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VFD vs Soft Starter for Conveyors: Preventing Gearbox Failure

You selected the right AGMA Class gearbox . You calculated the belt tension perfectly. But the moment you hit "Start," the belt snaps or the gearbox makes a terrifying clunk. The culprit is likely your Starting Method . In conveyor systems, the starting torque profile matters more than steady-state power. Note: We previously discussed VFDs as Energy Savers for pumps and fans. For conveyors, however, the goal is not lowering your electric bill—it is preventing your gearbox from exploding. Table of Contents 1. The Physics of Shock Loads 2. Why Soft Starters Stall Conveyors 3. The VFD Torque Advantage 4. Comparison: Cost vs. Protection 5. Final Verdict Advertisement 1. The Physics of Shock Loads When an AC induction motor starts Direct-On-Line (DOL), it draws 600% to 800% of its rated current (Inrush Current). More importantly, it produces a sudden spike known as Locked-Rotor Torqu...
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NX Motion Simulation Part 3: Slider Joints & Linear Drivers

In [Part 2 of this series], we finished setting the driver for the revolute joint of the indexing mill. Now, we will set up the Punch Die.

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Step 1: Setting up the Slider Joint

The movement of the punch die is different from the indexing mill. It moves only in linear motion along the Z-axis. The joint for this kind of movement is called a "Slider" joint.

Procedure:
1. Select Joint command.
2. Select "Slider" joint icon.
3. Select the "Die" link we created earlier.

4. Click "Orientation on the first link" → Select "Point".
5. Select the center point of the cylinder to define the joint origin.

6. Select "Vector" → Click the bottom face of the cylinder (defines the downward Z-axis).
7. Rename to "J_Die".
8. Click Ok.

Step 2: Defining the Linear Driver

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1. Right-click joint "J_Die" → Edit.
2. Set Motion Driver to "Constant".
3. Enter Velocity: 50 mm/s (Placeholder value).
4. Click Ok.

Step 3: Running the Animation (Digital Prototyping)

Now we run a preliminary test to ensure the joints are moving correctly.

Settings:
• Time: 1.8 seconds (Cycle time for 2,000 pcs/h).
• Steps: 360 (One step per degree).

Interference Detection: The Crash Test

As expected, because we are using simple "Constant" drivers, the parts collide! This confirms why we need Excel-Driven Motion Profiles to synchronize them perfectly.

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