Conveyor Dynamic Analysis

Helix
Technologies

delta-T6
Copyright, 1991-2015 © Helix Technologies Pty Ltd
Introduction

• Helix Technologies was established in 1991 and

Helix software has been exported to more than 25
countries around the world.
• Engineering Software - Conveyor Design and Pipe
Design software
• delta-T5 Static or Rigid body design software.
• Market Research showed need for a Conveyor
Dynamic Analysis program.
Research into Dynamic
Analysis since 1999
• Various sources such as Bulk Solids Handling by
TransTech Publications
• Engineering Journals and Doctoral Thesis.
• Libraries incl. Delft, Hannover UNI
• Mathematical Skills Required.
• Consultant - Dr Michael Fisher, Assoc. Professor of
Mathematics at UWA.
Mathematical Model

mi V  Ti 1 t   Ti t   mi g sin   Wi t   Fm
.

• Kelvin solid model

Delta-T5 Dynamic Analysis
module
• Uses ‘Static’ Calculation model to capture conveyor
geometry, equipment sizes, power ratings etc.
• Additional ‘Dynamic data’ input - Belt modulus,
Spring Constant, Delay times and Damping factors.
• Drive Torque Control vs Speed Control Input
• Operating conditions - Starting, Stopping Loading
• Boundary Conditions can be changed by user - not
hard coded into program
Dynamic Data Input

• Simple parameters required

• Belt Modulus
• Program Calculates Spring Constant, delay time Tau
• Enter Calculation Run time in seconds
• Choose Starting / Stopping Condition
Dynamic Data Input Form

• Belt Modulus
• Calculate Delay Time
• Select Operating
Condition
• Press Calculate
Torque Speed Curve

• Program allows user to input any profile

• Can model DOL, Fluid Coupling, Wound Rotor Motor, VVVF, Variable
Speed Drives
Wound Rotor Motor Curve

Resistors are switched to control Starting

torque between 150% and 110% in this case

• Example of Wound Rotor Motor profile

Speed Control / Regenerative Conveyors

• Aborted Start
can be modelled

Regenerative Load

• Torque Speed curve needs to be extended beyond the 100%

Full load Speed %
• Tension waves tend to force drive over design speed
• Motor acts as brake beyond synchronous speed
Drive Speed vs Time curves

• Enter any Time speed relationship

‘S’ Curve Velocity Ramp

 t2  T
vt   V   1  4  2 2 ,  t  T
t •S curve
 T T  2

•Any function
 2t
2

vt   V  2
T
,0  t 
T  2
•Paste from Excel

• You can add any shape Velocity Ramp for Drive Pulley
• Includes ‘S’ curves, Linear ramp, Dwell periods
Multiple Drives / Delay Times

• Any Number of Drives can be modelled

• Each Drive can have different starting curves
• Delay times can be added
• Aborted Start can be modelled
Dynamic Calculation

• Calculation Run time depends on conveyor

• Typically 60,000 calculation results each for Velocities,
Tensions, Strains
• 2 seconds up to 20 minutes on Pentium 4/2.4GHz PC
• Stiff belt (high modulus) lightly loaded is worst case
• Variable Step Runge Kutta adjusts calculation to requirements
• Progress form indicates progress
• Cancel Calculation button
Summary of Dynamic Calculation
Procedure
Run 2
• Data Input - simple and easy to use
sample
• Drive Torques vs Speed relationships. calculations
• Drive Speed vs Time Ramp
• Delay Times on Multiple Drives.
• Dynamic Calculations.
• Graphic Presentation
• Print & Export Reports to Word, PDF etc.
Calculation Examples

• Level Conveyor Starting

• Level Conveyor Stopping
• Inclined Conveyor Stopping
• Holdback Tensions
• Compare Torque Control Start vs Speed
Control Start
Example Level CV 01

• 2600m long level

• 3,500 tph
• ST1600 x 1,200 wide belt
• 945 kW installed power
• Dual Drives 130% FLT
• Brake at Tail
CV 01 Drive Torque

• Wound Rotor Motor on all 3 drives

CV 01 Belt Velocities

• Final Speed is
regulated by
Torque Speed
Curve
• Variable Speed
Conveyors can be
modelled by
reducing speed %
CV 01 Belt Velocity Zoomed in
CV 01 Belt Tensions

• Note tension oscillations

during starting
• Caused by Wound Rotor
motor steps
CV 01 Static Calc Tensions

• Rigid body calcs shows max T = 374 kN

• Dynamic calcs show max T = 474 kN
CV 01 Belt Tensions 3D

• Note Tension steps at primary and secondary drives

CV 01 Belt Tensions 3D

• Same graph rotated to different angle

CV 01 Takeup Travel
 CV 01 Stopping - Velocities

• Stops in about 14 seconds - rigid body calcs = 10.59 seconds

CV 01 Stopping - Tensions

• Note belt slip when slack side tension drops

CV 01 Stopping - Tensions 3D

• Note peak tension after brake

CV 01 Stopping - Tensions 3D Rotated

• Note low tensions

before drives
CV 01 Stopping - Tensions 2D

• Low tension point

identified from 3D
graph and plotted in 2D
Inclined Conveyor Starting 3 Drives

• 2900m long 500m lift

• Wound Rotor motors
starting 130% FLT
• Empty belt absorbed
power is only 225 kW
• Conveyor starts very
quickly

• 3 x 630 kW drives - starting empty

• Large Tension waves force drive over speed - destructive
Inclined Conveyor Starting 1 Drive

• Secondary Drive Starts

conveyor
• Primary Drive has delay
time starting empty
• Reduced tension waves
• Equipment operating
within design limits

• 1 x 630 kW secondary drive - starting empty

Inclined Conveyor Tensions 1 Drive
starting

• Starting Secondary Drive

• Reduced tension waves
• Still significant waves
• Beware High lift conveyors
starting empty
Level - Inclined Holdback Example CV 03

• 1000m long 50m lift

• 710 kW installed
• 2,500 tph
• 1500mm wide class
2000/5 ply fabric belt
• Effect of Holdback on Belt
velocities and tensions
CV 03 Stopping Belt Velocities -
no holdback

• Holdback not fitted

• Drive Velocity drops
quickly
• Tail velocity steady
and then drops
• Both slow to zero in
about 7.5 seconds
• Belt starts to run
backwards
• Indicated by
negative velocities
CV 03 Stopping Belt Tensions - no
holdback

• Holdback not fitted

• Drive Tension drops
quickly as Torque is
removed
• Tensions decay and
settle at equilibrium
CV 03 Stopping Belt Velocities - with
holdback

• Holdback fitted
• Drive Velocity drops
quickly
• Tail velocity steady
and then drops
• Drive drops to zero
and is prevented
from running
backwards
• Tail reverses
momentarily and
then stops
CV 03 Stopping Belt Tensions -
with holdback

• Holdback fitted
• Drive Tension drops
quickly as Torque is
removed
• Tensions decay
• After drive stops
Tension increases as
Holdback activates
• Required Holdback
Tension can be read
from graph
• Peak and Steady
Holdback Tension
shown
Declined CV 04 Example

• 1590m long 77m lower

• 250 kW Tail Drive
• 2,500 tph 3m/s coal
• 1600mm wide class
1250/4 ply fabric belt
• Effect of Holdback on
Belt velocities and
tensions
• Takeup before tail drive
• Brake on tail drive
Declined CV 04 Belt Velocities

• VSD Start
• High Velocity
at Head
Declined CV 04 Belt Tensions

• VSD Controlled Start

• Tension Rise as Drive
begins to act as a brake
• Red line = into drive
• Yellow line = out of drive
Declined CV 04 Belt Tensions 3D

• VSD Controlled Start

• Tension Rise as Drive
begins to act as a brake
Declined CV 04 Brake Released

• Belt Velocities
• Brake Released on Fully
Loaded Conveyor
• Takes 23 seconds for Drive
to reach design speed of
3m/s
Declined CV 04 Stopping

• Belt Velocities
• Brake at Tail
• About 30 seconds to stop (average)
• Rigid body calcs = 29.76 seconds
Declined CV 04 Brake Tensions

• Red Line = Into Brake

(Slack Side)
• Yellow Line = Out of Brake
(Tight Side)
• Steady state clamping
force is shown
Torque Control vs Speed Control

• 1000m long level CV

• 250 kW Drive
• 2,500 tph 5.2 m/s coal
• 1200mm wide class
500/5 ply fabric belt
• 140% FLT Torque
Controlled Start 30
seconds to start

OR
• 30 second ‘S’ curve
velocity ramp

• Which is best ?
Speed Control Belt Velocities
Speed Control Belt Tensions

• 168 kN max tension

Torque Control Belt Velocities

• Velocity fluctuates
with tension waves
Torque Control Belt Tensions 2D

• 112 kN max tension

Speed Control 3d Tensions

• Torque Control is better for this conveyor -

each CV is different
Dynamic Program Verification
• Uses proven delta-T software as basis for capturing data,
equipment sizing and basic conveyor design
• Dynamic calculations have been verified against Matlab results
• Comparison of results against many published papers e.g Muja
Conveyor etc.
• Results depend on input data, method of calculation employed
e.g some published results do not use Torque control, only
Speed control because it is easier to program and solve
• delta-T uses instantaneous f factor, variable drive torque & has
flexible design options so can be matched to any conveyor
• Ongoing process of verification with our customers
Operating System Requirements -
Delta-T5 Dynamic Version

• Stand alone program - no 3rd party software

required
• Requires Windows 32 bit OS i.e Windows 98, 2000,
XP
• Pentium 4 x 2.4 GHz with 512 Mb RAM and
1024x768 SVGA recommended
• Competent Conveyor Design Engineer
Marketing of delta-T5 Dynamic Program

• Program Licences will be sold as a complete

package
• Includes full rigid body version of delta-T
• Training to be integral part of sale
• Software support and upgrades are available
• Price of software not yet determined - target is to
get it down to between $15,000 to $20,000
Close
• Helix aimed to produce a flexible, powerful design
program which can be used by experienced
conveyor design engineers
Acknowledgements
• Dr Michael Fisher
• Dave Beckley
• Dr Lloyd Townley Helix
Technologies
• All previous publishers of papers
delta-T5
Copyright, 1991-2003 © Helix Technologies Pty Ltd