Development of a mathematical model for belt stretch using transient dynamics of medium-duty Polyvinyl Chloride-based belt conveyors

This study uses a mathematical modelling technique to present the transient stretch behaviour synthesis of Polyvinyl Chloride (PVC) belts in medium-duty conveyor systems. The mechanical properties (stretch behaviour) of PVC belts, a vital component of industrial material transport, are evaluated using modern dimensional analysis methods of Buckingham Pi on different parameters. The research analyzes conveyor design and operational parameters using mathematical modelling and Response Surface Methodology (RSM) to improve efficiency and dependability. The objective is to enhance operational perception and forecasting performance under diverse load circumstances. RSM explores variable interactions and finds optimal conditions for minimising downtime and maximising throughput through organised experiments and statistical analysis. Medium-duty belt conveyors from several industries were surveyed for field data. It covers operational output and input variables. The mathematical model emphasises transitory behaviours, involving fluctuations in output parameters. The conveyor design and operation model optimises energy efficiency, component life, and maintenance intervals. Field measurements verify model outputs, confirming their effectiveness and confidence. Results show that the maximum belt stretch reached 12.5 mm under full load conditions, and the proposed dynamic model predicts stretch with an accuracy of 94.3% compared to empirical measurements. The goodness of fit obtained by the analysis is SSE-24.64, R2-0.8587, Adjusted R2-0.801, and RMSE-0.7091. The mathematical model obtained by this interdisciplinary work provides a base to connect biopolymers and resin-epoxy-based hybrid composites to conveyor belt materials, helping develop high-performance medium-duty conveyor systems.