DESIGN AND ANALYSIS OF A MODULAR BELT WINDER FOR BELT WIDTH ≤ 2400MM X Ø6 METERS WITH A CARRYING CAPACITY OF 50 TONS

Abstract

Belt conveyors are material transportation systems widely used in the mining, power generation, and manufacturing industries due to their ability to move large quantities of material efficiently and continuously. This system has replaced conventional methods such as haul vehicles, thereby increasing productivity and reducing operational costs. One of the main challenges in operating belt conveyors is the installation and replacement process of the belts, especially for large-sized belts. This process requires specialized tools such as a belt winder, which functions to quickly, safely, and controllably wind and unwind the belt. This study aims to design and analyze a modular belt winder capable of winding and unwinding conveyor belts with widths up to 2400 mm, diameters up to 6 meters, and a maximum load capacity of 50 tons. The design process includes product benchmarking, selection of local materials, and dimension adjustments according to Indonesian land transportation regulations (Minister of Transportation Regulation No. 60 of 2019). A structured engineering design approach is applied through conceptual design, initial modeling, and mechanical analysis of key components such as shafts, bearings, gears, drive systems, and supporting structures. The design results show that the belt winder has dimensions in the operational configuration of 5,516 × 5,490 × 3,900 mm and in the transportation configuration of 5,841 × 2,400 × 2,990 mm. All components operate within safe stress limits, with a minimum safety factor of 2 for rotating elements and above 6 for the supporting structure. The torque required to wind a 50-ton load is 31.718,93 N·m, with a pump power of 33.18 kW at 1,272 rpm.