Conveyor Component Design
CDI provides wide range of conveyor component design, analysis and testing on pulley, belt, structure, load share device and other parts. The component design is an integral part of our advanced conveyor engineering.
Component Design – Idler Rotation Resistance Testing
The rotational resistance test system developed by Conveyor Dynamics enables the rotational resistance on rollers used in overland belts to be accurately measured with an accuracy of +/- 0.1N. Furthermore, the system was developed to comply with DIN 22112 and SANS 131 standards. The resistance to rotation of the rollers is an important variable during the design and operation of the overland system as it is directly related to power demand.
Component Design – Pulleys
CDI uses our proprietary PSTRESS software to do rapid design prototyping of high-tension pulleys. This software uses a combination of analytic calculations and FEA to determine the principal von Mises stresses and fatigue stresses. Because of the analytic elements in the software, this analysis is complete in a matter of seconds, allowing our design engineers to quickly modify the pulley design to eliminate stress risers and stress concentrations. The final design is then put through rigorous a rigorous FEA study to validate the initial design calculations.
|Goodman Diagrams – Pulley Analysis|
|Pulley Finite Element Analysis|
Component Design – Idler Frames
CDI idler frame designs utilize pipe elements and rounded or tapered idler support brackets. This design minimizes damage to the belt that occurs when an idler is lost while the belt is running.
|Idler Frame Component Design|
Component Design – Ground Modules and Triangular Truss Gantries
|Ground Module Component Design||Triangular Truss Component Design|
Component Design – Conveyor Structure Analysis
We use RISA, Staad and Ansys to analyze different parts of the conveyor structure, from idler support to shiftable head stations. The analysis provides detailed stress and deformation result and checks against national structural codes. It also enables optimization that reduces cost and improves functionality.
|Conveyor Triangular Truss Structural FEA using RISA|
|Shift-able Conveyor Head Station Structural FEA using Ansys|
|Shift-able Conveyor Stringer Structural FEA using Ansys|
Component Design – Maintenance Trolleys
CDI designs maintenance trolleys for our elevated triangular or box truss gantries. These trolleys eliminate the need for walkways on the gantries, which reduces the structural load on the triangular gantry design. The end result is a gantry with a high strength-to-weight ratio.
|Walkway-Free Trolley Dangote Overland, Nigeria, 2006
Maintenance trolley designed without a walkway, which reduces costs. Project was for horizontally curved, 6.9 km overland conveyor with elevated truss and trolley.
See project details. See video from trolley.
|Walkway-Free Trolley Adani Dahej Port, India, 2013
Maintenance trolley designed without a walkway, which reduces costs. Project was for horizontally curved, 3.8 km overland conveyor with elevated truss and trolley.
See project details.