Linyit kömür taşıyan bantlı konveyörün tasarımı, analizi ve kontrolü

Abstract

Bugün endüstride işletme ekonomisine en fazla etki eden faktörlerden biri malzeme iletimidir. Bantlı konveyörler, sürekli malzeme iletiminde bir çok uygulama alanları içinde en elverişli sistemi oluştururlar. Erişilebilen yüksek taşıma kapasitesi, uzun mesafelere yük taşıma yeteneği, transport yolunun kavisli olabilmesi, basit tasarım, hafif yapı, güvenilir işletme gibi özellikler bantlı konveyörleri en çok kullanılan transport makinası durumuna getirmiştir. aşınan malzemeler kuru veya ıslak, pülverize hububatta olduğu gibi tane veya kömürde olduğu gibi parça halinde olabilir. Endüstride yaygın olarak kullanılmasını sebebi yüklü miktarlarda malzeme iletimidir. Bantlı konveyörler, sürekli malzeme iletiminde bir çok uygulama alanları içinde en elverişli sistemi oluştururlar. Yüksek kapasitede taşıma yeteneği, uzun mesafelere malzeme taşıma yeteneği, basit tasarım, hafif yapı, güvenilir işletme gibi özellikler bantlı konveyörleri en çok kullanılan transport makinası durumuna getirmiştir. Aşınan malzemeler kuru veya ıslak, pülverize hububatta olduğu gibi tane veya kömürde olduğu gibi parça halinde olabilir. Bu çalışmada, 500 metre uzaklığa linyit kömürü taşıyan pnömatik gergi kontrollu bantlı konveyör çalışılmıştır. Bantlı Konveyörün 3D modellemesi Unigrafics® programı kullanılarak yapılmış olup, bantlı konveyör üzerinde belli kısımların Hypermesh® programı kullanılarak gerilme hesabı yapılmıştır. 3D tasarım matematik hesaplar ile doğrulanmıştır. Sonuç olarak bant germe sistemi üzerine yeni yaklaşım getirilmiştir. Bantlı konveyörlerde, bant germe operasyonu genellikle karşı ağırlık veya vidalı mekanizmalar sayesinde uygulanmaktadır. Tasarlanmış olan bu konveyörün en büyük farkı; gerilme sistemin pnömatik mekanizmaya sahip olmasıdır. İlaveten germe mekanizması pnömatik sistem sayesinde bantı yukarıya doğru veya aşağıya doğru sıkıştırabilmektedir. Bu sayede germe rulosu hem kendi ekseni etrafında dönebilmekte olup, hem de yukarı aşağı hareket edebilmektedir.

Transport of materials is a major topic in industrial areas. Belt conveyor systems are mostly used in the transport of continuous materials. Properties of the transport machines include; • Obtaining high transport capacities, • Transporting to materials distance places, • Having radius in belt conveyor systems, • Easy design, • Lightweight structure, Wearing materials may be wed or dry as pulverizing grain or maybe component type as coal. The repute of belt conveyor systems comes from its easy application with design and project examples. Additionally, its popularity depends on its savings in the field of time, place, and money. Besides, goods are handled in very hard conditions with developing belt conveyor systems. In this research, pneumatic tension controlled belt conveyor system with a length of 500 meters has been studied. 3D modeling of this conveyor system has been performed using the Unigraphics® program and stress calculation of certain areas on the conveyor has been made using the Hypermesh® program. The present 3D design has been verified with mathematical calculations. Belt tensioning operation in belt conveyors has generally performed thanks to a system with screw mounted on main drive roll or made with a counterweight system. The greatest difference of this designed conveyor is that its tensioning system has been made using a pneumatic system. Additionally, the tensioning mechanism can jam the belt by moving upwards and downwards on a rail system thanks to the pneumatic system. By this means, the tensioning roll can rotate around it's own axis and can also move upwards and downwards. Generally, components of the belt conveyors systems include the following systems; • Materials transporting belt system • Upper and lower rolls • Excitation and diversion pulleys and conveyor driving systems • Tensioning systems • Assistant components In the estimation of belt width, the major factors are transporting materials size and flowability properties of the materials. Because of these factors, belt width is generally obtained from charts. But, this is just an initial thing and if the speed of the belt system is lower than the maximum allowable speed, then it will be taken as a real value for the belt width. The diameter, length, and also weight of the upper and lower rollers are obtained because of belt width from the related charts. After, spacing between the upper rollers is obtained because of belt width and bulk density of the material from the related charts. Additionally, the spacing of upper rollers at the loading section of the conveyor is taken as half of the normal value. Spacing of lower rollers is taken as 2 times the spacing of upper rollers. The Belt conveyor model was transferred to Hypermesh® to run the belt conveyor. Generally, The run analysis in this dissertation is the static analysis and inertia relief analysis. After this, the related model was being meshed and then properties of the materials used in the belt conveyor system were assigned.Gradually, contact and contact types were determined. All limitation was assigned and also applied for obtaining the last result of all of the conditions. Belt conveyor systems can have a mechanical or counterweighted like elevator system. The greatest difference of this designed conveyor is that its tensioning system has been made using a pneumatic system. Additionally, the tensioning mechanism can jam the belt by moving upwards and downwards on a rail system thanks to the pneumatic system. By this means, the tensioning roll can rotate around it's own axis and can also move upwards and downwards. Later, the purpose of the belt conveyor was expressed, and also a belt conveyor which has 1 m/s velocity, 500 t/h capacity, and 500 meters horizontal length was projected with charts to carry lignite coal. Conveyor belt system may be arranged and constructed if the following information is related to the capacity limitation, properties of the material, which would be conveyed, a form of material, bulk density of the material to be transferred, transferring height, and method of feeding. Parameters related to this information are required to obtain the drive power at the selected belt speed.A higher belt speed results in every case in lower belt tensions and in most cases a narrow belt. When we compare between analytical calculations and finite element method for pulleys and pulleys' shafts were made, seems to what critical analysis made. After the comparison, the conclusion didn't match with each other for the rear pulleys and pulleys' shafts. This represents analytical calculations is incapable to determine all type of stresses but a certain percentage of the accuracy obtained. According to a conclusion, some suggestions were given in the conclusion. In this dissertation, conventional belt conveyor system; Design of the belt conveyor system is not related to the conventional belt conveyor system and is also aimed at the original belt conveyor design. The design criteria of the belt conveyor system are as below. • Terms of manufacturability compliance, • Easy assembly and disassembly structure, • Maintenance cost, • Ergonomic suitability, • Designing symmetrical parts, • Pneumatic drive tensioning system. Consequently, a novel approach has been exhibited on design and belt tensioning.