BSM - Bulk Solids Modelling
The Modelling Process
Information Required
Cost Benefit Analysis
Model Construction
About Us
Bulk Solids Modelling
+61 (0)8 9776 0164
+61 (0)488 061 407
Send us an email
Model Construction

Models are constructed by our highly skilled model maker in transparent polyacrylate in such a way that the inside surface of the model reflects the inside surface of the full scale chute, including the wear liners.

From the drawings provided, the models are first developed by computer in 3D to provide the necessary information for construction in polyacrylate. The joins are all calculated by this process and are carefully mitred and glued at the appropriate angle. This type of construction differs considerably from fabrication in steel, where thickness is small in relation to overall scale. Typical thicknesses of plastic used are 2, 3 and 6 mm, and the construction techniques have more in common with cabinetmaking than steel fabrication. The use of fully mitred joins ensures that there are no discontinuities at the joins, no matter how complex they are.

Reinforcing and mounting geometry is tailored to suit plastic fabrication. Much of the structural reinforcement in the steel fabrication can be eliminated in the scale model, but flanges between components of an assembly are dimensioned so as to provide suitable stiffness in the model.

Curved surfaces are calculated and formed by heat treatment using turned and occasionally hand-formed or CNC templates, with careful allowance for anisotropic effects during forming. As with all other joins, the edges of curved components are mitred to fit their mating parts.

The end result of this process is a model that provides unmatched accuracy of the geometry of the full scale chute as well as providing a clear view of the internal flows and appropriate structural rigidity.


Belts are sized to scale for the application. BSM have developed specialised belts for scale model purposes that are capable of duplicating the troughing angles of full scale belts. Conventional belts on small conveyors are not capable accurately duplicating troughing angles due to their inherent stiffness. BSM’s developments have overcome this hurdle.

The conveyors used for modelling are slider bed conveyors. These are the only type suitable for modelling at the scales used. For any particular application, the slider bed is tailor made to duplicate the idler configuration in the full scale system.

Belt speeds are controlled by variable speed drives and are set to match the scale equivalent of the full scale belt speed, according to the scaling rules used.

This attention to detail provides unequalled accuracy of simulation of full scale geometry.

Head Pulleys

The head pulleys used in models are constructed precisely to scale, allowing for the lagging on the pulley. The width of the pulley is also to scale, so that the pulley fits inside the head box, duplicating the full scale situation. There is no need to have cut outs in head box to allow for over-width head pulleys as was the case in the early days of the technology.

The vertical position of the head pulley is set in relation to the slider bed so as to accurately mimic the transition geometry of the full scale conveyor. This provides the most accurate possible simulation of the material trajectory.

Test Facility

Our dedicated test facility comprises 300 square metres of floor space. Three separate circuits can be run any one time. All fabrication and testing is provided on-site. Ancillary equipment such as screens is fabricated on site to suit the application.

The test facility is located adjacent to some of South Western Australia’s premier tourist attractions and there is a large range of accommodation options available for visitors, some within easy walking distance.

Continuous improvement

BSM is constantly seeking to improve the modelling process. The innovations in the existing process will be apparent to anyone experienced in modelling and there are constant improvements to the overall modelling process being developed on an ongoing basis.