包钢烧结热返矿链板输送机设计【含6张CAD图纸】
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The Design of High Speed Belt ConveyorsG. Lodewijks, The Netherlands.SUMMARYThis paper discusses aspects of high-speed belt conveyor design. The capacity of a belt conveyor is determined by the belt speed given a belt width and troughing angle. Belt speed selection however is limited by practical considerations, which are discussed in this paper. The belt speed also affects the performance of the conveyor belt, as for example its energy consumption and the stability of its running behavior. ENERGY CONSUMPTIONClients may request a specification of the energy consumption of a conveyor system, for example quantified in terms of maximum kW-hr/ton/km, to transport the bulk solid material at the design specifications over the projected route. For long overland systems, the energy consumption is mainly determined by the work done to overcome the indentation rolling resistance . This is the resistance that the belt experiences due to the visco-elastic (time delayed) response of the rubber belt cover to the indentation of the idler roll. For in-plant belt conveyors, work done to overcome side resistances that occur mainly in the loading area also affects the energy consumption. Side resistances include the resistance due to friction on the side walls of the chute and resistance that occurs due to acceleration of the material at the loading point.The required drive power of a belt conveyor is determined by the sum of the total frictional resistances and the total material lift. The frictional resistances include hysteresis losses, which can be considered as viscous (velocity dependent) friction components. It does not suffice to look just at the maximum required drive power to evaluate whether or not the energy consumption of a conveyor system is reasonable. The best method to compare the energy consumption of different transport systems is to compare their transport efficiencies.1 TRANSPORT EFFICIENCYThere are a number of methods to compare transport efficiencies. The first and most widely applied method is to compare equivalent friction factors such as the DIN f factor. An advantage of using an equivalent friction factor is that it can also be determined for an empty belt. A drawback of using an equivalent friction factor is that it is not a pure efficiency number. It takes into account the mass of the belt, reduced mass of the rollers and the mass of the transported material. In a pure efficiency number, only the mass of the transported material is taken into account.The second method is to compare transportation cost, either in kW-hr/ton/km or in $/ton/km. The advantage of using the transportation cost is that this number is widely used for management purposes. The disadvantage of using the transportation cost is that it does not directly reflect the efficiency of a system.The third and most pure method is to compare the loss factor of transport . The loss factor of transport is the ratio between the drive power required to overcome frictional losses (neglecting drive efficiency and power loss/gain required to raise/lower the bulk material) and the transport work. The transport work is defined as the multiplication of the total transported quantity of bulk material and the average transport velocity. The advantage of using loss factors of transport is that they can be compared to loss factors of transport of other means of transport, like trucks and trains. The disadvantage is that the loss factor of transport depends on the transported quantity of material, which implies that it can not be determined for an empty belt conveyor.2 INDENTATION ROLLING RESISTANCEFor long overland systems, the energy consumption is mainly determined by the work done to overcome the indentation rolling resistance. Idler rolls are made of a relatively hard material like steel or aluminum whereas conveyor belt covers are made of much softer materials like rubber or PVC. The rolls therefore indent the belts bottom-cover when the belt moves over the idler rolls, due to the weight of the belt and bulk material on the belt. The recovery of the compressed parts of the belts bottom cover will take some time due to its visco-elastic (time dependent) properties. The time delay in the recovery of the belts bottom cover results in an asymmetrical stress distribution between the belt and the rolls, see Figure 1. This yields a resultant resistance force called the indentation rolling resistance force. The magnitude of this force depends on the visco-elastic properties of the cover material, the radius of the idler roll, the vertical force due to the weight of the belt and the bulk solid material, and the radius of curvature of the belt in curves in the vertical plane.Figure 1: Asymmetric stress distribution between belt and roll It is important to know how the indentation rolling resistance depends on the belt velocity to enable selection of a proper belt velocity.Figure 2: Loss factor (tanb) of typical cover rubberFirstly, the indentation rolling resistance depends on the vertical load on the belt, which is the sum of the belt and the bulk material weight. If the vertical load on the belt decreases with a factor 2 then the indentation rolling resistance decreases with a factor 2.52 (2 4/3). The bulk load decreases with increasing belt speed assuming a constant capacity. Therefore, the indentation rolling resistance decreases more than proportionally with increasing belt speed.Secondly, the indentation rolling resistance depends on the size of the idler rolls. If the roll diameter increases with a factor 2 then the indentation rolling resistance decreases with a factor 1.58 (2 2/3). In general the idler roll diameter increases with increasing belt speed to limit the bearing rpms to maintain acceptable idler life. In that case the indentation rolling resistance decreases with increasing belt speed.Thirdly, the indentation rolling resistance depends on the visco-elastic properties of the belts cover material. These properties depend on the deformation rate, see Figure 2. The deformation rate in its turn depends on the size of the deformation area in the belts bottom cover (depending on belt and bulk load) and on the belt speed. In general the indentation rolling resistance increases with increasing deformation rate (and thus belt speed), but only to a relatively small account.Fourthly, the indentation rolling resistance depends on the belts bottom cover thickness. If the bottom cover thickness increases with a factor 2 then the indentation rolling resistance increases with a factor 1.26 (2 1/3). if a bottom cover is increased to account for an increase in belt wear with increasing belt speed, then the indentation rolling resistance increases as well.It should be realized that the indentation rolling resistance, although important, is not the only velocity dependent resistance. The rolling resistance of the idler rolls for example depends on the vertical load as well as on their rotational speed. The effect of the vertical load, which directly depends on the belt speed, is large. The effect of the rotational speed is much smaller. Another resistance occurs due to acceleration of the bulk solid material at the loading point. This resistance increases quadratically with an increase in belt speed assuming that the bulk material falls straight onto the belt. This will affect smaller, in plant belt conveyors in particular.3 RUBBER COMPOUNDSThe indentation rolling resistance depends on the visco-elastic properties of the belts bottom cover as discussed in the preceding section. This implies that the rolling resistance can be decreased by selecting a special low indentation rolling resistance (rubber) compound that is available on the market today. A small premium has to be paid for this special compound, but costs can be limited by applying it for the bottom cover only and using a normal wear-resistant compound for the carrying top cover. In that case turnovers are required to fully use the energy saving function of the bottom compound.A Quantitative indication of the level of indentation rolling resistance is the indentation rolling resistance indicator tan/E 1/3, where tan is the loss angle and E the storage modulus of the compound. Compounds with a reasonable indentation rolling resistance performance have indicators below 0.1. Figure 3 shows these indicators for typical medium to good performing rubbers. As can be seen in that figure, the choice for a specific rubber compound affects the energy consumption of the belt conveyor, in particular as a function of the ambient temperature.One comment (warning) must be made. A special belt with low indentation rolling resistance compound should never be selected if only one conveyor belt manufacturer offers it. In that case the conveyor system can only perform in accordance with its design specifications when that specific belt is used. It is much better, also cost wise, to specify the upper limit of the resistance indicator as given above that can be met by more than one conveyor belt manufacturer.Figure 3: Indentation rolling resistance indicators for fourdifferent rubbers as a function of temperature.CONCLUSIONIt is not easy to determine the relationship between the belt speed and the belts energy consumption. This is partly because the calculation of the indentation rolling, which forms the largest part of the rolling resistance, requests detailed knowledge of the visco-elastic properties of the used rubber compound. In addition the (unknown) velocity dependent components of the coulomb friction and seal and viscous drag of the roller bearings play an important role. Also the resistances that occur at transfer stations, in particular due to the acceleration of the bulk solid, play a role especially at high belt speeds.高速带式输送机的设计G. Lodewijks, The Netherlands. G. Lodewijks 荷兰SUMMARY摘要：This paper discusses aspects of high-speed belt conveyor design.本文论述的是高速带式输送机的设计。The capacity of a belt conveyor is determined by the belt speed given a belt width and troughing angle.带式输送机的输送能力是由带的宽度和槽角给定的带的速度决定的。然而皮Belt speed selection however is limited by practical considerations, which are discussed in this paper.带速度的选择受限于实际的考虑因素，这是本文将讨论的。皮带速度也影响输送带的工作表现，如其能量的消耗和运行的稳定性。The belt speed also affects the performance of the conveyor belt, as for example its energy consumption and the stability of its running behavior.3 ENERGY CONSUMPTION能源消耗 Clients may request a specification of the energy consumption of a conveyor system, for example quantified in terms of maximum kW-hr/ton/km, to transport the bulk solid material at the design specifications over the projected route.客户可以要求一个输送系统能源消耗的详细说明，例如设计规格超过计划规格，运输散装固体材料就要最大限度的量化条件kw-hr/ton/km。长久陆地系统For long overland systems, the energy consumption is mainly determined by the work done to overcome the indentation rolling resistance 9.，能源消耗主要取决于所做的工作，以克服压痕滚动阻力。皮带所受的阻力取决于橡胶带粘弹性（时间延迟），粘弹性的效应掩饰了托辊的压痕。作For in-plant belt conveyors, work done to overcome side resistances that occur mainly in the loading area also affects the energy consumption.为在厂的带式输送机所做的工作是克服沿边阻力，沿边阻力主要发生在负重区，也影响能源的消耗。Side resistances include the resistance due to friction on the side walls of the chute and resistance that occurs due to acceleration of the material at the loading point.沿边阻力包括溜槽壁的摩擦产生的阻力和在装料点物料的加速度产生的阻力。皮带输送机The required drive power of a belt conveyor is determined by the sum of the total frictional resistances and the total material lift.所需的驱动功率，是由摩擦阻力的总数和所要提升物料的总和决定的。The frictional resistances include hysteresis losses, which can be considered as viscous (velocity dependent) friction components.这个摩擦阻力包括滞后损耗，它可以被视为粘性（速度而定）摩擦组件。 It does not suffice to look just at the maximum required drive power to evaluate whether or not the energy consumption of a conveyor system is reasonable.它不足以仅从最大所需驱动功率来评价一个输送系统的能源消耗是否是合理的。 The best method to compare the energy consumption of different transport systems is to compare their transport efficiencies.比较不同运输系统的能源消耗，最好的方法是比较它们的运输效率等。 3.1 TRANSPORT EFFICIENCY1 运输效率 There are a number of methods to compare transport efficiencies.有许多方法来比较运输效率。The first and most widely applied method is to compare equivalent friction factors such as the DIN f factor.首先并最广泛应用的方法是比较当量摩擦因素，如按DIN F系数。利用当量摩擦系数An advantage of using an equivalent friction factor is that it can also be determined for an empty belt.的优点是，它也可以由一个空皮带确定。采用当量摩擦系数的缺点是，它不是一个纯效率数字。It takes into account the mass of the belt, reduced mass of the rollers and the mass of the transported material.考虑到皮带的大量化，就要减少了托辊的数量和运送物资的数量。In a pure efficiency number, only the mass of the transported material is taken into account.纯粹的效率高低，仅有材料的运送量，是在考虑之列。 The second method is to compare transportation cost, either in kW-hr/ton/km or in $/ton/km.第二种方法是比较运输成本，要么kw-hr/ton/km要么$/ton/km。The advantage of using the transportation cost is that this number is widely used for management purposes.比较运输成本的优点在于输送成本广泛用于管理策划。The disadvantage of using the transportation cost is that it does not directly reflect the efficiency of a system.采用运输成本的不利之处是，它没有直接地反映着一个体系的效率。The third and most pure method is to compare the loss factor of transport 10.第三种且最“纯粹的”方法是比较运输损耗因子。运输The loss factor of transport is the ratio between the drive power required to overcome frictional losses (neglecting drive efficiency and power loss/gain required to raise/lower the bulk material) and the transport work.损耗因子是驱动电源必须克服的摩擦损失（忽略传动效率和功率损耗/增益须提高/降低大宗材料）和运输工作两者的比例。The transport work is defined as the multiplication of the total transported quantity of bulk material and the average transport velocity.运输工作是被定义为原料的总运输量和平均运输速度的乘积。采用运输损耗因子的The advantage of using loss factors of transport is that they can be compared to loss factors of transport of other means of transport, like trucks and trains.好处是它们能与其他运输方式的损失因子作比较，如卡车和火车。The disadvantage is that the loss factor of transport depends on the transported quantity of material, which implies that it can not be determined for an empty belt conveyor.缺点是运输损耗因子依赖于材料的运输量，这意味着它不能被一个空载的带式输送机决定。 3.2 INDENTATION ROLLING RESISTANCE2 压痕滚动阻力 For long overland systems, the energy consumption is mainly determined by the work done to overcome the indentation rolling resistance.长期陆路系统，能源消耗主要取决于所做的工作，以克服压痕滚动阻力。 Idler rolls are made of a relatively hard material like steel or aluminum whereas conveyor belt covers are made of much softer materials like rubber or PVC.托辊是由比较硬质的材料制成，如钢或铝，而输送带由许多柔软材料做成，如橡胶或PVC 。The rolls therefore indent the belts bottom-cover when the belt moves over the idler rolls, due to the weight of the belt and bulk material on the belt.因此当皮带在托辊上运动时，辊子就缩进在皮带的下面，这取决于在皮带上的皮带和散装物料的重量。皮带下层的压缩部分的The recovery of the compressed parts of the belts bottom cover will take some time due to its visco-elastic (time dependent) properties.回弹，将需要一些时间，由于其粘弹性（时间依赖性）的性能。皮带下层弹复The time delay in the recovery of the belts bottom cover results in an asymmetrical stress distribution between the belt and the rolls, see Figure 2.时间的延迟导致了带和托辊间应力的不对称分布，见图1 。This yields a resultant resistance force called the indentation rolling resistance force.这个产生抵抗的力量称为压痕滚动阻力。The magnitude of this force depends on the visco-elastic properties of the cover material, the radius of the idler roll, the vertical force due to the weight of the belt and the bulk solid material, and the radius of curvature of the belt in curves in the vertical plane.这股力量的大小，依赖于皮带下层材料的粘弹性性能、托辊的半径和压力，压力取决于皮带和散装固体物质的重量，以及在垂直面内变形部分的曲率半径。 Figure 2: Asymmetric stress distribution between belt and roll 7.图1 皮带和辊之间的不对称应力分布It is important to know how the indentation rolling resistance depends on the belt velocity to enable selection of a proper belt vel重要的是要知道压痕滚动阻力是如何取决于皮带速度，以便选择一个适当的带速。Firstly, the indentation rolling resistance depends on the vertical load on the belt, which is the sum of the belt and the bulk material weight.首先，压痕滚动阻力取决于皮带上的垂直载荷，这个载荷是由带和散装材料的重量的总和产生的。 If the vertical load on the belt decreases with a factor 2 then the indentation rolling resistance decreases with a factor 2.52 (2 4/3).如果垂直载荷对带减少一个因子2 ，压痕滚动阻力就减小一个因子2.52（ 2 4 / 3 ）。假设恒容量，The bulk load decreases with increasing belt speed assuming a constant capacity.部分负荷减少于带速的增加。 Therefore, the indentation rolling resistance decreases more than proportionally with increasing belt speed.因此，压痕滚动阻力减少的比例比带速的增加要多。 Secondly, the indentation rolling resistance depends on the size of the idler rolls.其次，压痕滚动阻力取决于托辊的尺寸。 If the roll diameter increases with a factor 2 then the indentation rolling resistance decreases with a factor 1.58 (2 2/3).如果托辊直径增大的一个因子2，压痕滚动阻力就减小的一个因子1.58 （ 2 2 / 3 ）。In general the idler roll diameter increases with increasing belt speed to limit the bearing rpms to maintain acceptable idler life.一般托辊直径随带速的增大而增大，以限制轴承的转速，保持可接受的托辊寿命。 In that case the indentation rolling resistance decreases with increasing belt speed.在此情况下，压痕滚动阻力随带速的增加而减小。 Thirdly, the indentation rolling resistance depends on the visco-elastic properties of the belts cover material.第三，压痕滚动阻力取决于皮带覆盖材料的粘弹性性能。 These properties depend on the deformation rate, see Figure 3.这些性能在很大程度上依赖于变形速度，见图2 。皮带往复运行的The deformation rate in its turn depends on the size of the deformation area in the belts bottom cover (depending on belt and bulk load) and on the belt speed.变形速度又取决于在皮带下层（取决于皮带及散装负载）变形区的规模和皮带速度。In general the indentation rolling resistance increases with increasing deformation rate (and thus belt speed), but only to a relatively small account.一般压痕滚动阻力随变形速度（因而带速）的增加而增加， 但相对来说仅仅是一小部分。 Figure 3: Loss factor (tanb) of typical cover rubber 7图2 典型橡胶层的损耗因子Fourthly, the indentation rolling resistance depends on the belts bottom cover thickness.第四，压痕滚动阻力取决于皮带下层的厚度。 If the bottom cover thickness increases with a factor 2 then the indentation rolling resistance increases with a factor 1.26 (2 1/3).如果下层厚度增大一个因子2，则压痕滚动阻力就增大一个因子1.26（ 2 1 / 3 ）。if a bottom cover is increased to account for an increase in belt wear with increasing belt speed, then the indentation rolling resistance increases as well.如果皮带下层宽度的增加并提高输送速度，则压痕滚动阻力也会有所增加。 It should be realized that the indentation rolling resistance, although important, is not the only velocity dependent resistance.应当看到，压痕滚动阻力虽然重要但不是速度唯一取决于的阻力。 就托辊的The rolling resistance of the idler rolls for example depends on the vertical load as well as on their rotational speed.滚动阻力举例来说，滚动阻力取决于竖向荷载以及其转速。The effect of the vertical load, which directly depends on the belt speed, is large.垂直载荷的影响直接取决于皮带速度，影响是大的。 相比之下，The effect of the rotational speed is much smaller.转速的影响是小多了。 Another resistance occurs due to acceleration of the bulk solid material at the loading point.另一阻力是在装载处由于散装固体物质下落产生的加速度产生的。假定该散装物料直线落在皮带上，This resistance increases quadratically with an increase in belt speed assuming that the bulk material falls straight onto the belt.这种阻力的增加是带速增加的二次方。This will affect smaller, in plant belt conveyors in particular.这影响也是较小的，尤其是输送木板类的带式输送机。 3.3 RUBBER COMPOUNDS3 橡胶化合物 作为之前部分的讨论，The indentation rolling resistance depends on the visco-elastic properties of the belts bottom cover as discussed in the preceding section.压痕滚动阻力取决于皮带下层的粘弹性性能。 This implies that the rolling resistance can be decreased by selecting a special low i
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