Design of belt conveyor for coal mines and optimization of design parameters

This study includes the history, advantages, disadvantages, design factors, conveyor profiles, use of belt conveyors, elements of belt conveyors, drive mechanisms, equations to be used and problem. With today's developing technology, more functional factories, mines, power plants and ports have emerged. With the work done, raw material processing and production have increased accordingly. The need for mines and production plants has increased the amount of materials and other industrial products and the need for them to move more easily, quickly and reliably. Transport technology; time, motion, and quantity parameters, providing the packing, transporting and storage of the burden; service and transaction components. It is not easy to put transport systems on a specific schedule or group them in a specific frame. Because many factors in the system (the type of material to be transported, the place to transmit, the desired economy, time, etc.) can change the whole system. For example, between the two points there is a small number of similarities between glass transport and concrete mortar transport except for the similarity of events. For transport system components it is however possible to make general classifications only taking into consideration the element characteristics. These are continuous carriers and intermittent carriers. The conveyors are in the continuous conveyor group. Conveyors have roll, chain, belt, floor and air type varieties. Belt conveyors provide enormous savings from time to time, from the necessary human power and from the economy, besides providing transport of materials. As the trucks and other material-carrying vehicles encounter large obstacles in harsh natural conditions, the banded conveyors easily pass through the high-slope terrain. Band conveyors will be a good choice if tons of materials will be transported at the unit time. Belt conveyors with a smaller human factor than the vehicles also provide a safe transport. Belt conveyors are frequently used in automotive, energy, food and mining industries. Advantages of belt conveyors work with low energy during operation. The tape is installed at a low cost and is maintained with cheap service fees. They can transport tons of material per hour and transport to locations within 62 km by using steel rope bands. The disadvantages are that if they do not work at full capacity so they produce low efficiency. Dust formation is also observed during operation. If a good design is not considered, high abrasions can occur on the conveyor belt and this can adversely affect the company economically. The most important component of belt conveyors is conveyor belt. The tape takes on the material to be transported and is constantly under pulling, stretching forces. It is desirable that the conveyor belt has properties such as low specific gravity, bending, low moisture retention, high strength and long life. Otherwise, a failure in the band during operation will cause the system to stop and economically lose. The tape line can be designed as non-sloping, down-sloping and up-sloping. The main frame of the conveyor belt forms the core (carcass). The material of the carcass can be from cotton, silk, polyamide, polyester, glass yarn and steel. The use of a steel frame ensures that the band is stronger and longer lasting against stresses. This allows material to be transported at longer distances. The steel extracts are split into 2 pieces. These are steel-core extracts and steel-sheet extracts. Another important element is drive drums. This is the first drive of the band and is called the driving drum which provides the advance of the band. The design and construction of a belt conveyor drive is based on the maximum belt pulling force and the length of the conveyor, as well as the pre-selected dimensions of the belt. Operating conditions during operation must be considered. The drums are manufactured by casting or by welding the ends of the sheet metal. Shapes are cylindrical or curved (barrel) shaped. An error to be made during manufacturing can lead to axial misalignment and in this case damage to the conveyor belt can occur. Tension and compression stresses occur in the belt during transmission. Accordingly, the thickness of the band, the tensile and compressive strength are the factors determining the diameter of the drum. The greater the diameter of the drum, the more difficult it is for a moment to be within its limits of strength. It can be lowered below the minimum diameter in bands that are not strong enough. Belt conveyors are mostly driven by electric motors. If the engine speed is greater than the drive drum, a gearbox with at least two stages should be installed. Depending on the ambient conditions, the characteristics of the components to be used and the characteristics of the material to be transported, They are designed from the beginning, from the tail or from the double drive. The sum of the power required to run the conveyor idle, the power needed to transport the material horizontally, the force required to transport the material vertically, the power required to accelerate the material, and other power losses is equivalent to driving the conveyor belt. However, attention should be paid to ambient conditions, environmental pollution and the efficiency of the electric motor when total power is calculated. In multi-drum systems, low-band stresses occur, but create additional costs due to additional motor and gear systems. For belt conveyor design, the characteristics of conveying material, density, belt characteristics, conveying length and slope must be known in order to calculate belt speed and drive power. While the drive system is selected for conveyor applications, attention must be paid to the power, speed control range, the number of stopping positions, the conditions of the use site, the change of moment and the relation with other drive systems. The wide range of elements should be examined and many questions should be answered. Important choice is variable speed drive with constant speed. Process, mechanical, electrical energy and cost conditions must be taken into account when choosing a drive system. Conveyor applications; Constant moment along the speed range, high starting torque, high inertia, high acceleration and deceleration moments, and load sharing between multiple drives require controlled downtimes. It also employs complex mechanisms with suitable speed and belt pulls, especially for longer conveyors, preferably operating at more natural frequencies. The motors are very important because the drive drum is in motion. Depending on the requirements of the system, the belt conveyors use alternating short-circuit motors, alternative ring motors and single motors. Direct current motors are systems that are magnetically rotated on the rotor, called the stator, by means of the moment force generated by the rotation of the mechanical power of the electrical power. It is a structure that generates mechanical motion by forward and backward polarity of the magnetic field generated by the current flowing through the coils that is by attracting opposite poles and converting the same polarity principle to circular motion. Calculations are made using the equations given and the standard charts. The problem is the transport of a stone cargo with 500 t/h in the line which is formed by two conveyors with 500m slope and 100m 30o slope. At the end of the calculations, the dimensions of the parts to be used in the belt conveyor have been obtained. Graphs of the changes of power and band forces were created using parameters of conveyor inclination, roll angle and reel groups. Various comments have been made.