Belt Rotation in Pipe Conveyors: Failure Mode Analysis and Overlap Stability Assessment
Sustainability
Abstract and Figures
Pipe conveyors provide sustainable solutions for environmentally sensitive or topographically complex powdered and bulk-solid handling processes; however, belt rotation is among the most critical failure modes of these equipment, influencing engineering, operational, and maintenance activities throughout the conveyors’ lifecycles. Position changes in the overlap are mechanical responses to uneven contact forces between the vulcanizing rubber belt and the idler rolls, owing to the highly nonlinear process of the belt folding from a trough to a tubular shape, and no method for quantifying the belt’s stability is currently available. In this study, we analyzed the failure mode of belt rotation and proposed a linearized model of an overlap stability index to evaluate the resilience of the overlap position through a case study of a short-flight curved pipe conveyor. Our proposal considers an interference model between the simulated torque of a curved flight in a pipe conveyor and the calculated torque of its equivalent straight flight by using kernel-smoothed density functions. It is adapted to incorporate adjustment factors for the filling degree based on simulations, the effect of the overlap in the forming force of the belt, the remaining useful life of the belt, and the coefficients of friction between the belt back cover and the idler rolls due to adhesion and hysteresis. An application was developed to calculate the belt’s rotational holding torque and rotary moment by processing real operational data, simulated contact forces, and the relevant equipment parameters. This analysis identified the reduced transverse bending stiffness and increased belt tension forces as the root causes for position changes with a loss of contact in the upper idler rolls of curved flights 10, 13, 15–16, and 17. The contributing factors included spots of augmented contact forces during the initial stages of the belt lifespan in curved flights 15–16, which presented unstable conditions due to increased opening forces, with an OSI of 0.8657. Furthermore, we proposed corrective and preventive action plans, an optimized replacement interval for the belt, and recommendations for design changes according to the relevant standards.
Figures - available from: Sustainability
This content is subject to copyright.
... Belt feeders with V-type stationary supports are the most common [1-3], which poses a big challenge due to the stability of the structure, both during operation and at standstill. This issue requires the testing of the feeder's stability [14] at the design stage and subsequent operational tests. A characteristic feature of these feeders is their installation in the workplace, on stationary or mobile supports. ...
... Belt feeders with Vtype stationary supports are the most common [1-3], which poses a big challenge due to the stability of the structure, both during operation and at standstill. This issue requires the testing of the feeder's stability [14] at the design stage and subsequent operational tests. A characteristic feature of these feeders is their installation in the workplace, on stationary or mobile supports. ...
... Belt feeders with Vtype stationary supports are the most common [1-3], which poses a big challenge due to the stability of the structure, both during operation and at standstill. This issue requires the testing of the feeder's stability [14] at the design stage and subsequent operational tests. The available literature is rich in issues related to various aspects of belt conveyors. ...
Belt conveyors, owing to their simple construction, high reliability and relatively low energy consumption, are the basic means of transporting loose and granular materials. Currently, thanks to continuous development, belt conveyors can reach a length of up to several kilometres, and their belt width can be more than two meters. Such possibilities are achieved thanks to increasingly better belts and drives. However, the most common are short belt conveyors with a length of up to 40 m and belt widths of up to 1 m, frequently referred to as belt feeders. Apart from the mining industry, they are widely used in power engineering, metallurgy and other industries (chemical plants, trans-shipment ports, storage yards, etc.). The design of machines, including belt feeders, is based on calculations. Modern design in technology is based on advanced computational methods and the possibilities of computer technology. Multi-variant simulation calculations are necessary, especially in the case of belt feeders, where none of the devices—despite the use of typical elements and subassemblies—are a repeatable solution. Only this procedure guarantees the selection of rational solutions already at the early stages of design. Therefore, in this article, an analytical model of a typical belt feeder was developed and its stability and forces in the supports were determined. This allowed the development of an application for testing the stability of the belt feeder at the design stage or when introducing structural changes.
... Given the inherent operational characteristics associated with these issues, it becomes imperative to establish a comprehensive monitoring and tracking system for the pipe belt. This system should be considered an integral component of a conditionmonitoring approach throughout its lifecycle [1]. ...
... Practical experiences have demonstrated that multiple causes and contributing factors may trigger belt rotation in pipe conveyors. These factors include environmental conditions, prolonged shutdowns during seasonal operations, bulk solids or belt properties, design or implementation flaws, and poor or omissive operation and maintenance practices, among other factors [1,58]. Furthermore, the repetitive flexural movement of the belt over time decreases its transverse bending stiffness and indentation rolling resistance, likely resulting in contact losses between the belt and the upper idler rolls [59]. ...
... The use of TBC for moving powdery and loose materials is considered in [7]. The results of the analysis of failure modes during belt rotation are presented, and a mathematical model and application for calculating the belt's holding moment and rotational moment are developed. ...
... Unlike [5,7], our research results of tubular-comb feeders take into account the presence of additional working elements (combs) on the inner surface of the pipe. This makes it possible to determine their influence on the horizontal movement of particles due to inertial forces. ...
The object of this study is the relationship between the structural and technological parameters of feeders for loose materials and the characteristics of particle flows at their outlet, namely: productivity and the magnitude of pulsations. The existing designs of this type of equipment were analyzed, and the most common methods for simulating their operation were determined. A structure of a tubular-comb feeder has been proposed, the performance of which is compared with the well-known screw feeder. Computer models of both structures were built based on the discrete element method. The simulation was carried out in the EDEM 2017 software environment. It was established that the resulting models take into account the discrete nature of the movement of loose materials and allow conducting research taking into account the physical and mechanical properties of individual particles. An experimental bench was fabricated for experimental verification of the modes of operation of the tubular-comb feeder. The performance of this type of feeder was determined for two pipe rotation speeds (6 and 10 rad/s). The amount of material flow pulsations in the outlet nozzle was also determined. The correspondence of the results of calculations based on the computer model to the real process was confirmed. The current study was carried out the steady modes of operation. It was established that with equal overall dimensions and speeds of rotation of the working bodies, the productivity of the screw feeder is 5...5.2 times greater than that of the tubular-comb feeder. But the latter provides 7.3...16.4 times smaller magnitude of pulsations of the flow of loose material. This makes it possible to reduce the heterogeneity of mixtures, especially in the case of using such feeders as part of continuous mixing systems. The results make it possible to analyze the operation of bulk material feeders and reduce their design time
... The wire feeder gear in a MIG 1300-watt welding machine continuously distributes energy, leading to material failure over time [1][2][3]. This failure disrupts the transmission of rotation to the feeder shaft, causing the wire to slip as it exits the torch [4]. The simplest solution would be to replace the faulty component with a new one [5]. ...
Material failure is a common occurrence in components subjected to continuous loads, often due to fatigue. In the MIG 1300-watt welding machine, the wire feeder gear transmission process continuously distributes energy, leading to eventual material failure. This failure disrupts the transmission of rotation to the feeder shaft, causing the wire exiting the torch to slip. To address this issue, reverse engineering technology is applied using computer-aided design (CAD), finite element analysis (FEA) assisted by computer-aided engineering (CAE), and computer-aided manufacturing (CAM), culminating in the production of prototypes with 3D printing technology. This research aims to repair the wire feeder gears by leveraging reverse engineering technology, which includes redrawing the gears and implementing developmental modifications using CAD/CAM tools. These modifications are then analyzed through FEA with CAE assistance, and the final prototype is produced using an Anet A8 V2 3D printer with Poly Lactic Acid (PLA) material.
... These forces govern the velocity of the belt, the tension within it, and its load-bearing capacity. The transient dynamics related to the initiation, acceleration, deceleration, and cessation of movement negatively impact the functionality of conveyors.Dynamic forces induce elongation and compression of the belt during these phases [4]. Improper maintenance of belt elongation may lead to misalignment, slippage, uneven load distribution, and potential injury to both the belt and the associated system components [5]. ...
In this research forecasts medium-duty conveyor belt stretch using a mathematical model. Because excessive belt stretch causes operational inefficiencies and mechanical difficulties, accurately modeling it enhances conveyor efficiency and longevity. Despite its importance, belt stretch prediction models for such applications are scarce, highlighting a literature gap. The study develops a mathematical model for belt stretch in medium-duty conveyors by employing the Buckingham π theorem and dimensional analysis. The study identifies key physical characteristics to simplify the system into dimensionless stretch behavior categories. The Buckingham theorem forms dimensionless groups to simplify belt stretch parameters and aid understanding. The experimental and simulation outcomes corroborated the model's predictions regarding belt elongation. The sensitivity of belt stretch to dimensionless groups suggests modifications to operational parameters in order to prevent potential complications. This study has implications for the design and maintenance of medium-duty belt conveyors. The optimized model assists engineers in predicting and mitigating belt elongation, thereby enhancing conveyor reliability and decreasing maintenance expenses. This study integrates theoretical frameworks and practical applications to enhance conveyor system technology and promote sustainability within the industry. Future experiments could validate the model across operational conditions and introduce more complex conveyor systems and materials.
... Currently, failure mode analysis during the development process still relies on the knowledge and experience of domain experts [1,2]. Analysis and assessment are typically conducted based on historical data, with strategies employed to integrate multiple expert opinions to establish failure mode priorities. ...
Failure Mode and Effects Analysis (FMEA) serves as a fundamental process in reliability analysis, providing critical insights into support system planning and equipment design optimization. However, traditional FMEA processes encounter several limitations, including restricted data availability, subjective expert assessments, and rigid structural requirements. The current evaluation approaches for expert opinions are constrained by small sample sizes, stringent requirements for structural consistency, and high demands for logical cohesion. To address these issues, this paper proposes a failure information fusion method utilizing a knowledge graph. By improving decision-making reliability and resource efficiency, the proposed method contributes to sustainable maintenance practices and operational sustainability. Furthermore, the method incorporates knowledge embedding technologies, facilitating reasoning through the transformation of graph structures into matrix representations. This process uncovers potential failure relationships and improves analytical depth. A case study involving an aircraft system is presented to demonstrate the method’s effectiveness and versatility, showcasing its potential to enhance reliability and support system planning.
The conveyor belt is by its structure a textile composite. As a load-supporting element of the conveyor, the belt withstands variable loads during its operations. In order to investigate the influence of the level and variability of loading on the life of the belt, tests were carried out on specimens in laboratory conditions. A testing device was specially designed and made for these tests that enabled precise control and monitoring of the loading as well as number of loading cycles up to fracture. This research provides an overview of the influence of fatigue loading on the fatigue life of the belt. The methodology of the conducted research is explained with a description of important technical parameters of the testing device. A physical experiment and a corresponding numerical simulation using the FEM method were carried out with multiple loading levels of belt specimens. Based on the obtained results, appropriate conclusions were made; at loads less than 70% of the breaking strength, the lifetime of the belt is very long. Attention was drawn to additional influences that could not be covered by the experiment and possible directions for further research were indicated.
Rubber material is widely used in railway vehicles due to its superior damping performance. The testing methods, fatigue, and aging theories of rubber materials are of great significance to improve the design, manufacture, and application of rubber components for railway vehicles. This work systematically introduces the constitutive theory, mechanical testing standards, and testing methods of rubber materials. Then, the aging mechanism is described and the research progress of rubber fatigue properties is reviewed from the perspectives of fatigue crack initiation and fatigue crack propagation. Moreover, the reinforcement methods of rubber materials are presented. Finally, according to the working conditions of rubber components in railway vehicle, the technical difficulties and future research trends of fatigue characteristics analysis of rubber materials and components are pointed out.
The use of deep learning on edge AI to detect failures in conveyor belts solves a complex problem of iron ore beneficiation plants. Losses in the order of thousands of dollars are caused by failures in these assets. The existing fault detection systems currently do not have the necessary efficiency and complete loss of belts is common. Correct fault detection is necessary to reduce financial losses and unnecessary risk exposure by maintenance personnel. This problem is addressed by the present work with the training of a deep learning model for detecting images of failures of the conveyor belt. The resulted model is converted and executed in an edge device located near the conveyor belt to stop it in case a failure is detected. A prototype built and tested in the field obtained satisfactory results and is shown as the feasibility of using deep learning and edge artificial intelligence in industrial mining environments.
Textile-reinforced conveyor belts are most widely used in various industries, including in the mining, construction, and manufacturing industries, to transport materials from one place to another. The conveyor belt’s tensile strength, which primarily relies on the property of the carcass, determines the area of application of the belt. The main aim of the current work was to investigate the influence of vulcanization temperature and duration of the vulcanization process on the tensile properties of the carcass part of the conveyor belt. An extensive experiment was carried out on the tensile properties of woven fabrics that were intended to reinforce conveyor belts by aging the fabrics at the temperature of 140 °C, 160 °C, and 220 °C for six and thirty-five minutes of aging durations. Afterward, the textile-reinforced conveyor belts were produced at vulcanization temperatures of 140 °C, 160 °C, and 220 °C for six and thirty-five minutes of vulcanizing durations. The influence of the vulcanization process parameters on the tensile property of fabrics utilized for the reinforcement of the conveyor belt was analyzed. In addition, the effect of the dipping process of woven fabric in resorcinol–formaldehyde–latex on the tensile property of polyester/polyamide 66 woven fabric (EP fabric) was investigated. The investigation results revealed that the tensile strength of the carcass of the conveyor belt was significantly affected by vulcanization temperature. The conveyor belt vulcanized at 160 °C for 35 min has shown the optimum tensile strength, which is 2.22% and 89.06% higher than the samples vulcanized at 140 °C and 220 °C for 35 min, respectively. Furthermore, the tensile strength and percentage elongation at break of conveyor belts vulcanized at 220 °C were almost destroyed regardless of the vulcanization duration.
Pipe conveyors are specially designed equipment for bulk solids handling in rough terrain regions or environmental-sensitive processes. Their structures are typically exposed to the weather, which allows dust and rainwater to access the idlers sealing along the conveyor, favored by the geometry of the panels. The steel idlers are manufactured by machining, welding, and assembling processes and tightness-test standards are performed to assess the sealing effectiveness. However, current methods do not address specific pipe conveyor characteristics or predominantly stationary conditions, such as seasonal shutdowns and long spare-part storage time. This study proposes an accelerated weathering method for investigating the influence of rainwater on the useful life of steel idlers applied to seasonal operations of pipe conveyors. A measurement apparatus was developed and a case study was conducted in a coal-handling system, using chemical oxidizing and rainwater. The results indicated the bearings’ moisture-corrosion caused by water ingression and seal compression, due to the absence of seals and axial freedom of the bearings, respectively. The proposed method presented a desirable evaluation strategy using a non-parametric test for small-sampled trials, which covered the sealing design review, storage condition inspection, and test self-assessment. Main preventive actions include sealing redesign and changing idlers' storage procedures.
Conveyor belt is one of the primary systems used in mining and industries to transport bulk materials in continuous/semi-continuous mode (Molnar et al., Wear 320:1–6, 2014) over the distances of few metres to several kilometres.
A missing roller in a hexagonal idler housing of the hose conveyor represents a failure that is often underestimated and overlooked. However, its consequences can often be serious and are manifested mainly on the conveyor belt or within the individual components of the hose conveyor. This type of failure is often identified late so there is no relevant method for its early identification. In most cases, this damage is registered by visual identification, which, however, is not easy to be performed on long transport routes. For this reason, it is therefore appropriate to identify such a type of failure by measuring force ratios. However, detailed research is needed to implement this approach. The paper presents research based on a series of experimental measurements to identify the interdependencies between a missing roller and subsequent changes in force ratios in the existence of such failures. A necessary condition for proper operation of pipe conveyors is the contact forces that arise between the guide rollers and the conveyor. The analysis of measurement results confirmed a strong dependence between the force ratios and a missing roller, which creates a precondition to identify existence of such a kind of failure in a hose conveyor. The observed differences in the magnitude of pressing forces are not constant and directly depend on the position in which the rollers are missing. The largest change in contact force was up to 407N in a specific position compared to correct, error-free state. The results of measurements made allow to formulate exact dependencies and define mutual relations of force ratios between individual roller positions.