Justification of geometrical parameters of lining plates for a belt conveyor drive drum

Belt conveyors are widely used in mining industry in open-pit and underground mining for moving bulkload in horizontal and inclined directions to the sites of processing. In order to create the best conditions of frictional contact between a belt and a drum, various methods of drive drum lining are used. The main lining material is rubber of different grades, providing proper coefficient of friction of a belt with a drum (within the range of 0.6–0.62). A drive drum lining material must have high wear resistance, thermal resistance, mechanical strength, ability not to accumulate electric charges on the surface and not to generate dangerous concentrations of toxic components (for example, chlorine gases, carbon monoxide) when heated. The use of ceramic lining opens up great opportunities for increasing lining durability and useful life of high capacity heavy-duty conveyors. The paper presents the results of the study of stress-strain state of belt conveyor drive drum ceramic lining plates. We used Solid Work Simulation environment in the study on the basis of the accepted analytical model of plate-belt contact for drive drum with diameter D = 1250 mm, belt width L = 1000 mm, and the belt entering branch tension value Se = 25400 daN with regard to the value, direction, and nature of the acting loads. On the basis of stress-strain analysis of alumina ceramics lining plates, the favorable geometrical parameters of the plate cleats (projections) and the required properties of lining material ensuring the proper load-carrying capacity at the contact with the belt rubber facing were found. It was established that a plate cleat diameter for heavy duty conditions should be not less than 4.5 mm and its end round R should be within the limits of 0.5–0.6 mm, and, in the base, 0.3–0.4 mm at a cleat height of 1.0–1.4 mm in order to prevent stress concentration in hazardous sections. It was also established that alumina ceramics bending strength must be no less than 350 MPa for effective functioning of rubber-ceramic lining. Simulation of a plate stress-strain state on exposure to alternating loads made it possible to identify characteristic areas with maximum stress concentration, which were foci of crack nucleation. Thus, it became possible to predict lining useful life.

belt conveyor, drive drum, ceramic lining, geometrical parameters, working section shape, stress concentration, properties, useful life

1. Galkin V. I., Dmitriev V. G., Diachenko V. P. et al. Modern theory of belt conveyors of mining enterprises. Moscow: Gornaya Kniga Publ.; 2005. 543 p. (In Russ.)

2. Andreyev A. V., Dyakov V. A., Sheshko E. E. Transport systems for open-pite mining. Textbook. Moscow: Nedra Publ.; 1975. 464 p. (In Russ.)

3. Volkov R. A., Gnutov A. N., Dyachkov V. K. et al. Conveyers. Handbook. Under the general editorship of Yu. A. Perten. Leningrad: Mashinostroenie Publ.; 1984. 367 p. (In Russ.)

4. Dmitrieva V. V, Aung K. P., Pevzner L. D., Htay W. Z. Development of a mathematical model of belt conveyor with twin-engine drive. In: International Academic Conference on Engineering, Technology and Innovations (IACETI-2016). Beijing, China. 2016. Pp. 5–8. URL: https://worldresearchlibrary.org/up_proc/pdf/454-14765147035-8.pdf

5. Aung K. P. Maintaining traction factor value of belt conveyor with two-engine drive. In: Third International Conference on Advances in Mechanical and Automation Engineering – MAE 2015. Rome, Italy. 2015. Pp. 45–48. https://doi.org/10.15224/978-1-63248-080-4-73

6. Polunin V. T., Gulenko G. N. Operation of heavy-duty conveyors. Moscow: Nedra Publ.; 1986. 344 p. (In Russ.)

7. Khachatryan S. A. Problems of reliability of conveyor transport in coal mines. St. Petersburg: St. Petersburg State Mining Institute (Technical University); 2004. 182 p. (In Russ.)

8. Galkin V. I., Sheshko E. E. Modern tapes for special tape conveyors. Mining Informational and Analytical Bulletin. 2016;(S1):382–395. (In Russ.)

9. Solovyh D. J. Computer simulation of the stress state of the belt conveyor drive pulley to assess the durability of welds. Mining Informational and Analytical Bulletin. 2015;(1):3–11. (In Russ.)

10. Dmitriev V. G., Asaenko V. V. The character of ring loading of a drive pulley belt conveyor with variable friction coefficient of belt with its surface. Mining Informational and Analytical Bulletin. 2011;(2):375–378. (In Russ.) URL: https://giab-online.ru/files/Data/2011/2/Dmitriev_2_2011.pdf

11. Verzhanskiy A. P., Solovykh D. Ya. Belt conveyor drums welded joints endurance assessment. Ugol’. 2016;(4):32–36. (In Russ.) https://doi.org/10.18796/0041-5790-2016-4-32-36

12. Dyakov V. A., Shakhmeister L. G., Dmitriev V. G. et al. Belt conveyors in mining industry. Under the editorship of A. O. Spivakovsky Мoscow: Nedra Publ.; 1982. 349 p. (In Russ.)

13. Mathaba T., Xia X. Optimal and energy efficient operation of conveyor belt systems with downhill conveyors. Energy Efficiency. 2017;10(2):405–417. https://doi.org/10.1007/s12053-016-9461-8

14. Trufanova I. S., Serzhan S. L. Improving Transportation Efficiency Belt Conveyor with Intermediate Drive. Journal of Mining Institute. 2019;237:331–335. https://doi.org/10.31897/pmi.2019.3.331

15. Ushanova S. E., Ziborova E. Yu. Increasing the durability of friction units for mining equipment and conveyor transport. Mining Information and Analytical Bulletin. 2020;5(S15):3–8. (In Russ.) https://doi.org/10.25018/0236-1493-2020-5-15-3-8

16. Mossakovsky V. I., Rudiakov G. Z., Salitrennik V. B. Study of interaction of conveyor belt and elastic lining of a drum. Izvestiya Dnepropetrovskogo gornogo instituta. 1967;(48):55–67 (In Russ.)

17. Zharikov V. S. Study of linings of drive drums for belt conveyors in coal mines. [Ph.D. thesis in Engineering Science]. Мoscow. 1973. (In Russ.)

18. Voznesensky A. S., Kidima-Mbombi L. K. Formation of synthetic structures and textures of rocks when simulating in COMSOL Multiphysics. Mining Science and Technology (Russia). 2021;6(2):65–72. https://doi.org/10.17073/2500-0632-2021-2-65-72

19. Mihailidis A., Bouras E., Athanasopoulos E. FEM analysis of a belt conveyor driving drum. In: 6 BETA CAE International Conference. 2015. URL: https://www.beta-cae.com/events/c6pdf/2C_2_AUTH.pdf

20. Marasova D., Ambrisko L., Andrejiova M., Grincova A. Examination of the process of damaging the top covering layer of a conveyor belt applying the FEM. Measurement. 2017;112:47–52. https://doi.org/10.1016/j.measurement.2017.08.016

21. Rozbroj J., Necas J., Gelnar D., et al. Validation of movement over a belt conveyor drum. Advances in Science and Technology-Research Journal. 2017;11(2):118–124. https://doi.org/10.12913/22998624/71183

22. Rybak J., Khayrutdinov M. M., Kuziev D. A., et al. Prediction of the geomechanical state of the rock mass when mining salt deposits with stowing. Journal of Mining Institute. 2022;253:61–70. https://doi.org/10.31897/PMI.2022.2

23. Gubanov S., Petsyk A., Komissarov A. Simulation of stresses and contact surfaces of disk rolling cutters with the rock when sinking in mixed soils. In: XVIII Scientific Forum “Ural Mining Decade” (UMD 2020). 2020;177:03008. https://doi.org/10.1051/e3sconf/202017703008

24. Perekutnev V. E., Zotov V. V. Modeling drive wheels of hoisting machines with rubber cables. Mining Informational and Analytical Bulletin. 2020;(6):105–114. (In Russ.) https://doi.org/10.25018/0236-1493-2020-6-0-105-114

25. Melezhik R. S., Vlasenko D. A. Load simulation and substantiation of design values of a pin flexible coupling with a flexible disk-type element. Mining Science and Technology (Russia). 2021;6(2):128–135. (In Russ.) https://doi.org/10.17073/2500-0632-2021-2-128-135