dragon-Flite conveyor can be calculated as the sum of the three contributing factors to the HP requirements. The total HP requirement is the sum of the HP to move the chain/flights and sprockets called the "Empty HP" + the HP to move the material in the conveyor called the "Live HP" + the HP to lift the material in an inclined situation called the "Lift HP".

Empty HP

The Empty Horsepower is the power required to overcome the friction in the power transmission system, chain/sprockets, and the flights dragging on the bottom of the trough. Empty HP can be calculated using the following formula.

Drag Conveyor Engineering Guide - Horsepower Calculation - KWS Manufacturing

HPE = Empty Horsepower Requirement
Wc = Weight per foot of Chain and Flight (Lb/ft)
L = Length of the Conveyor (ft)
S = Speed of the Chain (ft/min)
Fc = Friction Factor of the Flights on the Bottom Housing

Note:
Frictional factor used in the above formula vary depending on the specific applications and products being conveyed. Testing may be required to determine the exact values to be used.

Live HP

The Live Horsepower is the power required to overcome the friction of the material sliding along the bottom of the housing over the length of the conveyor. Live HP can be calculated using the following formula.

Drag Conveyor Engineering Guide - Live Horsepower Calculation - KWS Manufacturing

HPL = Live Horsepower Requirement
Wm = Weight per foot of Material Being Conveyed (Lb/ft)
L = Length of the Conveyor (ft)
S = Speed of the Chain (ft/min)
Fm = Friction Factor of the Material on the Bottom Housing

Note:
Frictional factor used in the above formula vary depending on the specific applications and products being conveyed. Testing may be required to determine the exact values to be used.

Lift HP

The Lift Horsepower is the power required to lift the material the required height of an inclined or bent leg conveyor. Lift HP can be calculated using the following formula.

Drag Conveyor Engineering Guide - Lift Horsepower Calculation - KWS Manufacturing

HPH = Lift Horsepower Requirement
R = Rate of Material Being Conveyed (Lb/hr)
H = Vertical Height the Material is to be Conveyed (ft)

Total HP

Using the Empty HP, Live HP, and Lift HP, the total Horsepower required to convey the material can be calculated using the following formula.

Drag Conveyor Engineering Guide - Total Horsepower Calculation - KWS Manufacturing

HPTotal = Total System Horsepower Requirement
HPE = Empty Horsepower Requirement
HPL = Live Horsepower Requirement
HPH = Lift Horsepower Requirement
E = Drive Efficiency

Chain Pull

Although a preliminary chain selection is required to calculate the Total HP, the actual maximum design chain pull is required in order to accurately select the appropriate chain for the conveying application. The design chain pull is calculated using the actual drive and motor selected and doing so will ensure the chain does not fail under upset conditions. Additional factors for design chain pull include the Speed Factor and Service Conditions. The design chain pull can be calculated using the following formula.

Drag Conveyor Engineering Guide - Chain Pull Calculation - KWS Manufacturing

P = Design Chain Pull (LB)
HPTotal = Total System Horsepower Requirement (HP)
S = Speed of the Chain (ft/min)
Sf = Speed Factor (Table 1)
SF = Product of Service Factors (Table 2)

Number
of
Teeth
Conveyor Speed (FPM)
10 25 50 75 100 125 150 175 200
6 0.917 1.09 1.37 1.66 2 2.4 2.97 3.57 4.41
7 0.855 0.971 1.13 1.27 1.44 1.61 1.31 2.04 2.29
8 0.813 0.909 1.04 1.16 1.26 1.37 1.49 1.63 1.76
9 0.794 0.87 0.98 1.07 1.17 1.26 1.36 1.45 1.55
10 0.775 0.84 0.943 1.02 1.09 1.16 1.24 1.31 1.37
11 0.758 0.82 0.901 0.971 1.03 1.09 1.15 1.22 1.28
12 0.741 0.787 0.862 0.926 0.99 1.05 1.1 1.16 1.21
14 0.735 0.769 0.833 0.885 0.935 0.98 1.02 1.07 1.11
16 0.725 0.763 0.813 0.855 0.893 0.935 0.971 1.01 1.05

Table 1 – Speed Factor (Sf)



Vs Vl Vo Vt Factor
Frequency of Shocks Character of Loading Operating Conditions Daily Operating Times  
Infrequent Uniform or Steady Clean and Moderate Temperature 8-10 Hr 1.0
Frequent Moderate Dusty 24 Hr 1.2
    Unprotected or Harsh   1.4
  Heavy     1.5

Table 2 – Service Factors (SF)

The above information and formulas are a conservative approach to drag conveyor horsepower and chain pull design. More detailed information can be found in the Standard Handbook of Chains by the American Chain Association.