Determination of rolling resistance

of belt conveyors using rubber

data: fact or fiction?
Prof.dr.ir. Gabriel Lodewijks
Belt conveying of bulk solids
Johannesburg, Republic of South Africa
14 - 18 January, 2013
1

Mechanical
Vermelding Engineering
onderdeel organisatie
and Marine Technology
Transport Engineering and Logistics

Contents

Introduction
Recent South African Projects
Visco Elasticity
Rheological Testing
Indentation Rolling Resistance
Discussion & Conclusions

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Introduction

23/07/2003

Supplier selection
Total cost of ownership
Design standards (DIN 22101)
Belt conveyor lay-out

Recent South Africa Projects

Coal Resources Utilization Project (CRU-II) (1999/2000)

Optimum (2001/2002)

Savmore (2001/2002)

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CRU-II, Hendrina
- 14.5 km overland system
- 1200 mm, ST 2200, 6+6
- 1050 mm, ST 1100, 6+4

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Optimum, Hendrina
- 21 km overland system
- 1200 mm, ST 1400, 6+4
- 1050 mm, ST 900, 6+4

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Savmore, Piet Retief

- 6.5 km overland system
- 900 mm, ST 1000, 6+5

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Visco Elasticity

Amplitude

(t)

Time [s]

Tension
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Applied strain

Elastic solid stress

Viscous fluid stress

Viscoelastic fluid stress

Visco-elasticity means losing energy

8

d '

(t ) '
d
'
(t) = (t - t )
dt
'
t
-

t
(t) = + g( ) exp(- ) d

0
t
(t) = + g j exp(- )
j
j=1
N

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g1

g2

gN

The trick is to pick the right parameters!

E1

E2

t
(t) = E1 + E2 exp(- )

From dynamic/mechanic tests we determine E1, E2, and

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10

E' [MPa]

tan( )

1000
1000 Hz
Hz
100
100Hz
Hz
10
10Hz
Hz
11Hz
Hz
0.1
0.1 Hz
Hz
0.01
0.01Hz
Hz

0.001 Hz
0.001 Hz

TT[ [C]C]

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11

Rheological Testing
(t)

Rheological test modes:

Steady, dynamic, transient mode

Strain, frequency, temperature, time,
time/cure sweep

Problem: number of tests or test
range?

Tension
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12

The dynamic frequency of oscillation directly links

the material time and laboratory time (Coxx-Merz
relation).
By employing the Boltzmann principle and timetemperature superposition, data can be obtained
to predict material behavior outside the range of
conventional rheometers.

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13

DMA testers rheometric dynamic mechanic analyser III

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14

Tension
Three point bending

Dual cantilever

Compression

Relation between tests and reality

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15

7.50E+07

0.75

5.00E+07

0.50

2.50E+07

0.25

0.00E+00

0.00
-30

-20

-10

10

20

30

40

50

Temperature [C]
E'

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E"

Tan(delta)

16

Tan(delta) [-]

E' and E" [Pa]

Mechanic-Dynamic Analysis - Rubber XYZ

Indentation Rolling Resistance

x
R
x=a

x=0

x = -b

y0
x' = a' x' = 0

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Vb

x' = -a'

17

Fz
Spring

Rigid base

E1 a x a + x E 2k
1 (a - x ) a x

(1 + k )1 - exp((x) = a
)

k a a

2Rh a a Rh
2

Today also for pipe and pouch belt conveyors

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18

Fz = (x)dx

Fz

Spring

M = (x)x dx
-b

Rigid base
x
R
x=a

x=0

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x' = -a'

fih*
fs = *
fim

Fi
fi =
Fz

fi = fs fim

x = -b

y0
x' = a' x' = 0

M
Fi =
R

Vb

19

f *ih
f *im
fi
f im

V [m/s]
Hunter (solid line), May et al. (dashed line),
uncorrected (dashdot line) and corrected (dotted line).
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20

nz

nh

nD

nV

nk

nT

Lachmann [1954]

1.50

0.5

van Leyen [1959]

1.40

0.8-1.0

Schwarz [1966]

1.14-1.34

0.81-1.02

Behrens [1967]

1.30

Quaas [1968]

1.24-1.40

Hettler [1976]

1.30

Kehlert [1977]

1.333-1.5

0.8

Gladysiewics [1983]

1.333

0.667

Kostrzewa [1985]

1.30

0.74

0.208

0.041

5.04

Jonkers, eq. (5.39)

1.333

0.333

0.667

f()

f(D 0 )

f(E')

Spaans, eq. (5.36)

1.333

0.667

f(D 0 )

Spaans, eq. (5.38)

1.333

0.333

0.667

f()

f(D 0 )

f(E')

equation (5.52)

1.333

0.333

0.667

f()

f(D 0 )

f(E')

Fi = C Fznz h n h D-nD VnV K-nN k TnT

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21

Discussion & Conclusions

We know that rubber plays a major role in belt
conveying

We now understand visco-elasticity

We know how to measure the relevant parameters

We have a model that can predict the indentation
rolling resistance

How about the repeatability?

How about the accuracy?
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22

7
6

E' [MPa]

5
4
3
2
1
0
-30

-20

-10

10

20

30

Temperature [C]
Extern laboratory rubber A
Extern laboratory rubber B

TU Delft laboratory rubber A

TU Delft laboratory rubber B

Repeatability
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23

Accuracy
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24

Determination of rolling resistance of

belt conveyors using rubber data: fact
or fiction?
Facts are that:

there are theoretical models to describe the viscoelastic behaviour of rubbers

there are models that predict the power consumption
of belt conveyors using rubber data

there are scientifically accepted methods to measure
the mechanic/dynamic properties of rubber (DMA)
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25


the performance of two rubber compounds can be

compared to each other.

the power requirements of a belt conveyor can be
estimated using computational design tools provided
that they are tuned for the results of the mechanic/
dynamic rubber compound tests performed on a
specific test facility.

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26

Fiction is:

the application of mechanic/dynamic properties of
rubber measured at a specific rheometer can be used
in any design model yielding the same accurate
prediction of the power consumption of the system.

the deviation between the power consumption of belt
conveyors predicted by theoretical models and
measured in practice can be less than 5%.

the indentation rolling resistance is always the driving
design parameter for long overland systems.

the measurement of power consumption of a new belt
conveyor should be done as soon as possible after
installation to enable comparison between theory and
practice.
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