12/06/2020 Sidewinder Conveyor Design Software | Sidewinder Conveyor Design Software

Overview

AC-Tek realized the industry’s need for a new, easy to use, conveyor design program
filled with the latest in technology and current industry standards. The Sidewinder
software is AC-Tek’s response to this need. It represents a new standard in easy to use
conveyor design software and engineering technology.
Below is a summary of many of the Sidewinder features. If you have any questions, or would like more information please contact
us.

Software Overview

Sidewinder was developed from the ground up using the

latest software development tools and years of conveyor design experience. The program’s features interface and entire hierarchical
structure was thoroughly laid out before development began. This resulted in a very flexible software package that can easily be
upgraded with new features and technology in the future. The program can handle conveyors of any geometry, length, and drive
configuration. Numerous advanced features have also been included such as; vertical and horizontal curve analysis, turnover and
transition stress and requirements, quick geometry input, auto sizing and calculations of major components, terrain modeling,
dynamic analysis, and much more.

Easy to Understand Inputs & Results

From day one, Sidewinder was design to be easy to use, with

easy to understand input and output data. Whether you’re designing a small in-plant conveyor, or a long overland system,
sidewinder can handle them all.

Sidewinder engineers have designed a simple data input layout unlike anything currently available. A single universal input screen
was designed to provide easy access to all relevant input data. Additionally, a single tabbed data output window allows quick access
to all relevant output data with problem areas highlighted showing potential problem areas.

International Standards & Calculation Methodologies (English and Metric Units)

Conveyors are found around the globe. From small in-plant conveyors to the large overland systems, and in all regions of the world.
The ability for the software to perform calculations in both standard and SI units was an obvious must. Additionally, users can quickly
switch units for all input and output data with a single mouse click. As there are several different calculation methodologies used
worldwide, we have chosen to include all which we feel are the most relevant. Both the universally accepted DIN and CEMA

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standards are available. Other published methodologies are also available (Jonkers, Spans, etc). These methods use the specific
belting rubber viscoelastic properties and other factors.

Multiple Language Support – All Inputs, Output, and Reports! (English / Spanish / Portuguese / Chinese / German /and more)

The software has been designed to support multiple languages for non-English speaking countries and areas. All inputs, outputs,
and full word reports are available in many languages. The users can also switch between languages at any time by simply pressing
the F12 key! Furthermore, if we don’t currently support your language we can send you an Excel spreadsheet in which you can fill in
with your specific language. We will then implement this directly into the software free of charge!

Chinese Language Spanish Language

Professional Quality Design Reports

(Microsoft Word & PDF formats)

High quality professional output files were at the top of the list when
determining the most important engineering features to include in Sidewinder. A custom report editor is built into the software, as
well as the ability to export reports directly to Microsoft Word documents and Adobe PDF files. Company logos and other custom
information can be specified in the software. Pulleys, brakes, and other major equipment lists are generated which can be directly
supplied for manufactures for quotations.

To view two example pdf report files click Report Basic.pdf, or Report Detailed.pdf

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Conveyor Geometry
One of the more difficult aspects of conveyor design is accurately inputting the conveyor profile. Sidewinder has three methods for
entering this information:

Easy Profile – Allows a basic conveyor profile to be entered using only a few conveyor elements. All basic information is entered on
a single screen and can easily be modified later. Dozens of standard conveyor configurations are available in order to minimize the
input requirements for the end user.

This is appropriate for most small conveyors (<1000 ft.) which have relatively simple profiles.

Standard Profile – Allows an unlimited number of vertical and horizontal curves

to be entered. This information can be directly entered, or imported from several standard drawing packages such as AutoCAD.
Each conveyor flight is treated individually, and vertical and horizontal curves are automatically subdivided at runtime to provide an
accurate representation of the conveyor.

This method allows drives, brakes, pulleys, loading points, trippers, and other

equipment to be positioned anywhere along either the carry or return sides.

The ability to easily view the conveyor as components and final layout removes the guess work, and potential input errors, when
analyzing a conveyor. These layouts are also automatically included in the output design reports.

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Integrated System Design

Many conveyor systems have a wide range of operating conditions. These include variations in:

Material properties and/or multiple material types

Conveyor load variations (incline or decline sections loaded, load on and off)
Hot summer time temperatures, to frigid winter conditions
Belt mass reduction and other changes due to cover wear and environmental factors
Idler bearing drag and motor efficiencies
Other factors

The core Sidewinder philosophy has been to treat the conveyor as a

“system” of design conditions, rather than as a simple design case. This design philosophy ensures that many conditions which may
have otherwise gone unchecked are accounted for in the design phase. For example, belt liftoff is automatically calculated using a
“worn” belt mass and the maximum corresponding belt tensions (belt inclines loaded, and high frictional conditions).

This is extremely valuable to both new and experienced engineers as it often highlights problems area which may have
otherwise gone unnoticed. A Sidewinder conveyor design therefore results in the most comprehensive conveyor design of any
software on the market.

Additionally, a single, simple input table allows all relevant design conditions to be entered. Byway conveying, reversible conveyors,
multiple materials and belt speeds, and various loading profiles can all be quickly and easily entered.

Custom Idler Types

Users can choose to use either a standard CEMA idler set, or a custom idler
set. Custom idler sets allow up to six independent custom idler rolls to be used. Additionally, each roll is customizable within each
idler set. This allows center rolls to have unique properties (length, bearing type, shaft size, etc) from wing or other rolls.

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Each conveyor element can have a unique idler set (up to eight different idler sets
can be entered). This allows impact idlers, transition idlers, and other idler sets to be entered and included in the output report.

Pipe conveyor design and other advanced features are also included.

Detailed L10 life calculations, bearing and shaft deflections, and other data is calculated for each conveyor element, and then
summarized in a single easy to read output table. Standard CEMA series sets, as well as SKF, FAG, and other manufacture
bearings series are included. Furthermore, all idler and bearing input data is fully user customizable.

Multiple Material Types & Byway Conveying

Up to five different material types may be entered for a single design. This is not only useful for analyzing worst case design
conditions (for example using the lowest material density for maximum cross sectional loading), but also allows the conveyor to
transport more than one material type.

Additionally, the material type is specified at each load station, and therefore the conveyor can be loaded with different materials at
the same time (different materials, and tonnages on the carry and return sides for example).

Dynamics – Starting / Stopping / Emergency

Stopping
Relatively long conveyors, or conveyors with large inclines or declines should have a flexible dynamic analysis preformed on them
(see dynamic analysis). However, ridged dynamic calculations are often more than adequate for short conveyors, and for preliminary

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estimation of the dynamic belt tensions and braking requirements.

The ridged dynamic input window of sidewinder allows a wide variety of options and the standard calculations automatically take into
account both “operational” stopping conditions, and “emergency stopping conditions”.

Starting of the conveyor may be done via a fixed starting time, or by using the maximum motor torque (squirrel cage motor) .
Breakaway motor torque is also calculated.

Belting and Belt Stresses

Sidewinder has combined a wide range of belting data from several of the leading belting manufacturers. This includes properties for
both fabric and steel cord belting.

Sidewinder’s “smart selection” capability will automatically estimate many of the most important belting parameters such as strength,
weight, modulus, and type.

Steel cord splice information, belt roll quantities, shipping and storage details, and other relevant belting information is automatically
calculated.

Pulley Shaft & Bearing Sizing

Pulley diameters, shaft stresses, bearing loads, allowable turndown ratios, and other important design information is automatically
calculated for each pulley. An accurate graphical representation for each pulley is displayed showing belt tensions, wrap angles, and
the pulley geometry.

Shaft safety factors and deflections are highlighted in RED to show problem areas. A pulley design page is also generated in the
standard report output. Both CEMA and AS-1403 standards are included with all intermediate calculation values.

Right Angle Drives with Overhung Loads

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Sidewinder includes an advanced workpage allowing overhung loads to be determined for various power conditons. These loads
can then be used in the normal pulley and shaft calcaution equations. Sidewinder allows the user to enter all known masses and the
center of gravity (CG) of each item. However, if these items are unknown Sidewinder can also estimate them using internal libraries
created from published user catalog data.

Horizontal Curve Calculations

The New 6th edition CEMA manual contains the basic horizontal curve calculations for belt conveyors. These equations and other
published methodologies from various technical papers have been implemented into the Sidewinder Software.

Easy to understand graphs showing belt displacements, edge stresses, side guide roll forces, and other critical information is given
for each horizontal curve section. Additionally, combined vertical and horizontal curve effects are taken into consideration as well as
idler forward tilt and other design options.

Pipe Conveyor Design

Pipe conveyor use and applications are becoming more popular around the world. Sidewinder allows pipe conveyors to be analyzed
and incorporates many specific equations for their proper design. This includes inputs for power calculations, as well as calculating
belt stresses in combined vertical and horizontal curve areas. Recommendations are given for cross sectional loading as a function
of material lump size and other factors.

Stock Pile Calculations (Live & Reclaim Volumes)

Conical Stockpiles
Linear Stockpiles
Radial Stackers
Multiple Reclaim Points (Circular and/or slotted)
Walls and other boundary conditions.
A combination of all of the above!
Export files directly to AutoCAD

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Material Load On / Load Off –

Simulations
Select any case (fully loaded, inclines, declines) and quickly calculate power and other important design data as the conveyor is
loaded and unloaded.

The designer can then quickly see how long a given condition occurs.

The image to the right shows the conveyor loaded from the lowest to highest elevation, and the corresponding power consumption,
and time above motor nameplate rating.

Power Breakdowns & Other Useful

Design Information
As Sidewinder has several calculation methodologies available it is very useful to quickly (and easily) view the individual breakdown
of the various power components. Sidewinder provides a pie chart for each load case showing this information.

This is just one example of the many standard features available in Sidewinder making it the easiest to use, and understand
conveyor design software package on the market today.

Vertical Curve Calculations

Both convex and conveyor curve radii are incorporated in the software. Belt lift off, center and edge stresses, belt buckling, and lift
off distances are calculated for each concave curve and every load case.

Likewise, belt stresses in convex curves and required idler spacing is also calculated. All cases are them summarized in an easy to
read data table. Users can quickly spot, and correct problem areas.

Loading Points & Belt Feeders (CEMA, Roberts, Bruff, Reisner)

Sidewinder included feeder belt and pullout force calculations from a range of international standards and published papers. These
include CEMA, Roberts, Bruff, and the Reisner methods. Up to ten different loading points can be entered. Loading points may be

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on either the carry or return side of the conveyor, and in either the forward or reverse direction (for reversible conveyors). Plugged
chute, and belt feeder calculations can also be included in the tension calculations to determine worst case motor power
requirements. All calculated data is conveniently output to provide the engineer with a full understanding of how the tensions are
calculated.

Belt Transitions (ISO 5293, Beckley, AC-Tek)

Every conveyor has a transition area at the head and tail end when the troughed belt transitions to a flat configuration before
traveling around the pulley. As belt tensions are often highest at the head pulley, belt edged stresses in these areas are also the
highest in the belt. However, many conveyor design calculation programs ignore these areas.

Sidewinder not only calculates the required transition lengths, but also outputs the required troughing idler angles, and packing
heights for each transition idler set.

Belt Turnovers
AC-Tek engineers are leaders in developing new conveyor design standards and equations. The calculations for belt turnovers is no
different, and have been published by one of AC-Tek’s owners, Mr. Lemmon (turnover paper).

These equations are incorporated into the software along with a very easy to use information window which allows the engineer to
determine the optimal turnover length and other design parameters.

Transfer Point Material Chute Sizing

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Careful attention must be paid to the maximum material buildup at the transfer point. Many times a long (high inertia) conveyor will
feed a short starting conveyor. In this case the long conveyor may take significantly longer to stop than the conveyor it is feeding.
Sidewinder will automatically analyze all loading conditions and frictional cases to determine the maximum material buildup at the
transfer point.

Terrain Modeling
This feature allows the 3D surfaces to be entered directly into the program. Both the horizontal and vertical profiles are coupled with
this surface. The surface data can be imported from CAD, GPS meshes, or other data. Cut and fill calculations can be preformed
and alternate conveyor routes can quickly and easily be analyzed.

Multiple Conveyor Project Files

Do you have a project with several conveyors? Want an easy way to summarize multiple conveyor designs? Well this feature is for
you. Select as many sidewinder input files as you wish and create a complete summary of the output results. Three output windows
are available:

Summary – Summary of each input file. One vertical column is added per sidewinder file. This is useful for quantity
and other information
Load Case – One row is added for each load case of every sidewinder file. This is useful when looking at the detailed
engineering and design of several files.
Pulleys – A summary of every pulley in each file.

“Multiple Conveyor Summary sheets” are very useful

when you have a single conveyor but perhaps several design revisions. You can open various designs (for the same conveyor) and
directly compare different designs to one another.

You can also save/open your “list” of summary files for future access. You can print any of the summary sheets by using the “print”
button. Or right click and “copy to clipboard” to export to Microsoft Excel or some other format.

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Custom User Preferences

Sidewinder allows many inputs and design criteria to be individually tailored for a specific user, project, or company. This is very
useful as these preferences can be shared between users allowing all engineers in the same company to design conveyor systems
using the same design criteria.

The user can also specify their own company logo which will then appear on all reports and word printouts.

Video Tutorials & Intelligent Tool Tips

Over 25 short video tutorials (5+ hours) are available for the
new, and experienced conveyor design engineer. Each tutorial focuses on a specific topic such as “vertical curves”, “feeder belts”,
“reversible conveyors”, and other areas of interest.

Our users have found that these tutorials are an excellent way to quickly become proficient users of the Sidewinder software.

The tutorials can be played using Windows media player, and stored on the user’s PC for quick and easy access.

Tool tips are available for all user data inputs. Each tool tip contains a descriptive meaning of
its purpose, default values, useful equations, and other valuable information.

AC-Tek also has full tech support for Sidewinder users who purchase an annual maintenance contract.

So what are you waiting for……. Give Sidewinder a try today!

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If you are in need of a conveyor design package, or are tired of struggling with your existing software, give Sidewinder a
try. We offer several pricing options to meet your design needs. Additionally, you can trade in your exiting or outdated conveyor
design software for a substantial cost savings on a new Sidewinder license. Please contact us for more information.

Home | Sidewinder | Overview | Pricing | Demo | Tutorials | Current Version | FAQ

© 2016 AC-Tek - All rights reserved 19415 594th Avenue, Mankato, Minnesota 56001 U.S.A Minnesota 507-345-5748
3911 East 132 North, Rigby, Idaho 83442 U.S.A Idaho 208-745-6914

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