Mechanical Design Handbook

Many belt conveyors that run perfectly at steady speed still fail during startup. Typical problems include motor tripping, gearbox shock, belt slip, or excessive mechanical stress. This article explains how to calculate the required starting torque and acceleration power for a belt conveyor , using practical engineering methods suitable for industrial design. To complement this article, you should also read our related guide on How to Calculate Motor Power and Torque for a Belt Conveyor , which covers steady-state running conditions. 1. Why Starting Torque Matters Motor power calculated for steady-state operation is often not sufficient for startup . At startup, the conveyor must overcome: Static friction (stiction) Inertia of belt, material load, rollers, and pulleys Gearbox and bearing losses Full load acceleration Most belt conveyor failures occur during startup, not during normal running. 2. Running Torque vs Starting Torque Running torque i...

Designing a belt conveyor may look simple, but incorrect motor sizing is one of the most common causes of conveyor problems such as motor overheating, belt slipping, gearbox failure, or poor acceleration. This article explains how to calculate the required motor torque and power for a belt conveyor using a clear step-by-step engineering method, including a realistic industrial example. 1. Why Motor Power and Torque Calculation Matters If the motor is: Undersized → motor stalls, trips, or overheats Oversized → unnecessary cost and poor energy efficiency Correct calculation ensures reliable starting, stable running speed, acceptable motor temperature, and long mechanical life. 2. Basic Belt Conveyor Parameters Conveyor geometry Conveyor length, L (m) Inclination angle, θ (degree) Drive pulley diameter, D (m) Load information Material mass on belt, m load (kg) Belt mass, m belt (kg) Operating conditions Belt speed, v (m/s) ...