Systems Design & Consulting

Route Selection – Feasibility & Optimization

3-D modeling of route topography allows CDI to optimize civil works and the placement of elevated or ground level steel support structures. Route optimization allows the comparison of design options to reduce cut and fill activities, eliminate material transfer points by appropriate placement of horizontal and vertical curves, and reduces potential conflicts with environmentally or politically sensitive neighbors. All of these in turn reduce the ultimate cost of building (CAPEX) and operating (OPEX) your conveyor system.

Terrain Modeling - Conveyor Design Cut and Fill Optimization Terrain Modeling - Low-res Animation Example of animated flythrough
Cut & Fill Optimization 
High-res Screenshot
Cut & Fill Optimization / Flythrough
Low-res Animation Example of animated flythrough.** Large graphic (3.43MB) **
Mine Transport Corridor - Aerial View Mine Transport Corridor - Topographic Route Layout with Cut and Fill Estimates
Mine Transport Corridor – Aerial View Mine Transport Corridor – Topographic Route Layout with Cut and Fill Estimates

Static and Dynamic Analysis

CDI’s BELTSTAT and BELTFLEX software enables us to accurately predict the behavior of the conveyor during the route selection phase of the project.  The analytic tools these software packages provide allow us to determine the forces and tensions along various conveyor routes and profiles, under a wide range of climatic conditions and material loads, and over the lifetime of the belt.

BELTSTAT Performs a Wide Range of Design Calculations
BELTSTAT Performs a Wide Range of Design Calculations

BELTSTAT calculates the forces and tensions for steady-state constant speed conditions, while BELTFLEX simulates the dynamic behavior of the conveyor during starting and stopping operations. BELTFLEX can simulate a wide variety of drive and brake control systems, including VFDs, fluid couplings, wound-round stepper motors, and constant torque and proportional torque braking systems. The control conditions developed during the BELTFLEX simulations can then be used to develop the speed control ramps for the PLC code that controls the drive and brake control system.

BELTFLEX – Typical Start-up Simulation

CDI also uses BELTSTAT and BELTFLEX as forensic analysis tools to simulate conveyors proposed by others, to audit their design, or on existing conveyor systems in order to duplicate and troubleshoot operational problems. This type of analysis can substantially reduce the amount of downtime involved in identifying and replacing a poorly designed or badly maintained component.

Equipment Sizing and Specifications

The static analysis provided by BELTSTAT includes a determination of component sizes and quantities, including

  • Belt width, speed, and strength.
  • No. and sizes of motors.
  • Gearbox ratio(s).
  • Brake torque requirements.
  • Flywheel mass and inertia (if required).
  • Holdback torque and load sharing (if required).
  • No. and sizes of pulleys.
  • No., sizes, and spacing of idlers.
  • Take-up tensions

In order to aid our clients in obtaining quality components, CDI can provide a set of equipment specifications for these items, as well as act as part of the clients QA inspection team for visits to vendors factories.