Analysis of the Influence of the Type of Belt on the Energy Consumption of Transport Processes in a Belt Conveyor

Results of tests into the energy-efficiency of belt conveyor transportation systems indicate that the energy consumption of their drive mechanisms can be limited by lowering the main resistances in the conveyor. The main component of these resistances is represented by belt indentation rolling resistance. Limiting its value will allow a reduction in the amount of energy consumed by the drive mechanisms. This article presents a test rig which enables uncomplicated evaluations of such rolling resistances. It also presents the results of comparative tests performed for five steel-cord conveyor belts. The tests involved a standard belt, a refurbished belt and three energy-saving belts. As temperature significantly influences the values of belt indentation rolling resistance, the tests were performed in both positive and negative temperatures. The results indicate that when compared with the standard belt, the refurbished and the energy-efficient belts generate higher and lower indentation rolling resistances, respectively. In order to demonstrate practical advantages resulting from the use of energy-saving belts, this article also includes calculations of the power demand of a conveyor drive mechanism during one calendar year, as measured on a belt conveyor operated in a mine. The replacement of a standard belt with a refurbished belt generates a power demand higher by 4.8%, and with an energy-efficient belt—lower by 15.3%.

The influence of belt cover thickness on conveyor belt indentation rolling resistance

One of the methods for lowering of energy consumption in the drive mechanisms of long horizontal belt conveyors is to reduce belt indentation rolling resistances. These resistances depend on a number of factors: bottom cover properties, bottom cover thickness, belt design, idler diameter, load, speed and frequency at which the belt passes on the idler (indentation frequency), as well as on temperature. Determining how these factors influence indentation rolling resistances of various conveyor belt types is of great importance. The article describes a small-scale method for testing indentation rolling resistance. The method allows analysis of the influence of various factors on indentation rolling resistances. The article presents the results of tests on how belt indentation rolling resistance is influenced by thickness of the belt bottom cover. The tests were performed on belts with various core types.

Research on Indentation Rolling Resistance Based on Viscoelasticity of Cover Rubber under a Conveyor Belt

Minimizing the power consumption of the belt conveyor is the common wish of all enterprises and even countries. Among all the resistances generated by the belt conveyor during the operation, the indentation rolling resistance accounts for the largest proportion and the power consumed is the largest. Therefore, accurately predicting and reducing the rolling resistance of indentation is the focus of current research. Firstly, based on the three-element Maxwell solid model, the dynamic loading experiments of cylindrical rubber made of conveyor belt cover material were carried out at different temperatures. The identification models of elastic moduli E2 and E3 and viscosity coefficient η2 in the three-element Maxwell model were obtained, and then the fitting functions of the three parameters were gotten, which can intuitively reflect the influence of temperature. Secondly, the mathematical model of the indentation rolling resistance was derived. The mathematical model is characterized by the direct parameters such as belt speed v, thickness of backing material h, the idler radius R, and the rubber viscoelastic parameters E2, E3, and η2 and the indirect parameters such as normal force P and temperature T. Afterwards, the effects of belt speed, normal force, temperature, idler radius, and thickness of underlay on the indentation rolling resistance were studied under different working conditions. After that, experimental testing and analysis were fulfilled using test equipment and compared with theoretical analysis results. The results prove that the theoretical results are basically consistent with the experimental results, in line with the actual engineering rules. Finally, the application of the results in practical engineering was analyzed superficially.

Investigation on indentation rolling resistance of belt conveyor based on Hertz contact theory compared with one-dimensional Winkler foundation

Based on Hertz contact theory and one-dimensional Winkler foundation combination with viscoelastic theory, the author derived theoretical formulas of indentation rolling resistance, respectively. Using the laboratorial apparatus of indentation rolling resistance, the author mainly concentrates on the error analysis about two kinds of theoretical formula which bear on indentation rolling resistance compared with experimental result. The reason why author employs Hertz contact theory to discuss indentation rolling resistance is that indentation rolling resistance is a sort of contact resistance. As a result, Hertz contact theory is generally applicable to study it. On the other hand, because conveyor belt has viscoelastic property, it is appropriate to use viscoelastic theory by the aid of three-parameter Maxwell viscoelastic model combination with one-dimensional Winkler foundation. Ultimately, this article infers that theoretical formula based on the Hertz contact is brief and clear compared with one-dimensional Winkler foundation in principle. However, it is noticeable that when the belt is at high speed, the reliability of formula based on Hertz theory has decreased obviously. This conclusion can give a beneficial reference for the energy saving of belt conveyor.