Cableway Conveyor Calculation and Design 
 4 Steps

In order to obtain the final operation design, it is necessary to perform the following steps:

Step #1 - Drawing
Make a drawing (or sketch) of the proposed system

Step #2 - Load Clearances & Trolley selection
Find clearances between loads at inclines and corners. This will determine the load pitch, angle of incline or decline, and sprocket diameter (See pages 23&24 ) 
Note! Load clearance at inclines and corners is less then on straight track sections, as illustrated.

Step # 3 - Line Pull Calculations
Line pull calculations are used to determine the number of drives required. Most systems will require only one drive; however the line pull should be calculated on each system (Ref. Line Pull Instruction, page 19, and Line Pull Work Sheet, pages 26-27.)

Step #4 - Pricing

By this point we have a system drawing (Step #1), trolley selection (Step #2), total track length (Step #?), and line pull requirement (Step #?). With the above information, simply refer to the AOC Cableway price book for system pricing.

Section II - Technical Data

Line Pull Calculations
The proper selection and location of the drive units is very important. This detail can be the difference between a smooth and satisfactory operating system and a poorly operating, troublesome one.

It is important, regardless of whether the calculations are being made by the user, sales engineer or factory, that complete information is available. The following list covers factors commonly necessary to consider when calculating line pull, which is the first step in the selection and location of the drive. 

      1. Maximum weight to be transported on a single trolley.
2. Maximum weight of attachment (If any) used to transport load.
3. Weight of cable and trolleys per foot (Use 4 pounds per foot)
4. Wheel coefficient of friction (use .03)
5. Location of loading and unloading points.
6. Total maximum number of loaded carriers on the system at one time,
7. Location of dips and rises and weather conveyor will be loaded or empty on these dips and rises.
8. Speed of the conveyor (If variable speed the high and the low).
9. Atmospheric conditions such as heat, cold, temperature changes, excessive moisture, fume an excessive dirt or dust.
10. With all of the above, and following the instructions given below, it is still necessary to exercise good judgment in the selection and location of the drive unit.

Generally it is desirable to have the drive located at the highest point in a system sp that a declining curve (if Multiplan system) is on the slack side of the drive. On monoplane systems the drive unit should be placed “downstream” of the off loading point.

Another good general rule to follow is to locate the drive so as to utilize a 180º curve, if possible and practical. In a relatively short and lightly loaded system this is not too important. However, it is always desirable to have as many driving lugs engaged in the drive sprocket at one time as possible.

Although only partial credit has been taken for the loads on the decline, the other portion has not been ignored. To simplify the calculations, we have not requested the additional line pull percentages due to negotiating vertical curves without sprockets and horizontal curves with sprockets. These additions have been taken care of in our general line pull calculation formula. 

There are many other things to take into consideration when analyzing a conveyor application: Overloading, loading on inclines contrary to specifications, unloading declines contrary to specifications, no lubrication contrary to instructions. Don’t forget that many conveyors are used for storage, even though not originally purchased for such purpose, and as a result are, many times, fully loaded while the original intent was to have them only partially loaded. This statement is made only for the purpose of impressing on the mind of the individual the necessity of carefully reviewing all the facts when calculating a cable conveyor system.  

Cableway Conveyor Menu

Cableway Conveyor Calculation and Design - 4 Steps

Technical Data

Sample Cableway Line Pull Calculation

Questions that need to be answered for your Cableway System

Drive Selection

Track and Fittings


Trolley Attachments

Load Clearance Chart - VERTICAL CURVES

Load Clearance Chart - HORIZONTAL CURVES

Drive Units

Idler Corners

Vertical Curves

Vertical Dip

General Data