Optimization of the cross section of a novel rail running conveyor system

The throughput of a belt conveyor system is the primary design parameter when considering a new installation, determined by the cross-section of the material on the belt, coupled with the belt speed. Optimizing this area not only improves efficiency, but also minimizes capital costs through the optimal selection of equipment. Whilst speed-related optimization has seen considerable attention, the cross-sectional area has largely been neglected due to existing design constraints of the system. Conventional belt conveyors typically utilize a 3-idler troughing configuration, which forms a trapezoidal cross-section with a parabolic surcharge. The rigidity of this support directly limits the geometry of the cross-section that may be considered. A new conveyor system developed at the University of Newcastle supports the conveyor belt by a rail-based carriage, with no relative movement between the belt and carriage. This configuration allows the cross-section of the belt to be freely optimized in order to maximize the material throughput for a given belt width, or alternatively to minimize the belt width for a given throughput. This article utilizes the calculus of variations to optimize the form of this cross section, and demonstrates that an increase in throughput of up to 30% is possible, compared to troughed installations.