Real-time monitoring of the rubber belt tension in an industrial conveyor

The paper presents a novel system for monitoring of the work of industrial belt conveyor. It is based on the strain gauges placed directly on the roller surface that measure pressing force of the belt on the roller. Automatical operation of the measurement system minimizes impact of an operator on the measurement results. Experimental researches included the stability of indications during 5 days, Type A uncertainty estimation and equipment variation EV calculations. Expanded uncertainty calculated for the level of confidence 95% was below 0.1% of the actually measured value, and percentage repeatability %EV = 9.5% was obtained. It can be considered satisfactory, since usually it is required %EV < 10% for new measurement systems.

Real-time monitoring of the rubber belt tension in an industrial conveyor

The paper presents a novel system for monitoring of the work of industrial belt conveyor. It is based on the strain gauges placed directly on the roller surface that measure pressing force of the belt on the roller. Automatical operation of the measurement system minimizes impact of an operator on the measurement results. Experimental researches included the stability of indications during 5 days, Type A uncertainty estimation and equipment variation EV calculations. Expanded uncertainty calculated for the level of confidence 95% was below 0.1% of the actually measured value, and percentage repeatability %EV = 9.5% was obtained. It can be considered satisfactory, since usually it is required %EV < 10% for new measurement systems.

Power Consumption Model of Permanent-Magnet Direct-Drive Belt Conveyor System Based on GACO–BP

Permanent-magnet direct-drive belt conveyors (PMDDBCs) rotate at high speed most of the time, resulting in a large number of invalid energy consumption. To realize the speed regulation of PMDDBC, it is necessary to clarify the relationship between the belt speed, coal quantity of the conveyor and total power of the system. Based on the BP neural network, this paper establishes the power consumption model of PMDDBC, which is related to coal quantity, belt speed and total power. Furthermore, an improved hybrid algorithm (GACO) that combines the advantages of genetic algorithm (GA) and ant colony optimization (ACO) is proposed to optimize the BP power consumption model. The GACO–BP power consumption model is obtained. The original power consumption model is compared with the GACO–BP power consumption model through experiments. Results demonstrate that the GACO–BP power consumption model reduces various prediction errors, while the optimization ability, prediction accuracy and convergence speed are significantly enhanced. It provides a reliable speed regulation basis for the permanent-magnet direct-drive belt conveyor system and also provides a theoretical reference for energy savings and consumption reduction in the coal industry.

Research on Segmented Belt Acceleration Curve Based on Automated Mechanical Transmission

An automated mechanical transmission (AMT) is proposed as a new soft starter for medium-scale belt conveyors in this paper. The AMT is used to start the belt conveyor and shift gears step by step to make the belt conveyor accelerate softly. Based on analyzing common soft-starting acceleration curves, a segmented belt acceleration curve is proposed as a new soft-starting acceleration curve. By analyzing the AMT soft-starting system, the system modeling is built and the AMT output shaft’s angular acceleration is proposed to be controlled to control the belt acceleration. The AMT soft-starting simulation model is established in the environment of AMESim, and simulation results of the soft-starting process from the first to eighth gear positions are given. The main parameter curves of the AMT soft-starting system including the belt, driving pulley, and AMT output shaft are analyzed. The simulation model can indicate the viscoelastic property of the belt. The simulation results prove that the segmented belt acceleration is appropriate for a medium-scale belt conveyor and provide a theoretical and reasonable basis for using an AMT as a soft starter.

Optimalisasi Kecepatan Belt Conveyor pada Praktikum Time Study di Laboratorium Teknik Perancangan Sistem Kerja

Tujuan penelitian ini untuk mengetahui kecepatan optimal belt conveyor pada praktikum time study di laboratorium Teknik Perancangan Sistem Kerja Politeknik ATI Makassar. Laboratorium Teknik Perancangan Sistem Kerja (TPSK) adalah sarana dan prasarana untuk kegiatan proses belajar mengajar, baik yang bersifat rutin kegiatan praktikum maupun eksidental berupa suatu tempat yang digunakan untuk percobaan dan pengamatan yang berhubungan dengan bidang ilmu teknik industri. Metode yang digunakan dalam penelitian ini adalah metode deskriptif, yaitu suatu metode yang bertujuan untuk memberikan gambaran yang sejelas­jelasnya tentang deskripsi time study di Laboratorium TPSK untuk menetapkan waktu baku melalui data dan pengukuran­pengukuran waktu kemudian hasilnya akan dibuat kesimpulan secara umum terhadap optimalisasi kecepatan belt conveyor. Jumlah populasi yang dipakai dalam penelitian ini adalah seluruh mahasiswa Teknik Industri Agro yang menjalani perkuliahan praktek pada Laboratorium TPSK jumlah populasi ±210 orang mahasiswa. Sampel yang dipakai dalam penelitian ini adalah mahasiswa yang praktek modul time studi sebanyak ±93 orang. Hasil pengujian keseragaman data pada percobaan ke dua menggunakan aplikasi miniTab guna menentukan reliability diperoleh 98,9 %. Hasil pengukuran yang dilakukan telah memenuhi syarat 95 % covidence Level dan 5 % Degree of Accuracy dengan bukti N’ ≤ N pada percobaan ke dua dengan kecepatan belt conveyor 1,5 m/s. Sehingga optimalisasi kecepatan belt conveyor praktikum time study di laboratorium teknik perancangan sistem kerja ada pada kecepatan 1,5 m/s.

Conceptual solutions for control systems of differential tensioners for belt conveyors

Differential tensioning devices for belt conveyors in general and intermediate drives of extended conveyors in the form of closed traction loops are a new type of automatic tensioning devices that differ from other known designs by the presence of a stepwise discrete belt tension control system with separation of compensation functions for belt stretching under load and control of its tension during the operation of the conveyor in order to create optimal modes of belt loading. The article analyzes the well-known and practical concepts of belt conveyor control systems in general. The possibility of controlling the traction force realized by the intermediate belt drive by controlling the tension of the traction and load-carrying belts is shown. On the basis of the analysis, conceptual solutions for control systems for differential tensioning devices of belt conveyors are proposed with the possibility of both autonomous use and application in the structure of an integrated conveyor control system. Possible structures of linear parts of differential tensioning devices are presented, as well as options for the implementation of executive parts that directly move tensioning elements.