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Article history: The effect of impact loading at the transfer point is often manifested by mechanical damage to a conveyor
Received 25 July 2017 belt. To describe the phenomena related to the conveyor belt damage caused by the impact of the
Received in revised form 17 August 2018 material, it is important to monitor the amount of the absorbed impact energy. Therefore, the focus of
Accepted 1 September 2018
the present article is on the identification of the effect of the conveyor belt’s structure (textile or steel
Available online 6 September 2018
conveyor belt carcass), as well as the strength, the material’s drop height and the drop weight on the rel-
ative amount of impact energy absorbed by a conveyor belt. The result of the article is determining the
Keywords:
capabilities of different conveyer belts through the monitoring and the identification of the relationship
Rubber-textile conveyor belt
Steel-cord conveyor belt
between the relative amount of the absorbed energy and the selected parameters.
Puncture resistance Ó 2018 Elsevier Ltd. All rights reserved.
Absorbed energy
https://doi.org/10.1016/j.measurement.2018.09.003
0263-2241/Ó 2018 Elsevier Ltd. All rights reserved.
A. Grincova et al. / Measurement 131 (2019) 362–371 363
The FEM method was also used in the monitoring of conveyor lel to the results for the double idler configuration (with a slight
belt damage and in the determination of the conditions in which deviation) and that is proportional to the length of the product
damage to the cover layer of the conveyor belt occurs [13]. Bajda flight. Halepoto [24] proposed a mathematical model for an
[14] presented the results of tests which allow defining the influ- energy-efficient conveyor system with the variable speed drive
ence of the conveyor belt design on the belt’s wear and tear, in par- (VSD). The proposed system would optimally switch a conveyor
ticular with regard to punctures. In this test, a belt’s puncture system to the on/idle/off status to minimise the energy consump-
resistance was determined by using a method based on calculating tion of the conveyor belt. An examination of the friction and sur-
the mean impact energy and the critical energy. The authors of face energy properties of belt conveyors was dealt with by [21].
another study, Bajda, Blazej and Jurdziak [15], described a new tool In this case, the friction at the interface of the raw material and
in determining a belt’s resistance to punctures. Their research was the belt cover layer was tested using the standard inclined-plane
carried out with a newly-developed high resolution magnetic diag- method, and the adhesion and stickiness were evaluated by deter-
nostic device intended for the assessment of the condition of steel mining the surface-free energies of the belt cover layer and the
cord conveyor belts. In addition to monitoring the belts during wood-plastic composites (WPCs) at temperatures of 23 and
their use on the conveyors, this device can be used as a new tool 100 °C. On the basis of these measurements, the authors investi-
in belt puncture investigations. Qiao et al. [16] monitored the lon- gated the key aspects of selecting the belt cover material and pro-
gitudinal tearing of conveyor belts while applying the method of posed a conveyor belt configuration for a prototype post-extrusion
Integrative Binocular Vision Detection (IBVD). The longitudinal process line.
tears on conveyor belts were also investigated by Binchao et al.
[17]. In order to detect the longitudinal tears, they applied the 2. Material and methods
method of Dual Band Infrared Detection (DBID) that is based on
a combination of mid-infrared and long infrared vision. The 2.1. Problem formulation
dynamic deformations of the conveyor belts were tested using a
specifically engineered testing machine, by the authors of the work The impact of transported material onto a conveyor belt often
and the results were described in their paper [18]. In this case, the causes damage that is classified as a puncture. This kind of damage
authors compared the experimental approach based on the pho- simultaneously affects the top cover layer, the carcass and the bot-
togrammetry technique with a model created by the FEM and tom cover layer of a conveyor belt. This kind of damage occurs
DEM methods. when a conveyor belt’s capacity to absorb the impact energy of
Authors Ilic and Wheeler [11] compared the results of labora- the material falling onto it is surpassed. In this article, we will
tory experiments and simulation of interactions between the num- examine how much energy a conveyor belt is able to absorb before
ber of bulk solid materials and the belt sag ratios, where the such damage will occur. The amount of the absorbed energy will be
outcomes led to improved methods of calculating the optimal expressed in relative terms, or as a percentage. The absorption of
loads on conveyor idler rolls and increasing the accuracy in pre- the impact energy also partially represents some damage to the
dicting the energy loss due to the bulk solid flexure. Zhang [12] internal and external structure of a conveyor belt.
describe the options for improving the energy efficiency of belt
conveyors that can be achieved at the level of the equipment and 2.2. Conveyor belts
the operation processes. An analytical energy model was designed
in compliance with the ISO 5048 standard. Off-line and an on-line There are several types of belts that are currently used on con-
parameter estimation schemes were also applied to identify the veyer systems. From a constructional point of view, the belt cate-
new energy model. Furthermore, a parametric energy model for gorisation depends on the carcass type, the covering method, the
energy management is proposed by Mathaba [5] for long belt material covering the carcass, the surface finishing, etc. The basic
conveyors. structural elements of a conveyor belt include the carcass (textile,
Another group of experts examined the energy losses occurring steel) and the cover layers, the thickness of which is affected by the
during the transportation of materials by belt conveyor systems. properties of the material being transported.
This was determined as a function of: the CB structure [19,20] The most frequently-used conveyor belts include rubber-textile
and the cover layer category [21], as well as the support system (Fig. 1) and steel-cord conveyor belts (Fig. 2). A carcass of a rubber-
structure [22,23] and the belt conveyor drive [18]. The authors of textile conveyor belt consists of one or more textile plies while the
the paper [20] dealt with the foundation and the parameter iden- carcass is reinforced with various types of natural or synthetic
tification of a rubber belt non-linear restoration model, while fibres. The carcass of steel-cord conveyor belt consists of steel
applying the second-order Fourier series. The results of the neural cords in various diameters and strengths.
network were then tested by experiments. These results may serve
as a theoretical basis for the development of an energy-saving rub- 2.3. Testing device
ber belt. Chen [19] simulated the cores of rubber belts with wire
ropes, where the properties of pressure resistance in the St2000 The experimental measurements were carried out using a test-
type of conveyor belt were researched. The authors created a sim- ing device intended for testing the puncture resistance of conveyer
ulation to serve as the basis for calculating the energy dissipation
of rubber conveyor belts. Qiu and Chai [22] analysed the energy
losses in conveyor systems caused by the indentation of the idler
into the rubber cover of the belt, and they proposed a model which
will be useful for the designing and optimisation of the energy con-
sumption in conveyor systems. In the model, in addition to the
energy losses with respect to the inlet provisions, accelerations
and the intake, as well as the resistance of the pulleys, scrapers
and the bending resistance of the rubber belt, we have to add other
factors, according to Brands [23]. This includes the resistance per
metre, as mentioned below, which has a greater influence the
longer the belt is, and the value of the impact load that runs paral- Fig. 1. Rubber-textile conveyor belt.
364 A. Grincova et al. / Measurement 131 (2019) 362–371
Ep1 Ep2
Erelat ¼ 100½% ð6Þ
The testing was carried out using a pyramidal impactor (Fig. 7), Ep1
which simulated the impact of a sharp-edged material. When we apply this method, we can determine what portion
(percentage) of the initial impact energy the conveyor belt is able
3. Theory/calculation to absorb. This portion of the initial impact energy can be further
designated as the relative amount of the absorbed energy.
3.1. Physical fundamentals In the relation (2) used for the calculation of the energy Ep ; the
weight m and the gravitational acceleration g are constants. There-
The amount of impact energy caused by the impact of the mate- fore, after the modification of the relation (5) we will get
rial onto a conveyor belt may be expressed as the amount of kinetic
mgh1 mgh2 h1 h2
energy Ek of an object with the weight m, with the velocity right Erelat ¼ ¼ ð7Þ
mgh1 h1
before the impact v . If we neglect the impact of the environment
(environmental resistance) and apply the law of the conservation It is evident that if we express the relative amount of the
of mechanical energy, then the amount of kinetic energy Ek of absorbed energy using the relation (7) at a random drop height,
the object right before the impact we will always reach the theoretical maximum value 1.
1
Ek ¼ mv 2 ð1Þ 3.2. Model formation
2
can be substituted by the amount of the potential energy Ep The relation between the explained (dependent) variable andthe
and the k-explanatory (independent) variables X j ; where
Ep ¼ mgh ð2Þ j ¼ 1; 2; . . . ; k; can be expressed by the following mathematical
of the object with the weight m, falling from the height h, where model:
g ¼ 9:81 m.s2 is the gravitational acceleration. The following Y ¼ f ðX; bÞ þ e; ð8Þ
applies:
where Y is the vector of the values of the explained variable Y; X is
1
Ek ¼ mv 2 ¼ mgh ¼ Ep ð3Þ the matrix of the values of explanatory variables Xj, where
2
A conveyor belt structure and the properties of the material
from which the conveyor belt is manufactured will result in a sub-
sequent bouncing of the material off the conveyor belt. If we
neglect the impact of the environment and we know the height
j ¼ 1; 2; . . . ; k; b is the vector of the model parameters, f(X,b) is the 4.1. Determination of the relative amount of absorbed energy and the
regression function, and e is the vector of the accidental errors. impact of the selected parameters
In our case, we will consider the linear regression model in the
following matrix form: Figs. 11 and 12 (resp. Figs. 13 and 14) illustrate examples of the
relative amount of absorbed energy after the first impact (resp. the
Y ¼ Xb þ e ð9Þ second impact) of the drop hammer onto the conveyor belt at all
The verification of the statistical significance of the model was the tested drop weights, where only four drop heights are used
carried out using the F-test of the statistical significance. The sta- for the purpose of clarity. The relative amount of absorbed energy
tistical significance of the regression model parameters was veri- was determined using the relation (7).
fied by applying the test of the statistical significance of the At each drop weight, falls from seven different drop heights
regression parameter. The measure of strength of the relationship were simulated. The differences between the obtained relative
between the variable Y and the joint effect of the k variables is amounts of the absorbed energy were minimal.
expressed by the multiple coefficient of determination R2. The mean values of the relative amounts of absorbed energy
after the first and second impacts of the drop hammer onto the
conveyor belt are indicated in Table 1.
4. Result The impact of the strength of the belt on the relative amount of
absorbed impact energy was significant in the case of the rubber-
The experimental tests were carried out with two types of textile conveyor belts (Fig. 9). At a strength of 2500 N.mm1, the
rubber-textile conveyor belts, P1250 and P2500, and for two types rubber-textile conveyor belt was able to absorb after the first
of steel-cord conveyor belts, ST1250 and ST2500. The input param- impact of the drop hammer approximately 40–50% of the impact
eters were the weight m of the falling material and the drop height energy. At a strength of 1250 N.mm1, the belt was able to absorb
h. The objectives of the experimental research were to: as much as 60–70% of the impact energy. However, the impact of
the strength on the relative amount of absorbed impact energy
identify the relative amount of the absorbed energy for both in the case of the steel-cord conveyor belts was negligible
conveyor belt types (P, ST) and to determine the impact of the (Fig. 10). At a strength of 2500 N.mm1, the steel-cord conveyor
parameters (conveyor belt strength, structure, drop weight, belt was able to absorb approximately 70–85% of the impact
drop height) on the relative amount of the absorbed energy; energy; while at a strength of 1250 N.mm1, the belt was able to
and absorb approximately 73–85% of the impact energy. These values
determine a model of the relationship between the relative were comparable for both belts. The results for the second impact
amount of the absorbed energy and the selected parameters. of the drop hammer onto the conveyor belt were similar (Figs. 11
and 12).
The real data of the measured heights with the time when the The impact of the conveyor belt structure on the relative
drop hammer impacted the conveyor belt (with a certain weight amount of the absorbed impact energy is evident: the rubber-
and at a certain drop height) is shown in Figs. 9 and 10. The graphs textile conveyor belts with determined properties were able to
were created for all four tested conveyor belt types. In the case of absorb a smaller relative amount of impact energy than the
the steel-cord conveyer belt, a puncture occurred with the drop steel-cord conveyor belts with the same properties.
hammer of 90 kg and a drop height of 1.8 m or higher. On the basis of an analysis of all the resulting values, we can
In the next part, we monitored only the first and the second state that with a growing drop weight (and also with a growing
impact of the drop hammer onto the conveyor belt.
Fig. 11. Relative amount of absorbed energy (first impact, rubber-textile conveyor belt).
drop height) the relative amount of the absorbed impact energy where b0 and bj for j ¼ 1; 2; . . . ; k are the model parameters, Y is the
decreases in the majority of cases. observed value of the explained variable Y; X j ;j ¼ 1; 2; . . . ; k; are the
k-explanatory (independent) variables, and e is the accidental error.
4.2. Creation of a model of the relationship between the relative First, we monitored the impact of the weight of the falling
amount of absorbed energy and the selected parameters material m and the drop height h on the relative amount of the
absorbed energy during the first and the second impact of the
We will consider the following conventional linear regression drop hammer onto the conveyor belt. For all the examined con-
model veyor belts, the point estimate of the regression model was as
X
k follows
Y ¼ b0 þ bj X j þ e; ð10Þ Y ¼ b0 þ b1 X 1 þ b2 X 2 or Erelat ¼ b0 þ b1 h þ b2 m ð11Þ
j¼1
368 A. Grincova et al. / Measurement 131 (2019) 362–371
Fig. 12. Relative amount of absorbed energy (first impact, steel-cord conveyor belt).
Fig. 13. Relative amount of absorbed energy (second impact, rubber-textile conveyor belt).
where b0 ; b1 and b2 are the point estimates of the model parame- Erelat ¼ b0 þ b1 h þ b2 m þ b3 CB þ b4 S ð12Þ
ters, whereas Y ¼ Erelat ; and X 2 ¼ m. The point estimates of the
The CB variable is a dichotomous qualitative variable, trans-
parameters, their statistical significance, the significance of the
formed into a numerical variable with a permutation of 1 for a
model and the coefficient of determination are listed in Tables 2
rubber-textile conveyor belt and with a permutation of 0 for a
and 3.
steel-cord conveyor belt. The S variable represents the conveyor
The regression models and the model parameters were statisti-
belt strength [N.mm1].
cally significant in all the cases (p-value < a).
The point estimates of the parameters, the significance of the
The regression model, expressing the relationship between the
model and the coefficient of determination are listed in Table 4.
relative absorption of the potential energy and the drop hammer
It was found that the regression models and the model parameters
weight (m), the drop height (h), the conveyor belt type (rubber-
were statistically significant.
textile, steel-cord), and the conveyor belt strength (S) is as follows:
A. Grincova et al. / Measurement 131 (2019) 362–371 369
Fig. 14. Relative amount of absorbed energy (second impact, steel-cord conveyer belt).
Table 1
Relative amount of absorbed energy – Interval within the whole range of the drop hammer heights.
50 kg 60 kg 70 kg 80 kg 90 kg
P2500
First impact 0.51 0.46 0.45 0.42 0.41
Second impact 0.49 0.45 0.43 0.41 0.39
P1250
First impact 0.67 0.67 0.65 0.65 0.64
Second impact 0.71 0.66 0.65 0.63 0.61
ST2500
First impact 0.78 0.75 0.75 0.74 0.74
Second impact 0.83 0.77 0.75 0.72 0.71
ST1250
First impact 0.80 0.79 0.78 0.78 0.78
Second impact 0.90 0.87 0.88 0.78 0.80
Table 2
Point estimate of the model parameters – first impact of the drop hammer (a = 0.05).
b0 b1 b2 R2 p-value
P2500
value 0.611 0.011 0.003 0.911 <<0.0001
p-value <0.0001 0.018 <0.0001
P1250
value 0.836 0.026 0.002 0.924 <<0.0001
p-value <0.0001 <0.0001 <0.0001
ST2500
value 0.986 0.033 0.003 0.933 <<0.0001
p-value <0.0001 <0.0001 <0.0001
ST1250
value 1.022 0.046 0.003 0.935 <<0.0001
p-value <0.0001 <0.0001 <0.0001
Table 3
Point estimate of the model parameters – Second impact of the drop hammer (a = 0.05).
b0 b1 b2 R2 p-value
P2500
value 0.571 0.014 0.002 0.944 <<0.0001
p-value <0.0001 <0.0001 <0.0001
P1250
value 0.827 0.013 0.002 0.890 <<0.0001
p-value <0.0001 0.014 <0.0001
ST2500
value 0.912 0.020 0.003 0.851 <<0.0001
p-value <0.0001 0.009 <0.0001
ST1250
value 1.112 0.023 0.003 0.884 <<0.0001
p-value <0.0001 0.027 <0.0001
Table 4
Point estimate of the model parameters (a = 0.05).
b0 b1 b2 b3 b4 R2 p-value
First impact
value 1.121 0.012 0.002 0.216 0.0001 0.887 <<0.0001
Second impact
Value 1.196 0.012 0.002 0.237 0.0001 0.903 <<0.0001
real materials onto the conveyor belts. The experiments simulated The results of this experimental research for the purpose of
various situations (impacts of materials of various weights, as well determining the ability of a conveyor belt to absorb the impact
as those dropped from various heights). The objective was to iden- energy indicate that there is the potential for further research, in
tify the ability of a conveyor belt to absorb the energy of the falling terms of the utilisation of new reinforcement materials resistant
material without causing a belt puncture. Within the scope of our to punctures, which have not yet been subjected to more detailed
experimental research, we came to the following conclusions: research.
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