Understanding dynamic analysis in conveyor system design: Expert insights from ROXON
How advanced simulation transforms conveyor safety and optimization for long-distance belt systems
When it comes to designing modern large-scale conveyor systems, spanning over many kilometers, the difference between static and dynamic analysis can mean the difference between safe, efficient operation and catastrophic failure. Dynamic analysis is a sophisticated engineering method that simulates how conveyor belts behave during transient events like starts and emergency stops. For long overland conveyors, it’s not optional — it’s essential for safety and performance.
Teemu Lahti, Manager for Projects & Modernizations at ROXON, explains why dynamic analysis has become essential for modern belt conveyor design.
What is dynamic analysis?
“Historically smaller conveyors have been designed using static calculation methods, which assume that the system is in a steady state running smoothly without changes. Dynamic analysis considers time-dependent behavior and goes much deeper into detailed and precise analysis of how belt elasticity and transient events affect in all operational situations,” explains Lahti.
Unlike traditional static calculations that treat the conveyor belt as a static element, dynamic analysis recognizes the belt for what it truly is: an enormous running rubber band stretched under tremendous tension.
“You can think of it as a rubber band that’s tensioned with enormous force, and suddenly when major changes in tensions occur, for example 3 kilometers away from the take up system, what happens then on the band?” Lahti illustrates. “Belt is like a series of springs that behaves in a certain way, and extremely complex mathematics are required to determine what happens there.”
The analysis simulates force changes at every point along the belt at every moment in time during all critical events like starts and stops. This level of detail becomes crucial when dealing with the massive forces involved in modern conveyor systems.
When do you need dynamic analysis?
An easy answer would be always, but as a rule of thumb, one could say that dynamic analysis becomes essential when:
- Conveyor length exceeds one kilometer
- Complex geometric configurations exist (for example steep downhill followed by steep uphill)
- High-capacity systems are in operation
“If we’re talking about conveyors over one kilometer, there’s always reason to contact ROXON and discuss whether there’s a need to do dynamic analysis, and what alternatives there are to optimize the equipment,” Lahti advises.
The technical challenge
The mathematics behind dynamic analysis are formidable. Lahti shows reports exceeding 300 pages of calculations as an example. “That’s where I feel I can add value – I can explain these down-to-earth results forward to design, what we actually need to do.”
This translation from complex mathematical models to practical engineering solutions is crucial for customers. Precise analysis enables optimal equipment sizing – robust enough for safety but not wastefully over-engineered. Get the sizing wrong in either direction and customers pay the price: undersized equipment creates safety risks, while oversized equipment wastes money on unnecessary capacity.
“At ROXON, we believe complex mathematics is worthless if we can’t explain it clearly. Our job is to make the customer’s life as easy as possible – that means translating technical complexity into practical solutions they can understand and act on.”
Why static analysis isn’t enough
Traditional static analysis analyzes the system in steady state, missing the dynamic forces that occur during real operation. For large systems, this gap matters.
“Dynamic analysis typically increases calculated forces by about 10%,” Lahti notes. “The final dimensioning values come from there.”
Beyond equipment sizing, dynamic analysis determines crucial operational parameters like optimal start and stop times to keep forces within safe limits. Emergency stop, aborted start and PLC-failure are typically the worst-case scenarios that will happen during the equipment’s lifetime, and these events must also be safe.
The safety and business case
For customers wondering why they should invest in dynamic analysis, Lahti’s answer is clear: “When talking about large equipment, it’s absolutely not a cost to investigate them thoroughly with dynamic analysis – it’s an absolute prerequisite to achieve an optimal solution that works safely and produces the capacity the customer wants. There is no other way.”
The investment pays for itself through multiple channels:
- Safety: Prevents catastrophic failures that could endanger personnel
- Optimization: Enables precise equipment sizing without over-dimensioning
- Reliability: Ensures systems operate within safe parameters
- Downtime Prevention: Avoids costly unplanned shutdowns
Expertise that makes the difference
In the Scandinavian market, specialized expertise in dynamic analysis for large-scale conveyor systems remains relatively rare. ROXON has built its reputation through consistent delivery of these advanced engineering services, with a focus on clear communication alongside technical capability. ROXON has developed the competences for decades and references of overland conveyors stretch to 80’s — the time before the dynamic analysis.
As conveyor systems continue to grow in scale and complexity, dynamic analysis has evolved from technical luxury to operational necessity.
For more information about dynamic analysis services and conveyor system optimization, contact ROXON’s engineering team. With decades of experience in large-scale conveyor projects, ROXON provides the technical expertise needed to ensure your conveyor systems operate safely and efficiently.