Failure and Prospects of Modification in a Belt Conveyor System

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International Journal on Mechanical Engineering and Robotics (IJMER)

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ISSN (Print) : 2321-5747, Volume-4, Issue-1-2, 2017 19

Failure and Prospects of Modification in a Belt Conveyor System– A Review

1Ravindra M. Burkul, ²Pranay Chaman, ³Naresh Kumar, ⁴Raushan Kumar, ⁵Ravi Shekhar Ram

1,2,3,4,5Department of Mechanical Engineering D Y Patil School of engineering Academy, Ambi Pune, India

Abstract—Belt conveyors offers continuous and effective transportation of material which is why they are widely used in industries and mineral ore extraction site. While designing a belt conveyor system, some parameters like work environment, operating conditions, safety and efficiency are needed to be considered and calculations are done on the basis of assumptions. For example, we assume belt and rollers are made up of isometric material which meansequal stress is going to distribute in all the direction on applying load. Practically, no such material exist in nature and hence load distributes unevenly or in other words, load distributes non-linearly throughout the material. The paper presents the review of belt conveyor design modification and latest technology used in different application to reduce failures and operational cost.The main focus is on drum and pulley failure, belt dimension, friction, efficiency, maintenance and safety. The design of the conveyor system changes with the requirements, however some of the parameters are common in most of the applications.

Keywords— Flat Belt Conveyor, Roller, Idler, Design, Material Handling, Goods Carrier, Failures, CAE, Ansys, Catia.

I. INTRODUCTION

In Industries, the task of mobilising goods (i.e. raw material or finished product) are carried out by „belt conveyor system‟ which is essentially a closed loop pre- tension belt (or chain in case of chain drive) sliding upon rollers (& idler) and driven by an actuator(s). Belt conveyor are most common in industries which are based on automatic machines because they are able to deliver work pieces to the operating machine continuously or over fixed intervals. Because of their constant operating speed, high efficiency and low operating cost; they are more acceptable than forklifts and other machines. Apart from manufacturing line, these system are appropriate for carrying goods over long distances such as in mineral extraction sighs where coal and mineral ores are extracted on a large scale and conveyed from fixed origin to fixed destination. It omits the effort and time to be consume in loading/unloading and hence boost productivity. Because of simplicity in design and employability, belt conveyors are needed to be optimised for a given environment and hence research and development accounting energy saving

&efficiency, friction, fire and safety, maintenance, inspection and cost is a subject of consideration.

II. LITERATURE SURVEY

Xiangwei Liu, et al. (Elsevier, Measurement, 2016):

The paper reports theoretical and experimental study on the pressure distribution caused by the bulk material loading on a belt. A theoretical model based on active and passive stress states of the bulk material has been presented to predict the pressure distribution pattern but the results are not yet verified. There has been no method for the measurement pressure distribution directly and satisfactorily. Author carried out direct experimental measurements of the pressure distribution on a running conveyor belt Using a tactile pressure sensor at different loading levels [(55% loading level), (75% loading level), and (100% loading level)]. The measured pressure is assessed using a conveyor scale and high pressure regions are identified. Comparing both the results shows that the tactile pressure sensor can produce acceptable measurements for scientific and engineering purposes. Author attested the applicability of SD model and tactile pressure sensors to measure pressure distribution on conveyor belts caused by the bulk loading.[1]

Jia Luo, et al. (Elsevier, Journal of Cleaner Production, 2014):In this paper, the author worked on closed-loop model predictive control (MPC) approach.

A belt conveyor system containing 6 belt conveyors in a coal-fired power plant is taken as an object of study.

Operation level is practical for field application. This paper employs optimization methodology to achieve cost-optimal operations of a belt conveyor. The energy efficiency can be improved at any one of the four levels:

operation, equipment,performance and technology.To adjust forecasting disturbance and execution disturbance, a proposal ofclosed-loop MPC approach is made. The disturbance of coal consumption rate forecasting and the disturbance of feed rate are further imposed on the two approaches, respectively.Simulation of two control approaches are investigated thoroughly.

By comparison, the MPC approach can obtain feasible solutions subject to forecasting disturbance and execution disturbance. [2]

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Tian Zuzhi et al. (Elsevier, International Journal of Mining Science and Technology, 2012):The author design a magneto-rheological soft starter test-bed considering theory of magnetic circuit design, the constitutive equations of a magneto-rheological fluid and the load properties of belt conveyors. Analysis is done on magnetic field distribution in the working gap and the current-speed relationship was investigated. A mathematical model for the time response was deduced by author. The modeling provides a foundation for reliable design and effective control of a MRSS system used for belt conveyors in a coal mine. The establishment of the model is mainly based on magnetic circuit design and the constitutive equation of a MRF.

The results show that a linear relationship between current and magnetic field is seen when the magnetic materials are not saturated and the magnetic field is uniform in the working section. The outer radius of the working section is the main working part of a MRSS.

The magnetic field in the working gap increases linearly with increase in current as long as the MRF and other magnetic parts are not magnetically saturated.

Experiments indicate that the magnetic field at the outer radial working section is uniform. The rotation speed of the driven shaft changes linearly with increasing time.

The response is rapid and can be as short as milliseconds. This meets the starting requirements of belt conveyors.[3]

Andrzej Pytlik (Elsevier, 2013): The testing of static and dynamic resistance of idlers‟ movements as well as the idlers‟ water-tightness and dust-tightness in accordance with the PN-M-46606:2010 standard have been designed and constructed in the Department of Mechanical Devices Testing – the Central Mining Institute. The paper describes the testing conditions of idlers which were subjected to a variety of factors, such that as close as possible to their actual operational conditions. It includes: dust, water, loads and variable rotational speed. This methodology allowed us to determine the suitability of a particular idler to certain operational conditions. The developed methodology for testing idlers has been licensed by the PCA (Polish Centre for Accreditation) with regards to the determination of radial resistance as well as the static and dynamic resistance of idler rotation. The durability tests of the idlers in a dusty environment, water accumulation or under load significantly extend the possibility to evaluate idlers for belt conveyors.[4]

Paul Munzenberger et al. (Elsevier, Measurment, 2016): It describes about the new purpose built laboratory test facility projected to measure theindentation rolling resistance of belt conveyor. It includes; load, belt speed, idler roller diameter, ambient temperature and bottom cover compound. The test facility enables a wide range of variables can be tested and provides data that can be used directly in the design of belt conveyors. This test facility will help in verifying the accuracy of existing and new models. Results were presented for a number of key parameters, including belt

speed, vertical load, idler roller diameter and cover compound etc.The test facility is designed to accept both fabric and steel cord belts and test over a range oftypical operating parameters and conditions.[5]

Terry King Pr. Eng. Design Engineer to the Bosworth Group of Companies presents a paper on Belt Conveyor Pulley Design – Why the Failures. A system for the design and dimensioning of conveyor belt pulleys, in a manner which permits use at drawing office or computational level, is laid out. The theoretical model is used to explain the reason for some common failures and to place in context some of the pulley construction features seen in recent years. Lastly, an account is given of the factors which limit the life of a pulley and a design is proposed for the next generation of long-life, low cost pulleys for the South African market.[10]

Gys van Zyl, Abdul Mohsin Al Sahli (Sabib T&I, 2013)studied about the Failure Analysis of Conveyor Pulley Shaft. The shaft of pulley of belt conveyor is failed during working. An investigation was performed to find out the cause of failure and factors which are contributing in failure of shaft. In his Investigation methods they examine about visual examination, optical and scanning electron microscope analysis, chemical analysis of the material and mechanical tests.

Daniyan (JAET, Jan 2016) studied and prepared his thesis on manufacturing industry, raw materials and products that are need to be conveyed from one manufacturing stage to another. Author observe material handling equipment must be design to facilate easy, cheap, fast and safe loading and unloading with least human effort. The paper discus the designed calculation of belt used to transport line stones over distances.

Harshavardhan A. Kadam, et al. (IJETT, 2016) studied belt conveyors in coal and mineral mine. A linear static structural analysis of stress is done on a roller shaft with the help of HyperMesh. By using design failure modes and effects of analysis (DFMEA) for systemic, proactive method for identifying where and how it might fail. [6]

Mr. Memane Vijay S, et al, (JETIR, May 2015) studied existing Belt conveyor system and optimizes the parts like Roller, L-channels and support, to minimize the overall weight of system.Geometrical modelling was done by using Catia V5R20 and finite modelling done in ANSYS14.5. Results of Linear static, Modal and Transient analysis of existing design and optimized design are compared to prove design is safe. [8]

III. INOFRMATION REQUIRED TO DESIGN ABELT CONVEYOR

1. Conveyor length (centre to centre distance of end pulley).

2. Angle of inclination or distance to be lifted.

3. Weight of material or loads to be applied.

4. Average size of material and largest size of material.

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5. Average and maximum capacity per hour.

6. Feed rate.

7. Loading and unloading methods.

8. Supporting structure.

9. Power availability.

1 & 2 determines suitable belt conveyor, 4 & 5 width, 5

& 6 speed, other parameters (line actuator, rubber covers, size of pulley, spacing no of idlers etc.) are also to be calculated.

IV. METHODOLOGY

1. Design modification:

a) Different designs in the field of drive mechanism used for reducing starting torque on drive pulley and operational efficiency.

b) Multi-step cam mechanism: A multi-step cam mechanism is specially used to drive the system for the self-orientation of the conveyed objects. It is also used for velocity reduction.[11]

c) Multi-conveyor system: A common control model is used operate a number of conveyors with combined driving system and handling speed variations and average flow time between adjacent pallets for profit maximization and reliability.[12]

2. Friction:

a) Traction and slip in a wheel driven belt conveyor: An extension of existing models used for flat belt conveyors to describe the relationship between traction and slip in a wheel drive belt conveyor with a curved surface.

b) Rolling contact phenomenon in a belt conveyor system: A simplified approach to describe the rolling contact phenomena that occur at the surface of a wheel driven rubber belt, determine the rolling friction due to repeating rolling motion.[13]

3. Drum and its failure:

a) Typical failure and processing: It explain the maintenance method of prevention and elimination of failure to ensure the normal operation of belt conveyor.[15]

b) Failure in collapsed heavy duty pulley: failure due to fracture of pulley is analysed by ANSYS.

c) Conveyor pulley shaft failure: The cause for failure of shaft in conveyor pulley is iron making company has been investigated.

d) Analysis of conveyor pulley using FEM: The integral analysis of pulley parts has been helpful in arriving at some broad design guidelines and stresses and deflections of its various parts has been described for reliable design of pulley by using FEM.

e) Fatigue in conveyor drum: The welded section of the drum roller cracks during work in progress probably because of the overloading of material. [16]

f) Conveyor pulley shaft failure: The JSW has investigated the cause of failure of shaft in pulley in iron making plant. Visual, metallographic, chemical testshows that fracture may occur and shaft may fail in shear because of overloading.[14]

4. Energy and efficiency:

a) Energy efficiency optimization: The energy efficiency describes in terms of performance efficiency, operation efficiency, equipment efficiency, and evaluates detailed description of factors responsible for energy consumption in belt conveyor system.

b) Optimal control of operational efficiency:

Controlling devices such as switching control and variable control devices may be proposed in the system to improve energy efficiency of heavy duty belt conveyors.

5. Failure in belts:

a) Failure due to time varying velocity:A longitudinal and transversal vibration will developed because of load varying condition of belt. Therefore frequencies of the speed fluctuations have an important rate in the dynamic Failure behaviour of the belt conveyor.[17]

b) Belt tension around a drum: Mechanical model is developed to imitate the starting of a drive drum with a distributed mass spring system for the belting. This system develops tension around a drive drum with the requirement for visco-elastic contraction when designing a drive system.[19,20]

c) Eco-design of belts: Designing of multilayer belt conveyor and optimizing their strength properties according to the environment and operating condition.

This can be possible by using nanostructure filler material that has a bright effect on the performance of belt conveyor and it developed or adopts modified and (Innovative) performance characteristics.[18]

6. Operation and maintenance:

a) Belt conveyor maintenance: It describe about the maintenance of system. It includes the maintenance of frame, accessories and each every parts of the system to increase the performance and efficiency of the system.[9]

b) Improvement in belt drive system: It represents methodology which describes strength &weakness in the maintenance management system, opportunities for improvement in the performance and evaluates maintenance key elements.[7]

V. CONCLUSION

Belt conveying system is widely used in places where large and continuous mobilisation of material is required. The design consideration of the system varies with the work environment, material to be conveyed and varies as per requirements. From cement industries to food packing plant, the material of belt, rollers and idlers

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changes. The effectiveness of a belt conveyor system design mainly depends upon drums & belt failures, equipment fateful accidents, energy & efficiency control and maintenance control. Above prospects of failures may be considered where applicable and accordingly remedies shall be made. Some common parameters are drum failure, energy efficiency, drive mechanism, friction and maintenance. A conveyor system with proper design (as per application) considering all parameters and inventing new approach towards online mounting of components may be considered innovative.

VI. ACKNOWLEDGMENT

First and foremost we would like to thank prof. R. M.

Burkul (Guide) for their indispensable support, priceless suggestions, valuable time and for giving us this opportunity to present this review.

Finally, we would like to thank our faculty members, friends and family for being supportive tous, without whom this review would not have been possible. Every work is an outcome of full-proof planning, continuous hard work and organising efforts. This work is a contribution of all the group members sincerely.

REFERENCES

[1] Xiangwei Liu, Yusong Pang, Gabriel Lodewijks,

“Theoretical and experimental determination of the pressure distribution on a loaded conveyor belt”, Elsevier-Measurement 77 (2016), pp. 307–

316.

[2] Jia Luo, Weijian Huang, Shirong Zhang, “Energy cost optimal operation of belt conveyors using model predictive control methodology”, Elsevieer-Journal of Cleaner Production (2014), pp. 1-10.

[3] Tian Zuzhi, HouYoufu, “Modeling a magneto- rheological soft starter for use with belt conveyors”,Elsevier-International Journal of Mining Science and Technology 22 (2012), pp.

385–389.

[4] Andrzej Pytlik, “DURABILITY TESTING OF IDLERS FOR BELT CONVEYORS”, Elsevier- Journal of Sustainable Mining, Vol. 12, (2013), No. 3, pp. 1–7

[5] Paul Munzenberger and Craig Wheeler,

“Laboratory Measurement of the Indentation Rolling Resistance of Conveyor Belts”, Elsevier- Measurement (2016).

[6] Harshavardhan A. Kadam, Nilesh S. Hyalij,

“Design and Analysis of Belt conveyor Roller shaft- A Review” IJETT –Volume 36 , Issue 1 November - June 2016, PP. 45 to 49 .

[7] “S Safi & B Bigdeli”, Maintenance Engineering Bureau Using Maintenance Data To Drive Improvement, Covaris Pty Ltd, ICOMS-2005 Paper 043.

[8] Mr. Memane Vijay S., Prof.N.S.Biradar,

“Design and Analysis of Belt Conveyor System of Sugar Industry for Weight Reduction” JETIR Issue 5 MAY 2015 Volume 2 PP.1475 to 1477.

[9] “Fenner D Dunlop Company”, Conveyor Belt Maintenance,2003,

www.fennerdunlopamericas.com.

[10] Terry King Pr. Eng “Belt Conveyor Pulley Design - Why the Failures?” B.Sc Mech.

Engineering (Hons.) Design Engineer to the Bosworth Group of Companies.

[11] Khaled khader, Sabry el-shakery, Raafatabou- elnasr,The Synthesis Of A MultiStep Cam Mechanism To Drive A Shaking Belt Conveyor, Elsevier Science Ltd, 1996.

[12] Chun-HsiungLan,The design of a multiconveyor system for profit maximization, Elsevier Limited,2002.

[13] A.J.G. Nuttall, G.Lodewijks, A.J. Klein Breteler, Modelling rolling contact phenomena in a pouch belt conveyor system, Elsevier Limited, 2006 [14] D. Satish Kumar, Pradeep Agarwal,

“Investigation of Conveyor Pulley Shaft Failures”, ASM International, 2011.

[15] Lihua ZHAO, Yin LIN, “Typical failure analysis and processing of belt conveyor”,2011.

[16] D. R. H. JONES, “Fatigue Failures Of Welded Conveyor Drums”, Elsevier Limited,1995 [17] G. SUWEKEN and W. T. VAN HORSSEN, “On

the Weakly Nonlinear, Transversal Vibrations of a Conveyor Belt with a Low and Time-Varying Velocity”, Kluwer Academic Publishers,2003.

[18] Chuen-Shii Chou a, Ching-Liang Liu, Chun- Sheng Tseng a, “Optimum conditions for field vulcanizing a fabric conveyor belt with a better capability of elongation”,2012.

[19] Krystyna Czaplicka, “Eco-design of nonmetallic layer composites with respect to conveyor belts”, Elsevier Limited,2003.

[20] S. Falkenberg and L. Overmeyer, “Doping of Conveyor Belt Materials with Nano structured Fillers to Adapt Innovative Performance Characteristics”, World Academy of Science, Engineering and Technology, 2009.

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