Optimizing belt tension and stretch dynamics: a modeling approach for medium-duty conveyor systems

Abstract Medium-duty conveyor belt stretch modelling and simulation are needed to understand belt dynamics during startup, steady-state, and deceleration. Simulations evaluate a mathematical model’s belt tension and stretch prediction accuracy. This paper introduces a novel mathematical model for predicting belt tension and stretch in medium-duty conveyor systems, utilizing field data from diverse industrial settings. The model’s primary innovation is its integration of dynamic simulation with dimensional analysis using Buckingham’s Pi theorem, which allows for the accurate representation of transient behaviors, a critical improvement over previous static models. Operational input and output parameters are included in the data. The model concentrates on transitory behaviours, which are essential in scenarios of output parameter fluctuation. A medium-duty conveyor system with 0.04 Nm torque was simulated using field data, focusing on belt friction and pulley impacts. Experimental and mathematical model data were compared to simulation results. Tension rises early in the operation, stabilizes at a steady state, and then declines significantly as the system decelerates on both tight and slack sides. Slack side tension peaked at 8,757 N and dropped to 3,183 N, while tight side tension ranged from 22,193 N to 23,809 N before falling to 8,633 N by 36 s. The belt stretch reached 5.73204 meters before falling to 5.72993 meters after 30 s. The mathematical model predicted dynamic belt behaviour based on simulation and agreement with the mathematical model. This precise alignment shows that the mathematical model may be applied in real life to assure safe operational limits, eliminate mechanical failures, and extend system durability. Future research should include load changes and environmental characteristics in more complex conveyor settings to improve model reliability.