Measurement 52 (2014) 22–32

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Measurement
journal homepage: www.elsevier.com/locate/measurement

Analysis of asymmetrical effect of tension forces in conveyor

belt on the idler roll contact forces in the idler housing
Vieroslav Molnár a,⇑, Gabriel Fedorko a, Beáta Stehlíková a, Marianna Tomašková b,
Zdenka Hulínová c
a
Faculty of Mining, Ecology, Process Control and Geotechnology, Technical University of Kosice, Park Komenskeho 14, 042 00 Kosice, Slovak Republic
b
Faculty of Mechanical Engineering, Technical University of Kosice, Letna 9, 042 00 Kosice, Slovak Republic
c
Faculty of Civil Engineering, Slovak University of Technology in Bratislava, Radlinskeho 11, 813 68 Bratislava, Slovak Republic

a r t i c l e i n f o a b s t r a c t

Article history: This paper analyses an impact of asymmetrical tension forces, which are occurring in the
Received 13 January 2014 conveyor belt, on the contact forces in the guiding idlers. It describes causes of an
Received in revised form 15 February 2014 increased wear-out of the conveyor belts due to an asymmetric tensioning of the trans-
Accepted 24 February 2014
port belt. There were investigated five measuring points loaded with a symmetrical and
Available online 4 March 2014
asymmetrical tensioning of a specimen section of the pipe conveyor transport belt, using
the Friedman test for the factor of asymmetry. The tension force determines also
Keywords:
changes of the contact force layouts in the individually investigated idler rolls. A newly
Tensioning of conveyor belt
Description of rheological properties of the
developed method was applied in order to identify states of the particular experimental
conveyor belt phases for the process of the transport belt tensioning and relaxation. This method is
Influence of asymmetry on the belt position based on differences of the contact force time behaviours. It is possible to present a
and on the belt damaging hypothesis, taking into consideration the obtained results that a side slipping of the run-
ning conveyor belt is caused by the tension force asymmetry also on the real operational
conditions.
Ó 2014 Elsevier Ltd. All rights reserved.

1. Introduction a large variety of the bulk materials. The pipe conveyor is a

A belt conveyor is one of the most often applied trans-
port equipment, which is used for transportation of the
bulk solids [1]. The belt conveyor is such kind of the trans-
port and handling machinery, which is specified to carry a
loose material and it is employed in the various industrial
branches, such as the mining industry, building industry,
metallurgical industry, as well as in the seaports, thanks
to its numerous advantages [2].
The tubular belt conveyor system (which is called also
the ‘‘pipe conveyor’’) is a specific type of the belt conveyor
with respect to its tubular shape and it is able to transport
⇑ Corresponding author. Tel.: +421 556023147; fax: +421 556028023.
E-mail address: vieroslav.molnar@tuke.sk (V. Molnár).
relatively important continuously working transport
equipment applied in the modern intensive production,
for example in the industry of metallurgy, industry of coal,
building industry and in the other different industrial
branches [3]. A safe and reliable operation of the pipe con-
veyors requires an application of the modern control
system.
The main purpose of design and development of the belt
conveyor control system is to minimize a physical labour
necessity, to reduce energy consumption, together with
reduction of the required information and in this way to in-
crease also the global efficiency of the conveyor operation,
as well as to reduce an occurrence of accidents [4].
A correct functioning of the control system requires
obtaining of the indicators that are able to predict a
possible emergence of the crisis situation on time. These

http://dx.doi.org/10.1016/j.measurement.2014.02.035
0263-2241/Ó 2014 Elsevier Ltd. All rights reserved.
 V. Molnár et al. / Measurement 52 (2014) 22–32
indicators should be able to evaluate also an optimal solu-
tion, which can lead even to a preventive shut down of the
whole transport system.
Petrikova et al. [5] presents an experimental and
numerical investigation of the conveyor belt behaviour.
The investigated belt is made from the carbon black filled
rubber, reinforced by the plain weave textiles. The
mechanical properties where investigated by means of
the tensile tests with the different loading rates, together
with the relaxation tests, whereas the friction coefficient
was measured, too. Makowski and Zimroz [6] analysed
new techniques of the local damage detection in a machin-
ery based on a stochastic modelling, using the adaptive
Schur filter. Hu and Li [7] studied a failure diagnostic strat-
egy of the belt conveyor. They applied a special failure
diagnostic method, which is based on the multi-sensor fuz-
zy information fusion. Prenner and Kessler [8] are dealing
with the development of an energy recovery system for
the belt conveyors. Czuba and Furmanik [9] performed an
analysis of a grain motion in the transfer area of the belt
conveyor. They presented a study of grain motion in a par-
allel chute and a methodology for calculation of the impact
angle and tangential speed of the grain at the point of
contact with the receiving conveyor belt. Yu et al. [10]
published an investigation and comparison of a soft-start
systems applied for the belt conveyors.
It is possible to utilize various research and analytical
methods during investigation process of the conveyor belt
properties. Fedorko et al. [11] studied a failure analysis of
the textile rubber conveyor belt, which is damaged by
the dynamic wear. Zimroz and Król [12] examined the
most frequent failures, types and the location of the fail-
ures together with their importance in the context of
maintenance of a conveyor belt transportation system.
Zhao and Lin [13] analysed two typical failure forms of
the rollers and transport belt of the belt conveyor and they
described the suitable maintenance methods for a preven-
tion and for failure elimination in order to ensure the nor-
mal belt conveyor operation. Liu and Wang used the
extenics theory to establish the matter-element model
for the quality evaluation of the belt conveyor [14]. Pang
and Lodewijks [15] applied the Finite Element Method
(FEM) for a research of the transport belt characteristics
in the case of pipe conveyors. This study presents a design
of the pipe conveyor test rig and the testing results. The
FEM was used in order to simulate the static behaviour
of the belt, which is embedded on one idler set of the pipe
conveyor. Fedorko and Ivančo [16] analysed the force con-
ditions in a belt of the classic belt conveyor by means of the
Finite Element Analysis method (FEA). Hu and Guo [17]
utilized a new method of the virtual prototyping technol-
ogy for the belt conveyor dynamic design in a connection
with investigation of the conveyor belt properties. Rao
et al. [18] investigated an influence of the constant cyclic
strain loading on the fatigue and fracture behaviour of
the steel cord/rubber composites. Kozhusko and Kopnov
[19] studied the fatigue behaviour of three types of the fab-
ric conveyor belt subjected to a shear loading. Hardygora
and Golosinska [20] defined the relationships between
the impact resistance of the belt and the design the mea-
suring and analysing of the acoustic emission from a belt
23
on different conditions inside an enclosure. Fazenda et al.
[21] dealt with acoustic diagnosis of driving belt physical
condition in enclosures. Bolden et al. [22] studied a struc-
tural impact damage under varying laboratory conditions.
Luo et al. [23] researched and analysed the belt-conveyors
using the purely mechanical belt-broken seizing machine.
Zhang and Steven [24] dealt with a dynamical analysis.
They monitored the conveyor’s starting and stopping
behaviour in order to improve a design and reliability of
the long overland pipe conveyor systems. Harrison [25]
calculated a safety factor for the high-tensioned inclined
belts using the NDT signal analysis.
The important factors of conveyor belts are electronic
expert systems described by various authors. Li et al.
[26] dealt with an intelligent detection system for mine
belt tearing based on machine vision. Wang et al. [27]
researched on belt conveyor monitoring and control sys-
tem. The fault detection and control of belt conveyor
were done through the on-site sensors information signal
collection by remote monitoring of belt conveyor and the
motor protection. Li et al. [28] suggested automatic de-
fect detection method for the steel cord conveyor belt
based on its X-ray images. Xu et al. [29] designed the
intelligent protection system of coal conveyor belt, which
can improve intelligent degree of the whole burning coal
transport and reduce the manual greatly and save a lot
of funds for enterprise. Li et al. [30] tested online moni-
toring and fault diagnosis system for belt conveyors
which can locate the position of the faulty idlers with
a limited number of sensors, which is important for
operating belt conveyors in practices. Górniak-Zimroz
et al. [31] applied GISs to support belt conveyor mainte-
nance management. They selected the GIS environment
and the database standard, based on MS access, was dic-
tated by the widespread use of the environments in the
mines. Aldrich et al. [32] dealt with online analysis of
coal on a conveyor belt by use of machine vision and
kernel methods.
2. Material and methods of experiment
2.1. Problem formulation
The transport belt of the pipe conveyor is a very cost-
demanding component involved in the framework of the
whole transport system. This statement is confirmed by a
fact that the high financial expenses are related not only
with the purchase of a new transport belt, but also every
process of the belt replacement requires an undesirable
down-time of the given technology and in this way it
causes the additional financial loses.
Therefore the producers are developing new construc-
tions of the transport belts with a sufficient resistance
and durability in order to ensure the belt operational time
as long as it is possible. This intention is also in the interest
of the projection agencies and belt conveyor users. A more
detailed analysis of the damaging processes and transport
belt wearing during operation is an important question,
which is relevant for each of the above-mentioned con-
cerned parts.
24 V. Molnár et al. / Measurement 52 (2014) 22–32

One of the most often occurring occasions that are caus-

ing an extensive wear-out of the transport belts of the pipe
conveyors, is an asymmetric layout of the tension forces,
which causes also changes of the contact forces on the
guiding idler rolls in the idler housing. This process cannot
be observed during the initial phase of the pipe conveyor
operation. However, there is available an effective tool,
namely it is application of a special testing equipment,
which enables to perform a detailed monitoring of the pro-
cess and recording of the individual data together with an
experimental simulation of the various possible situations.
The transport belt has to be tensioned during the pipe
conveyor operation equally in order to transfer the circum-
ferential driving force from the driving pulley to the trans-
port belt and to ensure in this way a continuous material
movement and transport. The equal arrangement of the
tension force is a necessary condition for a correct transfor- Fig. 2. The missing idler roller in the idler housing as a result of the
unequal tension force.
mation of the transport belt from the flat shape to the
piped shape.
The pipe conveyor transport belt, which is tensioned
unequally, is exposed to the various kinds of the wearing
process that are arising simultaneously.
The first kind of the wear is a gradual change of the ini-
tially equal distribution of the belt mechanical characteris-
tics in the belt cross section. A result of this wear-out
process is an excessive stretching of the belt, which can
lead to the dynamical wearing of the transport belt finally.
The second kind of the wear, which is caused by the un-
equal tensioning, is a mechanical damage of the upper and
bottom covering layer as well as mechanical damage of the
belt side edge due to a cyclic repeating friction between
the belt and the conveyor supporting steel structure in-
stalled along the transport way. If the initial signals advis-
ing this wearing process are neglected, this situation can
result in a damage of the inner belt construction (Fig. 1).
Such kind of the transport belt damage is a serious nega- Fig. 3. Detail of damaged rubber-covering layer of the pipe conveyor
tive occurrence, which is able to cause a total destruction transport belt.
of the transport belt.
Another consequence of the unequal tensioning of the
conveyor belt is a side slipping of the belt from the driving A damage of the pipe conveyor transport belt due to an
and tensioning pulley during a current operation. Such unequal tensioning can be eliminated by means of a simple
phenomenon is able to cause a withdrawal of one or more mechanical device. This mechanical device serves for
idler rolls from the idler housing (Fig. 2) and if the belt is returning of the slipping belt back to the correct position.
running further despite of this critical situation, the empty However, this system is not reliable fully. From this reason
holder of the idler roller is able to cut up the belt totally it is suitable to apply also another system. It should be an
(Fig. 3). automatic electronic expert system applied in the frame-
work of the pipe conveyor current operation. The main
task of this system is monitoring and adjustment of the
transport belt position. It is based on a continuous moni-
toring of the selected idler housing characteristics.
Change of the contact force values in the guiding rollers
is one of the possible identification factors that are able to
predict occurrence of an undesirable shifting of the trans-
port belt. The contact forces are changing due to a mutual
interaction among the transport belt and guiding rollers.
An occurrence of asymmetric tensioning is a phenome-
non, which is typical for all kinds of the belt conveyors
operating with the rubber-textile or steel-cord conveyor
belts. The primary consequence of the asymmetric tension-
Fig. 1. Side edge wearing of the transport belt due to a friction between ing is a gradual damage of the conveyor belt edge in all
the belt and the steel construction as a result of the unequal tension force. these cases. If this phenomenon is neglected, so the
 V. Molnár et al. / Measurement 52 (2014) 22–32 25

damaged zone is extending towards the middle of belt and Table 1

the internal structure of the belt (textile structure or steel- Parameters of measurements.

cord structure) is damaged. At the same time there is also a Marking of Description Kind of Working
risk of a side slipping of the belt from the idler rolls or pul- measurement asymmetry notations
leys, which causes a stopping of operation, at least or there M1 Symmetrical TF23 = TF24 TF23 = TF24
is necessary a replacement of the whole belt, at worst. tensioning
M2 Asymmetry, TF23 > TF24 TF23 > TF24
difference 1000 N
2.2. Test equipment M4 Asymmetry, TF23 < TF24 TF23 < TF24
difference 1000 N
M5 Asymmetry, TF23 > TF24 TF23  TF24
The 8 m long specimen of the transport belt was fixed
difference 2000 N
into the test equipment, which was described closely in M6 Asymmetry, TF23 < TF24 TF23  TF24
Molnár et al. [33] according to Figs. 1 and 2 with a designa- difference 2000 N
tion of the idler housings and idler rolls.

3. Theory/calculation experiments [34]. Some of the partial tasks had to be

The experimental analysis was divided into the five
individual steps, taking into consideration a knowledge
base created during a study of the damage process of the
pipe conveyor transport belts. The individual steps are
interconnected mutually in a sequence. Therefore it is nec-
essary to perform these steps precisely in order to obtain
the correct and accurate partial results. The procedure
(Fig. 4) is based on a determination of the experiment final
task and it corresponds to the rules valid for a design of
solved due to the test equipment characteristics.
3.1. Task of the experiment
The main purpose of the experiment is to verify,
whether a change of the transport belt tensioning causes
also a change of the contact forces with regard to the sym-
metry or asymmetry of the tension forces.
3.2. Regimes of the experiment

There were realised measurements using the parame-

ters according to Table 1 in order to investigate an influ-
ence of the asymmetry during tensioning of the transport
belt.

(a) The set-up of the factor asymmetry is realised using

tensioning in the test equipment positions marked
ID23 and ID24 (This procedure is described closely
according to Fig. 1 in Molnár et al. [33]). The abbre-
viation TF means the Tension Force – so, it describes
character of the operation.
(b) The determined values of the tension force were
selected according to the experiments using the
results published in Molnár et al. [35,36,33]. The
tension force TFTotal, which is a sum of two forces
in the given experimental equipment TFTo-
tal = TF23 + TF24, was defined by the values
6000 N, 12,000 N, 18,000 N, 24,000 N and 30,000 N.
(c) The data were recorded by means of the sampling
frequency 10 Hz, thus every 0.1 s.
(d) Two educated persons performed a change of the
tension force independently. Each of the persons
adjusted one tension force TF23 and TF24 on the val-
ues according to the items (a) and (b). The testing
equipment remained 60 s without an intervention
after each set-up process and afterwards the tension
force was changed. A growing change of the tension
force was realised in this way.

3.3. Data obtaining for the measured values analysis

The facts known about the measuring equipment and

Fig. 4. Procedure for analysis of tension force asymmetry in conveyor the resulting consequences were taken into consideration
belt. for determination of a methodology specified for
26 V. Molnár et al. / Measurement 52 (2014) 22–32
Fig. 5. Time behaviour of the contact forces and tension forces in the idler housing No. 2 for the tension force TFTotal 12,000 N, 18,000 N and 24,000 N.
evaluation of the factor asymmetry influence. The belt ten-
sioning was performed manually by two service persons
simultaneously. From this reason it was not possible to
keep a fully synchronisation of the time behaviour during
the process of the tension force increasing.
The model – test equipment is a static one and after
achieving of the required tension force the system is stabi-
lised. Jump movements of the transport belt on the idler
rolls are typical for this stable state.
A ‘‘relaxation creep’’ of the transport belt material is an-
other important attribute. The both aspects are influencing
the contact forces. Fig. 5 presents the time behaviour of the
contact forces and tension forces in the idler housing No. 2
for the tension force TFTotal 12,000 N, 18,000 N and
24,000 N. The horizontal axis detects the absolute time of
the experiment. There are two vertical axes: the axis of
the contact forces in the idler rolls ID7–ID12 is on the left
and the axis of the tension forces TF23 a TF24 is on the
right.
Fig. 5 represents end of endurance with the tension
force defined at the value TFTotal = 12,000 N for the kind
of asymmetry TF23  TF24. The next phase is tensioning.
The vertical line ‘‘Line 1’’ defines a time, which was neces-
sary for achieving of the tension force TF23 – it was
reached the maximum value before the endurance. Ten-
sioning at the TF24 was not finished in this time. The fol-
lowing time interval in the graph illustrates the
endurance phase with the adjusted tension force value
18,000 N. It is possible to see a decrease of the TF23 and
TF24 during this phase. The time behaviour of the contact
force in the ID11 is decreasing during the endurance phase
(blue colour) and the time behaviour in the ID12 is increas-
ing in a polynomial form. The measuring process continues
during the next tensioning phase. The beginning of this
phase is marked with the vertical line ‘‘Line2’’, which en-
ables recording of a delay in the position TF23 in compar-
ison to the position TF24, as well as monitoring of reactions
from the tensioning, i.e. the change of the contact forces in
the positions ID7–ID12.
It was necessary to determine a methodology for a
selection of data obtained from the measured contact
forces M1–M6 for every tension force in order to evaluate
the factor asymmetry:
(a) In the same phase of the experiment.
(b) In the same time from beginning of the relaxation
phase.
(c) For the same tension force.
3.3.1. The same phase of the experiment
The data used for analysis are obtained from the relax-
ation phase with regard to the defined task of the
experiment.
3.3.2. The same time from beginning of the relaxation phase
This time was determined up to 30 s. The first vertical
line in the graph (Line 1) – i.e. the end of the tensioning
phase is the time point 248.1 s in the absolute time of
the experiment. The second vertical line (Line 2) – i.e. the
end of the relaxation phase and beginning of a new ten-
sioning phase is the time point 310.2 s in the absolute time
of the experiment. So, the difference between the ‘‘Line 1’’
and ‘‘Line 2’’ is approx. 60 s. The analysed data are coming
from the middle part of the relaxation phase. This brief
analysis confirms a complying with the experimental
methodology by the service persons.
It is not possible to determine exactly a start point of
the relaxation phase according to the records obtained
from the measurements and determination of the start
point using the graph is time demanding and subjective.
From this reason it was proposed a method of the phase
analysis based on the differences between successive
values. This method is founded on a logical assumption
that during the tensioning phase a difference between
two successive values of the tension forces is a positive
number. The evaluated tension force value is the TFTotal.
A calculation process, which used the given sampling
frequency, was not able to determine the boundary of
 V. Molnár et al. / Measurement 52 (2014) 22–32
the tensioning phase uniquely. From this reason the differ-
ence between the successive values was calculated using
the step 1–25 in the time interval from 233.9 s to 248.9 s
in the absolute time of the experiment. This modification
simulated a reduction of the sampling frequency. There
was also specified a number of negative differences for
each step during the given time interval – i.e. a number
of wrong signals concerning finishing of the tensioning
phase.
The shortest possible step D = 13 was determined from
the calculations and the wrong signals about finishing of
the tensioning phase were eliminated in this way.
Fig. 6 illustrates a reduction of negative differences in
the tensioning phase (transition of the curves below the
x-axis) if the difference step is increasing. The step D = 15
(1.5 s) and the number 10 of successive negative signs of
the signals were selected in order to determine the end
of tensioning phase
During the time between two tensioning phase, i.e. ap-
prox. in the middle of interval, the tension force differences
are oscillating about the zero level for all steps and the sys-
tem is stable sufficiently. This fact confirms a suitability of
the adopted decision to use the data obtained in the time
30 s after the relaxation phase beginning.
3.3.3. The same tension force
The largest problem was to meet a requirement of the
same tension force during the measuring process. It was
impossible to keep the same tension force on the given
Fig. 6. Time behaviour of negative difference reductions in the tensioning phase with an increasing step of difference.
27
conditions. From this reason the factor of asymmetry was
evaluated using only a relative method taking into consid-
eration results from the previous calculations Molnár et al.
[36,33], that documented a dependence of the contact
force values on the tension forces values, as well as mutual
relations among the contact forces.
There were applied 100 successive values of the contact
forces in each of the positions ID1–ID18 for the every de-
fined tension force in the given time of the relaxation
phase. The arithmetic mean for each kind of asymmetry
and for each position is a basis for the next calculations.
The idler housing No. 1 with the positions ID1– ID6, the id-
ler housing No. 2 with the positions ID7–ID12 and the idler
housing No. 3 with the positions ID13–ID18 were evalu-
ated individually, whereas the sum of contact forces in
the every idler housing = 1. A ratio of the contact force in
each of the idler housing positions was defined as a new
variable, which is evaluated for the every kind of asymme-
try. Calculation of a new variable is presented in Table 2
and in Fig. 7, where the contact force [N] distributions
are summarized and the contact force ratios in the individ-
ual positions ID1–ID18 are arranged, as well.
3.4. Selection of statistical method for influence evaluation of
the factor ‘‘tension force asymmetry’’ and its application
3.4.1. Determination of the factor evaluation criteria
An impact of the factor is considered to be relevant, if
the change of tensioning symmetry causes a change of
28 V. Molnár et al. / Measurement 52 (2014) 22–32

Table 2
Contact force [N] distributions and contact force ratios in the individual positions ID1–ID18.

TFTotal determined at 24,000 N, Measurements M1 TF23 = TF24

Position ID1 ID2 ID3 ID4 ID5 ID6 Sum No. 1
Average contact force [N] 354 169 375 223 370 624 2116
Ratio 0.167 0.080 0.177 0.105 0.175 0.295 1.00
Position ID7 ID8 ID9 ID10 ID11 ID12 Sum No. 2
Average contact force [N] 73 35 119 192 171 176 767
Ratio 0.096 0.045 0.155 0.250 0.223 0.230 1.00
Position ID13 ID14 ID15 ID16 ID17 ID18 Sum No. 3
Average contact force [N] 158 107 80 71 27 33 214
Ratio 0.739 0.501 0.372 0.331 0.128 0.154 1.00

Fig. 7. Contact force ratios in the individual positions ID1–ID18.

the contact force distributions in the positions of the idler
rolls in the idler housing. The ratios for each of the mea-
surements M1–M6 were determined and the matrixes of
the measured results were created consequently for each
of the positions ID1–ID18, as it is presented in Table 3 for
the position ID7. The corresponding values between Tables
2 and 3 are marked with italics.
3.4.2. Statistical test and its evaluation
The matrix of results has an internal structure of a dou-
ble classification with one result for each combination of
the factor levels. It is possible to say, taking into consider-
ation method of the matrix obtaining that application of a
non-parametric test was more suitable. The configuration
meets a requirement concerning the data arrangement
for the Friedman test. The groups were created by means
of the defined factor asymmetry of the TF23 in relation
to the TF24. The block factor was the tension force. In the
case that the null hypothesis about a conformity of the
group distribution functions will be neglected, it will be
realized a multiply comparison according to the Nemenyi
method [37].
The calculations were realised using the same input
data matrixes, together with the block factor asymmetry
and with the group factor tension force.
4. Results

Table 3 Table 4 presents results of the statistical hypothesis

Matrix of the measured results for the position ID7.
testing.
Measurements at ID7
Tension force [N] M1 M2 M4 M5 M6 4.1. Evaluation of the statistical test results
TFTotal = 12,000 0.080 0.092 0.092 0.104 0.103
TFTotal = 18,000 0.089 0.094 0.087 0.097 0.090 4.1.1. Factor of asymmetry
TFTotal = 24,000 0.096 0.103 0.097 0.104 0.099
The obtained results proved a fact that if the tension
TFTotal = 30,000 0.104 0.108 0.108 0.114 0.108
forces are not symmetrical, so the contact force
 V. Molnár et al. / Measurement 52 (2014) 22–32 29

Table 4
Results of the statistical hypothesis testing.

Position Test criterion Friedman Set-up of asymmetry for Test criterion Friedman test for factor Set-up of tension force for
test for factor asymmetry statistically relevant tension force statistically relevant
M1, M2, M4, M5, M6 difference TFTotal = 12,000 N, TFTotal = 18,000 N, difference
TFTotal = 24,000 N, TFTotal = 30,000 N
ID1 13.4 M5–M6 14.04 12,000 N–30,000 N 12,000 N–
24,000 N
ID2 3 15 12,000 N–30,000 N
ID3 12.6 M5–M6 15 12,000 N–30,000 N
ID4 8.8 15 12,000 N–30,000 N
ID5 7.8 15 12,000 N–30,000 N
ID6 13 M5–M6 M4–M5 11.88 12,000 N–30,000 N 12,000 N–
24,000 N
ID7 12.4 M1–M5 12.12 12,000 N–30,000 N 18,000 N–
30,000 N
ID8 7.4 15 12,000 N–30,000 N
ID9 7.4 11.88 12,000 N–30,000 N 18,000 N–
30,000 N
ID10 7.6 11.16 18,000 N–30,000 N
ID11 4.6 8.28 12,000 N–30,000 N
ID12 5.4 6.12
ID13 7 15 12,000 N–30,000 N
ID14 6.2 15 12,000 N– 30,000 N
ID15 12.2 M1–M6 15 12,000 N–30,000 N
ID16 8.2 15 12,000 N–30,000 N
ID17 11 M1–M6 15 12,000 N–30,000 N
ID18 8.6 15 12,000 N–30,000 N
Critical value 8.80 7.8

distributions are changing only in several positions from
the group ID1–ID18.
In the case of the idler housing No. 1 influenced are the
positions ID1, ID3 and ID6. A statistically relevant
difference in the distribution function, concerning a popu-
lation of selections, was recorded for levels of the factor
M5–M6, i.e. for the opposite asymmetry of the type
TF23  TF24 and TF23  TF24. A similar situation is in
the position ID6 also between the levels M4 and M5, thus
TF23 < TF24 and TF23  TF24. Fig. 8 illustrates a change in
distribution of the contact forces in the position ID7 due to
the factor of asymmetry.
In the case of the idler housing No. 2 the factor of asym-
metry was relevant statistically only for the position ID7
and between the levels M1 and M5, i.e. TF23 = TF24 and
TF23  TF24.
In the case of the idler housing No. 3 the factor of asym-
metry was relevant statistically for the positions ID7 and
ID17, between the levels M1 and M6, thus TF23 = TF24 a
TF23  TF24.
4.1.2. Factor tension force
The results confirmed a finding that a change of the
tension force causes a change of the contact force
distributions in the positions ID1–ID18, excepting the
position ID12. The limit values TFTotal = 12,000 N and
TFTotal = 30,000 N are situated among the results of the
statistically important differences between the individual
levels. Fig. 9 illustrates a change of the contact force distri-
butions in the position ID7 due to the tension force factor.
Figs. 10 and 11 describe differences caused by the
change of tensioning symmetry for the TFTotal = 24,000 N.

Fig. 8. Change in distribution of the contact forces due to the factor asymmetry.
30 V. Molnár et al. / Measurement 52 (2014) 22–32

Fig. 9. Change in distribution of the contact forces due to the factor tension force.

Fig. 10. Differences caused by the change of tensioning symmetry for the asymmetry 1000 N.

Fig. 11. Differences caused by the change of tensioning symmetry for the asymmetry 2000 N.

A difference of the contact force ratios between the asym- represents a state for the symmetric distribution M1
metric and symmetric set-up of the tension forces was ap- TF23 = TF24. The changes caused by the change of symme-
plied in order to present the change. The horizontal axis try are depictured in the graph. The changes for the
 V. Molnár et al. / Measurement 52 (2014) 22–32
asymmetry 1000 N are in Fig. 10 and the changes for the
asymmetry 2000 N are in Fig. 11.
4.2. Summarization of results
The results of statistical testing confirm a truth that a
change of the tension force asymmetry causes also a
change of the contact force distribution. Another factor,
which influences the change of the contact force distribu-
tions, is a tension force value. Concurrence of both these
factors cannot be confirmed or rejected according to the
realized analysis.
5. Conclusions
The transport belt installed in the pipe conveyor, which
is tensioned unevenly, is subjected to the various kinds of
wearing simultaneously. The symmetrical distribution of
the tension force is an unavoidable condition of a correct
transformation of the belt from the flat shape into the
cylindrical shape. The main task of the described experi-
ment was to investigate, whether a change of the belt ten-
sioning, the symmetry or asymmetry of the tension forces,
causes a change of the contact forces. The achieved results
emphasize a reality that the asymmetrical loading due to
asymmetry of the tension forces influences distribution
of the contact forces. Layout of the contact forces is af-
fected also by the tension force values. It is possible to pos-
tulate a hypothesis that a deviation from the direct belt
running, i.e. the belt slipping, is caused by the asymmetry
of the tension forces also on the real operational condi-
tions. The experimental results pointed out a difference
in the contact force distributions in the case of limit values
of the tension forces 12,000 N and 30,000 N. A new method
was developed for identification of the experiment phase
(tensioning and relaxation), which is based on differences
of the contact force time behaviours.
The obtained results create a new information base,
which can be used for online monitoring of the operational
parameters of the pipe conveyor. One of the online moni-
toring purposes is prediction of a damage possibility for
the transport belt or prediction of a possible operational
condition worsening. It is necessary to develop a new elec-
tronic measuring system in order to perform the online
monitoring of the pipe conveyor current operation. This
system can be developed using also the presented experi-
mental results and it will mean an important contribution
to increasing of the operational safety, as well as reliability
of the pipe conveyor.
The next research should be focused on investigation of
the asymmetry effect during tensioning of the transport
belt, which is conveying a material.
Acknowledgments
This work is a part of research project VEGA 1/0922/12
Research of effect of material characteristics and techno-
logical parameters of conveyor belts on size of contact
forces and resistance to motion in pipe conveyors with
experimental and simulation methods. This work is a part
31
of research project VEGA 1/0258/14 Study of input param-
eter relations for interoperable transport efficiency based
on mathematical model application.
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