圆管带式输送机的研究进展及其设计计算方法
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摘要
圆管带式输送机是近年来受到广泛关注与应用的特种带式输送机。对圆管带式输送机结构设计与改进、设计计算方法、性能的理论研究与测试等进行了回顾;通过总结国内外圆管带式输送机实例和研究进展,分析了输送带宽度与管径的关系、输送带弯曲性能、运行阻力等方面的问题,梳理了圆管带式输送机的发展趋势。针对目前设计机理与输送带特性相关概念混淆的问题,从力学的角度明确了成形力、接触力(反弹力)、成槽性和横向弯曲刚度的关系,分析可知接触力包含输送带的重力,不能直接反映输送带的横向弯曲刚度,建议用成形力来表征输送带弯曲性能或横向弯曲刚度。根据实际应用和CEMA(Conveyor Equipment Manufacturers Association)推荐的输送带搭接宽度,指出了国内现行标准存在搭接宽度过大的问题,建议采用带宽管径比来表示带宽与管径的关系,并提出了搭接宽度的计算式。由于圆管带式输送机的圆管直径由外径表示,但输送带的厚度对承载物料截面积影响显著,给出了考虑输送带厚度和搭接宽度的确定圆管带式输送机带宽、管径的新方法及圆管带式输送机的成管阻力、成形阻力和曲线段阻力的修正计算式。所提出的计算方法考虑了输送带的横向刚度和张力等影响因素,与现有方法相比更接近于实际,且已经在圆管带式输送机工程设计中应用,为圆管带式输送机的进一步发展提供了依据。
Pipe conveyor is a kind of special belt conveyor which has extensive attention and has been widely used in recent years.Firstly,the structural design and improvement,design calculation method,theoretical research and test of performance for pipe conveyor were reviewed.Secondly,the relationship between the belt width and the pipe diameter,the bending performance and the running resistance of the belt were analyzed and the development trend of circular pipe belt conveyor was combed by summarizing the examples and research progress of the pipe belt conveyor domestic and abroad.Since the design mechanism and the belt characteristics were confused,the forming force could be used to characterize the bending performance of the belt or the transverse bending stiffness of the conveyor belt mechanically.The transverse bending stiffness of the conveying belt couldn't be directly reflected by the contact force for the gravity action of conveyor belt.Thirdly,a formula for calculating lap width,according to actual application and recommended by CEMA,of conveyor belt was put forward by the bandwidth and diameter ratio,which the excessive width of laps was simulated with the domestic standard.Finally,a new method,considering belt thickness and lap width,to determine the width and diameter of the pipe conveyor was provided because the diameter of pipe was presented by the outer diameter butthe cross-sectional area of the bearing material was influenced by the belt thickness,and the calculation formula of pipe resistance,forming resistance and bending resistance of pipe conveyor was presented.The provided method and influence factors including transverse stiffness and forming force are applied in the engineering design of pipe conveyor,which is closer to reality than the existing methods.It provides a basis for the further development of the pipe conveyor.
Pipe conveyor is a kind of special belt conveyor which has extensive attention and has been widely used in recent years.Firstly,the structural design and improvement,design calculation method,theoretical research and test of performance for pipe conveyor were reviewed.Secondly,the relationship between the belt width and the pipe diameter,the bending performance and the running resistance of the belt were analyzed and the development trend of circular pipe belt conveyor was combed by summarizing the examples and research progress of the pipe belt conveyor domestic and abroad.Since the design mechanism and the belt characteristics were confused,the forming force could be used to characterize the bending performance of the belt or the transverse bending stiffness of the conveyor belt mechanically.The transverse bending stiffness of the conveying belt couldn't be directly reflected by the contact force for the gravity action of conveyor belt.Thirdly,a formula for calculating lap width,according to actual application and recommended by CEMA,of conveyor belt was put forward by the bandwidth and diameter ratio,which the excessive width of laps was simulated with the domestic standard.Finally,a new method,considering belt thickness and lap width,to determine the width and diameter of the pipe conveyor was provided because the diameter of pipe was presented by the outer diameter butthe cross-sectional area of the bearing material was influenced by the belt thickness,and the calculation formula of pipe resistance,forming resistance and bending resistance of pipe conveyor was presented.The provided method and influence factors including transverse stiffness and forming force are applied in the engineering design of pipe conveyor,which is closer to reality than the existing methods.It provides a basis for the further development of the pipe conveyor.
引文
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[8]STAPLES P,METHA A K.Indo gulf copper smelter pipe conveyor[J].Bulk Solids Handling,2001,21(5):510-514.
[9]NEUBECKER I.An overland pipe conveyor with 22horizontal and 45vertical curves connecting coal mine with rail load out[J].Bulk Solids Handling,1998,18(3):457-462.
[10]HINKELMANN R,SANDER U.FLEXOPIPE:from conveyor belt to conveyor pipe[J].Bulk Solids Handling,1993,13(3):581-588.
[11]HORAK R M.Improved idler panel design for pipe conveyor[J].Bulk Solids Handling,1997,17(4):521-526.
[12]HORAK R M.A new technology for pipe or tube conveyors[J].Bulk Solids Handling,2003,23(3):174-180.
[13]RAMJEE S,STAPLES P.Pipe conveyors for infrastructure projects:innovative solution for conveyor systems[J].Bulk Solids Handling,2015,35(4):20-27.
[14]HINTERHOLZER S,KESSLER F,GRABNER K,et al.Belt conveyor technology:research on a pipe conveyor with a completely new belt guidance[J].Bulk Solids Handling,2001,21(6):614-620.
[15]KESSLER F.Pipe conveyor with a completely new belt guidance[C]//The International Materials Handling Conference and Exhibition 2003,Johannesburg,Jul.23-24,2003.
[16]ZHANG Y.Efficient elevated conveyor structure and better maintenance using self powered trolley[C]//SME Annual Meeting,Salt Lake City,Feb.23-26,2014.
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[19]LOEFFLER F J.Pipe/tube conveyor:a modern method of bulk material transport[J].Bulk Solids Handling,2000,20(4):431-435.
[20]王鹰,杜群贵,韩刚,等.环保型连续输送设备:圆管状带式输送机[J].机械工程学报,2003,39(1):149-158.WANG Ying,DU Qun-gui,HAN Gang,et al.Environment-protecting continual conveyor:pipe belt conveyor[J].Journal of Mechanical Engineering,2003,39(1):149-158.
[21]HAGER M,WIEDENROTH J.Studies on the behaviour of hose(tube)belt conveyors[J].Bulk Solids Handling,1996,16(2):9-17.
[22]ZAMIRALOVA M E,LODWIJKS G.Pipe conveyor test rigs:design,application and test results-Part A[J].Bulk Solids Handling,2014,34(5):40-45.
[23]HTTE S,OVERMEYER L,WENNEKAMP T,et al.Form force behaviour of pipe conveyors in different curve radii[J].Bulk Solids Handling,2011,31(3):164-169.
[24]NUTTALL A J G,LODWIJKS G,KLEIN BRETELER A J,et al.Modelling rolling contact phenomena in a pouch belt conveyor system[J].Wear,2006,260(9/10):1081-1089.
[25]ZAMIRALOVA M E,LODWIJKS G.Energy consumption of pipe belt conveyors:indentation rolling resistance[J].FME Transactions,2012,40(4):171-176.
[26]ZAMIRALOVA M E,JANDEN K M B,LODWIJKS G.Indentation rolling resistance of pipe belt conveyors using three-dimensional generalized Maxwell viscoelastic model[C]//11th International Conference on Bulk Materials Storage,Handling and Transportation,Newcastle,Jul.2-4,2013.
[27]ZAMIRALOVA M E,LODWIJKS G.Pipe conveyor test rigs:design,application and test results-Part B[J].Bulk Solids Handling,2014,34(6):38-46.
[28]ZAMIRALOVA M E,LODWIJKS G.Pipe conveyor test rigs:design,application and test results-Part C[J].Bulk Solids Handling,2015,35(1):42-49.
[29]ZAMIRALOVA M E,LODWIJKS G.Measurement of apipe belt conveyor contact forces and cross section deformation by means of the six-point pipe belt stiffness testing device[J].Measurement,2015,70:232-246.
[30]LODWIJKS G,ZAMIRALOVA M E.Design aspects of pipe conveyors[C]//12th International Conference on Bulk Materials Storage,Handling and Transportation.Darwin,Jul.11-14,2016.
[31]ZAMIRALOVA M E,LODWIJKS G.Review of the troughability test ISO 703for quantifying a uniform transverse bending stiffness for conveyor belts[J].Archives of Civil and Mechanical Engineering,2017,17(2):249-270.
[32]FEDOKO G,MOLNR V,KOPAS M,et al.Application of FEM analysis for development of a pipe conveyor test stand[J].Bulk Solids Handling,2015,35(2):46-50.
[33]ZHENG Q J,XU M H,CHU K W,et al.A coupled FEM/DEM model for pipe conveyor systems:analysis of the contact forces on belt[J].Powder Technology,2017,314:480-489.
[34]ZHANG Y,STEVEN R.Pipe conveyor and belt:belt construction,low rolling resistance and dynamic analysis[C]//Society of Mining.Metallurgy and Exploration 2012 Annual Meeting,Washington,Seattle,Feb.19-22,2012.
[35]ZHANG Y.Extended reach:overland pipe conveyor with low rolling resistance belt[J].Bulk Solids Handling,2013,33(4):16-21.
[36]日本规格协会.ゴムコンベャの计算式と性能试验方法:JIS B8805—1976[S].东京:日本规格协会,1976:1-5.Japanese Standards Association.Method of calculations and test for rubber belt conveyors:JIS B8805—1976[S].Tokyo:Japanese Standards Association,1976:1-5.
[37]日本规格协会.ゴムベルトコンベャの计算式:JIS B8805—1992[S].东京:日本规格协会,1992:1-5.Japanese Standards Association.Rubber belt conveyors with carrying idlers-calculation of operating power and tensile forces:JIS B8805—1992[S].Tokyo:Japanese Standards Association,1992:1-5.
[38]龚欣荣.管状带式输送机简介[J].矿山机械,2000(8):43-46.GONG Xin-rong.Brief introduction of techniques for pipe belt conveyor[J].Mining&Processing Equiment,2000(8):43-46.
[39]Conveyor Equipment Manufacturers Association.Beltconveyors for bulk materials[M].7th ed.Naples:The Conveyor Manufacturers Association,2014:50-401.
[40]CONTITECH.CONTI?PIPE high-speed closed-trough belt conveyor systems for especially tight curves and high productivity[EB/OL].(2017-04-05)[2017-06-07]https://www.contitech.de/getmedia/7672bdb4-5b4a-4445-9dcc-05595af76ca5/CBG9016-En-Conti-Pipe.pdf.
[41]STEVEN R.Conveyor belt rubbers minimize your power consumption,maximize your capacity[C]//11th International Conference on Bulk Materials Storage,Handling and Transportation.Newcastle,Jul.2-4,2013.
[42]周毅.输送带反弹力测试系统的研制[J].中国橡胶.2009,25(17):35-37.ZHOU Yi.Research on conveyor belt elasticity test system[J].China Rubber.2009,25(17):35-37.
[2]STAPLES P.The history of pipe conveyors[J].Bulk Solids Handling,2002,22(3):210-213.
[3]中国机械工业联合会.圆管带式输送机:JB/T 10380—2013[S].北京:机械工业出版社,2014:1-10.China Machinery Industry Federation.Pipe belt conveyor:JB/T 10380—2013[S].Beijing:China Machine Press,2014:1-10.
[4]中国石油和化工联合会.钢丝绳芯管状输送带:HG/T4224—2011[S].北京:化学工业出版社,2012:1-6.China Petroleum and Chemical Industry Federation.Pipe conveyor belts of steel cord construction:HG/T 4224—2011[S].Beijing:Chemical Industry Press,2012:1-6.
[5]中国石油和化工联合会.织物芯管状输送带:HG/T4225—2011[S].北京:化学工业出版社,2012:1-5.China Petroleum and Chemical Industry Federation.Pipe conveyor belts of textile construction:HG/T 4225—2011[S].Beijing:Chemical Industry Press,2012:1-5.
[6]王晨光,龚欣荣,王健礼,等.安康尧柏水泥石灰石矿山管状带式输送机的应用[J].中国水泥,2011(7):82-85.WANG Chen-guang,GONG Xin-rong,WANG Jian-li,et al.Ankang Yaobai cement limestone mine belt conveyor application[J].China Cement,2011(7):82-85.
[7]MINKIN A,JUNGK A,HONTSCHA T.Belt replacement at a long distance pipe conveyor[J].Bulk Solids Handling,2012,32(6):16-21.
[8]STAPLES P,METHA A K.Indo gulf copper smelter pipe conveyor[J].Bulk Solids Handling,2001,21(5):510-514.
[9]NEUBECKER I.An overland pipe conveyor with 22horizontal and 45vertical curves connecting coal mine with rail load out[J].Bulk Solids Handling,1998,18(3):457-462.
[10]HINKELMANN R,SANDER U.FLEXOPIPE:from conveyor belt to conveyor pipe[J].Bulk Solids Handling,1993,13(3):581-588.
[11]HORAK R M.Improved idler panel design for pipe conveyor[J].Bulk Solids Handling,1997,17(4):521-526.
[12]HORAK R M.A new technology for pipe or tube conveyors[J].Bulk Solids Handling,2003,23(3):174-180.
[13]RAMJEE S,STAPLES P.Pipe conveyors for infrastructure projects:innovative solution for conveyor systems[J].Bulk Solids Handling,2015,35(4):20-27.
[14]HINTERHOLZER S,KESSLER F,GRABNER K,et al.Belt conveyor technology:research on a pipe conveyor with a completely new belt guidance[J].Bulk Solids Handling,2001,21(6):614-620.
[15]KESSLER F.Pipe conveyor with a completely new belt guidance[C]//The International Materials Handling Conference and Exhibition 2003,Johannesburg,Jul.23-24,2003.
[16]ZHANG Y.Efficient elevated conveyor structure and better maintenance using self powered trolley[C]//SME Annual Meeting,Salt Lake City,Feb.23-26,2014.
[17]MINKIN A,BRSTING P,BECKE N,et al.Pipe conveying the next stage[EB/OL].[2016-07-04][2017-06-07].http://www.bulk-solids-handling.com/?q=topics/conveying-transportation/mechanical-belt-conveyorsystems/pipe-conveying-next-stage.
[18]VAKA G A.Pipe conveyors:development and advantages[J].Bulk Solids Handling,1998,18(3):451-455.
[19]LOEFFLER F J.Pipe/tube conveyor:a modern method of bulk material transport[J].Bulk Solids Handling,2000,20(4):431-435.
[20]王鹰,杜群贵,韩刚,等.环保型连续输送设备:圆管状带式输送机[J].机械工程学报,2003,39(1):149-158.WANG Ying,DU Qun-gui,HAN Gang,et al.Environment-protecting continual conveyor:pipe belt conveyor[J].Journal of Mechanical Engineering,2003,39(1):149-158.
[21]HAGER M,WIEDENROTH J.Studies on the behaviour of hose(tube)belt conveyors[J].Bulk Solids Handling,1996,16(2):9-17.
[22]ZAMIRALOVA M E,LODWIJKS G.Pipe conveyor test rigs:design,application and test results-Part A[J].Bulk Solids Handling,2014,34(5):40-45.
[23]HTTE S,OVERMEYER L,WENNEKAMP T,et al.Form force behaviour of pipe conveyors in different curve radii[J].Bulk Solids Handling,2011,31(3):164-169.
[24]NUTTALL A J G,LODWIJKS G,KLEIN BRETELER A J,et al.Modelling rolling contact phenomena in a pouch belt conveyor system[J].Wear,2006,260(9/10):1081-1089.
[25]ZAMIRALOVA M E,LODWIJKS G.Energy consumption of pipe belt conveyors:indentation rolling resistance[J].FME Transactions,2012,40(4):171-176.
[26]ZAMIRALOVA M E,JANDEN K M B,LODWIJKS G.Indentation rolling resistance of pipe belt conveyors using three-dimensional generalized Maxwell viscoelastic model[C]//11th International Conference on Bulk Materials Storage,Handling and Transportation,Newcastle,Jul.2-4,2013.
[27]ZAMIRALOVA M E,LODWIJKS G.Pipe conveyor test rigs:design,application and test results-Part B[J].Bulk Solids Handling,2014,34(6):38-46.
[28]ZAMIRALOVA M E,LODWIJKS G.Pipe conveyor test rigs:design,application and test results-Part C[J].Bulk Solids Handling,2015,35(1):42-49.
[29]ZAMIRALOVA M E,LODWIJKS G.Measurement of apipe belt conveyor contact forces and cross section deformation by means of the six-point pipe belt stiffness testing device[J].Measurement,2015,70:232-246.
[30]LODWIJKS G,ZAMIRALOVA M E.Design aspects of pipe conveyors[C]//12th International Conference on Bulk Materials Storage,Handling and Transportation.Darwin,Jul.11-14,2016.
[31]ZAMIRALOVA M E,LODWIJKS G.Review of the troughability test ISO 703for quantifying a uniform transverse bending stiffness for conveyor belts[J].Archives of Civil and Mechanical Engineering,2017,17(2):249-270.
[32]FEDOKO G,MOLNR V,KOPAS M,et al.Application of FEM analysis for development of a pipe conveyor test stand[J].Bulk Solids Handling,2015,35(2):46-50.
[33]ZHENG Q J,XU M H,CHU K W,et al.A coupled FEM/DEM model for pipe conveyor systems:analysis of the contact forces on belt[J].Powder Technology,2017,314:480-489.
[34]ZHANG Y,STEVEN R.Pipe conveyor and belt:belt construction,low rolling resistance and dynamic analysis[C]//Society of Mining.Metallurgy and Exploration 2012 Annual Meeting,Washington,Seattle,Feb.19-22,2012.
[35]ZHANG Y.Extended reach:overland pipe conveyor with low rolling resistance belt[J].Bulk Solids Handling,2013,33(4):16-21.
[36]日本规格协会.ゴムコンベャの计算式と性能试验方法:JIS B8805—1976[S].东京:日本规格协会,1976:1-5.Japanese Standards Association.Method of calculations and test for rubber belt conveyors:JIS B8805—1976[S].Tokyo:Japanese Standards Association,1976:1-5.
[37]日本规格协会.ゴムベルトコンベャの计算式:JIS B8805—1992[S].东京:日本规格协会,1992:1-5.Japanese Standards Association.Rubber belt conveyors with carrying idlers-calculation of operating power and tensile forces:JIS B8805—1992[S].Tokyo:Japanese Standards Association,1992:1-5.
[38]龚欣荣.管状带式输送机简介[J].矿山机械,2000(8):43-46.GONG Xin-rong.Brief introduction of techniques for pipe belt conveyor[J].Mining&Processing Equiment,2000(8):43-46.
[39]Conveyor Equipment Manufacturers Association.Beltconveyors for bulk materials[M].7th ed.Naples:The Conveyor Manufacturers Association,2014:50-401.
[40]CONTITECH.CONTI?PIPE high-speed closed-trough belt conveyor systems for especially tight curves and high productivity[EB/OL].(2017-04-05)[2017-06-07]https://www.contitech.de/getmedia/7672bdb4-5b4a-4445-9dcc-05595af76ca5/CBG9016-En-Conti-Pipe.pdf.
[41]STEVEN R.Conveyor belt rubbers minimize your power consumption,maximize your capacity[C]//11th International Conference on Bulk Materials Storage,Handling and Transportation.Newcastle,Jul.2-4,2013.
[42]周毅.输送带反弹力测试系统的研制[J].中国橡胶.2009,25(17):35-37.ZHOU Yi.Research on conveyor belt elasticity test system[J].China Rubber.2009,25(17):35-37.