Sidewinder Manual

Sidewinder v6.
Conveyor Design Software
User Manual
Revision 6.87
Advanced Conveyor Technologies, Inc.

19415 594th Ave - Mankato, MN 56001 - U.S.A.
Phone: 507-345-5748 e-mail: info@actek.com
Sidewinder Conveyor Design Software - Manual August - 2017
Table of Contents
1.0 INTRODUCTION .................................................................................................................................................5
2.0 INSTALLATION...................................................................................................................................................6
2.1 NETWORK LICENSES ............................................................................................................................................8
2.1.1 HASP Network Licenses .............................................................................................................................. 8
2.1.2 SafeNet Network Licenses ......................................................................................................................... 10
2.2 SIDEWINDER UPDATES....................................................................................................................................... 13
3.0 SIDEWINDER - OVERVIEW ........................................................................................................................... 14
3.1 SIDEWINDER TOOLBAR ...................................................................................................................................... 14
3.2 SIDEWINDER QUICK START................................................................................................................................ 15
4.0 INPUT - GENERAL ............................................................................................................................................ 19
4.1 PROJECT INFORMATION ............................................................................................................................. 20
4.2 DESIGN CRITERIA ...................................................................................................................................... 24
4.3 LOAD CONDITIONS .................................................................................................................................... 31
4.4 FRICTIONAL CONDITIONS .......................................................................................................................... 37
5.0 INPUT - MAIN PAGE ..................................................................................................................................... 39
5.1 MATERIAL ................................................................................................................................................. 40
5.2 TAKE-UP.................................................................................................................................................... 43
5.3 BELTING .................................................................................................................................................... 46
Belt - Details ...................................................................................................................................................... 51
Belt - Splice ........................................................................................................................................................ 54
Belting - Curves ................................................................................................................................................. 56
Belting - Transitions........................................................................................................................................... 58
Belt - Sidewall (Pocket Belt Conveyors) ............................................................................................................ 60
Belt - Pipe (Pipe Conveyors).............................................................................................................................. 63
5.4 IDLERS....................................................................................................................................................... 64
5.5 MOTORS .................................................................................................................................................... 70
Motor Type: Squirrel Cage (SC, SCSS) and Wound Rotor Motor ..................................................................... 70
Flywheel and Brake Disk Inertia ....................................................................................................................... 71
VFD Motors ....................................................................................................................................................... 74
Fluid Couplings (TV, TVV, TVVS, VSFC) .......................................................................................................... 76
5.6 REDUCERS ................................................................................................................................................. 77
5.7 BRAKES ..................................................................................................................................................... 82
5.8 BACKSTOPS ............................................................................................................................................... 87
5.9 PULLEYS / SHAFTS..................................................................................................................................... 88
Pulley Dimensions and Type .............................................................................................................................. 88
Shaft Input Data ................................................................................................................................................. 90
Bearing Input Data ............................................................................................................................................ 90
Hub Input Data .................................................................................................................................................. 91
Design Criteria .................................................................................................................................................. 92
Overhung Load .................................................................................................................................................. 92
AS-1403 .............................................................................................................................................................. 94
CEMA – kf for Bearing and Hub ........................................................................................................................ 95
Low Speed Coupling .......................................................................................................................................... 95
Fillet Distance & Radii ...................................................................................................................................... 95
Other .................................................................................................................................................................. 96
5.10 DYNAMICS ................................................................................................................................................ 97
Starting ............................................................................................................................................................... 97
Operational Stop ................................................................................................................................................ 99
Emergency Stop.................................................................................................................................................. 99
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Chute Fill – Receiving Conveyor ..................................................................................................................... 100

5.11 LOAD POINTS – FEEDER BELTS AND SKIRTBOARD ELEMENTS ................................................................ 101
5.12 STRUCTURAL........................................................................................................................................... 110
6.0 INPUT - CONVEYOR PROFILE & GEOMETRY ................................................................................... 115
6.1 VERTICAL PROFILE.................................................................................................................................. 116
6.1.1 Geometry Input .................................................................................................................................. 117
6.1.2 Element Type ..................................................................................................................................... 122
6.1.3 Element Context Menu, Quick Buttons, and Short Cuts .................................................................... 131
6.1.4 Enter Dimension from Pulley Centers ............................................................................................... 133
6.1.5 Adjust to End (Ctrl-J) ........................................................................................................................ 134
6.1.6 Divide Element Option....................................................................................................................... 134
6.1.7 Move Point of Intersection ................................................................................................................. 137
6.1.8 DXF Import........................................................................................................................................ 138
6.1.9 CSV Import ........................................................................................................................................ 146
6.1.10 DXF Export ................................................................................................................................... 147
6.1.11 Idler Spacing Table ....................................................................................................................... 148
6.1.12 Show Station Label........................................................................................................................ 157
6.1.13 Auto Calculate Wrap Angles ......................................................................................................... 157
6.1.14 Return Side Offset ......................................................................................................................... 157
6.1.15 Maximum Element Size ................................................................................................................. 157
6.1.16 Vertical Radius Misalignment Tolerance ...................................................................................... 157
6.1.17 Show Imported Ground Line ......................................................................................................... 158
6.1.8 Element Plot....................................................................................................................................... 158
6.2 CONVEYOR PROFILE ................................................................................................................................ 160
6.2.1 Columns in Conveyor Profile............................................................................................................. 162
6.2.2 Defining custom load cases ............................................................................................................... 164
6.2.3 Cell Selecting .......................................................................................................................................... 166
6.3 HORIZONTAL PROFILE ............................................................................................................................. 167
6.3.2 DXF/CSV Import Dialog ................................................................................................................... 169
6.3.3 DXF Export........................................................................................................................................ 169
6.3.4 Move Points ....................................................................................................................................... 169
6.4 GROUND PROFILE .................................................................................................................................... 170
6.4.1 2D Ground Profile ............................................................................................................................. 172
6.4.2 3D Ground Terrain ............................................................................................................................ 172
7.0 OUTPUT WINDOWS ................................................................................................................................... 176
7.1 PULLEY IMAGES ...................................................................................................................................... 177
7.2 PROFILE IMAGE ....................................................................................................................................... 180
7.3 COMPANY LOGO ..................................................................................................................................... 180
7.4 EDITOR .................................................................................................................................................... 182
7.5 REPORT OPTIONS .................................................................................................................................... 183
7.5.1 Conveyor Load Cases ........................................................................................................................ 183
7.5.2 Conveyor Load Case Details ............................................................................................................. 183
7.5.3 Take-up Details .................................................................................................................................. 183
7.5.4 Pulley & Brake Details ...................................................................................................................... 184
7.5.5 Vertical Curve Details ....................................................................................................................... 184
7.5.6 Belt Flap Details ................................................................................................................................ 185
7.5.7 Transitions & Turnover Details ......................................................................................................... 185
7.5.8 All Material & Idler sets .................................................................................................................... 185
7.5.9 Element Summary Details .................................................................................................................. 185
8.0 ADVANCED OPTIONS ................................................................................................................................ 186
8.1 LOAD ON/OFF WORK PAGE .................................................................................................................... 186
8.2 TURNOVERS ............................................................................................................................................ 190
8.2.1 Allowable Stresses ............................................................................................................................. 191
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8.2.2 Turnover Output ................................................................................................................................ 192

8.2.3 Turnover Work Page .......................................................................................................................... 193
8.2.4 Belt Input Grid ................................................................................................................................... 194
8.2.5 Turnover Length and Tension Grid ................................................................................................... 197
8.2.6 Plotting Scales ................................................................................................................................... 197
8.2.7 Results and Output ............................................................................................................................. 197
8.3 HORIZONTAL CURVES ............................................................................................................................. 203
8.4 OVERHUNG LOAD WORK PAGE............................................................................................................... 204
8.6 STOCKPILE CALCULATIONS ..................................................................................................................... 208
9.0 REPORTS AND EXPORTING (EXCEL / CAD) ....................................................................................... 215
MICROSOFT WORD REPORT .................................................................................................................................. 216
PROFILE PLOT ........................................................................................................................................................ 217
PULLEY ARRANGEMENT PLOT ............................................................................................................................... 218
CAD EXPORTING................................................................................................................................................... 220
10.0 USER OPTIONS .................................................................................................................................. 224
10.1 EQUIPMENT LIBRARY & DATABASE ........................................................................................................ 224
10.2 USER CATALOGS ..................................................................................................................................... 226
10.3 PREFERENCES .......................................................................................................................................... 227
10.3.1 System Preferences ....................................................................................................................... 227
10.3.2 Language....................................................................................................................................... 229
10.3.3 Belting ........................................................................................................................................... 230
10.3.5 Report Preferences ........................................................................................................................ 235
10.3.6 Idler Preferences ........................................................................................................................... 237
10.3.7 Shaft Design Preferences .............................................................................................................. 239
11.0 PROJECTS FILES ............................................................................................................................... 240
12.0 REFERENCE PAPERS ....................................................................................................................... 245
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1.0 Introduction
Thank you for your interest in our Sidewinder conveyor design software. This manual will
discuss how to use the Sidewinder software, and describes the meanings of all input and output
data. This manual assumes that the reader is familiar with basic conveyor design principles. It is
not meant to be a “How to Design Conveyors” instruction manual. If the user is not familiar
with basic conveyor principles, they should refer to the following literature:
1. Belt Conveyors for Bulk Materials – CEMA 5th, 6th, and 7th Editions.
2. DIN 22101 & ISA 5048 Standards.
3. Phoenix Design Fundamentals, Goodyear Red Book, and other literature from manufactures.
4. The plethora of papers devoted to bulk solids handling.
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2.0 Installation
The Sidewinder software consists of three parts. These are the software installation CD-ROM,
White USB memory Stick, and a RED or GREEN Sentinel HASP USB hardware dongle.
Sidewinder is supported under Microsoft Windows 2000, ME, XP, Vista, Windows 7, and
Windows 10.
To install Sidewinder, insert the CD-ROM (or White USB memory dongle) into your computer
and double click on the “Sidewinder Setup.exe” file.
You must agree to the license terms and conditions and select an installation directory.
After installation is complete you must install the USB hardware driver. This is done by running
the “HASP User Setup.exe” file. User who purchased the software before August 2017 should
use the “Sentinel Protection Installer.exe” file. See the image below for your type of USB
dongle.
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Sidewinder will install three directories on your computer. The “bin” directory contains all
required Sidewinder installation files and the main “Sidewinder.exe” executable. The
“Examples” directory contains various example files, and Sidewinder tutorial files which
accompany the video tutorial series. The user manual is installed in the “User Manual” directory
along with an “Updates.pdf” file. The updates file is automatically updated whenever an online
update is performed. It contains detailed information on new features and changes.
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2.1 Network Licenses

There are two types of Network installations. If purchased the Sidewinder software before
August 2017, you would have a classic Safenet dongle and as such need to follow the
instructions in section 2.1.2. If you purchased the software after August 2017 follow the HASP
Network setup in section 2.1.1.
2.1.1 HASP Network Licenses

Users will need to install the “HASP User Setup.exe” file to be able to use the
network licenses.
Users can check the status of the license via a web browser. Simply open your
preferred browser and go to:
http://192.168.1.1:1947 or http://localhost:1947
Where 192.168.1.1 is the IP address of the sever computer with the HASP dongle installed.
This will bring up the Sentinel Admin Contorl Center.
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Clicking on the “Products” menu will show the Sidewinder License.
Full instruction for using the control center can be found by clicking on the “HELP” menu in the
lower left side of the window.
Note: The “server.ip” file (section 2.1.2 below) is NOT used with the HASP dongles. The
Sentinel Admin Control Center contains all Network setup and funcionality.
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2.1.2 SafeNet Network Licenses

Network users must install the Sidewinder software and Safenet Protection USB
drivers (Sentinel Protection Installer 7.6.8.exe) on a local PC. This computer will
have the USB dongle physically plugged into it.
All remote network users will also need to install both the Sidewinder software and the Safenet
Protection USB drivers. Additionally, network users must manually copy the “server.ip” file
(found in the /Sidewinder/Network installation directory) to the “Sidewinder/bin”
directory. This is an ASCII text file that informs Sidewinder to search the local network for an
available software license.
To speed up the server search, you can edit this file and enter the specific server IP address on
the first line. This will allow the Sidewinder software to start much faster.
Users can view the current server status by accessing port 6002 from their web browser. This is
done by accessing the sever computer, port 6002. For example: http://192.168.110.123:6002
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On a network license you can see what user is accessing the software by clicking on the "Key #"
column in the Sentinel License Monitor window.
A screen will appear showing the user name, and login time.
Please note that as of January 2014 Java has added extra security and as such you will need to
explicitly add the ip address in the java control panel. This can be done as shown below:
1. Open the java control panel (in windows 7 simply go to the search bar and type
"configure java").
2. Under the "Security" tab, click the "Edit Site List" button and add the IP address (for
example: http://192.168.0.1:6002) in the site exception list as shown below.
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Network administrators should also note that the port required for the Safenet USB key is TCP
6002, and 6001 UDP. However, if this needs to be changed for firewall or other reason it can be
done using the "loadserv.exe" executable found in the Safenet installation directory. This is
shown below:
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2.2 Sidewinder Updates

After installation you may want to check for any new Sidewinder updates. This can be done by
selecting “Check for Updates” found under the “Help” taskbar menu. You will need internet
access to complete this process.
If an update is found, Sidewinder will prompt you to automatically download and install the
update.
After the download is complete, Sidewinder will step you though the remaining update process.
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3.0 Sidewinder - Overview

After installing the software and USB drivers, insert the USB key into an open USB slot on your
computer. You can start Sidewinder from the “Start – Programs – Sidewinder” menu on the
windows taskbar.
3.1 Sidewinder Toolbar

The Sidewinder toolbar contains quick shortcuts to the most commonly used input and output
data windows. The three main user windows are highlighted in red. Each of these will be
discussed in detail in section 4.0.
Open – Opens an existing Sidewinder input file

Save – Saves the current Sidewinder file
Reports – Generates a word document conveyor design report (see section 7)
Project Files – Project files allow multiple conveyors to be views and printed together
Language – Specify the user language to be used for all inputs and outputs
System Units – Switches all input and output values to the opposite measurement system
(Metric to Imperial, or Imperial to Metric)
General Input Window – Contains general information about the system including solution
methodology, design criteria, and specific load cases (see section 4.1).
Geometry Input Window – The conveyor profile, vertical & horizontal curves, drive/pulley
arrangements, loading points, idler spacing, and other information about the conveyor geometry
are entered here (see section 5).
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Main Output – This is the main input/output window. It contains the details for all the major
conveyor input parameters except the conveyor geometry (see section 4.2).
Detailed Output – This window contains detailed output information on the current conveyor
design (see section 6).
Solve – Solves the current conveyor calculations and updates all output data windows.
3.2 Sidewinder Quick Start

When you first open Sidewinder you have the option of starting a “New” file, or “Opening” an
existing file.
If you select the “New” button on the toolbar then a new blank Sidewinder input file will be
created. You will then see the “Easy Profile” input window shown below. This window lets you
quickly enter the basic geometry of a conveyor. The user can then click on the “Head” and “Tail”
layout buttons and chose for a number of preset layouts.
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In the figure below the user has specified 3 elements, with a dual drive at the head, and a
horizontal take-up at the tail.
The user can also enter other information about the conveyor design. This includes the idler
spacing, motor wrap angles, backstop and brake locations, turnovers, and other details.
Sidewinder uses the “Easy Profile” information to create the “Vertical Profile” of the conveyor.
The vertical profile (next window tab at the top) contains a breakdown of each individual
element. These “elements” represent the points where the belt tensions and other conveyor
design parameters will be calculated.
For many conveyors the Easy Profile window will be sufficient to provide a complete conveyor
design. However, an unlimited number of elements as well as and drive configurations can be
manually entered in the “Vertical Profile”. Please see section 5.0 for more information on using
the vertical conveyor profile.
After entering the conveyor geometry the user can select either the “Info” button or the “Main”
button on the toolbar. The “Info” (short for Project Information) allows the user to enter general
information about the project. Client names, conveyor descriptions, load cases, design criteria,
and other specifications are entered here. Please see section 4.1 for further details.
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For now select the “Main” button on the toolbar. This will show the main Sidewinder window
and is where you will spend most of your time.
Now right click on the Material “Type” input (Unspecified) and select “Copper, Ore” from the
CEMA pull down list. Next click on the “tonnage” input (you will notice that the material name,
density, and surcharge information have been automatically filled in when you selected Copper
Ore). Enter 2500, for the tonnage. You screen should look like this:
Now click on the calculation button on the toolbar (circled above).
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Once the calculations have been run you will notice the output data window is filled in the lower
right corner. This window shows all the calculation results as well as the automatically selected
equipment. Note how many (actually almost all) of the input variables were left blank, however
Sidewinder has selected values as needed.
Clicking on the “Material” tab shows a cross sectional view of the material loading.
All of the input and output tabs and windows are described in the following chapters.
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4.0 Input - General

This window can be opened by clicking the button on the tool bar. It consists of three
important areas of information:
1. Project Information – General information, filenames, and calculation methods

2. Design Criteria – Input data specifying the design requirements for the conveyor
3. Load Conditions – Input data on each relevant load condition for the conveyor
Each of these areas will be discussed individually in the following sections.
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4.1 Project Information
Project Name – Name of the project to be printed on output reports and for future reference.
Conveyor Name – Name of the individual conveyor (e.g. CV-002, or CR034)
Location – Geographic location (used for output report labels only).
Client Name – Name of the client (used for output report labels only).
Designer – Engineer responsible for the conveyor design.
Description – General description of the conveyor. This is printed at the top of the output report
Designer Comments – General comments for the designer to refer back to. This information is
not printed out and thus can contain specific data that only the designer wants to know.
Ambient Temperature – This is the normal operating temperature for the conveyor. This
temperature is used for all “normal friction” load cases (load cases are discussed in section
4.3.1).
System Units – The working units for the file. Note input/output units can be switched at any
time by simply clicking the units ( ) toolbar button.
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Add Revision to Filename – The user can select a two letter extension to be added to the based
filename. For example if the file name is “conveyor xyz.swi” and the “Add Revision Number to
Filename” is checked, then the new filename will be “conveyor xyz_0A.swi”. This is a handy
and useful way of naming conveyors which may have different revisions throughout the design
processes.
Equipment Tags & Commodity Codes - If the user checks this checkbox then additional inputs
will appear for all the major equipment (belting, idlers, pulleys, drives, reducers, brakes, etc).
These new inputs allow specific equipment tag numbers and commodity codes to be input. An
equipment tag number is UNIQUE to each part, whereas the commodity code is unique to a
group of components. For example, a conveyor may have three 200 kW motors on it. All three
motors may have the same commodity code (assuming they are all identical), however each may
have a unique equipment tag.
Pulley tags are shown on the "vertical profile" input page, however the page width must be
expanded for these input to be shown.
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Users can output all tags to the report by selecting the "Equipment Tags / Commodity Codes"
checkbox before creating the conveyor report.
Lock File – If this checkbox is enabled, the calculations cannot be re-run. The file can be
opened, and the report printed, but neither the input nor output data may be modified. This is
useful when a design has been completed and is similar to giving a file “read only” user
privileges.
Note: when the checkbox is checked, the user has the option of entering a password. If a
password is entered then the file cannot be “unlocked” without re-entering the password.
Solution Methodology – This selects which calculation methodology will be used for the
conveyor calculations. The user should refer to the appropriate literature for details on each
calculation methodology as this is outside the scope of this manual.
The primary solution methodologies are:
CEMA 5th – Used the 5th edition of the CEMA book for all belt tension calculations.
If the CEMA 7th edition is used the user can select between the various rubber types as
described in the CEMA book.
DIN / ISO – Uses the DIN 22101 and ISO 5048 design methodology. When this method is
selected, two additional input boxes are shown. If the equivalent friction factor “f” is left blank,
Sidewinder will estimate a value based on the conveyor length and capacity.
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The “Cs” factor input accounts for all other losses on the conveyor system. There are three
options for this input:
1. If this value is left blank it will be selected based on the length of the conveyor (as per
the DIN/ISO selection table).
2. The user can manually enter the Cs value
3. The Cs factor can be calculated based on the actual conveyor components. In this
case the pulley drag, belt scraper drag, loading point forces, and other items are each
individually calculated. For example, the ISO 5048 methods provides equations for
calculating pulley drag based on belt tensions and other factors. If this option is
selected sidewinder will calculate the “resulting” Cs factor and show this on the
output page for the user’s information.
Oszter, Behrends & Vincent – Methodology as described in the paper “Large Capacity Belt
Conveyors – Motion Resistance Evaluation” by Z.F. Oszter, W.K Behrends, and D. Vincent.
This paper is based off experimental data obtained on several high-tonnage conveyor systems. It
is therefore only recommend to be used on these types of systems.
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4.2 Design Criteria

The design criteria page has two purposes: First, when user inputs are left blank Sidewinder will
try to estimate the required values based on the criteria specified in this table. The second
purpose for this table is to highlight problems with the conveyor design output values.
For example, if the belt rating is not input, Sidewinder would select an appropriate rating based
on the required belt safety factor. Conversely, if the belt rating is input, then Sidewinder would
alert the user (highlight output cell red) if the belt safety factor exceeds the design criteria value.
Most input have values for started stat running, and momentary (or steady state design level 2
case).
Safety Factor (Fabric Belting) – This is the allowable nominal safety factor for fabric belting.
This will either be input as the nominal value, or the “splice” value based on the “fabric belt
criteria” above.
For example: A 5 ply belt with a nominal safety factor of 10:1, would have a splice safety factor
of 10 * (5-1) / 5 = 8. Some designers required a minimum splice safety factor of 8, whereas
others prefer to base their designs on the nominal belt safety factor.
The table below shows a comparison between the two methods. The yellow section shows the
results when using a “nominal” belt safety factor of 10:1. For an EP-800 N/mm belt, the
allowable splice tension would be 80 kN, regardless of the number of fabric plies in the belt.
However, there is normally one less ply in the splice region (due to the belt vulcanization
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process) and thus the splice safety factor is a function of the number of plys. A designer using a
nominal safety factor of 10:1 for a 3 ply belt, would results in a splice safety factor of only 6.7:1.
The green section shows the results when the splice safety factor is constant (with the
recommended DIN value of 8:1). In this case the allowable splice tension varies from 80 kN
down to 50 kN. Therefore the “nominal” belt safety factor will vary from 10:1 to 16:1.
Safety Factor Example - EP-800 N/mm Fabric Belt

Allowable Allowable
Rating Splice Splice
per ply Nominal Tension Splice Splice Tension Nominal
Plys (N/mm) S.F. (N/mm) S.F. S.F. (N/mm) S.F.
5 160.0 10.0 80.0 8.0 8.0 80.0 10.0
4 200.0 10.0 80.0 7.5 8.0 75.0 10.7
3 266.7 10.0 80.0 6.7 8.0 66.7 12.0
2 400.0 10.0 80.0 5.0 8.0 50.0 16.0
Safety Factor (Steel Cord Belting) – This is the allowable nominal safety factor for steel cord
belting. Unlike fabric belting this value is always specified as the “nominal” belt safety factor.
The generally accepted value for steel cord belting is 6.67:1
Safety Factor (Momentary Column) – This multiplier defines the allowable safety factor for
momentary operating tensions.
It is also used for all design level 2 cases (running and dynamic) as these cases are “by
definition” momentary conditions.
For example:
Nominal belt safety factor = 6.67:1
Dynamic multiplier = 1.15
Then the allowable safety factors are:
6.67:1 - Design Level 1 - Running

5.80:1 - Design Level 1 - Starting and Stopping
5.80:1 - Design Level 2 - All Cases
Local Safety Factor Multiplier – This is the minimum allowable steady state stress in the belt. It
is used to determination of minimum vertical curve radius (edge stresses for convex curves and
center stress for concave curves). It is also used in belt turnovers, transition length calculations,
and other such areas.
Minimum Steady State Stress – This is the minimum allowable steady state stress in the belt.
Used for determination of minimum vertical curve radius. For dynamic cases the program uses
the smaller of either 1% of the belt rating, or the above value.
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Maximum Allowable Sag (Running) – This is the allowable percent sag during steady state
running conditions.
Maximum Allowable Sag (Momentary) – This is the allowable percent sag during momentary
conditions. This includes design level 1 dynamic conditions, as well as all design level 2 cases
(running and dynamic) since these cases are by definition momentary conditions.
Pulley Friction Factors (Rubber Lagging) – This is the allowable coefficient of friction
between belt and pulley for rubber lagged pulleys during running conditions.
Pulley Friction Factors (Ceramic Lagging) – This is the allowable coefficient of friction
between belt and pulley for ceramic lagged pulleys during running conditions
For example, if the rubber lagging friction value is 0.28, and the multiplier is 1.15, then the
allowable momentary friction value for rubber lagging is 0.32.
Pulley Shaft Design Criteria

This is the design criteria used for the shaft sizing of all pulleys.
Only Design Level 1 cases are used for pulley shaft design calculations (which are based on
fatigue loads). Design Level 2 cases are by definition uncommon and would not normally be
used for the shaft design. If the user wants to use a design level 2 case for the shaft calculations,
then that case should be made as a design level 1! Remember, you can set the design level on
the 'Load Conditions' page.
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Pulleys and shaft should still always be checked by the manufacture for maximum structural
loads and other cases. Pulley manufactures need to verify that under these conditions the pulley
will not fail.
Here is how the new design criteria inputs work:
The resulting conveyor tensions (maximum values of running or momentary depending on the
user input) are multiplied by the pulley tension multiplier. All High Tension (HT) pulleys are
multiplied by the HT multiplier. All other pulleys (medium tension, low tension, and snubs) use
the 'Other' pulley tension multiplier input. This is the value that is then used for the pulley shaft
fatigue design calculations.
Include Dynamics
If the ' Include Dynamics ' input is set to 'Yes' then the starting and stopping tensions are also
used for the pulley design. Only Design level 1 starting and stopping tensions are used. The
pulley tension multiplier is NOT used on top of the dynamic tensions (i.e. the multiplier is
set to 1 for the dynamic tensions).
For example: If the running tension of a high tension pulley is 125, the HT multiplier is set to
1.1, the starting tension is 150, and the 'Include Dynamics' input is set to 'Yes", then Sidewinder
will use the larger of either 125 * 1.1 (137.5) or 150. In this case 150 would be used.
Running 100% Power Case

If the ' Running 100% Power ' is set to 'Yes', then Sidewinder automatically creates, and runs, an
extra hidden case (similar to the structural load case calculations). This extra case uses the fully
loaded normal friction condition, but it increases the material loading until 100% motor
nameplate power is reached. Additionally, all reducer losses are set to zero (for maximum
driving torque and tensions). The tensions for this case are again multiplied by the appropriate
'pulley tension multiplier'.
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Sidewinder will take the larger tension value of either all Design Level 1 cases, or this extra
'100% motor power' case. The starting and stopping dynamics for the extra 100% motor power
case are NOT used (even if the users selects 'Yes" to Include dynamics). Only the steady state
running tensions are used for this extra case. This is recommend and by design. Should the user
want to design the shaft with 100% nameplate power and include the dynamics, then they would
simply need to create an additional load case using an increased tonnage to achieve 100% motor
rating.
Like the structural tensions, you can look at the extra "100% motor power" tensions on the
Details -> Elements output page as shown below:
Pulley Shaft Design Criteria - Extra Case Options

This input has been expanded to give the engineer even more control on the shaft design
tensions. Sidewinder will take the larger tension value of either: All Design Level 1 cases, or
this 'extra' case. The starting and stopping dynamics for the extra case are NOT used (even if the
users selects 'Yes' to Include dynamics). Only the steady state running tensions are used for this
extra case.
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The available options are:
None
Don't use or check any other extra cases. This option just uses the regular Design Level 1 cases.
100% NP
If the ' 100% NP' is selected, then Sidewinder automatically creates, and runs, an extra hidden
case (similar to the structural load case calculations). This extra case uses the fully loaded
normal friction condition, but it increases the material loading until 100% motor nameplate
power is reached. Additionally, all reducer losses are set to zero (for maximum driving torque
and tensions). The tensions for this case are again multiplied by the appropriate 'pulley tension
multiplier'.
Str. Case
This option uses the tensions calculated from the Structural Load Case. This is very similar to
the 100% NP case, except the user has more control over exactly how the 100% motor nameplate
condition is created. Note the Structural tensions do NOT include the 'Structural Tension
Multiple', but do include the appropriate shaft design tension multiplier (ie Sidewinder correctly
does not add safety factor on top of safety factor). Again this is meant to be very similar to the
100 NP case, but will a bit of added extra control by the user.
Mtr/Blt/PT
This option uses the installed Motor Power, Belt Rating, and Pulley Type to determine the belt
tension. Tensions are taken as follows:
Tension = Belt Rating * Belt Width / Nominal Running Belt Safety factor * PTMultipler
PtMultiplier = 1 for high tension pulley, 0.8 for Medium Tension, 0.65 for Low, and 0.50 for
snub pulleys.
The T2 pulley tensions is always equal to the T1 tension, except for drives pulleys where T2
tension is equal to T1 minus 50% of the motor torque. One could argue to use 100% motor
torque, but 50% is more conservative as it will result in a higher T2 tension.
Motor torque is set to 150% motor nameplate torque if Mtr/Blt/PT option is selected (otherwise
it is set to the T1-T2 value).
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Fabric Belt Criteria

This input sets the design criteria for fabric belting. Its value will default to the user specified
option on the “Preferences” page.
The “nominal” selection uses the nominal belt safety factor for selecting the required belt
strength, and highlighting problem areas.
The ‘splice’ option selects the belt rating based on the splice safety factor (this method takes the
number of belt plys into account).
Location
This specifies the location to be used when selecting default values. For example, in Europe a
standard belt with is 1400 mm, however in Africa the standard is 1350 mm. When creating a new
file this value will default to the location specified in the preferences option.
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4.3 Load Conditions

Load conditions provide one of Sidewinders most powerful features. It allows the engineer to
view and analyze many different loading conditions of the conveyor. These include: Fully
Loaded, Empty, Inclines Loaded, Declines Loaded, High Friction conditions, Low Friction
conditions, and many more. Furthermore, different conveyor loadings, material types, belt
speeds, and other variations can be examined.
The “Load Conditions” option section box on the left allows the user to pick one of following
three conveyor design options:
Basic (Full/Empty) – Normal friction – This option results in Sidewinder performing the empty
belt and fully loaded belt calculations using only the normal friction conditions.
Full/Empty – High/Low friction – This option results in Sidewinder performing the empty belt
and fully loaded belt calculations using the normal and high and low friction conditions.
Incline / Decline (High / Low Friction) – This is perhaps the most used option as it not only
includes the full and empty cases, but also two commonly used worst-case conditions which
represent the maximum and minimum expected belt tension and power consumption.
When this option is selected, two additional load cases will be shown. The first “All Inclines &
Flat Sections” will load only the flat, and incline section of the conveyor. In many cases, this
will be the same as the “fully” loaded condition. The second additional load case is for only
loading the “Decline” sections of the conveyor. On an incline conveyor this would be the same
as the empty belt condition.
An example conveyor with a decline section, followed by an incline section, is shown below.
The red line represents the conveyor profile, and the blue line the loading of the conveyor.
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In addition to specifying the actual material loading of the conveyor, Sidewinder also allows the
users to look at various friction levels and conditions. On most conveyors, the exact values for
many components cannot be specified with absolute certainty. For example, the drag of the
idlers can vary significantly between idler types, manufactures, and ambient temperatures. For
this reason the engineer must design the conveyor to allow for these variations in parameters.
This is done by selecting various “frictional design conditions” as shown below.
In this case, the user has specified six (6) total loading/friction combinations. For the “All
Incline + Flat Sections” conveyor loading, the conveyor calculations will be performed for the
“Low” friction, “Normal” friction, and “High” frictional condition.
In addition to various load cases and friction conditions, other important inputs can be specified.
For example, let’s say the conveyor was to operate at two speed and tonnages. The primary case
might be 3,000 T/H and 700 fpm. These values would be entered on the main page (under the
material and belt input sections). However the designer might also be interested in increasing the
belt capacity by 25%. This case can be easily added by simply including a “Tonnage Multiplier”
of 1.25. For this condition the belt speed might need to be increased (i.e. if a VFD drive is being
used) to 4.0 m/s. This condition is the first option highlighted in the red box below.
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Alternatively, the designer may want to run two different material types on the conveyor. Again,
there is no reason to make two separate Sidewinder files. Instead an additional load case can
simply be added specifying a different material type (Material Type “2” in this case), with a
different tonnage, belt speed, etc!
Another option may be to investigate the belt tension and power requirements to start a conveyor
for which the feeding point has been overloaded on shutdown. In this case the conveyor must
include the “Loading Point Pullout Forces” required to overcome the shearing and other
additional forces at the transfer point feed location. This option can be quickly investigated by
entering the “flooded” feed point (i.e. 1 for this first feed point, or 1,2,3 if the conveyor would
have three feed points which were all flooded, etc).
New load cases can be added by “Right Mouse Clicking” on the Load Case column. A pull
down list of all available load case options will be listed. This list includes a plethora of
different conditions and load on/off scenarios. On many conveyors the worst case may not be
obvious at first. However, the ability to be able to quickly investigate all potential worst case
design conditions allows the designer to quickly spot potential problems, and eliminate other
cases which may not be crucial.
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As you can see, the load condition input table is very important, and also very powerful. A
single file can contain the results of many different design cases, and “what if” scenarios.
A summary of the input values is as follows:
Fixed ID – The fixed ID cannot be changed. This tag is shown in the column label of the
conveyor profile on the geometry input page.
User ID – This 2 character ID, plus the friction level, will be shown in all load case tab pages.
For example the Fully Loaded Normal friction case would be shown as "FL-N” and the Incline
Loaded High friction case would be shown as "IL-H".
Load Case – This name is used in the output for identification. The load case name may be
edited.
Low Friction – Check this box to create the low friction case as defined in "Frictional
Conditions" tab above.
Normal Friction – Check this box to create the nominal friction case. The nominal frictional
case uses the values in the various input tables.
High Friction – Check this box to create the high friction case as defined in "Frictional
Conditions" tab above.
Tonnage Multiplier – The tonnage for each load case can be specified here. If the input value is
less then 10, all material tonnages are multiplied by this value. (e.g.. 1.5 x 3000 T/H = 4500
T/H). If the input value is greater than 10, then that value is used as the tonnage for the load case
(e.g.. 4500 T/H).
Material Set – Defines the material type for each load point. If there is more than one loading
point, you may place different materials in each feeder by entering multiple materials separated
by commas. For example, if you have three load points entering "3,2,4" will place:
Material type 3 in Load Point 1

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If a material type for a feeder is not specified, then it defaults to the first material type in the list.
Speed – The belt velocity for conveyor with variable speed motors can be modified with this
multiplier. If the motor type is not a "VSD" this multiplier is ignored.
Temperature – Temperature for this load case. Note this input will overwrite any temperature
input on the Frictional Conditions tab (Low/High Friction cases)
Belt Mass Multiplier – Multiplier for the belt mass. This input will overwrite the input values on
the Frictional Conditions tab (Low/High Friction cases)
Brake Multiplier – Multiplies all brake torques by this value. This is useful for checking the
stopping times for the conveyor in the new and worn brake pad conditions.
Take-up Tension – The take-up tension of the load case can be modified (for automatic &
gravity take-up types only). If input value is greater then -0.25 and less then +0.25 then this
percentage is added to the input take-up tension (i.e. take-up tension = (1 + input value)*(input
take-up tension). Otherwise, this amount is added to the input take-up tension. (i.e. take-up
tension = input value + input take-up tension).
Note: The take-up tension on the main input page must be specified or this input is ignored.
Load Pt. Pullout Forces – At some loading points it is possible that material can build up in the
transfer chute during certain conveyor shutdowns. This option allows these pullout forces to be
included in the belt tension calculations (i.e. when the conveyor would be restarted).
For example, if you have three loading points entering "2" would include the extra pullout forces
at load point 2. Entering "1,2,3" would include the pullout forces for all loading points (1,2 and
3).
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Extra Drag Case – The user can specify extra drag on any element for any load case. Below
shows 3 different "extra drag" cases. The extra drag is input on the "Conveyor Profile" page.
Reverse Conveyor – Check this box if the belt runs in reverse for this load case.
Design Level – Design Level 1 signifies normal operation load cases (such as fully loaded and
empty). Design Level 2 signifies momentary or unusual load cases (such as inclines or declines
only loaded).
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4.4 Frictional Conditions

The friction condition table sets the design criteria when creating the high friction and low
friction design cases.
Temperature – Ambient operating temperature for frictional case. For the low friction case (low
power) enter the MAXIMUM expected temperature. For the high friction case (highest power)
enter the MINIMUM expected temperature.
Belt Bottom Cover Change – This amount of belt is added to the belt bottom cover. Enter a
negative number to reduce thickness.
By default the program will reduce the bottom cover thickness (for wear) by 0.5mm, and
increase the cover by 0.5mm to account for manufacturing tolerances.
Belt Top Cover Change – This amount of belt is added to the belt top cover. Enter a negative
number to reduce thickness. By default the program will reduce the top cover thickness (for
wear) to 35% of the nominal thickness, and increase the top cover by 0.5mm to account for
manufacturing tolerances.
Mechanical Efficiency – The total mechanical efficiency of the drive system is

increased/decrease by this value.
Accessory Multiplier – Miscellaneous drag values are multiplied by this number. These drags
include: pulley bearing and belt resistant drags; skirt and slider bed drags; user input drag.
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Rubber Loss Factor (non DIN Calculation Methods) – The Ky (rolling resistant) values are
multiplied by this number.
DIN f Factor (non DIN Calculation Methods) – Din factor for selected friction case. Values
above 0.1 are assumed to be multipliers of the nominal din factor.
Idler Drag Multiplier (DIN Calculation Method) – The nominal idler seal and bearing drags are
multiplied by this number.
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5.0 Input - Main Page

The main input page shows the most commonly accessed input and output information used
by the conveyor designer. The figure below shows the separation between input and output
information.
The input windows include: material, take-up, structural, belting, idlers, motors, reducers,
brakes, backstops, pulleys, and dynamic information. The output information is shown in the
lower left window. It contains a variety of output data and information which can be selected by
clicking on any of the output tabs at the bottom.
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5.1 Material
The material input area allows the user to specify the specific material properties. Furthermore,
Sidewinder allows up to four (4) different materials to be specified.
Material Set – Up to four (4) different materials can be entered by selecting the corresponding
material “#” option button. For most conveyors only one material type is used in the
calculations. However, in some conveyors, the user may want to include the calculations for
different material densities or other properties. Or some conveyors may transport more than one
material type (or have different material on the carry/return sides). This is easily be achieved in
Sidewinder by selecting the appropriate material type and entering the material properties
(density, tonnage, etc).
To use different material types, the user needs to add these on the “Load Conditions” table as
shown below. In this case two additional “Fully Loaded” conditions will be calculated using the
properties for “Material Sets” 2 and 3.
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Tonnage – Material Tonnage for the selected material. Hint: If the conveyor has two different
tonnages but the same material properties, the second tonnage can be entered as an additional
“Load Condition” using the “Tonnage Multiplier” column as shown below. Since most
conveyors have both a design tonnage and an expected operating, which is the loading that the
mine expect operate in normal operation, there is a special case called "Operating Tonnage" that
can be selected from the predefined load cases. The default tonnage multiplier is 0.85 of the
tonnage of material set #1. Note that in "Tonnage Multiplier" you can also enter the exact
tonnage as demonstrated in the "FA" load case, where the tonnage is defined at 1500 tph.
Material – Material type description. Selecting pull down list will fill in material properties with
CEMA standard values. This input is only used as a description for output purposes.
Density – Typically, the lowest material density is used since this will result in the minimum
material edge distance.
Maximum Lump Size – Largest lump size of material on the belt. A circular lump is shown on
the material cross sectional loading profile.
Note: This value is used to select the belt width (if left blank) and in the universal idler L10
calculations (Dynamic Material Factor), i.e. a larger lump size will generally result in a higher
dynamic material factor, and a lower idler L10 rating.
Lump Shape Factor – Aspect ratio of the lump shape. This value can be 0 to 10. A value less
than 1.0 (say 0.4) would result in a lump with its length equal to the maximum lump size and a
height of 0.4 times this size. A value greater than 1.0 (say 3.0) would result in a lump with a
length of 3 times the maximum lump size, and a height equal to the lump size.
The graphic below shows a lump shape factor of 0.5 and 2.0.
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Lump shape factor = 0.5 Lump shape factor = 2

Note: a factor > 1 will increase the lump size
Surcharge Angle – Surcharge angle is different from the angle of repose. The angle of repose is
the angle which the material will make when stacked in a pile (i.e. a stockpile). The surcharge
angle however is the angle made if the material is moving or slightly vibrated. This angle will
normally be 5-15 degrees less than the angle of repose.
The surcharge angle is used to plot the material cross sectional loading.
Internal Friction Angle – The internal friction angle is used when calculating the material
pullout forces at a material feed point. The material shearing friction factor (fi) is equal to 0.8
times the SIN of this value.
For Example: If the normal vertical material load above the feeder is 1000 N, and the internal
friction angle is 50 degrees, then the additional pullout force would be: 1000 N * 0.8 * sin(50º) =
613 N. The default value is equal to the surcharge angle plus 18 degrees.
Tonnage Calculator
There is a button located next to the Tonnage input. This button brings up a simple tonnage
calculator window which is very handy when determining the annual conveyor throughput (or
back calculating the tonnage requirements based on annual or daily throughput requirements).
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5.2 Take-up
The take-up tension is the “heart” of most conveyor systems. This devices sets the baseline belt
tension and is thus of critical importance. The take-up tension needs to be sufficient enough to
prevent belt slippage on the drive pulleys and minimize belt sag and material spillage along the
conveyor. Properly determining the required take-up tension is crucial to an optimal conveyor
design. Although Sidewinder will estimate the required take-up tension, the user should
ALWAYS specify this value by the completion of the design processes.
Take-up Type – The take-up can be gravity, fixed, automatic winch control, or hydraulic
cylinder.
For a gravity-take-up system, the take-up pulley tension remains constant and the take-up
position varies depending on the material loading.
In a fixed take-up system, the take-up pulley is not allowed to move, and therefore the beltline
tension at the take-up pulley will vary based on the loading. In this case the input beltline tension
(entered below) is specified for the empty belt steady state running condition (EM-N load case).
This fixes the take-up pulley position, and all other conditions will be determined from this state.
For an automatic winch take-up system, the take-up acts like a gravity take-up (tension is
constant, and the pulley can move) for all running conditions. However during starting and
stopping the take-up pulley displacement is fixed.
The hydraulic cylinder control works in the same manner as an automatic winch take-up system.
If automatic winch control or hydraulic cylinder is selected, an additional input will be shown on
the take-up tension input line below. This input allows a pre-tension value to be entered for the
starting case. If this value is entered, the take-up tension during starting will be set to this value.
Belt Line Tension – Input the beltline tension at the take-up pulley. The take-up mass would be
twice the beltline tension (divided by gravity) for a hanging counter weight (1:1 reeving), and
would be a function of the cable reeving for the other options.
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If a fixed take-up is used, this value represents the steady state beltline tension for the EMPTY
belt condition (EM-N case).
If an automatic winch control or hydraulic cylinder is used, this value represents the steady state
beltline tension for each load case (full, empty, partial loading).
Additionally, the automatic winch control allows a pre-tension to be entered in the first cell for
starting. If this value is entered, the take-up tension during starting will be set to this value.
Cable Reeving Ratio – This represents the cable reeving ratio between the take-up pulley and
take-up mass (pulley:coutnerweight). By clicking on the input box, a pull-down list will appear
showing the most common cable ratios.
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The figures below show reeving ratios of 0:0 (hanging counterweight), 1:1, and 4:2. The
required take-up mass and take-up mass displacement will be calculated from the belting tension
and specified reeving ratios.
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5.3 Belting
The belting input widow contains information about the conveyor belt construction. There are 5
sub-menus which include:
1. Belt – The most commonly used belting input information

2. Details - Additional and more detailed belting information which may be entered.
3. Splice – Information regarding the splice and number of belt rolls
4. Curves - Specific input data regarding the vertical and horizontal curve calculations.
5. Transitions – Transition calculation method and geometry
Each of these windows will be described below.
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Conveyor Type
Selecting the conveyor type will add/remove various inputs and outputs. Default calculation
values such as belt speed, belt width, required pulley diameters, etc. are calculated based on the
conveyor type. The output reports also reflect the conveyor type input. Available conveyor types
are:
Troughed Conveyors - General conventional troughed conveyor utilizing a 2-6 roll carry side
idler frame.
Pocket Conveyors - A new calculation method for pocket belt conveyors. When this option is
selected an additional "Sidewall" tab will be shown on the belting input. Sidewall and cleat data
can be entered or selected from the built in library.
Pipe Conveyors - This options is for pipe conveyor design. If this option is selected a 6 roll
idlers set will be selected on the carry and return side. Transition lengths, and other details will
reflect pipe conveyor design criteria rather than troughed belt criteria.
Feeder Belts - This options automatically adds the pullout forces to the fully loaded case (i.e.
"1" is entered in the "Load Pt. Pullout Force" column in the Load Conditions"" input table). The
user should still choose the desired calculation method on the "Load Point" input page (Arnold,
Bruff, Roberts, CEMA, etc).
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Speed at 100% Motor Nameplate / Speed for FL-N Case – Normally, the belt speed is entered at
100% motor nameplate. The motor gearbox ratio is then calculated from this value. For example
if the motors are 4 pole 60 Hz the motor RPM will be 1800 at zero load, and approximately 1765
at 100% motor nameplate rating. The input speed would select a gearbox ratio based on the fully
load condition (i.e. 1765 rpm). When the demand power is less than the nameplate rating, the
belt speed will be slightly faster because the motor RPM will be higher (i.e. at 50% load the
motor RPM would be ~1783 rpm). If a gearbox ratio is specified, then this input is not used
since the belt speed would be calculated from the motor RPM, the gearbox ratio, and the pulley
diameter.
Alternatively, the belt speed can also be input for the “Fully Load – Normal Friction” case. In
this case the gearbox ratio will be calculated using the belt speed entered and the motor RPM
under the fully loaded case. For example, if the conveyor power was 80% for the fully loaded
case, then the gearbox ratio would be calculated based on the motor RPM at 80% (rather than
100%).
To change from "Speed at 100% Motor Nameplate " to "Speed for FL-N Case", go to the Details
tab, and change "Belt Speed Input Method".
The reason for these two different input methods is purely in response to the end users choice.
Some users prefer to have the gearbox ratio calculated from 100% nameplate power since this
value will stay constant regardless of the calculated fully loaded power. Other users may want to
enter the belt speed for the fully loaded case and hence prefer this input method.
Note: If a VSD motor type is selected, then the motor RPM will be adjusted for each load case
to match the input belt speed. This is typically how a VSD control works resulting in a constant
belt speed regardless of the conveyor loading.
Note: The gearbox ratio is calculated using the belt speed and an “effective” pulley diameter.
The effective pulley diameter is equal to:
Effective diameter = Bare diameter + 2 * lagging thickness + 2 * belt bottom cover thickness
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Type – Select auto, fabric, or steel cord belting. If you press the button, you can have
Sidewinder enter manufacturer catalog data.
After you select a specific belt, Sidewinder will tell you the catalog data that has been entered, as
per the graphic below. It will also inform you of required pulley diameters, and required belt
width for troughability requirements. Finally, Sidewinder will also enter data on the "Load
Support/Troughability/Pulley Diam" table in the Details tab (see below).
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Width – The width of the conveyor belting.
Rating – When working in metric units, the belt rating is specified as the ultimate breaking
strength of the belt. When using imperial units the rating is specified as the working strength of
the belt.
Number of fabric plys in belt – Number of fabric plys in the belt. This will affect the belt mass,
the required pulley diameters, and the splice safety factors.
Top Cover Thickness – Distance from the belt cords (or top fabric layer) to the top of the belt.
Larger belt cover thicknesses are necessary for abrasive materials.
Bottom Cover Thickness – The bottom (pulley side) belt cover thickness.
Users can quick select the belt cover thickness by right clicking to show an input window with
standard sizes (especially handy for imperial units).
Weight – Belt mass per unit length. The belt mass will automatically be calculated for each
friction case depending on the belt cover thickness and other input parameters.
Elastic Modulus – Belt modulus depends on the belt type, rating, and number of plys (for fabric
belts).
Rubber Rolling Loss Factor – The Ky values are multiplied by this factor. This value may vary
from 0.40 to 1.35 depending on the belt’s bottom cover rubber compound.
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Belt - Details
The details tab contains more specific information about the conveyor belt construction.
Manufacture / Name – Description for belting type and manufacture. This information is only
used in the output report.
Cover Grade – This input is for the user report printout only. It will not affect the conveyor
calculations. For example the user could enter 'DIN X/X', or 'RMA II', and this information
would be included on the output report.
A right click menu with common covers is also available. This input does not affect the
calculations and is only for report outputting.
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Rubber Density – Density of rubber for calculating belt mass. Default value is 1200 kg/m3 (75
bs/ft3).
Core Belt Thickness – Thickness of the core belt. The total belt thickness is equal to the top and
bottom covers plus this value. If unspecified Sidewinder will calculate this based on the belt
rating and number of plys (for fabric belting).
Core Belt Weight – The total belt weight is the sum of the top and bottom cover masses
(calculated from their thickness) plus this value.
Permanent Elongation – Percent elongation of the belt for take-up travel requirements. Default
is 1.3% for fabric belting and 0.1% for steel cord belting.
Fillet Radius – This is the radius of the belt at the idler roll junctions.
Trougability / Load Support / Pulley Diameter Inputs

Specific data for load support, troughability, and pulley diameters can be entered. This data is
automatically entered if the user selects any of the belt in the user library (currently over 300+
belts). By clicking on the "Enter Data" button the input window below will be shown and data
can be input.
If the current belt width is not acceptable (for either troughability or load support) this will be
shown on the belting output page and the item highlighted in red.
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Minimum High Tension Pulley Diameter – If not input the required diameter for all other
pulleys will be calculated from:
Fabric Belts
Medium Tension = 82.5% of High Tension
Low Tension = 82.5% of Medium Tension
Snub = 82.5% of Low Tension
Steel Cord Belts

Medium Tension = 80% of High Tension
Low Tension = 75% of Medium Tension
Snub = 82.5% of Low Tension
Belt Speed Input Method – When using a squirrel cage motor, or fluid coupling, the belt speed
changes as a function of the motor demand power (e.g. the motor slip curve, and fluid coupling
slip). For example, a 1750 rpm motor will operate at ~1800 rpm under no load, and ~1750 rpm
under full load. Since the gearbox ratio and pulley diameters are fixed, the belt speed must
change with the demand power (e.g. an empty conveyor runs slightly faster than a loaded one).
Sidewinder allows the user to specify the belt speed (thus calculating the reducer ratio and other
variables. The speed can be input at 100% motor nameplate rating (100% MNP), or selected
such that the fully loaded normal friction case (FL-N Case) results in the input speed.
The reducer ratio will then be calculated based on the input speed and selected method. All other
load cases will be calculated using this reducer ratio. When creating a new file, this value will
default to the value in the preferences option.
Belt Scraper Drag Force – Additional drag force for each belt scraper. By default, sidewinder
assumes one belt scraper at the head pulley, and one V-plow at the tail. The default value is 5 lbs
per inch of belt width (0.875 N/mm).
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Belt - Splice
The splice tab contains details on the belt splice, take-up positing and belt roll storage.
Number of Splice Steps – Number of steps in a single belt splice.
Cable Diameter – Cable diameter used for steel cord belt construction. This value is used to
calculate the minimum pulley diameter and for the splicing properties of the belt. This value is
ignored for fabric belts.
The required cable diameter is estimated by averaging the requirements from several belting
manufactures. Thus, the actual cable diameter will vary based on the belting manufacture, cable
supplier, and conveyor location.
Number of Cables – Number of cables in parent belt.
Cable Breaking Strength – Breaking strength of an individual cable.
Splice Step Length – Length a single splice step. The total splice length is the number of splice
steps times this value, plus the bias angle (18 degrees).
Transition Length – Length from the normal belt pitch to where the splice begins. This is the
area where the cables are bent from their normal position to the splice position. This is NOT the
bias angle or distance.
Free Belt Edge Gap – This is distance from the edge of the belt to the edge of the outer cable of
the splice. This value will affect the gap between cables in the splice.
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Take-up Splicing Method - This input allows the designer to ESTIMATE where the take-up
pulley should be positioned when installing the belts final splice. Two methods can be used.
The first method assumes constant belt sag on both the carry and return sides. The second
method is based on calculating the actual belt tensions. The splicing tension is selected as 5%,
10%, or 20% of the belt rating (or as 1.0, 2.5, 5.0, or 10 tons).
The tensions are then calculated around the belt. This is done from the head, tail, and take-up
positions (three separate calculations) with the lowest value being selected. The lowest value is
selected as the final belt splice is normally always at the tail for an incline belt, and at the head
for a decline belt as the belt mass helps to ‘pre-tension the belt’.
Based on the either of the above methods a total belt length is determined. This length is then
referenced to the empty belt steady state running position (which is always selected as the zero
take-up position in sidewinder).
The pre belting splice position is then shown on the take-up tab of the ‘detailed’ output page. In
some cases this position may be above the incoming take-up pulleys. Some designers may argue
that this length should be included in the total take-up displacement. However other designers
feel this length is ‘historically’ include in the permeate displacement take-up length that is
already built into the model.
This additional output is only added a convenient reference point for the designer, and does not
affect the required take-up displacement requirements or any other calculation.
Roll Storage Type – Shipping method for the belting. Options are: Single roll, Cassette roll (two
single rolls wound together), or a Racetrack roll (elongated single roll).
Belt Roll Diameter – Maximum diameter of storage roll. If a racetrack roll type is selected, the
length of the roll is 1.55 times the diameter. Thus a 2.7 m diameter racetrack roll would be 4.2 m
long.
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Belting - Curves
The curves tab contains details on how the vertical and horizontal curves are calculated.
Use Worn Mass for Belt Lift-Off Calculations – This specifies if the worn belt weight will be
used to determine the minimum vertical curve radius to prevent belt lift-off for all load cases. For
example, the fully loaded normal friction case calculations use the normal belt mass in its
calculations. However if this option is set to 'Yes' then the vertical curve lift-off calculations and
required radii for that case will also be calculated using the worn belt mass (as specified by the
cover thickness on the 'friction conditions' page).
If this option is set to 'No' then only the belt mass for each specific case would be used.
'Yes' is the default value since this will always result in the most conservative vertical curve
calculation.
Loading for Extra Liftoff Case –Sidewinder will perform the belt liftoff calculations for this
'extra' load case and show the results on the 'Detailed Output Page' under the 'Vertical Curves'
tab. This radius is often used as the required radius for trippers and other vertical curves where
belt liftoff cannot be avoided and hold down rolls are used. The default value is 15% load, but
some users prefer to use 25%.
Vertical Curve Tension Location – Location in the vertical curve where the belt tensions will be
selected. By default sidewinder will anlized every element in the curve and select the location
with the maximum/minimum belt tensions (i.e. the most conservative design option). However,
some users prefer to use the belt tensions at the midpoint of the curve.
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Horizontal Curve (checkbox) – Check this box to add horizontal curves to the conveyor. The
geometry input page will then show a page for entering the plan view horizontal curve profile of
the conveyor.
Calculation Method - Calculation method for horizontal curves.

CEMA Methodology outlined in CEMA, Sixth Edition
Methodology outlined by Grimmer and Kessler in Bulk Solids Handling, Vol
GK
12 No 4
Side Guide Roll Max Load (N)

Allowable force on side guide roll. Used to calculate required side guide roll spacing. Sideguide
rolls are currently not available for the CEMA or Grimmer and Kessler methods.
Side Guide Roll Gap (mm)

Distance between outer edge of wing roll and side guide roll. Sideguide rolls are currently not
available for the CEMA or Grimmer and Kessler methods.
Belt/Idler Friction Ratio

This factor is multiplied to the friction factor as defined by Grimmer and Kessler on idlers with
forward title. For example, if you wish the friction between belt and the idler to be 50% less
then enter a value of 0.5. If the idlers in the horizontal curve do not have forward tilt, this
variable will not affect the calculations since the calculations assume no restrainig friction with
idlers that do not have forward tilt.
Material Follow Factor

This factor determine the extent to which the material follows lateral belt movement. For
example, if the material follow factor is 0.75 and the belt displaces 100 mm, then the material
will displace 75 mm.
Surcharge Angle Limit (deg)

This factor determines the maximum material displacement.
Once the material surcharge angle hits this limit, the material is not allowed any further
displacement. This value should be at least 5 degrees greater than the surcharge angle.
ISO 703 Belt Troughability

Belt troughability as defined by ISO 703. This factor used to determine belt stiffness and is used
in the calculations as defined by Grimmer and Kessler.
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Belting - Transitions
The transitions tab contains details on how the belt transition lengths are calculated.
Transition Type – Three transition types are available in sidewinder.
Simple – This method uses the calculations based on D. Beckley’s transition paper. Maximum
and minimum belt tensions are taken from the belt rating and safety factors specified in the
design criteria (not the actual belt operating tensions).
ISO 5293 – This method uses the 2004 ISO calculations to determine the required transition
lengths. Transition lengths are calculated for each individual load case (empty, loaded, low/high
friction, etc). The required transition length for the steady start running and moment condition is
given for each load case, and also summarized in the output. Any pulley offset height can be
entered.
Beckley - This method uses the equations from David Beckley’s 1982 ‘Belt Conveyor Transition
Geometry’ paper published in Bulk solids handling. As per the paper both inline and an
‘optimized’ pulley height can be specified. Additionally for the optimal pulley height the idler
spacing can also be entered. In this case the required trough angles, and idler packing heights are
calculated and shown in the output.
Edge Stress Multiplier – Running –This is the allowable edge stress in the belt transition during
running conditions. This value is divided by the nominal belt safety factor. For example if the
nominal belt safety factor is 10, and the user enters 1.10, the allow edge stress will be 10 / 1.10 =
9.09. If this input is left blank then the ‘Local Safety Factor Multiplier’ specified in the Design
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Criteria page is used (this is the value used to calculate the allowable edge stress in convex
curves, and the default value is 1.10.).
Edge Stress Multiplier – Momentary – This is the allowable edge stress during momentary
conditions, and for all steady state running load cases which are specified as ‘Design Level 2’
conditions (see load case inputs). It is important to note that the allowable edge stress for
momentary conditions is also divided by the Dynamic Safety Factor Multiplier’ specified in the
Design Criteria page (default value of 1.15). Thus if the nominal belt safety factor is 10, and the
dynamic safety factor is 1.15, and the user enters 1.10 in this input, then the allowable safety
factor at the edge of the belt in the transition section would be: 10 / 1.15 / 1.10 = 7.91. If this
input is left blank then the ‘Local Safety Factor Multiplier’ specified in the Design Criteria page
is used.
Idler Spacing Method –This input is only available for the ‘Beckley method’. Rather then an
equal idler spacing (the default value), it allows the user to see where the idlers would be spaced
if they were positioned ever 5 degrees. Thus if a 35 trough angle is being used, this option
would show the user the spacing (and idler packing heights) for 30, 25, 20, 15, 10, and 5 degree
idlers.
Length – Length of the transition. If this input is left blank then Sidewinder will use the
transition length from the element table (if a transition element has been input).
Idler Spacing – Idler spacing is used to output the idler banking angles and idler packing height
for each transition idler frame.
Elevation –Elevation of the pulley above the top of the middle roll. ISO 5293 recommends using
1/3 of the troughing height for elevated pulleys.
The Beckley method allows either a flat or elevated pulley to be selected. This is the distance
that the pulley is raised above the middle idler roll. If an elevated pulley is selected then the
optimal pulley elevation will be calculated.
The output formatting has been standardized between each method so the engineer can quickly
and easily compare methods. The auto selection of the required length has also been improved.
The default method is CEMA 7th, however AC-Tek recommends using the Beckley method as it
is the most accurate.
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Belt - Sidewall (Pocket Belt Conveyors)
The Sidewall tab appears when the conveyor type is set to "Pocket belt". It contains details on
the belt sidewall and cleat dimensions.
Sidewall Height – Height of the Sidewalls measured from the top of the belt. This is typically at
least 20 mm higher than the cleat height.
Free Belt Edge Gap – Distance from the belt edge to the outside of the sidewall. The useable
pocket width is:
Pocket Width = Belt Width - 2 x Free edge distance - 2 x Sidewall Thickness
Sidewall Thickness – Thickness of the Sidewall (one side).
Sidewall Weight – Weight of the sidewall (one side only). The total belt weight is the sum of:
The core belt weight + 2 x sidewall weight + cleat weight x pocket width / cleat spacing
Min Drive Pulley Diameter – The minimum pulley diameter for the driving pulleys. This is
typically 3 x the sidewall height (or based on the belt rating & construction).
Min Inflexion Pulley Diameter – The minimum pulley diameter for inflexion pulleys. This is
typically 4 x the sidewall height.
Cleat Type – Type of cleat to be used. A range of built in Sidewall belting and cleats (T, C, and
TC) are available by right clicking on the input cells. The user can quickly and easily select the
required size to meet their specific need.
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Cleat Height – Height of the cleat is measured from the belt line to the top of the cleat. For
slopes <75 degrees this should be at least 0.9 x the maximum lump size. For slopes >75 degrees
this should be at least 1.5 x the maximum lump size.
Cleat Spacing – Spacing between cleats. This must be at least two times the minimum lump size.
Cleat Weight –Weight of the cleat per unit length. The total weight for one cleat is then equal to
the cleat weight times the pocket width. The total belt weight is the sum of:
The core belt weight + 2 x sidewall weight + cleat weight x pocket width / cleat spacing
Cleat Base Width – Width of the bottom part of the cleat.
Cleat Angle – The angle the C, or TC sloped cleat section makes.
Cleat Thickness – The thickness of the upper part of the cleat.
Cleat Base Thickness – The thickness of the base of the cleat.
TC Length A – The distance from the top of the belt to where the TC cleat begins to slope.
The output window shows both a front view, and also a side view with the maximum material
slope of the conveyor. Useful output data such as the percent loading, maximum tonnage, and
cross sectional area for both the flat and sloped profiles is calculated.
Conveyor layouts are also shown, and everything can be exported to CAD with ease.
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Required pulley diameters for driving and inflection pulleys are calculated and graphically
shown with the sidewall belting.
As with conventional troughed conveyors many inputs can be left blank and Sidewinder will
intelligently select standard components as required. Output reports include all additional pocket
belt information and calculations.
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Belt - Pipe (Pipe Conveyors)
The Pipe tab appears when the conveyor type is set to "Pipe Conveyor". It contains details on
the pipe dimensions and forming forces.
Pipe Diameter – The input radius is the distance between the top and bottom idler faces (i.e.
outside diameter of the belting).
Pipe Ky Factor – To account for the belt’s forming forces, and the additional indentation losses
on the upper three rolls, a “Pipe Ky Input Factor” is used. This factor is multiplied by the normal
3-roll Ky value to account for these extra forces. The default value is 1.4, but the user can enter
any value they desire based on the belt construction and other factors. Additional idler drag is
already taken into account with the 6 roll idler set. Both standard and non-standard rolls can be
used. Initial forming forces (200 lbs) are also automatically added at all transition locations.
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5.4 Idlers
The idler input window allows up to eight (8) different idler sets to be entered. The individual
properties for each set can be entered on the front page. However, each individual roll for each
set can also be customized using the “Custom Set” input window.
There are two basic idler input methods.
Universal – This allows each idler (and/or each individual roll) to be defined individually. The
bearing series can be specified and the idler L10 life will be determined for each roll of the set.
This method is much more flexible, and allows more control over the idler design and
specifications.
CEMA – This method uses the U.S. standards of rated idler sets. These are classified as
“B,C,D,E,F” series idlers, with sizes from 4” to 8” in diameter. However the CEMA method
uses the “CIL” or Calculated Idler Load for the entire idler SET. This is different from the
universal method which calculates the idler life for each individual roll.
The CEMA manufactures association has specified the allowable “Load Rating” for various idler
sets. For example a CEMA C5 idler set (3-roll) used on a 36” belt, with a 35 degree troughing
angle, has an allowable load rating of 837 lbf. The CIL for the idler set is then calculated based
on the actual material loading, installation tolerances, and many other factors; it is then compared
to the allowable load rating.
Input values for both idler sets will be described below.
Number of Rolls – Number of rolls in idler set.
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Bearing Series – Bearing series used in the idler roll. Several standard bearing series can be
selected by right clicking on the input cell. The selection of a bearing series will specify the
“dynamic” and “static” load capacity of the bearing and thus affect the idler L10 life. The
bearing selection will also specify the roll shaft diameter if this has been left blank.
Troughing Angle – This is the angle made between the center and wing rolls, or the vee angle of
a two roll set. If a 4 or 5 idler set is used, a second input line will appear in which the user can
also specify the troughing angle of the putter set.
Roll Diameter – Outer diameter of the idler roll.
Shaft Diameter – Diameter of the idler shaft.
Total Drag for Set – Total drag of all rolls from bearings and seals. I.e. if the expected drag for
one idler roll was 1.5 N, and a 5 idler set was used, then this input would be 7.5 N (1.5 x 5).
Forward Tilt – Some installations are installed with a small forward tilt. This can help improve
tracking of the belt, but it also adds additional drag forces. These forces can be calculated using
the normal load on the idler set and the tilting angle.
Fn * sin(forward tilt) * tan(idler angle).

Where Fn = Normal force over the wing idlers (belt mass portion + material mass
portion)
Idler Installation & Alignment – This value accounts for the idler installation misalignment drag
forces. It is determined from the conveyor calculation methodology.
DIN / ISO
The DIN/ISO standard does not include idler drag forces directly. These are “lumped” into the
user input equivalent friction factor “f”.
CEMA 5th
Misalignment tolerance calculated by the 5th edition methodology.
0.0068 * (Wb + Wm) * Si (per idler set)
CEMA 6th Edition Methodology
Excellent - Permanent ridge structure with precise angular alignment - 0.375 inches
Good - Permanent ridge structure installed without alignment measurements - 0.5 inches
Fair - Mounted independent, imprecise footings - 0.75 inches
Poor - Movable or unstable footings, roof hung, or other difficult installation - 1.5 inches
CEMA 6th edition methods also assume a 0.1 inch manufacturing tolerance and a friction factor
of 0.5.
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For more information see pages 110-112 of the CEMA 6th edition book.
Garland = Garland Idler (Extra friction added per CEMA 6)

E=Excellent, G=Good, F=Fair, P=Poor Alignment
Second column is friction factor for idler misalignment, forward tilt, and Garland idlers.
Idler Type – Inline / Offset / Garland / ES Idler – This information is used in the report printout.
It is also used to estimate the gap between rolls to better estimate the belt loading as shown
below (inline vs. offset):
Inline vs. offset idler type – Set the gap between rolls
Idler Manufacture – Entering the specific idler manufacture will allow Sidewinder to better
select default idler values.
Custom Rolls Tab

Each roll of the idler set can be fully customized using the universal method. The user selects
the “Custom Set” tab, and then clicks on the option button for the desired idler set to be
customized (1, 2, 3, etc).
The figure below shows some custom idler information entered for idler set 1. In this case a
different bearing is used for the center and wing idlers. Also the wing idler will have a 152 mm
diameter roll, versus the center roll diameter of 172 mm. The length of the center roll has also
been shortened.
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Bearing Series – The bearing series for each roll. The “static” and “dynamic” load capacities
will automatically be specified if a standard value is used.
Roll Diameter – Individual Diameter for each roll
Shaft Center Diameter – The shaft diameter for the roll.
Roll Drag – The roll drag for each individual roll. Note: this is entered per roll, unlike the
general page where the roll drag is entered for the entire idler set. If the drag for each roll was
1.5 N then a 3-roll set would be entered as 1.5 for the wing, and 1.5 for the center (i.e. NOT 3.0
for the wing roll).
Length – Length for the individual roll.
Rotating Mass – Rotating mass for each roll. The rotating mass affects the total inertia of the
conveyor and thus the starting and stopping forces.
Horz. Curve Forward Tilt – If the roll has a forward tilt, this can be entered here. This value is
used in the horizontal curve calculations.
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Static Load Capacity – As defined in the SKF bearing catalog. This value is used to determine
the L10 life of each bearing, and thus the entire idler set.
Dynamic Load Capacity – As defined in the SKF bearing catalog. This value is used to
determine the L10 life of each bearing, and thus the entire idler set.
Shell Thickness – Wall thickness of the idler shell. If entered, this value will be used to estimate
the idler mass and inertia (if not specified).
Inertia – Inertia for roll.
Nonsymmetrical Roll Angle – Idler troughing angle of opposite side roll in degrees. If left blank
both rolls angles will be the same.
Nonsymmetrical Roll Length – Idler length of opposite roll.
Shaft Support Length – This is the distance between the center support points for the idler. This
distance is important as it is used to determine the shaft deflection of the idler roll.
Distance from Bearing to Support – This is the distance from the center of the idler bearing to
the center of the idler support position. This distance is important as it is used to determine the
shaft deflection of the idler roll.
Inside Diameter Hollow Shaft – If idler shaft is hollow, then enter the inside diameter this
dimension is for the center portion (between bearing) of the shaft
Gap Between Idlers – This is the gap between idler rolls. For example, Garland idler sets have
wider gaps than a fixed idler set.
Shell Type – Allows the user to specify various idler types. This includes the following:
Steel - Regular steel shell idlers.

Impact - Impact, or other equally spaced rubber disk idlers.
1-Roll - Rubber disk single roll return sets. Uses three closely spaced disks on each end.
2-Roll - Rubber disk Vee roll return sets. Uses three closely spaced disks on one side only.
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Number of Disks – If a rubber disk idler type is specified above, then the actual number of disks
can be specified here.
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5.5 Motors
The motor input page contains all relevant information regarding the conveyor motors. The
input will change according to the motor type selected. The following graphic shows the base
input.
The available motor types are listed below:
Motor Type: Squirrel Cage (SC, SCSS) and Wound Rotor Motor
Type – Squirrel cage, wound rotor motor, and fluid coupling calculated belt speed based on
motor RPM, slip, pulley diameter, and reducer ratio such that belt speed varies with demand
power. For variable speed drives the motor RPM changes to match input belt speed. All motors
must be of the same type.
Number of Motors on Pulley – Enter the number of motors on this pulley (1 or 2).
Nameplate Rating per Motor – Enter nameplate rating per motor. For example, if a drive pulley
has two 250 kW motors, then enter 250 here and '2' for the number of motors above.
Motor Voltage – Voltage of motors. This input is for information only – it does not affect
calculations.
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Synchronous RPM – Synchronous speed of motor. Default value is 1500 RPM (1800 RPM for
North America) for motor ratings less than 2800 kW. If motor rating is greater than 2800 kW,
default is 6 poles (1000 RPM or 1200 RPM).
Starting Torque – This value is used in conjunction with the "Dynamics - Starting”. The value is
multiplied by the motor nameplate rating to determine the motor torque available during starting.
The starting time is then calculated from this value. Depending on the starting option selected on
the dynamic tab, the full load demand torque can be used instead of the nameplate torque.
This is often used for fixed filled fluid couplings that have their initial fill levels set in the field
based on a specified startup time for the fully loaded condition.
If the starting control is set to "Use a fixed starting time," then this value is ignored.
Motor Slip – Motor slip at 100% nameplate rating. The default value is 1.5%.
Inertia - Motor – High speed inertia of motor.
Flywheel and Brake Disk Inertia
Inertia – Flywheel – High speed inertia of flywheel on each motor. Note if there are two motor,
then there will be two flywheels, so total flywheel inertia on the drive pulley is number of motors
x flywheel inertia.
If the motor has a high speed brake and the brake disk is doubling as a flywheel, then the
flywheel inertia should be set to zero and the dimension of the brake disk must be entered.
For example, suppose you want a 20 kg∙m2 flywheel on a motor. If you don’t have a high speed
brake, simple enter 20 in the “Inertia – Flywheel” input box.
The plan view of the drive assembly will show the flywheel:
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However, if the drive assembly also has a high speed brake and the brake disk will double for the
flywheel, then “Inertia – Flywheel” should be zero. Then go to the “Brakes” tab and enter the
brake disk diameter and thickness to obtain the correct inertia.
Note that the flywheel inertia is zero. The plan view shows brake disk (dimensionally correct):
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If you enter a flywheel and have a high speed brake, Sidewinder will include the inertia for both
a flywheel disk and a brake disk. If you do not enter a brake disk size, Sidewinder will auto
select an appropriate size disk for the brake rating.
The plan view will show both the flywheel and brake disk.
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VFD Motors
If you select VFD for motor type, the input will change:
Sidewinder will set “Starting Torque” to zero since this input has no meaning for VFD. The
starting time will be adjusted proportional to the conveyor length.
For VFD, the following input is available. Both of these inputs are generally not used. They are
for special situation where you purposely require that the motors do not load share evenly.
Running Torque Limit (%) – This input allows you to limit the motor torque of a specific motor.
In the following example, the motor torque of the secondary drive is limited to 80% nameplate.
When the required power is less than 80% the motors will load share. When motor power is
greater than 80%, the secondary torque will be 80% and the primary will adjust upwards to take
up the additional power.
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Motor Load Cell Tension – This is a special input that will allow you to adjust motor torque to
achieve a target tension point on the slack (low tension) side of the drive pulley. The assumption
is that a load cell will be placed at the low tension side of the pulley. The motor torque is then
proportional to the load cell. The following graphic shows the tool tip for this input.
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Fluid Couplings (TV, TVV, TVVS, VSFC)
If you select a fluid coupling for motor type, the input will change:
TV = fixed filled fluid coupling

TVV = fixed filled fluid coupling with delay chamber
TVVS = fixed fill fluid coupling with enhanced delay chamber
VSFC = variable speed fluid coupling
Fluid Coupling Size – Right click for a list of standard coupling sizes. When selected, the high
and low speed inertia values are automatically updated below.
Note: If the fluid coupling size is left blank then Sidewinder will show the required size (i.e. 562,
750, etc) in the motor output tab.
Coupling Slip at 100% Nameplate – Fluid coupling slip at 100% demand power. The coupling
efficiency is also equal to this value. (coupling efficiency = input speed / output speed). The
default value is 3.0% for fluid couplings.
Inertia –Input Fluid Coupling – High speed inertia of the the input (or motor side) of the fluid
coupling
The user can right click on the ‘Fluid Coupling Size’ input (only shown when a fluid coupling
type is selected in the first input line above) and choose a specific type. This selection will
automatically fill in both the input, and the output fluid coupling inertias based on the
manufactures catalog.
Note: If the fluid coupling size is left blank then Sidewinder will show the required size (i.e. 562,
750, etc) in the motor output tab.
Inertia – Output Fluid Coupling – High speed inertia of the output (or reducer side) of the fluid
coupling
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5.6 Reducers
The reducer input page contains all relevant information regarding the conveyor reducers.
Manufacture – Various reducer manufactures are available. If you select a reducer manufacture
from the list, Sidewinder will use the manufactures’ catalog and calculate a frame size and exact
gearbox ratio for you. You can then enter the exact (catalog) reducer ratio in the Sidewinder
input to calculate the exact belt speed (based, of course, on pulley diameter and motor RPM)
Reducer Ratio – The exact reducer ratio can be entered here. The motor output RPM (adjusted
for the demand power slip), pulley diameter, belt thickness, and reducer ratio are then used to
determine the real belt speed (unless a VFD drive is used, in which case the motor RPM will be
varied to match the user input speed).
Frame Size – Catalog frame size or ID number.
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Configuration – Can be right angle, parallel, or shaft mounted reducer. This input does not
affect calculations, however, the plan view of the motor will correctly reflect the configuration.
Right Angle or Shaft Mounted Parallel
Number of Stages – The number of stages is used to calculate the gearbox efficiency and select
the correct frame size and gearbox ratio.
Efficiency Loss per Stage – The Efficiency loss per stage times the number of stages gives the
reduce efficiency at 100% loading. The default value is 1.5% per stage. The user can enter the
number of reducer stages (usually 2 or 3) and then loss per stage (default value is 1.5%). If these
are left blank, sidewinder will assume a three-stage reducer and thus a reducer efficiency of
95.5% (1.5% x 3 = 4.5% loss).
Service Factor – Reducer service factor. Default value is 1.5.
Gearbox Churning Constant – The churning loss coefficient is used to determine the reducer
losses below the nameplate rating. The reducer loss is calculated by (x + (1 - x) * percent power)
* reducer efficiency * input power where x = churning loss coefficient (0 - 1).
If x = 1, then the reducer loss is a constant (i.e. independent of the current absorbed power). It is
equal to the reducer efficiency * motor nameplate power.
If x = 0, then the reducer loss is equal to the reducer efficiency * absorbed motor power for that
case.
The default and recommend value is 0.65.
Inertia - Reducer – High speed inertia of the reducer.
V-Belt Type - V-Drive Belt Type from the ABB Baldor Dodge Catalog (A,B,C,D,3V,5V,8V)
Number of V-Belt - Number of V-Drive Belts
Motor Sheave Diameter - Diameter of sheave on the motor (for V-Belts).
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Reducer Sheave Diameter - Diameter of sheave on the reducer (for V-Belts).
Chain or V-Belt Reduction Ratio – If the motor is coupled to the gearbox by a chain or v-belt,
then enter this ratio here.
Note: If a chain or v-belt is used, then the "Other Efficiency Losses" input on the motor tab page
should also be entered (recommend value of 5% or more) to account for the added losses.
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Belt Driven Reducers - Dodge Torque Arm II

The ability to easily use belt driven reducer has been added. Furthermore, the entire lineup of
the Dodge TA-II units have been included.
To use a belt driven system simply select the manufacture as a "Dodge Torque arm II", or you
can enter "Shaft Mount" as the "Configuration" on the reducer input page.
Not only will Sidewinder selected the appropriate reducer unit, it will give the exact catalog
reducer ratio. Furthermore, the motor frame size, and required minimum sheave sizes are also
determined. From this the software will select the required V-Belt series (AX, BX, C, D, 3V,
5VX, 8V, etc) as well as the number of V-belts!
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If you want a different ratio the user can enter a reducer ratio (like 15, or 25) and then sidewinder
will try and get a reducer that matched that size. The user can also pick a specific belt type and
other input data to base the selection on.
The maximum shaft bore size is output on the motor outage and highlighted in red if it is too
small. A wide range of other data is also output on the motor output page and the word report.
We hope you all enjoy this new feature!!!
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5.7 Brakes
The brake input page contains all relevant information regarding the conveyor brakes.
Location (Low/High Speed Shaft) – Specifies if the brake is located on the high speed or low
speed side of the shaft. Only brakes on driven pulleys may be specified as high speed.
Number per Pulley (1 or 2) – Specifies if there is one brake, or two (i.e. both sides), on the
pulley. If not specified then the number of brakes is equal to the number of drives
on that pulley. I.e. if there are two drives then it is assumed both have a brake.
Nameplate Rating per Brake – This is the nominal rating of brake, which is the normal expected
brake torque. If a brake clamping force and disk diameter are input below then this value is
calculated using:
Torque = (2 * µ * Fc) * (D - Pt) / 2
where:
Fc - Clamping Force
µ - Coefficient of Friction
D - Brake Disk Outer Diameter
Pt - Pad Width (~ 50-70 mm for high speed brakes and 130-200 mm for low speed brakes)
If there are two brakes then the total brake torque is double this value. The beltline braking force
is the total brake torque divided by the effective pulley diameter.
Manufacture – Brake Manufacture - For report output only.
Brake Model – Brake Caliper Model - For report output only.
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Auto Selection
The user can select from various built in brakes and standard brake disk sizes by right clicking
on the manufacture.
When a specific brake caliper is selected, the clamping force, maximum clamping force, loss of
force per mm, and other details are automatically filled in. The output data not only contains the
brake caliper details, but also the maximum and minimum (worn) braking torque. These torques
can then been added as additional load cases. This will ensure the bake is sufficiently sized to
stop the conveyor even under worn braking conditions, but also check that it is not oversized
such that it compromises the maximum belt tensions, pulley shaft limits, belt lift off in vertical
curves, and other design criteria.
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Number of Calipers – Number of brake calipers per brake disk.

The default value is 1.If there is an overhung load, or balanced braking is required, then this
should be set to 2.
Clamping Force – Clamping force per brake (Fc).
Brake Disk Diameter – Outer diameter of disk brake (D).
Brake Disk Thickness – Thickness of disk brake. This affects the brake heat capacity and inertia.
Maximum Clamping Force – This is the maximum braking torque in the new condition. This
value should be used in a separate load case to determine the maximum belt stresses and
minimum stopping times. The default value is 20% above the minimum clamping force without
any pad wear (new condition). In this case the coefficient of friction is set to 0.45.
Maximum Pad Wear – This is used in conjunction with the loss of force below to determine the
minimum clamping force. The minimum clamping force should be used in a separate load case
to ensure the brake is large enough to stop the conveyor in the required times. The default value
is 2.5 mm of pad wear before the brake would need to be adjusted.
Loss of Force (%) – This is the loss of caliper braking force per mm (or per inch).It is used to
determine the minimum clamping force. The minimum clamping force should be used in a
separate load case to ensure the brake is large enough to stop the conveyor in the required times
The default value is 10% per mm of pad wear. In this case the coefficient of friction is set to
0.35.
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Brake Load Cases

Maximum and minimum braking conditions for the fully loaded, inclines loaded, and declines
loaded conditions can be selected from the load conditions pull down list.
You can view a new braking tutorial from: https://youtu.be/Xh7DefdPrxs
If the user selects a nominal brake torque, a required disk size and brake disk clamping force is
calculated. However, it is important to understand that all spring applied brakes operate within a
specified design range. The brake disk torque is calculated using the following formula.
Torque = (2 * µ * Fc) * (D - Pt) / 2
where:
Fc - Clamping Force
µ - Coefficient of Friction
D - Brake Disk Outer Diameter
Pt - Pad Width (~ 50-70 mm for high speed brakes and 130-200 mm for low speed brakes)
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The three "design" ranges for the brake clamping force are:
Nominal Clamping Force - This is the expected normal clamping force of the brake.
Maximum Clamping Force - This is the maximum expected clamping force for the
brake. This value is normally specified in the manufactures catalog for a given brake. If it
is left blank Sidewinder will default to 120% of the nominal clamping force.
Minimum Clamping Force - This is the minimum clamping force for the brake in it worn
condition. This is calculated using the maximum allowable pad wear and the percent loss
of brake force per mm of pad wear. Normally 2-3 mm of brake pad wear is typical before
pad replacement (Sidewinder defaults to 2.5 mm of wear if unspecified). The loss of force
per mm is normally specified in the manufacture catalog (if unspecified Sidewinder
assumes 10% loss per mm).
Additionally, the nominal expected coefficient of friction is assumed to be 0.40. However in the
maximum braking torque condition this value is increased to 0.45. In the worn condition this
value is deceased to 0.35.
From these values Sidewinder automatically calculates both the minimum and maximum
expected braking torque range for a specific brake. These additional cases can then be added as
additional load cases and checked by the designer to ensure the brake is correctly size.
These details are included in the Sidewinder design report and allow the brake manufacture to
provide a correctly sized brake based on these values. This prevents brakes from being oversized
(which is very common) when only a nominal braking torque is specified.
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5.8 Backstops
The backstop input page contains all relevant information regarding the conveyor backstops.
Location (Low/High Speed Shaft) – Specifies if the backstop is located on the high speed or low
speed side of the shaft.
Note: Only backstops on driven pulleys may be specified as high speed
Number per Pulley (1 or 2) – Specifies if there is one backstop, or two backstops (i.e. both
sides), on the pulley.
Nameplate Rating per Backstop – This is the maximum torque the backstop is capable of
applying.
Safety Factor / Nameplate Multiplier – If left blank the backstop rating will be sized off the
total installed motor power, times the motor starting torque, divided by the number of backstops.
However if a backstop safety factor is entered in this input, then it will be used in place of the
starting torque multiplier above.
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5.9 Pulleys / Shafts

The pulley and shaft input page contains all relevant information regarding the conveyor pulleys
and shafts.
Pulley Dimensions and Type
Pulley Type – Pulley Type (High Tension, Medium Tension, Low Tension, or Snub). This will
determine the required pulley diameter and other default pulley inputs when the user does not
specify them. If left blank, Sidewinder will determine the appropriate type by belt tensions and
wrap angle.
Pulley Diameter – Bare pulley diameter (i.e. not including lagging).
When using the DIN calculation method, the pulley diameters are based on the new DIN 22101
standard. This method uses a lookup table based on the core belt thickness and the fully loaded
running tensions.
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The CEMA methods use a pulley diameter of 175 times the cable diameter for steel cord belts,
and an internal lookup table (based on number of belt plies) for fabric belting.
Medium tension pulleys are one standard size smaller then high tension pulleys. Low tension
and snub pulleys are then one additional size smaller (with the exception of pulleys greater than
1000 mm which in some cases can be reduced further).
Lagging Thickness – Default value is 12 mm (0.5 inches) for ceramic lagging, and 10 mm
(0.375 inches) for rubber lagging.
Ceramic Lagging – Check this box if the pulley has ceramic lagging. This affects the allowable
coefficient of friction to prevent belt slip. The coefficient of friction is specified on the “Design
Criteria” project page. The maximum allowable tension ratio is then equal to:
TR = T1 / T2 * e ^ (theta * f).
Face Width – Pulley face width.
Pulley Drag – This is the bearing and belt flexural losses for each pulley of the given type. If
left blank this defaults to:
CEMA 5th - Tight side 150 to 240 degrees, 200 lbs/pulley

Slack side 150 to 240 degrees, 150 lbs/pulley
All other pulleys less than 150 degrees, 100 lbs/pulley.
CEMA 6th - Function of belt type, wrap angle, and tensions (see CEMA 6th manual
page 126 for details).
DIN 22101 – Included in Cs factor (which is a function of conveyor length).
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Shaft Input Data
Shaft Material – Shaft material. Left

click to select from library.
Tensile Fatigue Yield
Standard
Strength Strength Strength
Materials
(MPa) (MPa) (MPa)
SAE 1018 444 200 220

SAE 1045 626 280 310
SAE 4140 726 330 415
EN8-N 510 230 245
EN8-Q 700 315 385
EN8-R 775 350 465
42CrMo4 833 375 460
AISI 4340 744 335 472
AISI 4140 655 295 417
AISI 1018 634 285 386
AISI 1045 585 265 505
AISI 1020 395 180 295
C45E 560 280 275
S355J2G3 450 225 285
2CrMo4V 900 450 550
EN19-R 775 350 495
Shaft Center Diameter – Shaft diameter at pulley center.
Bearing Input Data
Bearing Centers – Distance between the centerline of the bearings.
Bearing Diameters – Shaft diameter at bearing.
Plummer Block – Name of the bearing plumber block, for example SNL 517. Specify this will
also set the correct bearing properties.
Bearing Series – ID number of the bearing to be used. For example 22324 for a SKF 100 mm
shaft. If a bearing is input Sidewinder will try to lookup the dynamic capacity for the bearing and
thus calculate the correct L10 life.
Dynamic Capacity – Dynamic capacity of bearing for determining L10 Life. L10 life is based
on the result force from the design tension. Design criteria for pulley design tensions are found
in the “Design Criteria” tab of the Info page.
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Hub Input Data
Hub Centers – Distance between the centerlines of the hubs.
Shaft Diameter at Hub – Shaft diameter at hub.
Hub Key Type – Hub key type determines the Kf factor. This factor is applied to the stress at the
shaft hub contact zone. The factors are:
None = 1.00
Profile = 0.63
Sled = 0.77
LD NF = 0.82 (Locking Device Notch Factor)
Locking Device – Type of locking device used

(XT Bushings, B-LOC, Ringfeder, BIKON).
The locking device will set the correct
dimensions for both the locking device and
hub. Left click to select from the internal
library.
End Disk Type – Type of end disk used on the pulley. Turbine type end disk can be used on
medium and low tension fabric belting. L-Bottom and T-bottom end disks are recommended for
steel cord belting.
Turbine T-Bottom L-Bottom
End Disk Thickness – End disk thickness.
Shell Thickness – Thickness of shell or rim.
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Design Criteria
Safety Factor – Yield stress and fatigue failure safety factor.
Max Shaft Deflection – Steel Cord – Allowable deflection of shaft for steel cord belts (minutes).
Max Shaft Deflection – Fabric Belting – Allowable deflection of shaft for fabric belts
(minutes).
Yield Strength – Yield strength. Leave blank to use default properties for above selected
material.
Fatigue Strength – Fatigue strength. Leave blank to use default properties for above selected
material.
Overhung Load
This section enters the overhung load for the shaft calculation. Sidewinder does not
automatically calculate an overhung load, even if you set the reducer to shaft-mounted. If you
wish the overhung load to be calculated in the shaft analysis you must manually enter the data.
The same overhung load is applied to the design tensions in the shaft analysis.
Overhung Load - Vertical – Overhung load in the vertical direction.
Overhung Load - Horizontal – Overhung load in the vertical direction.
Distance to Bearing Centers – Distance from the bearing center to the location of the overhung
load. The center of the overhung load is typically the center of the gearbox.
One Side / Both Sides – If the overhung load is on both sides.
Shaft Diameter – Shaft diameter at overhung load.
Note that the overhung load can be estimated in the “Overhung Load Work Page”, which is
reached by “Advanced” menu. See the description for this work page in the Advanced Chapter.
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Briefly, after you have entered or estimated component masses and distances, you can right-click
to on the “Output Calculation” grid to send results to the “Pulley / Shaft” input grid. See below:
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AS-1403
Sidewinder calculates shaft stresses according to both CEMA and the ASA 1403 standards. The
following inputs are specifically for the AS 1403 calculation.
K Factor (Hub) – AS-1403 K factor at the hub.

The default value is 1.3 for a keyless hub
The default value is 1.3 + 0.2 * 1.3 = 1.56 for a profile key
The default value is 1.3 + 0.2 * 1.1 = 1.52 for a sled key
K Factor (Bearing) – AS-1403 K factor at the bearing. The default value is 1.5
The AS-1403 results are shown in the AS-1403 tab in the Details. The selected line in the “Shaft
Summary” grid are shown in the detailed results of the AS-1403 grid. Note that the listed results
in the Shaft Summary grid are per CEMA calculation, even if enter the factors for the AS-1403.
Therefore, the “Minimum Safety Factor”
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CEMA – kf for Bearing and Hub
kf Factor (Hub) – CEMA kf factor at the hub. CEMA B105 does not define fatigue stress
concentration factors (kf) for a hub which uses a locking device.
Annealed Quench and drawn

(<200 BHN) (>200 BHN)
Locking device 0.82 0.82
Profile Keyway 0.63 0.50
Sled Runner Keyway 0.77 0.63
Note that the default value (depending on keyway type at hub) is normally determined from the
“Hub Key Type” input. If you enter a value in this input (kf Factor) it will override the default
value.
kf Factor (Bearing) – CEMA kf factor at the bearing. CEMA B105 does not define fatigue
stress concentration factors (kf) for the bearing. The default value is 1.0
Low Speed Coupling
Coupling Distance – Distance from the bearing center to the coupling face (ie end of the shaft).
Coupling width – This is the total width of one side of the low speed coupling (not both halves).
Note: The stresses at the coupling are calculated at the coupling center. Thus the distance from
the pulley center is equal to:
Bearing center distance + coupling distance - 1/2 the coupling width..
K Factor (Coupling) – Shrink fit stress concentration factor (K for AS-1403 & Kt for CEMA
method)at the coupling. The default value is 2.0.
Mass (Coupling) – Mass of low speed coupling. If entered, overhung load for low speed
coupling will be calculated.
Fillet Distance & Radii
Hub Fillet Distance – Distance from the hub center to the inside turndown radius.
Hub Fillet – Fillet radius at the hub turndown.
Bearing Fillet Distance – Distance from the bearing center to the turndown radius.
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Bearing Fillet – Fillet radius at the bearing turndown.
Coupling Fillet Distance – Distance from the bearing center to the coupling turndown radius.
Coupling Fillet Radius – Fillet radius at the coupling turndown.
Other
Pulley and Shaft Weight – Pulley and shaft weight used to calculate the pulley loads. Does
NOT include the weight of the bearings.
CEMA Pulley Diameter SF – If this value is entered the required pulley diameter will be
calculated using the 'CEMA B105.1 Pulley Specification' (table 1 - page 8). This specification is
only valid for fabric belting, with belt tensions less than 1000 PIW, and 60″ and lower pulley
diameters. The table has been extrapolated to 90″ pulleys therefore the user must verify the
design with the pulley and belting manufactures.
This factor is multiplied by the pulley 'Design Tension'. For example, if the maximum running
tension is 100 PIW and the 'Pulley Tension Multiplier' (in Design Criteria) is set to 1.10, and a
value of 1.2 is entered in this cell, then the pulley 'Design Tension' would be 110 PIW (100 *
1.1) and the CEMA lookup table tension (for pulley diameter sizing) would be 132 PIW (110 *
1.2).
This multiplier only affects the required pulley diameter output, and does not affect the pulley
Design Tensions.
If this input is left blank, the pulley diameters will be sized based on either the 'DIN' criteria (if
'DIN' is selected as the calculation method), or using averaged values obtained from various
belting manufactures (function of rating and number of plys)
Allowable Bearing Turndown (%) – Sets the allowable turndown ratio at the bearing.
A value of 10 would allow a 10% turndown (i.e. a shaft diameter of 100 mm and a bearing
diameter of 90 mm). The default value is 20% (i.e. a minimum bearing diameter of 80% of the
shaft diameter).
Manufacture – Manufacture of pulley.
Lagging Pattern – Patter cut into the lagging.
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5.10 Dynamics
The dynamic input page contains all relevant information regarding the conveyor starting and
stopping behavior.
There are three dynamic conditions calculated in Sidewinder. These are:
1. Starting – Accelerating the belt from rest.
2. Operational Stop – Stopping procedure used when a planned shutdown of the

conveyor is to be performed.
3. Emergency Stop – Stopping procedure when an unplanned stop occurs. This may
include a pull cord trip, power failure, or other abnormal condition.
Starting
These option buttons are used to specify the motor torque, or acceleration time of the conveyor.
Fluid Coupling – This option is used for a fixed filled fluid coupling (TV, TVV, or TVVS).
Starting torque for this option depends on values for ′Minimum Starting Torque (%)′ and
′Starting Torque (%)′ on the Motors tab. Starting torque is:
Starting Torque = Min Starting Torque + (Starting Torque - Min Starting Torque) * Running Torque
For example, if the min starting torque is set to 80%, starting torque set to 145%, and the running
power is 77%, then starting torque will be 130% for this load case.
The above calculation is used to get a reasonable estimate the starting torque of a fixed fill fluid
coupling. Fixed filled fluid coupling will typically result in varying starting torque depending on
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the total inertia of the conveyor and friction levels. For example, since an empty belt normally
has both low inertia and low friction it will start up relatively fast and the maximum torque
during starting does not reach the same level as a fully loaded belt since the belt comes to full
speed before the fluid coupling has completely filled.
If the demand power of a load case is 100%, then starting torque will be the Starting Torque.
However, at lower demand power the starting torque is reduced. The starting torque always will
be at least the Minimum Starting Torque. This method of estimating starting torque for fixed fill
fluid coupling is typically more reasonable than simply assuming all load cases have the
maximum starting torque.
Use the maximum input motor torque - This method uses the starting torque input value on the
motor input page. This torque is used for each load case, and thus the starting time of the
conveyor (and acceleration rate) will vary for each load case.
Use the max starting torque (based on full-load demand power) - This method is the same as
the above method except it assumes 100% torque is based on the fully-loaded normal case (not
the motor rating). For example, if the fully loaded and normal friction case (FL-N) has a running
power of 77% and Starting Torque is set to 145%, then starting torque will be 1.45*0.76 = 110%
for all load cases.
Use a fixed stating time - This method uses a fixed acceleration time for all load cases. Thus all
load cases will start in the same time; however the motor torque will vary for each case. This
method is similar to the operation of a VFD, variable speed fluid coupling, or DC drive system.
Breakaway Multiplier – The user can enter a breakaway multiplier to ensure that the motors for
small conveyors have enough torque to start the system under the worst case conditions. This
multiplier ONLY affects the “Breakaway Torque %” output on the motor properties output page.
All drag components (except material lift) are multiplied by the breakaway input value for the
starting condition. The output value can then be compared to the “locked motor torque” value
for the conveyor drive being used to ensure the motor can begin accelerating the system. The
default value is 2.
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Include Motor Inertia – If this option is selected the starting calculations will take the motor
inertia into account when determining the conveyor acceleration time. If the conveyor has a
fluid coupling then this input should be unchecked as the motor comes up to full speed well
before the coupling torque reaches its maximum values.
Operational Stop
These option buttons are used to specify the deceleration time of the conveyor.
Turn motors off & drift to a stop – The motors are turned off and the belt is allowed to drift to
rest. Most small conveyors operate in this manner (direct drive, fluid couplings, etc)
Turn motors off & apply maximum braking torque – The motors are turned off and all brakes
are fully applied (using the braking torque specified on the brake input page).
Use motors to decelerate conveyor – The motors are used to decelerate the conveyor in a fixed
time. The required motor torque will vary for each load case. This method is similar to the
operation of a VFD, or DC drive system.
Turn motors off & apply the required braking torque for deceleration time – The motors are
turned off and the amount of braking torque is determined by the user specified deceleration
time. This would simulate a proportional braking control. All load cases will stop in the
specified deceleration time, but the required braking torque would vary with each load case. If
the drift time of the conveyor is less than the specified deceleration time, then the applied brake
torque is zero and the belt will drift to rest. If the required braking torque is above 100% of the
user input value, then only the input value is used and the belt will stop in the time calculated for
this torque (i.e. longer then the user specified value since the brake can only apply 100% torque).
Apply Capstan (Fix Take-up) – This option assumes the gravity take-up is equipped with a
capstan brake which is applied during stopping. During stopping the take-up pulley is assumed
to be fixed. A capstan brake on the take-up can be used to prevent low tensions during stopping
that may occur on some conveyor with a gravity take-up.
Emergency Stop
These option buttons are used to specify the deceleration time of the conveyor in a power failure
or emergency condition. On many conveyors this will be the same as the operational stopping
method. However, on more complex conveyors this method will be different. In all cases the
motors are offline.
Drift Stop – The motors are turned off and the belt is allowed to drift to rest
Apply maximum brake torque – The motors are turned off and all brakes are fully applied (using
the braking torque specified on the brake input page).
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Apply braking torque required for deceleration time – The motors are turned off and the
amount of braking torque is determined by the user specified deceleration time. This would
simulate a proportional braking control. All load cases will stop in the specified deceleration
time, however the required braking torque would vary with each load case. If the drift time of
the conveyor is less than the specified deceleration time, then the applied brake torque is zero
and the belt will drift to rest. If the required braking torque is above 100% of the user input
value, then only the input value is used and the belt will stop in the time calculated for this torque
(i.e. longer then the user specified value since the brake can only apply 100% torque).
Chute Fill – Receiving Conveyor

The bottom inputs on the Dynamics Tab are used to calculate material fill volumes in transfer
chutes. If the transfer chute is at the head such that the transfer chute is receiving material, then
select “Receiving Conveyor” option.
To determine the worst case condition, the minimum “emergency stopping time” should be
entered for the receiving conveyor. The running speed of the receiving conveyor is also
required. The default speed for the receiving conveyor is the same as the feeding conveyor
(which is the conveyor being calculated).
The figure above shows the material buildup for the fully loaded normal friction case when the
receiving belt stops in 5 seconds, and has a speed of 3.5 m/s. In this case the design conveyor
has a speed of 3.5 m/s and takes 10 seconds to stop. Under these conditions there will be
approximately 1.65 m3 of material buildup at the transfer point.
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5.11 Load Points – Feeder Belts and Skirtboard Elements

The load point input page contains all relevant information regarding the conveyor loading
points. The conveyor can have multiple load points. Input data for each load point can be entered
by selecting the load point number button (see highlighted green boxes in image below).
Likewise, the user can select the output load point information by clicking the respective load
point button. The load point input page is also used for feed belt type conveyor calculations.
It should be noted that “Pullout” forces are ONLY included if the users specifies them in the
“Load Conditions” input table (shown below). Entering “1” would include pullout forces for
loading point #1, “2” would be for loading point #2, or “1,2,3” would be for loading points 1,2,
and 3, etc.
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If the conveyor type is set to "Feeder Belt" then the first Fully Loaded normal friction case will
by default include a "1" in the Load Point Column as shown below.
There are several calculation methods as described below:
Arnold - Arnold, Mclean, & Roberts, 1980. Bulk Solids Storage, Flow and Handling. 2nd ed.
This method considers the surcharge at the outlet as being the difference between the weight of
the material in the hopper section plus the surcharge Qc at the transition minus the vertical wall
support. They used the original Jenike method for the initial normal wall pressures in the hopper.
Reisner - Uses the 'Normal Wall Pressure' (oW) at the hopper outlet. Provides a good
approximation for belt, apron and table feeders during flow. No initial filling (start-up factor) is
given, however Reisner indicates that initial loads are 2 to 4 times higher if the bin is filled from
completely empty and only 1.1 to 1.2 times higher if the bin is not completely emptied before
refilling. A default start-up value of 2.5 is used for this method.
Bruff (Including end effects) - Flow conditions are approximated by taking the weight of a
block of bulk solid of height = 4 x R (where R = hydraulic radius) above the hopper outlet. End
effects are included. A default start-up factor of 4.0 is recommended in this paper.
Johanson - Half of Bruff's method and always neglects the end effects for a long slotted outlet.
No initial filling (start-up factor) is given. A default start-up value of 3.0 is used.
Roberts - Similar to the Arnold method only the flow case (qf) is base on assuming the major
consolidation pressure acts downward at the outlet. Equation 29 from Roberts paper 'Wall
Pressure-Feeder Load Interractions in Mass Flow Hopper/Feeder Combinations', Bulk Solids
Handling, Vol 6, Num 4, August 1986 is used for qf.
CEMA - Uses the weight of a block of material above the slot opening. The volume is calculated
by entering an internal material build up angle for the flow condition (typically 70-80 degrees).
No information is given for the startup condition and thus Sidewinder uses a vertical block with a
height of 2.5 times the slot width. Alternatively, the user can enter a start factor (input below)
for the initial starting condition.
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CEMA states the coefficient of friction at the shear plane to be:
u = tan(internal friction angle),
However, Sidewinder follows Roberts original recommendation and uses
u = sin(internal friction angle) which seems to give more reasonable

(yet still conservative) results.
The user can enter any value they feel comfortable using for this value.
Custom - Allows the user to enter a qi and qf factor.
An example based on Roberts original BELTCON 2 paper is included and can be found in the
/Sidewinder/Examples directory. The paper compares several different methods for a typical
belt feeder and is a good start for users wanting to understand some of the basic theories behind
feeder belt designs. It can be downloaded from:
http://www.saimh.co.za/beltcon/beltcon2/paper27.html
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Pullout Forces
All methods calculate the pullout force by taking the vertical loading and multiplying by a
shearing coefficient (u).
Thus: F = u * vertical load.
Where 'u' is typically taken as:
u = 0.4 - Reisner & Bruff methods

u = Sin(internal friction angle) - CEMA method.
u = 0.8 * Sin(internal friction angle) - Arnold, Reisner, Johanson, and Roberts methods.
The specific inputs depend on the calculation method selected:
Slot Length - Length of the slot opening where material is discharged. This value is used
to calculate the material volume above the slot, and thus the pullout forces. If left blank, and the
conveyor is less than 20 m (assumed to be a feeder belt) Sidewinder will default to 80% of the
element length. Otherwise Sidewinder will use 1/3 of the element length, with a maximum slot
length of 2 m. When possible the user should specify the actual slot opening length to more
accurately determine the material volume and vertical shear loads.
Slot Width at Front –The slot width at front of feeder is used to calculate the material volume
and the material cutoff height (below). The default value is 2/3 the belt width for troughed idler
sets, and the belt width minus the required edge distance for single roll sets.
Slot Width at Rear –Slot width at rear of feeder. The default value is the slot width at the front,
except for the CEMA method which uses the front width minus a 1.0 degree taper angle. If a
front and rear width are entered then the slot width is taken as the average value.
(B) - Average Slot Width = 1/2 * (Front Width + Rear Width).
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Material Buildup Angle – This angle is used to calculate the vertical material volume and shear
load under the hopper for the CEMA method. This area is shown in yellow on the Load Pt output
page.
CEMA 6th edition recommends an angle which varies from 70-85 depending on the material
properties. The default value is 75 degrees for the flow condition, and 90 degrees for the initial
starting condition. If 90 degrees is used then the "Material Cutoff Height" input will default to
2.5 times the slot width.
Material Cutoff Height –This value effects the total volume of material above the slot, and thus
the vertical load and resulting pullout shear forces.
Note: This distance is measured from the BELTLINE (not from the shear plane) to the top of the
material. The default value is 2.5 times the average slot width.
The maximum value (cut off limit) is 10 times the average slot width.
Width of the hopper (D) - Width of the hopper
Length of the hopper (D2) - Length of the hopper - Enter the hopper width for a bin,
or the slot length for plane flow. Defaults to the slot length above.
Hopper Half Angle (alpha) - Angle of the lower hopper walls with respect to the vertical.
Typically 20-40 degrees. The default value is 30 degrees.
Hopper Wall Friction Angle (phi2) - Friction angle of the material against the upper hopper/bin
walls. (Typically 20-30 degrees for coal on stainless to carbon steel)
Material Height in Bin - (H) - Height of material inside the bin.
Material Surcharge Height in Bin (Hs) - Free height of material above the hopper/bin
Only used for the Mclead/Roberts methods as an added vertical pressure term.
Hopper Wall Friction Angle (phi) - Friction angle of the material against the lower hopper
walls. The default value is hopper wall friction angle (if entered) or 30 degrees.";
Flow Factor (qf) -Non-dimensional surcharge factor for the flow condition.
Start Factor (qi) -Non-dimensional surcharge factor for the initial condition.
Shear Coefficent - (u) - Material shear coefficient.

The material shearing force is F = u * Q, where Q is the vertical load.
u = 0.4 - Reisner & Bruff methods

u = Sin(internal friction angle) - CEMA method
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u = 0.8 * Sin(internal friction angle) - Arnold, Reisner, Johanson, and Roberts methods
Bin Shape Factor (mb) - Roberts defines three shape factors.
One for the hopper exit into the belt (m)

One for the bin above the hopper (mb)
One the for the material surcharge above the bin (ms)
Hopper Symmetry Factor (mb = 1 for a conical hopper, mb = 0 for a plane-flow hopper).
The surcharge factor is automatically calculated in Sidewinder as follows:
If the 'Slot length / hopper width' ratio is greater than 0.66 and less than 1.5 the hopper is
assumed to be conical (m = 1). Otherwise the hopper is assumed to be plane-flow (m = 0)
Surcharge Shape Factor (ms) - If the 'hopper length / hopper width' ratio is greater than 0.66
and less than 1.5 the hopper is assumed to a long rectangular cylinder (mb = 1). Otherwise the
hopper is assumed to be square or circular (ms = 0)
Startup Factor - The feeder pullout forces are multiplied by this value for the starting condition.
The default values are:
Arnold - (qi/qf) Calculated according to the Arnold & Mclean paper.

Reisner - Default value of 2.5.
Bruff - Default value of 4.0.
CEMA - Default value of 2.5 (not specifed in the literature).
Johanson - Default value of 3.0.
Roberts - (qi/qf) Calculated according to Roberts 1986 paper.
Custom - (qi/qf), or if entered then qi = qf * start up factor
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Skirtboard Forces
This input group is used to calculate the forces on the sidewalls. This is true for both the
hopper/slot skirtboards, and any external skirtboard elements. For external skirtboards the
sidewall force is:
Hopper/Slot Sidewalls (under the load point)

Force = mu * K * (2 * Fv + Density * g * B* Skirtboard Length * Material Depth) * Material Depth / B
Where:
Fv = Vertical Force of material above slot
B = Average Hopper opening width
External Sidewalls (outside of the load point)

Force = mu * K * Density * g * Skirtboard Length * Material Depth * Material Depth
Where:
mu = Coefficient of friction between material and sidewalls - TAN (Wall friction angle)
K = Pressure ratio
g = gravity
Skirtboard Length = Length of external skirtboard, or element length for skirtboard only elements
Material Depth = Depth of material against the skirtboard
The Sidewall forces under the hopper/slot opening are similar to those above. However, in this
case the vertical load of the material (yellow volume) increases the sidewall pressure.
Skirtboard Material Depth (Running / Pullout) – If left blank this value will be calculated using
a zero degree surcharge angle. This results in the maximum depth of material on the sidewalls.
The material depth is used to calculate the normal force on the sidewalls.
Sidewall Force = mu * K * Density * g * Skirtboard Length * Material Depth * Material Depth

Where: K = Pressure ratio (see input below)";
Skirtboard Friction Factor – Friction factor (mu) of material against the skirtboard walls.
Where: mu = TAN(Wall Friction Angle).
The default value is 1.0 (i.e. a wall friction angle of 45 degrees)
Pressure Ratio – Ratio of the vertical force to the sidewall force. For vertical walls, this value
varies from 0.4 for free flowing material, to 1.0 for an initial surge filling. For diverging walls
this value can be calculated from:
K = (1-SIN(angle)/(1+SIN(angle))
Where: angle = Materials effective angle of internal friction.
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If left blank, this value will default to 0.65. However, if the conveyor is fully-skirted or has long
skirtboard sections, a value of 0.40 may be more realistic (although less conservative).
It should be noted that this method is identical to the CEMA 5th method. The CEMA method
also assumes a wall friction angle of 45 degrees (i.e. the skirtboard friction factor is equal to 1.0),
but it combines the material density and effective internal angle of repose into a single value.
This is published as a lumped “Cs” factor. In our opinion, this “Cs” factor is hard to understand,
and it makes more logical sense to enter these values individually.
However, for users who want to use the standard CEMA method, the table below lists all CEMA
materials and their corresponding Cs factor.
To achieve the same Cs factor using Sidewinder, the user can leave the skirtboard friction factor
blank (i.e. default value of 1.0) and then enter the “Pressure Ratio“ factor from the table. For
example if “Iron Ore” were used, instead of entering a Cs factor of 0.276, the user would enter
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the pressure ratio as 0.199. The default pressure ratio of 0.65 will normally result in a more
conservative design then CEMA.
Skirtboard Seal Drag – Factor to account for the rubber seal drag between the skirtboard and the
belt. The CEMA default value is 3 lbs/ft (44 N/m) for each side.
Skirtboard Length – Length of the skirtboard that is past the end of the opening slot length.
Skirtboard Width – Used to calculate the material depth on the skirtboards. Default value is 2/3
of the belt width.
Sliderbed Friction Factor – This is assumed to be installed under the length of the slot opening.
The slider bed force will then be calculated as:
Slide Bed Force = mu * Vertical Load
Where:
Vertical Load without Pullout Forces = Slot Length * (Wm + Wb)
Vertical Load with Pullout Forces = Total vertical load used in the shear calculations
(yellow volume shown on plot)
Enter a value here if a slider bed is used. The slider bed force will then be calculated using the
vertical load times this friction factor.
Common values are:
UHMW Polyethylene = 0.55

Urethane = 0.84
Steel = 0.92
Wood = 1.00
Initial Material Speed – This term is used to calculate the acceleration forces of the material.
The default value is 0 (i.e. the material must be fully accelerated from rest).
Shear Plate Position – Some feeders have a shear plate located past the end of the chute.
If so enter this length here.
Skirtboard Shear Plate – If a shear plate length is specified above, then enter the shear plate
height here.
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5.12 Structural
The structural input and output tabs allow the user to estimate the required stinger size and show
the complete layout for the conveyor. A graphical view is shown in the output window (which
can also be exported to AutoCAD with all correct dimensions by right clicking on the window).
Stringer deflections for the empty, loaded, and flooded belt conditions are all output on the
"Structure" output page.
The "Zoom" option buttons will switch between the following three views: the cross sectional
profile only, the cross sectional view and one stringer set, and all three stringer sets.
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A range of carry and return idler configurations are available. Please see the tooltip for more
details on the possible choices. The following page shows some of the possibilities.
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Configuration = 1:1 (Carry side to Return side idler spacing ratio)
Configuration = 1:1.5
Configuration = 1:2
Configuration = 1:3
Configuration = 1:4
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Right clicking on the stringer channel allows the selection of standard metric and imperial
channel sizes. It is trivial to add additional stringer sections (tubular, rectangular channels, etc).
Please just let us know if what standard sizes you would like to see added and we will included
them.
The output data includes the deflections of the stringer midpoint for various load cases. Also
shown are the loads used to calculate these deflections.
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6.0 Input - Conveyor Profile & Geometry
This window can be opened by clicking the button on the tool bar. It consists of 4 tabs:
1. Vertical Profile
2. Conveyor Profile
3. Horizontal Profile
4. Ground Profile
The “Vertical Profile” and “Conveyor Profile” are always visible. However, the “Horizontal
Profile” and “Ground Profile” are only visible if the checkbox “This conveyor has horizontal
curves” in “Horizontal Curve” in the main input window is checked (Figure 4.3a).
Checkbox to access to Horizontal and Ground Profile tabs
The conveyor geometry is input in the “Vertical Profile” and “Horizontal Profile” tabs. These
two tabs allow the user to enter the conveyor geometry in terms of intersection points, pulley
arrangements, idler spacing, and special elements. Sidewinder then automatically builds the
final conveyor geometry and places the results in the “Conveyor Profile” tab.
The carry strand is the first to be entered. The vertical (and horizontal, if applicable) profiles are
input as intersection points (IP). A radius is input at each vertical IP. Sidewinder will
automatically determine if the radius is convex or concave, depending on the incoming and
outgoing slopes.
Advanced Conveyor Technologies, Inc.

19415 594th Ave - Mankato, MN 56001 - U.S.A.
Phone: 507-345-5748 e-mail: info@actek.com
Sidewinder simplifies the return strand with the special “Return” element. This element creates
the return strand by offsetting the carry elements. The user defines the end point of the return
element. Multiple return elements may be used.
6.1 Vertical Profile

The “Vertical Profile” tab is where the vertical profile of the conveyor in entered. There are
three main panels. The first is a spreadsheet format where the geometry is entered. The bottom
window is a plot of the conveyor geometry. On the right hand side are various buttons and
options for controlling and entering the geometry data.
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6.1.1 Geometry Input

The vertical geometry input spreadsheet has 12 columns. You may right-click on each column,
which will present a column-specific context menu.
The geometry of the conveyor is entered as IP (intersection point). The first point is always (0,
0) and subsequent points are the IP points. A radius may be entered at each IP point. Each
element consists of station and elevation (location of IP point), length and height, radius at IP
point, and element type.
The element length and station are the projected length of element on the x-axis. The figure
below shows an example conveyor profile. The first element has a length of 100 m and a height
of 15 m. The true length is 101.1 m. The length and height input of element 1 is therefore 100
and 5 m respectively.
Conveyor Profile
Element Input
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A. Station
This is the station of the element. Station is at the beginning of the element.
B. Elevation
This is the elevation of the element. The station is at the beginning of the element.
C. Element Length
This is the length of the element.
D. Element Height
This is the height of the element.
E. Slope
There are really two columns for slope; the first is slope in degrees, and the second is
slope in grade (%). Double clicking on the column header will switch between degrees
and percent grade. Alternatively, expanding or maximizing the Sidewinder window will
show both columns.
F. Radius
Enter the radius at the IP. Positive radius means convex curve. Negative radius means
concave curve. As you move through the elements, the allowable radius is shown in the
small panel just below the spreadsheet. Also shown is the allowable radius assuming the
radii of the two adjacent IP’s are set to zero.
Sidewinder will not allow you to enter a radius that will not fit.
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Allowable Radius
G. Element Type
Element type is further detailed in the next section. This column is used to set elements
to special types such as a pulley, motor, etc.
H. Belt Load %
This column is only applicable if the element is a loading point. It is the percentage of
design tonnage that is placed on the belt at the loading point.
I. Extra Acc Type

You can add an extra accessory on an element. By default Sidewinder places one belt
cleaner on the head pulley. If you have more than one belt cleaner, add them in this
column.
The extra accessory can be:
1. SBC - Single belt cleaner
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2. DBC – Double belt cleaner

3. TBC – Triple belt cleaner
4. NBC – Force no belt cleaner: This prevent Sidewinder from adding the default belt
cleaner
5. SVP – Single V-Plow
6. DVP – Double V-Plow
7. MDP – Material discharge plow
8. BS – Belt scale
9. TI – Training Idler
10. MS – Magnetic Separators
K. Pulley Wrap
Enter the pulley wrap angle. If “Auto Calculate Wrap Angle” is checked then the wrap
angle is auto calculated according to the two adjacent elements.
It is best to add a normal element (i.e. not “Return”) after a pulley so that the wrap angle
is calculated correctly. If a “Return” element is placed before or after a pulley, then
Sidewinder must guess at the element slope and so the calculated wrap angle may not be
correct.
Right click on the wrap angle of a pulley to bring up the wrap angle context menu. Here
you may specify the pulley diameter and whether the wrap is clockwise or counter-
clockwise.
If Sidewinder incorrectly places the wrap direction, you may force the correct wrap
direction by typing “1” for clockwise, and “-1” for counter-clockwise in the wrap angle
column. Sidewinder will then auto-update according to the direction input.
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L. Pulley Type ID
Pulleys are grouped by type. All pulleys in a group have the same properties (i.e.
diameter, lagging, etc.). Pulley dimensions and specifications are defined in the main
input window, in the “Pulley / Shafts” tab. The pulley diameter and lagging thickness
can also be set by right-clicking on the pulley ID cell.
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6.1.2 Element Type

Figure 3.4.1a shows the element table with the element type context menu. This context menu is
obtained by selecting the “Element Type” column and then a “right click” on the mouse. The
element type may also be selected by a pull down (Figure 3.4.1b) menu, which is activated by
clicking on the element type cell.
Figure 3.4.1a Element Type Selection via Context Menu
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Figure 3.4.1b Element Type Selection via Pull Down
A. Normal
This is a normal element with a length and height.
B. Loading Point
Material is loaded onto the belt at this location. Material acceleration force is added to the
calculation based on the change in “Belt Load %” column. Multiple load points are okay. The
picture below shows a conveyor with 4 load points where 25% tonnage is placed at each load
station. Skirtboards are placed between each load point.
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The loading plot for the above conveyor is shown below. The “load line” (in blue) is adjusted
downward to show partially loaded (i.e. <100%) elements.
Load points may also be placed on the return strand. An example of this is “complex.swi” (can
open via Help  Demo Examples  Horizontally Curved Conveyor System). The figure below
shows a load point on the return strand.
For load points on the return strand, material acceleration is only added for load cases which the
return strand is indeed loaded.
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C. Loading Point (Reverse Direction)

This element type is for reversible conveyors. The figure below shows a reverse load point.
Material acceleration is only added for reversible load cases. However, drag force due to skirts
is added in both forward and reverse load cases.
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D. Side Skirtboards on Element

This element is for sections where material is not being added but there are skirtboards.
Additional sliding forces are added for skirtboard elements.
E. Flat Transition Section

This is a “flat transition,” or sometimes called a “full trough transition.” This element type may
be placed at either tail or discharge pulleys. Placing this element type will cause Sidewinder to
calculate the stresses and idler configuration for the length of this element.
F. Elevated Pulley Transition Section

This is an “elevated pulley transition,” or sometimes called an “elevated trough transition.” This
element type may be placed at either tail or discharge pulleys. Placing this element type will
cause Sidewinder to calculate the stresses and idler configuration for the length of this element.
G. Pulley
This is a pulley. You must also enter the pulley type in “Pulley Type ID” column. The “Pulleys
/ Shafts” tab on the main input page will have input columns for the maximum number of pulley
types entered in the element page. For example, if you enter “4” for a pulley type in the “Pulley
Type ID” column, then there will be 4 input columns in “Pulleys / Shafts” tab. All pulley
information, including diameter, is entered in the “Pulleys / Shafts” tab in the main input.
H. Pulley & Backstop

This is a pulley with a low speed backstop.
I. Take-up Pulley
This is the location of the take-up. You must enter one and only one take-up. Take-up type is
specified in the “Take-up Input Data” on the main input page.
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J. Motor
Set the element type to “Motor” for all motors.
K. Motor & Brake

Set the element type to “Motor & Brake” for all pulleys that have both a motor and brake.
L. Motor & Backstop

Set the element type to “Motor & Backstop” for all pulleys that have both a motor and a
backstop.
M. Motor & Brake & Backstop

Set the element type to “Motor & Brake & Backstop” for all pulleys that have a motor, brake,
and backstop.
N. Motor & Take-up

This is for a pulley that is both motor and take-up. The take-up type must be gravity.
O. Brake
This is a brake-only pulley.
P. Brake & Backstop

This is a pulley with a brake and a backstop.
Q. Helical Turnover
Set the element to “helical turnover” at the location a simple helix turnover with no supports at
the ¼ and ¾ positions. The length of this element will be length of the turnover in the
calculations.
R. Helical Turnover with ¼ Roll Supports

If a turnover has ¼ and ¾ support rolls, then use this element type. The length of this element
will be length of the turnover in the calculations.
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S. Return Element
The return element is a special element that follows the carry strand back to the tail pulley. This
element is especially useful on conveyors with vertical curves.
This element matches the carry side elements with a vertical offset as entered in “Return side
offset” (lower right input grid). The “return” element matches the carry strand up to the
coordinate in the following element. For example, entering (0, 0) in (station, elevation) in the
element after the “return” element will cause the whole return strand to be made.
The figure below shows an example Return element. It is placed between the head pulley and
return pulley.
Please note that if the “return” element is placed adjacent to a pulley, then the wrap angle of the
pulley may not be auto-calculated correctly. In the example above, the head pulley (with a
motor) shows a wrap angle of 166 degrees, which is not correct. The inaccuracy has to do with
the many possibilities that the return element can encounter.
To correct the wrap angle error, simply add an element before and after the “return” element.
The figure below shows the correctly input return strand.
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Multiple return elements may be placed on the return strand. An example of when this is
necessary is with a tripper. The figure below shows a conveyor with a tripper. The return strand
is incorrectly entered as single element. The return strand follows the tripper and is therefore
incorrect.
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The figure below shows the return strand correctly entered with two “return” elements. The first
“return” element goes to point (125, 2.5). The following element then has a length of 40 m
which goes underneath the tripper. Then a second “return” element is entered to finish the return
strand.
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6.1.3 Element Context Menu, Quick Buttons, and Short Cuts

The input spreadsheet has several macros to operate on the conveyor elements and rows. The
following two figures show the element table context menu and quick buttons. The context
menu is obtained by right-clicking any of the first seven columns (# to Radius).
Element Context Menu
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Element Table Quick Buttons
The quick buttons can also be run by keyboard shortcuts as shown in the table below:
Shortcut What is does

Ctrl-A Insert a row Above current select row
Ctrl-B Insert a row Below current select row
Ctrl-F Insert 5 rows Below current select row
Ctrl-D Delete selected row
Ctrl-J Adjust current flight so that last flight meets first flight – See Section 6.1.5
Ctrl-M Combines current row + next row
Ctrl-X Brings up “Divide Element Options” context Menu
Ctrl-C Copy element table to the clipboard (to paste in excel, etc.)
Ctrl-Z Undo (sometimes several “undos” are required to undo the last operation)
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6.1.4 Enter Dimension from Pulley Centers

Often times the distance between pulley centers is known. For example, in the figure below, the
distance between pulleys is known. However, in Sidewinder you must enter the element length
between pulleys.
To auto-calculate the element length and height, first add the two pulleys and the element
between the pulleys. Then select “Element Dimensions from Pulley Centers” from the element
table context menu. Enter the horizontal and vertical distance between pulleys and then select
the correct line (shown by color). There are four lines since there are four possible solutions.
Sidewinder will then update the length and height for the element, which, for the example, is
(-1.08, -0.13).
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6.1.5 Adjust to End (Ctrl-J)

This shortcut adjusts the current flight so that the last flight meets up with the first flight. This
short cut is only meant to be used on the return side. The following table explains how this
shortcut works depending on the element type.
Element Type What is does:

Normal element Adjust length and height of current flight so that first and last element match
Return Adjust the special “return” elements to match end and beginning
“Normal” following
Adjust the special “return” elements to match end and beginning
“Return”
“Pulley” Nothing
6.1.6 Divide Element Option

The Divide Element Options dialog can be opened by “Ctrl-X”, the element context menu (right-
click), or by pressing the button. The dialog is shown below:
There are five options for dividing an element.
A. Divide into N equal elements (Ctrl-1)

This option divides the current element by N equal length elements.
B. Divide into two elements (Ctrl-2) by first element length

This option divides the current element into two elements. The first elements will have the
specified length.
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C. Divide into two elements (Ctrl-3) by second element length

This option divides the current element into two elements. The second elements will have
the specified length.
D. Divide at station length (Ctrl-4)

This option divides the current element into two elements at the specified station.
E. Create Point of Intersection (Ctrl-5)

This option finds the point of intersection (IP) of the two adjacent elements. It then deletes
the current element and extends the adjacent element to the IP.
For example, suppose the conveyor in the figure below requires a vertical radius of 100 m.
Due to the short length of element #4, the maximum radius is only 45 m.
Therefore element #4 is “divided” with option 5, with the results shown in the following
figure. Now the 100 m radius can be entered.
135
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6.1.7 Move Point of Intersection

Sidewinder allows you to move an IP (point of intersection) point in the element table without
changing the adjacent IP’s. This can be done with the Move IP buttons
or by the graphical method:
If you use the Move IP buttons, simply select the element and press one of the arrows according
to the direction you wish to move. Remember that the IP is at the beginning of the element. The
two input boxes define the distance that the IP will move. You may change the distance in either
box. The default distance is 1 vertically and 10 horizontally.
The graphical method is accessed by right-clicking in the profile plot and then selecting Move
Point. The mouse cursor will then change to move IP cursor ( ). Position the mouse over an IP
and then drag the IP to the desire point.
137
This function is especially useful for aligning the conveyor profile on top of a ground profile that
has been imported on the “Ground Profile” tab. The plot below shows the conveyor profile and
the ground profile (purple line).
The IP was move with the graphical method. Below is the result:
6.1.8 DXF Import

The dxf import dialog window is an easy way to transfer the conveyor geometry from a CAD
program. Understanding the import method will facilitate importing the profile from CAD.
Sidewinder expects to find a single polyline in the dxf file. When Sidewinder reads the DXF
file, it searches for a polyline. It will attempt to import the first polyline it finds. Everything but
the first polyline is ignored.
The polyline can have the following:
1. Straight lines
2. Radii for vertical concave and convex curves. Any radius greater than 9 is assumed to be
a vertical radius.
3. Radii for pulleys. Any radius less than 9 is assumed to be a pulley.
The polyline should be drawn from the tail to the head in the direction of belt velocity.
In the simplest form, the polyline can be a series of straight lines. An example of such is line is
below:
138
The polyline is 4 segments. The figure below shows the dxf dialog import for this dxf file. The
lines are imported. Each vertex is made an intersection point.
This is the imported geometry:
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You may also draw the radii into the CAD file. The figure below shows the same example
above except that the radii are drawn in the polyline.
The dxf import dialog now imports the polyline with the radii:
140
You may also draw the pulley in the polyline. Pulleys at the head have now been added to the
polyline and imported. Note that the pulleys are correctly imported. Pulleys of the same
diameter will be the same type. After importing, you will have to change pulleys to motors,
take-up, etc.
141
A. Import Options
There are four import options:
The first option “Overwrite current profile” simply deletes ALL current elements and then
imports the new profile. This is the default option.
The second option “Insert as carry side” deletes all elements before the first pulley and then
imports the new profile from the dxf file. This option is very useful if you need to change the
conveyor profile, but pulleys and the return strand remain the same.
The third option “Insert elements at beginning of current profile” adds the imported elements
at the beginning of the current profile, so the existing elements are not deleted.
The last option “Insert elements below the current location” adds the imported elements
below the currently selected element.
B. Import Scale
Sidewinder allows you to change the importation scale. The conveyor profile is normally
drawn in mm (metric) or in inches (imperial). However, Sidewinder expects units of meters
or feet.
The dialog window has options for the most common scales. You can also enter a custom
scale. A scale of 1000:1 means that the drawing is in mm but will import as meters, so the
imported lengths will be divided by 1000.
The x and y scale do not have to be the same.
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C. Import Option – Mirror Conveyor

In Sidewinder the tail end is at the left and the head is at the right (conveyor runs from left to
right). If the drawing of the conveyor is drawn right to left, then use the “Mirror Conveyor”
option to mirror the profile. Below is an example of a conveyor profile that was drawn from
right to left.
Note that the dialog box shows the first point with a blue start and the last point with a green
triangle ( ). This is to help see how the profile was drawn.
The imported geometry is shown below (without Mirror Conveyor option). Notice that the
profile is backwards and the lengths are negative.
143
Checking the Mirror Conveyor option will import this profile correctly.
144
D. Import Option – Reorder Conveyor

If you draw the polyline backwards (from head to tail), then use the “Reorder Conveyor” option
to change the order of the elements. This option will make the last point the first point, and the
first point the last point. Below is a profile that was drawn backwards. Note that the green
triangle ( ) is on the left, and the blue start ( ) is on the right.
Checking the “Reorder Conveyor” fixes the order.
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6.1.9 CSV Import

The csv import dialog is the same as the dxf import dialog. The only difference is that data is
imported from a csv (comma separated) file.
The csv file must contain two columns. The first column must be Station of the element, and the
second column is the Elevation of the element. Below is a csv file showing the correct format
for importing:
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6.1.10 DXF Export

The conveyor profile may be exported to dxf file format that can be read by CAD programs. To
export, simply press the “Export Profile to dxf” and then select the file location and name. The
default name is the name of the Sidewinder file with the dxf file extension.
Sidewinder exports the following:
1. Polyline with conveyor IP points (layer PROFILE-IP)

2. Polyline with vertical radii (layer PROFILE-VC)
3. Polyline with meshed elements (layer PROFILE-ELEMENT)
4. Polyline with ground profile as imported from the Ground Profile table if it exists (layer
GROUND-PROFILE)
5. Pulleys (layer PULLEY)
6. Pulley labels (layer LABEL) next to each pulley
7. Idler geometry (below)
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6.1.11 Idler Spacing Table

The Idler Spacing Criteria table allows you to easily define the idler spacing on both the carry
and return strands. The table is shown below:
The first four rows define the idler spacing on the carry strand.
The 1st row defines the nominal idler spacing on the carry strand. The carry strand is defined as
the first element to the head pulley. The head pulley is defined as the pulley with the largest
distance from the first element.
The 2nd, 3rd, and 4th row should be used to redefine the idler type and spacing on the carry strand
for special items. This is mostly used to reduce the idler spacing in curves (vertical or
horizontal).
Likewise, row 5 defines the idler type and spacing on the return strand, which is the element
after the head pulley to the last element. Rows 6, 7, and 8 redefine the idler type and spacing on
the return strand for special items.
Row 9 defines the idler type and spacing in load points. Row 10 defines the idlers in transitions.
148
The columns in this table are used to define where the idler spacing is to be changed from the
nominal.
A. Radius Column
The “Radius <” column is used to change the idler spacing in convex curves. The input value is
the largest radius below which all idlers will be set to the specified type and spacing. For
example, assume the nominal carry spacing is 1.0 m, but you wish to reduce the spacing to 0.5 m
in all convex curves that have a radius less than 1000 m. Then, in row 2 you would enter 0.5 in
Spacing and 1000 in the Radius column as shown below:
The result is shown below:
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It is also possible to use multiple rows to put different spacing in different curves. For example,
assume the nominal idler spacing is 3. However in convex curves less than 500, the spacing
must be reduced to 2 and in curves less than 375 the spacing will be reduced to 1.
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B. Start and End Columns

The “Start >” and “End <” columns redefine the idler spacing between the start station and end
station.
For example, assume the nominal idler spacing is 1.0 but you wish to reduce the spacing to 0.5
between station 200 and 450. Then enter 0.5 in Spacing, 200 in Start > and 450 in End <, as
shown below:
151
Sidewinder did NOT break up the elements to have an element begin at 200 and one end at 450.
You must do this manually (use the Divide dialog – ctrl-x to divide the elements at 200 and 451):
152
C. Horz. Curve Column

This column works in the same manner as the “Radius <” column except it operates on
horizontal curves. The input radius is the largest radius which will be changed. For example,
assume the nominal carry spacing is 3.0 m but you wish to reduce the spacing to 1.5 m in
horizontal curves than have a radius less than 1750. Then in row 2 you will enter 1.5 in Spacing
and 1750 in the Horz. Curve column as shown below:
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D. Start Pulley & End Pulley Column

The Start Pulley and End Pulley Columns are used to change idler type and spacing using pulley
location. For example if a tripper conveyor has return idler on the carry strand after the tripper,
then use enter the tripper pulley number in “Start Pulley” and the head pulley number in “End
Pulley”. In the example below, the idler type is changed to 2 (return idlers) and spacing
increased to 3 after the tripper pulley:
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155
E. Combination
All four rows (1 to 4 for carry, and 5 to 8 for return) may be used. Priority is given to the lower
rows. So if you enter conflicting criteria, then the lowest rows will govern the idler type and
spacing. It’s always a good idea to review the Conveyor Profile tab to ensure the selected idler
spacing is as you intend.
The two tables show correct and incorrect input for changing spacing in two different radii.
Correct
This input will put Si = 2 for
R>350 and R<450, and Si = 1.5
for R<350
Incorrect
This input will put Si = 2 for all R
R<450
You can also combine criteria. For example, if you wish Si=2.0 for R<450 if station < 2100, and
Si = 1.5 for R<450 if station > 2100. This is the correct input:
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6.1.12 Show Station Label

This option places labels at each point showing the element station.
6.1.13 Auto Calculate Wrap Angles

See Section 6.1.1.K for the Auto Calculate Wrap Angle option.
6.1.14 Return Side Offset

This is the distance between carry and return strands when the special “Return” element is used.
6.1.15 Maximum Element Size

When the conveyor is meshed (in Conveyor Profile), this will be the maximum element length.
6.1.16 Vertical Radius Misalignment Tolerance

This number determines how finely meshed a vertical radius will be. It is the maximum distance
between an element midpoint and the actual vertical curve arc.
Reducing this value will result in more meshed element in the vertical curves. The default value
is 250 mm. Generally, the default value is sufficient, but it can be changed to fit your needs.
Below is an example of a convex curve with an 18 degree up and down slope with various
tolerances.
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Vertical radius misalignment tolerance = 9 (two elements)
Vertical radius misalignment tolerance = default (12 elements)
Vertical radius misalignment tolerance = 0.05 (20 elements)
6.1.17 Show Imported Ground Line

If you have imported a ground profile, then this checkbox will turn on/off the line in the vertical
profile line. See Section 6.4.
6.1.8 Element Plot

The bottom window of the Vertical Profile tab is the element plot. Left-clicking in the window
will bring up a context menu with various options:
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A. Reset View
This option will reset the window to the default zoom limits.
B. Pan
Pan the conveyor. The cursor changes to a hand ( ) during the pan.
C. Zoom
This option zooms in/out with the mouse. The cursor changes to the magnifying glass ( ).
Left-click and hold will either zoom in (move mouse up) or zoom out (move mouse down).
The current aspect ratio is maintained in the zoom.
D. Zoom Window
This option zooms into the selected window. A 1:1 aspect ratio is not maintained.
E. Zoom Window 1:1

Do a zoom window. The final selected view will have a 1:1 aspect ratio.
You may also do a zoom window 1:1 by left-click, hold, drag, and then release. When you
left-click and drag, the green dashed box-window will appear. When you release the mouse
click, Sidewinder will zoom into the chosen limits.
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F. 1:1 Aspect Ratio

Force a 1:1 aspect ratio on the current view.
G. Hide Vertical Gridlines

Shows or hides the vertical gridlines.
H. Move Point
This enables the move point macro. See Section 6.1.7.
I. Divide Element
This option will split the current element into two equal parts.
J. Combine Element
This will combine the current element. Same as Ctrl-M.
A. Copy to Clipboard
This will copy the current view into the clipboard as a bitmap.
6.2 Conveyor Profile

The “Conveyor Profile” tab contains the final geometry of the conveyor.
The final geometry is defined from the information entered in the vertical and horizontal profile
tabs. The data in vertical and horizontal profiles are merged to make the final elements.
Most columns in this tab cannot be modified.
The exceptions are:
1. Idler Spacing
2. Set #
3. Extra Drag
4. Custom load case columns, which are labeled “Load C1”, “Load C2”, etc.
5. Banking Angle
6. Inside SGRS (Side Guide Roll Spacing)
7. Outside SGRS (Side Guide Roll Spacing)
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The last three columns are only visible if the conveyor has horizontal curves.
Very rarely will you need to modify the Idler Spacing. The Idler Spacing Criteria table in the
Vertical Profile tab allows the user to sufficiently define the idler spacing for nearly all
conveyors. However, the idler spacing may be modified in the Conveyor profile tab.
A word of caution: If you modify any of the columns in the conveyor profile tab and then change
the conveyor geometry in the vertical profile tab, you will have to recheck/update the data
entered in the conveyor profile tab.
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6.2.1 Columns in Conveyor Profile

The columns in Conveyor Profile are similar to those in Vertical Profile. However, intersection
points (IP) are not shown as the conveyor has been meshed.
A. #
This is the element number.
B. Element Type
If the element in not a normal belt section, it is labeled according to its type.
C. Station
Station is the projected distance of element on the x-axis. See Section 6.1.1 for further
clarification.
D. True Length
This is the true length of the element.
If it is a straight section:
, where l and h are the projected length and height of the element.
If it is a vertical curve element:
, where R is the radius and is the arc angle of the element.
E. Element Height
This is the change in elevation of the element
F. Vert. Radius
A concave radius is negative. A convex radius is positive.
G. Idler Spacing
Idler spacing is initially defined by the Idler Spacing Criteria table in Vertical Profile.
However, the idler spacing may be changed in this column.
H. Set
This is the idler type. Idler types are defined in the Idler Spacing Criteria table in Vertical
Profile. The idler set may be changed in Conveyor Profile. Specifications of the idler types
are defined on the Main Input Page in the Idler Input Data table.
I. Extra Drag
The extra drag column is included so that the user may add extra drag or force to the point at
any point. This may be for such things as a plow, bad alignment, plug chute, etc. as the user
deems necessary.
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J. Acc Type
If an extra accessory was defined in the vertical profile, it will be shown here.
K. Horz. Radius
If horizontal radii are defined in the Horizontal Profile tab, then they are meshed into the
final geometry.
L. Bank Ang.
Banking angles are initially set to zero and must be manually entered by the user or by use of
the Horizontal Curve Work Page. Banking angle of idlers are always to tilt upwards towards
the inside radius of the horizontal curve.
Inside Side Guide Roll
Outside Side Guide Roll

Inside of Horizontal Curve
M. Inside SGRS
This is the Inside Side Guide Roll Spacing. Enter the spacing of side guide rolls on the
inside edge of the belt. Sideguide rolls are currently not available for the CEMA or Grimmer
and Kessler methods.
N. Outside SGRS
This is the Outside Side Guide Roll Spacing. Enter the spacing of side guide rolls on the
outside edge of the belt. Sideguide rolls are currently not available for the CEMA or
Grimmer and Kessler methods.
The remaining columns are load case definition columns.
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6.2.2 Defining custom load cases

Sidewinder allows the user to define five custom load cases. The user adds the custom load case
in the “Load Case” input table in the Project Info Page (See Section 4.1.1). Once a custom load
case is included in the Load Condition table, a column will be added in the Conveyor Profile tab.
The figure below shows a custom load. The User ID and Load Case name may be modified.
However, the “Fixed ID” cannot be changed. Custom load cases have the Fixed ID of C1, C2,
C3, C4, and C5.
In Conveyor Profile tab, you may define the loading of the custom case. To facilitate the
loading, you may right click on the custom load case column to bring up the load case context
menu as shown below.
Once you select the desired load case, you may further refine it by manually changing the
loading. In the example, the conveyor is loaded from the top of the hill to the head pulley.
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Custom load case
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6.2.3 Cell Selecting

Selecting a cell will highlight the element in the conveyor plot.
Note that by selecting a cell in the load case definition columns, the profile plot shows which
elements are loaded. Dark-blue represents elements on the carry strand. Light-blue represents
elements on the return strand.
Profile plot showing return strand loaded
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6.3 Horizontal Profile

The Horizontal Profile tab allows you to enter the plan (horizontal curves) profile of the
conveyor if it is not straight.
This tab is, by default, not visible. To show this profile, you
must check “This conveyor has horizontal curves” in the
Horizontal Curve tab on the main input page.
There are two grids to allow you to enter the horizontal curve data. If you enter data on one grid,
the other grid will be automatically updated.
The first grid (left-hand side) contains the intersection points of the horizontal profile. In this
grid you enter the (x,y) coordinates of each intersection point and the radius a the IP.
The second grid (right-hand side) contains the segments geometry of the horizontal curves.
The Station column is the plan distance (i.e. projected length on a flat plane) and identical to the
station in the vertical profile. The horizontal profile plot shows the station at each point along
the length of the conveyor.
Element Length column is the length of the segment. For a straight segment, it is simply the
length or in terms of x,y coordinates:
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L= .
For a horizontal curve, the length is:
Where RH is the radius of the horizontal curve, and θ is the included angle of the curve.
Arc Angle column is the included angle of a horizontal curve. Radius is the horizontal radius.
The Slope column is the angle (in degrees) of the current segment. You can only change the
slope if it not between two curved segments.
When entering the horizontal curve data, it is best if the slope of the first segment is between -90
and +90 degrees. Sidewinder does not always interpret data correctly if the slope of the first
element is not between -90 to +90 degrees.
Below is an example horizontal profile.
The Sidewinder input for this conveyor is shown below:
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6.3.2 DXF/CSV Import Dialog

The horizontal curve profile may be imported from CAD files via a dxf file. See section 6.1.8
for details of dxf importation. Of course, only the horizontal profile is imported on this page.
Vertical profile and pulley geometry is imported in the Vertical Profile tab.
6.3.3 DXF Export

The horizontal profile may be exported to a dxf file. The dxf file will contain the following:
1. Polyline with intersection points (layer HC_IP)

2. Polyline with horizontal radii (layer HC_R)
3. Text showing the station of each point along the length of the conveyor (layer STATION)
6.3.4 Move Points

Intersection points may be modified with the Move Point buttons. These
buttons work in the same fashion as the Move buttons in the Vertical Profile
tab (see Section 6.1.6)
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6.4 Ground Profile

The ground profile allows you to enter the ground terrain in either 3D or 2D. Its main purpose is
to facilitate the design of the conveyor profile, both vertically and horizontally. Once the ground
profile has been entered on this tab, it can be imported into the vertical profile.
This tab is, by default, not visible. To show this profile, you
must check “This conveyor has horizontal curves” in the
Horizontal Curve tab on the main input page.
The graphic below shows the Ground Profile tab.
Once the ground terrain has been imported, you can turn on the ground profile in the Vertical
Profile tab. To do this check the “Show” checkbox ( ) next to the
“Import Ground Line,” button in the Vertical Profile tab. This will show a purple line in the
vertical profile plot. The two graphics below show the vertical profile with and without the
ground line showing.
The cuts and fill required can now be easily optimized in Sidewinder.
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Vertical profile with ground line
Vertical profile without ground line
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6.4.1 2D Ground Profile

You may import a 2D ground profile in either the Vertical Profile tab or in the Ground Profile
tab. See Section 5.1.7 for importing polylines into Sidewinder. The polyline of the ground
profile should run from left to right. The imported ground profile line does not affect the
conveyor calculations in any way.
In the Vertical Profile tab, the 2D ground profile is imported by pressing the “Import Ground
Line” button ( ).
In the Ground Profile tab, the 2D ground profile is imported by pressing the “Load 2D Surface
Data File” button ( ).
After importing the ground line, check “Show” to show the ground line in the vertical profile
plot.
6.4.2 3D Ground Terrain

Sidewinder can import a 3D terrain model. This allows the user to define both the horizontal and
vertical profile within Sidewinder. This is a very powerful tool when designing an overland
conveyor in which multiple routes are to be considered. It also facilitates the optimization of the
cuts and fills along the length of the conveyor.
The 3D terrain model is imported trough a CAD dxf file format. The dxf file must contain the
3D FACE object representing the terrain model. The model has the following requirements:
1. Each 3D FACE object must be square (have four corners and dx=dy) in the xy plane.
The z plane represents the elevation of each corner.
2. All 3D FACE objects must be the same size.
3. The grid of the 3D FACE objects should be rectangular.
4. The file must be saved in dxf format.
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Top View of 3D model in CAD
Isometric View of 3D model in CAD
Once you import the 3D terrain, you can enter/import the horizontal alignment (See Section 5.3).
The ground profile will then be determined from the 3D model in the Ground Profile tab. Below
is an example horizontal profile (this 3D model is an example Sidewinder file in the Help menu).
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The graphic below shows the resulting ground profile.
The 3D model may be rotated, panned, and zoomed. It may be shown as a wireframe, contours,
or a solid model. Below is the example in isometric view with a solid model coloring.
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The horizontal alignment can easily be changed, and Sidewinder updates the ground profile. The
example, below is an alternate route with the new ground profile.
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7.0 Output Windows

The main Sidewinder output window is shown below. The left hand tabs correspond to each
individual load case (see section 4.1.3 - Load Conditions). Selecting a load case will show the
output values for that condition. The tabs at the bottom show all available output information for
each load case.
The “Detailed Output” window ( accessed from the toolbar menu) has the same layout and
format. The load case tabs are on located on the right hand side with individual output items at
the bottom. However the individual output items contain more detailed information and the
windows are full-sized, which allows easier viewing.
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7.0 Report
Sidewinder generates a report in the Rich Text Format (RTF). The RTF is a format that most
word processors are able to read.
The report generation page is reached by pressing the

bottom, Ctrl-F, or selecting “Print Report” from the “File”
menu.
7.1 Pulley Images

The output report includes plots of the pulleys and vertical profile. These plots are adjustable in
the report creation page.
Sidewinder will automatically group pulleys together. Normally there are two locations, head
and tail. However, if there is a pulley group (such as a tripper or booster drive) in the middle of
the conveyor, then Sidewinder will find and group these pulleys.
Occasionally, you may wish to add a pulley image to the report. You can add two additional
images to a report by checking the checkboxes next to last two image items. The zoom setting
for these groups will initially be set for the whole conveyor. You must then zoom into the pulley
you wish to be included in the report.
The labels on the pulley can be dragged to a new position. The picture below shows the default
location of labels.
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To move a label, simply left-click (and hold the left-click down) and drag the label to a new
position. During the drag position, the cursor will change from an arrow ( ) to a hand ( ). The
image below shows the label being dragged to a new location.
Dragging the labels will clarify the pulley picture:
Right clicking in the pulley plot, will bring up a context menu:
A. Pan
Pan allows you to drag the pulley group and move it to new location on the canvass.
B. Zoom Window
This will allow you to draw a box around the area into which you wish to zoom:
C. Zoom
This function allows you to zoom in or out.
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D. Zoom All
Zooms all the way out so the entire conveyor is in the canvass.
E. Reset
Zooms back to the default limits for the pulley group.
F. Edit Pulley Label

Sidewinder places a default name on each pulley. However, you can change the name of
each pulley. Place the cursor over the label, left click to bring up the context menu, select
“Edit Pulley Label”, and then rename the pulley.
G. Edit Pulley Group Name

Sidewinder gives each pulley group a name which is used in the report. These names can be
edited by selecting the image name to be changed, and then right-clicking on it.
H. Copy to Clipboard
Copy the pulley picture to the clipboard.
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7.2 Profile Image

The profile plot can be edited by selecting this option from the drive and pulley images.
As with the pulley labels, the vertical curve labels may be moved (by clicking and dragging) and
renamed with the context menu.
7.3 Company Logo

Sidewinder will add a custom logo to the output report. The logo is specified in the Preference
window, which is opened in the “File” menu then “Preferences”:
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This brings up the Preference window:
To use a company logo, check “Use custom company logo”. To set the logo, push the “Get
Logo” button. This will bring up an Open File dialog. Select the graphics file to be used in the
output report.
It is recommended that the dimensions of the graphics file be approximately 400 pixels. The
width and height of the logo does not have to be equal. The preference page also allows you to
place the logo at a custom spot in the report. The image below shows the locations of Width,
Vertical offset, and Horizontal offset for the custom logo.
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7.4 Editor
Sidewinder first makes the report in the RTF format. The RTF report is created in the same
directory where the *.swi file resides. After creation, the report is opened in the default editor.
The default editor is set in the Preference window, which is opened in the “File” menu then
“Preferences”. Check “Use Microsoft Word as the default editor” to make Word the editor.
Otherwise, Sidewinder will open the report in a custom word editor.
If you select to use Microsoft word but Sidewinder is unable to find it, then Sidewinder will use
the custom editor. The image below shows the custom editor. You can modify, print, and save
the output report with this editor.
The custom editor has a Help file that can be accessed via the menu.
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7.5 Report Options

There are several tables that can be optionally printed in the output report. The graphic below
show these options.
Double clicking on grey square will select/unselect all checkboxes. The following sections
detail the additional information these options print.
7.5.1 Conveyor Load Cases

This will include a graphical plot of the material loading profile for each load case.
7.5.2 Conveyor Load Case Details

This option prints the following tables:
1. Maximum Belt Tensions

2. Minimum Belt Tensions
3. Maximum Case Belt Tensions
4. Minimum Case Belt Tensions
5. Demand Power
6. Din Factor and Total Equivalent Mass
7. Equivalent Belt Line Mass Summary Not Including Motor Inertia
8. Stopping Times
7.5.3 Take-up Details

A page showing all relevant take-up information will be included in the report.
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7.5.4 Pulley & Brake Details

1. Pulley Shaft Stress Analysis

2. Running Drive Tension by Load Case
3. Required Pulley Diameter
4. Pulley Shaft Geometry
5. Brake Properties (if there is an existing brake)
6. Backstop Properties (if there is an existing backstop)
7.5.5 Vertical Curve Details

1. Summary of Vertical Curve on Carry Strand

2. Summary of Vertical Curve on Return Strand
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7.5.6 Belt Flap Details

This option prints a plot of the belt flap along the length of the conveyor. An example plot is
shown below. The plot is a summary of all load cases. The green line ( ) is the
lower value of belt flap. The purple line ( ) is the maximum flap ratio. So the
actual belt flap will lies between these two limits.
The x-axis is the absolute station of the conveyor, meaning the carry strand is station 0 to the
head pulley station and the return strand goes from the head pulley to 2*conveyor length.
7.5.7 Transitions & Turnover Details

This option prints the required dimensions for head and tail transitions.
7.5.8 All Material & Idler sets

Some conveyors have more than one material set or multiple types of carry idlers. In the “Cross
Sectional Loading” section of the report, only the standard idler and material set (Idler type 1 and
2, and material set 1) are printed.
If you select this option, all idler and material type combinations will be printed in the report.
7.5.9 Element Summary Details

This option prints the following:
1. Summary of Conveyor Elements Table

2. Summary plot of belt tension
3. Element Tension Table
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8.0 Advanced Options

The following graphic shows the work pages on the Advanced tab.
8.1 Load On/Off Work Page

The Load On/Off Work Page is reached by selecting “Advanced” and then “Load On/Off
Calculations” ( ) in the menu.
This will bring up the Load On/Off Work Page:
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Two charts are shown on this page. The top chart shows demand power as the conveyor is
loaded from empty to the selected load case and then unloaded to empty. The second chart
shows the loading on the conveyor.
This work page is especially useful for conveyors with momentary load cases that have multiple
inclines and declines. For example, consider a conveyor with a three inclines and two declines
as shown below:
This has several momentary load conditions which must be considered. The two worst case
loadings are all inclines loaded and all declines loaded. The question then is: How long do these
partial loading cases last?
The Load On/Off work page answers this question.
This work page has three inputs, which are:
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1. Calculation Time Step (sec): This is loading step time. Increasing the time will reduce
calculation time but output data will be coarser. Decrease the time step to refine output
data.
2. Max Allowable Nameplate Power (%): The plot will draw a line at this upper limit and
then indicate how much time the demand power exceeds this limit.
3. Min Allowable Nameplate Power (%): The plot will draw a line at this lower limit and
then indicate how much time the demand power is below this limit.
For our example, Sidewinder shows both the load case and the demand power versus time as the
conveyor loads and unloads. The plot below shows that the demand power is above 100% for
30.4 seconds as three inclines are loaded and then unloaded.
The plot below shows that the power is regenerative for 147 seconds if both declines are loaded
and then unloaded.
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The plots also show the minimum and maximum power.
Pressing the “Calculate All” button will cause Sidewinder to calculate all load cases. Checking
the “Animate Calculations” checkbox will animate the loading and demand power plots showing
the conveyor loading and unloading.
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8.2 Turnovers
Turnovers are used to flip the belt over on the return strand so that the clean side of the belt stays
in contact with the return idlers.
Turner type and location are specified in the Vertical Profile tab. Sidewinder calculates turnover
stresses and sag displacement for either simple helix type turnovers. The turnovers can be
specified with or without middle support rolls.
Helical turnover without support rolls
Helical turnover with support rolls at quarter points
If turnovers are specified, Sidewinder will calculate stresses and sag for each load case, which is
shown in the main output in the Turnover tab.
Stresses in belt turnovers are from three main components, which are:
1. Belt tensions
2. Stresses from the twisting: Twisting increases the stress at the edge and causes
compression in the center.
3. Stresses from bending caused by belt sag: Bending increases the stress at the bottom edge
and decreases the stress at the top edge.
The maximum stress occurs at the bottom edge in the turnover. The minimum stress occurs in
the belt center.
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These stresses are explained in detail in reference paper No. 1.
8.2.1 Allowable Stresses

Sidewinder applies the same criteria for stresses in vertical curves to turnover stresses. The
Design Criteria tab in the Info Page is where you input allowable stresses.
“Local Safety Factor Multiplier” defines the allowable stress at the bottom and top edge of the
belt in the turnover.
“Dynamic Safety Factor Multiplier” defines allowable stress during momentary conditions. The
following two formulas are how the allowable safety factor is determined:
Allowable Running S.F. = SF / LSFM

Allowable Momentary S.F. = SF / LSFM / DSFM
Where
SF = nominal allowable safety factor

LSFM = Local Safety Factor Multiplier (Sidewinder default = 1.10)
DSFM = Dynamic Safety Factor Multiplier (Sidewinder default = 1.15)
For example if the nominal allowable safety factor of the belt is 6.7:1 and Local Safety Factor
Multiplier is set at 1.10, then the allowable safety factor at the belt’s edge is 6.09. During
momentary condition, the allowable SF is 5.30 is DSFM = 1.15.
“Minimum Steady State Stress” defines the allowable minimum stress during steady state
condition. The default value is 5 N/mm or 30 PIW.
For good turnover design, the minimum running stress should exceed the minimum allowable
stress and the maximum stress should be below the allowable as defined above.
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8.2.2 Turnover Output

Turnover stresses and sag are calculated for each load case. These calculations are then
summarized for all load cases. The graphic below shows the summary output for turnover
stresses and sag.
The top table lists the turnover location, length, and type. The bottom table lists minimum
tension and minimum stress, maximum tension and corresponding maximum stress and safety
factor of the bottom edge.
If a stress does not meet the design criteria, the corresponding cell is highlighted in an
orange-brown color, as shown below.
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8.2.3 Turnover Work Page

The turnover work page is included in Sidewinder to allow the engineer to easily and correctly
design the turnover. Calculations and results from the turnover work page are NOT saved.
The turnover work page is reached by selecting “Advanced” and then “Turnover Work Page” as
shown below:
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The turnover work page is shown below:
There are three main windows on this page. The bottom left hand window selects the turnover
location and type. In the “Calculation Method” option box, the user indicates if the turnover has
support rolls at the quarter points. In the “Turnover Select” box, choose the turnover location
(head or tail) with the pull-down list and then select the tension range (steady state or
momentary). Sidewinder will update the values in “Turnover Length and Tension” input grid
based on your selections.
8.2.4 Belt Input Grid

The top window has three input grids allowing you to manually change the calculation
parameters. The “Belt Input” grid contains the necessary information for the belt. The default
values normally do not need to be changed. However, if you wish to see the effect of changing
the belt mass, modulus, etc. then you may do so with this input grid.
After changing any values, you must press the “Solve” button.
A right-click on the “Belt Input” grid will bring up an option to change the belt rating:
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Click on “Change Belt Rating” to automatically update the belt mass, modulus, and rating
according the new belt rating.
Effective Thickness of Belt is used to determine the bending stiffness of the belt. The default
value is set at 1 mm and is normally acceptable. The only time to change this value is if
Sidewinder is having convergence difficulty.
Length of Horizontal BC (%) is only applicable for turnover with quarter point rolls. This
distance defines the location at which horizontal displacement must be zero. The figure below
shows this length.
The quarter support rolls reduces the vertical displacement and bending stresses. However, they
also force the belt out of the horizontal belt line since any downward displacement also results in
horizontal displacement at the quarter point support rolls.
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The figure below illustrates how this boundary condition effects the calculation of a turnover
with support rolls at the quarter point. The quarter point support rolls force the displacement in
the horizontal and vertical planes to be equal at the support roll location. The displacement plot
below is for a 44 m turnover. At x=0 and x=44 m, the vertical displacement is zero. At x=¼*44
(11 m) and x=¾*44 (33 m) the horizontal and vertical displacements are equal because of the
support rolls. However, the Length of Horizontal B.C is set at 10% (4.4 m). So at x=-4.4 and
x=48.4 m the horizontal displacements are zero.
Increasing the horizontal B.C. allows more displacement in the horizontal plane, which then
allows higher displacement in the vertical plane.
The default value for this boundary condition is 10% of the turnover length, which is a
reasonable value for this input.
Turnover Horizontal Displacement

150
100
Displacement (mm)
50
-50
Vertical Displacment (mm)
Horizontal Displacement (mm)
-100
-5 0 5 10 15 20 25 30 35 40 45 50
Distance from End Roll (m)
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8.2.5 Turnover Length and Tension Grid

The “Turnover Length and Tension” input grid allows you to change the length and tension
range.
After changing any values, you must press the “Solve” button.
8.2.6 Plotting Scales

The “Plotting Scales” input grid allows you to manually set the plotting scales.
The “Number of Divisions in Turnover” is the number of divisions in the turnover length for the
numerical calculation. The default value is 100 and does not need to be changed.
The rest of the input values define the minimum and maximum values for the y-axis.
The output can be plotted by Length or Tension. Plotting by Length is the default. After
changing any values, you must press the “Replot” button.
8.2.7 Results and Output

The output plots graphically show the results of turnover calculation. The plots in this section
are for a 44 m long turnover with a 1500 mm belt with a rating of ST-1000 N/mm.
The graphic below shows the stresses in a turnover:
Turnover Stress
Turnover Sag
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Good turnover design requires that the stresses in the center of the belt not be compressive
(negative) and that the maximum stress be within acceptable limits. The turnover usually has an
optimal length in which the minimum stress is maximized.
Below is a plot for minimum stress of the example turnover. The steady state tension is 81 kN.
Note that the minimum stress is maximized at about 44 m. If the turnover length is less than 33
m or greater than 57 m, the center stresses will be compressive.
The second plot shows the safety factor of the bottom edge of the belt. Its optimal length is
approximately 45 m to 50 m. Therefore, the best length for the turnover is approximately 44 m.
In general, it is best to minimize the length of the turnover to reduce the amount of sag while
maintaining positive stress in the center portion and ensuring that the edge stress is at acceptable
levels.
Minimum Stress at Steady Station Tension
198
Minimum Safety factor at Steady Station Tension
199
A. Max Stress
This tab shows the maximum stress at each length and tension. Stresses are in N/mm or in PIW.
The maximum stress occurs at the bottom edge of the turnover.
The label and legend on all the plots may be manually moved by left-clicking on the label and
then dragging to the desired location.
B. Min Safety Factor

The minimum safety factor is simply the belt rating divided by the maximum stress.
200
C. Min Stress
This plot shows the minimum stress in the turnover which occurs near the turnover and belt
center.
D. Sag
This plot shows the maximum belt sag of the turnover. Belt sag is the displacement of the
midpoint of the belt.
201
E. Percent Belt Sag

This plot shows the belt sag as a percentage of the turnover length.
F. Results
The grid in this tab is simple the numerical results of the turnover calculations.
202
8.3 Horizontal Curves

The horizontal curve work page allow the belt displacements to be estimated in horizontally
curved conveyors.
203
8.4 Overhung Load Work Page

The overhung work page is used to estimate the additional shaft loads when using shaft mounted
drive configurations. The user can click the "Estimate Input Variables" to estimate these loads,
weights, and the basic geometry of the shaft mounted system. However, the location of the
support arm (distance "E") can vary greatly in real life, and thus these estimates should be
checked once the final swing base system has been selected and designed.
Normally these additional overhung loads are not significant (with proper swing base design and
support distance selection). However, engineers should be aware of "Reverse" drive orientations
which can indeed impose significant overhung loads. In the normal configuration the overhung
load decreases as the conveyor is loaded and torque is increased. The increasing motor reaction
torque lifts the motor and equalizes the overhung load. However in "Reverse" motor
configurations an increasing motor torque also increases the overhung load. These increased
load can be significant and can cause coupling and shaft failures if not properly included in teh
design loads.
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In either the normal or reveres configurations the maximum resulting overhung loads are
calculated. Three final resulting load cases are calculated (Empty running, Fully loaded running,
and loaded Starting). The user can select the value they want to use and that can then be entered
on the pulley and shaft input page. The two required values are:
Overhung Load - Vertical - The maximum vertical overhung Load
Distance to bearing Center - Distance from the center of the bearing to the overhung load
For the users convenience these values can automatically be transfer from the overhung load
work page by "right clicking" on the Load and selecting which load, and pulley type the engineer
wants to use.
All data and input on the work page are saved as part of the sidewinder file for later use.
205
Users can also enter the low speed coupling distance.
This information is all used to calculate the resulting shaft stresses. The detailed shaft page
shows the additional bending moment at the bending (Bending Moment Point "E") as well at the
coupling stresses (Point "G").
206
8.5 Transfer Chute Design

Newton is a general purpose Discrete Element Method (DEM) simulation package used to
quickly and accurately model three-dimensional behavior of granular flow. A variety of
constitutive models have been included to model a wide range of material properties including
wet, sticky, cohesive material. Material degradation, surface wear, impact damage, energy
dissipation, and other fundamental parameters can easily be analyzed.
207
8.6 Stockpile Calculations

The stockpile calculations are completely separate from all other calculations in Sidewinder.
Up to ten (10) stockpile and reclaim points can be entered. Note the user can move the vertical
black separator bar to show more columns (or use the right/left arrow keys to scroll over).
208
Material Inputs
The top window allows the basic material data to be entered. This includes the material density,
stacking angle, reclaim angle, and rathole angle.
Ratholes can be used for circular reclaim points as well as liner slots. The rathole height is used
in conjunction with the rathole angle as shown below.
209
The ground level allows a stockpile to be calculated above the specified reclaim location. The
Cutoff height allow the top of the pile to the "cut off". Each of these inputs is shown below:
The grid resolution controls the internal calculation method and is a tradeoff between higher
resolution and faster calculation times. The user should note there is typically much more error
in the exact stacking and reclaim input values than the variance in the resolution of the
calculation itself.
Stock Piles Inputs

The height and length (Linear Distance) of each stockpile can be entered.
Alternatively, the user can enter a diameter for a stockpile input rather than the height. In this
case the height is based off the stacking angle. If both a height and diameter are entered the
height is used (i.e. the diameter is ignored). If the linear distance is left blank a circular stockpile
is assumed.
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The Center X & Y is the location of the center of the pile. This is useful when entering and
aligning multiple piles.
Radial Stackers
A radial stacker can be simulated using the radial stacker input values. The stacker can be shown
by right clicking the output window and selecting "Show Radial Stacker".
The minimum and maximum conveyor extension are to simulate a telescoping conveyor. These
are used in conjunction with the Extension steps to simulate the number of individual piles for
each sweep angle.
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The entire stacker can also be "pulled back" to create multiple stacking piles if desired as shown
below.
Reclaim Points
Up to ten reclaim points can be entered. The diameter (opening side) of the reclaim point must
be entered. The X & Y center of the reclaim point should be specified as well as the the slot
length and rotation angle (as viewed from a plan view).
212
Walls
Up to ten walls can be entered. The X/Y center controls the center of the wall. The rotation, and
slope of the wall can be adjusted accordingly as shown below.
213
Circular walls can be entered. If the circular radius is POSITIVE all data within the circle will
be included and all other data excluded.
If the radius is NEGATIVE all data inside the circle will be excluded as shown below.
214
9.0 Reports and Exporting (Excel / CAD)

The printer button ( ) will take you to the report and CAD export page. The following graphic
shows the available options for the report and CAD export.
The top section “Additional Information” will add sections to the output report if you check
them. The small button ( ) in the right-top corner will either check or uncheck all boxes if you
push it. None of these selections affect the CAD export.
The next section “Drive and pulley images” allows you to control what pulley arrangement
graphics will be added to the the report and CAD export. Each option in this section has a check
box and a radio button. If checked, the corresponding graphic will be added to the report or
CAD drawing. By default, “Profile Plot”, “Tail Arrangement”, and “Head Arrangement” will
be selected. You may also add “Middle Arrangement” and “Other Pulley” to the report and
drawing.
215
MicroSoft Word Report

All reports are fully editiable in MicroSoft Word. The document map will show all major
headers fro each section. Users of Word 2008 and above can also save these report as Adobe
"pdf" files if desired.
216
Profile Plot
To modify the profile plot, select the radio button for “Profile Plot”:
This will place the conveyor profile in the graphic. In the profile plot, the curve labels may be
moved by simply hoovering the mouse arrow over the label, then left-click to pick up the label,
and then move the label to desired location.
You may also edit the label text by hoovering the mouse arrow over the label, then right-click
and select “Edit Label”. You can then change the label text.
Finally, if you wish to copy the profile plot to the clipboard, simple right-click anywhere in the
profile plot and select “Copy to Clipboard”.
217
Pulley Arrangement Plot

There are several option to modify each pulley arrangement plot, shown below:
Reset – Current Window: This option resets the current pulley arrangement to the default.
Reset – All Windows & Labels: This option resets all current pulley arrangements to the
default.
Pan: Select this option to drag the pulley arrangement to a different location.
Zoom Out: Select this option to quickly zoom out
Zoom Window: Select this option to zoom by user selected window
Zoom All: Select this option to zoom so that full conveyor is shown
Zoom +/-: Select this option to zoom in / out. Left click and move mouse up to zoom out. Left
click and move mouse down to zoom in.
Edit Pulley Label: Select this option to custom edit a pulley label.
Copy to Clipboard: copies the pulley arrangement to the clipboard.
218
These views are then shown in the output reports.
219
CAD Exporting
Selecting the "CAD" exporting button will allow the user to save a "dxf" CAD file of the current
conveyor and results.
This file can then be opened in several commercial CAD software programs such as AutoCAD.
The dxf file contains a range of use engineering data and details. All items have been scaled
properly and are dimensionally correct. The window below shows a zoomed in view of the
general CAD export data.
220
CAD users should note that they can correctly dimension any of the windows by setting the
"Dimension Style". Each window shows scaling, and the user can select that scale to show any
additional dimensions they like.
221
The pulley windows show each pulley "Type", as well as a belt tension vector view of all pulleys
on the conveyor that uses that specific pulley "Type".
Again additional dimensions can be added and scaled properly by setting the correct scale in the
AutoCAD "Dimension Style Manager" window.
222
The material trajectory "zoom" view will be output to match the current zoom level on the
"Trajectory" output window of sidewinder. The user can zoom in/out by clicking on the zoom
buttons in this window before exporting the CAD file to show more, or less, of the material
trajectory.
223
10.0 User Options

10.1 Equipment Library & Database
Users can set their own library files for pulleys, material, and belting. The library files are stored
in the default user directory, however the file location can be changed on the preferences page.
All files are stored as basic text files. Thus users can edit them in excel or any other external
method they choose. This is very handy and you can then cut and paste data for external sources.
If data is entered for any item a new library input button will be shown (see image below). If
you click this button you will get a pull down list of all the equipment you have entered.
224
Below is an example of adding a material to the material library file. The material is then
available from the user library list.
Here is an example of adding a Belt to the user library file. The belting is then availed from the
user library list.
And finally the pulley input window. Pulleys can be "copied" from a current sidewinder file in
the pulley input page, and then "pasted" into the user library. This is a very hand feature when
making your own libraries.
225
10.2 User Catalogs

Users may create a “Catalogs” directory. This directory can contain any number of
subdirectories. The purpose of this directory is for the user (or a company) to be able build their
own library of information.
The image below shows AC-Tek’s catalog library and some of the subdirectories. Each of these
directories appears under the “Help” -> “Catalogs” menu from within Sidewinder. The Catalogs
directory has several subdirectories such as “Belting”, “Idlers”, and “Motors & Reducers”. In
the “Belting” directory there are further subdirectories such as ContiTech, Goodyear, Phoenix,
etc. Then in each manufacture directory there are several pdf catalogs such as “Coal
Quest.pdf”in the Goodyear directory. This allows the user to quickly reference the “Coal Quest”
catalog at any time by going to the Sidewinder “Help” menu, and navigating to the “Coal Quest”
manual.
This is only meant as a convent, and flexible, way for users (and companies) to organize
conveyor design information and catalogs.
You could for example create a directory called “literature” and place important papers or
specifications in it.
Only pdf files can be placed in these directories.
226
10.3 Preferences
This window is where you input your preference and default values for Sidewinder. This
window is through the “User” menu and then “Preferences,” as below:
The preference window is shown below:
To save changes, press the Save button. Pressing the Cancel button will discard any changes
made.
10.3.1 System Preferences

System preferences define your location, language, and units.
227
A. Default system units

Defines the default units to be used. Note that input/output units can be changed at any time
by pressing the Units button ( ) on the button strip. Input and outputs are always labels to
clearly show which system is being used.
B. Country / Location
Define your default location. The location affects default values when you leave input blank.
For example, standard belt widths are different in Europe than in North America. So if you
leave belt width blank, Sidewinder may select different belt widths depending on location.
Location is overridden by the input Location in the Design Criteria table. The Location input
in the preference window will set the location in a newly created Sidewinder file.
228
C. Imperial units show belt tension

If you are using Imperial units, Sidewinder will show belt tensions in lbs or in PIW.
Tension units in kip Tension unit is PIW
D. User Catalog Directory Location

This input sets the location of the user catalog directory.
E. User Library Folder Location

This input sets the location of the user library.
10.3.2 Language
Sidewinder currently supports English, Spanish, Portuguese, and Finnish. Select your default
language with the pull down list.
If you select a language other than English, you may switch between English and your
selected language by pressing F8.
AC-Tek makes no claims or guarantees regarding the correctness of the language translation.
It is the end user’s responsibility to ensure that the translation is correct. You must agree to
this before switching to another language.
Many of the translations take more space in the input/output fields. Sometimes a label will
get cut off because its length is too long. An example is the Material Mass on the load case
summary, which is abbreviated in English as “Mat. Mass.” In Spanish, this label gets cut off
and it may be unclear.
If this happens, you may expand or maximize the Sidewinder window to enlarge the label’s
width. Below the expanded label widths are shown:
229
Spanish – Sidewinder window

English Spanish – Default window size
expanded
10.3.3 Belting
A. Belt Speed Input Method
This option determines how the belt speed input is defined, which affects how the reducer
ratio is selected.
If “100% Motor Nameplate” is selected, Sidewinder will assume you want the input belt
speed at 100% motor nameplate. Therefore, the reducer ratio is selected so that the actual
belt speed will be equal to the input value at 100% motor nameplate.
If “Fully Loaded Case” is selected, Sidewinder will assume you want the input belt speed at
the Fully Loaded Case. Therefore, the reducer ratio is selected so that the fully loaded –
nominal load case (FL-N) belt speed equals the input speed.
This option is meaningless if you input the reducer ratio.
For example, assume the following conveyor:
Length = 300 m
Lift = 70 m
Tonnage = 1000 T/H
Belt width = 1000 mm
Si = 1.0 x 4.0 m
Motor = 500 kW coupled to fluid coupling (extra 3% slip)
Belt speed input = 3.2 m/s
The motor utilization is approximately 50%. If you select “100% Nameplate” the actual belt
speed will be higher than 3.2 m/s due to the motor slip and low motor utilization. Sidewinder
selects the reducer ratio so that the belt speed will be 3.2 m/s at 100% motor torque. Below,
the output is shown for this case. The belt speed is 3.27 m/s and the reducer ratio is
28.910:1.
230
To set the belt speed to 3.2 m/s, then change the preference to “Fully Loaded Case” in the
preference or change the option “Belt Speed Input Method” in “Details” tab. Sidewinder will
select the reducer ratio so that the fully loaded – nominal friction case will have a belt speed
equal to the input belt speed. The reducer ratio is 29.580:1.
231
B. Show steel cord belt rating as

If you are working in imperial units, you can show belt rating in metric (ST) units as steel
cord belt are normally rating in metric units.
C. Fabric belt safety criterion

Sets the fabric belt safety factor design criterion type to either “Splice” or “Nominal”. See
Safety Factor (Fabric Belting) in Design Criteria.
232
D. Design Criteria Defaults
The following inputs define the default design criteria:
Momentary Safety Factor (Fabric)

Momentary Safety Factor (Steel Cord)
Local Safety Factor Multiplier (Running)
Local Safety Factor Multiplier (Momentary)
Loading for extra belt-off case (%)
Allowable cross sectional loading (%)
Allowable belt sag (Run / Dyn)
Use Worn Mass for Lift-Off Calculation
These design criteria variables set the default values when a new Sidewinder calculation file is
made. The following graphic shows where the default values are set in individual calculation
files.
233
10.3.4 File Preferences

File Preferences are shown below:
A. Default directory for new files

Press the “Select” button to set your default directory for saving files.
B. Create a backup file when opening a file (.swb)

If this option is checked, Sidewinder will copy the current *.swi file to *.swb when you
initially open the file.
C. Add revision number to filename for new files

This option tells Sidewinder to check “Add Revision to Filename” in the Info page when
creating a new file.
D. Show tool tips for input data values

This option tells Sidewinder to show tool tips on input labels. Below is an example tool tip.
The tool tips are a quick and easy way to understand input values.
E. Auto save file

This option will auto save you Sidewinder file every 10 minutes. Note that the current file is
overwritten when it is auto-saved.
234
F. Show file revision information when opening older files

The option tells Sidewinder to display an information window when you open a Sidewinder
file that is older than the current version, an example is shown below.
10.3.5 Report Preferences

The following inputs show the default report variables:
Company Name: This is your company name, and is placed in the title block of the output
report.
235
Designer: Name of engineer making the calculation. This is place in Project Input Data.
Use Microsoft Word as the default editor: When you press the “Report” button ( ),
Sidewinder makes an RTF file (Rich Text Format), and then open it up. If you have Microsoft
Word installed, it will use Word to open the file (if this option is checked). Otherwise,
Sidewinder comes with a custom word editor which will be used, as shown below.
236
10.3.6 Idler Preferences

The following graphic shows idler preferences:
Default idler methodology

This option sets the default method for calculating idler load and life in a new file, which can
by Universal or CEMA. The actual method is always determined by method selection on the
Idler Input Data window:
Allowable idler speed (rpm): This value indicates at what rpm the idler rotational speed will be
flagged if it is exceeded. In the following example, the carry idler speed is 654 rpm, which
exceed the preference value of 650 rpm, so it is flagged in red. If roll diameter is not entered,
Sidewinder will increase roll diameter so that the allowable idler speed is not exceeded.
237
Allowable idler shaft deflection: This is the allowable deflection of the idler shaft. If bearing
size is not selected, bearing size will be increased so that allowable shaft deflection is not
exceeded. If shaft deflection exceeds the allowable, then output shaft deflection will be flagged
red. In the following example, shaft deflection on idler set #2 is flagged.
Default idler installation tolerance: Sets “Vertical Installation Tolerance” in the L10 Life Input
Data table.
Default L10 miscellaneous reduction factor: Sets “Misc Reduction Factor” in the L10 Life
Input Data table.
238
Preferred Manufacture: This pull-down list allows you to select default geometries for idlers
based on various manufactures.
10.3.7 Shaft Design Preferences

The options in Shaft Design Preferences set initial design criteria values in the Pulley & Shaft
Input Data table. The preference input values are shown below:
When you create a new file, they will be used in “Pulley & Shaft Input Data”:
239
11.0 Projects Files

The "Project Files" pages allows the user to review, summarize, and print data from a number of
conveyors designs.
This feature is very useful when working on a project that includes many conveyors.
240
Files can be added, and removed using the green "+" and "-" buttons on the toolbar. Multiple
files can be selected by holding the "Crtl" key, or the "Shift" key.
Once Sidewinder files have been added the calculations and equipment are shown on the four
output tabs at the bottom. These pages show:
Summary Tab - A summary of all the main details for the conveyors.
Load Cases Tab - All load cases, power requirements, belt tensions, and safety factors.
Pulley Tab - All pulley details and tensions for all load cases.
Equipment Tab- All unique equipment for the selected conveyors.
241
The Equipment tab page summarizes all the equipment used on multiple conveyors. In the
image below two (2) conveyors use a 1800 mm wide ST-3150 N/mm belting and the total
required belt length (conveyor 1 + conveyor 2) is 5916 m.
The summary includes belting, motors, pulleys, and brakes. The required "matching" parameters
are shown in the list. For example a motor "match" is assumed if the type, nameplate rating, and
RPM are the same. For pulleys the diameter, lagging type, face width, shaft & bearing
diameters, and bearing centers must match.
The idea is that users can now select several conveyors for a project and quickly get a good
estimate of the total equipment requirements.
242
Excel Exporting Options

As with the individual sidewinder files, a very nicely formatted excel output option can be
exported. This includes the "summary", "Load cases", "Pulleys", and the new "Equipment"
output pages.
Global Variable Change

You can change a variable for multiple files when working with a project. To use the global
variable change select “Options” -> “Global variable Change”, then simply select the input
viable and its value. You can also choose to save the files (i.e. permanently update the files with
the value), or just run the calculations and look at the results. For example, if you have 5
conveyors that you have added to a “project” and want to change the tonnage for all five, simply
select “tonnage” as the input variable, enter the new tonnage (say 1000), and then click “solve”.
243
General Tips:
• Users can double click on the file name (top of each column) to quickly open that
particular file.
• Right clicking on a column brings up a menu to remove or replace the current file.
244
12.0 Reference Papers

1
Lemmon, Ryan. (2002), “Local Stresses in Belt Turnovers in Conveyor Belts”, Bulk Material
Handling by Conveyor Belts IV – 2002 SME Conference
2
Oszter Behrends Vincent (Dec 1980), “Large Capacity Conveyors - Motion Resistance
Evaluation” Mining Engineering, pg 1715-1721
3
K.J. Grimmer and F.Kessler (1992) “The Design of Belt Conveyors with Horizontal Curves”
Bulk Solids Handling, October 1992, pp. 557-563
4
CEMA (2007), Belt Conveyors for Bulk Materials, 2nd Printing
5
Phoenix Conveyor Belts (2004), Phoenix Conveyor Belts Design Fundamentals – New DIN
22101
6
Kruse D. & R. Lemmon (2007) “A Comparison Of Various Belt Tension Calculation
Methodologies Including Cema 6th Edition” BELTCON 13, South Africa
7
Spaans (1991), “Calculation of the Main Resistance of belt conveyors” Bulk Solids Handling,
Volume 11, No 4.
8
Kruse, D. J. (2005), “Data Acquisition Techniques and Measurement Equipment for Belt
Conveyors” BELTCON 13, South Africa
9
Kruse, D. J. (2004), State-of-the-Art Data Acquisition Equipment and Field Measurement
Techniques for Conveyor Belts SME Annual Convention
10
G. Lodewijks & D. Kruse (1998), The Power of Field Measurements - Part I, Bulk Solids
Handling, 3/1998, pg. 415-426.
11
David J. Kruse (2002), Optimizing Conveyor Take-up Systems using Dynamic Analysis and
the Implementation of Capstans, Bulk Material Handling by Conveyor Belts IV – 2002 SME
Conference
245

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Sidewinder v6.

Conveyor Design Software

Advanced Conveyor Technologies, Inc.

Chute Fill – Receiving Conveyor ..................................................................................................................... 100

8.2.2 Turnover Output ................................................................................................................................ 192

2. DIN 22101 & ISA 5048 Standards.

4. The plethora of papers devoted to bulk solids handling.

2.1 Network Licenses

2.1.1 HASP Network Licenses

This will bring up the Sentinel Admin Contorl Center.

Clicking on the “Products” menu will show the Sidewinder License.

2.1.2 SafeNet Network Licenses

2.2 Sidewinder Updates

3.0 Sidewinder - Overview

3.1 Sidewinder Toolbar

Open – Opens an existing Sidewinder input file

Reports – Generates a word document conveyor design report (see section 7)

3.2 Sidewinder Quick Start

Now click on the calculation button on the toolbar (circled above).

4.0 Input - General

1. Project Information – General information, filenames, and calculation methods

Each of these areas will be discussed individually in the following sections.

4.1 Project Information

Conveyor Name – Name of the individual conveyor (e.g. CV-002, or CR034)

Location – Geographic location (used for output report labels only).

Designer – Engineer responsible for the conveyor design.

The primary solution methodologies are:

4.2 Design Criteria

Safety Factor Example - EP-800 N/mm Fabric Belt

Then the allowable safety factors are:

6.67:1 - Design Level 1 - Running

Pulley Shaft Design Criteria

Here is how the new design criteria inputs work:

Running 100% Power Case

Pulley Shaft Design Criteria - Extra Case Options

The available options are:

Fabric Belt Criteria

4.3 Load Conditions

A summary of the input values is as follows:

Material type 3 in Load Point 1

4.4 Frictional Conditions

Mechanical Efficiency – The total mechanical efficiency of the drive system is

5.0 Input - Main Page

Lump shape factor = 0.5 Lump shape factor = 2

1. Belt – The most commonly used belting input information

Each of these windows will be described below.

Width – The width of the conveyor belting.

Trougability / Load Support / Pulley Diameter Inputs

Steel Cord Belts

Number of Splice Steps – Number of steps in a single belt splice.

Number of Cables – Number of cables in parent belt.

Cable Breaking Strength – Breaking strength of an individual cable.

Calculation Method - Calculation method for horizontal curves.

Side Guide Roll Max Load (N)

Side Guide Roll Gap (mm)

Belt/Idler Friction Ratio

Material Follow Factor

Surcharge Angle Limit (deg)

ISO 703 Belt Troughability

Transition Type – Three transition types are available in sidewinder.

Belt - Sidewall (Pocket Belt Conveyors)

Sidewall Thickness – Thickness of the Sidewall (one side).

Cleat Base Width – Width of the bottom part of the cleat.

Cleat Angle – The angle the C, or TC sloped cleat section makes.