Conveyor Engineering: Overland Conveyor Design using BeltStat

About Beltstat

Since 1981 Conveyor Dynamics Beltstat has been used for design and analysis of overland conveyor systems, today BeltStat is continuously updated and able to output the most relevant conveyor parameters by using a free body dynamic model to quickly provide:

  • Belt Tensions
  • Required Power
  • Starting/Stopping Times
  • Starting/Stopping Torque

The greater lengths and capacities of today’s conveyors require tools that go beyond the traditional catalog guidelines traditionally used by designers, at CDI by building numerical simulation on top of the CEMA Algorithm, BeltStat is able to calculate conveyors using CEMA 7 and DIN 22101 Standard which works well for shorter conveyors, the software also includes a house developed hybrid model which mixes both standards and internal developments called CEMA7-DIN 22123 Hybrid solver.

Make sure to have a windows machine available, Download the latest version of BeltStat and log-in with your credentials. If you don’t have a license, feel free to contact me on and I can send you a trial username to test the software for 7 days.

IMPORTANT DISCLAIMER: as any software tool, the experience of the designer is one of the key elements to reach a sound design or conclusion; garbage in garbage out.

In this article we will build and evaluate a brand new conveyor in Peru that was not able to start after being commissioned, a common problem at many new and old sites that can be quickly evaluated using Beltstat. The following picture shows the conveyor diagram with a general outline of the components and the profile of the conveyor that we can use to build our model.

Getting Started

After getting the software installed and reading the software manual we can start by selecting one of the prebuilt conveyor profiles and entering distance between centers, design tonnage, belt speed and general conveyor information. After clicking ok, the resulting conveyor will be shown on the geometry view port with a table showing several parameters that we will use to refine our model:

  • Beltstat Quickstart Screen

While quick start profiles can be useful, I personally like to draw each individual section using the mouse, starting from the tail pulley and drawing each each individual section (alternatively, BeltStat allows importing a dxf) using the Insert Station Button and then clicking on the viewport:

Once reaching the head station, we can make one additional section and change its flight ID to DRV pulley which will generate the head pulley we needed, we can set diameters and wrap angle as required, before continuing to the take up section of the conveyor with all of the required pulleys:

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