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...
Key Geometric Calculations In Part 2 , we analyzed the loads. Now, we must size the geometry. Designing a chain drive involves a specific sequence: determining the sprocket size, estimating the center distance, calculating the required chain length in "pitches," and then recalculating the exact center distance. Search for "Machine Elements in Mechanical Design" Advertisement 1. Pitch Diameter The pitch diameter is the theoretical circle that passes through the centers of the chain pins. D1 = Pitch Diameter of Driver Sprocket (Small) D2 = Pitch Diameter of Driven Sprocket (Large) N1 = Number of Teeth on Driver N2 = Number of Teeth on Driven p = Chain Pitch D 1 = p sin( 180 / N 1 ) Calculator Note: Most calculators default to Degrees mode. If using Degrees : Use 180 / N If using Radians (e.g., Excel): Change 180 to Ï€ → sin(Ï€ / N) ...