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Procedia Earth and Planetary Science 15 (2015) 702 – 711

World Multidisciplinary Earth Sciences Symposium, WMESS 2015

Experimental Tests of Selected Constituents of Movement

Resistance of the Belt Conveyors Used in the Underground Mining
Miroslav Bajdaa, Robert Krola*
a
Wroclaw University of Technology, Machinery System Department, Na Grobli 15, 50-421 Wrocáaw, Poland

Abstract

During the design of conveyor belts, optimization attempts are taken firstly to reduce the energy consumption, this is obtained by
reducing the main resistances of the conveyor. The biggest savings of energy may be expected in rational belts and idlers
selection, and in some cases in unconventional solutions of the route, stretching and spillover equipment. The tests on movement
resistance of the belt conveyor, carried out over recent years in the Machinery Systems Department of the Wrocáaw University of
Technology, allowed to define precisely the impact of many construction and operational factors on the energy consumption of
transport. At present, research work is carried out, oriented to find the optimal solutions for the belt conveyors used in
underground mines. Due to different capacity values, construction that is more compact, more difficult installation and operation
conditions, the solutions developed for open-pit mining cannot be directly adopted. The paper proposes a stand test methodology
on the identification of key constituents of belt conveyor movement resistance and presents the results of pilot experimental tests.
These tests aimed to define the optimal construction features of energy saving on the conveyor belt, having low resistance of
rolling on idlers and bending resistance on pulleys under underground mine conditions.
© 2015
© 2015The TheAuthors.
Authors. Published
Published by Elsevier
by Elsevier B.V.is an open access article under the CC BY-NC-ND license
B.V. This
Peer-review under responsibility of the organizing committee of WMESS 2015.
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibilty of the Organizing Commitee of WMESS 2015.
Keywords: Belt conveyor; energy savings conveyor belt; experiments.

1. Introduction

Commonly used transport means in the Polish mining industry are belt conveyors, which drove out previously
used cyclic transport, in most of industries. The range of applications and differentiations resulting from the profile
of mining activity, require a design and production of belt conveyor components with the highest care.

* Corresponding author. Tel.: +48 71 320 48 76.

E-mail address: robert.krol@pwr.edu.pl

1878-5220 © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibilty of the Organizing Commitee of WMESS 2015.
doi:10.1016/j.proeps.2015.08.098
 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711 703

The breaks or limitations in the transported mass stream, forced by individual elements of belt haulage, directly
lowers the effectiveness of the entire technological system. Thus, already at the design stage of belt conveyors,
optimization attempts are taken oriented, first, to reduce the energy consumption. This is achieved by lowering the
main resistance of the conveyor (Furmanik, 2014; Krol, 2013; Gladysiewicz et al.,2008). The savings in energy
consumption may be expected in a rational selection of belt and idlers, and in some unconventional route course,
through stretching and spillover of equipment drives (Gladysiewicz and Kawalec, 2003). Very important is also the
influence of many construction parameters of the conveyor on the operation cost. For example, the spacing of upper
idler supports on the movement resistance of conveyor (Gladysiewicz et al., 2013; Gladysiewicz and Kawalec,
2011). Effectiveness of those efforts depends, first, on the diagnosis of the impact of randomness operational loads
and on defining the influence of essential construction factors on generated resistance of belt conveyor movement
(Krol, 2013). Research on belt conveyor movement resistance, carried out over the recent years in the Machinery
Systems Department of the Wrocáaw University of Technology, allowed to identify precisely the impact of many
construction and operation parameters on transport energy consumption (Gladysiewicz et al., 2012; Bajda, 2009;
Gladysiewicz and Kawalec, 2006). The efforts were focused first on conveyors used in open-pit mining, and
research methodology spawned new approaches for optimization and modernization of construction elements of the
belt conveyor (belt, idlers, pulleys, stretching devices, indirect (bust) drives). Application of the research results in
QNK-TT calculating system, enabled a multi-criteria analysis of the transport task solution, defined, among other
things, by variant models of output stream (Krol, 2013; Dworczynska et al., 2012 and 2013; Gladysiewicz et al.,
2010).
At present on Wrocáaw University of Technology, research, focused on finding the optimal solutions for the
conveyors used in underground mines, are carried out. In these mines, due to different capacity ranges, more
difficult installation and operation conditions, is not possible to apply directly the solutions worked out for open-pit
mining (Kawalec et al., 2009). Experience from the up to date modernization works, clearly indicates the wide range
of possible energy savings, resulting first of all, from using the energy efficient conveyor belts (Lodewijks, 2011;
Bajda and Hardygora, 2007; Hager and Hintz, 1993; Hintz, 1993), therefore, the efforts are primarily concentrated
on rational selection of the belt, based on the experimental test results.
In total movement resistance, for horizontal belt conveyors, resistance of rolling on idlers placed on the belt
conveyor route has the biggest contribution (ca. 50-60% of main resistance) (fig.1).

Ws

Wf Sliding resistance
of a belt
Flexure resistance 10%
of bulk material
5-10%

Belt’s rolling resistance

Wk Idlers turning resistance
50-60%
15-20%

Bending resistance
of a belt We
8-15%

Wb

Fig.1. Participation of main resistance components along the top belt strand
of horizontal belt conveyor.

One should remember also, that the essential impact on main drives sizing in conveyors used in the underground
mines, beside the resistance of belt rolling on idlers, has movement resistance reckon to the lumped resistance. Since
they are characterized by shorter routes, numerous pulleys in belt drive, stretching or storing systems (fig.2) having
definitely smaller diameters in comparison with the ones used in open-pit mines, what only increases the
participation of bending resistance in the total resistance of belt conveyor movement.
704 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711

Fig.2. Example of calculation model of the Legmet conveyor drive station.

The methodology of stand tests concerning identification of key components of resistance of conveyor belt
movement, developed in Machinery Systems Department of Wrocáaw University of Technology, was proposed in
the paper. The results of pilot experimental research aimed to define optimal construction characteristics for energy
saving conveyor belt, having low resistance of rolling on idlers and low bending resistance on pulleys in
underground mine conditions, were presented here as well.

2. Testing the resistance of belt rolling on idlers (indentation resistance)

Resistance of belt rolling on idlers result from cyclic compressing the bottom side cover plate by the carrying
idlers. After leaving the idler, belt returns to the original shape with the delay resulting from the attenuation losses of
the cover plate material. It causes the conversion of part of kinetic energy of belt rolling into heat energy
(Gladysiewicz, 2003). Basing on the analysis of research studies on the phenomena occurring in the belt during the
conveyor operation i.e. dumping and friction in connection with the process of periodical belt deformation, Bajda
(2009) proposed the methodology of laboratory tests. Thus, he constructed special measuring stand, where the
projection of real conditions of cooperation between idler and belt is possible, as well as identification of the
relationship between properties of belt cover plate and resistance of belt rolling on idlers. The results of laboratory
test aimed to evaluate the applicability of different types of conveyor belts used in open-pit mining were presented
by Bajda (2009), Bajda and Hardygora (2009), Bajda et al. (2007) and Bukowski et al. (2011). The experiments are
based on analyze of car (trolley) movement on the inclined plane, stuffed with conveyor belt. This way, the
conditions, where only two components of movement resistance, i.e. resistance of belt rolling on idlers and
resistance of idlers rotation, are present. Since the resistance of idlers rotation may be determined experimentally,
separately for each idler (Krol and Kisielewski, 2014; Bukowski et al., 2011; Gladysiewicz and Kawalec, 2005),
there is a possibility to define the second component – the resistance of belt rolling on idlers.
The measuring stand consists of four main assemblies (fig.3):
x car with two idlers,
x section with inclined plane used for car acceleration,
x measuring section, where the distance of the idler free rolling on the belt is measured,
x car braking assembly.
Loading car is made of two idlers and a frame. Idler rollers are placed in the frame, to which additional loads may
be added, what changes the pressure between idlers and the belt. During the test the car is accelerated on the inclined
plane to the required speed. Than along the measuring section, as a result of rolling resistance and idlers rotation
resistance, the speed decreases. The time of car movement on the belt was measured using three photometrical
sounders Tacho1-Tacho3 connected with the Pulse measuring system manufactured by Bruel&Kjear.
To interpret the results it is assumed that the resistance of car rolling on the belt and resistance of idlers rotation is
constant, thus the assumption about constant average acceleration (retardation) of car along measuring section may
be adopted.
 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711 705

Fig.3. Measuring stand for testing the rolling resistance.

The belt on measuring stand is 500 mm wide. In order to refer the results of tests to real conditions, the unit
rolling resistance, i.e. resistance converted to the unit of idler length, should be used.
The unit resistance of belt rolling on idlers - We in [N/m] measured on the stand, after the diagram showed on fig. 4,
is calculated from the formula (1):
§ 2I ·
We ¨ m  2r ¸ ˜ a  2W k  W p
© r ¹ (1)
Wp m ˜ g ˜ sin E
(2)

Wk – sum of rolling resistance of two idlers, N; Wp – resistance of car lifting, N; m – weight of car, kg; a –
retardation, m/s2; Ir – moment of inertia of idler, kg×m2; r – radius of idler, m; g – acceleration of gravity, m/s2; ȕ –
slope angle of measuring part of plane; b – belt width, m.

2,198 m
Tacho 2
2,188 m
Tacho 3

Tacho 1
R

D ß

Fig.4. Diagram of metering system on the stand for measuring the resistance of idlers rolling on the belt.

During each measurement nine (9) results of time vs. distance traveled by idlers, are obtained. They are
approximated by the following equation:
a ˜t2
s  vo ˜ t  s0
2 (3)

Testing the rolling resistance was made for two belt section marked as T1 and T2 and appointed as a prototypes,
basing on parameters previously determined in the laboratory, deciding about the rolling resistance, i.e. dumping
factor and modulus of elasticity of belt cover rubber (Kawalec and Wozniak, 2013). All samples were made of
St2500 type belt - 7000 mm long, 500 mm wide and having 8 mm thick bottom side cover plate. The distance of free
706 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711

rolling of idler car on the belt was determined for the car weighting 242.6 kg (2328 N). The car retardation was
calculated basing on recorded times of passage between measuring points. Test were made in the temperature of
18r0,5oC, and the results, i.e. average time of car passage along the belt are presented in table 1 and on fig.5.
Table 1. Comparison of the measurements results for T1 and T2 belts.

Probe Tacho1 Probe Tacho3 Probe Tacho2

Distance of free rolling of idler car on the belt;
0 0.273 0.769 2.186 2.459 2.955 4.390 4.663 5.159
s [m]
Average time of car passage along the belt T1; t [s] 0 0.0810 0.2265 0.6910 0.7884 0.9696 1.5721 1.7063 1.9679
Average time of car passage along the belt T2; t [s] 0 0.0813 0.2271 0.6944 0.7926 0.9756 1.5917 1.7298 2.0023

a) T1 b) T2
6 6
y=Ͳ0,425x2 +3,459x+6EͲ05 y=Ͳ0,438x2 +3,455xͲ 0,000
5 R²=1 5 R²=1

Distance, s[m]
4 4
Distance, s[m]

3 3

2 2

1 1

0 0
0 0,5 1 1,5 2 2,5 0 0,5 1 1,5 2 2,5
Time, t[s] Time, t[s]

Fig.5. Distance s [m] passed by car vs time t [s] recorder for no. 1 belt (a) and no. 2 belt (b).

Basing on the results, the car retardation in the uniformly retarded motion and then the resistance of belt rolling
on idlers were calculated. The results are included in table 2.

Table 2. The results of rolling resistance research

Belt symbol T1 T2
Test temperature (belt), oC 18.2 18.5
Belt widht, [m] 0.405 0.402
Retardation of loaded car unite, a [m/s2] 0.8506 0.8772
The unit resistance of belt rolling on idlers, We [N/m] 27.4 36.7

Results of testing the above belts were compared with the values for belts with steel cords having the comparable
strength parameters, used in open-pit mines. The results of test, presented in Komander et al. (2010), where rolling
resistance of two belt samples marked as XW and X4, had been determined, were used here. The comparative
specification contains table 3. XW sample was taken as standard one and with reference to this belt, the energy
saving effect was determined. For T1 belt the energy saving of ca. 8 % was obtained. Bearing in mind that it is a belt
with carrying and bottom side cover plate, made of slow-burning rubber mix, the result should be regarded as very
good one. While T2 belt sample had ca. 23% higher energy consumption than the standard belt.

3. Testing the resistance of bending the belt on pulleys (wrap resistance)

The to date methods of determining the resistance of bet bending on pulleys are based on empirical models and
results from before many years (Gladysiewicz, 2013; Golka et al., 2007). In many cases, it is difficult to use the
relationships derived from laboratory tests for multiply textile belts or belt with steel cords, to the contemporary
constructions. Since the precise defining of bending resistance of belt on pulleys is possible only by experiments, the
measuring stand for identification of this component of conveyor belt movement resistance, was designed and
constructed in the Machinery Systems Department of the Wrocáaw University of Technology. Fig. 6 shows the
measuring stand for testing the bending resistance of belt on pulleys. It is made up of two pulleys having the same
 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711 707

diameter, and between them, the tested conveyor belt is spread. Pulleys are mounted on the stand’s frame. To record
and preview the sensor readings during the tests, special software enabling the analysis and compilation of
measurement results, in any chosen configuration, was used.

Fig. 6. View of model of the wrap resistance test stand.

Diagram of rewinding (scrolling) the belt on measuring stand is presented on fig. 7. Drive pulley (4) is connected
with 5.5 kW moto reducer, controlled by frequency converter, what provides the possibility of fluent control of
engine rotation, and thus the linear velocity of belt. On pulley’s shaft, the tensometric system for measuring torque
moment, is installed. Belt return pulley (2), seated movably in the bearing frame, is stretched by two hydraulic
cylinders. It enables to apply the force of belt stretch, required by the testing program. Measurement of belt stretch
force is possible using two force sensors F1 and F2 placed in belt stretching system. Drive and return pulleys have
the same diameter (Kisielewski et al., 2014).

Fig. 7. The scheme of the wrap resistance test stand: 1- conveyor belt, 2- return pulley, 3- tensioning unit, 4- drive pulley, 5- drive shaft, 6- gear
motor, F1, F2- readings from the force sensors in tensioning unit, Rb- pulleys radius, Fs- tangential force, Ms- torque momentum on the drive shaft.

The first phase of test was determining the self resistance of the stand - W0 as a function of belt stretching force.
During that phase, on the stand, instead of belt, the single flitting loop, was installed (fig. 8). It is assumed, that the
resistance of textile bending is zero, so the measured resistance of movement includes only the self resistance of
stand, comprising the resistance of bearing pairs of both pulleys. Measurement for the textile mounted instead of
belt allowed to determine the self-characteristic of the stand (Kisielewski et al., 2014). Within the obtained range of
changes of textile (belt) stretching force, the movement resistance W0, is calculated from the formula:
‫ܯ‬௦
ܹ଴ ൌ ‫ܨ‬௦ ൌ ሾܰሿǡ (4)
ܴ௕
where: Fs- peripheral force on drive pulley, N, Ms- torque moment measured on drive pulley’s shaft, Nm, Rb – radius
of drive pulley, m.
708 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711

Fig.8. Stand for testing the resistance of belt bending on pulleys with flitting.

Measured self resistance of the stand are presented on 6a. The values of movement self resistance of the stand for
difference forces in the flitting, overlap each other. It is due the almost zero bending resistance of flitting and
unnoticeable impact of stretching force of flitting (radial force on pulleys) on friction resistance of bearing pairs of
both pulleys. Owning to such nature of self resistance of the stand, it was decided to present them as one averaged
curve. The averaged curve of self resistance of the stand for testing the resistance of belt bending on pulleys, is
presented on figure 9 b.

300 300
F = 1,1 kN
F = 3,1 kN
250 250
F = 5,0 kN
F = 7,4 kN

200 F = 12,6 kN 200

Opory wáasne, W0 , N

Opory wáasne, W0 , N

F = 14,8 kN
F = 9,7 kN
150 150

100 100

50 50

0 0
50 250 500 750 1000 1250 1500 50 250 500 750 1000 1250 1500
Obroty silnika, ns, obr./min, (V taĞmy 3,8 m/s przy 1500 obr/min) Obroty silnika, ns , obr./min, (V taĞmy 3,8 m/s przy 1500 obr/min)

Fig.9. Self resistance of stand movement vs. rotational speed of engine recorded in temp. of 16 °C:
a) for set force values in flittings, b) averaged..

Then, as a part of experiment, T1 and T2 belts accepted for the test, were installed on the stand, and within the
assumed scope of stretching force changes, the total movement resistances WT, of the stand was measured, using the
same relationship (4). The difference of the movement resistance values WT and W0, for equally set stretching force,
is recognized as the belt bending resistance on two pulleys W2b. Thus, the search bending resistance of belt being
tested - Wb, constitutes a half of W2b resistance value. The stand enables also to determine experimentally the
influence of pulley diameter on belts bending resistance by using additional, easy to install, cylindrical distance ring
having specified thickness.
For each belt sample, the equal range of rotational speed of engine was taken, and at the same time, the level of
assumed forces in the belt and similar ambient temperature was maintained. The test results are listed in table 3.
 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711 709

Table 3. Comparison of bending resistance on pulleys for tested belts

Engine rpm, Bending resistance,
Linear velocity of the belt, v
ns Wb
obr./min m/s Belt no. 1 Belt no. 2
Force in the belt F=10±0,5kN
50 0,1 123,8 145,1
250 0,6 196,1 217,4
500 1,3 202,0 250,1
750 1,9 210,2 276,1
1000 2,6 213,4 288,2
1250 3,2 224,2 299,1
1500 3,8 230,5 305,3
Force in the belt F=13±0,5kN
50 0,1 143,4 159,0
250 0,6 215,7 235,8
500 1,3 221,7 268,5
750 1,9 225,4 290,1
1000 2,6 224,1 302,1
1250 3,2 243,9 317,5
1500 3,8 250,1 323,7
Force in the belt F=16±0,5kN
50 0,1 165,7 185,2
250 0,6 229,1 257,5
500 1,3 235,0 281,3
750 1,9 243,2 307,4
1000 2,6 246,4 319,4
1250 3,2 257,3 330,3
1500 3,8 263,5 336,5
Force in the belt F=20±0,5kN
50 0,1 188,0 236,5
250 0,6 251,4 308,8
500 1,3 257,3 332,6
750 1,9 256,6 340,8
1000 2,6 259,8 361,8
1250 3,2 270,6 372,7
1500 3,8 276,9 405,7
Force in the belt F=27±0,5kN
50 0,1 217,7 256,0
250 0,6 272,2 323,9
500 1,3 287,1 361,1
750 1,9 295,3 413,8
1000 2,6 307,3 425,9
1250 3,2 327,1 454,6
1500 3,8 333,4 469,8

The tests disclosed, with regard of both tapes, the essential impact of stretching force on the resistance of belt
bending on pulleys. In both cases, curves of bending resistance increase with gradually growing force of belt
stretching. Furthermore, during the tests, the impact of belt speed on the value of recorded bending resistance of belt
loops used in the tests, was noticed. Within the range of set speeds i.e. from 50 to 1500 rpm, the T1 belt bending (for
taken stretching forces), increased on average by ca. 64%.
In the case of T2 belt, intensification of belt resistance increase, for the taken belt speed range is clearer. For the
all analyzed variants of belt stretching force, the average increase of bending resistance amounting ca. 90%, was
estimated. It should also noticed, that nature of bending resistance changes for individual belt is similar and results,
among other things, from the material features of particular construction solutions. For the highest values of force in
710 Miroslav Bajda and Robert Krol / Procedia Earth and Planetary Science 15 (2015) 702 – 711

the belt, T2 sample has 41% bigger bending resistance than T1 sample (fig. 10b). In the case of the lowest force
values, the difference is lower, and amounts 32% (fig.10a).

600 600

TaĞma 2, F=10,2 kN
500 500

TaĞma 1, F = 9,5 kN
400

Opór przeginania, Wb, N

400
Opór przeginania, Wb, N

300 300

200 200
TaĞma 2, F=26,2 kN

100 100
TaĞma 1, F = 27,2 kN

0 0
50 250 500 750 1000 1250 1500 50 250 500 750 1000 1250 1500
Obroty silnika, ns, obr./min, (V taĞmy 3,8 m/s przy 1500 obr/min) Obroty silnika, ns , obr./min, (V taĞmy 3,8 m/s przy 1500 obr/min)

Fig.10. Comparison of bending resistance on pulleys for T1 and T2 tested belt samples:
a) for the lowest force values in the belt F=10±0,5kN,
b) for the highest force values in the belt F=27±0,5kN.

4. Conclusions

1. Energy saving belt designed for underground mines apart from adequate parameters ensuring the minimal
rolling resistance should be characterized by parameters, which will guarantee the minimal bending resistance
on pulleys. The proposed testing methods enabled to compare two belts with regard of generated movement
resistance on the belt conveyor.
2. Test results of belt bending resistance on pulleys are concurrent with measurements of specific movement
resistance, which were carried out on the special stand with inclined plane. They showed, that belt marked as
T1, in both experimental tests demonstrated lower values of the components of movement resistance being
tested.
3. T1 has about 34% lower rolling resistance on idlers than T2 belt, and with regard of standard belts with similar
strength parameters, used in the open-pit mining belt conveyors, the decrease of rolling resistance amounting ca.
8% was noticed.
4. In conveyors operating in underground mines, which experience many belt bends, the estimated power required
to overcome the movement resistance in two-pulley drive station reach the value of 10 kW (Gladysiewicz,
2003). Taking also into consideration additional bends on pulleys of stretching system (especially in case of
using two-car, follow-up stretching device) and in the belt loop, one should expect considerable power
necessary to overcome the belt bending resistance on all pulleys. Experimental stand tests confirmed the
essential influence of stretching force as well as rotational speed on the value of the resistance of belt bending
on pulleys. For the biggest force in the belt (F=27±0,5kN), taken during the tests and at the rotational speed of
engine of n=1500 rpm, T2 belt has 41% higher bending resistance on the pulley than T1 belt.
5. Presented test results confirm the effectiveness of proposed research methods and are the valuable source of
information while seeking optimal solution with regard of conveyor belts designed for underground mines.

Acknowledgements

This paper was financially supported partly by the Polish Ministry of Science and Higher Education as scientific
project No S40111.

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