Sidewinder Manual

Advanced Conveyor Technologies, Inc. 19415 594th Ave - Mankato, MN 56001 - U.S.A. Phone: 507-345-5748 e-mail: [email protected]

Sidewinder Plus v4.5

Conveyor Design Software

User Manual

Revision 1.13

Sidewinder Conveyor Design Software - Manual June - 2011

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1.0 INTRODUCTION ................................................................................................................................................. 4

Table of Contents

2.0 INSTALLATION ................................................................................................................................................... 5

2.1 NETWORK LICENSES ............................................................................................................................................ 7 2.2 SIDEWINDER UPDATES ......................................................................................................................................... 9

3.0 SIDEWINDER - OVERVIEW ........................................................................................................................... 10

3.1 SIDEWINDER TOOLBAR ...................................................................................................................................... 10 3.2 SIDEWINDER QUICK START................................................................................................................................ 11

4.0 INPUT WINDOWS ............................................................................................................................................. 15

4.1 GENERAL INPUT WINDOW ................................................................................................................................. 15 4.1.1 Project Information .................................................................................................................................. 16 4.1.2 Design Criteria ........................................................................................................................................ 18 4.1.3 Load Conditions ....................................................................................................................................... 20 4.1.4 Frictional Conditions ............................................................................................................................... 26

4.2 MAIN PAGE INPUT WINDOWS ............................................................................................................................ 28 4.2.1 Material .................................................................................................................................................... 29 4.2.2 Take-up..................................................................................................................................................... 31 4.2.3 Belting ...................................................................................................................................................... 33 4.2.4 Idlers ........................................................................................................................................................ 41 4.2.5 Motors ...................................................................................................................................................... 46 4.2.6 Reducers ................................................................................................................................................... 48 4.2.7 Brakes ...................................................................................................................................................... 50 4.2.8 Backstops ................................................................................................................................................. 52 4.2.9 Pulleys / Shafts ......................................................................................................................................... 53 4.2.10 Dynamics ................................................................................................................................................ 56 4.2.11 Load Points – Feeders and Skirtboard Elements ................................................................................... 61

4.3 PREFERENCE WINDOW .............................................................................................................................. 67 4.3.1 System Preferences................................................................................................................................... 67 4.3.2 Language .................................................................................................................................................. 69 4.3.3 Belting ...................................................................................................................................................... 70 4.3.2 File Preferences ................................................................................................................................... 73 4.3.3 Report Preferences .............................................................................................................................. 74 4.3.4 Shaft Design Preferences ..................................................................................................................... 74

5.0 CONVEYOR PROFILE AND GEOMETRY ................................................................................................... 75

5.1 VERTICAL PROFILE.................................................................................................................................... 76 5.1.1 Geometry Input .................................................................................................................................... 77 5.1.2 Element Type ....................................................................................................................................... 82 5.1.3 Element Context Menu, Quick Buttons, and Short Cuts ...................................................................... 91 5.1.4 Enter Dimension from Pulley Centers ................................................................................................. 93 5.1.5 Adjust to End (Ctrl-J) .......................................................................................................................... 94 5.1.6 Divide Element Option ......................................................................................................................... 94 5.1.7 Move Point of Intersection ................................................................................................................... 97 5.1.8 DXF Import .......................................................................................................................................... 98 5.1.9 CSV Import ........................................................................................................................................ 106 5.1.10 DXF Export ................................................................................................................................... 107 5.1.11 Idler Spacing Table ....................................................................................................................... 108 5.1.12 Show Station Label........................................................................................................................ 117 5.1.13 Auto Calculate Wrap Angles ......................................................................................................... 117 5.1.14 Return Side Offset ......................................................................................................................... 117 5.1.15 Maximum Element Size ................................................................................................................. 117


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5.1.16 Vertical Radius Misalignment Tolerance ...................................................................................... 117 5.1.17 Show Imported Ground Line ......................................................................................................... 118 5.1.8 Element Plot....................................................................................................................................... 118

5.2 CONVEYOR PROFILE ................................................................................................................................ 120 5.2.1 Columns in Conveyor Profile............................................................................................................. 122 5.2.2 Defining custom load cases ............................................................................................................... 124 5.2.3 Cell Selecting .......................................................................................................................................... 126

5.3 HORIZONTAL PROFILE ............................................................................................................................. 127 5.3.2 DXF/CSV Import Dialog ................................................................................................................... 129 5.3.3 DXF Export ........................................................................................................................................ 129 5.3.4 Move Points ....................................................................................................................................... 129

5.4 GROUND PROFILE .................................................................................................................................... 130 5.4.1 2D Ground Profile ............................................................................................................................. 132 5.4.2 3D Ground Terrain ............................................................................................................................ 132

6.0 OUTPUT WINDOWS ................................................................................................................................... 136

7.0 REPORT ......................................................................................................................................................... 137

7.1 PULLEY IMAGES ...................................................................................................................................... 137 7.2 PROFILE IMAGE ....................................................................................................................................... 140 7.3 COMPANY LOGO ..................................................................................................................................... 140 7.4 EDITOR .................................................................................................................................................... 142 7.5 REPORT OPTIONS .................................................................................................................................... 143

7.5.1 Conveyor Load Cases ........................................................................................................................ 143 7.5.2 Conveyor Load Case Details ............................................................................................................. 143 7.5.3 Take-up Details .................................................................................................................................. 143 7.5.4 Pulley & Brake Details ...................................................................................................................... 144 7.5.5 Vertical Curve Details ....................................................................................................................... 144 7.5.6 Belt Flap Details ................................................................................................................................ 145 7.5.7 Transitions & Turnover Details ......................................................................................................... 145 7.5.8 All Material & Idler sets .................................................................................................................... 145 7.5.9 Element Summary Details .................................................................................................................. 145

8.0 TURNOVERS................................................................................................................................................. 146

8.1 ALLOWABLE STRESSES ........................................................................................................................... 147 8.2 TURNOVER OUTPUT ................................................................................................................................ 148 8.3 TURNOVER WORK PAGE ......................................................................................................................... 149

8.3.1 Belt Input Grid ................................................................................................................................... 150 8.3.2 Turnover Length and Tension Grid ................................................................................................... 153 8.3.3 Plotting Scales ................................................................................................................................... 153 8.3.4 Results and Output ............................................................................................................................. 153

9.0 LOAD ON/OFF WORK PAGE .................................................................................................................... 159

REFERENCE PAPERS .......................................................................................................................................... 162


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1.0 Introduction Thank you for your interest in our Sidewinder conveyor design software. This manual will discuss how to use the Sidewinder software, and describes the meanings of all input and output data. This manual assumes that the reader is familiar with basic conveyor design principles. It is not meant to be a “How to Design Conveyors” instruction manual. If the user is not familiar with basic conveyor principles they should first refer to the following literature: 1. Belt Conveyors for Bulk Materials – CEMA 5th & 6th Editions. 2. DIN 22101 & ISA 5048 Standards. 3. Phoenix Design Fundamentals, Goodyear Red Book, and other literature from manufactures. 4. The plethora of papers devoted to bulk solids handling.


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2.0 Installation The Sidewinder software consists of two parts. These are the software installation CD-Rom and a Sentinel USB hardware dongle. Sidewinder is supported under Microsoft Windows 2000, ME, XP, and Vista. To install Sidewinder insert the CD-Rom into your computer and double click on the “Setup.exe” file on the CD-Rom drive. You must agree to the license terms and conditions and select an installation directory. After installation is complete you must install the USB hardware driver. This is done by running the “Sentinel Protection Installer.exe” file found in the root directory of the CD-Rom. Sidewinder will install three directories on your computer. The “bin” directory contains all required Sidewinder installation files and the main “Sidewinder.exe” executable. The “Examples” directory contains various example files, and Sidewinder tutorial files which accompany the video tutorial series. The user manual is installed in the “User Manual” directory along with an “Updates.pdf” file. The updates file is automatically updated whenever an online update is performed. It contains detailed information on new features and changes.

Users may also create a “Catalogs” directory. This directory can contain any number of subdirectories. The purpose of this directory is for the user (or a company) to be able build their own library of information. The image below shows AC-Tek’s catalog library and some of the subdirectories. Each of these directories appears under the “Help” -> “Catalogs” menu from within Sidewinder. The Catalogs directory has several subdirectories such as “Belting”, “Idlers”, and “Motors & Reducers”. In the “Belting” directory there are further subdirectories such as ContiTech, Goodyear, Phoenix, etc. Then in each manufacture directory there are several pdf catalogs such as “Coal Quest.pdf”in the Goodyear directory. This allows the user to quickly reference the “Coal Quest”


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catalog at any time by going to the Sidewinder “Help” menu, and navigating to the “Coal Quest” manual.

This is only meant as a convent, and flexible, way for users (and companies) to organize conveyor design information and catalogs. You could for example create a directory called “literature” and place important papers or specifications in it.


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2.1 Network Licenses Network users must install the Sidewinder software and USB drivers on a local PC. This computer will have the USB dongle installed on it. All network users must also install both the software and USB drivers. Additionally, they must copy the “server.ip” file (found on the “Network” directory on the CD-ROM) to the “Sidewinder/bin” installation directory. This ASCII text file informs Sidewinder to search the local network for an available software license. To speed up the sever search, you can edit this file and enter the specific server IP address on the first line. This will allow the end users Sidewinder software to startup much faster.

Users can view the current server status by accessing port 6002 from their web browser. This is done by accessing the sever computer, port 6002. For example: http://192.168.110.123:6002

http://192.168.110.123:6002/�


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Network administrators should also note that the port required for the safenet USB key is TCP 6002, and 6001 UDP. However, if this needs to be changed for firewall or other reason it can be done using the ladserv.exe executable. This is shown below:


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2.2 Sidewinder Updates After installation you may want to check for any new Sidewinder updates. This can be done by selecting “Check for Updates” found under the “Help” taskbar menu. You will need internet access to complete this process.

If an update is found, Sidewinder will prompt you to automatically download and install the update.

After the download is complete, Sidewinder will step you though the remaining update process.


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3.0 Sidewinder - Overview After installing the software and USB drivers, insert the USB key into an open USB slot on your computer. You can start Sidewinder from the “Start – Programs – Sidewinder” menu on the windows taskbar.

3.1 Sidewinder Toolbar The Sidewinder toolbar contains quick shortcuts to the most commonly used input and output data windows. The three main user windows are highlighted in red. Each of these will be discussed in detail in section 4.0.

Open – Opens an existing Sidewinder input file

Save – Saves the current Sidewinder file

Reports – Generates a word document conveyor design report (see section 7)

Units – Switches all input and output values to the opposite measurement system (Metric to Imperial, or Imperial to Metric)

General Input Window – Contains general information about the system including solution methodology, design criteria, and specific load cases (see section 4.1).

Geometry Input Window – The conveyor profile, vertical & horizontal curves, drive/pulley arrangements, loading points, idler spacing, and other information about the conveyor geometry are entered here (see section 5).

Main Output – This is the main input/output window. It contains the details for all the major conveyor input parameters except the conveyor geometry (see section 4.2).


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Detailed Output – This window contains detailed output information on the current conveyor design (see section 6).

Solve – Solves the current conveyor calculations and updates all output data windows.

3.2 Sidewinder Quick Start When you first open Sidewinder you have the option of starting a “New” file, or “Opening” an existing file.

If you select the “New” button on the toolbar then a new blank Sidewinder input file will be created. You will then see the “Easy Profile” input window shown below. This window lets you quickly enter the basic geometry of a conveyor. The user can then click on the “Head” and “Tail” layout buttons and chose for a number of preset layouts.


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In the figure below the user has specified 3 elements, with a dual drive at the head, and a horizontal take-up at the tail.

The user can also enter other information about the conveyor design. This includes the idler spacing, motor wrap angles, backstop and brake locations, turnovers, and other details. Sidewinder uses the “Easy Profile” information to create the “Vertical Profile” of the conveyor. The vertical profile (next window tab at the top) contains a breakdown of each individual element. These “elements” represent the points where the belt tensions and other conveyor design parameters will be calculated. For many conveyors the Easy Profile window will be sufficient to provide a complete conveyor design. However, an unlimited number of elements as well as and drive configurations can be manually entered in the “Vertical Profile”. Please see section 5.0 for more information on using the vertical conveyor profile. After entering the conveyor geometry the user can select either the “Info” button or the “Main” button on the toolbar. The “Info” (short for Project Information) allows the user to enter general information about the project. Client names, conveyor descriptions, load cases, design criteria, and other specifications are entered here. Please see section 4.1 for further details.


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For now select the “Main” button on the toolbar. This will show the main Sidewinder window and is where you will spend most of your time.

Now click on the Material “Type” input and select “Copper, Ore” from the pull down list. Next click on the “tonnage” input (you will notice that the material name, density, and surcharge information will be automatically filled in when you leave the Material Type input box). Enter 2500, for the tonnage. You screen should look like this:

Now click on the calculation button on the toolbar (circled above). Once the calculations have been run you will notice the output data window is filled in the lower right corner. This window shows all the calculation results as well as the automatically selected equipment. Note how many (actually almost all) of the input variables were left blank, however Sidewinder has selected values as needed.


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Clicking on the “Material” tab shows a cross sectional view of the material loading.

All of the input and output tabs and windows are described in the following chapters.


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4.0 Input Windows

4.1 General Input Window This window can be opened by clicking the button on the tool bar. It consists of three important areas of information:

1. Project Information – General information, filenames, and calculation methods 2. Design Criteria – Input data specifying the design requirements for the conveyor 3. Load Conditions – Input data on each relevant load condition for the conveyor

Each of these areas will be discussed individually in the following sections.


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4.1.1 Project Information

Project Name – Name of the project to be printed on output reports and for future reference. Conveyor Name – Name of the individual conveyor (e.g. CV-002, or CR034) Location – Geographic location (used for output report labels only). Client Name – Name of the client (used for output report labels only). Designer – Engineer responsible for the conveyor design. Description – General description of the conveyor. This is printed at the top of the output report Designer Comments – General comments for the designer to refer back to. This information is not printed out and thus can contain specific data that only the designer wants to know. Ambient Temperature – This is the normal operating temperature for the conveyor. This temperature is used for all “normal friction” load cases (load cases are discussed in section 4.3.1). System Units – The working units for the file. Note input/output units can be switched at any time by simply clicking the units ( ) toolbar button.


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Revision – The user can select a two letter extension to be added to the based filename. For example if the file name is “conveyor xyz.swi” and the “Add Revision Number to Filename” is checked, then the new filename will be “conveyor xyz_0A.swi”. This is a handy and useful way of naming conveyors which may have different revisions throughout the design processes. Lock File – If this checkbox is enabled, the calculations cannot be re-run. The file can be opened, and the report printed, but neither the input nor output data may be modified. This is useful when a design has been completed and is similar to giving a file “read only” user privileges. Note: when the checkbox is checked, the user has the option of entering a password. If a password is entered then the file cannot be “unlocked” without re-entering the password. Solution Methodology – This selects which calculation methodology will be used for the conveyor calculations. The user should refer to the appropriate literature for details on each calculation methodology as this is outside the scope of this manual.

The primary solution methodologies are: CEMA 5th – Used the 5th edition of the CEMA book for all belt tension calculations. CEMA 6th – Used the 6th edition of the CEMA book for all belt tension calculations. DIN / ISO – Uses the DIN 22101 and ISO 5048 design methodology. When this method is selected, two additional input boxes are shown. If the equivalent friction factor “f” is left blank, Sidewinder will estimate a value based on the conveyor length and capacity. The “Cs” factor input accounts for all other losses on the conveyor system. There are three options for this input:

1. If this value is left blank it will be selected based on the length of the conveyor (as per the DIN/ISO selection table).

2. The user can manually enter the Cs value 3. The Cs factor can be calculated based on the actual conveyor components. In this

case the pulley drag, belt scraper drag, loading point forces, and other items are each individually calculated. For example, the ISO 5048 methods provides equations for calculating pulley drag based on belt tensions and other factors. If this option is selected sidewinder will calculate the “resulting” Cs factor and show this on the output page for the user’s information.


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Oszter, Behrends & Vincent – Methodology as described in the paper “Large Capacity Belt Conveyors – Motion Resistance Evaluation” by Z.F. Oszter, W.K Behrends, and D. Vincent. This paper is based off experimental data obtained on several high-tonnage conveyor systems. It is therefore only recommend to be used on these types of systems.

4.1.2 Design Criteria The design criteria page has two purposes: First, when user inputs are left blank Sidewinder will try to estimate the required values based on the criteria specified in this table. The second purpose for this table is to highlight problems with the conveyor design output values. For example, if the belt rating is not input, Sidewinder would select an appropriate rating based on the required belt safety factor. Conversely, if the belt rating is input, then Sidewinder would alert the user (highlight output cell red) if the belt safety factor exceeds the design criteria value.

Fabric Belt Criteria – This input sets the design criteria for fabric belting. Its value will default to the user specified option on the “Preferences” page. The “nominal” selection uses the nominal belt safety factor for selecting the required belt strength, and highlighting problem areas. The ‘splice’ option selects the belt rating based on the splice safety factor (this method takes the number of belt plys into account).


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Safety Factor (Fabric Belting) – This is the allowable nominal safety factor for fabric belting. This will either be input as the nominal value, or the “splice” value based on the “fabric belt criteria” above. For example: A 5 ply belt with a nominal safety factor of 10:1, would have a splice safety factor of 10 * (5-1) / 5 = 8. Some designers required a minimum splice safety factor of 8, whereas others prefer to base their designs on the nominal belt safety factor. The table below shows a comparison between the two methods. The yellow section shows the results when using a “nominal” belt safety factor of 10:1. For an EP-800 N/mm belt, the allowable splice tension would be 80 kN, regardless of the number of fabric plies in the belt. However, there is normally one less ply in the splice region (due to the belt vulcanization process) and thus the splice safety factor is a function of the number of plys. A designer using a nominal safety factor of 10:1 for a 3 ply belt, would results in a splice safety factor of only 6.7:1. The green section shows the results when the splice safety factor is constant (with the recommended DIN value of 8:1). In this case the allowable splice tension varies from 80 kN down to 50 kN. Therefore the “nominal” belt safety factor will vary from 10:1 to 16:1.

Safety Factor Example - EP-800 N/mm Fabric Belt

Plys

Rating per ply (N/mm)

Nominal S.F.

Allowable Splice

Tension (N/mm)

Splice S.F.

Splice S.F.

Allowable Splice

Tension (N/mm)

Nominal S.F.

5 160.0 10.0 80.0 8.0 8.0 80.0 10.0 4 200.0 10.0 80.0 7.5 8.0 75.0 10.7 3 266.7 10.0 80.0 6.7 8.0 66.7 12.0 2 400.0 10.0 80.0 5.0 8.0 50.0 16.0

Safety Factor (Steel Cord Belting) – This is the allowable nominal safety factor for steel cord belting. Unlike fabric belting this value is always specified as the “nominal” belt safety factor. The generally accepted value for steel cord belting is 6.67:1 Dynamic Safety Factor Multiplier – This multiplier defines the allowable safety factor for momentary operating tensions. It is also used for all design level 2 cases (running and dynamic) as these cases are “by definition” momentary conditions. For example: Nominal belt safety factor = 6.67:1 Dynamic multiplier = 1.15 Then the allowable safety factors are: 6.67:1 - Design Level 1 - Running 5.80:1 - Design Level 1 - Starting and Stopping


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5.80:1 - Design Level 2 - All Cases Local Safety Factor Multiplier – This is the minimum allowable steady state stress in the belt. It is used to determination of minimum vertical curve radius (edge stresses for convex curves and center stress for concave curves). It is also used in belt turnovers, transition length calculations, and other such areas. Minimum Steady State Stress – This is the minimum allowable steady state stress in the belt. Used for determination of minimum vertical curve radius. For dynamic cases the program uses the smaller of either 1% of the belt rating, or the above value. Maximum Allowable Sag (Steady State) – This is the allowable percent sag during steady state running conditions. Maximum Allowable Sag (Dynamic) – This is the allowable percent sag during momentary conditions. This includes design level 1 dynamic conditions, as well as all design level 2 cases (running and dynamic) since these cases are by definition momentary conditions. Pulley Friction Factors (Rubber Lagging) – This is the allowable coefficient of friction between belt and pulley for rubber lagged pulleys during running conditions. Pulley Friction Factors (Ceramic Lagging) – This is the allowable coefficient of friction between belt and pulley for ceramic lagged pulleys during running conditions Pulley Friction Factors (Dynamic Multiplier) – The allowable coefficient of friction during dynamic conditions is increased by this multiplier. For example, if the rubber lagging friction value is 0.28, and the multiplier is 1.15, then the allowable momentary friction value for rubber lagging is 0.32. Location – This specifies the location to be used when selecting default values. For example, in Europe a standard belt with is 1400 mm, however in Africa the standard is 1350 mm. When creating a new file this value will default to the location specified in the preferences option.

4.1.3 Load Conditions Load conditions provide one of Sidewinders most powerful features. It allows the engineer to view and analyze many different loading conditions of the conveyor. These include: Fully Loaded, Empty, Inclines Loaded, Declines Loaded, High Friction conditions, Low Friction conditions, and many more. Furthermore, different conveyor loadings, material types, belt speeds, and other variations can be examined.


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The “Load Conditions” option section box on the left allows the user to pick one of following three conveyor design options: Basic (Full/Empty) – Normal friction – This option results in Sidewinder performing the empty belt and fully loaded belt calculations using only the normal friction conditions. Full/Empty – High/Low friction – This option results in Sidewinder performing the empty belt and fully loaded belt calculations using the normal and high and low friction conditions. Incline / Decline (High / Low Friction) – This is perhaps the most used option as it not only includes the full and empty cases, but also two commonly used worst-case conditions which represent the maximum and minimum expected belt tension and power consumption. When this option is selected, two additional load cases will be shown. The first “All Inclines & Flat Sections” will load only the flat, and incline section of the conveyor. In many cases, this will be the same as the “fully” loaded condition. The second additional load case is for only loading the “Decline” sections of the conveyor. On an incline conveyor this would be the same as the empty belt condition. An example conveyor with a decline section, followed by an incline section, is shown below. The red line represents the conveyor profile, and the blue line the loading of the conveyor.

In addition to specifying the actual material loading of the conveyor, Sidewinder also allows the users to look at various friction levels and conditions. On most conveyors, the exact values for many components can not be specified with absolute certainty. For example, the drag of the idlers can vary significantly between idler types, manufactures, and ambient temperatures. For


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this reason the engineer must design the conveyor to allow for these variations in parameters. This is done by selecting various “frictional design conditions” as shown below.

In this case, the user has specified six (6) total loading/friction combinations. For the “All Incline + Flat Sections” conveyor loading, the conveyor calculations will be performed for the “Low” friction, “Normal” friction, and “High” frictional condition. In addition to various load cases and friction conditions, other important inputs can be specified. For example, let’s say the conveyor was to operate at two speed and tonnages. The primary case might be 3,000 T/H and 700 fpm. These values would be entered on the main page (under the material and belt input sections). However the designer might also be interested in increasing the belt capacity by 25%. This case can be easily added by simply including a “Tonnage Multiplier” of 1.25. For this condition the belt speed might need to be increased (i.e. if a VFD drive is being used) to 4.0 m/s. This condition is the first option highlighted in the red box below.

Alternatively, the designer may want to run two different material types on the conveyor. Again, there is no reason to make two separate Sidewinder files. Instead an additional load case can simply be added specifying a different material type (Material Type “2” in this case), with a different tonnage, belt speed, etc!


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Another option may be to investigate the belt tension and power requirements to start a conveyor for which the feeding point has been overloaded on shutdown. In this case the conveyor must include the “Loading Point Pullout Forces” required to overcome the shearing and other additional forces at the transfer point feed location. This option can be quickly investigated by entering the “flooded” feed point (i.e. 1 for this first feed point, or 1,2,3 if the conveyor would have three feed points which were all flooded, etc). New load cases can be added by “Right Mouse Clicking” on the Load Case column. A pull down list of all available load case options will be listed. This list includes a plethora of different conditions and load on/off scenarios. On many conveyors the worst case may not be obvious at first. However, the ability to be able to quickly investigate all potential worst case design conditions allows the designer to quickly spot potential problems, and eliminate other cases which may not be crucial.

As you can see, the load condition input table is very important, and also very powerful. A single file can contain the results of many different design cases, and “what if” scenarios. A summary of the input values is as follows:


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Fixed ID – The fixed ID cannot be changed. This tag is shown in the column label of the conveyor profile on the geometry input page. User ID – This 2 character ID, plus the friction level, will be shown in all load case tab pages. For example the Fully Loaded Normal friction case would be shown as "FL-N” and the Incline Loaded High friction case would be shown as "IL-H". Load Case – This name is used in the output for identification. The load case name may be edited. Low Friction – Check this box to create the low friction case as defined in "Frictional Conditions" tab above. Normal Friction – Check this box to create the nominal friction case. The nominal frictional case uses the values in the various input tables. High Friction – Check this box to create the high friction case as defined in "Frictional Conditions" tab above. High Friction Reduced Belt Mass – Check this box to create a high friction case, but with the reduced belt mass. This case is useful for more accurately determining belt liftoff radii requirements in concave curves. Tonnage Multiplier – The tonnage for each load case can be specified here. If the input value is less then 10, all material tonnages are multiplied by this value. (e.g.. 1.5 x 3000 T/H = 4500 T/H). If the input value is greater then 10, then that value is used as the tonnage for the load case (e.g.. 4500 T/H). Material Set – Defines the material type for each load point. If there is more than one loading point, you may place different materials in each feeder by entering multiple materials separated by commas. For example, if you have three load points entering "3,2,4" will place: Material type 3 in Load Point 1

Material type 2 in Load Point 2 Material type 4 in Load Point 3

If a material type for a feeder is not specified, then it defaults to the first material type in the list. Speed – The belt velocity for conveyor with variable speed motors can be modified with this multiplier. If the motor type is not a "VSD" this multiplier is ignored. Take-up Tension – The take-up tension of the load case can be modified (for automatic & gravity take-up types only). If input value is greater then -0.25 and less then +0.25 then this percentage is added to the input take-up tension (i.e. take-up tension = (1 + input value)*(input take-up tension). Otherwise, this amount is added to the input take-up tension. (i.e. take-up tension = input value + input take-up tension).


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Note: The take-up tension on the main input page must be specified or this input is ignored. Load Pt. Pullout Forces – At some loading points it is possible that material can build up in the transfer chute during certain conveyor shutdowns. This option allows these pullout forces to be included in the belt tension calculations (i.e. when the conveyor would be restarted). For example, if you have three loading points entering "2" would include the extra pullout forces at load point 2. Entering "1,2,3" would include the pullout forces for all loading points (1,2 and 3). Reverse Conveyor – Check this box if the belt runs in reverse for this load case. Design Level – Design Level 1 signifies normal operation load cases (such as fully loaded and empty). Design Level 2 signifies momentary or unusual load cases (such as inclines or declines only loaded).


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4.1.4 Frictional Conditions The friction condition table sets the design criteria when creating the high friction and low friction design cases.

Temperature – Ambient operating temperature for frictional case. For the low friction case (low power) enter the MAXIMUM expected temperature. For the high friction case (highest power) enter the MINIMUM expected temperature. Belt Bottom Cover Change – This amount of belt is added to the belt bottom cover. Enter a negative number to reduce thickness. By default the program will reduce the bottom cover thickness (for wear) by 0.5mm, and increase the cover by 0.5mm to account for manufacturing tolerances. Belt Top Cover Change – This amount of belt is added to the belt top cover. Enter a negative number to reduce thickness. By default the program will reduce the top cover thickness (for wear) to 35% of the nominal thickness, and increase the top cover by 0.5mm to account for manufacturing tolerances. Mechanical Efficiency – The total mechanical efficiency of the drive system is increased/decrease by this value. Accessory Multiplier – Miscellaneous drag values are multiplied by this number. These drags include: pulley bearing and belt resistant drags; skirt and slider bed drags; user input drag.


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Rubber Loss Factor – The Ky (rolling resistant) values are multiplied by this number. DIN f Factor – Din factor for selected friction case. Values above 0.1 are assumed to be multipliers of the nominal din factor. Idler Drag Multiplier – The nominal idler seal and bearing drags are multiplied by this number.


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4.2 Main Page Input Windows The main input page shows the most commonly accessed input and output information used by the conveyor designer. The figure below shows the separation between input and output information.

The input windows include: material, take-up, belting, idlers, motors, brakes, pulleys, and dynamic information. The output information is shown in the lower left window. It contains a variety of output data and information which can be selected by clicking on any of the output tabs at the bottom.


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4.2.1 Material The material input area allows the user to specify the specific material properties. Furthermore, Sidewinder allows up to four (4) different materials to be specified.

Material Set – Up to four (4) different materials can be entered by selecting the corresponding material “#” option button. For most conveyors only one material type is used in the calculations. However, in some conveyors, the user may want to include the calculations for different material densities or other properties. Or some conveyors may transport more than one material type (or have different material on the carry/return sides). This can easily be achieved in Sidewinder by selecting the appropriate material type and entering the material properties (density, tonnage, etc). To use different material types, the user needs to add these on the “Load Conditions” table as shown below. In this case two additional “Fully Loaded” conditions will be calculated using the properties for “Material Sets” 2 and 3.

Type – Material type description. Selecting pull down list will fill in material properties with CEMA standard values. This input is only used as a description for output purposes. Tonnage – Material Tonnage for the selected material. Hint: If the conveyor has two different tonnages but the same material properties, the second tonnage can be entered as an additional “Load Condition” using the “Tonnage Multiplier” column.


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Density – Typically, the lowest material density is used since this will result in the minimum material edge distance. Maximum Lump Size – Largest lump size of material on the belt. A circular lump is shown on the material cross sectional loading profile. Note: This value is used to select the belt width (if left blank) and in the universal idler L10 calculations (Dynamic Material Factor). I.e. a larger lump size will generally result in a higher dynamic material factor, and a lower idler L10 rating. Surcharge Angle – Surcharge angle is different from the angle of repose. The angle of repose is the angle which the material will make when stacked in a pile (i.e. a stockpile). The surcharge angle however is the angle made if the material is moving or slightly vibrated. This angle will normally be 5-15 degrees less then the angle of repose. The surcharge angle is used to plot the material cross sectional loading. Internal Friction Angle – The internal friction angle is used when calculating the material pullout forces at a material feed point. The material shearing friction factor (fi) is equal to 0.8 * the SIN of this value. For Example: If the normal vertical material load above the feeder is 1000 N, and the internal friction angle is 50 degrees, then the additional pullout force would be: 1000 N * 0.8 * sin(50) = 613 N. The default value is equal to the surcharge angle plus 18 degrees.


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4.2.2 Take-up The take-up tension is the “heart” of most conveyor systems. This devices sets the baseline belt tension and is thus of critical importance. The take-up tension needs to be sufficient enough to prevent belt slippage on the driving pulleys and minimize belt sag and material spillage along the conveyor. Properly determining the required take-up tension is crucial to an optimal conveyor design. Although Sidewinder will estimate the required take-up tension, the user should ALWAYS specify this value by the completion of the design processes.

Take-up Type – For a gravity-take-up system, the take-up pulley tension remains constant and the take-up position varies depending on the material loading. In a fixed take-up system, the take-up pulley is not allowed to move, and therefore the beltline tension at the take-up pulley will vary based on the loading. In this case the input beltline tension (entered below) is specified for the empty belt steady state running condition. This fixes the take-up pulley position, and all other conditions will be determined from this configuration. For an automatic winch take-up system, the take-up acts like a gravity take-up (tension is constant, and the pulley can move) for all running conditions. However during starting and stopping the take-up pulley displacement is fixed. If the automatic winch control is selected, an additional input will be shown on the take-up tension input line below. This input allows a pre-tension value to be entered for the starting case. If this value is entered, the take-up tension will behave as if it were a gravity-take-up for the starting case. Belt Line Tension – Input the beltline tension at the take-up pulley. The take-up mass would be twice the beltline tension (divided by gravity) for a hanging counter weight (1:1 revving), and would be a function of the cable revving for the other options. If a fixed take-up is used, this value represents the steady state beltline tension for the EMPTY belt condition. If an automatic winch control is used, this value represents the steady state beltline tension for each load case (full, empty, partial loading). Additionally, the automatic winch control allows a pre-tension to be entered in the first cell for starting. If this value is entered, the system will behave as if it were a gravity-take-up during starting.


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Cable Revving Ratio – This represents the cable revving ratio between the take-up pulley and take-up mass. By clicking on the input box, a pull-down list will appear showing the most common cable ratios.

The figures below show revving ratios of 0:0 (hanging counterweight), 1:1, and 4:2. The required take-up mass and take-up mass displacement will be calculated from the belting tension and specified revving ratios.


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4.2.3 Belting The belting input widow contains information about the conveyor belt construction. There are 4 sub-menus which include:

1. Belt – The most commonly used belting input information 2. Detailed – Additional and more detailed belting information which may be entered 3. Other – Information regarding the number of belt rolls and pipe conveyor belt inputs 4. Horizontal Curves – Specific input data regarding the horizontal curve calculations.

Each of these windows will be described below.

Type – Select auto, fabric, or steel cord belting.


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Width – The width of the conveyor belting. Speed at 100% Motor Nameplate / Speed for FL-N Case – Normally, the belt speed is entered at 100% motor nameplate. The motor gearbox ratio is then calculated from this value. For example if the motors are 4 pole 60 Hz the motor RPM will be 1800 at zero load, and approximately 1765 at 100% motor nameplate rating. The input speed would select a gearbox ratio based on the fully load condition (i.e. 1765 rpm). When the demand power is less than the nameplate rating, the belt speed will be slightly faster because the motor RPM will be higher (i.e. at 50% load the motor RPM would be ~1783 rpm). If a gearbox ratio is specified, then this input is not used since the belt speed would be calculated from the motor RPM, the gearbox ratio, and the pulley diameter. Alternatively, the belt speed can also be input for the “Fully Load – Normal Friction” case. In this case the gearbox ratio will be calculated using the belt speed entered and the motor RPM under the fully loaded case. For example, if the conveyor power was 80% for the fully loaded case, then the gearbox ratio would be calculated based on the motor RPM at 80% (rather then 100%). The reason for these two different input methods is purely in response to the end users choice. Some users prefer to have the gearbox ratio calculated from 100% nameplate power since this value will stay constant regardless of the calculated fully loaded power. Other users may want to enter the belt speed for the fully loaded case and hence prefer this input method. Please see section 4.1.2 “Design Criteria - Belt Speed Input Method” for more detailed information. Note: If a VSD motor type is selected, then the motor RPM will be adjusted for each load case to match the input belt speed. This is typically how a VSD control works resulting in a constant belt speed regardless of the conveyor loading. Note: The gearbox ratio is calculated using the belt speed and an “effective” pulley diameter. The effective pulley diameter is equal to:

Effective diameter = Bare diameter + 2 * lagging thickness + 2 * belt bottom cover thickness

Rating – When working in metric units, the belt rating is specified as the ultimate breaking strength of the belt. When using imperial units the rating is specified as the working strength of the belt. Top Cover Thickness – Distance from the belt cords (or top fabric layer) to the top of the belt. Larger belt cover thicknesses are necessary for abrasive materials. Bottom Cover Thickness – The bottom (pulley side) belt cover thickness. Number of fabric plys in belt – Number of fabric plys in the belt. This will affect the belt mass, the required pulley diameters, and the splice safety factors.


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Weight – Belt mass per unit length. The belt mass will automatically be calculated for each friction case depending on the belt cover thickness and other input parameters. Elastic Modulus – Belt modulus depends on the belt type, rating, and number of plys (for fabric belts). Permanent Elongation – Percent elongation of the belt for take-up travel requirements. Default is 1.3% for fabric belting and 0.1% for steel cord belting. Fillet Radius – This is the radius of the belt at the idler roll junctions. Rubber Rolling Loss Factor – The Ky values are multiplied by this factor. This value may vary from 0.40 to 1.35 depending on the belt’s bottom cover rubber compound.

Manufacture – Description for belting type and manufacture. This information is only used in the output report. Cover Grade – This input is for the user report printout only. It will not affect the conveyor calculations. For example the user could enter 'DIN X/X', or 'RMA II', and this information would be included on the output report. Rubber Density – Density of rubber for calculating belt mass only. Default value is 1200 kg/m3 (75 bs/ft3). Core Belt Thickness – Thickness of the core belt. The total belt thickness is equal to the top and bottom covers plus this value. Core Belt Weight – The total belt weight is the sum of the top and bottom cover masses (calculated from their thickness) plus this value.


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Belt Speed Input Method – When using a squirrel cage motor, or fluid coupling, the belt speed changes as a function of the motor demand power (e.g. the motor slip curve, and fluid coupling slip). For example, a 1750 rpm motor will operate at ~1800 rpm under no load, and ~1750 rpm under full load. Since the gearbox ratio and pulley diameters are fixed, the belt speed must change with the demand power (e.g. an empty conveyor runs slightly faster than a loaded one). Sidewinder allows the user to specify the belt speed (thus calculating the reducer ratio and other variables. The speed can be input at 100% motor nameplate rating (100% MNP), or selected such that the fully loaded normal friction case (FL-N Case) results in the input speed. The reducer ratio will then be calculated based on the input speed and selected method. All other load cases will be calculated using this reducer ratio. When creating a new file, this value will default to the value in the preferences option. Minimum High Tension Pulley Diameter – Minimum diameter for all high tension pulleys. The required diameter for all other pulleys will be calculated from:

Medium Tension = 82.5% of High Tension Fabric Belts

Low Tension = 82.5% of Medium Tension Snub = 82.5% of Low Tension

Medium Tension = 80% of High Tension Steel Cord Belts

Low Tension = 75% of Medium Tension Snub = 82.5% of Low Tension

Belt Scraper Drag Force – Additional drag force for each belt scraper. By default, sidewinder assumes one belt scraper at the head pulley, and one V-plow at the tail. The default value is 5 lbs per inch of belt width (0.875 N/mm). Pipe Diameter – If this value is specified, any 6 roll idler sets will be assumed to form a pipe conveyor shape. The input radius is the distance between the top and bottom idler faces (i.e. outside diameter of the belting). To account for the belt’s forming forces, and the additional indentation losses on the upper three rolls, a “Pipe Ky Input Factor” has been added. This factor is multiplied by the normal 3-roll Ky value to account for these extra forces. The default value is 1.75, but the user can enter any value they desire based on the belt construction and other factors. Additional idler drag is already taken into account with the 6 roll idler set. Both standard and non-standard rolls can be used. Initial forming forces (200lbs) are also automatically added at all transition locations.


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Pipe Ky Factor – Ky multiplier due to the increased belt contact on the upper idlers. The default value is 1.75.


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Number of Splice Steps – Number of steps in a single belt splice. Cable Diameter – Cable diameter used for steel cord belt construction. This value is used to calculate the minimum pulley diameter and for the splicing properties of the belt. This value is ignored for fabric belts. The required cable diameter is estimated by averaging the requirements from several belting manufactures. Thus, the actual cable diameter will vary based on the belting manufacture, cable supplier, and conveyor location. Number of Cables – Number of cables in parent belt. Cable Breaking Strength – Breaking strength of an individual cable. Splice Step Length – Length a single splice step. The total splice length is the number of splice steps times this value, plus the bias angle (18 degrees). Transition Length – Length from the normal belt pitch to where the splice begins. This is the area where the cables are bent from their normal position to the splice position. This is NOT the bias angle or distance. Free Belt Edge Gap – This is distance from the edge of the belt to the edge of the outer cable of the splice. This value will affect the gap between cables in the splice. Roll Storage Type – Shipping method for the belting. Options are: Single roll, Cassette roll (two single rolls wound together), or a Racetrack roll (elongated single roll).


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Belt Roll Diameter – Maximum diameter of storage roll. If a racetrack roll type is selected, the length of the roll is 1.55 times the diameter. Thus a 2.7 m diameter racetrack roll would be 4.2 m long.

Use Worn Mass for Belt Lift-Off Calculations – This specifies if the worn belt weight will be used to determine the minimum vertical curve radius to prevent belt lift-off for all load cases. For example, the fully loaded normal friction case calculations use the normal belt mass in its calculations. However if this option is set to 'Yes' then the vertical curve lift-off calculations and required radii for that case will also be calculated using the worn belt mass (as specified by the cover thickness on the 'friction conditions' page). If this option is set to 'No' then only the belt mass for each specific case would be used. 'Yes' is the default value since this will always result in the most conservative vertical curve calculation. Loading for Extra Liftoff Case –Sidewinder will perform the belt liftoff calculations for this 'extra' load case and show the results on the 'Detailed Output Page' under the 'Vertical Curves' tab. This radius is often used as the required radius for trippers and other vertical curves where belt liftoff cannot be avoided and hold down rolls are used. The default value is 15% load, but some users prefer to use 25%. Vertical Curve Tension Location – Location in the vertical curve where the belt tensions will be selected. By default sidewinder will anlized every element in the curve and select the location with the maximum/minimum belt tensions (i.e. the most conservative design option). However, some users prefer to use the belt tensions at the midpoint of the curve.


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Horizontal Curve (checkbox) – Check this box to add horizontal curves to the conveyor. The geometry input page will then show a page for entering the plan view horizontal curve profile of the conveyor.

Transition Type – Three transition types are available in sidewinder. Simple – This method uses the calculations based on D. Beckley’s transition paper. Maximum and minimum belt tensions are taken from the belt rating and safety factors specified in the design criteria (not the actual belt operating tensions). ISO 5293 – This method uses the 2004 ISO calculations to determine the required transition lengths. Transition lengths are calculated for each individual load case (empty, loaded, low/high friction, etc). The required transition length for the steady start running and moment condition is given for each load case, and also summarized in the output. Any pulley offset height can be entered. Beckley - This method uses the equations from David Beckley’s 1982 ‘Belt Conveyor Transition Geometry’ paper published in Bulk solids handling. As per the paper both inline and an ‘optimized’ pulley height can be specified. Additionally for the optimal pulley height the idler spacing can also be entered. In this case the required trough angles, and idler packing heights are calculated and shown in the output. Edge Stress Multiplier – Running –This is the allowable edge stress in the belt transition during running conditions. This value is divided by the nominal belt safety factor. For example if the nominal belt safety factor is 10, and the user enters 1.10, the allow edge stress will be 10 / 1.10 = 9.09. If this input is left blank then the ‘Local Safety Factor Multiplier’ specified in the Design Criteria page is used (this is the value used to calculate the allowable edge stress in convex curves, and the default value is 1.10.).


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Edge Stress Multiplier – Momentary – This is the allowable edge stress during momentary conditions, and for all steady state running load cases which are specified as ‘Design Level 2’ conditions (see load case inputs). It is important to note that the allowable edge stress for momentary conditions is also divided by the Dynamic Safety Factor Multiplier’ specified in the Design Criteria page (default value of 1.15). Thus if the nominal belt safety factor is 10, and the dynamic safety factor is 1.15, and the user enters 1.10 in this input, then the allowable safety factor at the edge of the belt in the transition section would be: 10 / 1.15 / 1.10 = 7.91. If this input is left blank then the ‘Local Safety Factor Multiplier’ specified in the Design Criteria page is used. Idler Spacing Method –This input is only available for the ‘Beckley method’. Rather then an equal idler spacing (the default value), it allows the user to see where the idlers would be spaced if they were positioned ever 5 degrees. Thus if a 35 trough angle is being used, this option would show the user the spacing (and idler packing heights) for 30, 25, 20, 15, 10, and 5 degree idlers. Length – Length of the transition. If this input is left blank then Sidewinder will use the transition length from the element table (if a transition element has been input). Idler Spacing – Idler spacing is used to output the idler banking angles and idler packing height for each transition idler frame. Elevation –Elevation of the pulley above the top of the middle roll. ISO 5293 recommends using 1/3 of the troughing height for elevated pulleys. The Beckley method allows either a flat or elevated pulley to be selected. This is the distance that the pulley is raised above the middle idler roll. If an elevated pulley is selected then the optimal pulley elevation will be calculated.

4.2.4 Idlers The idler input window allows up to eight (8) different idler sets to be entered. The individual properties for each set can be entered on the front page. However, each individual roll for each set can also be customized using the “Custom Set” input window. There are two basic idler input methods. Universal – This allows each idler (and/or each individual roll) to be defined individually. The bearing series can be specified and the idler L10 life will be determined for each roll of the set. This method is much more flexible, and allows more control over the idler design and specifications. CEMA – This method uses the U.S. standards of rated idler sets. These are classified as “B,C,D,E,F” series idlers, with sizes from 4” to 8” in diameter. However the CEMA method uses the “CIL” or Calculated Idler Load for the entire idler SET. This is different from the universal method which calculates the idler life for each individual roll.


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The CEMA manufactures association has specified the allowable “Load Rating” for various idler sets. For example a CEMA C5 idler set (3-roll) used on a 36” belt, with a 35 degree troughing angle, has an allowable load rating of 837 lbf. The CIL for the idler set is then calculated based on the actual material loading, installation tolerances, and many other factors; it is then compared to the allowable load rating. Input values for both idler sets will be described below.

Number of Rolls – Number of rolls in idler set. Bearing Series – Bearing series used in the idler roll. Several standard bearing series can be selected by right clicking on the input cell. The selection of a bearing series will specify the “dynamic” and “static” load capacity of the bearing and thus affect the idler L10 life. The bearing selection will also specify the roll shaft diameter if this has been left blank. Troughing Angle – This is the angle made between the center and wing rolls, or the vee angle of a two roll set. If a 4 or 5 idler set is used, a second input line will appear in which the user can also specify the troughing angle of the putter set. Roll Diameter – Outer diameter of the idler roll. Shaft Diameter – Diameter of the idler shaft. Total Drag for Set – Total drag of all rolls from bearings and seals. I.e. if the expected drag for one idler roll was 1.5 N, and a 5 idler set was used, then this input would be 7.5 N (1.5 x 5). Forward Tilt – Some installations are installed with a small forward tilt. This can help improve tracking of the belt, but it also adds additional drag forces. These forces can be calculated using the normal load on the idler set and the tilting angle.


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Fn * sin(forward tilt) * tan(idler angle). Where Fn = Normal force over the wing idlers (belt mass portion + material mass portion)

Idler Installation & Alignment – This value accounts for the idler installation misalignment drag forces. It is determined from the conveyor calculation methodology.

The DIN/ISO standard does not include idler drag forces directly. These are “lumped” into the user input equivalent friction factor “f”.

DIN / ISO

Misalignment tolerance calculated by the 5th edition methodology. CEMA 5th

0.0068 * (Wb + Wm) * Si (per idler set)

CEMA 6th Edition Methodology

Excellent - Permanent ridge structure with precise angular alignment - 0.375 inches Good - Permanent ridge structure installed without alignment measurements - 0.5 inches Fair - Mounted independent, imprecise footings - 0.75 inches Poor - Movable or unstable footings, roof hung, or other difficult installation - 1.5 inches

CEMA 6th edition methods also assume a 0.1 inch manufacturing tolerance and a friction factor of 0.5. For more information see pages 110-112 of the CEMA 6th edition book. Garland = Garland Idler (Extra friction added per CEMA 6) E=Excellent, G=Good, F=Fair, P=Poor Alignment Second column is friction factor for idler misalignment, forward tilt, and Garland idlers. Idler Type – Inline / Offset / Garland / ES Idler – This information is used in the report printout. It is also used to estimate the gap between rolls to better estimate the belt loading as shown below (inline vs. offset):


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Inline vs. offset idler type – Set the gap between rolls Idler Manufacture – Entering the specific idler manufacture will allow Sidewinder to better select default idler values.

Each roll of the idler set can be fully customized using the universal method. The user selects the “Custom Set” tab, and then clicks on the option button for the desired idler set to be customized (1, 2, 3, etc).

Custom Rolls Tab

The figure below shows some custom idler information entered for idler set 1. In this case a different bearing is used for the center and wing idlers. Also the wing idler will have a 152 mm diameter roll, versus the center roll diameter of 172 mm. The length of the center roll has also been shortened.

Bearing Series – The bearing series for each roll. The “static” and “dynamic” load capacities will automatically be specified if a standard value is used. Roll Diameter – Individual Diameter for each roll


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Shaft Center Diameter – The shaft diameter for the roll. Roll Drag – The roll drag for each individual roll. Note: this is entered per roll, unlike the general page where the roll drag is entered for the entire idler set. If the drag for each roll was 1.5 N then a 3-roll set would be entered as 1.5 for the wing, and 1.5 for the center (i.e. NOT 3.0 for the wing roll). Length – Length for the individual roll. Rotating Mass – Rotating mass for each roll. The rotating mass affects the total inertia of the conveyor and thus the starting and stopping forces. Horz. Curve Forward Tilt – If the roll has a forward tilt, this can be entered here. This value is used in the horizontal curve calculations. Static Load Capacity – As defined in the SKF bearing catalog. This value is used to determine the L10 life of each bearing, and thus the entire idler set. Dynamic Load Capacity – As defined in the SKF bearing catalog. This value is used to determine the L10 life of each bearing, and thus the entire idler set. Shell Thickness – Wall thickness of the idler shell. If entered, this value will be used to estimate the idler mass and inertia (if not specified). Inertia – Inertia for roll. Nonsymmetrical Roll Angle – Idler troughing angle of opposite side roll in degrees. If left blank both rolls angles will be the same. Nonsymmetrical Roll Length – Idler length of opposite roll. Shaft Support Length – This is the distance between the center support points for the idler. This distance is important as it is used to determine the shaft deflection of the idler roll. Distance from Bearing to Support – This is the distance from the center of the idler bearing to the center of the idler support position. This distance is important as it is used to determine the shaft deflection of the idler roll. Inside Diameter Hollow Shaft – If idler shaft is hollow, then enter the inside diameter this dimension is for the center portion (between bearing) of the shaft Gap Between Idlers – This is the gap between idler rolls. For example, Garland idler sets have wider gaps than a fixed idler set. Shell Type – Allows the user to specify various idler types. This includes the following:


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Steel - Regular steel shell idlers. Impact - Impact, or other equally spaced rubber disk idlers. 1-Roll - Rubber disk single roll return sets. Uses three closely spaced disks on each end. 2-Roll - Rubber disk Vee roll return sets. Uses three closely spaced disks on one side only. Number of Disks – If a rubber disk idler type is specified above, then the actual number of disks can be specified here.

4.2.5 Motors The motor input page contains all relevant information regarding the conveyor motors.


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Type – Squirrel cage, wound rotor motor, and fluid coupling calculated belt speed based on motor RPM, slip, and pulley diameter such that belt speed varies with demand power. For variable speed drives the motor RPM changes to match input belt speed. All motors must be of the same type. Fluid Coupling Size – Right click for a list of standard coupling sizes. When selected, the high and low speed inertia values are automatically updated below. Note: If the fluid coupling size is left blank then Sidewinder will show the required size (i.e. 562, 750, etc) in the motor output tab. Number of Motors on Pulley – Enter the number of motors on this pulley (1 or 2). Nameplate Rating per Motor – Enter nameplate rating per motor. For example, if a drive pulley has two 250 kW motors, then enter 250 here and '2' for the number of motors above. Synchronous RPM – Synchronous speed of motor. Default value is 1500 RPM (1800 RPM for North America). Maximum Starting Torque – This value is used in conjunction with the "Dynamics - Operational Start Options”. The value is multiplied by the motor nameplate rating to determine the motor torque available during starting. The starting time is then calculated from this value. Depending on the starting option selected on the dynamic tab, the full load demand torque can be used instead of the nameplate torque.


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This is often used for fixed filled fluid couplings that have their initial fill levels set in the field based on a specified startup time for the fully loaded condition. If the starting control is set to "Use a Fixed Starting Time," then this value is ignored. Motor Slip – Motor slip at 100% nameplate rating. The default value is 1.5%. Coupling Slip at 100% Nameplate – Fluid coupling slip at 100% demand power. The coupling efficiency is also equal to this value. (coupling efficiency = input speed / output speed). The default value is 3.0% for fluid couplings. Inertia - Motor – High speed inertia of motor (see notes for maximum stating torque above). Inertia –Input Fluid Coupling – High speed inertia of the the input (or motor side) of the fluid coupling The user can right click on the ‘Fluid Coupling Size’ input (only shown when a fluid coupling type is selected in the first input line above) and choose a specific type. This selection will automatically fill in both the input, and the output fluid coupling inertias based on the manufactures catalog. Note: If the fluid coupling size is left blank then Sidewinder will show the required size (i.e. 562, 750, etc) in the motor output tab. Inertia – Output Fluid Coupling – High speed inertia of the output (or reducer side) of the fluid coupling Inertia – Flywheel – High speed inertia of flywheel on each motor

4.2.6 Reducers The reducer input page contains all relevant information regarding the conveyor reducers. Note: The TOTAL mechanical efficiency is broken into two parts. One part is the reducer itself. The user can enter the number of reducer stages (usually 2 or 3) and then loss per stage (default value is 1.5%). If these are left blank, sidewinder will assume a three-stage reducer and thus a reducer efficiency of 95.5% (1.5% x 3 = 4.5% loss).

The second part of the loss is the “Other Efficiency Losses” on the motor input page. This would be blank (zero) for direct online or a VFD motor, but would be 2-5% for a fluid coupling or other such system.


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Manufacture – Various reducer manufactures are available. If you select a reducer manufacture from the list, Sidewinder will use the manufactures’ catalog and calculate a frame size and exact gearbox ratio for you. You can then enter the exact (catalog) reducer ratio in the Sidewinder input to calculate the exact belt speed (based, of course, on pulley diameter and motor RPM)

Reducer Ratio – The exact reducer ratio can be entered here. The motor output RPM (adjusted for the demand power slip), pulley diameter, belt thickness, and reducer ratio are then used to determine the real belt speed (unless a VFD drive is used, in which case the motor RPM will be varied to match the user input speed). Chain or V-Belt Reduction Ratio – If the motor is coupled to the gearbox by a chain or v-belt, then enter this ratio here. Note: If a chain or v-belt is used, then the "Other Efficiency Losses" input on the motor tab page should also be entered (recommend value of 5% or more) to account for the added losses. Frame Size – Catalog frame size or ID number.


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Number of Stages – The number of stages is used to calculate the gearbox efficiency and select the correct frame size and gearbox ratio. The default value is 3. Efficiency Loss per Stage – The Efficiency loss per stage times the number of stages gives the reduce efficiency at 100% loading. The default value is 1.5% per stage. Service Factor – Reducer service factor. Default value is 1.5. Gearbox Churning Constant – The churning loss coefficient is used to determine the reducer losses below the nameplate rating. The reducer loss is calculated by (x + (1 - x) * percent power) * reducer efficiency * input power where x = churning loss coefficient (0 - 1). If x = 1, then the reducer loss is a constant (i.e. independent of the current absorbed power). It is equal to the reducer efficiency * motor nameplate power. If x = 0, then the reducer loss is equal to the reducer efficiency * absorbed motor power for that case. The default and recommend value is 0.65. Inertia - Reducer – High speed inertia of the reducer.

4.2.7 Brakes The brake input page contains all relevant information regarding the conveyor brakes.


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Location (Low/High Speed Shaft) – Specifies if the brake is located on the high speed or low speed side of the shaft. Note: Only brakes on driven pulleys may be specified as high speed. Number per Pulley (1 or 2) – Specifies if there is one brake, or two (i.e. both sides), on the pulley. Nameplate Rating per Brake – This is the maximum torque the brake is capable of applying.


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4.2.8 Backstops The backstop input page contains all relevant information regarding the conveyor backstops.

Location (Low/High Speed Shaft) – Specifies if the backstop is located on the high speed or low speed side of the shaft. Note: Only backstops on driven pulleys may be specified as high speed Number per Pulley (1 or 2) – Specifies if there is one backstop, or two backstops (i.e. both sides), on the pulley. Nameplate Rating per Backstop – This is the maximum torque the backstop is capable of applying.


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4.2.9 Pulleys / Shafts The pulley and shaft input page contains all relevant information regarding the conveyor pulleys and shafts.


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Pulley Type – Pulley Type (High Tension, Medium Tension, Low Tension, or Snub). This will determine the required pulley diameter and other default pulley inputs when the user does not specify them. Pulley Diameter – Bare pulley diameter (i.e. not including lagging). When using the DIN calculation method, the pulley diameters are based on the new DIN 22101 standard. This method uses a lookup table based on the core belt thickness and the fully loaded running tensions. The CEMA methods use a pulley diameter of 175 times the cable diameter for steel cord belts, and an internal lookup table (based on number of belt plies) for fabric belting. Medium tension pulleys are one standard size smaller then high tension pulleys. Low tension and snub pulleys are then one additional size smaller (with the exception of pulleys greater then 1000 mm which in some cases can be reduced further). Lagging Thickness – Default value is 12 mm (0.5 inches) for ceramic lagging, and 10 mm (0.375 inches) for rubber lagging. Ceramic Lagging – Check this box if the pulley has ceramic lagging. This affects the allowable coefficient of friction to prevent belt slip. The coefficient of friction is specified on the “Design Criteria” project page. The maximum allowable tension ratio is then equal to: TR = T1 / T2 * e ^ (theta * f). Face Width – Pulley face width. Pulley Drag – This is the bearing and belt flexural losses for each pulley of the given type. If left blank the pulley drag will default to the CEMA or DIN specification. Shaft Material – Shaft material. Bearing Centers – Distance between the centerline of the bearings. Hub to Bearing – Distance from the center of the hub to the center of the bearing. This is also called the 'x' distance in the CEMA manual. Hub Key Type – Hub key type (Kf factor - 0.63 Profile, 0.77 Sled). Bearing Diameters – Shaft diameter at bearing. Hub Diameter – Shaft diameter at hub. Shaft Center Diameter – Shaft diameter at pulley center.


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Safety Factor – Yield stress and fatigue failure safety factor. Max Shaft Deflection – Steel Cord – Allowable deflection of shaft for steel cord belts (minutes). Max Shaft Deflection – Fabric Belting – Allowable deflection of shaft for fabric belts (minutes). Yield Strength – Yield strength. Leave blank to use default properties for above selected material. Fatigue Strength – Fatigue strength. Leave blank to use default properties for above selected material. Overhung Load – Overhung load in the vertical direction. Distance to Bearing Centers – Distance from the bearing center to the location of the overhung load. The center of the overhung load is typically the center of the gearbox. One Side / Both Sides – If the overhung load is on both sides. Shaft Diameter – Shaft diameter at overhung load. Hub Fillet Distance – Distance from the hub center to the inside turndown radius. Bearing Fillet Distance – Distance from the bearing center to the turndown radius. Pulley and Shaft Weight – Pulley and shaft weight. Rim Thickness – Rim thickness. End Disk Thickness – End disk thickness.


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4.2.10 Dynamics The dynamic input page contains all relevant information regarding the conveyor starting and stopping behavior.

There are three dynamic conditions calculated in Sidewinder. These are:

1. Operational Start – Accelerating the belt from rest. 2. Operational Stop – Stopping procedure used when a planned shutdown of the conveyor is to be performed. 3. Emergency Stop – Stopping procedure when an unplanned stop occurs. This may include a pulley cord trip, power failure, or other abnormal condition.

These option buttons are used to specify the motor torque, or acceleration time of the conveyor. Operational Start

Various users have stated that in some instances, the motor starting torque for fluid couplings could be reduced. For example a specific fluid coupling may have a maximum starting torque of 145%. However, the fully loaded demand power may perhaps only be 75% of nameplate rating. In many cases the fill level of the coupling is set to start the conveyor in given time period under fully loaded conditions. The question is therefore: Should we use 145% of motor NAMEPLATE torque, or use 145% of the fully loaded demand power? Some users argue that using 145% of nameplate is more conservative and thus should be used (and the coupling could be accidentally


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filled to this level and thus the drives could produce this output torque). Others feel that using 145% of the demand power is more reasonable, and using motor nameplate rating is too conservative in many cases. Sidewinder lets you do both. Simply pick the method you want to use.

“Use Maximum Starting torque Based on 100% Nameplate” “Use Maximum Starting torque Based on Full Load Demand Power”

Be aware, if your full normal case demand power is significantly less than, say, your incline load case, then the incline load case may be underpowered for starting. I.e. if your starting torque is, say, 145%, and Full demand is 40%, and you select the starting torque option based on full load demand power your starting torque will be around 60%. Thus, if you have a load case that required 90% nameplate to run, it obviously won’t start (nor would it in the real world…ok you just blow the coupling plug due to excessive heat). Sidewinder will warn you about this and you will see a RED warning of “N.E.P” – Not Enough Power. Note: Some may argue that the starting torque should be based on the actual demand power for each case. I.e. an empty belt at a demand power of 20% should use a starting torque of 20% (demand) times the 145% (coupling depend) value. There is some truth to this, and the real world actually lies somewhere between this torque value, and the full load demand power fill level (say 80% x 145%). However that value is usually MUCH closer to the demand power torque (it is fill level related) than it is to the current demand power. Additionally, at low power this philosophy results in very low starting torque, which, in turn, results in excessively long starting times. In practice, belts starting at low demand power (an empty belt for example) will start much quicker than a fully loaded belt, again confirming that the real torque curve lies on the upper side of this spectrum. Use the maximum input motor torque - This method uses the starting torque input value on the motor input page. This torque is used for each load case, and thus the starting time of the conveyor (and acceleration rate) will vary for each load case. Use the max starting torque (based on full-load demand power) - This method is the same as the above method except it assumes 100% torque is based on the fully-loaded normal case (not the motor rating). Use a fixed stating time - This method uses a fixed acceleration time for all load cases. Thus all load cases will start in the same time; however the motor torque will vary for each case. This method is similar to the operation of a VFD, or DC drive system. Breakaway Multiplier – The user can enter a breakaway multiplier to ensure that the motors for small conveyors have enough torque to start the system under the worst case conditions. This multiplier ONLY affects the “Breakaway Torque %” output on the motor properties output page. All drag components (except material lift) are multiplied by the breakaway input value for the starting condition. The output value can then be compared to the “locked motor torque” value


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for the conveyor drive being used to ensure the motor can begin accelerating the system. The default value is 2.

Include Motor Inertia – If this option is selected the starting calculations will take the motor inertia into account when determining the conveyor acceleration time. If the conveyor has a fluid coupling then this input should be unchecked as the motor comes up to full speed well before the coupling torque reaches its maximum values.

These option buttons are used to specify the deceleration time of the conveyor. Operational Stop

Turn motors off & drift to a stop – The motors are turned off and the belt is allowed to drift to rest. Most small conveyors operate in this manner (direct drive, fluid couplings, etc) Turn motors off & apply maximum braking torque – The motors are turned off and all brakes are fully applied (using the braking torque specified on the brake input page). Use motors to decelerate conveyor – The motors are used to decelerate the conveyor in a fixed time. The required motor torque will vary for each load case. This method is similar to the operation of a VFD, or DC drive system. Turn motors off & apply the required braking torque for deceleration time – The motors are turned off and the amount of braking torque is determined by the user specified deceleration time. This would simulate a proportional braking control. All load cases will stop in the specified deceleration time, but the required braking torque would vary with each load case. If the drift time of the conveyor is less then the specified deceleration time, then the applied brake torque is zero and the belt will drift to rest. If the required braking torque is above 100% of the


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user input value, then only the input value is used and the belt will stop in the time calculated for this torque (i.e. longer then the user specified value since the brake can only apply 100% torque).

These option buttons are used to specify the deceleration time of the conveyor in a power failure, or emergency condition. On many conveyors this will be the same as the operational stopping method. However, on more complex conveyors this method will be different. In all cases the motors are offline.

Emergency Stop

Drift Stop – The motors are turned off and the belt is allowed to drift to rest Apply maximum brake torque – The motors are turned off and all brakes are fully applied (using the braking torque specified on the brake input page). Apply braking torque required for deceleration time – The motors are turned off and the amount of braking torque is determined by the user specified deceleration time. This would simulate a proportional braking control. All load cases will stop in the specified deceleration time, however the required braking torque would vary with each load case. If the drift time of the conveyor is less then the specified deceleration time, then the applied brake torque is zero and the belt will drift to rest. If the required braking torque is above 100% of the user input value, then only the input value is used and the belt will stop in the time calculated for this torque (i.e. longer then the user specified value since the brake can only apply 100% torque).


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Receiving Belt Speed / Emergency Stopping Time / Receiving Belt Width – These three inputs are used to determine the material build at the discharge transfer point of the conveyor. The three inputs represent information about the receiving conveyor (i.e. the conveyor onto which the material will be transferred). To determine the worst case condition, the minimum “emergency stopping time” should be entered for the receiving conveyor. I.e. if the receiving belt stops in 5 seconds when fully loaded, but 10 seconds when empty, then 5 seconds should be entered. Sidewinder will then calculate the material build up at the transfer point for each load case. The figure below shows the material buildup for the fully loaded normal friction case when the receiving belt stops in 5 seconds, and has a speed of 2 m/s. In this case the design conveyor has a speed of 3.5 m/s and takes 10 seconds to stop. Under these conditions there will be approximately 1.1 m3 of material buildup at the transfer point.


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4.2.11 Load Points – Feeders and Skirtboard Elements The load point input page contains all relevant information regarding the conveyor loading points. The conveyor can have multiple load points. Input data for each load point can be entered by selecting the load point number button (see highlighted green boxes in image below). Likewise, the user can select the output load point information by clicking the respective load point button.

It should be noted that “Pullout” forces are ONLY included if the users specifies them in the “Load Conditions” input table (shown below). Entering “1” would include pullout forces for loading point #1, “2” would be for loading point #2, or “1,2,3” would be for loading points 1,2, and 3, etc.


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This input group is used to calculate the material volume above the hopper opening (yellow area shown on the pullout force plot). This volume is then used to calculate the vertical load, and in-turn, the required material shear force. The material shearing force is equal to the vertical force x 0.8 x the SIN of the internal friction angle (material input page).

Pullout Forces

For example: If the volume of material above the slot was 5 m3, the material density was 950 kg/ m3, and the internal friction angle was 50 degrees, then the additional pullout force would be:

(5 * 950 * 9.81) * 0.8 * SIN(50) = 28.5 kN Slot Length – Length of the slot opening where material is discharged. This value is used to calculate the material volume above the slot, and thus the pullout forces. If left blank, and the conveyor is less then 20 m (assumed to be a feeder belt) Sidewinder will default to 80% of the element length. Otherwise Sidewinder will use 1/3 of the element length (with a maximum slot length of 2 m). When possible, the user should specify the actual slot opening length to more accurately determine the material volume and vertical loading. Slot Width at Front – The slot width at front of feeder is used to calculate the material volume and the material cutoff height (below). The default value is 2/3 the belt width for troughed idler sets, and the belt width minus the required edge distance for single roll sets. Material Buildup Angle – Material build up angle is the angle which will be used to calculate the vertical material volume and shear load under the hopper. This area is shown in yellow on the “Load Pt” output page. Use a value of 90 degrees for a conservative design. In this case the "Material Cutoff Height” input below will default to 2.5 times the above slot width. CEMA 6th edition uses an angle which varies from 70-85 depending on the material properties. The default value is 90 degrees.


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Material Cutoff Height – This value affects the total volume of material above the slot, and thus the vertical load and resulting pullout shear forces. This input will default to 2.5 times the slot width for a buildup angle of 90 degrees (above).

This input group is used to calculate the forces on the sidewalls. This is true for both the hopper/slot skirtboards, and any external skirtboard elements. For external skirtboards the sidewall force is:

Skirtboard Forces

Force = mu * K * Density * g * Skirtboard Length * Material Depth * Material Depth External Sidewalls

Where: mu = Coefficient of friction between material and sidewalls - TAN (Wall friction angle) K = Pressure ratio g = gravity Skirtboard Length = Length of external skirtboard, or element length for skirtboard only elements Material Depth = Depth of material against the skirtboard The Sidewall forces under the hopper/slot opening are similar to those above. However, in this case the vertical load of the material (yellow volume) increases the sidewall pressure.

Force = mu * K * (2 * Fv + Density * g * B* Skirtboard Length * Material Depth) * Material Depth / B Hopper/Slot Sidewalls

Where: Fv = Vertical Force of material above slot B = Average Hopper opening width Material Depth on Skirtboards – If left blank, this value will be calculated using a zero degree surcharge angle. This results in the maximum depth of material on the sidewalls. The material depth is used to calculate the normal force on the sidewalls. Skirtboard Friction Factor – Friction factor (mu) of material against the skirtboard walls. Where: mu = TAN(Wall Friction Angle). The default value is 1.0 (i.e. a wall friction angle of 45 degrees) Pressure Ratio – Ratio of the vertical force to the sidewall force. For vertical walls, this value varies from 0.4 for free flowing material, to 1.0 for an initial surge filling. For diverging walls this value can be calculated from:

K = (1-SIN(angle)/(1+SIN(angle))

Where: angle = Materials effective angle of internal friction.


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If left blank, this value will default to 0.65. However, if the conveyor is fully-skirted or has long skirtboard sections, a value of 0.40 may be more realistic (although less conservative). It should be noted that this method is identical to the CEMA 5th method. The CEMA method also assumes a wall friction angle of 45 degrees (i.e. the skirtboard friction factor is equal to 1.0), but it combines the material density and effective internal angle of repose into a single value. This is published as a lumped “Cs” factor. In our opinion, this “Cs” factor is hard to understand, and it makes more logical sense to enter these values individually. However, for users who want to use the standard CEMA method, the table below lists all CEMA materials and their corresponding Cs factor.

To achieve the same Cs factor using Sidewinder, the user can leave the skirtboard friction factor blank (i.e. default value of 1.0) and then enter the “Pressure Ratio“ factor from the table. For


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example if “Iron Ore” were used, instead of entering a Cs factor of 0.276, the user would enter the pressure ratio as 0.199. The default pressure ratio of 0.65 will normally result in a more conservative design then CEMA. Skirtboard Length – Length of the skirtboard that is past the end of the opening slot length. Skirtboard Width – Used to calculate the material depth on the skirtboards. Default value is 2/3 of the belt width. Skirtboard Seal Drag – Factor to account for the rubber seal drag between the skirtboard and the belt. The CEMA default value is 3 lbs/ft (44 N/m) for each side. Sliderbed Friction Factor – This is assumed to be installed under the length of the slot opening. The slider bed force will then be calculated as:

Slide Bed Force = mu * Vertical Load

Where:

Vertical Load without Pullout Forces = Slot Length * (Wm + Wb) Vertical Load with Pullout Forces = Total vertical load used in the shear calculations

(yellow volume shown on plot) Enter a value here if a slider bed is used. The slider bed force will then be calculated using the vertical load times this friction factor. Common values are:

UHMW Polyethylene = 0.55 Urethane = 0.84 Steel = 0.92 Wood = 1.00

Initial Material Speed – This term is used to calculate the acceleration forces of the material. The default value is 0 (i.e. the material must be fully accelerated from rest).

Advanced Conveyor Technologies, Inc. 19415 594th Ave - Mankato, MN 56001 - U.S.A. Phone: 507-345-5748 e-mail: [email protected]

4.3 Preference Window This window is where you input your preference and default values for Sidewinder. This window is through the “File” menu and then “Preferences,” as below:

The preference window is shown below:

To save changes, press the Save button. Pressing the Cancel button will discard any changes made.

4.3.1 System Preferences System preferences define your location, language, and units.


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A. Default system units Defines the default units to be used. Note that input/output units can be changed at any time by pressing the Units button ( ) on the button strip. Input and outputs are always labels to clearly show which system is being used.

B. Country / Location Define your default location. The location affects default values when you leave input blank. For example, standard belt widths are different in Europe than in North America. So if you leave belt width blank, Sidewinder may select different belt widths depending on location.

Location is overridden by the input Location in the Design Criteria table. The Location input in the preference window will set the location in a newly created Sidewinder file.


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C. Imperial units show belt tension as If you are using Imperial units, Sidewinder will show belt tensions in lbs or in PIW. Tension units in kip Tension unit is PIW

D. Default idler methodology This option sets the default method for calculating idler load and life in a new file, which can by Universal or CEMA. The actual method is always determined by method selection on the Idler Input Data window:

4.3.2 Language Sidewinder currently supports English, Spanish, Portuguese, and Finnish. Select your default language with the pull down list.

If you select a language other than English, you may switch between English and your selected language by pressing F8. AC-Tek makes no claims or guarantees regarding the correctness of the language translation. It is the end user’s responsibility to ensure that the translation is correct. You must agree to this before switching to another language.


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Many of the translations take more space in the input/output fields. Sometimes a label will get cut off because its length is too long. An example is the Material Mass on the load case summary, which is abbreviated in English as “Mat. Mass.” In Spanish, this label gets cut off and it may be unclear. If this happens, you may expand or maximize the Sidewinder window to enlarge the label’s width. Below the expanded label widths are shown:

English Spanish – Default window size Spanish – Sidewinder window expanded

4.3.3 Belting Belt Speed Input Method (also see section 4.1.2)

This option determines how the belt speed input is defined, which affects how the reducer ratio is selected. If “100 Motor Nameplate” is selected, Sidewinder will assume you want the input belt speed at 100% motor nameplate. Therefore, the reducer ratio is selected so that the actual belt speed will be equal to the input value at 100% motor nameplate. If “Fully Loaded Case” is selected, Sidewinder will assume you want the input belt speed at the Fully Loaded Case. Therefore, the reducer ratio is selected so that the fully loaded – nominal load case (FL-N) belt speed equals the input speed. This option is meaningless if you input the reducer ratio. For example, assume the following conveyor:

Length = 300 m Lift = 70 m Tonnage = 1000 T/H Belt width = 1000 mm


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Si = 1 x 3 m Motor = 500 kW coupled to fluid coupling (extra 2% slip) Belt speed input = 3.2 m/s

The motor utilization is approximately 50%. If you select “100% Nameplate” the actual belt speed will be higher than 3.2 m/s due to the motor slip and low motor utilization. Sidewinder selects the reducer ratio so that the belt speed will be 3.2 m/s at 100% motor torque. Below, the output is shown for this case. The belt speed is 3.26 m/s and the reducer ratio is 24.390:1.


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If you select “Fully Loaded Case” in the preference, then the output belt speed is 3.2 m/s. Sidewinder is selecting the reducer ratio so that the fully loaded – nominal friction case will have a belt speed equal to the input belt speed. The reducer ratio is 24.830:1.


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4.3.2 File Preferences File Preferences are shown below:

A. Default directory for new files

Press the “Locate” button to set where a new file will be saved.

B. Create a backup file when opening a file (.swb) If this option is checked, Sidewinder will copy the current *.swi file to *.swb when you initially open the file.

C. Add revision number to filename for new files This option tells Sidewinder to check “Add Revision to Filename” in the Info page when creating a new file.

D. Show tool tips for input data values This option tells Sidewinder to show tool tips on input labels. Below is an example tool tip.

The tool tips are a quick and easy way to understand input values.


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E. Auto save file This option will auto save you Sidewinder file every 10 minutes. Note that the current file is overwritten when it is auto-saved.

F. Save on Calculate Option The option tells Sidewinder whether or not to save the current file when you recalculate. The first option “Automatically save file” will save and overwrite the current file. If you use this option, it is a good idea to check “Create a backup file when opening a file” since the current file is overwritten. The second option will prompt you to save (and overwrite) the current file. The last option does not save the file upon recalculating. Remember to save the file before exiting Sidewinder!

4.3.3 Report Preferences Report options are discuss in Section 7 (Report).

4.3.4 Shaft Design Preferences The options in Shaft Design Preferences set initial design criteria values in the Pulley & Shaft Input Data table. The preference input values are shown below:

When you create a new file, they will be used in “Pulley & Shaft Input Data”:


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5.0 Conveyor Profile and Geometry This window can be opened by clicking the button on the tool bar. It consists of 4 tabs:

1. Vertical Profile 2. Conveyor Profile 3. Horizontal Profile 4. Ground Profile

The “Vertical Profile” and “Conveyor Profile” are always visible. However, the “Horizontal Profile” and “Ground Profile” are only visible if the checkbox “This conveyor has horizontal curves” in “Horizontal Curve” in the main input window is checked (Figure 4.3a).

Checkbox to access to Horizontal and Ground Profile tabs The conveyor geometry is input in the “Vertical Profile” and “Horizontal Profile” tabs. These two tabs allow the user to enter the conveyor geometry in terms of intersection points, pulley arrangements, idler spacing, and special elements. Sidewinder then automatically builds the final conveyor geometry and places the results in the “Conveyor Profile” tab. The carry strand is the first to be entered. The vertical (and horizontal, if applicable) profiles are input as intersection points (IP). A radius is input at each vertical IP. Sidewinder will automatically determine if the radius is convex or concave, depending on the incoming and outgoing slopes. Sidewinder simplifies the return strand with the special “Return” element. This element creates the return strand by offsetting the carry elements. The user defines the end point of the return element. Multiple return elements may be used.


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5.1 Vertical Profile The “Vertical Profile” tab is where the vertical profile of the conveyor in entered. There are three main panels. The first is a spreadsheet format where the geometry is entered. The bottom window is a plot of the conveyor geometry. On the right hand side are various buttons and options for controlling and entering the geometry data.


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5.1.1 Geometry Input The vertical geometry input spreadsheet has 12 columns. You may right-click on each column, which will present a column-specific context menu. The geometry of the conveyor is entered as IP (intersection point). The first point is always (0, 0) and subsequent points are the IP points. A radius may be entered at each IP point. Each element consists of station and elevation (location of IP point), length and height, radius at IP point, and element type.

The element length and station are the projected length of element on the x-axis. The figure below shows an example conveyor profile. The first element has a length of 100 m and a height of 15 m. The true length is 101.1 m. The length and height input of element 1 is therefore 100 and 5 m respectively.

Conveyor Profile

Element Input


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A. Station

This is the station of the element. Station is at the beginning of the element.

B. Elevation This is the elevation of the element. The station is at the beginning of the element.

C. Element Length This is the length of the element.

D. Element Height This is the height of the element.

E. Slope There are really two columns for slope; the first is slope in degrees, and the second is slope in grade (%). Double clicking on the column header will switch between degrees and percent grade. Alternatively, expanding or maximizing the Sidewinder window will show both columns.

F. Radius Enter the radius at the IP. Positive radius means convex curve. Negative radius means concave curve. As you move through the elements, the allowable radius is shown in the small panel just below the spreadsheet. Also shown is the allowable radius assuming the radii of the two adjacent IP’s are set to zero. Sidewinder will not allow you to enter a radius that will not fit.


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Allowable Radius

G. Element Type Element type is further detailed in the next section. This column is used to set elements to special types such as a pulley, motor, etc.

H. Belt Load % This column is only applicable if the element is a loading point. It is the percentage of design tonnage that is placed on the belt at the loading point.

I. Extra Acc Type You can add an extra accessory on an element. By default Sidewinder places one belt cleaner on the head pulley. If you have more than one belt cleaner, add them in this column.

The extra accessory can be: 1. SBC - Single belt cleaner


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2. DBC – Double belt cleaner 3. TBC – Triple belt cleaner 4. NBC – Force no belt cleaner: This prevent Sidewinder from adding the default belt

cleaner 5. SVP – Single V-Plow 6. DVP – Double V-Plow 7. MDP – Material discharge plow 8. BS – Belt scale 9. TI – Training Idler 10. MS – Magnetic Separators

K. Pulley Wrap Enter the pulley wrap angle. If “Auto Calculate Wrap Angle” is checked then the wrap angle is auto calculated according to the two adjacent elements.

It is best to add a normal element (i.e. not “Return”) after a pulley so that the wrap angle is calculated correctly. If a “Return” element is placed before or after a pulley, then Sidewinder must guess at the element slope and so the calculated wrap angle may not be correct. Right click on the wrap angle of a pulley to bring up the wrap angle context menu. Here you may specify the pulley diameter and whether the wrap is clockwise or counter-clockwise. If Sidewinder incorrectly places the wrap direction, you may force the correct wrap direction by typing “1” for clockwise, and “-1” for counter-clockwise in the wrap angle column. Sidewinder will then auto-update according to the direction input.


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L. Pulley Type ID Pulleys are grouped by type. All pulleys in a group have the same properties (i.e. diameter, lagging, etc.). Pulley dimensions and specifications are defined in the main input window, in the “Pulley / Shafts” tab. The pulley diameter and lagging thickness can also be set by right-clicking on the pulley ID cell.


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5.1.2 Element Type Figure 3.4.1a shows the element table with the element type context menu. This context menu is obtained by selecting the “Element Type” column and then a “right click” on the mouse. The element type may also be selected by a pull down (Figure 3.4.1b) menu, which is activated by clicking on the element type cell.

Figure 3.4.1a Element Type Selection via Context Menu


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Figure 3.4.1b Element Type Selection via Pull Down A. Normal This is a normal element with a length and height. B. Loading Point Material is loaded onto the belt at this location. Material acceleration force is added to the calculation based on the change in “Belt Load %” column. Multiple load points are okay. The picture below shows a conveyor with 4 load points where 25% tonnage is placed at each load station. Skirtboards are placed between each load point.


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The loading plot for the above conveyor is shown below. The “load line” (in blue) is adjusted downward to show partially loaded (i.e. <100%) elements.

Load points may also be placed on the return strand. An example of this is “complex.swi” (can open via Help Demo Examples Horizontally Curved Conveyor System). The figure below shows a load point on the return strand. For load points on the return strand, material acceleration is only added for load cases which the return strand is indeed loaded.


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C. Loading Point (Reverse Direction) This element type is for reversible conveyors. The figure below shows a reverse load point. Material acceleration is only added for reversible load cases. However, drag force due to skirts is added in both forward and reverse load cases.


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D. Side Skirtboards on Element This element is for sections where material is not being added but there are skirtboards. Additional sliding forces are added for skirtboard elements. E. Flat Transition Section This is a “flat transition,” or sometimes called a “full trough transition.” This element type may be placed at either tail or discharge pulleys. Placing this element type will cause Sidewinder to calculate the stresses and idler configuration for the length of this element.

F. Elevated Pulley Transition Section This is an “elevated pulley transition,” or sometimes called an “elevated trough transition.” This element type may be placed at either tail or discharge pulleys. Placing this element type will cause Sidewinder to calculate the stresses and idler configuration for the length of this element.

G. Pulley This is a pulley. You must also enter the pulley type in “Pulley Type ID” column. The “Pulleys / Shafts” tab on the main input page will have input columns for the maximum number of pulley types entered in the element page. For example, if you enter “4” for a pulley type in the “Pulley Type ID” column, then there will be 4 input columns in “Pulleys / Shafts” tab. All pulley information, including diameter, is entered in the “Pulleys / Shafts” tab in the main input. H. Pulley & Backstop This is a pulley with a low speed backstop. I. Take-up Pulley This is the location of the take-up. You must enter one and only one take-up. Take-up type is specified in the “Take-up Input Data” on the main input page.


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J. Motor Set the element type to “Motor” for all motors. K. Motor & Brake Set the element type to “Motor & Brake” for all pulleys that have both a motor and brake. L. Motor & Backstop Set the element type to “Motor & Backstop” for all pulleys that have both a motor and a backstop. M. Motor & Brake & Backstop Set the element type to “Motor & Brake & Backstop” for all pulleys that have a motor, brake, and backstop. N. Motor & Take-up This is for a pulley that is both motor and take-up. The take-up type must be gravity. O. Brake This is a brake-only pulley. P. Brake & Backstop This is a pulley with a brake and a backstop. Q. Helical Turnover Set the element to “helical turnover” at the location a simple helix turnover with no supports at the ¼ and ¾ positions. The length of this element will be length of the turnover in the calculations.

R. Helical Turnover with ¼ Roll Supports If a turnover has ¼ and ¾ support rolls, then use this element type. The length of this element will be length of the turnover in the calculations.


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S. Return Element The return element is a special element that follows the carry strand back to the tail pulley. This element is especially useful on conveyors with vertical curves. This element matches the carry side elements with a vertical offset as entered in “Return side offset” (lower right input grid). The “return” element matches the carry strand up to the coordinate in the following element. For example, entering (0, 0) in (station, elevation) in the element after the “return” element will cause the whole return strand to be made. The figure below shows an example Return element. It is placed between the head pulley and return pulley.

Please note that if the “return” element is placed adjacent to a pulley, then the wrap angle of the pulley may not be auto-calculated correctly. In the example above, the head pulley (with a motor) shows a wrap angle of 166 degrees, which is not correct. The inaccuracy has to do with the many possibilities that the return element can encounter. To correct the wrap angle error, simply add an element before and after the “return” element. The figure below shows the correctly input return strand.


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Multiple return elements may be placed on the return strand. An example of when this is necessary is with a tripper. The figure below shows a conveyor with a tripper. The return strand is incorrectly entered as single element. The return strand follows the tripper and is therefore incorrect.


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The figure below shows the return strand correctly entered with two “return” elements. The first “return” element goes to point (125, 2.5). The following element then has a length of 40 m which goes underneath the tripper. Then a second “return” element is entered to finish the return strand.


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5.1.3 Element Context Menu, Quick Buttons, and Short Cuts The input spreadsheet has several macros to operate on the conveyor elements and rows. The following two figures show the element table context menu and quick buttons. The context menu is obtained by right-clicking any of the first seven columns (# to Radius).

Element Context Menu


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Element Table Quick Buttons The quick buttons can also be run by keyboard shortcuts as shown in the table below:

Shortcut What is does Ctrl-A Insert a row Above current select row Ctrl-B Insert a row Below current select row Ctrl-F Insert 5 rows Below current select row Ctrl-D Delete selected row

Ctrl-J Adjust current flight so that last flight meets first flight – See Section 5.1.4

Ctrl-M Combines current row + next row Ctrl-X Brings up “Divide Element Options” context Menu

Ctrl-C Copy element table to the clipboard (to paste in excel, etc.)

Ctrl-Z Undo (sometimes several “undos” are required to undo the last operation)


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5.1.4 Enter Dimension from Pulley Centers Often times the distance between pulley centers is known. For example, in the figure below, the distance between pulleys is known. However, in Sidewinder you must enter the element length between pulleys.

To auto-calculate the element length and height, first add the two pulleys and the element between the pulleys. Then select “Element Dimensions from Pulley Centers” from the element table context menu. Enter the horizontal and vertical distance between pulleys and then select the correct line (shown by color). There are four lines since there are four possible solutions. Sidewinder will then update the length and height for the element, which, for the example, is (-1.08, -0.13).


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5.1.5 Adjust to End (Ctrl-J) This shortcut adjusts the current flight so that the last flight meets up with the first flight. This short cut is only meant to be used on the return side. The following table explains how this shortcut works depending on the element type.

Element Type What is does: Normal element Adjust length and height of current flight so that first and last element match

Return Adjust the special “return” elements to match end and beginning “Normal” following

“Return” Adjust the special “return” elements to match end and beginning

“Pulley” Nothing

5.1.6 Divide Element Option The Divide Element Options dialog can be opened by “Ctrl-X”, the element context menu (right-click), or by pressing the button. The dialog is shown below:

There are five options for dividing an element. A. Divide into N equal elements (Ctrl-1)

This option divides the current element by N equal length elements.

B. Divide into two elements (Ctrl-2) by first element length This option divides the current element into two elements. The first elements will have the specified length.


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C. Divide into two elements (Ctrl-3) by second element length

This option divides the current element into two elements. The second elements will have the specified length.

D. Divide at station length (Ctrl-4) This option divides the current element into two elements at the specified station.

E. Create Point of Intersection (Ctrl-5) This option finds the point of intersection (IP) of the two adjacent elements. It then deletes the current element and extends the adjacent element to the IP. For example, suppose the conveyor in the figure below requires a vertical radius of 100 m. Due to the short length of element #4, the maximum radius is only 45 m.

Therefore element #4 is “divided” with option 5, with the results shown in the following figure. Now the 100 m radius can be entered.


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5.1.7 Move Point of Intersection Sidewinder allows you to move an IP (point of intersection) point in the element table without changing the adjacent IP’s. This can be done with the Move IP buttons

or by the graphical method:

If you use the Move IP buttons, simply select the element and press one of the arrows according to the direction you wish to move. Remember that the IP is at the beginning of the element. The two input boxes define the distance that the IP will move. You may change the distance in either box. The default distance is 1 vertically and 10 horizontally. The graphical method is accessed by right-clicking in the profile plot and then selecting Move Point. The mouse cursor will then change to move IP cursor ( ). Position the mouse over an IP and then drag the IP to the desire point.


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This function is especially useful for aligning the conveyor profile on top of a ground profile that has been imported on the “Ground Profile” tab. The plot below shows the conveyor profile and the ground profile (purple line).

The IP was move with the graphical method. Below is the result:

5.1.8 DXF Import The dxf import dialog window is an easy way to transfer the conveyor geometry from a CAD program. Understanding the import method will facilitate importing the profile from CAD. Sidewinder expects to find a single polyline in the dxf file. When Sidewinder reads the DXF file, it searches for a polyline. It will attempt to import the first polyline it finds. Everything but the first polyline is ignored. The polyline can have the following:

1. Straight lines 2. Radii for vertical concave and convex curves. Any radius greater than 9 is assumed to be

a vertical radius. 3. Radii for pulleys. Any radius less than 9 is assumed to be a pulley.

The polyline should be drawn from the tail to the head in the direction of belt velocity. In the simplest form, the polyline can be a series of straight lines. An example of such is line is below:


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The polyline is 4 segments. The figure below shows the dxf dialog import for this dxf file. The lines are imported. Each vertex is made an intersection point.

This is the imported geometry:


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You may also draw the radii into the CAD file. The figure below shows the same example above except that the radii are drawn in the polyline.

The dxf import dialog now imports the polyline with the radii:


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You may also draw the pulley in the polyline. Pulleys at the head have now been added to the polyline and imported. Note that the pulleys are correctly imported. Pulleys of the same diameter will be the same type. After importing, you will have to change pulleys to motors, take-up, etc.


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A. Import Options

There are four import options:

The first option “Overwrite current profile” simply deletes ALL current elements and then imports the new profile. This is the default option. The second option “Insert as carry side” deletes all elements before the first pulley and then imports the new profile from the dxf file. This option is very useful if you need to change the conveyor profile, but pulleys and the return strand remain the same. The third option “Insert elements at beginning of current profile” adds the imported elements at the beginning of the current profile, so the existing elements are not deleted. The last option “Insert elements below the current location” adds the imported elements below the currently selected element.

B. Import Scale Sidewinder allows you to change the importation scale. The conveyor profile is normally drawn in mm (metric) or in inches (imperial). However, Sidewinder expects units of meters or feet. The dialog window has options for the most common scales. You can also enter a custom scale. A scale of 1000:1 means that the drawing is in mm but will import as meters, so the imported lengths will be divided by 1000.

The x and y scale do not have to be the same.


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C. Import Option – Mirror Conveyor

In Sidewinder the tail end is at the left and the head is at the right (conveyor runs from left to right). If the drawing of the conveyor is drawn right to left, then use the “Mirror Conveyor” option to mirror the profile. Below is an example of a conveyor profile that was drawn from right to left. Note that the dialog box shows the first point with a blue start and the last point with a green triangle ( ). This is to help see how the profile was drawn.

The imported geometry is shown below (without Mirror Conveyor option). Notice that the profile is backwards and the lengths are negative.


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Checking the Mirror Conveyor option will import this profile correctly.


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D. Import Option – Reorder Conveyor If you draw the polyline backwards (from head to tail), then use the “Reorder Conveyor” option to change the order of the elements. This option will make the last point the first point, and the first point the last point. Below is a profile that was drawn backwards. Note that the green triangle ( ) is on the left, and the blue start ( ) is on the right.

Checking the “Reorder Conveyor” fixes the order.


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5.1.9 CSV Import The csv import dialog is the same as the dxf import dialog. The only difference is that data is imported from a csv (comma separated) file. The csv file must contain two columns. The first column must be Station of the element, and the second column is the Elevation of the element. Below is a csv file showing the correct format for importing:


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5.1.10 DXF Export The conveyor profile may be exported to dxf file format that can be read by CAD programs. To export, simply press the “Export Profile to dxf” and then select the file location and name. The default name is the name of the Sidewinder file with the dxf file extension. Sidewinder exports the following:

1. Polyline with conveyor IP points (layer PROFILE-IP) 2. Polyline with vertical radii (layer PROFILE-VC) 3. Polyline with meshed elements (layer PROFILE-ELEMENT) 4. Polyline with ground profile as imported from the Ground Profile table if it exists (layer

GROUND-PROFILE) 5. Pulleys (layer PULLEY) 6. Pulley labels (layer LABEL) next to each pulley 7. Idler geometry (below)


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5.1.11 Idler Spacing Table The Idler Spacing Criteria table allows you to easily define the idler spacing on both the carry and return strands. The table is shown below:

The first four rows define the idler spacing on the carry strand. The 1st row defines the nominal idler spacing on the carry strand. The carry strand is defined as the first element to the head pulley. The head pulley is defined as the pulley with the largest distance from the first element. The 2nd, 3rd, and 4th row should be used to redefine the idler type and spacing on the carry strand for special items. This is mostly used to reduce the idler spacing in curves (vertical or horizontal). Likewise, row 5 defines the idler type and spacing on the return strand, which is the element after the head pulley to the last element. Rows 6, 7, and 8 redefine the idler type and spacing on the return strand for special items. Row 9 defines the idler type and spacing in load points. Row 10 defines the idlers in transitions.


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The columns in this table are used to define where the idler spacing is to be changed from the nominal. A. Radius Column The “Radius <” column is used to change the idler spacing in convex curves. The input value is the largest radius below which all idlers will be set to the specified type and spacing. For example, assume the nominal carry spacing is 1.0 m, but you wish to reduce the spacing to 0.5 m in all convex curves that have a radius less than 1000 m. Then, in row 2 you would enter 0.5 in Spacing and 1000 in the Radius column as shown below:

The result is shown below:


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It is also possible to use multiple rows to put different spacing in different curves. For example, assume the nominal idler spacing is 3. However in convex curves less than 500, the spacing must be reduced to 2 and in curves less than 375 the spacing will be reduced to 1.


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B. Start and End Columns The “Start >” and “End <” columns redefine the idler spacing between the start station and end station. For example, assume the nominal idler spacing is 1.0 but you wish to reduce the spacing to 0.5 between station 200 and 450. Then enter 0.5 in Spacing, 200 in Start > and 450 in End <, as shown below:


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Sidewinder did NOT break up the elements to have an element begin at 200 and one end at 450. You must do this manually (use the Divide dialog – ctrl-x to divide the elements at 200 and 451):


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C. Horz. Curve Column This column works in the same manner as the “Radius <” column except it operates on horizontal curves. The input radius is the largest radius which will be changed. For example, assume the nominal carry spacing is 3.0 m but you wish to reduce the spacing to 1.5 m in horizontal curves than have a radius less than 1750. Then in row 2 you will enter 1.5 in Spacing and 1750 in the Horz. Curve column as shown below:


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D. Start Pulley & End Pulley Column The Start Pulley and End Pulley Columns are used to change idler type and spacing using pulley location. For example if a tripper conveyor has return idler on the carry strand after the tripper, then use enter the tripper pulley number in “Start Pulley” and the head pulley number in “End Pulley”. In the example below, the idler type is changed to 2 (return idlers) and spacing increased to 3 after the tripper pulley:


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E. Combination All four rows (1 to 4 for carry, and 5 to 8 for return) may be used. Priority is given to the lower rows. So if you enter conflicting criteria, then the lowest rows will govern the idler type and spacing. It’s always a good idea to review the Conveyor Profile tab to ensure the selected idler spacing is as you intend. The two tables show correct and incorrect input for changing spacing in two different radii. Correct

This input will put Si = 2 for R>350 and R<450, and Si = 1.5 for R<350

Incorrect

This input will put Si = 2 for all R R<450

You can also combine criteria. For example, if you wish Si=2.0 for R<450 if station < 2100, and Si = 1.5 for R<450 if station > 2100. This is the correct input:


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5.1.12 Show Station Label This option places labels at each point showing the element station.

5.1.13 Auto Calculate Wrap Angles See Section 5.1.1.K for the Auto Calculate Wrap Angle option.

5.1.14 Return Side Offset This is the distance between carry and return strands when the special “Return” element is used.

5.1.15 Maximum Element Size When the conveyor is meshed (in Conveyor Profile), this will be the maximum element length.

5.1.16 Vertical Radius Misalignment Tolerance This number determines how finely meshed a vertical radius will be. It is the maximum distance between an element midpoint and the actual vertical curve arc.

Reducing this value will result in more meshed element in the vertical curves. The default value is 250 mm. Generally, the default value is sufficient, but it can be changed to fit your needs. Below is an example of a convex curve with an 18 degree up and down slope with various tolerances.


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Vertical radius misalignment tolerance = 9 (two elements)

Vertical radius misalignment tolerance = default (12 elements)

Vertical radius misalignment tolerance = 0.05 (20 elements)

5.1.17 Show Imported Ground Line If you have imported a ground profile, then this checkbox will turn on/off the line in the vertical profile line. See Section 5.4.

5.1.8 Element Plot The bottom window of the Vertical Profile tab is the element plot. Left-clicking in the window will bring up a context menu with various options:


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A. Reset View

This option will reset the window to the default zoom limits.

B. Pan Pan the conveyor. The cursor changes to a hand ( ) during the pan.

C. Zoom This option zooms in/out with the mouse. The cursor changes to the magnifying glass ( ). Left-click and hold will either zoom in (move mouse up) or zoom out (move mouse down). The current aspect ratio is maintained in the zoom.

D. Zoom Window This option zooms into the selected window. A 1:1 aspect ratio is not maintained.

E. Zoom Window 1:1 Do a zoom window. The final selected view will have a 1:1 aspect ratio. You may also do a zoom window 1:1 by left-click, hold, drag, and then release. When you left-click and drag, the green dashed box-window will appear. When you release the mouse click, Sidewinder will zoom into the chosen limits.


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F. 1:1 Aspect Ratio Force a 1:1 aspect ratio on the current view.

G. Hide Vertical Gridlines Shows or hides the vertical gridlines.

H. Move Point This enables the move point macro. See Section 5.1.7.

I. Divide Element This option will split the current element into two equal parts.

J. Combine Element This will combine the current element. Same as Ctrl-M.

A. Copy to Clipboard This will copy the current view into the clipboard as a bitmap.

5.2 Conveyor Profile The “Conveyor Profile” tab contains the final geometry of the conveyor. The final geometry is defined from the information entered in the vertical and horizontal profile tabs. The data in vertical and horizontal profiles are merged to make the final elements. Most columns in this tab cannot be modified. The exceptions are:

1. Idler Spacing 2. Set # 3. Extra Drag 4. Custom load case columns, which are labeled “Load C1”, “Load C2”, etc. 5. Banking Angle 6. Inside SGRS (Side Guide Roll Spacing) 7. Outside SGRS (Side Guide Roll Spacing)


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The last three columns are only visible if the conveyor has horizontal curves. Very rarely will you need to modify the Idler Spacing. The Idler Spacing Criteria table in the Vertical Profile tab allows the user to sufficiently define the idler spacing for nearly all conveyors. However, the idler spacing may be modified in the Conveyor profile tab. A word of caution

: If you modify any of the columns in the conveyor profile tab and then change the conveyor geometry in the vertical profile tab, you will have to recheck/update the data entered in the conveyor profile tab.


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5.2.1 Columns in Conveyor Profile The columns in Conveyor Profile are similar to those in Vertical Profile. However, intersection points (IP) are not shown as the conveyor has been meshed. A. #

This is the element number.

B. Element Type If the element in not a normal belt section, it is labeled according to its type.

C. Station Station is the projected distance of element on the x-axis. See Section 5.1.1 for further clarification.

D. True Length This is the true length of the element. If it is a straight section: , where l and h are the projected length and height of the element. If it is a vertical curve element: , where R is the radius and is the arc angle of the element.

E. Element Height This is the change in elevation of the element

F. Vert. Radius A concave radius is negative. A convex radius is positive.

G. Idler Spacing Idler spacing is initially defined by the Idler Spacing Criteria table in Vertical Profile. However, the idler spacing may be changed in this column.

H. Set This is the idler type. Idler types are defined in the Idler Spacing Criteria table in Vertical Profile. The idler set may be changed in Conveyor Profile. Specifications of the idler types are defined on the Main Input Page in the Idler Input Data table.

I. Extra Drag The extra drag column is included so that the user may add extra drag or force to the point at any point. This may be for such things as a plow, bad alignment, plug chute, etc. as the user deems necessary.


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J. Acc Type If an extra accessory was defined in the vertical profile, it will be shown here.

K. Horz. Radius If horizontal radii are defined in the Horizontal Profile tab, then they are meshed into the final geometry.

L. Bank Ang. Banking angles are initially set to zero and must be manually entered by the user or by use of the Horizontal Curve Work Page. Banking angle of idlers are always to tilt upwards towards the inside radius of the horizontal curve.

Inside of Horizontal Curve

Inside Side Guide Roll

Outside Side Guide Roll

M. Inside SGRS

This is the Inside Side Guide Roll Spacing. Enter the spacing of side guide rolls on the inside edge of the belt.

N. Outside SGRS This is the Outside Side Guide Roll Spacing. Enter the spacing of side guide rolls on the outside edge of the belt.

The remaining columns are load case definition columns.


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5.2.2 Defining custom load cases Sidewinder allows the user to define five custom load cases. The user adds the custom load case in the “Load Case” input table in the Project Info Page (See Section 4.1.1). Once a custom load case is included in the Load Condition table, a column will be added in the Conveyor Profile tab. The figure below shows a custom load. The User ID and Load Case name may be modified. However, the “Fixed ID” cannot be changed. Custom load cases have the Fixed ID of C1, C2, C3, C4, and C5.

In Conveyor Profile tab, you may define the loading of the custom case. To facilitate the loading, you may right click on the custom load case column to bring up the load case context menu as shown below.

Once you select the desired load case, you may further refine it by manually changing the loading. In the example, the conveyor is loaded from the top of the hill to the head pulley.


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Custom load case


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5.2.3 Cell Selecting Selecting a cell will highlight the element in the conveyor plot. Note that by selecting a cell in the load case definition columns, the profile plot shows which elements are loaded. Dark-blue represents elements on the carry strand. Light-blue represents elements on the return strand. Profile plot showing return strand loaded


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5.3 Horizontal Profile The Horizontal Profile tab allows you to enter the plan (horizontal curves) profile of the conveyor if it is not straight.

This tab is, by default, not visible. To show this profile, you must check “This conveyor has horizontal curves” in the Horizontal Curve tab on the main input page.

There are two grids to allow you to enter the horizontal curve data. If you enter data on one grid, the other grid will be automatically updated. The first grid (left-hand side) contains the intersection points of the horizontal profile. In this grid you enter the (x,y) coordinates of each intersection point and the radius a the IP. The second grid (right-hand side) contains the segments geometry of the horizontal curves.

The Station column is the plan distance (i.e. projected length on a flat plane) and identical to the station in the vertical profile. The horizontal profile plot shows the station at each point along the length of the conveyor. Element Length column is the length of the segment. For a straight segment, it is simply the length or in terms of x,y coordinates:


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L= .

For a horizontal curve, the length is: Where RH is the radius of the horizontal curve, and θ is the included angle of the curve. Arc Angle column is the included angle of a horizontal curve. Radius is the horizontal radius. The Slope column is the angle (in degrees) of the current segment. You can only change the slope if it not between two curved segments. When entering the horizontal curve data, it is best if the slope of the first segment is between -90 and +90 degrees.

Sidewinder does not always interpret data correctly if the slope of the first element is not between -90 to +90 degrees.

Below is an example horizontal profile.

The Sidewinder input for this conveyor is shown below:


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5.3.2 DXF/CSV Import Dialog The horizontal curve profile may be imported from CAD files via a dxf file. See section 5.1.8 for details of dxf importation. Of course, only the horizontal profile is imported on this page. Vertical profile and pulley geometry is imported in the Vertical Profile tab.

5.3.3 DXF Export The horizontal profile may be exported to a dxf file. The dxf file will contain the following:

1. Polyline with intersection points (layer HC_IP) 2. Polyline with horizontal radii (layer HC_R) 3. Text showing the station of each point along the length of the conveyor (layer STATION)

5.3.4 Move Points Intersection points may be modified with the Move Point buttons. These buttons work in the same fashion as the Move buttons in the Vertical Profile tab (see Section 5.1.6)


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5.4 Ground Profile The ground profile allows you to enter the ground terrain in either 3D or 2D. Its main purpose is to facilitate the design of the conveyor profile, both vertically and horizontally. Once the ground profile has been entered on this tab, it can be imported into the vertical profile.

This tab is, by default, not visible. To show this profile, you must check “This conveyor has horizontal curves” in the Horizontal Curve tab on the main input page.

The graphic below shows the Ground Profile tab.

Once the ground terrain has been imported, you can turn on the ground profile in the Vertical Profile tab. To do this check the “Show” checkbox ( ) next to the “Import Ground Line,” button in the Vertical Profile tab. This will show a purple line in the vertical profile plot. The two graphics below show the vertical profile with and without the ground line showing. The cuts and fill required can now be easily optimized in Sidewinder.


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Vertical profile with ground line

Vertical profile without ground line


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5.4.1 2D Ground Profile You may import a 2D ground profile in either the Vertical Profile tab or in the Ground Profile tab. See Section 5.1.7 for importing polylines into Sidewinder. The polyline of the ground profile should run from left to right. The imported ground profile line does not affect the conveyor calculations in any way. In the Vertical Profile tab, the 2D ground profile is imported by pressing the “Import Ground Line” button ( ). In the Ground Profile tab, the 2D ground profile is imported by pressing the “Load 2D Surface Data File” button ( ). After importing the ground line, check “Show” to show the ground line in the vertical profile plot.

5.4.2 3D Ground Terrain Sidewinder can import a 3D terrain model. This allows the user to define both the horizontal and vertical profile within Sidewinder. This is a very powerful tool when designing an overland conveyor in which multiple routes are to be considered. It also facilitates the optimization of the cuts and fills along the length of the conveyor. The 3D terrain model is imported trough a CAD dxf file format. The dxf file must contain the 3D FACE object representing the terrain model. The model has the following requirements:

1. Each 3D FACE object must be square (have four corners and dx=dy) in the xy plane. The z plane represents the elevation of each corner.

2. All 3D FACE objects must be the same size. 3. The grid of the 3D FACE objects should be rectangular. 4. The file must be saved in dxf format.


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Top View of 3D model in CAD

Isometric View of 3D model in CAD

Once you import the 3D terrain, you can enter/import the horizontal alignment (See Section 5.3). The ground profile will then be determined from the 3D model in the Ground Profile tab. Below is an example horizontal profile (this 3D model is an example Sidewinder file in the Help menu).


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The graphic below shows the resulting ground profile.

The 3D model may be rotated, panned, and zoomed. It may be shown as a wireframe, contours, or a solid model. Below is the example in isometric view with a solid model coloring.


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The horizontal alignment can easily be changed, and Sidewinder updates the ground profile. The example, below is an alternate route with the new ground profile.


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6.0 Output Windows The main Sidewinder output window is shown below. The left hand tabs correspond to each individual load case (see section 4.1.3 - Load Conditions). Selecting a load case will show the output values for that condition. The tabs at the bottom show all available output information for each load case.

The “Detailed Output” window ( accessed from the toolbar menu) has the same layout and format. The load case tabs are on located on the right hand side with individual output items at the bottom. However the individual output items contain more detailed information and the windows are full-sized, which allows easier viewing.


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7.0 Report Sidewinder generates a report in the Rich Text Format (RTF). The RTF is a format that most word processors are able to read. The report generation page is reached by pressing the bottom, Ctrl-F, or selecting “Print Report” from the “File” menu.

7.1 Pulley Images The output report includes plots of the pulleys and vertical profile. These plots are adjustable in the report creation page.

Sidewinder will automatically group pulleys together. Normally there are two locations, head and tail. However, if there is a pulley group (such as a tripper or booster drive) in the middle of the conveyor, then Sidewinder will find and group these pulleys. Occasionally, you may wish to add a pulley image to the report. You can add two additional images to a report by checking the checkboxes next to last two image items. The zoom setting for these groups will initially be set for the whole conveyor. You must then zoom into the pulley you wish to be included in the report. The labels on the pulley can be dragged to a new position. The picture below shows the default location of labels.


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To move a label, simply left-click (and hold the left-click down) and drag the label to a new position. During the drag position, the cursor will change from an arrow ( ) to a hand ( ). The image below shows the label being dragged to a new location.

Dragging the labels will clarify the pulley picture:

Right clicking in the pulley plot, will bring up a context menu:

A. Pan

Pan allows you to drag the pulley group and move it to new location on the canvass.

B. Zoom Window This will allow you to draw a box around the area into which you wish to zoom:

C. Zoom This function allows you to zoom in or out.


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D. Zoom All

Zooms all the way out so the entire conveyor is in the canvass.

E. Reset Zooms back to the default limits for the pulley group.

F. Edit Pulley Label Sidewinder places a default name on each pulley. However, you can change the name of each pulley. Place the cursor over the label, left click to bring up the context menu, select “Edit Pulley Label”, and then rename the pulley.

G. Edit Pulley Group Name Sidewinder gives each pulley group a name which is used in the report. These names can be edited by selecting the image name to be changed, and then right-clicking on it.

H. Copy to Clipboard Copy the pulley picture to the clipboard.


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7.2 Profile Image The profile plot can be edited by selecting this option from the drive and pulley images.

As with the pulley labels, the vertical curve labels may be moved (by clicking and dragging) and renamed with the context menu.

7.3 Company Logo Sidewinder will add a custom logo to the output report. The logo is specified in the Preference window, which is opened in the “File” menu then “Preferences”:


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This brings up the Preference window:

To use a company logo, check “Use custom company logo”. To set the logo, push the “Get Logo” button. This will bring up an Open File dialog. Select the graphics file to be used in the output report. It is recommended that the dimensions of the graphics file be approximately 400 pixels. The width and height of the logo does not have to be equal. The preference page also allows you to place the logo at a custom spot in the report. The image below shows the locations of Width, Vertical offset, and Horizontal offset for the custom logo.


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7.4 Editor Sidewinder first makes the report in the RTF format. The RTF report is created in the same directory where the *.swi file resides. After creation, the report is opened in the default editor. The default editor is set in the Preference window, which is opened in the “File” menu then “Preferences”. Check “Use Microsoft Word as the default editor” to make Word the editor. Otherwise, Sidewinder will open the report in a custom word editor. If you select to use Microsoft word but Sidewinder is unable to find it, then Sidewinder will use the custom editor. The image below shows the custom editor. You can modify, print, and save the output report with this editor.

The custom editor has a Help file that can be accessed via the menu.


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7.5 Report Options There are several tables that can be optionally printed in the output report. The graphic below show these options.

Double clicking on grey square will select/unselect all checkboxes. The following sections detail the additional information these options print.

7.5.1 Conveyor Load Cases This will include a graphical plot of the material loading profile for each load case.

7.5.2 Conveyor Load Case Details This option prints the following tables:

1. Maximum Belt Tensions 2. Minimum Belt Tensions 3. Maximum Case Belt Tensions 4. Minimum Case Belt Tensions 5. Demand Power 6. Din Factor and Total Equivalent Mass 7. Equivalent Belt Line Mass Summary Not Including Motor Inertia 8. Stopping Times

7.5.3 Take-up Details A page showing all relevant take-up information will be included in the report.


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7.5.4 Pulley & Brake Details This option prints the following tables:

1. Pulley Shaft Stress Analysis 2. Running Drive Tension by Load Case 3. Required Pulley Diameter 4. Pulley Shaft Geometry 5. Brake Properties (if there is an existing brake) 6. Backstop Properties (if there is an existing backstop)

7.5.5 Vertical Curve Details This option prints the following tables:

1. Summary of Vertical Curve on Carry Strand 2. Summary of Vertical Curve on Return Strand


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7.5.6 Belt Flap Details This option prints a plot of the belt flap along the length of the conveyor. An example plot is shown below. The plot is a summary of all load cases. The green line ( ) is the lower value of belt flap. The purple line ( ) is the maximum flap ratio. So the actual belt flap will lies between these two limits. The x-axis is the absolute station of the conveyor, meaning the carry strand is station 0 to the head pulley station and the return strand goes from the head pulley to 2*conveyor length.

7.5.7 Transitions & Turnover Details This option prints the required dimensions for head and tail transitions.

7.5.8 All Material & Idler sets Some conveyors have more than one material set or multiple types of carry idlers. In the “Cross Sectional Loading” section of the report, only the standard idler and material set (Idler type 1 and 2, and material set 1) are printed. If you select this option, all idler and material type combinations will be printed in the report.

7.5.9 Element Summary Details This option prints the following:

1. Summary of Conveyor Elements Table 2. Summary plot of belt tension 3. Element Tension Table


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8.0 Turnovers Turnovers are used to flip the belt over on the return strand so that the clean side of the belt stays in contact with the return idlers. Turner type and location are specified in the Vertical Profile tab. Sidewinder calculates turnover stresses and sag displacement for either simple helix type turnovers. The turnovers can be specified with or without middle support rolls. Helical turnover without support rolls

Helical turnover with support rolls at quarter points

If turnovers are specified, Sidewinder will calculate stresses and sag for each load case, which is shown in the main output in the Turnover tab. Stresses in belt turnovers are from three main components, which are:

1. Belt tensions 2. Stresses from the twisting: Twisting increases the stress at the edge and causes

compression in the center. 3. Stresses from bending caused by belt sag: Bending increases the stress at the bottom edge

and decreases the stress at the top edge. The maximum stress occurs at the bottom edge in the turnover. The minimum stress occurs in the belt center.


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These stresses are explained in detail in reference paper No. 1.

8.1 Allowable Stresses Sidewinder applies the same criteria for stresses in vertical curves to turnover stresses. The Design Criteria tab in the Info Page is where you input allowable stresses.

“Local Safety Factor Multiplier” defines the allowable stress at the bottom and top edge of the belt in the turnover. “Dynamic Safety Factor Multiplier” defines allowable stress during momentary conditions. The following two formulas are how the allowable safety factor is determined:

Allowable Running S.F. = SF / LSFM Allowable Momentary S.F. = SF / LSFM / DSFM

Where SF = nominal allowable safety factor LSFM = Local Safety Factor Multiplier (Sidewinder default = 1.10) DSFM = Dynamic Safety Factor Multiplier (Sidewinder default = 1.15) For example if the nominal allowable safety factor of the belt is 6.7:1 and Local Safety Factor Multiplier is set at 1.10, then the allowable safety factor at the belt’s edge is 6.09. During momentary condition, the allowable SF is 5.30 is DSFM = 1.15. “Minimum Steady State Stress” defines the allowable minimum stress during steady state condition. The default value is 5 N/mm or 30 PIW. For good turnover design, the minimum running stress should exceed the minimum allowable stress and the maximum stress should be below the allowable as defined above.


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8.2 Turnover Output Turnover stresses and sag are calculated for each load case. These calculations are then summarized for all load cases. The graphic below shows the summary output for turnover stresses and sag.

The top table lists the turnover location, length, and type. The bottom table lists minimum tension and minimum stress, maximum tension and corresponding maximum stress and safety factor of the bottom edge. If a stress does not meet the design criteria, the corresponding cell is highlighted in an orange-brown color, as shown below.


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8.3 Turnover Work Page The turnover work page is included in Sidewinder to allow the engineer to easily and correctly design the turnover.

Calculations and results from the turnover work page are NOT saved.

The turnover work page is reached by selecting “Advanced” and then “Turnover Work Page” as shown below:


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The turnover work page is shown below:

There are three main windows on this page. The bottom left hand window selects the turnover location and type. In the “Calculation Method” option box, the user indicates if the turnover has support rolls at the quarter points. In the “Turnover Select” box, choose the turnover location (head or tail) with the pull-down list and then select the tension range (steady state or momentary). Sidewinder will update the values in “Turnover Length and Tension” input grid based on your selections.

8.3.1 Belt Input Grid The top window has three input grids allowing you to manually change the calculation parameters. The “Belt Input” grid contains the necessary information for the belt. The default values normally do not need to be changed. However, if you wish to see the effect of changing the belt mass, modulus, etc. then you may do so with this input grid. After changing any values, you must press the “Solve” button. A right-click on the “Belt Input” grid will bring up an option to change the belt rating:


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Click on “Change Belt Rating” to automatically update the belt mass, modulus, and rating according the new belt rating. Effective Thickness of Belt is used to determine the bending stiffness of the belt. The default value is set at 1 mm and is normally acceptable. The only time to change this value is if Sidewinder is having convergence difficulty. Length of Horizontal BC (%) is only applicable for turnover with quarter point rolls. This distance defines the location at which horizontal displacement must be zero. The figure below shows this length.

The quarter support rolls reduces the vertical displacement and bending stresses. However, they also force the belt out of the horizontal belt line since any downward displacement also results in horizontal displacement at the quarter point support rolls.


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The figure below illustrates how this boundary condition effects the calculation of a turnover with support rolls at the quarter point. The quarter point support rolls force the displacement in the horizontal and vertical planes to be equal at the support roll location. The displacement plot below is for a 44 m turnover. At x=0 and x=44 m, the vertical displacement is zero. At x=¼*44 (11 m) and x=¾*44 (33 m) the horizontal and vertical displacements are equal because of the support rolls. However, the Length of Horizontal B.C is set at 10% (4.4 m). So at x=-4.4 and x=48.4 m the horizontal displacements are zero. Increasing the horizontal B.C. allows more displacement in the horizontal plane, which then allows higher displacement in the vertical plane. The default value for this boundary condition is 10% of the turnover length, which is a reasonable value for this input.

Turnover Horizontal Displacement

-100

-50

0

50

100

150

-5 0 5 10 15 20 25 30 35 40 45 50

Distance from End Roll (m)

Dis

pla

cem

ent

(mm

)

Vertical Displacment (mm)

Horizontal Displacement (mm)


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8.3.2 Turnover Length and Tension Grid The “Turnover Length and Tension” input grid allows you to change the length and tension range. After changing any values, you must press the “Solve” button.

8.3.3 Plotting Scales The “Plotting Scales” input grid allows you to manually set the plotting scales. The “Number of Divisions in Turnover” is the number of divisions in the turnover length for the numerical calculation. The default value is 100 and does not need to be changed. The rest of the input values define the minimum and maximum values for the y-axis. The output can be plotted by Length or Tension. Plotting by Length is the default. After changing any values, you must press the “Replot” button.

8.3.4 Results and Output The output plots graphically show the results of turnover calculation. The plots in this section are for a 44 m long turnover with a 1500 mm belt with a rating of ST-1000 N/mm. The graphic below shows the stresses in a turnover: Turnover Stress

Turnover Sag


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Good turnover design requires that the stresses in the center of the belt not be compressive (negative) and that the maximum stress be within acceptable limits. The turnover usually has an optimal length in which the minimum stress is maximized. Below is a plot for minimum stress of the example turnover. The steady state tension is 81 kN. Note that the minimum stress is maximized at about 44 m. If the turnover length is less than 33 m or greater than 57 m, the center stresses will be compressive. The second plot shows the safety factor of the bottom edge of the belt. Its optimal length is approximately 45 m to 50 m. Therefore, the best length for the turnover is approximately 44 m. In general, it is best to minimize the length of the turnover to reduce the amount of sag while maintaining positive stress in the center portion and ensuring that the edge stress is at acceptable levels. Minimum Stress at Steady Station Tension


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Minimum Safety factor at Steady Station Tension


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A. Max Stress This tab shows the maximum stress at each length and tension. Stresses are in N/mm or in PIW. The maximum stress occurs at the bottom edge of the turnover. The label and legend on all the plots may be manually moved by left-clicking on the label and then dragging to the desired location.

B. Min Safety Factor The minimum safety factor is simply the belt rating divided by the maximum stress.


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C. Min Stress This plot shows the minimum stress in the turnover which occurs near the turnover and belt center.

D. Sag This plot shows the maximum belt sag of the turnover. Belt sag is the displacement of the midpoint of the belt.


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E. Percent Belt Sag This plot shows the belt sag as a percentage of the turnover length.

F. Results The grid in this tab is simple the numerical results of the turnover calculations.


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9.0 Load On/Off Work Page The Load On/Off Work Page is reached by selecting “Advanced” and then “Load On/Off Calculations” ( ) in the menu.

This will bring up the Load On/Off Work Page:


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Two charts are shown on this page. The top chart shows demand power as the conveyor is loaded from empty to the selected load case and then unloaded to empty. The second chart shows the loading on the conveyor. This work page is especially useful for conveyors with momentary load cases that have multiple inclines and declines. For example, consider a conveyor with a three inclines and two declines as shown below:

This has several momentary load conditions which must be considered. The two worst case loadings are all inclines loaded and all declines loaded. The question then is: How long do these partial loading cases last? The Load On/Off work page answers this question. This work page has three inputs, which are:

1. Calculation Time Step (sec): This is loading step time. Increasing the time will reduce calculation time but output data will be coarser. Decrease the time step to refine output data.

2. Max Allowable Nameplate Power (%): The plot will draw a line at this upper limit and then indicate how much time the demand power exceeds this limit.

3. Min Allowable Nameplate Power (%): The plot will draw a line at this lower limit and then indicate how much time the demand power is below this limit.

For our example, Sidewinder shows both the load case and the demand power versus time as the conveyor loads and unloads. The plot below shows that the demand power is above 100% for 30.4 seconds as three inclines are loaded and then unloaded.


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The plot below shows that the power is regenerative for 147 seconds if both declines are loaded and then unloaded.

The plots also show the minimum and maximum power. Pressing the “Calculate All” button will cause Sidewinder to calculate all load cases. Checking the “Animate Calculations” checkbox will animate the loading and demand power plots showing the conveyor loading and unloading.


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Reference Papers 1 Lemmon, Ryan. (2002), “Local Stresses in Belt Turnovers in Conveyor Belts”, Bulk Material Handling by Conveyor Belts IV – 2002 SME Conference 2 Oszter Behrends Vincent (Dec 1980), “Large Capacity Conveyors - Motion Resistance Evaluation” Mining Engineering, pg 1715-1721 3 K.J. Grimmer and F.Kessler (1992) “The Design of Belt Conveyors with Horizontal Curves” Bulk Solids Handling, October 1992, pp. 557-563

4 CEMA (2007), Belt Conveyors for Bulk Materials, 2nd Printing

5 Phoenix Conveyor Belts (2004), Phoenix Conveyor Belts Design Fundamentals – New DIN 22101 6 Kruse D. & R. Lemmon (2007) “A Comparison Of Various Belt Tension Calculation Methodologies Including Cema 6th Edition” BELTCON 13, South Africa 7 Spaans (1991), “Calculation of the Main Resistance of belt conveyors” Bulk Solids Handling, Volume 11, No 4.

8 Kruse, D. J. (2005), “Data Acquisition Techniques and Measurement Equipment for Belt Conveyors” BELTCON 13, South Africa

9 Kruse, D. J. (2004), State-of-the-Art Data Acquisition Equipment and Field Measurement Techniques for Conveyor Belts SME Annual Convention

10 G. Lodewijks & D. Kruse (1998), The Power of Field Measurements - Part I, Bulk Solids Handling, 3/1998, pg. 415-426.

11 David J. Kruse (2002), Optimizing Conveyor Take-up Systems using Dynamic Analysis and the Implementation of Capstans, Bulk Material Handling by Conveyor Belts IV – 2002 SME Conference

Documents

Sidewinder Manual