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Static testing evaluation of pipe conveyor belt for different tensioning forces

  • Vieroslav Molnár EMAIL logo and Martin Sabovčík
Published/Copyright: December 10, 2019
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Open Engineering
From the journal Open Engineering Volume 9 Issue 1

Abstract

The paper analyzes static tests of pipe conveyors using various statistical indicators and points out the mutual interactions between individual roller stands. Individual measurements were performed on a physical model of a pipe conveyor, while the methodology and procedure were verified by experiments. 15 repetitions of the given series of measurements were selected, which was a compromise between time demands and statistical requirement. Normal contact forces on the individual rollers of three hexagonal roller stands acting on the conveyor belt for different tension forces in the static state (conveyor belt without movement and without transported material) were evaluated. The LabVIEW Signal Express 2010 program from the National Instruments Company was used to record the measured data. The measurements were evaluated by Microsoft Office Excel.

Keywords: Measurement; physical model; pipe conveyor; conveyor belt; contact force; tensioning force; idler roll

1 Introduction

During normal operation, the conveyor belt of the pipe conveyor is exposed to various influences, which cause its static and dynamic wear. Abrasions, cuts and cracks and incorrect operating conditions are the main causes of wear.

Research into the contact forces on the pipe conveyor rollers in terms of durability, reliability and wear on the conveyor belt, is currently an issue which is increasingly at the forefront of researchers, designers, pipe conveyor manufacturers and their users [1, 2, 3, 4, 5, 6].

A very effective way of obtaining real values of contact forces between the conveyor belt and the guide rollers in the continuous transport of bulk materials using pipe conveyors is the use of specially designed test equipment. In cooperation between the PHOENIX Conveyor Belt Systems GmbH and the Institute of Transport and Automation Technology (ITA) a research project was realised [7]. The CKIT Company, in cooperation with the Mining University of Leoben, has developed a testing device for pipe conveyors [8]. Further research is known in the field of determining the real values of contact forces between the conveyor belt and the guide rollers of the pipe conveyor [9, 10, 11, 12, 13, 14].

This paper analyzes normal contact forces on individual rollers of three hexagonal idler housings acting on conveyor belt for different tension forces in static state - conveyor belt without movement and without conveyed material, pointing out mutual interactions between individual roller stands.

2 Methods

The physical model of the pipe conveyor in Figure 2 was preceded by the creation of its 3D geometric model shown in Figure 1. The physical model is used to measure normal contact forces (CF) on the individual rollers of three hexagonal idler housings acting on the conveyor belt for 5 different tensioning force levels (TF) in static condition - conveyor belt without movement and without transported material. Both models contain three identical hexagonal idler housings No.1, No.2, No.3.

  1. Hexagonal idler housing No.1 – characterizes the state of closing the conveyor belt,

  2. Hexagonal idler housing No.2 - characterizes the normal operation of the conveyor belt,

  3. Hexagonal idler housing No.3 - characterizes the state of fixation of the conveyor belt by means of clamping screws.

Figure 1 3D geometric model of a pipe conveyor [9]
Figure 1

3D geometric model of a pipe conveyor [9]

Figure 2 Physical model of a pipe conveyor
Figure 2

Physical model of a pipe conveyor

The physical model of the pipe conveyor (Figure 2) contains 18 strain gauges at positions ID1-ID18 on three hexagonal idler housings and 2 strain gauges at positions ID23, ID24 on the tensioning plate (Figure 1). The 5 different levels of TF are derived by the sum of the tensioning forces at positions ID23 and ID24. The position of straing gauges on all three idler housings is shown in Figure 3.

Figure 3 Marking the positions of strain gauges on idler housings No.1, No.1, No.3 [12]
Figure 3

Marking the positions of strain gauges on idler housings No.1, No.1, No.3 [12]

Table 1 contains the characteristics of strain gauges on the physical model of pipe conveyor, in Table 2 are their parameters.

Table 1

The characteristics of strain gauges

Measuring pointMarking of the measuring pointType of strain gaugeNumber of strain gauges
IdlerID1 ÷ ID18KDI 50018 pcs
housingsSingle
TensionID23, ID24KDI 1.5 kN2 pcs
platetens
Table 2

Strain gauge sensor parameters

Type of strain gaugeKDI 500 SingleKDI 1.5 kN tens
Capacity [N]80015900
Sensitivity [mV / V]11
Accuracy [%]55

In the physical model, an older conveyor belt already in operation (Figure 4) with the parameters displayed in Table 3 was used.

Figure 4 Detail of mounting the end of the conveyor belt
Figure 4

Detail of mounting the end of the conveyor belt

Table 3

Basic characteristics of the conveyor belt and experimental testing equipment

Type of the conveyor beltEP500/3 HP 5+3 D
Polyester rubber-textile conveyor beltEP
Strength of the belt500N·mm−1
Pipe shaped beltHP
Top cover thickness5mm
Bottom cover thickness3mm
Category: transport of materials with the recommended belt surface temperature +150∘CD
Length of the conveyor belt8000mm
Width of the conveyor belt800mm
Thickness of the conveyor belt20mm
Diameter of the pipe shaped conveyor belt200mm
Distance between the idler housings1000mm
Diameter of the idler rolls76mm

2.1 The measurement chain and description of automated measurement of TF and CF

On the physical model of pipe conveyor, the National Instruments LabVIEW Signal Express 2010 measuring apparatus was installed, which sequentially records data from individual strain gauges and exports it to Microsoft Office Excel for further processing and mutual comparison. Figure 5 shows the connection of an automated measurement measuring chain that sequentially records CF and TF values from individual sensing sites using strain gauges.

Figure 5 Connection of the measuring chain
Figure 5

Connection of the measuring chain

The results were processed in the form of tables and graphs [15]. Figure 6 shows a set of A/D converters from the National Instruments.

Figure 6 Set of A/D converters
Figure 6

Set of A/D converters

The course of 15 automated repeated measurements and their evaluation was carried out according to a preplanned procedure. At first, the verification of strain gauge sensors was performed using calibration curves. Measurement time courses were recorded for both 5-level stretching and release at once, as shown in Figure 7.

Figure 7 The time course of TF measurement at positions ID23, ID24
Figure 7

The time course of TF measurement at positions ID23, ID24

The measurement procedure according to Figure 7:

  1. Waiting time approximately 30s

  2. Gradual stretching to a given value in [N]

  3. Waiting time approximately 120s

  4. Gradual stretching to a given value in [N]

  5. Waiting time approximately 120s

  6. Gradual stretching to a given value in [N]

  7. Waiting time approximately 120s

  8. Gradual stretching to a given value in [N]

  9. Waiting time approximately 120s

  10. Gradual stretching to a given value in [N]

  11. Waiting time approximately 120s

  12. Gradual stretching to a given value in [N]

  13. Waiting time approximately 120s

  14. Gradual stretching to a given value in [N]

  15. Waiting time approximately 120s

  16. Gradual stretching to a given value in [N]

  17. Waiting time approximately 120s

  18. Gradual stretching to a given value in [N]

  19. Waiting time approximately 120s

  20. Gradual complete release of the conveyor belt.

3 Results

Figure 8 shows the CF progression for a hexagonal roller stand No.1 using a spatial surface graph. On the x-axis, the positions of the strain gauges ID1 ÷ ID6 belonging to hexagonal idler housing No.1 for 5 TF levels are shown. On the Y axis, the resulting CF values for the strain gauges ID1 ÷ ID6 positions are shown. The position of each strain gauge is displayed above each CF course.

Figure 8 The course of CF for hexagonal idler housing No.1
Figure 8

The course of CF for hexagonal idler housing No.1

The course of CF shown in Figure 9 shows the course of the hexagonal roller stand No.2 using a spatial surface graph. On the x-axis there are the positions of the strain gauges ID7 ÷ ID12 belonging to hexagonal idler housing No.2 for 5 TF levels. On the Y axis, the resulting CF values for the positions of the strain gauges ID7 ÷ ID12 are shown. The position of each strain gauge is displayed above each CF course.

Figure 9 The course of CF for hexagonal idler housing No.2
Figure 9

The course of CF for hexagonal idler housing No.2

Figure 10 shows the course of CF for the hexagonal roller stand No.3 using a spatial surface graph. On the x-axis, there are the positions of the strain gauges ID13 ÷ ID18 that belong to the hexagonal idler housing No.3 for 5 TF levels. On the Y axis, the resulting CF values for the positions of the strain gauges ID13 ÷ D18 are shown. The position of each strain gauge is displayed above each CF course.

Figure 10 The course of CF for hexagonal idler housing No.3
Figure 10

The course of CF for hexagonal idler housing No.3

4 Discussion

The results of individual measurements were not always as expected. Some strain gauge sensors showed no results due to deformation of the conveyor belt or if the conveyor belt did not touch the strain gauge sensor, which could have happened due to the inertia of the deformation of the conveyor belt when the conveyor belt was packed between repetitive measurements for several days. In this case, the measured data showed low or even negative values.

Different CF courses for 5 TF levels were obtained from the CF waveforms for strain gauges ID1 ÷ ID6 belonging to idler housing No.1. The maximum CF = 727.8N was at position ID6 at the total value of TF = 28000N. The minimum CF = 108.8N was at position ID2 at the total value of TF = 16000N. Anomalies were observed at the ID4 position, where the course of CF was constant during the 30 sec, 60 sec and 90 sec of settling for the TF amounts monitored, respectively.

From the CF waveforms for strain gauges ID7 ÷ ID12 belonging to idler housing No.2, different CF courses were measured for 5 TF levels. The maximum CF = 229.1N was at position ID10 at the total value of TF = 28000N. The minimum CF = 22.7N was at position ID8 at the total value of TF = 16000N. A variety of CF results could have been observed in tensioning and releasing the conveyor belt after 30 sec, 60 sec, and 90 sec of settling.

From the CF waveforms for strain gauges ID13 ÷ ID18 belonging to idler housing No.3, different CF courses were observed for 5 TF levels. The maximum CF = 144.1N was at position ID13 at the total value of TF = 28000N. The minimum CF = - 44.8N was at position ID16 at the total value of TF = 28000N. It was possible to observe the diversity of CF results in tensioning and releasing the conveyor belt after 30 sec, 60 sec and 90 sec of settling. Anomalies were observed at the ID18 position, where the course of CF after 30 sec, 60 sec and 90 sec of settling was constant and even negative for the observed TF amounts.

From the course of CF shown in Figures 8, 9, 10, the order of loading of the individual idler rolls in the idler housings was determined - as is displayed in Table 4.

Table 4

The order of idler roll loading in each idler housings

Idler housingIDThe order of idler roll loading
No.1ID13.
ID26.
ID34.
ID45.
ID52.
ID61.
No.2ID75.
ID86.
ID94.
ID101.
ID113.
ID122.
No.3ID131.
ID142.
ID153.
ID165.
ID174.
ID186.

5 Conclusion

Despite frequent use of pipe conveyors, the issue of tracking CF on idler rolls is relatively neglected. Nevertheless, CF significantly influence the performance characteristics of pipe conveyors and represent an important factor in the continuous transport of raw materials. As a result of further research on this issue, a large volume of measured data needs to be processed. Therefore, there are often problems in terms of both time processing and evaluation.

The paper points out a suitable way of evaluating individual CF measurements on a physical model of a pipe conveyor in dependence on TF, while the respective methodology and procedure were verified by experiments. The data obtained from the individual CF measurements from the rollers acting on the conveyor belt for various TFs in a static state (the conveyor belt does not move) were categorized into a whole and then investigated and analyzed from different perspectives separated from measurement errors or eventual operator errors. Data was analyzed by means of statistical characteristics using charts and tables in Microsoft Office Excel. The obtained results will be used in further follow-up research, which will bring useful new knowledge for the theory, practice as well as for the production of conveyor belts.

Acknowledgement

This work is a part of the following projects: VEGA 1/0403/18, VEGA 1/0063/16, KEGA 012 TUKE-4/2019, KEGA 013TUKE-4/2019, APVV SK-SRB-18-0053.

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Received: 2019-08-21
Accepted: 2019-09-13
Published Online: 2019-12-10

© 2019 V. Molnár and M. Sabovčík, published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/eng-2019-0069
Keywords for this article
Measurement; physical model; pipe conveyor; conveyor belt; contact force; tensioning force; idler roll
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  74. Design of clamping structure for material flow monitor of pipe conveyors
  75. Risk Minimisation in Integrated Supply Chains
  76. Use of simulation model for measurement of MilkRun system performance
  77. A simulation model for the need for intra-plant transport operation planning by AGV
  78. Operative production planning utilising quantitative forecasting and Monte Carlo simulations
  79. Monitoring bulk material pressure on bottom of storage using DEM
  80. Calibration of Transducers and of a Coil Compression Spring Constant on the Testing Equipment Simulating the Process of a Pallet Positioning in a Rack Cell
  81. Design of evaluation tool used to improve the production process
  82. Planning of Optimal Capacity for the Middle-Sized Storage Using a Mathematical Model
  83. Experimental assessment of the static stiffness of machine parts and structures by changing the magnitude of the hysteresis as a function of loading
  84. The evaluation of the production of the shaped part using the workshop programming method on the two-spindle multi-axis CTX alpha 500 lathe
  85. Numerical Modeling of p-v-T Rheological Equation Coefficients for Polypropylene with Variable Chalk Content
  86. Current options in the life cycle assessment of additive manufacturing products
  87. Ideal mathematical model of shock compression and shock expansion
  88. Use of simulation by modelling of conveyor belt contact forces
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