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关键词：: DX型钢丝绳芯丝绳芯带式输送机设计图纸

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DX型钢丝绳芯带式输送机设计

54页 16000字数说明书+外文翻译+4张CAD图纸【详情如下】

DX型钢丝绳芯带式输送机设计说明书.doc

外文翻译--钢绞线带式输送机的发展.doc

张紧装置.dwg

总装图.dwg

机头部.dwg

重锤清扫器.dwg

DX型钢丝绳芯带式输送机设计.gif

QQ截图20140110213946.gif

机头部.gif

全部文件.gif

张紧装置.gif

重锤清扫器.gif

轴承端盖.gif

轴承透盖.gif

摘要I

AbstractII

第1章绪论1

1.1 前言1

1.2 带式输送机的发展史1

1.2.1国外带式输送机的发展1

1.2.2国内带式输送机的发展2

1.2.3国内外带式输送机的差距2

1.2.4带式输送机的发展趋势3

1.3 带式输送机的分类3

1.4 带式输送机的特点及应用4

第2章带式输送机的整体设计方案5

2.1 方案的确定5

2.2 工作原理7

第3章带式输送机的主要部件与功能10

3.1 输送带10

3.1.1输送带的发展10

3.1.2输送带的种类及差异10

3.1.3输送带的要求11

3.1.4钢丝绳芯输送带11

3.2 拉紧装置12

3.2.1拉紧装置的作用12

3.2.2拉紧装置的分类及特点12

3.3 托辊14

3.3.1托辊的结构及作用14

3.3.2托辊的选择14

3.4清扫装置16

3.4.1清扫器的作用16

3.4.2清扫器的形式16

3.5 传动滚筒、改向滚筒17

3.5.1传动滚筒的分类17

3.5.2改向滚筒的选取18

3.5.3环形胀套19

3.6 机架的设计与选取20

3.6.1机头探架20

3.6.2中间支架20

第4章带式输送机的设计计算21

4.1 设计参数21

4.2 根据实际输送量计算带宽21

4.3 运行阻力23

4.4 牵引力及运行功率28

4.5 输送带张力计算29

4.6 输送带强度验算31

4.7 滚筒直径的确定31

4.8驱动装置的选型及计算32

4.8.1电动机的选型32

4.8.2液力偶合器的选型32

4.8.3减速器的选型33

4.8.4联轴器的选型36

4.8.5制动器的选型及计算37

4.9 拉紧力计算40

4.10 托辊的选取41

4.10.1 静载荷计算41

4.10.2 动载荷计算43

结论45

致谢46

参考文献47

附录149

附录256

摘要

带式输送机自它诞生以来，经过200多年不断完善和改进，已进入电力，冶金，煤炭，化工，矿山，港口等各行各业之中。其机构简单，输送物料范围广，输送量大，运距长，对线路适应性强，装卸料十分方便，可靠性高，营运费低廉，基建投资省，耗能低，效率高，维修费少。

本设计为DX型钢丝绳芯式带式输送机，采用机头双滚筒驱动，在保证滚筒不发生打滑的前提下来传递较大的功率，降低输送带的张力和提高使用寿命。文中根据第二滚筒围包角用足，依此算出输送机的各种参数，进行结构设计。由于倾角较大，按第二滚筒围包角用足进行等驱动功率单元法分配，本设计采用分配，得出尾部张力最小，根据布置原则，张紧装置一般布置在输送带张力最小处，所以本文采用重载车式张紧装置进行张紧。如今，带式输送机正向长距离、高带速、大功率、大运量的大型化方向发展，使其在煤炭行业得到广泛应用。

关键词带式输送机双滚筒驱动张紧

Abstract

The belt conveyer with continue development and improvement has entered all trades and professions such as power, metallurgy, coal, chemical engineering, mine and port since being born for more than 200 years. Its construction is simple , it is broad to transport stock scope, it is big to transport quantity, the length of haul distance has strong adaptability for line, handling material is very convenient, reliability is high , it can reduce investment in basic construction, high efficiency, low maintenance cost.

The design is DX model core type belt conveyer of wire rope, the machine header adopts two cylinder drives ,in guarantee cylinder do not occur the prerequisite with slippery dozen transmit greater power, reduce raising the tension of belt conveyer and improve service life. In writing according to second cylinder surround bale angle use enough, according to this various parameters that make conveyer finally, carry out structural design. Since inclination is greater, according to second cylinder wait for drive with foot power unit law distribution, this design adopts 1: 1 is distributed , it is minimum to reach tail tension, basis arrange principle, tension station arranges normally, is in the tension minimum place of conveyer belt , so, this paper use the burden vehicle tension equipment to tighten. Now belt conveyer’s development towards to long distance, high belt speed, great power and high transportation, and the advantage of this kind of conveyer realizes easily, make extensive application in coal industry.

Keyword Belt conveyer two cylinder drive tight

1.1 前言

　　　带式输送机自1795年被发明以来，经过两个世纪的发展，已被电力、冶金、煤炭、化工、矿山、港口等各行业广泛采用。特别是第三次工业革命带来了新材料、新技术的采用，使带式输送机的发展步入了一个新纪元。当今，无论从输送量、运距、经济效益等各方面来衡量，以成为全国争先发展的行业。随着我国工业生产自动化程度的不断提高，带式输送机这一类古老、经济适用而又现代化的连续输送机械，是国民经济中不可缺少的关键设备[1]。

1.2 带式输送机的发展史

　　　皮带运输机有着200多年的发展史，影响深远。自1972年圆管胶带输送机诞生后就在国外迅速普及，到2004年已有余种运输机在世界各地生产并使用。进入21世纪，我国发明了可伸缩、可升降的圆管胶带输送机；气垫式圆管胶带输送机；中摩式圆管胶带输送机和圆管胶带输送机用高温耐热胶带、无缝托辊组[12]。

　　　1.2.1国外带式输送机的发展

　　　国外带式输送机技术发展的很快，其主要表现在个方面：一方面是带式输送机的功能多元化、应用范围扩大化；另一方面是带式输送机本身的技术与装备有了巨大的发展，尤其是长距离、大运量、高带速等大型带式输送机已成为发展的主要方向。其核心技术是开发应用于了带式输送机动态分析与监控技术，提高了带式输送机的运行性能和可靠性。

内容简介：: 7519字数钢绞线带式输送机的发展托马森（英）总经理钢绞线带式输送机有限公司摘要：早期带式输送机的发展被认为是与钢绞线带式系统相同的需求而发展起来的，其本质就是各种设计原理与槽形带式输送机突出部分的优缺点进行比较，而这一部分的发展恰恰表明，在传送系统中最可能也最有用的发展，就是对其外形轮廓的改进，这些使得在一些大型钢绞线设计建造中，考虑安装长达52千米的螺纹槽系统（2个）。钢绞线带式输送机发展在1795年时，最初的带式输送机不便于操作，而且仅涉及一些简单的外形，直到1850年后，随着世界范围内的谷物货量大量增加，促使传送带技术有了较大的改进。第一种形式的传送机是在一个槽形及其内运行的水平传送带，其工作原理是引进导轮系统用滚动摩擦来替代滑动摩擦，以便减少传送中的摩擦损失。随着需求的不断增长以及大量的集中装卸货物的需要，使得在这一时期最普遍的货物带式输送机。草型带式输送机以及钢绞线带式输送机都获得较大发展。在1860年后期，大量使用带有锥形或蝶形滚动导轮的槽形带式传送机，直到1890年才过时被淘汰。1865年倾向于将直线集中器或跨轮引入到传送机发明设计中，这使得托马斯.罗宾在1896年获得该产品的专利权，被认为是历史上第一台槽形带式输送机。从那时起，许多重大改进在跨轮传送带和操作结构等一些细节方面。但在1900年早期，所有的槽形带式输送机都具有相同的外型，在外型上并没有改进。同最初的机器相比，钢绞线带式输送机真正意义上获得较大成功的发展是在1952年，而在1859年，最早期的设计形式之一，如图一所示。图中包括两条平行无较差的皮带制成胶质的传送带，被按一定距离贴附在弯曲的金属表面上，使得这种帆布式槽形带式输送机正常运行，也有许多相似的输送带类型，但它们承受从动带被刚性的贴附在主动带上，这些基本相同的缺点这也导致许多缺点例如：主动带并不能完全与草图设计吻合，或者是润滑剂承受重压，最终从主动带脱落等。图一钢绞线传动带系统成功地克服了这些缺点，并且这一技术被大范围的用在传送机长距离的应用中。现在一种单臂长54米的螺纹槽系统已经被考虑在设计中。钢绞线传送带系统设计原理的基本不同在于采用一种圆形的金属线形式的主动带，而不是传统的将从动带附着在主动带上。第一步改变致力于克服通过三角皮带轮式运行中的水平传送带被钢绞线替代所产生的困难。第二步改变是着眼于钢绞线传送带系统本身可以进行操作，这与早期设计的目标恰恰相反。主动带主要依附于从动带上，这些钢绞线被放置在传送带表面压制好的滑轨上，它或许是紧依靠摩擦力是钢绞线传送带在主动带上向后滑行，然而同所有带式输送机依靠摩擦力在传送带上运载货物相比，钢绞线时仅需满足在传送带和主动钢绞线间的摩擦力应大于在传送带和货物之间的摩擦力，这应使得传送带制动器仅仅牢固在主动钢绞线上。钢绞线带式输送机也可用于特殊形式的表面，在斜面传送机整体系统中等级是21，一些特殊形式的可达28，在传动钢绞线上不存在打滑脱落的现象。钢绞线带式输送机伴随着发动机进一步发展而发展的，当发动机功率达到300千瓦时（被认为是最杰出的设计）；由此而开始建造长达3000米，功率8000千瓦的传送机。钢绞线传送给与槽形传送机除在工作方式上不同，其它一些末端的输出单元是相似的，也联合从动带与主动带，一个典型的例子是上部的卸货装置，如图六所示：图六明显地，除传动单元终端设备之外的其他设备要比传统的槽形带式输送机复杂得多，并且占据更多的空间，特别是在考虑张力等作用下更是如此，这并不是真正意义上的传动装置，而是仅对其功率额定值进行比较，当它满负载时，需能控制运处的钢绞线传送机正常工作。传动钢绞线的张力模数保持在相对低的水平是为了获得较低的初始扭矩，并且当每个传动钢绞线拉紧时，张力系统需要占据较大的空间，并且更复杂，如图七所示：图七后期的钢绞线带式输送机设计理念与传统的非常相似的，在传送机中也存在摩擦，并且垂直找平装置是一系列的悬垂链，但如果应用于不同的领域，应考虑各种不同的性能，且考虑降低传送机的摩擦损失，可以通过减少动件的数量和重量，这种损失正常值为30%，而额定的摩擦损失取决于工作中的传送带与货物之间的损失，而采用滑轮装置可大大减少这种损失，理论上测量能答曰降低10%的损失，做一基本比较，这一事实很令人吃惊。关于摩擦损失已经证实往往很难克服，并且所有的观测数据和设计标准，显示出不同的测试结果，另外摩擦损失取决于各种因素，此外，输送机摩擦将随着安装和维护的温度，寿命和标准变化。在一些大型设备安装中，比较部分摩擦值至少在一个基本设计中能看到如下不同之处：传统型钢绞线型回转件数量10076 可动件数量10064摩擦损失 10067 钢绞线带式输送机的垂直找平系统与槽形机设计和计算原理是相同的，必须进行反复测试确保悬垂链脱落这样的事情不会发生。钢绞线传送带被定义为横向坚固纵向轻柔的带式输送机，而从动带依附于两条平行主动带的侧翼或边缘部分。减速齿轮箱和活动单元来对主动钢绞线进行控制，以及对不同钢绞线拉伸张力的差别超界调整。此外，每一根主动钢绞线在工作中允许承受不同的拉伸力。钢绞线传送带独特的特点是体现在传送带上，最初是一种加强橡胶传送带，被铸造在以450毫米为间隔的弹簧搭接片上，这些搭接片伸出起搭架轮之外，如图二所示，并且机械的附着在金属制动器上，橡胶传送带与主动钢绞线相连，这可以被一种铸造结构所代替，如图三所示，一些较小的交叉搭接片以间隔100毫米的距离完全铸造在传动带和制动器上，以便使主动钢绞线仅仅固定在传动带边缘。最近，已经对此作进一步改进，如图四，当货物在其上移动时，制动器仅仅控制主动钢绞线，这也使得当发生超重时，增加传送带的稳定性。另外可以采用更好的交叉搭接片。图二图三图四长期集中使用传送机，最终得更换传送带，这是很正常的，或者是由于表面的摩擦损失造成的,或许是机械性的损坏，但主要取决各个部分的寿命，例如影响橡胶、化合物寿命的因素有热障、光照和氧化等，因此必须发展特种橡胶化合物来增加其寿命。主动钢绞线的特点使它可以近似的被那些金属线大小、抗疲劳性和内部的润滑性符合钢绞性设计特点的金属线所代替。有一些叙对变电镀，同向顺捻每一根细金属线或金属绳，通常这些金属性能应达到直径60毫米，并且断面负荷达到260吨，随着钢绞线带式系统的张力的增加应特别注意尽量减少金属线接头的数量，当主动钢绞线承重100吨时，每一部分都是如此。顺着传送带每间隔5到10米有一个直径大约300毫米的三角皮带轮，显然这些皮带轮应具有坚固的齿轮结构，但实际上这些皮带轮被设计为表面可替换的橡胶值得滑轮，这些滑轮成对出现在交接臂上，传送带本身能平衡每一个滑轮上的负载，如图五所示，在所有的传动机设计中都应基本的考虑避免钢绞线脱轨情况发生，应谨慎的设计悬垂链，众所周知，悬垂链本身就能避免滑落，在设计中，钢绞线带式系统应用同样，但是若有效的防止滑落发生却极有可能增加负载条件和限制初始扭矩。图五钢绞线带式输送机在设计最主要不同在于将从动传送带于主动钢绞线分开较好的设计方案，应将它们和在一起，而分开它们是方便于在设计上给与更多的灵活性，并且能够引起传统带式输送机没有涉及的理念，且能更广泛的应用在许多领域，传送带可以是直得，也可以是弯曲的，如图八所示，它可以允许达到320的角度仍保持主动带的基本特征，但得结合两个环形从动带，这一特征的30 被用于钢绞线传动带的安装调试。其他的设计原理广泛应用于前面提到的，当住主动系统里传送带较足时的操作，这一独特的特征，使得主动单元也可以同某些电子设备相连，但得将其防止在无尘干净的环境中，这种灵活性也使得从动装置可以放置在传送机的任一点，也可以将货物直接通过主动钢绞线传递，钢绞线带式输送机的其他部分（拉力系统）涉及的独特性，毫无疑问，它将比槽形带式输送机更复杂占据更多的空间。图八存在许多原因但其最根本原因在于每一条主动钢绞线和从动带常须承担设备的拉力牵引。从动带上的拉力微不足道的，它必须满足主动带上的张力作用，尤其是在一个长的平面输送机，拉里几乎都由主动单元承受这种传送机，在初始指令期间主动钢绞线的拉伸运动可以替代，在整台传送机开动前，这种效应被储存在从动带拉力系统中，当然当传送机停止运行时，将被释放。在一个长达15000米的传送机可以被拉伸80米，同槽形带式输送机相比，钢绞线传送机占据如此大的空间最主要时期必须满足主动钢绞线和长期拉伸和相对高的弹性拉伸作用。固定的拉伸范围大约是1，在它首次运行几百小时后，这已被制造商消除在制造阶段，但传统做法还是在钢绞线接头处留有足够的空间，以便于引入额外的钢绞线时的需要模数的选择可以控制弹力，减少弹力，减少所占空间，同时有效的弹性可以保证获得较低的终止扭矩。从锻件方面的信息可以看出钢绞线带式系统同槽形带式系统有许多方面完全相同，但也存在一些不同之处。大多数的传送机是较短的且低功率的，毫无疑问，槽形带式输送机带动许多传送机的发展，然而在一些长距离或者起吊升起来运输货物的领域，细胶线带式输送机展示其特殊优点，且其独特的设计时它来这些领域成为唯一选择。若想准确的定义出钢绞线传送带的应用领域是有些困难的，几乎三分之一被应用于没有太大的竞争的领域，每一种情况下，它们被选择是由于某一些方面的特征，基本上钢绞线传送带一般不适合那些短的普通传送机应用的领域，这主要取决于终端设备的大小，另外终端设备的花费包括传送机的每一部分，在钢绞线传送系统的中，一般不给予考虑动力需求的花费，在摘要中，当前的钢绞线传送带的竞争领域似乎是：供率低于750千瓦的斜面输送机，或者是长度少于3000米的水平输送机，并不是钢绞线传送带的竞争的主要领域。当这些参量进一步提高时，钢绞线带式输送机选择的首要产品成为更有竞争力。在水平输送机中，摩擦损失的能量是相当大的，这边增加了钢绞线传送带的运行费用，此外在其他方面并没有什么本质区别。在钢绞线带式系统中较有意义的发展是对当前锻件的改进，未来几年这应是首要的花费，在运行费用方面，这包括对主动钢绞线的每一根金属线的股线都要加强，最初的试验结果展示其抗老化、其寿命是传统金属绳的3倍，钢绞线带式系统最近的发展表明，其完全可以同长距离的绳索运输相竞争。虽然现在还没有被考虑，当前在澳大利亚西部的Worsley Alumina Ptr:Ltd公司正在建造一个有两个螺纹槽系统，长达52000米钢绞线带式输送机系统。Worsley Alumina Ptr:Ltd位于西澳大利亚附近，设备的整体部分由量太钢绞线带式输送机串联组成，并且经由陆路运输将吕土岩从矿山运到精制厂。在凉台传送机交叉处，货物表皮左旋50，通过花道进入第二个传送机，在两台输送机间，主动传送机的角度和张力单元系统都应相互协调、适应。传送机必须标准化且几乎各部件零件均可互换。长度 31000米 21000米标高 72米 14米货物铝土岩密度 1520kb/m3额定功率2040m.t.p.h年产量（吨） 9.06106带宽 900毫米运行速度 6.35m/s主动带 57千米（直径）间距 4.75米功率 5300kw 3600kw如果条件许可，钢绞线传送机将能获得进一步发展，可以将传送带的长度扩展到更长。作者非常感谢得到Worsley Alumna Pty.Ltd公司的帮助和相关的资料。本文涉及：1传送带输送机的标高来自Hetzel and Albright John Wiley & sons2带式输送机的抗阻力数据来自H.P.Lachman .附录2DEVELOPMENT OF THE CABLE BELT CONVEYORlan Main Thomson BSc (Eng.)Managing DirectorCable Belt LtdSummary The early development of belt Conveying is discussed showing how the Cable belt system developed from the same requirements. The various design concepts are compared with those of the troughed belt conveyor highlighting the areas of advantage and disadvantage. The areas of conveying where the Cable Belt system is most useful and the likely developments are outlined. These and other developments have led to many major conveyor installations including a 2 flight 52 km system being constructed to the Cable Belt design. Development of the Cable Belt ConveyorThe origin of the belt conveyor is not easy to clearly identify but there are references to simple forms as early as 1795. However it was not until the dramatic increase in the world trading of grain after 1850 that major improvements were made. The first form of conveyor was a flat belt running in a trough which was quickly improved by the introduction of straight idlers to replace sliding friction by rolling friction. The need to increase the capacity and centralise the material load led to the appearance at the same time of both of the most common forms of heavy duty belt conveyors, the troughed belt conveyor and the Cable Belt conveyor. In the late 1860s the use in troughed belt conveyors of straight rollers with conical or dished ends was obsolete until the early 1890s. The introduction in 1865 of inclined straight concentrator idlers led to the conveyor in the Thomas Robins Jnr. patent of 1896, which is regarded as the first troughed belt conveyor. Since that date whilst there have been many important improvements in the detail of the idler, belt and drive construction, the basic concept of the troughed belt conveyor is the same as outlined in the work completed in the early 1900s. The Cable Belt conveyor principle whilst of earlier origin was not developed in a truly successful form until 1952.One of the earliest forms was that developed in 1859 and shown in the sketch fig. 1. This consisted of two parallel endless leather or rubber belts to which were attached at intervals curved meta1 spreaders supporting a canvas trough. There were many other similar conveyors but they all suffered from the same basic defect that the carrying belt was rigidly attached to the driving belts. This led to the disadvantages that the drive belts do not stretch alike and that the spreader bars are stressed and eventually break free from the drive belts. The Cable Belt system successfully overcame these defects and since its introduction has generally been accepted in the conveyor field for Long distance applications. A substantial proportion of the single flight conveyors over 5 km long that have been installed are now of the Cable Belt design. The fundamental design differences made in the Cable Belt system were to use a round drive belt in the form of a wire rope, and not to attach the carrying belt to the drive belts. The first of these changes was aimed at getting over the difficulty of training to run in parallel a pair of flat belts by substituting positively located round cables running in grooved pulleys. Early Belt Conveyor Fig 1The second change was the point that allowed the Cable Belt system to operate successfully in contrast to the other earlier attempts. The carrying belt merely rests on the drive cables, these cables sitting within shoes which are moulded on the be1t surfaces. It may seem that depending on friction alone the Cable Belt is liable to have the belt slip backwards on the drive cables. However as all belt conveyors depend on friction between the belt and the material carried to allow them to operate at all, the only requirement is that the friction between the belt and the drive cables should be greater than between the belt and the material. This was achieved by shaping the belt shoes to grip the drive cables. It has been possible using Cable Belt belting with specially formed surfaces to run on slope conveyor systems where the overall grade is 21 and with particular sections of 28, without experiencing slipping of the belt on the drive cables. Whilst the Cable Belt conveyor was developed at a time when the powers available of up to 300 kW were regarded as outstanding the basic concept is still retained even when now, single conveyors of 30000 metre length and 8000 kW power are being built. The terminal units are similar to those in a conventional troughed conveyor except that they also serve to separate and rejoin the carrying belt and drive cables. A typical example of a head discharge unit is shown in fig. 6.Obviously the terminals other than the drive unit are more complex than in a conventional troughed conveyor and take up more space particularly in the case of the tensioning arrangements. This is not true of the drive as for a comparable power rating it is compact and has the advantage that it can be located remote from the Cable Belt conveyor belt line. Head Discharge Unit Fig 6As the modulus of elasticity of the drive cables is kept relatively low in order to allow the use of very low starting torques and each drive cable is tensioned, the tension system does require substantial take-up space and is more complex as is illustrated in fig. 7. Typical Tensioning Arrangement Fig 7The concepts behind the design of the Cable Belt conveyor are very similar to a conventional conveyor in that there is conveyor friction and the vertical alignment is a series of catenaries but of course the factors used vary considerably because of the different characteristics. The conveyor friction losses are considerably reduced principally because of the significantly lower number and weight of moving parts in a comparable system. This reduction is normally in the order of 30%. In addition the friction losses due to the working of belt and material as they pass over the idlers are significantly less. it has been determined empirically that there is in the order of a 10% reduction in the friction losses. The establishing of the facts, even on a comparative basis, with regard to conveyor friction has proved difficult as all the data is empirical and the various design standards can show markedly different results. In addition conveyor friction will vary with temperature, age and standards of installation and maintenance. However in a recent major installation it has been possible to compare the friction values, at least on a design basis and as can be seen below these bear out the differences. ConventionalCable BeltNumber of Rotating Parts10076Weight of Moving Parts10064Friction Losses10067In determining the vertical alignment of the Cable Belt system whilst the formulae and calculation are the same, great care must be exercised as it is not possible to allow lift off in catenaries to occur. Early Cable Belt Belting Fig 2Intermediate Cable Belt Belting Fig 3Modern Cable Belt Belting Fig 4The Cable Belt is best defined as a belt conveyor with a laterally rigid but longitudinally flexible carrying belt which is supported at or near its edges on two parallel endless looms of drive cable, these cables in turn being supported at intervals by grooved pul1eys. The integral reduction gear and drive unit drives both drive cab1es and incorporates a differential to equalise tensions in the cables. In addition each of the drive cable circuits is separately tensioned to allow for the differential stretch of these during operation. The unique feature of the Cable Belt system is the belt. Originally this was a fabric reinforced rubber belt which had moulded into it spring steel straps at 450 mm intervals. These straps protruded beyond the edges of the bell as illustrated in fig. 2, and had mechanically attached to them a metal shoe with rubber Lining where it gripped the drive cable. This was superseded by a one piece moulded construction shown in fig. 3 where smaller cross section straps at intervals of 100 mm were moulded entirely within the belt and the shoes to grip the drive cables were continuous mouldings along the edge of the belt. Typical 4 Pulley Line Stand Fig 5Recently a further change was made, illustrated in fig. 4 whereby the shoes which grip the drive cable on the material carrying run have been moved inwards. This increases the stability of the belt when subjected to overloading and in addition allows the use of smaller cross section straps.Angle Station Fig 8It is normal that on a typical long centre conveyor the eventual replacement of the belt is not for reasons of abrasion of the surface or mechanical damage, but due to the various ageing processes that affect rubber compounds such as heat, sunlight, and ozone. As a result it has been necessary to develop special synthetic rubber compounds that are inherently resistant to ageing. The specification of the drive cables whilst similar superficially to a normal wire rope are specially made to a Cable Belt specification with design criteria laid down for individual wire size, fatigue life and internal lubrication. They are of galvanised construction, Langs Lay with either a fibre or wire rope core. Currently they are used in sizes up to 60 mm diameter and breaking loads of 260 tonnes. As this is the tension reinforcing member of the Cable Belt system great attention is paid to reducing the number of splices and drive cables of up to 100 tonnes weight for each section have been used. Along the line of the conveyor it is supported at intervals of between 5 and 10 metres by grooved pulleys approximately 300 mm in diameter. Previously these pulleys were of a hardened steel construction but the current design is for a pulley with a replacement rubber lined tread. These pulleys are mounted in pairs on articulated arms which allow the conveyor to self align and equalise the loads on each pulley as can be seen in fig. 5. Whilst this condition is normally avoided in all conveyor design, it is essential, to prevent derailment of the drive cables, to design catenaries correctly and conservatively. As is well known the normal catenary formulae are approximations which allow a factor of safety against lift off. In designing the Cable Belt system the same formulae and factors are used, but effectively the protection against lift off is increased by determining worst possible loading conditions and limiting the starting torques. This situation is helped in that the conveyor friction is such and modulus of the drive cables is selected to ensure that there is virtually no additional breakaway torque required even to start a long flat overland Cable Belt system. The major difference in designing a Cable Belt conveyor lies in the separation of the carrying belt and the drive cables. Whilst good design practice requires that they should be kept together, the ability to separate them does give considerable flexibility in design and allows the introduction of concepts unknown in the conventional belt conveyor. The most widely used of these is in the many circumstances where a straight line route or one incorporating curves is not feasible, and the unit known as an angle station is employed. As can be seen from fig. 9 this allows any angle up to 320 to be accommodated and still retain the feature of a single drive but incorporate two separate carrying belt circuits. This feature is used in about 30% of the Cable Belt installations. The other concept that is widely used is as mentioned earlier, the ability to place the drive unit remote from the belt line. This feature, which is unique, allows the drive unit and its associated electrical equipment to be located in a position with easy access for maintenance but away from the dust and dirt associated with a conveyor discharge or return belt line. This flexibility also allows the drive unit to be placed at any point in the conveyor, including if necessary on the material carrying run of the drive cables. The other part of the Cable Belt design that is unique is the tensioning system and there is no doubt that this is more complex and takes greater space than would be required in a troughed belt conveyor. There are several reasons for this but the principal reason is the necessity to provide equipment to separately tension each drive cable and the carrying belt. Whilst the tension in the carrying belt is nominal it is still necessary to cater for the drive cable tension movement, particularly in long flat conveyors which, of necessity, are tensioned at or near the drive unit. In such conveyors the tension movement of the drive cables is substantial during the start sequence. Before the whole conveyor is moving the effect is that it is necessary to store in the carrying belt tension system a length of belt equivalent to the elastic stretch of the drive cables. This of course is released when the conveyor stops. In a typical 15000 metre long conveyor this stretch can be up to 80 metres. The main reason for taking up a greater space than a troughed belt conveyor is the necessity to cater for both the permanent stretch and the relatively high elastic stretch of the drive cables. The permanent stretch of about 1% which occurs in the first few hundred hours of running could be eliminated during manufacture but it conveniently provides the necessary space for splicing of the cable as well as generating extra cable which can be used when resplicing is necessary The choice of the modulus that governs the elastic stretch is a compromise between minimising the stretch to reduce the space requirements and having sufficient stretch to ensure very low breakaway torques. As can be seen from the foregoing information the Cable Belt system while fulfilling the same role in many ways is quite different from the troughed belt conveyor. As most conveyors are of short length and low horsepower there is no doubt that the troughed belt conveyor is the correct solution for many conveyor applications. However in those areas of long lengths or high lifts the Cable Belt system often shows decisive advantages and in those cases where its unique design concepts can be used it may be the only choice. To define the precise applications which a Cable Belt system is suitable for is difficult, as nearly one third of the systems installed are in applications in which they were not the most competitive solution. In each case they were chosen for one of the unusual features that the system offers. As a general rule the Cable Belt in its current form is not technically suitable for short centre conveyors mainly due to the size of the terminals. In addition to the cost of the terminal equipment the main cost component of any belt conveyor, the belt, in the Cable Belt system has a constant cost irrespective of the power requirements. This 1oads the capital cost on low power conveyors but reduces it on high power conveyors in comparison with a troughed belt conveyor. In summary the current competitive situation of the Cable Belt system appears to be :- In slope conveyors of less than 750 kW or level conveyors of less than 3000 metre length the Cable Be1t is not the most competitive solution. Above these parameters the Cable Belt becomes increasingly competitive in capital cost.In leve1 conveyors where the power due to friction losses is a substantial part of the total, the operating costs of the Cable Belt system are becoming increasingly attractive. In other cases there does not appear to be any significant differences.There is one significant development of the Cable Belt system which is currently undergoing fiel

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