Documente Academic
Documente Profesional
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IN PARTIAL FULFILLMENT OF
THE REQUIREMENTS
IN ME 521A MACHINE DESIGN II
UNIVERSITY OF SOUTHEASTERN PHILIPPINES
COLLEGE OF ENGINEERING
SUBMITTED BY
MAY 2019
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Table of Contents
CHAPTER I .......................................................................................................... 1
INTRODUCTION ............................................................................................... 1
1.2 Objectives of the Study ............................................................................... 3
1.3 Statement of the Problem ............................................................................ 3
CHAPTER II ......................................................................................................... 4
2.1 Related Literature ........................................................................................ 5
2.1.1. Belt Conveyors ..................................................................................... 6
2.1.2. Bucket Conveyors .............................................................................. 11
2.1.3. Screw Conveyors ............................................................................... 12
2.2 Related Studies ......................................................................................... 14
2.2.1. Belt Conveyors ................................................................................... 14
2.2.2. Bucket Conveyors .............................................................................. 16
2.2.3. Screw Conveyors ............................................................................... 18
CHAPTER III ...................................................................................................... 21
3.1 Design Considerations .............................................................................. 21
3.2 Design Criteria........................................................................................... 21
3.3 Mechanical Drawing .................................................................................. 21
REFERENCES ................................................................................................... 22
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CHAPTER I
INTRODUCTION
Presented below are the background and objectives of the study, as well as
division of work an individual is assigned into. The aggregate of bulk material used
materials and can be treated as continuous thus, are moved in large quantities
In the United States, 52% of the electricity comes from coal generation.
These plants require massive amounts of coal; a typical 109 kWh/year coal power
plant heats water to 540˚C to produce high pressure steam and in order to meet
those demands, the plant burns 14 000 tons of coal every day. The coal that goes
approximately 5 cm in size before it is loaded into the inlet hopper. Coal contains
many impurities. Coal in the Midwest typically contains a lot of sulfur. The pyritic
sulfur, from the mineral FeS, is relatively easy to remove. The coal can be ground
and washed with water. The heavier FeS particles fall to the bottom and can be
poor flow characteristics, it commonly has been the practice to convey such
in an elongated tube. In the use of such conveyors, however, it has been found
that the flow rates of sluggish and cohesive bulk materials is poor, difficult to
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control, thus a substantial amount of torque is required to operate such conveyors
and such materials tend to build up in the tube around the auger which often is
of control of the flow rates in such conveyors, it is difficult to accurately meter such
In the screw conveyor, the material partially fills the voids between flights
and is transported due to the rotating screw effect. Overfilling inhibits transport due
to rotation of the particulate material. The belt conveyor is primarily used for
chain or belt carries a series of evenly-spaced buckets that dig into the material at
the lower entry chute/hopper and carry it over the top sprocket, where it is
2005).
and control of the particulate solids, are basically systems of individual machines
from one materials handling machine into the feeding hopper of another. At this
point the kinetic energy (and some potential energy) in the material is lost and
further energy is often required to feed the material to the next machine, as
between the horizontal conveyor in the centre and elevator. The material does not
necessarily flow in the familiar way that many liquids do. There is always friction in
the machine elements and this is present even when the machine is not loaded
with any material. Additionally, the coal will exhibit friction both internally as it
moves against itself and externally as it slides against machine members. When a
machine is operating 24 hours per day for the whole year (except for down-time)
the friction energy can amount to a considerable cost. The machine designer
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needs to understand where energy is lost and how to maximize the efficiency of
improved system and method for conveying bulk materials having poor flow
characteristics with the use of a screw, belt, and bucket type conveyors in which
the flow rate of sluggish and cohesive bulk materials is improved, the torque
required to drive the augers of such conveyors is reduced and a build-up in the
eliminated. This design relates to an improved system and method for handling
bulk materials such as coal, and more particularly to an enhanced system and
process for conveying metered amounts of such materials having poor flowability.
1. How to develop a conveyor system design that would enable the transport
of 50 tph of coal?
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CHAPTER II
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In this chapter, the proponent presented the synthesis of related literature, and
studies that are related on the origins, mechanism, design, and efficiency of the
various conveyor systems designed by the researcher, namely, belt, bucket, and
screw conveyors. The literature came from books, online journals, research
mechanical methods of handling materials. This has been to such an extent that
in the western world almost everything, including food, raw minerals, building
materials and finished products, has probably been mechanically handled many
times before it reaches the consumer. The materials handling industry is not only
and distribution systems (for example, US companies invest over $90 billion
industry is very broad, covering almost all industries, including mining, mineral
students, but the internal and external friction of the particulate materials will need
screw conveyor may have unusually high friction loss due to the fact that all
carrying surfaces rub against the bulk solids, whereas a belt conveyor, which
carries the material on a belt supported by rollers, will usually offer a considerably
familiar with the general machine element design, engineering design processes,
2005).
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2.1.1. Belt Conveyors
Belt conveyors are, in most cases, the most cost-effective solution for
handling bulk material mass flows over short and medium conveying distances.
The belt is a key component of these conveyors and its dynamic characteristics
to mechanical energy. Its energy efficiency can be divided into four components:
efficiency. The improvement of energy efficiency can easily put to the operation
efficiency and equipment efficiency for most energy systems. It holds true for belt
profits due to unnecessarily high capital and operating costs (Mcnearny & Nie,
2000).
belt conveyors are no different. Although belt conveyors have always been an
overland conveyors. The main resistances of a belt conveyor are made up of:
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• Idler Resistance
• Alignment
to overcome gravity (lift) make up the required power to move the material.
its components as per Figure 1 with lift making up the largest single component
Figure 1
At the 2004 SME annual meeting, Walter Kung of MAN Takraf presented a
The longest conveyor in this system (PC2) was 16.28 km in length with
475m of lift. The most important system fact was that 50% of the operating power
(~4000 kW at 1783 mtph and 4.6 m/s) was required to turn an empty belt therefore
power efficiency was critical. Very close attention was focused on the idlers, belt
cover rubber and alignment. One way to document relative differences in efficiency
is to use the DIN 22101 standard definition of “equivalent friction factor- f” as a way
to compare the total of the main resistances. In the past, a typical DIN f used for
design of a conveyor like this might be around 0.016. MAN Takraf was estimating
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over 30%. This reduction contributed a significant saving in capital cost of the
commissioning showed the value to be 0.0075, or even 30% lower than expected.
Mr. Kung stated this reduction from expected to result in an additional US$100,
Unquestionably, the most efficient way to transport material from one point
distances by conveyor, the possibility of conveying in a straight line is less and less
likely as many natural and man-made obstacles exist. The first horizontally curved
conveyors were installed many years ago, but today it seems just about every
overland conveyor being installed has at least one horizontal change in direction.
easily.
stockpile to the ship loader at the Tianjin China Port Authority installed on 2003.
of Australia, this 9 km overland carries 6000 mtph with 4x1500 kW drives installed.
The Wyodak Mine, located in the Powder River Basin of Wyoming, USA, is the
production since 1923. It currently utilizes an overland (Figure 4) from the new pit
to the plant 756m long (2,482 ft) with a 700m (2,300 ft) horizontal radius. This
proves a conveyor does not need to be extremely long to benefit from a horizontal
turn.
has been the distribution of power along the conveyor path. Is has not been
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uncommon to see drives positioned at the head and tail ends of long conveyors
and let the tail drive do the work of pulling the belt back along the return run of the
conveyor. But now that idea has expanded to allow designers to position drive
been around for a long time. The first application in the USA was installed at Kaiser
Coal in 1974. It was shortly thereafter that underground coal mining began
consolidating and long wall mines began to realize tremendous growth in output.
were looking for ways to increase the size of mining blocks in order to decrease
the percentage of idle time needed to move the large mining equipment from block
to block. Face widths and panel lengths were increasing. When panel lengths were
increased, conveyance concerns began to appear. The power and belt strengths
needed for these lengths approaching 4 -5 km were much larger than had ever
been used underground before. Problems included the large size of high power
drives not to mention being able to handle and move them around. And, although
moving to steel reinforced belting that was much heavier and harder to splicing.
Since long wall panel conveyors are constantly advancing and retreating (getting
longer and shorter), miners are always adding or removing rolls of belting from the
system. Moreover, since vulcanized splicing takes several times longer to facilitate,
lost production time due to belt moves over the course of a complete panel during
development and mining would be extreme. Now the need surpassed the risk and
the application of intermediate drives to limit belt tensions and allow the use of
underground coal mining. Many mines around the world have incorporated it into
their current and future mine plans to increase the efficiency of their overall mining
operations. The tension diagram in Figure 5 shows the simple principal and most
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significant benefit of intermediate belt conveyor drives. This flat, head driven
conveyor has a simple belt tension distribution as shown in black. Although the
Figure 5
average belt tension during each cycle is only about 40% of the peak value, all the
belting must be sized for the maximum. The large drop in the black line at the head
pulley represents the total torque or power required to run the conveyor. By splitting
the power into two locations (red line), the maximum belt tension is reduced by
almost 40% while the total power requirement remains virtually the same. A much
smaller belt can be used and smaller individual power units can be used. To extend
the example further, a second intermediate drive is added (green line) and the
peak belt tension drops further. The tunnelling industry was also quick to adopt this
technology and even take it to higher levels of complexity and sophistication. But
the main need in tunnelling was the necessity of using very tight horizontal curves.
elasticity in high capacity and/or long length conveyors during stopping and starting
can lead to incorrect selection of the belting, drives, take-up, etc. Failure to include
• Drive slip
• Breakaway torque
• Holdback torque
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• Load sharing between multiple drives
takes belt elasticity into account during stopping and starting be considered in
these critical, long applications. A model of the complete conveyor system can be
achieved by dividing the conveyor into a series of finite elements (Alspaugh, 2004).
9.81 𝐻𝑊𝑚
𝑃𝑜𝑤𝑒𝑟 (𝑘𝑊 ) = [ ] (𝐿𝑣 ) [𝑘𝑋 + {𝑘𝑌(𝑊𝑚 + 𝑊𝑏) + 0.015𝑊𝑏} + ]
1000 𝐿
where:
Figure 6
buckets to convey bulk material in horizontal, inclined, and vertical paths. The
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buckets remain in carrying position until they are tipped to discharge the material.
Bucket Conveyors are integrated with double strand roller chains that can
lift the load on a horizontal and inclined profile. Ideal for handling abrasive and hot
material, these bucket conveyors are known for their strong body and low power
consumption. These are used for vertical transportation of bulk and small grain
cosmetics, chemical, ceramic and glass industry, but also for transportation of bulk
An ideal design for bucket conveyor is one with a pair of parallel draw
elements between which the buckets are supported on spindles about which they
rotate pendulum fashion. Forward rollers are mounted on the ends of the spindles
and rear rollers are mounted at the opposite edge of the bucket. Each bucket has
a flange or lip which overlaps the top edge of an adjacent bucket. The rollers on
the buckets engage guide rails to properly orient the buckets as they pass over
return gears and from the loading area to the dumping area and back again. By
maintaining proper orientation of the buckets, the load level of each bucket and
thus the capacity of the conveyor is increased. The bucket conveyor is of simple
design, has low wear and high conveying capacity (Glowatzki, 1988).
flighting that operates inside a casing. Powered by an electric motor and suitable
gearing, the screw conveyor usually operates in one direction only to move fine
bulk material such as meal, seed, and coal (Britannica, 2019). The said system is
composed of several parts. It is composed of a pipe with a welded steel strip that
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is formed into a continuous helix. The helix is referred to as the flighting. The
distance along the pipe from one point on the flighting to the next similar point is
called the “pitch”. Couplings and shafts refer to the mechanisms by which
two screw conveyors are joined. Hangers are used to provide support and
maintain alignment of the screw conveyor. The screw conveyor may be housed in
a “tube” or “trough”. The tube is a hollow cylinder, whereas the trough has a “U”
shape, hence the term “U-trough” augers.The theoretical capacity of a full screw
conveyor is:
𝐶𝑐𝑎𝑝 = (𝐷 2 − 𝑑 2 )(𝑃𝑁)(36.6)
where:
determine because of the variations between different augers and materials. The
following equation estimates the horsepower required for an auger operating in the
horizontal positioning.
where:
L = conveyor length, ft
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F = material factor.
The horsepower in equation must be adjusted for horsepower under 5.0 hp:
Screw conveyors become less efficient when they are used to convey
material vertically. Capacity decreases with inclination about 30% for a 15°
inclination and about 55% for a 25° inclination. Relying heavily upon friction for
their operation, screw conveyors tend to wear rapidly, especially their flighting, and
they are inefficient in use of energy. Torque on the screw can be substantial;
therefore, less-expensive units with lightweight shafts should be driven from the
input end, especially if the flighting is not attached continuously along the shaft.
This wraps the flighting more tightly about the shaft due to torsional deflection,
increasing greatly its torsional rigidity. If driven from the discharge end, shaft
deflection compresses the flighting, which may lead to its buckling and, in extreme
cases, to breaking of the welds and crumpling of sections of flighting inside the
tube. The limiting angle depends upon the coefficient of sliding friction of the corn
on steel and the pitch-to-diameter ratio of the screw. Capacity decreases as slope
Belt conveyors are widely used for handling bulk material over short to
compared to other transport methods. Energy cost forms a large part of the
operational cost (up to 40% of belt conveyor systems. As a whole, the material
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handling is consuming a considerable proportion of the total power supply, for
instance, 10% of the electricity supply is consumed by the material handling sector
handling, which is one of the development focuses of the belt conveyor technology.
The idler, belt and drive system are the main targets for equipment efficiency. The
entire longitudinal main resistances are transferred via the idlers; hence the idlers
have a great impact on the efficiency of belt conveyors. The energy consumption
The performance of the belt is crucially influenced by the flexure resistance, which
is the most important contributing factor to total resistance. Energy optimized belts
are developed by improving the structure and rubber compounds of the belts and
operational level.
the system components and time, or through the coordination of the system and
human operators. They coordinate the on/off status of the belt conveyors and time
efficiency. However, these methods are designed to save cost instead of energy
because they just shift the work to different period of time according to the time-of-
use (TOU) tariff. In the literature, speed control is recommended for energy
efficiency of belt conveyor systems. The aim is to control the belt speed to keep a
constantly high amount of material along the whole belt. The proper coordination
of feed rate and belt speed is believed to have high operation efficiency in the
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Nowadays, the idea of speed control has been adopted by industry and
control employs lower level control loops or multi-speed drive to improve the
laser scanner and the radiation density measuring device are needed to measure
the loading level, which is the control variable of the current control strategy.
Furthermore, the current control strategy cannot be used to deal with the system
constraints and external constraints, such as TOU tariff and storage capacities,
a conveying system.
The main purpose of the paper was to introduce optimal control to belt
strategy and a VSD based optimal control strategy were proposed. Started with
energy calculation model of belt conveyors, then the optimal switching control
problem and the VSD based optimal control problem for operation efficiency of belt
conveyor systems were formulated. The researchers took the TOU tariff into
the two optimal control strategies to drive the operation of the belt conveyor system
in its optimal efficiency. They made use of a coal conveying system, including five
belt conveyors, in a coal-fired power plant as a case study. The optimal switching
control strategy, the VSD based optimal control strategy and the current control
strategy was applied to the said coal conveying system, respectively (Zhang & Xia,
2010).
A bucket conveyor of the present type is known from German Pat. No. 2546
748 in which the adjacent lip of each bucket engages the lip of the neighbouring
bucket to prevent the contents of the buckets from spilling in the loading area. For
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this purpose, the interlocking bucket lips are hook-shaped, which also serves the
purpose of maintaining a distance between each lip and the lip which it overlaps
buckets to swing positively and adopt a stable position. However, this is also a
swing bucket conveyor system, its design will suffer from the same disadvantages
and prevent them from tipping. The purpose of the design is to provide a bucket
conveyor which does not suffer from the disadvantages of known bucket
conveyors, i.e., a system of simple design and consequently low cost, which
provides high conveying capacity and which furthermore does not incorporate
components subject to high wear rates. The fundamental concept of the design
described above and avoiding their disadvantages. This bucket conveyor operates
partially like a swing bucket conveyor so that the bucket fill level and thus the
capacity of the system are relatively high. On the other hand, unlike existing type
of bucket conveyors, this system does not require any complex means of control,
since care is taken to insure that the buckets cannot tip out of the conveyor path
against the bearing direction of the support lips. As in the case of existing bucket
conveyor systems, the buckets will also adopt positions in which the filling opening
faces downwards and the load tipped out. The means of preventing spillage may
consist of fixed bearing rails comprising cam surfaces on which the side of the
buckets opposite the side from which the bucket is suspended are preferably
supported by means of lateral studs or rollers. Orientation of the buckets may also
engage with corresponding counter stops in adjacent buckets or on the draw gear.
These stops and/or counter stops may be formed by sizing the walls of adjacent
buckets and the distances between them, so that as the buckets tend to tip away
from the conveyor path, they collide with one another and tipping is thus prevented.
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A further way of preventing tipping consists of employing springs with which the
means are provided for preventing the buckets quite simply from hanging down
from their spindles as they are conveyed upwards, which would tend to limit the
load level. These means insure that the buckets are displaced from their hanging
that the load level and thus the capacity of the conveyor are increased. Displacing
or swinging the buckets sideways away from their hanging position exerts
transverse loads on the draw gear or endless chain which it is perfectly able to
accept. The displacement resulting from these lateral tractive forces can be
compensated by providing the guide rails with a suitable cam configuration. The
draw gear can be maintained in a normal straight position, despite the side forces
exerted upon it, provided support rollers on the bucket are fitted. An especially
counter guide rail. Any of the components of the draw gear or any special parts
can slide along the counter guide surface; however, the best solution is to employ
guide rollers which can be provided quite simply on extensions of the spindles
about which the buckets are allowed to swing freely. In another version of the
invention, the two guide surfaces consist of the two opposite edges of a guide rail,
both ends of which are preferably sickle-shaped so that the rollers can run on and
off them easily and smoothly. A fixed stop may be provided to abut the side of the
bucket at the entry point so that the buckets are slightly tipped at this point, allowing
the lateral projections to run up onto the guide surfaces (Glowatzki, 1988).
A screw conveyor of the present type is known from US Pat. No. 7,137,759
B1. Its principal object is achieved by providing a bulk material handling system
generally consisting of means for holding a supply of such material; means for
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conveying the material including a first conduit formed of a permeable material
spaced from the permeable conduit, providing a chamber there between, and an
auger disposed in the permeable conduit for transporting material received through
the inlet to the outlet thereof, means for rotatable driving the auger, and means for
supplying a fluidizing gas under pressure to the chamber whereby such fluidizing
gas penetrates the inner permeable conduit encasing the auger, which forms a
boundary layer consisting of a mixture of fluidizing gas and particles of the bulk
enhancing the flow of material propelled by the auger. In such an arrangement, the
flow rate may be more readily controlled by simply controlling the speed of the
drive motor for the auger. More accurate amounts of material may be metered
simply by monitoring the feed rate of material being discharged from the screw
conveyor, comparing such feed rate with a selected feed rate and correspondingly
adjusting such feed rate by controlling the speed of the drive motor for the screw
conveyor, monitoring the loss of weight of material fed into the screw conveyor,
comparing such loss of weight with a selected weight and adjusting the speed
and/or discontinuing the operation of the drive motor; and monitoring a gain of
weight of material discharged from such screw conveyor, comparing such weight
discontinuing the operation of the drive motor. The supply of fluidizing air to the
inner conduit of the screw conveyor surrounding the auger functions not only to
improve the flow rate of sluggish and cohesive materials through the screw
conveyor but reduces the amount of torque required to drive the auger of the
conveyor, permits more precise control of the flow rate and prevents the build-up
controllable amounts of bulk material may be conveyed from a first site to a second
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site for processing or other purposes. In the arrangement utilizing a flow meter to
measure the mass flow rate from the screw conveyor, it is possible to operate such
system in a batch mode by numerically integrating the mass flow rate signal from
the solid mass flow meter although the accuracy may not be as good as the weight
gain or weight loss systems. Although a single auger profile is illustrated, it further
is to be understood that augers of different flights may be utilized within the scope
of the invention including helicoids, ribbon, cut, cut and folded, fixed or adjustable
mixing paddles, non-metallic, hollow, brush and other flights. It further will be
placed in service. The provision for supplying fluidizing air to the material flow
passageways of the conveyor not only enhances the flow rate of the material being
conveyed and reduces if not eliminates the deposit of material but provides for a
more precise metering of the material being conveyed and substantially reduces
the torque required to drive the conveyor. From the foregoing detailed description,
it will be evident that there are a number of changes, adaptations and modifications
of the present invention, which come within the province of those persons having
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CHAPTER III
METHODOLOGY
This chapter presented the measures taken in developing the design; with
utilizing design considerations and criteria as its main purpose. Also, the
mechanical drawing for the belt, screw, and bucket conveyor systems are
presented herein.
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REFERENCES
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Glowatzki, W. (1988). Patent No. 4,770,287. Isernhagen 2, Fed. Rep. of
Germany.
Hou, Y.-f., & Meng, Q.-r. (2008). Dynamic characteristics of conveyor belts.
JournalL of China University of Mining and Technology, 2-6.
Velury, J., & Kennedy, W. (1992). A systematic procedure for the selection of
bulk material handling equipment. International Journal of Production
Economics, 233-240.
Zhang, S., & Xia, X. (2010). Optimal control of operation efficiency of belt
conveyor systems. Applied Energy - Elsevier, 9-18.
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