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Typical conveyor belt.
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Objectives: From an industry specific perspective, there is continuous pressure on manufacturing companies to reduce
the operating expenditure by reducing the electricity cost by developing the energy efficient equipment and products
especially conveyor systems. Methods/Statistical Analysis: Conveyor belts are the material handling equipment that...
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From an industry specific perspective, there is continuous pressure on manufacturing companies to reduce the operating expenditure by reducing the electricity cost by developing the energy efficient equipment and products
especially conveyor systems. Conveyor belts are the material handling equipment that is widely used in industry to move the mat...
Citations
... The simulations revealed that using multiple actuators reduced the maximum stress on the conveyor belt in both non-stationary and stationary conditions. Halepoto and Khaskheli [18] proposed an energy-efficient model for a conveyor system that controls several actuator units, thereby increasing its efficiency. Khodusov et al. [19] dealt with the causes of dynamic stress during the movement of a conveyor belt with material load. ...
This paper deals with research on the operational process monitoring of a pipe conveyor for the needs of online diagnostics. The aim of this research is to verify the possibility of identifying the selected pipe conveyor’s failures in its straight section during operation (a missing roller in the idler housing, absent material on the conveyor belt) with the use of a discrimination method. This is an attempt to implement digital transformation with the aim of verifying its possibilities and limitations. The basis for discrimination is a continuous measurement and evaluation of measured values of contact forces in certain rollers’ positions in the hexagonal idler housing. Within this research, eight different measurement regimes were implemented. The use of the method was verified with simulated data using the trace table. We aimed to create prerequisites for online monitoring, which, based on digital transformation, will be deployed to control a transport system. The measurement was realized with the maximum tension force of 28,000 N. From the measurements, a decision-making algorithm was proposed to identify selected failures in the pipe conveyor operation with the use of the discrimination method. Within the algorithm, classifying criteria were determined, in the range of 57 N ÷ 251 N. The results confirm the method’s suitability for its practical assurance of pipe conveyors’ failure-free operation, as the failures were always identified sufficiently in advance, thanks to which, in practice, there was no further damage to the diagnosed devices.
... An energy efficient conveyor system has been developed by using variable speed drive (VSD) mechanism resulting energy saving in different running conditions. 27 In a similar study, an optimal switching control and a VSD based system has been proposed which is suitable to improve the energy efficiency of belt conveyor systems at the different operational levels, where benefits are derived after considering time-of-use tariff, ramp rate of belt speed, and other system constraints. 25 A Similar study conducted in another research where soft starters and VSDs are used to reduce starting torque and load detecting switching system to reduce number of operating hours. ...
In this research work, different parameters have been studied which affect the energy consumption of belt conveyors. The effect of conveying distance and vertical lift on energy consumption was studied in detail by collecting energy consumption and other associated data of belt conveyors from different cement plants and analyzed with the help of different statistical analysis. The highest specific energy consumption was found to be 0.0011 kWh/Ton‐m in the smallest belt conveyor of 15 m and the lowest specific energy consumption was found to be 0.0007 kWh/Ton‐m in the longest belt conveyor of 100 m. Specific energy consumption is reduced up to 36% per ton‐meter of material conveying in the longest belt conveyor compared with the smallest belt conveyor. On the contrary, the specific energy consumption for different vertical lifts is found almost the same. Hence, it can be suggested that for horizontal conveying, the series of belt conveyors should be replaced with a single long conveyor to achieve maximum conveying efficiency and to lower specific energy consumption. The above study will be helpful for heavy industries such as cement plants, steel plants, and so forth to reduce their energy consumption on belt conveyors and achieve the environmental sustainability goals. At the last part of the study an equation is derived for estimating energy consumption in belt conveyors by applying multiple regression analysis. The proposed equation will be helpful for estimation of energy consumption of belt conveyors according to which the decision for conveyor length can be taken.
... However, to optimize feed rate and belt speed while reducing energy consumption, the energy models of belt conveyors are of great importance [46]. Modelling energy requirements of belt conveyor systems with regard to dynamic loading was evaluated by Halepoto and Khaskheli [56]. A belt conveyor analytical model for optimizing its operating parameters such as operating efficiency, load shifting and operation scheduling was proposed by Zhang and Xia [57]. ...
The mining industry is facing sustainable development challenges, among which the energy efficiency issues seem to be of major importance. As transport of the mined ore is considered as one of the most energy intensive operations, the improvement of its energy efficiency is a key indicator in terms of sustainable actions taken by mining companies. In open-pit mines, the material handling operations are mostly performed with trucks. Their electrified version-truck trolley systems-surpass diesel trucks' efficiency while comparing the increased production capacity and the reduction of maintenance cost and fuel consumption. The paper analyzes the opportunities and benefits of the replacement of an ore transport system based on hauling trucks with a regenerative belt conveying in an open-pit mine. Presented case study has been analyzed from energy consumption and environmental impact reduction perspectives. Generally, conception of a regenerative conveyor is based on recuperation of energy or continuous braking needed while a conveyor is running downhill. Energy generated during the braking process (converted from the potential gravitational energy of the conveyed material) is fed back to the electrical grid. Then the regenerative conveyor can be considered as a machine that mines energy as an additional by-product of an exploited deposit. It was shown that difference in transportation cost between haul trucks and energy efficient regenerative conveyors is around 95%. The paper points the conditioning elements to allow the implementation of a regenerative belt conveyor system.
... The ECU acts as the controller in an automobile. Its job is to oversee, regulate and alter the various ongoing operations of a vehicular electronic system [29]. ...
Since the launch of automobile, the focus has been on the improvements in the performance of the vehicle. The well-known camshaft based engines have proven their worth in the automobile industry but scope of improvement is still possible. One particular technique which improves the power drive of a vehicle is to adapt the camless technology. The camless engines allow the removal of camshaft and other mechanical components making the overall engine design much lighter and compact in size and the valves in the cylinder head are operated and controlled through electronic switching. These predecessor engines used poppet valves which did produce prominent results over the years but when it comes to the successor camless engines, the poppet valves are not the best option of technology to incorporate. These valves limit in terms of lift profiles, operational ranges at defined RPMs, have plenty of bulky components, have seating issues and etc. These limiting factors limit the operation of camless engines to lower RPM values. This research work focuses to reduce the limitations of the camless engines due to poppet valves by introducing the shutter valve and modelling it for the control of both the intake and exhaust shutter valves in the light of the different devised cases. The modelled valves allow the operation in efficient conditions for better fuel average and power output of the vehicle, which was investigated and analyzed by two case studies. The first case is focused towards the efficiency of the intake shutter valve model and it was proven by conducting a series of simulations through MATLAB. The produced graphs resulted in an ideal intake shutter valve opening percentage based on the desired fuel average and torque output requirements. The adjustment of the opening is in the hands of the driver and the type of drive requirements. In second case study, Dyno runs were performed over varied tire load using a same engine. The reduction in the dimensions and the weight of the tires resulted in an increase in the horse power of the vehicle according to the weight power ratio of the vehicle. These case studies and the proposed Shutter Valve model design will bring a revolution in Automobile industry in terms of fuel efficiency and optimal utilization of engine output power.
... One of the main reasons for utilising VSDs is to maintain a consistent throughput along the length of the entire system, in addition to controlling the transient behaviour of the system during starting and stopping [7]. This is shown to significantly increase the operational efficiency of the system which can be viewed in the cited literature [8][9][10][11]. Zhang and Xia [3,12] also considered the operational efficiency of belt conveyors. However, they focused on the optimisation of the system utilising an energy model of belt conveyors. ...
The energy consumption of modern belt conveying systems has reduced considerably over the past few decades. Although extensive research has been conducted into the production of energy-efficient belt conveyors, significant scope remains to further reduce the energy consumption, especially when heavily loaded or long overland belt conveyors are considered. A new rail-based conveyor system has been developed to reduce the energy consumption of heavily loaded and long overland conveyors. The new technology is aptly named the Rail Conveyor due to its combination of two well-established transportation technologies. The Rail Conveyor merges the benefits of both belt conveyor technology and rail transport to produce an energy-efficient and cost-effective bulk material transportation system. This paper presents a comparison between the energy consumption and motion resistances of the Rail Conveyor system and conventional belt conveyors. The Rail Conveyor is a continuous bulk material transportation system that, due to track wheels running on steel rails, shares a rolling resistance similar in magnitude to railway systems. Due to the effective elimination of the indentation rolling resistance and belt and bulk material flexure resistance within the Rail Conveyor system, an approximate reduction of 50% in energy consumption can be achieved when compared to conventional belt conveyors.
... However, energy usage by individual appliance is quite difficult to estimate. Non-Intrusive appliance load monitoring provides households with cost-effective real-time monitoring of end-use appliances to help them understand their consumption pattern and become part and parcel of energy conservation strategy [6]. ...
... Consumer or end-user shall mean any person who is the registered customer of the utility being supplied with electricity by the concerned distribution utility or any person authorized as the registered customer to occupy the premises and enjoy electric services [6]. In this context, a consumer unit is characterized by receiving electricity from the distribution utility, with individual metering and corresponding to a single consumer. ...
Considering the energy scarcity, the active participation of residential consumers is vital for a
successful implementation of the smart grid vision. At the application level, Smart Energy Homes
are considered as Sub-Smart Grid equipped with smart sensing nodes and intelligent appliances
for monitoring and control of residential appliances load consumption to open the doors of
consumer driven energy management and control.
In this research work, we have design and simulate a consumer driven multi-agent based home
energy monitoring and management system for four agents; flat, comfort, cost and composite
reactive agents. For multi-agent programming JADE (Java Agent DEvelopment Framework)
platform is used and for the control of smart energy home JaCoMo (Jason CArtAgO Moise)
platform is used with demand2control protocol.
For the simulation and analysis of proposed model, again a co-simulation platform GridMat
(Matlab toolbox) is used which integrates the physical worlds (power systems through GridLABD) and cyber world (control through MATLAB). The GridMat platforms integrates the smart
metering technology, DSM technology i.e., consumers active participation by adopting dynamic
Time of Use price signals and load scheduling for smart home energy management and
optimization. Simulation results confirm that by adopting proposed optimization algorithm a
significant amount of energy not only can be saved also easing system network load stress but
consumers can be significantly save their electric bills without much of sacrificing their comfort
level.
Coal transportation at PT XYZ in Tanah Laut Regency, South Kalimantan Province uses a transportation equipment such conveyors. The conveyor structure is made of low carbon steel which is susceptible to corrosion. Corrosion that occurs in the conveyor structure is caused by damage to the coating due to contact with the environment. Therefore this research was carried out on the conveyor structure with the aim of knowing the type of corrosion and corrosion control methods applied to the conveyor structure. The measurement methodology used on the conveyor structure with a length of 90 meters and 25 test points is based on thickness reduction of the conveyor structure using Ultrasonic Thickness Gauge TT 130. This measurement obtain information about the actual thickness of the conveyor structure which then becomes the input for calculating the Corrosion Rate and Remaining Life of the conveyor structure.The research conditions from 2015-2019 showed rainfall of 206.78 mm/year, air temperature of 28.09OC, and humidity of 78.78%. These environmental conditions will cause corrosion when interacting with the conveyor structure. Corrosion that occurs on the conveyor structure is a type of uniform corrosion. Corrosion control is carried out on the conveyor structure by using the three layers system coating method. This system consists of primary coating using Seaguard 5000, intermediate coating using Sherglass FF, and top coating using Aliphatic acrylic modified polyurethane. Abstrak. Pengangkutan batubara di PT XYZ di Kabupaten Tanah Laut, Provinsi Kalimantan Selatan menggunakan alat angkut berupa conveyor. Struktur conveyor yang digunakan berbahan dasar baja karbon (low carbon steel) yang rentan terjadi korosi. Korosi yang terjadi pada struktur conveyor disebabkan karena adanya kerusakan pada coating akibat kontak dengan lingkungan. Oleh karena itu dilakukanlah penelitian pada struktur conveyor dengan tujuan untuk mengetahui jenis korosi dan metode pengendalian korosi yang diaplikasikan pada struktur conveyor. Metodologi pengukuran yang digunakan pada struktur conveyor sepanjang 90 meter dan 25 test point ini berdasarkan pengurangan ketebalan struktur conveyor menggunakan Ultrasonic Thickness Gauge TT 130. Pengukuran ini membantu dalam mengetahui tebal aktual struktur conveyor yang selanjutnya menjadi input untuk perhitungan Corrosion Rate dan Remaining Service Life struktur conveyor. Kondisi penelitian dari tahun 2015-2019 menunjukkan curah hujan sebesar 206,78 mm/tahun, temperatur udara sebesar 28,09OC, dan kelembapan udara sebesar 78,78%. Kondisi lingkungan ini akan menyebabkan korosi ketika berinteraksi dengan struktur conveyor. Korosi yang terjadi pada struktur conveyor merupakan jenis korosi merata. Metode pengendalian korosi yang diaplikasikan pada struktur conveyor adalah metode coating three layers system. Sistem ini terdiri dari primer coating menggunakan Seaguard 5000, intermediate coating menggunakan Sherglass FF, dan top coating menggunakan Aliphatic acrylic modified polyurethane.
The article considers the causes of dynamic stress when moving a conveyor belt with a material. The main factors of the occurrence of the dynamic resistance in the conveyor system are defined. It is demonstrated what the propagation speed of perturbations substantially depends on the loading level of the conveyor system with the material. When constructing a model of dynamic stresses, Hooke’s law was used, which is an accurate approximation for most solid bodies, as long as the forces and deformations are small enough. In the article, the main attention is given to the causes of dynamic stresses at the start of the conveyor system. When calculating the deformations, the inertia forces of the moving material and tape are considered. The analysis of the appearance of dynamic stresses at a constant value of the conveyor belt acceleration and the linear nature of the change in the value of the conveyor belt acceleration was carried out.
Controlling the amount of material flow coming from the accumulated bunker to the input of the conveyor line and controlling the speed of the conveyor belt are common ways to reduce the energy consumption of the transport system. However, most works do not take into account transients associated with a change in the speed of the conveyor belt or a change in the input material flow. As a result of transient processes acceleration or deceleration of the conveyor belt occurs and dynamic stresses arise. These dynamic stresses can exceed the permissible values. In this study, the task of analyzing the causes of dynamic stresses in the transition process is considered. When constructing a model of dynamic stresses, the Hooke’s law was used. The model of resistance to the movement of the conveyor belt is adopted in accordance with DIN 22101: 2002–08. The analysis of the propagation of waves of dynamic stresses in the conveyor belt has done. The formation of dynamic stresses as a result of the addition of the forward and backward waves is considered.
In order to ensure ecological transport without failure requirements for the transport of bulk materials by continuous conveyor systems, careful attention should be given to the proper shape of the conveyor belt which is provided by positioning the idler rolls in the idler housing of the pipe conveyor. This paper presents the research on idler housing contact forces (CF) at the cross-section of the loaded conveyor belt filled up to 37.5% and 75%, resulting in a multiple linear regression model in the form: CF = β0 + β1TF + β2M + ε, where TF is the tension force and M is the material filling volume. Based on it, the relative changes of the contact forces were subsequently processed. From the analysis obtained, the position of the most suitable placement of the strain gauge contact force sensors on the idler rolls is proposed, in view of the timely detection of the warning values for failure analysis.
