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The conveyor belt is one of the most operational critical equipment’s in the mining industry, they are mostly used in the transportation of crushed materials from the crushing station to where there’ll be further processed. Due to the increasing complexity of belt conveyor systems, managing their integrity has become even more difficult, as they are now used across various industries, environments and carry materials of different weight variations, leaving them susceptible to failures (1). This paper provides an industry specific knowledge on belt conveyor systems, their respective components, and how they are configured using fault tree analysis to predict the different branches of event that can contribute to the failure of a belt conveyor system. The use of fault tree analysis sheds more light on how cascading failures can occur, where the failure of one component leads to the failure of the overall system. (2) Keywords: RCFA, FMEA Opex, FTA, Capex, Eca, Ttf, Ttr.

The existence of conveyor foreign objects poses a serious threat to the service life of conveyor belts, which will cause abnormal damage or even tearing, so fast and effective detection of conveyor foreign objects is of great significance to ensure the safe and efficient operation of belt conveyors. Considering the need for the foreign object detection algorithm to operate in edge computing devices, this paper proposes a hybrid compression method that integrates network sparse, structured pruning, and knowledge distillation to compress the network parameters and calculations. Combined with a Yolov5 network for practice, three structured pruning strategies are specifically proposed, all of which are proven to have achieved a good compression effect. The experiment results show that under the pruning rate of 0.9, the proposed three pruning strategies can achieve more than 95% compression for network parameters, more than 90% compression for the computation, and more than 90% compression for the size of the network model, and the optimized network is able to accelerate inference on both Central Processing Unit (CPU) and Graphic Processing Unit (GPU) hardware platforms, with a maximum speedup of 70.3% on the GPU platform and 157.5% on the CPU platform, providing an excellent real-time performance but also causing a large accuracy loss. In contrast, the proposed method balances better real-time performance and detection accuracy (>88.2%) when the pruning rate is at 0.6~0.9. Further, to avoid the influence of motion blur, a method of introducing prior knowledge is proposed to improve the resistance of the network, thus strongly ensuring the detection effect. All the technical solutions proposed are of great significance in promoting the intelligent development of coal mine equipment, ensuring the safe and efficient operation of belt conveyors, and promoting sustainable development.

The throughput of a belt conveyor system is the primary design parameter when considering a new installation, determined by the cross-section of the material on the belt, coupled with the belt spee...

Modern industrial technologies require raw materials of high purity from suppliers, especially due to the possible presence of inclusions of heterogeneous metals in them. The existence of metallic inclusions of heterogeneous metals in the raw materials leads to equipment failure, a decrease in the quality of output products, and, consequently, large financial losses. Since the main method of transporting raw materials in the industry is still a conveyor belt, this imposes additional conditions to control and remove metallic inclusions. For various reasons, current methods for removing metallic inclusions in the conveyor belt do not fully meet the needs of modern production. The main issue related to existing removal systems is the lack of intelligent interaction between these systems and the absence of information exchange between systems that detect and remove metallic inclusions. An alternative method for removing metallic inclusions of heterogeneous metals from loose medium has been proposed, which implies the tandem operation of the system that detects metallic inclusions and the system that removes them. The tandem operation of the two systems makes it possible to exchange information about a detected metallic inclusion and, as a result, to more flexibly use tools for the removal of metallic inclusion depending on the size and location of the metallic inclusion relative to the conveyor belt axis. At the same time, the control unit of the removal system makes it possible to control the conveyor belt itself, which allows the removal of complex metallic inclusions using the reverse of the electric drive of the belt, as well as enables a control check of the fact of removal. The developed algorithm of the removal system was implemented in the programming environment TIA-Portal. The introduction of this removal system could reduce the number of metallic inclusions in raw materials by 15‒20 %; moreover, its application is not limited to only one sector of the national economy

The demagnetization of permanent magnet electric roller of coal mine belt conveyor will reduce the comprehensive performance of electric roller. In serious cases, the belt conveyor will stop suddenly or burn down, leading to the failure of normal production and safety accidents on the site. In this paper, starting from the A-phase current and output torque angles under different degrees of loss of magnetic fault, the B–H curve is fitted by linear ratio, and the reverse electromotive force is modeled by numerical analysis method. A diagnosis method for the degree of demagnetization of permanent magnet electric roller on account of the mathematical model of back electromotive force is presented. In this paper, a 200 KW permanent magnet electric roller used in a mine is taken as the research object. The finite element model is established by ANSYS Electronics Desktop and the demagnetization simulation of model is carried out. The model of mathematics on account of the back electromotive force is compared with a model of finite element simulation, and the back electromotive force waveform of the two methods is basically the same, and the error is less than 5%. The mathematical model based on the reverse electromotive force proposed in this paper can accurately reflect the degree of loss of magnetization of the motor, and the calculation results are accurate, which is conducive to determining the state of the permanent magnet electric roller more effectively, and provides a theoretical basis for predicting and diagnosing the failure of loss of magnetization of the permanent magnet electric roller.

In this work, we are studying during experiments with a flat belt conveyor system with different speeds such as 30, 60, 90, 120 and 150 R.P.M. In this study, it is also included that the observations of the different load capacities (Grams) at different outlet times (Hours). The design of the flat belt conveyor system is very important for the specific speed range of the material handling system from place to place, which depends on the effective length of the belt.

The article attempts to establish the basic patterns in the formation of loads in the structure of the conveyor frame due to changes in the design position of the constituent elements based on analytical calculations. The amortization replacement of rollers and the establishment of a change in the projected resource caused the change in the design position.The aim of the work is to study the interaction of the elements of the belt conveyor on the convex region of the profile when the design position changes and to determine the change in the resource of the roller support elements. The purpose of the work is formulated from the analysis of unplanned stops and premature replacement of conveyor elements, in particular conveyor rollers, on the convex region of the profile.To achieve this goal the influence of the geometric parameters of the convex section of the belt conveyor profile on the force interaction of the belt and roller supports was considered, and the change in the resource of the roller bearings was determined.To characterize the geometric parameters of the convex section of the belt conveyor, the following were selected: the number of roller supports, the distance between the roller supports, the radius of curvature of the conveyor profile, the angle of the curved section. The mathematical model is based on the belt equilibrium equation, which contains the tension forces of the conveyor belt and the forces from the action of roller supports. Particular attention is paid to establishing the effect of changing the geometric parameters of the convex section on the roller bearing life. It has been established that a decrease in the radius of the transitional convex section as a result of a change in the initial design position by 2.4 times leads to an increase in the force acting on the roller support by 161%. It was found that the increase in force is the reason for the rapid exit from the operational state of the rolling bearings of the roller bearings, as evidenced by the intensive drop in the resource of the rollers (18 times).The proposed algorithm for determining the main parameters of the force interaction of the elements of the belt conveyor on the convex region of the profile will make it possible to predict the resource and prevent the conveyor from leaving the premature operational state.

Conventionally, a series of several individual conveyors is necessary to realise long conveyor lines. This segmentation creates critical transfer points for the transport of goods. The number of transfer points and the overall height can be minimised by direct drives based on magnetic toothed belts and carriers attached to the mat chains. For example, a modular belt conveyor with an overall height of 100 mm and a width of 1 m can reach a length of well over 10 m. The friction between the mat chain and the sliding plane can be reduced by using alternative sliding partners such as a textile or a sliding support made of wood-based materials. These measures increase process and work safety and allow the system to be designed to be energy efficient.

The article presents the results of research of the Gwarek 1200 belt conveyor. The work aimed to determine the possible benefits of changing the type of rollers used. It was expected that the change of the rollers from N-type to C-type will reduce the costs of energy consumed by the conveyor drive system. This part of the research was carried out in a hard coalmine at the levelof 665 m. The test was given the entire power unit in terms of the starting power demand and rated power in realtime. Measurement works were carried out before and after the modernization of the conveyor for 5 years. Moreover, it was decided to extend the research to include vibroacoustic tests, aimed at determining the technical condition by measuring vibrations. It is expected that based on the analysis of vibration signals in the long term will allow to develop a method for diagnosing belt conveyor rollers and to quickly detect their malfunction under normal operating conditions.

The article presents the results of the experimental study of the motor drum temperature regime of a short belt conveyor. A description of the experimental stand, as well as the equipment used, is presented. The paper describes the test procedure, the initial conditions for testing at each stage. These conditions imply the nature of the change in the initial tension of the belt, the level of conveyor load, design features of the motor drum, in particular the use of a lining or the use of smooth steel shell during testing. The primary results obtained are presented in the form of decoded thermograms of the working area of the motor drum. The generalized processed results of the experimental studies are systematized in the form of graphical dependencies, which are united according to the objects of study: a motor drum, a leaving belt branch, and an entering belt branch. On the basis of the results obtained, the corresponding conclusions are made, which are the law descriptions of the thermal mode of operation with regard to the motor drum, as well as the belt branches in contact with it.

The paper contains the results of the probabilistic modelling of joint operation of multidrive belt conveyors in case of their full load as well as without cargo. As a result, modelling demonstrates the need of additional reservation of drive power when designing multidrive belt conveyors. On the basis of the modelling, operational principles of joint operation of belt conveyors are established when there are random slide deviations of their engines. These deviations represent specific conditions of electric motors distribution between the drives as well as the influence features of their parameters on the distribution of the carrying and tractive belts.

Pipe belt conveyor is a new type of environmentally friendly and efficient bulk conveying equipment. In the design of the roller, the belt and the driving motor of pipe belt conveyor, the sag resistance is a key parameter. Meanwhile, the normal force between the conveyor belt and the roller group is the other important factor need be considered and has a great influence on the sag resistance. This paper analyzes a pipe belt conveyor with a diameter of 150 mm to study the calculation method of normal force. And the relationship between the normal force and the sag resistance is explored. Firstly, the normal force is decomposed into three components related to the forming force of belt, material gravity and belt gravity. So it can be expressed as a linear combination of these three quantities, and the coefficients of each component are obtained based on the dynamic analysis of belt-roller. The results show that the coefficient is mainly affected by the material filling rate, and is almost not affected by the distance between the rollers and the density of the material. The calculation method of the normal force is eventually obtained. Secondly, the normal force in the case of different material filling rates is tested by experiments, and the calculation method of the normal force is verified. Thirdly, the variation law of the sag resistance in the case of different roller group spacing and material filling rate is studied by the dynamic model. It is found that the roller group spacing and material filling rate affects the sag resistance by changing the normal force. There is a power function relationship between the sag resistance and the normal force. In the case of different roller group spacing and material filling rate, the relationship among the sag resistance and the normal force remains unchanged. This study results are of great significance to the design of pipe belt conveyor.

Margin occurs where a design is overspecified with respect to the minimum required. Margin may be desirable to mitigate risk and absorb future changes, but at the same time, may be undesirable if the overspecification deteriorates the design’s performance. In this article, the margin value method (MVM) is introduced to analyse an engineering design, localise the excess margin, and quantify it considering change absorption potential in relation to design performance deterioration. The method provides guidance for improving a design by prioritising excess margin that provides relatively little advantage at high cost, and that could, therefore, be eliminated to improve design performance. It shows how the value of excess margin depends on its localisation in the design parameter network, the importance of design performance parameters, and the importance of absorbing potential future changes. The method is applied to a belt conveyor design. This case indicates that the method is practicable, reveals implications, and suggests opportunities for further work.

The particulars of using diagonal plows in transport lines conveying batch and cullet to the hoppers of glass furnace chargers are examined. An improved design of a diagonal plow equipped with an electromagnetic vibrator is presented. An adaptive algorithm controlling the unloading of batch and cullet from a belt conveyor is presented. It is shown that additional mixing of these materials on the belt is possible.

Self-Aligning Troughing Roller (SATR) is one of the critical components in belt conveyor; it is a very critical component in riding the belt conveyor in fault free condition. SATR arrangement has a long roll to support the given belt and handle maximum load per cross-section. SATR has machine elements like ball bearing, central shaft and the external shell. In belt conveyor system certain faults such as bearing fault (BF), central shaft fault (SF), combined bearing flaw and central shaft fault (BF& SF) occur frequently. Fault diagnosis in SATR essentially forms a classification problem. A prototype setup has been designed and fabricated; Different faults such as bearing fault (BF), central shaft fault (SF), combined bearing flaw and central shaft fault (BF& SF) are introduced one at a time and the corresponding vibration signals have been acquired from the setup . Followed by this step a set if statistical parameters were computed which forms the feature set and classified using Artificial Neural Network (ANN) algorithms and decision tree algorithms. At the outset, decision tree algorithm shows superior performance in terms of classification accuracy. The whole effort is to bring out the best number of features for maximum efficiency. A tenfold cross validation was performed to validate the results.

Idlers are typical rotating parts of a belt conveyor carrying the conveyor belt and materials. The complex operating noise and unstable features lead to poor accuracy of sound-based idler fault diagnosis. This paper proposes a fault diagnosis method for belt conveyor idlers based on Transformer’s dynamic self-attention (DSA). Firstly, the A-weighted time-frequency spectrum of the idler sound is extracted as the input. Secondly, based on the DSA block, the multi-frequency cross-correlation DSA algorithm is designed to extract the cross-correlation features between different frequency bands in the input feature map, and the global DSA algorithm is applied to perceive and enhance the global correlation features in parallel. Finally, the cross-correlation and global correlation features are concatenated and linearly projected into a fault-type space to diagnose typical bearing and roller faults of idlers. The method makes full use of the relevant information scattered in different frequency bands of the idler running sound under complex working conditions and reduces the negative effect of the strong running noise on the extraction of weak fault features. Experimental results show that the fault diagnosis accuracy is 94.6% and the latency is 27.8 ms.

Predictive maintenance strategies for the mining sector are of utmost importance considering the automated behavior of industrial systems and the oftentimes inaccessible environment around belt conveyor systems. In this paper, we present a model combining IoT sensors and dead-reckoning modeling, focused on early theoretical work in the field of modeling the behavior of belt conveyor systems to act as a decision support tool in maintenance strategies, by estimating the remaining useful life (RUL) of rotating components in a belt conveyor system. The estimation of RUL is a function of the degradation of the ball bearings in idler rollers due to the forces acting on the rollers during the conveyance of material. The forces occur due to the material loading, the belt weight, roller shell weight, and the idler misalignment load (IML). Furthermore, the dynamics of bulk material during conveyance can be modeled in several ways considering earth pressure theory. A model considering this is derived from the Krausse Hettler method to determine the forces acting on the wing rollers of a thee-roll idler trough set by the notion that the bulk material undergoes active and passive stress states during conveyance. The model is further compared and extended to the works of Sokolovski, to get a bounded delta RUL reduction estimate on the roller bearings in each idler set of a belt conveyor system.

In this paper, we are studying the flat belt conveyor system using of D.C. motor with various speed, in this way we are used the 12 V. D.C. motor, flat belt which having 2mm thickness, speed controller, inlet container and outlet container for the purpose of finding the maximum material handling rate with speed.

The purpose of research: to improve the efficiency of belt conveyors by optimizing the service life of the conveyor belt for various designs of loading devices and their operating conditions.The issues of optimizing the parameters of loading devices are described in detail in [1], in which the equations of the goal are given in terms of performance criteria, the strength of the interaction of the load with the belt, the loading angle of the load on the tape, geometric parameters and the limitations of the range of variable parameters. The solution to the problem of optimizing loading devices is performed by randomly searching for the best solutions, which allows determining the Poreto set at minimal cost. However, the studies performed do not take into account the structural reliability of the loading device and the chute wear under the action of bulk cargo.This article discusses the multi-criteria task of optimizing the design of the loading devices of belt conveyors when loaded with bulk cargo. The solution of the task was carried out in two stages: optimization of the structural scheme according to the criteria of perfect construction of loading devices at the minimum cost of their manufacture and selection of the best options, taking into account the criterion - the difference between the speeds of the load the tape and projected onto its plane of movement at which the tape wear is minimal.It is established that the values of the coefficient of perfection of loading devices vary within 0,86-0,88, and the minimum service life of the chute, depending on the type of loading and the abrasiveness of bulk cargo ranges from 2000 to 12000 hours.The multi-criteria problem of optimizing the design parameters of various types of loading devices has been solved, under which the economically viable service life of a conveyor and chute of loading device.

The paper presents the findings of the investigative study on the features of electric drives in the continuous run modes (which correspond to the run modes of belt conveyor drives) using frequency converters and operating with the natural mechanical characteristics. The description of the test bench in the form of the generalized mechanism of the hoisting machine is provided. The paper formulates features and limitations of the heat control procedure taking into account environmental conditions and surface conditions of the research object. The sequence of the experiment is provided. The thermograms of the thermal photography are obtained and interpreted. The data is presented as temperature curves of the research object. The analysis of the data made it possible to confirm correctness of the recommendations proposed earlier on taking into account the type of the drive controlling system when building probabilistic mathematical models of the tractive force distribution, particularly when solving the task of computational distribution conservation of the tractive efforts between the drives.

Aiming at the problem in measuring the nonuniformly distributed pressure generated by the pipe belt conveyor when conveying raw coals, a hexagonal adjustable pressure measuring device for the idler group is proposed. The dynamic model of the pipe belt conveyor clamping-type roller group is established. In order to simplify the calculation process of mechanical analysis, the modal analysis is carried out to determine the factors which will influence the pressure. The pipe diameter and filling rate are selected as the key control factors by the sensitive analysis of pressure of the pipe belt conveyor clamping type roller group. An adjustable diameter-type supporting roller group experiment device is self-designed, and the dynamic pressure change of the roller group and each roller pressure are tested. The results show that the average error between the simulated and tested values of the pressure of the idler group at different filling rates is 7.3%; the theoretical and simulated values of the pressure of the idler group are in good agreement with the experimental values. The study provides a theoretical basis and experimental reference for the design and application of pipe belt conveyors.

The paper is concerned with the problems associated with starting a long conveyor driven by an induction motor. We consider the dynamic loads in the conveyor belt during start-up, which cause slippage of the conveyor belt on the traction drum leading to its premature deterioration. The relevance of the topic is associated with the high cost of the conveyor belt reaching 60% of the cost of the entire conveyor and more. The aim of the work is to ascertain the possibilities of reducing the wear of the conveyor belt, for example, through the use of the possibilities provided by the system of the electric drive. The possibility of reducing the probability of the conveyor belt slippage by increasing the initial belt tension is noted. However, constant high tension also accelerates belt deterioration. To solve this problem, the use of automatic tension control devices is proposed, as well as the reduction of dynamic loads in the belt by using soft starters based on a thyristor voltage converter, which regulates the amplitude of voltage on the motor stator. The features of an asynchronous motor heating when starting with a constant speed of rotation of the magnetic field are discussed. The interrelation between the start-up duration and the motor stator winding heating with the dynamic loads occurring in the conveyor belt in start-up modes is considered. Modeling results obtained using the Simulink package are presented. Since long start-up modes of asynchronous electric drives based on thyristor voltage converters can lead to motor overheating, especially when the conveyor is restarted under full load and in hot climates, it is advisable to use automatic conveyor belt tension control devices during start-up modes thereby reducing premature belt deterioration together with a decrease in the conveyor motor heating.

A new belt conveyor design providing the possibility of changing the conveyor belt cross section depending on the flow of transported bulk material has been proposed. A procedure for determining the load on the hold-down lever rotation mechanism is presented. A calculation of the value of equivalent load applied to the coupler (considering crimping) is provided, which allows selecting the inner diameter and trapezoidal thread parameters of the coupler, calculating the screw pair moments of resistance, and choose the appropriate size of the gear motor.

Semiconductor industry is one of the most important industries in the world. One current trend of this industry is the increase of wafer size, from 300 to 450 mm, to improve throughput and lower cost. However, this change also brings challenge for 450-mm wafer fabs. One challenge is the difficulty of moving and handling the 450-mm wafers due to their increased size and weight. Another challenge is the need to prioritize lots in the shop floor so that hots can receive fast service to satisfy customer needs. Due to some specific advantages, the conveyor-based automated material handling system (AMHS) has been considered to be the next-generation transportation system for wafer transport in a 450-mm wafer fab. However, this kind of systems remains to have some problems, such as optimizing its performance, particularly with transport congestion. Hence, this study proposes a new heuristic preemptive dispatching method, termed remaining time algorithm (RTA), to operate an AMHS based on activated roller belt (ARB). In addition, the loop structure of the AMHS has been rearranged and some buffer components have been added into this AMHS. To investigate its effectiveness, the RTA has been compared to two previously proposed dispatching methods, the new heuristic preemptive dispatching belt (a-HPDB) in Wang et al. (Appl Sci 7:780, 2017) and the heuristic preemptive dispatching belt (HPDB) in Wang et al. (Comput Ind Eng 96:52–60, 2016). In terms of average lot delivery time, the simulation results show that for hot lots, the RTA is 1.38% and 8.77% better than the a-HPDB and HPDB, respectively; for normal lots, the RTA is 14.49% and 28.39% better than the a-HPDB and HPDB, respectively. Hence, the RTA is concluded being an effective dispatching method that can better deal with congestion problem, improve lot delivery time, and yield better system performance.

The article is devoted to the design of the drive unit of a continuous transport machines, i.e. the leading suspension of a special belt conveyor – a conveyor with a suspended belt and a distributed drive. The paper provides an analysis of known designs of conveyor suspension with a suspended belt and specifies their common general weaknesses. The authors show the original technical solution of the universal roller suspension, equipped with an individual motor-gear drive, as well as a drive roller pressure device, and its main advantages. The authors developed and showed a mathematical model designed to optimize the characteristics of the metal structure of one of the most metal-consuming elements of the considered drive suspension as the carrier section and taking into account structural, strength and stiffness limitations. In their paper, the authors showed the implementation of the proposed mathematical model: the stress-strain state of the metal structure of the drive suspension is calculated using the example of the basic design. It is established that the basic drive suspension has excessive strength, weight and exceeded geometric parameters of the rods. The authors made the conclusion about the need for multi-criteria optimization of the metal construction of the drive suspension, as well as the study of the influence of the configuration parameters of the drive suspension on its weight and size characteristics.

In this paper, a detailed literature review of indentation rolling resistance (IRR) in pipe belt conveyors is provided. Pipe belt conveyors offer an alternative to overcome the technical limitations of trough belt conveyors. However, pipe belt conveyor systems are more complex than trough belt conveyors, and the system’s life cycle can be significantly affected by some important technical aspects. Based on analytical formulations deduced from Jonkers to Rudolphi and the mathematical models used for pipe belt conveyors with regard to IRR, the influence of variables such as belt speed, vertical load, back cover thickness, idler radius, temperature, panel spacing, transverse stiffness, number of cycles, filling degree, and linear belt mass is discussed. The dimension standards for belt conveyors are shown, as well as relevant experimental methods currently available for measuring the IRR. Several main belt manufacturers of low rolling resistance compounds are noted.

Belt conveyors are used for the transportation of bulk materials in a number of different branches of industry, especially in mining and power industries or in shipping ports. The main component of a belt conveyor is its belt, which serves both as a support for the transported material along the conveyor route and as an element in the drive transmission system. Being crucial to the effective and reliable operation of the conveyor, the belt is also its most expensive and the least durable element. A conveyor belt comprises a core, covers and edges. A multiply textile belt, in which the core is constructed of synthetic fibers such as polyamide, polyester or aramid, is the oldest and still the most commonly used conveyor belt type. The plies are joined with a thin layer of rubber or another material (usually the material is the same as the material used in the covers), which provides the required delamination strength to the belt and allows the plies to move relative to each other as the belt is bent. Belts are installed on the conveyors in a closed loop in order to join belt sections, whose number and length depend on the length and type of the belt conveyor. Belts are joined with each other in a splicing procedure. The cutting of the belt core causes belt splices to be prone to concentrated stresses. The discontinued core also causes the belt to be the weakest element in a conveyor belt loop. The article presents the results of strength parameter tests that were performed on laboratory and industrial splices and indicated the reasons for the reduced strength of conveyor belt splices. Splice strength is reduced mainly due to incorrect preparation of the spliced surfaces and to different mechanical parameters of the spliced belts.

The electrohydraulic equipment of the coal gangue belt conveyor has been widely studied in recent years, but studies have been limited to the traditional hydraulic system with proportional valve and servo valve as control elements. Because of their own structural characteristics, proportional valves and servo valves have inherent defects such as low reliability, high cost and a long debugging cycle. It is necessary to carry out technological innovation and upgrading. This paper presents a hydraulic system scheme which uses digital valves instead of proportional valves and servo valves to control the belt conveyor propulsion system. Firstly, the system scheme is described in detail. Secondly, the simulation model of the control element digital valve is established, and its dynamic characteristics are analyzed in detail. Finally, the displacement tracking control of the new system is carried out to verify the feasibility of the proposed control scheme. The results show that the new digital hydraulic control system can effectively achieve the displacement control function of the belt conveyor propulsion system.

For the conveyor belt, variable material flow influences the energy efficiency of the speed control technology significantly. The fluctuation of material flow on the conveyor belt will lead to the detrimental vibrations on both the belt and the conveyor while the conveyor works at certain speeds. In order to improve the model inaccuracy caused by the uniform bulk material flow assumption in the current conveyor belt model, the paper establishes a high-precision dynamic model that can consider speed control of a conveyor belt under non-uniform bulk material transportation. In this dynamic model, a non-uniform bulk material distribution model is firstly proposed based on laser scanning technology. Then, a high-precision longitudinal dynamic model is proposed to investigate the dynamic behavior of a belt conveyor. Considering the micro-units of actual load on a conveyor belt, it can well describe the transient state of the conveyor belt. These models can be used to determine the optimal speed for safety and energy conservation in operation. Experimental results are used to validate the proposed dynamic model for analyzing belt mechanical behavior under non-uniform bulk material distribution on the belt. The results show that the proposed models can be used for optimizing the operating procedures of belt conveyor systems.

In order to reduce the high electricity cost of the belt conveyor system in a coal mine, a virtual energy storage model of the belt conveyor system is proposed based on the coal storage ability of silo. Through coordinated control of belt speed, feed rate, silo load rate and arrival time of the train, the virtual energy storage ability of silo is utilized to realize the power balance considering distributed generations in different period in response to the time-varying electricity price. The case study indicates that the optimal scheduling method in this paper can effectively reduce the electricity cost of the belt conveyor by 61.29%, and improve the power consumption level of the distributed generations, which can help realize the green and effective operation of the belt conveyor system.

There was suggested a probabilistic mathematical model of tractive effort distribution among the drives of multidrive belt conveyors. This model takes into account (in an inverted way) speed variations of different points of tractive and carrying belt forms using an artificial increase in probabilistic interval boundaries of slide departures of drive engines. Taking into consideration the given mathematical model, an integrated approach to traction calculation of belt conveyor of conventional construction and random configuration is formulated. This approach is based on presentation of units of the traction calculation process in the form of classifying characteristics with the corresponding mathematical description. The set of these classifying characteristics for each unique engineering case forms the corresponding specific equation systems of traction calculation.

This paper uses the Kelvin-Voigt viscoelastic model to establish the continuous dynamic equations for tail hammer tension belt conveyors. The viscoelastic continuity equations are solved using the generalized coordinate method. We analyze various factors influencing longitudinal vibration of the belt conveyor by simulation and propose a control strategy to limit the vibration. The proposed approach and control strategy were verified by several experimental researches and cases. The proposed approach provides improved accuracy for dynamic design of belt conveyors.

At present, one may witness the development and improvement of conveyor transport, in particular, a specialized suspended belt conveyor with a load-carrying belt. The use of methods of reducing the mass of the conveyor metal structure is an urgent task at the initial stage of its design. A mathematical model of the linear section metal structure of the conveyor with a suspended load-carrying belt was developed. The undertaken research resulted in presenting the values of stresses and deflections appearing in the linear section metal structure of various designs, depending on different productivity of the suspended belt conveyor. Based on the studies performed, it was revealed that the use of modern approaches, in particular optimization approach, to the design of the conveyor metal structure allows improving the weight and dimensions of the entire conveyor.

In the present paper, an index is proposed for belt conveyors that represents the evaluation of the overall functional/design efficiency by considering both energy and service performance. To obtain index value, energy consumption data - that are extracted from a detailed energy analysis of the examined conveyor - are correlated to service performance data derived from the analysis of material handling capability of the conveyor within the context of the set operational requirements and functional conditions. The proposed index is exemplified through a case study of a simple inclined belt conveyor for which a detailed energy consumption model is developed. Different technical specifications and operational conditions are tested. The proposed approach proves that the index depicts adequately the effect of any design solution or operational decision to the overall efficiency of the conveyor.

The finite element methods are used in many disciplines by the development of products, typically in mechanical engineering (for example in automotive industry, biomechanics, etc.). Some modern programs of the finite element's methods have specific tools (electromagnetic, fluid and structural simulations). The finite elements methods allow detailed presentation of structures by bending or torsion, complete design, testing and optimization before the prototype production. The aims of this paper were to the model of conveyor belt passage by driving drum. The model was created by the program Abaqus CAE. The created model presented data about forces, pressures, and deformation of the belt conveyor.

This article describes a new continuous conveying technology for the transportation of bulk materials. The new technology merges the benefits of both belt conveyor technology and railway to produce...

Purpose As indentation rolling resistance accounts for the major part of the total resistance of belt conveyors, the purpose of this paper is to compute it using a proper method. Design/methodology/approach First, an approximate formula for computing indentation rolling resistance is offered. In this formula, a one-dimensional Winkler foundation and a three-parameter viscoelastic Maxwell solid model of the belt backing material are used to determine the resistance to the motion of a conveyor belt over idlers. The velocity of the belt is an important operating parameter in the working conditions of the belt conveyor. What is more, a set of experimental apparatus which can measure the value of indentation rolling resistance is designed. Findings With the help of the experimental apparatus, the authors obtained a series of measured data under different belt speeds. Finally, a computation example that is provided for a typical rubber compound backing material shows the comparison between measured results and theoretical results which offers the influence of speed on rolling resistance. Originality/value This study provides the design of an apparatus, and finds the relationship between belt speed and indentation rolling resistance.

Development and application of pneumatic flexible shaft couplings have been in the center of our department research activities for a long time. These couplings are able to change torsional stiffness by changing pressure in their flexible elements – air bellows. Until now we have dealt with the use of pneumatic flexible shaft couplings for tuning mechanical systems working with periodically alternating load torque at steady state. Some mechanical systems, however, operate with a static load torque at constant speed (e.g. hoists, elevators, etc.), where it is necessary to consider the suitability of shaft coupling in terms of load torque at transient conditions (run-up and braking). Therefore we decided to analyze the use of pneumatic flexible shaft couplings also in this type of mechanical systems on an example of conveyor belt drive.

This article presents findings from a research program to investigate the interaction between bulk solids and a conveyor belt during transportation. The research involved measuring and simulating the loads acting on a conveyor belt during transportation for a number of bulk solid materials and belt sag ratios. Laboratory experiments and simulations on a moving belt conveyor were undertaken, where the pressure acting on the surface of the belt due to the interaction with the bulk solid was measured for the first time using Tekscan® pressure sensors. The experimental results are compared to existing theoretical methods and to simulations undertaken using the Discrete Element Method (DEM). Good correlation between the measured experimental data and the simulations was found, with the outcomes leading to improved methods to calculate loads on conveyor idler rolls and increased accuracy in predicting the energy loss due to the bulk solid flexure.

Belt conveyors can be partially loaded due to the variation of bulk material flow loaded onto the conveyor. Speed control attempts to reduce the belt conveyor energy consumption and to enable the green operations of belt conveyors. Current research of speed control rarely takes the conveyor dynamics into account so that speed control lacks applicability. Based on our previous research, this paper will provide an improved three-step method to determine the minimum speed adjustment time. This method can be summarized as Estimation-Calculation-Optimization and ECO in short. The ECO method takes both the potential risks and the conveyor dynamics into account. It is expected to keep belt conveyors in good dynamic behaviors in transient operations. After discussing the ECO method, this research takes a long inclined belt conveyor of an import dry bulk terminal as case study. Based on the suggested acceleration time, a speed controller is built and computational simulations are carried out to evaluate the energy savings and the conveyor dynamics. Experimental results prove that the application of the ECO method ensures the healthy dynamic performance of belt conveyors under speed control in transient operations. Annually, the average electricity consumption of the single conveyor can be reduced by over 10% with around 90 tons reduction of CO 2 emission. The direct economic benefit can reach up to more than €10,000 in terms of the electricity utilization per year.