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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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About Mechanical Design Handbook

About Mechanical Design Handbook

Mechanical Design Handbook is a technical blog focused on practical mechanical engineering design and calculation methods.

The purpose of this site is to provide clear, step-by-step explanations of commonly used engineering calculations, with an emphasis on real-world industrial applications rather than purely theoretical treatment.

Topics Covered

  • Belt conveyor motor power and torque calculations
  • Starting torque and acceleration analysis
  • Machine and mechanism design fundamentals
  • Engineering automation using Excel and VBA
  • Practical numerical examples for design reference

Who This Site Is For

This site is intended for mechanical engineers, design engineers, automation engineers, engineering students, and anyone interested in applied mechanical design.

Disclaimer

All content on Mechanical Design Handbook is provided for educational and informational purposes only. While care is taken to ensure accuracy, the information should always be verified against applicable standards, codes, and professional engineering practices before use.

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