The project was completed in 2011.

Cable belt conveyer

The distinctive feature of the Cable Belt Conveyer is separation of functions: the transport function is performed by the belt; the traction is performed by the cables.

The belt lies on the cables, at the same time the cables lie on the rollers. The cables and the belt with them together are moved by a driving station, located near the conveyer head (unload place). In the ends of the conveyer the cables are withdrawn from under the belt and are conducted to driving or by-pass sheaves.

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Thanks to such a structure, in comparison with an ordinary belt conveyer, the less power consumption, bigger speed and less quantity of the roller supports are provided.

Required characteristics

The Cable Belt Conveyer had to be used for the mining, when the soil cargo is moved toward unload place with one direction.

The Cable Belt Conveyer had to have one turning in vertical plane, without turning in horizontal plane. The unloading point was located at the height 23м.

From the very beginning of the Conveyer development following actions performed in parallel: subject investigation, analysis of analogues, conception elaboration, principle schema creation, traction calculation. The principle schema and the traction calculation created as very flexible ones, because many parameters were not yet defined or changed in time. Such flexibility was complicated but effective.

The structure description

The principle schema and setting-up of the conveyer basic components. 

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Then there were performed:

In parallel, there was performed the development of conveyer detailed structure in first iteration, before stress calculations.

The regular zone of the conveyer consisted of the frames with the rollers at the balance beams, supporting the cables with the belt. The frames installed with 5 m pitch. All rollers (at the frames, at load and unload stations) in their basis had one single centre boss, domestically mass produced, what allows to decrease cost. The roller lining was an easy detachable polyurethane profiled ring.

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According to the task, unload station had to be placed at 23 m height. In this case there was the necessity to place end part of the conveyer at a horizontal truss. The 60 m length truss was installed on two supports:

The unload station was placed at the end of the truss. There was a frame with following aggregates attached:

The by-pass sheaves of the cables were installed in to their own frames. After the turn at the by-pass sheaves the cables conducted directly under the lower by-pass barrel of the belt thanks to slant position of the cable by-pass sheaves. Thus, unloaded part of the belt was supported by cables.

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The driving station had intermediate position, as near as possible to the conveyer head. Such a position complicated the conveyer structure but placed heavy components of the driving station at the end of the truss is high-risk.

On the represented schema of the driving station it was difficult to reach circumscribe angle of driving sheave more then 215°, but required driving power weakly depends on that. Much more it depended on friction coefficient between the belt and the lining of the driving sheave.

Thus this schema was very simple. Additional advantage was absence of reverse bend of the cable what is positive for cable resource. This schema has been developed in ECAR and it was an innovation not applied before.

The support of upper (loaded) part of conveyer in driving station zone was the same as for regular frames. For the lower part of conveyer there were installed rollers lifting over cables and supporting the belt. The cables withdrawn from under lifted belt with deflecting sheaves and conducted to the driving sheaves.

Then the cable directed toward the belt thanks to slant position of by-pass sheave. The cable conducted under the belt with deflecting sheaves.

The driving station had concrete basis.

The driving and by-pass sheaves were installed in frames.

The driving sheave had detachable aluminum lining.

The drive consisted of electric motor, reduction gear, muffs and breaks.

The deflecting sheaves were installed in brackets on concrete basis.

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The load station was a frame with following aggregates attached:

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The cable tension station was located behind the load station.

This position leaded to increasing of the tension, because the longer distance from the driving station, the bigger required tension. But with such a schema of the conveyer structure became simple because of additional tension sheaves absence. The sheaves of the tension station combined by-pass and tension functions. Moreover there was decreased resistance in this case.

The withdrawal of the cables from under the belt was analogous to the unload station with following peculiars:

The electric winch of the cable tension station consisted of:

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The belt tension station was located behind the load station also, because that was preferable to pull the belt in the same zone as for the cable, otherwise there is the risk of the belt and the cables separation. Moreover, this schema was simple.

The cart of the belt tension station had following aggregates:

The cart moved along rails.

The gravity loading devise of belt tension consisted of:

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In irregular zones, the frames with supporting rollers had different height to provide smooth turning in vertical plane. The smoothness was necessary to avoid separation of cables from the rollers. Thus, the weight of the cables and the belt exceeded vertical constituent of the tension. Otherwise, there was the necessity of enough complicated devise with cable and belt separation. Such a devise would be high loaded and add resistance.

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The conveyer had protection from atmospheric precipitations, as in some conditions start and work of the conveyer could be impossible.

To shorten the term of the conveyer construction, one of the priorities was the definition of loads to concrete bases, which could be made by building company before completion of the conveyer development. Thus, there were performed stress calculation of the supporting frames and definition of loads from the supporting frames and the end truss to their supports.

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The project was stopped by customer at the beginning of working designing.