The greatest challenge in conveyor design is to establish rolling losses.  Belt tension, and hence power requirement and torque, are directly related to to rolling resistance (10-20 %) and the gravitational lift (fall) of the bulk material.

 Rolling resistance is a complex interaction between belt cover rubber and the steel idler support.   There are 3D geometrical effects of sag and troughing, material flexural forces, idler bearing forces and temperature influences.  Vertical and horizontal curves in the profile affect belt tension.

 4 Models are  used in a simulataneous computation to investigate variance between CEMA, DIN, Visco indentation  and Non-Linear rolling models.

 A design audit can usually reult in a solution fix for conveyor problems.

 The slide show provides a summary  of some of the graphs displayed in a design analysis report.

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