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Design Aspects of Multiple Driven Belt Conveyors Design Aspects of Multiple Driven Belt Conveyors Ashley Nuttall Cover illustration: Courtesy of Fenner-Dunlop B.V. Design Aspects of Multiple Driven Belt Conveyors Proefschrift ter verkrijging van de graad van doctor aan de Technische Universiteit Delft, op gezag van de Rector Magnificus prof. dr. ir. J.T. Fokkema, voorzitter van het College voor Promoties, in het openbaar te verdedigen op maandag 26 november 2007 om 12:30 uur door Ashley Jan George NUTTALL werktuigkundig ingenieur geboren te Rotterdam. Dit proefschrift is goedgekeurd door de promotor: Prof. dr. ir. G. Lodewijks Samenstelling promotiecommissie: Rector Magnificus, Voorzitter Prof. dr. ir. G. Lodewijks, Technische Universiteit Delft, promotor Prof. dr. ir. B. De Schutter, Technische Universiteit Delft Prof. dr. J.A. Ferreira, Technische Universiteit Delft Dr. ir. A. van Beek, Technische Universiteit Delft Prof. dr.-ing. L. Overmeyer, Institute of Transport and Automation Technology Prof.dr. ir. D.J. Rixen, Technische Universiteit Delft TRAIL Thesis Series no. T2007/12, the Netherlands TRAIL, Research School TRAIL Research School PO Box 5017, 2600 GA Delft The Netherlands Phone: +31 (0) 15 278 6046 Fax: +31 (0) 15 278 4333 E-mail: [email protected] ISBN 978-90-5584-092-2 Keywords: multiple drives, belt conveyor, dynamics, motion resistance, traction, wear Copyright © 2007 by Ashley Nuttall All rights reserved. No part of the material protected by this copyright notice may be reproduced or utilised in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage and retrieval system, without written permission from the author. Printed in The Netherlands Preface In 1992 Dunlop-Enerka BV, located in Drachten, the Netherlands, started to develop a pouch shaped closed belt conveyor system called the Enerka-Becker System (or E-BS). It featured a revolutionary method of supporting the belt and included a multipoint drive system. Although multiple drives were integrates into the design of this conveyor system, little was actually known about how to coordinate the spatially distributed drive stations. As this system was only built with relatively small belt lengths (under 500 meters) and a small motor spacing, the belt stress caused by the introduction of drive forces was relatively low and not a limiting factor for the system. Therefore, a simple control method sufficed. However, the question was if larger systems would still work with this simple control method. Gabriël Lodewijks, who had also been involved with part of the development of the E-BS, also identified this issue. As little was known with respect to the implementation of multiple drives not only in the E-BS, but also in more conventional belt conveyor systems, he formulated a research proposal for the coordinated control of multiple driven belt conveyor system. This proposal formed the base for my PhD research. Initially, the focus was put on the coordinated control of the multi- motor layout. However, as little was know about how the current simple control method adopted in the E-BS would perform in a large scale application, the focus was shifted to identifying problems that can be expected when adapting this method of control. My special thanks goes to Gabriël Lodewijks, who inspired me with his fascination of applying scientific research on belt conveyor systems and who encouraged me throughout my research. Without his enthusiasm and drive this thesis would not have been possible. In addition I would like to thank Ton Klein Breteler for his ideas and guidance during my PhD work. This research was also performed in cooperation with Fenner-Dunlop BV. The support I received from Michiel Eijpe and his colleagues is greatly appreciated. I would also like to thank all the colleagues from Transport Engineering and Logistics for their interest in my research, sharing ideas on different subjects and the pleasant working environment. Last but not least I would like to thank my mum, dad and family for their love and support, and my friends just for being who they are. i ii Design Aspects of Multiple Driven Belt Conveyors Contents Preface........................................................................................................................................ i 1 Introduction .................................................................................................................. 1 1.1 Multiple driven belt conveyors....................................................................................... 1 1.2 Distributed drive power and tension control .................................................................. 5 1.3 Research questions and scope of study .......................................................................... 7 1.4 Outline of thesis.............................................................................................................. 8 2 Multiple driven transport systems.............................................................................. 9 2.1 Mechanical drive configurations.................................................................................... 9 2.1.1 Single drive configuration.............................................................................................. 9 2.1.2 Multiple drive configuration......................................................................................... 11 2.2 Categorisation of multiple driven systems ................................................................... 13 2.3 Existing multiple driven transport systems with flexible links .................................... 16 2.3.1 Belt conveyors.............................................................................................................. 16 2.3.2 Printing presses............................................................................................................. 17 2.3.3 Trains............................................................................................................................ 19 2.3.4 Chain conveyors........................................................................................................... 21 2.3.5 Fuel cell car concept..................................................................................................... 22 2.4 Comparison of systems ................................................................................................ 23 3 Existing models for belt conveyor systems............................................................... 27 3.1 Main components of the Enerka-Becker System ......................................................... 27 3.1.1 Belt ............................................................................................................................... 28 3.1.2 Belt support.................................................................................................................. 30 3.1.3 Drive units.................................................................................................................... 30 3.1.4 Loading station............................................................................................................. 32 3.1.5 Discharge and belt turnover.......................................................................................... 33 iii iv Design Aspects of Multiple Driven Belt Conveyors 3.2 Belt dynamics ............................................................................................................... 33 3.3 Motion resistances........................................................................................................ 35 3.3.1 Main resistances........................................................................................................... 36 3.3.2 Secondary resistances................................................................................................... 40 3.3.3 Slope resistances........................................................................................................... 43 3.3.4 Special resistances........................................................................................................ 43 3.4 Drive stations................................................................................................................ 43 3.4.1 Induction motor and inverter........................................................................................ 44 3.4.2 Gear reduction box and drive wheel............................................................................. 48 4 Modelling resistance in the E-BS .............................................................................. 49 4.1 Indentation rolling resistance in the E-BS.................................................................... 49 4.1.1 Modelling the belt’s viscoelastic surface ..................................................................... 49 4.1.2 Maxwell model............................................................................................................. 51 4.1.3 Pressure distribution and rolling friction due to hysteresis .......................................... 52 4.1.4 Finding the Maxwell parameters.................................................................................. 56 4.1.5 Results .......................................................................................................................... 58 4.2 Resistance in horizontal curves .................................................................................... 60 4.2.1 Modelling the curve resistance....................................................................................
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