Академический Документы
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Heinz Hller
1. Introduction
The design of reliable belt conveyors, particularly for steady operating conditions, is governed by numerous standards and regulations. The design engineer has to pay special attention to the starting and braking sequences with a view to the service life and the capital cost of the belt. These operating conditions can be influenced positively by judicious use of hydrodynamic couplings in belt conveyor drives.
TP P
TT T
1: Physical regularities
Commensurate with physical laws, hydrodynamic couplings (turbo couplings) are classified as fluid machines. These machines are characterised by torque being transmitted proportionally to the square of the input speed. If portrayed graphically, this is designated as primary behaviour or slip parabola [2]. The operating behaviour (secondary behaviour) can be represented by the characteristic relationship of the performance figure ( = f (v) (characteristic curve)
(Fig. 2). Usually, the characteristics of a turbo coupling are described as a function of the torque depending on the speed ratio v = nT/nP of various fillings (secondary performance chart). Depending on coupling type and filling volume, the magnitude and shape of relevant characteristic curves may vary considerably. In order to achieve a mass flow which transmits power, a difference in speed between pump and turbine is required
TA
max. filling
TN
min. filling
TN
min. filling
even during nominal operation. This difference is mainly quoted as slip s = 1 = v. For start-up and overload couplings, the characteristic curve occurring during continuous operation should be as steep as possible, in order to keep the slip during nominal operation at a minimum. In the high slip range up to the breakaway point TA , the curve should run horizontal to achieve torque limitation. Absolute levels of torque can be transmitted by varying the fluid level. For variable-speed and fill-controlled couplings, the curve for any filling should fall continuously while the speed is increasing. In this way, controlled start-up phases with narrow torque limitation are possible. If the interception between coupling curve and load curve is clear-cut, it is possible to set stable operating points below the nominal speed, e. g. for inspection of the unloaded conveyor. Developing a curve which is perfect for the application solely in accordance with hydraulic laws is still very difficult. Coupling curves are therefore mainly determined during tests. The primary and secondary characteristics of a coupling are best illustrated in a three-dimensional diagram (Fig. 3). When looking at the system, such a graph is useful if the torque being built up during motor run-up is sufficiently high to break away the conveyor. Fig. 3 shows all relevant hydrodynamic correlations. As a result of the reciprocal
3: Basis of coupling design
Hydrodynamic couplings
Variable speed coupling fill controlled coupling Variable filling during operation
Setting of filling
Innerdelay chamber
Scooptube
Discharge pump
Standing housing
Rotating house
3
Designation of blades: P=pump
4
T=turbine
action between primary and secondary function, coupling curves can be achieved that take into account criteria such as time, speed, slip and filling volume.
their design or type. Apart from the steady-state characteristics of a conveyor, its start-up and retardation behaviour must also be taken into consideration when a coupling is selected. With reference to VDI standards, the couplings suitable for belt conveyors can be classified as shown in Fig. 4. The classification depicts two basic types with seven individual designs that would normally be used for materials handling. The constant-fill coupling is the most popular type used for bulk materials handling (Fig. 5), due to its uncomplicated de-
5: Constant-fill coupling with delay chamber and annular chamber TVVS (Design 2).
sign, minimum maintenance and very competitive cost. This coupling type is filled with operating fluid prior to commissioning, and there is no external oil supply. For designs 2 and 3 (Fig. 4), the operating fluid for the coupling is distributed differently, particularly for operating conditions other than continuous operation (e. g. starting and stopping). This coupling type is mainly chosen to enable a no-load start of the motor, torque limitation and to influence the torsional vibration behaviour. Their basic characteristic curve corresponds to the one shown in Fig. 2 for start-up and overload couplings. Variable-speed and fill-controlled couplings are used on belt conveyors with special requirements relating to the build-up of tensile force, torque limitation and operating behaviour. Variable-speed couplings which allow altering the fluid level in the working chamber are available in two basic designs. These couplings are equipped with an additional external fluid circuit which can be used for varying the fluid level as well as cooling. For design 4 (Fig. 6), the fluid level is set by means of a radially movable scoop tube. The design may be varied by different arrangements of scoop tube, oil tank and oil supply. In principle, the performance
Fig. 7: Variable-fill coupling with discharge pump DTPK (Design 5)
chart refers to the design shown for variable-speed and fill-controlled couplings. With designs 5, 6 and 7, the fluid level is determined by matching the supply flow rate with the discharge rate of fluid at the spray nozzles. Pilot or control valves are used as actuators in the supply flow. Design 5 (Fig. 7) distinguishes itself by its compact design, good control behaviour and lower losses compared to designs 6 and 7.
Dependent on its type and design, the hydrodynamic coupling can aid the asynchronous motor in several ways. The load on the motor during start-up resulting from load torque and the mass to be accelerated is solely determined by the coupling; the belt conveyor is virtually separated from the motor. The coupling torque is built up from zero with the square of the motor speed. For identical nominal operating conditions, the amount of start-up load can be selected from a wide range. Depending on their design, constant-fill fluid couplings can build up a considerable amount of torque during motor startup (Characteristic curves a to c). Empty variable-speed couplings, on the other hand, just generate a slip torque which can be regarded as insignificant (Characteristic curve d). Even the constant-fill coupling of design 1 without delay chamber already provides noticeably softer motor start in the peak current range. It allows torque to build-up in seconds rather than milli-seconds and its operating fluid provides additional thermal storage capacity on for start-up. The graph in Fig. 8 also shows how this type has developed in recent years from T to TVV and TVVS couplings with delay chamber and annular chamber.
The application of variable-speed and fillcontrolled couplings of designs 4 to 7 eliminates the disadvantageous features of asynchronous motors almost completely.
Fig. 8: Build-up of coupling torque in relation to motor speed with output (turbine wheel) at standstill.
condition of the conveyor. Applications are usually found in combination with gear motors.
Design 1 Type T
T TA~0.4-0.6 s TN
Design 2 Type TW
(TV) TA~0.5-1 s
T TN
TA relative to T = 1 TN
Design 1 (T coupling):
Suitable for shorter belt conveyors with a possible torque limitation of up to 1.8 times the nominal torque at good nominal slip. The torque is not adapted to the load
T TN
As a result of the fluid volume being separated during start-up (V, VV, S), centrifugally operated valves (F) control the emptying of the delay chamber (Y) as a function of slip, to produce an optimum starting characteristic. This is achieved with standard components common to all couplings used for crushers, chain conveyors, etc.
such as creep speed (variable-speed couplings) and regenerative braking. These operating conditions have to be discussed in more detail with the coupling manufacturer.
in a close chain of materials handling machinery. In synergy with other machines and equipment, the conveyor should guarantee a continuous flow of materials. The start-up control and operation monitoring system of individual conveyors and their drive systems should be suitable for integration into a central control system,
5. Examples of application
In the materials handling industry, an individual belt conveyor is often just a link
TX TX n nN
TOL
TPartial load
Gearbox
fig. 13: 560 kW drive unit for underground application 750 DTP fill-controlled coupling with water as operating medium
Fig. 12:
in order to ensure that the entire plant can be operated automatically. Arduous starting conditions can be caused by weak electrical systems and/or the build-up of dirt and dust, which can be endemic in mines, etc. For such complex installations, variablespeed with adjustable scoop tube or variable-fill couplings are the preferred choice. Drives with variable-speed couplings allow the motors to be started in sequence while the coupling is drained, which minimises the strain on the electrical system. The belt conveyor can only
Fig. 14: TVVS constant-fill coupling operation
be started after receiving green light from the general operation monitoring system (voltage, speed, lubrication pressure, etc.). With integrated systems it is particularly important that the starting sequences and starting times of the individual conveyors are adapted with each other. Therefore, start-up times should be adjustable, independent of the load condition (Fig. 11). After the release signal from the monitoring system, the conveyor is started by a micro-processor-controlled start-up system. The control system is designed as a multi-stage control cascade with diffe-
rent parameters. The torque build-up time is used as the main control variable until the conveyor has broken away, while constant acceleration is used as a control variable after conveyor break-away. Subordinate control circuits can be used in order to monitor whether the torque limits, the operating fluid temperature and, with multi-motor system, the load sharing are correct. Specific start-up problems can be solved either by using a drive unit complete with start-up controller and an interface that is compatible with the central control system (Fig. 12), or a compact coupling unit (Fig. 13) that can be integrated into the customers own system. In practice, companies often use different coupling types for various belt conveyors, in order to achieve optimum operating conditions. Compared to a variable-speed coupling, the constant-fill coupling type TVVS (Fig. 13) with its simpler design offers sufficient performance characteristics for belt conveyor applications. This coupling has been developed specifically for the super soft start of belt conveyors. In addition to its internal delay chamber it also features an external annular chamber. The following paragraph describes the distribution of the operating fluid and its effect on the operation of the coupling for the three operating conditions standstill, 100% slip and normal operation.
Voith Turbo GmbH & Co. KG PO. Box 15 55 D-74555 Crailsheim Germany Phone (0 79 51) 32 - 0 Fax (0 79 51) 32 - 5 00 http:/www.voithturbo.de E-Mail info-turbo@voith.de
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When the conveyor is at standstill, the operating fluid is distributed to the three chambers (delay chamber, working chamber and annular chamber). During motor start-up and 100% slip the operating fluid level in the delay chamber remains almost constant, while the external annular chamber is filled with fluid from the working chamber as a result of centrifugal effect during the initial motor revolutions. The remaining fluid in the working chamber builds up a very low torque from standstill. The working chamber is then filled (time-dependent via internal nozzles) with the fluid from the delay chamber. In this way it is possible to achieve a low starting torque during motor run-up with ensuing smooth build-up of torque and low slip in normal operation (see Fig. 9). The smooth torque build-up and the adaptation to existing load conditions have been proven on the test stand while the customer was present (Fig. 15). A belt conveyor was simulated by a fixed fly-wheel mass and a controlled mechanical multiple-disc brake; a squirrel-cage motor rated at 200 kW/1500 rpm was used as the driver. The torque MK transmitted by the coupling was measured versus time. In each case, the start of the
Fig. 15: Characteristic torque curve of a type 487 TVVS coupling. Torque adaptation capability was proven on the test stand
measurements was initiated by motor speed. In all load conditions, from empty conveyor (1) to overloaded conveyor (3) the coupling builds up the torque required for that condition. In condition (1) the belt conveyor was started already during the motor run-up phase, in condition (2) start-up took place approximately 7 seconds after motor run-up, while it occurred after approximately 22 seconds when the conveyor was overloaded, but still with excellent torque limitation. Measurements and data collected at Hanover University are based upon a well co-ordinated conveyor system which runs steeply uphill, with two drums and a three-motor head drive.
The motors are started consecutively. After the motor run-up, the torque which is proportional to the power consumption, is only slightly in excess of that necessary to run the conveyor at constant speed (permanent power). This good torque limitation is only possible in very well balanced systems, as the characteristic curve for constant-fill couplings will always show slight modulations as a result of its operating principle.
6. Summary
The application of hydrodynamic couplings on belt conveyors and the operating principles of these couplings are governed by the criteria on which individual coupling types or designs are selected. The aforementioned examples can only be regarded as an extract of the numerous applications for hydrodynamic couplings on belt conveyors for bulk material conveying.
Fig. 16: Steep belt conveyor system with type 562 TVV constant-fill coupling
VDI regulation 2153: Hydrodynamic Power Transmission - April 1994 VDI Regulation 3602 Belt conveyors for bulk materials, part 2, draft 1996 Funke, H.: Hydrodynamic couplings in conveyor systems, Lecture at Esslingen Technische Akademie, - April 1984 Hller, H.: Control of drive units by means of hydrodynamic couplings, VDI-Z, Special, Oil Hydraulics and Pneumatics 1/1989Measurements carried out at Hanover University on behalf of Voith Turbo, Crailsheim.
Cr 579 e 01/99. 1 K&E Printed in Germany Subject to modification due to technical development.
7. Bibliography