輸送機(jī)的設(shè)計(jì)與計(jì)算 Conveyor Belt Design and calculation

CONVEYORBELTTECHNIQUE

DESIGNANDCALCULATION

Index

1Introduction

1.1Foreword

1.2Developmentchronology,developmentaims

1.3Dunlop-Enerkatestrig

2BeltConveyors

2.1Basicsketch,concept,description

3.DriveSystems

3.1Pulleyarrangement,conveyingsystems

3.2Singlepulleyheaddrive,Dualpulleyheaddrive,Headandtaildrive,

generalcriteria

3.3Drivecomponents

Pulleymotor,Gearedmotor,Motor-gears-Couplings

4Couplings

4.1Couplingtypes,fixedcoupling,flexiblecoupling,fluidcoupling,

hydrodynamiccoupling

4.2Start-upprocedure

4.3Runbackprevention(holdback)

5.DrivePulley

5.1Forcetransmission,Eytelweinlimitations,slip,creep

5.2Frictionfactor出，angleofwrapa

6.Take-up(tension)Systems

6.1General,fixedtake-up,gravityweighttake-up,regulatedtake-up

tension

7DetectionDevices

7.1Belttensiondetection,off-trackdetection,beltslipdetection,

longitudinalslittingsafetydevice

8CleaningDevices

8.1General,groundrules

8.2Cablescraper,transversescraper,fanscraperstaggeredscraper,

rotaryscraper(vertical)

8.3Rotaryscraper(horizontal)rappingroller,beltturnover,highpres-

surewatercleaning

9Load

9.1General,bulkloads,pieceloads,bulkdensity,angleofrepose/sur-

charge,lumpsize,classification

9.2Temperature,moisture,chemicalcharacteristics,pHvalue,angleof

inclination

10ConveyorBelt

10.1General,beltconstruction

10.2Carcase,plymaterial

10.3Covers,coverqualities(DIN/ISO)

10.4Specialqualities,coverthicknessratio

10.5Angleofinclinationvalues,coverthicknessvalues

10.6DUNLOPcoverqualities,specifications

10.7BasicMaterials

10.8Beltspecification,DUNLOPbelttypes

Index

11Design

11.1Maindata,beltspeed,standardvalues,recommendedvalues

11.2Beltwidths,standardwidths,minimumbeltwidth,idlerarrange-

ment,idlerspacing

11.3Idlerspacing(recommendedvalues)idlerrotation,idlerrolldiame-

ter,standardidlerrolllengthsL

11.4Photograph

11.5Crosssectionalareaofload,comparisonvariouscrosssections

11.6Conveyorcapacity,loadstreamvolume,loadstreammass,degree

offilling,reductionfactor

11.7Powerrequirement,electricmotortypelist

11.8Adjustmentfactors

11.9Belttypes

11.10Pulleydiameters,standarddiameters

11.11Pulleyrotation,pulleyloading

11.12Averagesurfacepressure,transmissioncapability,start-uptorque

11.13Troughingtransition,pulleylift

11.14Convexverticalcurvevalues

11.15Concaveverticalcurve,curveco-ordinates

11.16Beltturnover,turnoverlength,values

11.17Horizontalcurve,values

12BasisofCalculation

12.1Resistancetomotion,mainresistance,secondaryresistance,slope

resistance,specialresistances

12.2PeripheralforceFu(working),summation

12.3FactorC(allowanceforsecondaryresistance)

12.4Fictitiousfrictionfactorf

12.5Massofrotatingidlerparts.Massofbelt

12.6Massofmaterialload.PeripheralforceFA(start-up)frictioncut-off

material/belt

12.7Start-upfactorKA,accelerationaA,take-offtime,acceleration

distance

12.8PeripheralforceFB(braking),delay,over-rundistance,brakingtor-

queofmotorMM,drivepoweratpulleyPT,motorpowerPM

12.9Degreeofefficiency內(nèi)nominalmotorpower(DIN)drivesystem

12.10Distributionofdrivepowerwithheadandtaildrive,distributionof

drivepowerwithdualpulleyheaddrive

12.11Factorxforvariousdriveconditions

12.12Distributionofdrivepowerwithdualpulleyheadandtaildrive

12.13Belttensions.andT2.Belttensioncorrection,fixedtake-up

12.14Correctionofbelttensionsmoveabletake-up

12.15Correctionofbelttensionsforminimumbelttensions

12.16Sequentialcalculationtoascertainbelttensions.toT4,force

distribution,individualresistances

12.17Sequentialcalculationforsinglepulleyheaddrive

12.18Sequentialcalculationfortaildriveandtaildrivebraking

12.19Sequentialcalculationforheadandtaildriveanddualpulleyhead

drive

12.20Sectionloadings

12.21Nominalbeltstrength,safetyfactor

12.22Selectionofbelttype(criteria)

12.23Selectionofbelttype(criteriacontinuation)

12.24Selectionofbelttype(criteriacontinuation)

12.25Beltreferencetoascertainabelttype

12.26Determinationoffallenergyattheloadingpoint

12.27Influenceofstressesonbeltselection

12.28Photograph

12.29Determinationoftroughingcapabilities

12.30Determinationofcoverthicknesses

12.31Determinationoftake-uptravel,values

n

Index

3

3JCalculationExample

32Dutydata,shortcalculation

(

3PeripheralforceFjandmotorperformancePM

Individualresistances,sequentialcalculation

3./3

35Sequentialcalculationforvarioustake-upsystems

36Beltsafety,pre-tension,take-uptravel

37Pulleydiameter,troughingtransition

38Convexandconcaveverticalcurve

39Controlofadditionalstresses

31Computercalculations

Photograph

4

1SliderBedBeltConveyors

4.42Supportingsurface,beltwidths,beltspeeds

4Conveyingcapacity,resistancetomotion

Frictionalresistance,frictioncoefficient|x(belt/supportingsurface)

4./3G

4Sloperesistance,specialresistances

46SpecialResistances(continued)

4.57Drivepower,belttension,peripheralforceFA

SafetyFactorS,nominalbeltstrengthKN

5

5JBucket日evatorBelts

sConveyingcapacity,bucketcontents,bucketshape

DegreeofFilling,speed

s,2

s3Loading,discharging

4

5Bucketspacing,beltwidth,mainresistance

Loadingresistance,secondaryresistance,peripheralforceFUz

5,56motorpower

57Start-upfactor,determinationofbelttype

)

58DeterminationofbelttensionsT-andT2

SafetyfactorS,frictioncoefficient出(belt/drivepulley)

59

10BeltstressT〕(loaddependent)pulleydiameter,numberofplies

5S.11Individualresistances,peripheralforceFj

s12Valuesfordegreeoffilling,bulkdensity,speed

s13Bucketshapesanddimensions

Bucketattachment,makingendlessjoint

III

Index

ATheoreticalVolumeStream

A.1Flatcarryingidlers,2rolltroughingidlers

A.23rolltroughingidlers

A.3Deeptroughing,garlandidlers

A.4Boxsectionbelt

A.5Steepconveyingbelts

A.6Corrugatededgebeltswithoutcleats

BMassesofRotatingIdlerRollers

B.1Standardidlers

B.2Cushionidlers,discidlers

CConveyorBeltThicknessesandweights

C.1BelttypesSUPERFORT,STARFLEX,DUNLOFLEX,TRIOFLEX,

FERROFLEX

C.2SteepinclinebeltsCHEVRON,HIGH-CHEVRON,MULTIPROF

C.3Sliderbedbelts,DUNLOPLASTbelts

C.4SteelcordbeltsSILVERCORD

rubbercleats

DSecondaryResistances

D.1Inertialandfrictionalresistanceattheloadingpoint

Frictionalresistancefromskirtplates(loadingpoint)

Frictionalresistancefrombeltcleaners

D.2Beltbending(flexing)resistance,pulleybearingresistance

ESpecialResistances

E.1Resistanceduetoidlertilt

Frictionalresistancefromskirtplatesbeyondtheloadingpoint

Resistanceduetosidewaysloaddischarge

Resistancefromtrippers

E.2Resistancetobeltsealingstripbeyondtheloadingpoint

Resistancefrommotionofbunkerdrag-outbelts

FDriveFactorsc1andc2

F.1Drivefactorsandc2value

GSafetyFactorS

G.1Beltsafety(definition)time/strengthbehaviour,reductions

G.2SafetyfactorsSforsteadyandnon-steadystateworkingandfor

temporarylocalisedpeakstresses

HStress-StrainCurve

H.1Elongationcharacteristics(hysteresiscurve)

H.2Stress-straincurve(diagram)

1AdditionalStresses

1.1Beltsafety,elasticmodulus

I.2ValuesforSmjn/elongationvaluekD

I.3Troughingtransition:safetyandelongation

I.4Troughingtransitionwithraisedpulley

1.5Concaveverticalcurves

I.6Convexverticalcurves

1.7Horizontalcurve

I.8Beltturnover

JRollDiameter

J.1Standardrolls,coiledroll,doublecoiledroll,'S'formcoiledroll,roll

onovalcore

J.2Diameterofstandardrolls(table)

IV

Index

K

1PulleyDiameters

K2PulleydiametersforDUNLOP-ENERKAbelttypes

.3PulleydiametersforDUNLOPLASTPVGandPVCbelts

KPulleydiametersforsteelcordbeltsSILVERCORD

.

K

CrownedPulleys

.L1

Dimensions,taper

L

ArrangementofRubberSupportingIdlerDiscs

MJ

Installationinstructions,measurements

M

ChemicalResistance

N1

M2Resistanceofthecarcase

M3Resistanceofthecovers

MResistanceofthecovers(continued)

SteepInclineInstallations

O1

2Hintsfortheimprovementofinstallationcomponents

OHintsfortheimprovementofinstallationcomponents(continued)

.

OEndlessSplicing

.1

P2Methods,hotvulcanising

PWarmvulcanization,coldvulcanisation,mechanicalfasteners

P

1MaterialCharacteristics

Q2Materialcharacteristics

Materialcharacteristics(continued)

Q3

.4Materialcharacteristics(continued)

Q5Materialcharacteristics(continued)

.6Materialcharacteristics(continued)

QMaterialcharacteristics(continued)

.

Q

.

Q

.Q

V

Dunlop-EnerkaBeltingDunlop-EnerkaFranceSari

P.O.Box86Z.l.desEbisoires

CenturionWay78370Plaisir

Farington,LeylandFrance

Preston,LancashirePR52EYTel.+33(0)130555419

UnitedKingdomFax+33(0)130540238

Tel.+44(0)1772433751Telex695608

Fax+44(0)1772623967

Telex627080

Dunlop-CCTs.a.Dunlop-Enerkab.v.

BoulevarddesCombattants64VisokovoPtnijProezd,1

7500Toumai127577,Moskow

BelgiumRussia

Tel.+32(0)69254811Tel.+70959018857

Fax+32(0)69226270Fax+70959012921

Telex57187

Dunlop-Enerkab.v.Dunlop-CCTs.a.

Postbus14Ovnatanyanastr.4

9200AADrachten340017,Donjetsk

TheNetherlandsTheUkraine

Tel.+31(0)512585555Tel.+380622955038

Fax+31(0)512585490Fax+380622323977

Telex46116

Dunlop-EnerkaGmbHDunlop-EnerkaS.L.

Friedrich-Bergius-Strasse10Pol.Ind.LesComes

41516GrevenbroichC/ltalia,Parc,70Nave3

Germany08700Igualada

Tel.+49(0)2181270100Barcelona

Fax+49(0)2181270130Spain

Tel.+34(9)38055446

Fax+34(9)38054269

Allinformationcontainedinthismanualhasbeenassembledwithgreatcare.Itrepresentsup-to-dateknowledgeandtechniquesandisbasedonourlongexperienceofthe

industry.Wewouldhoweveradviseyouthatmodificationsmaybenecessarytocaterfornewtechnicaldevelopments.Allinformation,guidevalues,commentsetc.aregiven

forguidancepurposesonlyandtheultimateresponsibilityfortheuseofthisinformationinconveyordesignandanysubsequentliabilityrestswiththeenduser,particularly

wherethesuitabilityofourproductsforcertainapplicationsisconcerned.Thedataandvaluesgivenarebasedonaveragevalues.

Introduction

ForewordConveyorbeltshavebeenusedfordecadestotransportbulkandunitloads.

Theyhaveprovedtheirwortheverywherebecausebeltconveyorinstallations

canbeadaptedtomeetnearlyalllocalconditions.Theyarework-safeand

economical.

Thedemandforeverincreasingcapacitiesandeverlongerconveyinglengths

hasacceleratedthedevelopmentofthebeltconveyortechnique,newmate-

rialsarebeingdeveloped,newconveyingsystemsarebeingplannedand

testedespeciallythosehavingregardtotheenvironmental.

Theconveyorbeltplaysthemajorpartinthewholesystemandhastoover-

comethemanyandvariedstresses.Inadditiontothiseveryconveying

problemisdifferentandneedscarefulplanningandselectionoftherightele-

mentsinordertoachievetheoptimumconveyingcapacityinaneconomical

way.

Thereareanumberofpracticalrules,valuesandexperienceswhichcanbe

usefulduringtheplanningstage.Thismanualaimstobeofassistanceto

operators,engineersandprojectpeopleandprovidesasubstantialamountof

elementarydata.Inadditionthereareanumberofinstructionsandhints

offeredtoenableaccuratecalculationsorchecksoninstallationcomponents

thatimpingeontherunningofthebelt.

Infuturetherew川bemoreandmoreuseofthecomputerforcalculations

anddimensioningofbeltconveyors.Withthisoftenthecorrelationofthe

valuationcriteriawillnolongerberecognizable.Thismanualshouldalsohelp

tounderstandthebackgroundtoacalculation,theselectioncriteriaforan

optimumbelttypeandtorecognizeaspecialoperatingcase.

AllnewstandardsDIN,EN,orISO,havebeentakenintoconsiderationas

wellastheresultsofindividualresearchstudies.Thedevelopmentscontinue

andwearegratefulforallhintsandpracticalexperiences.

July1994

Introduction

ChronologicalUntilthemid1970'sconveyorbeltdevelopmentandtechnologywasconcen-

Developmenttratedonthesearchforappropriatematerialsforthebeltandthesolvingof

driveproblems.Inthefirstinstancetransmissionoftractionplayedapart.As

thedemandgrewforconveyorsoflargercapacityandlongerlength,addition-

alrequirementseffectingthebelthadtobeconsideredandresearchedsuch

asgreaterworkload,elongation,slitresistanceandendlesssplicejointing.

from1870Trialswithplaincottonbelts.

upto1914Firstrubberconveyorbeltsdevelopedfromdrivebelts.

1921FoundingoftheEnerkafactory.Manufactureofdrivebelts

andlaterconveyorbelts.

1923/1924Firstuseofbeltsunderground,notasuccessduetodrive

problems.

1926FirstbeltswithrobustBalatareinforcedcovers.

from1928UseofbeltswithMacocottonplies.

from1933DevelopmentofRayon/cottonbeltsandpurerayonbelts.

Transitionfromnaturalrubbertosyntheticrubberforprotec-

tionofcarcase.

from1939Increaseduseofrayonandsyntheticrubber.

1941/1942UseofPVCbeltsaboveground.

1942Steelcordbeltsusedforthefirsttimeformajorlonghaul

installationsintheUnitedStates.

from1945Furtherdevelopmentofrayonbelts.

Introductionofmixedmaterialfabricsincludessyntheticweft.

1954/1955Developmentofhightensilestrengthbeltse.g.pliesfrom

rayon,polyamideandpolyester.Coverrubberswithvarious

surfacedesigns.Steepinclinebeltingwithprofilesandcleats.

from1955DevelopmentanduseofsteelcordbeltinginEurope.

from1970UseofAramideasreinforcingmaterialforthecarcase

from1980Developmentofnewconveyorsystemse.g.thetube

conveyor,hammockconveyor.

Thisbriefhistoryillustratesthemoreimportantstagesinconveyorbeltdeve-

lopment.Thesearchfornewmaterialsbecamenecessarybecauseofthe

everincreasingdemandstooptimiseinstallationconstructionsuchaspulley

diameters,verticalandhorizontalcurvesetc.andthedemandsofnew

conveyingsystems.

DevelopmentGoals?Optimisingconveyorbeltreinforcingmaterialsi.e.exploittotheir

maximumstrengthlimitstoobtainoptimumworkinglifeeconomy.

?Optimumdimensioningofinstallationcomponentse.g.pulleydiameters,

idlers,bearingsandshafts,troughingtransitions,driveandtake-upsystems.

?Adaptationofcoverqualitytoeachdutyi.e.coverqualitytoprovide

optimumsolutionatthemosteconomicalcost.

?Manufactureofconveyorbeltsandinstallationconstructionwiththe

environmentinmind.

1.2

Introduction

DUNLOP-ENERKAToassistinfuturedevelopmentofnewbelttypesandsplicejoiningtechni-

BeltTestingRigques,Dunlop-Enerkahavedevelopedandinstalledanewtypeofbelttesting

rig.Theprincipalintentionofthetestingmethodsistosimulateactualopera-

tingconditionsencounteredbyabeltinservice.

Withthisrigitispossibletosimulatechangingstresses,bendingchanges,

applymaximumpre-tension,usevariouspulleydiameters,observebeltslipto

capacitylimitsetc.Analysingthetestdatacanenableoptimumusetobe

madeofconveyorbeltmaterialsandbeltconveyorstherebyprovidingmore

economicaloperations.

1.3

BeltConveyor

ConstructionAninstallationconsistsofadrivesystem,atake-upsystem,additionalcom-

ponentsandtheprincipalitem,theconveyorbelt.Inadditiontotheconven-

tionalconveyorthereareotherconveyorsystemdevelopmentsinwhichthe

beltistheconveyingelement.

BasicSketch

ComponentsMotor18BeltRunCounter

MotorCoupling19OffTrackControl

Brake20BeltSteeringIdler

DriveTransmission21PullWire

AntiRunback22EmergencySwitch

DriveCoupling23ConveyorBelt

PulleyBearings24BrushRoller

DrivePulley25Scraper

TailPulley26Plough

DeflectionorSnubPulley27DeckingPlate

ImpactIdlerGarland28Cowl(HeadGuard)

12CarryingSideIdler29BaffleBar

13ReturnSideIdler30DeliveryChute

14GuideRoller31ChuteLining

15CounterWeightTake-up32SkirtBoard

16ScrewTake-up33UpperBeltLocation

17Take-upWeight34LowerBeltLocation

ExplanationBeltconveyor-fixedposition

Flatconveying

Mobileconveyor

Withwheels

Troughedconveying

Withoutwheels

2.1

DriveSystems

DriveSystemsAdrivesystemconsistsofallcomponentsthatprovidefordriving,start-up

andbrakingforces.Thetransmissionoftractionpowerfromthedrivepulley

isdependentuponthefollowingfactors:

?Angleofwrapathebeltmakesonthedrivepulley

?Frictioncoefficient秣betweenbeltanddrivepulley

?PreTensionTv.

PulleyArrangement

andBeltPath

ConveyorSystemsTheabovesketchesofdrivesystemsandbeltpathsareoftheclassicaland

mostfrequentlyusedtypes.Additionallythereareanumberofnewproven