Conveyor Design Excel Tool – Motor Power, Belt Tension, Gearbox & Trajectory

Description
Conveyor Engineering Calculator (V12) – Excel Toolkit for Bulk Material Handling

This advanced Excel-based tool is designed for engineers who need a practical, structured approach to conveyor design and reliability screening.

It combines multiple engineering calculations into one integrated system, allowing you to evaluate power requirements, belt tensions, pulley sizing, gearbox selection, and belt construction in a single workflow.

Built from real-world experience in bulk material handling operations, this tool reflects the type of calculations used in mines, ports, terminals, cement plants, sugar mills, and fertilizer facilities.

What This Tool DoesPower & Resistance Calculations

• Installed motor power
• Carrying and return resistance
• Lift resistance
• Effective belt tension (Te)
  
  

Belt Tension Analysis

• Tight side tension (T1)
• Slack side tension (T2)
• Effective tension (Te)
• Take-up tension and load
• Gravity take-up mass estimation
  
  

Gearbox & Motor Screening

• Motor speed selection
• Gearbox ratio calculation
• Motor running and start torque
• Gearbox output torque
• Basic gearbox selection checks
  
  

Pulley Sizing

• Drive pulley sizing check
• Tail, snub, and bend pulley checks
• Pulley sizing linked to belt class and application
  
  

Advanced Belt Selection (V12 Upgrade)

This version includes a structured approach to belt selection:

• Belt construction types (EP, NN, Steel Cord)
• Number of plies (textile belts)
• Fabric rating per ply
• Estimated carcass rating
• Cover thickness (top and bottom)
• Cover grade selection
  
  

Belt Class Range Included:

10, 12.5, 15, 18, 20, 24, 25, 31.5, 40 N/mm

The tool checks whether your selected belt class is suitable based on calculated tensions.

Commodity-Based Selection

Select the material being conveyed and its size class:

• Coal
• Iron Ore
• Manganese Ore
• Copper Ore
• Clinker
• Cement
• Fertilizer
• Sugar
• Aggregate
• Limestone
  
  

The calculator automatically suggests:

• Belt class
• Belt construction
• Number of plies
• Cover thickness and grade
• Minimum pulley diameters
  
  

This significantly improves early-stage design decisions.
Material Trajectory & Chute Design

Includes a built-in trajectory model to support transfer design:

• Discharge trajectory
• Impact location
• Recommended chute position
• Visual trajectory graph
  
  

Useful for improving:

• transfer efficiency
• spillage control
• chute design alignment
  
  

Engineering Dashboard (Printable)

The workbook generates a clean, printable summary dashboard showing:

• Motor power
• Belt tensions (T1, T2, Te)
• Gearbox ratio and checks
• Pulley sizing status
• Belt selection summary
• Sag screening
• Take-up system results
• Commodity and belt class selection
• Trajectory and chute summary
  
  

Designed for:

• internal design reviews
• engineering reports
• client presentations
  
  

What You Receive

A structured Excel workbook including:

• Inputs sheet
• Motor Power calculations
• Belt Tension module
• Belt & Pulley selection
• Commodity-based belt library
• Trajectory model
• Dashboard (print-ready)
• Assumptions and notes
  
  

Who This Is For

This tool is ideal for:

• Mechanical Engineers
• Reliability Engineers
• Conveyor Designers
• Mining Engineers
• Cement Plant Engineers
• Bulk Material Handling Specialists
• Maintenance and Project Engineers
  
  

Important Note

This calculator is intended for preliminary engineering design and screening purposes.

Final design decisions should always be verified against:

• manufacturer specifications
• applicable standards
• detailed engineering calculations
  
  

Why This Tool Is Different

Most spreadsheet tools only calculate one aspect.

This tool integrates:

• mechanical calculations
• belt selection logic
• application-based recommendations
• visual outputs
  
  

into a single, practical engineering workflow.