Development of Mathematical Model Using Dimensional Analysis and Buckingham π Theorem for Belt Stretch of Medium-Duty Belt Conveyors

Abstract

Belt conveyors transport materials in mining, manufacturing, and logistics. They deliver large products great distances cheaply. Changeable loading during start-up, halt, and operation causes belt strain, affecting performance and reliability. An unmanaged belt stretch can misalign, impair efficiency, and prematurely deteriorate, increasing operational expenses and downtime. This study is important because it covers medium-duty belt conveyor belt stretch under transient dynamics. We used dimensional analysis and the Buckingham π theorem to create a mathematical model to analyze the complicated interplay between belt stretch components. The dimensionless study includes belt tension, material properties, load distribution, and operational circumstances. This research aims to create a credible mathematical model for belt stretch predictions in transitory scenarios and optimize it for commercial use. Experimental and simulation results supported the model's belt stretch forecast. Belt stretch sensitivity to dimensionless groups recommends operational parameter changes to avoid issues. This study affects medium-duty belt conveyor design and maintenance. The optimized model helps engineers anticipate and reduce belt stretch, boosting conveyor reliability and lowering maintenance costs. Theory and practice are combined in this study to improve conveyor system technology and industry sustainability.