The ever higher outputs of conveyor systems, especially in mining applications increase the need for detailed information on start-up behaviour during the project stage. With the simulation tool Turbosim, engineers can evaluate complete drive trains with hydrodynamic couplings to achieve higher planning safety and reduce operating risks.

Conveyor systems in mining applications are reaching

higher and higher outputs. On the one hand, this makes

increasing demands on materials and functionality, on the

other hand, plant engineers request detailed information

on the anticipated start-up behaviour already during the

project stage.

Voith Turbosim is a simulation tool for the evaluation of

drive trains with hydrodynamic couplings. This applies

especially to belt conveyors. Voith Turbosim simulates the

actual operating torque and consequently serves as a

basis for dynamic plant calculations. The software

program allows the computer-supported design of fluid couplings, provides higher

planning safety, reduces operating risks, and helps with the evaluation of output

reserves. In order to minimize risks that might occur during the design and

commissioning phase, computer programs for the evaluation of critical operating

conditions of belt conveyor systems are becoming increasingly popular. If belt tensioning

forces, the lift-off of the belt, belt slip, or voltage drops can be evaluated already during

the project stage, the risk of a later operating failure is much reduced.

The increasing output rates of conveyor systems also affect the drive system; after all,

the start-up procedure plays an important role for the load on the belt. Here, the torque

characteristics of the fluid coupling are a key factor. They decide the start-up behaviour

of the driven machine and hence ensure that belt conveyors start smoothly.

Select a picture to open the gallery (2 Pictures)

THE ENTIRE OPERATING PROCEDURECAN BE SIMULATED

The introduction of torque to the belt via the hydrodynamic coupling can be optimised by

demand-oriented curve characteristics. But the characteristic curves of hydrodynamic

couplings cannot be calculated mathematically.

Overland belt conveyor with

hydrodynamic couplings in the

drive trains.

GALLERY

Page 1 of 2Plant Engineering benefits from Simulation Software

11/12/2010http://www.bulk-solids-handling.com/index.cfm?pid=9351&pk=260323&print=true&pri...

id4168484 pdfMachine by Broadgun Software - a great PDF writer! - a great PDF creator! - http://www.pdfmachine.com http://www.broadgun.com

The calculation program Turbosim therefore has a comprehensive database of the

characteristic curves of constant-fill couplings collected during empiric studies in test

series. These curves focus, for example, on start-up times, the possible number of

subsequent start-ups and the behaviour of the motors. As these characteristic curves

are processed directly, plant engineers receive near-realistic representations. Once

these limitations have been taken into account, the start-up procedure can be simulated.

The simulation covers the entire operating process. The program consists essentially of

two elements. The first element is used for the automatic pre-selection of a coupling

type on the basis of fixed criteria. For this purpose, the plant operator provides the

central performance data of the system (speed, load collective, motor output, and mass

inertia).

With this data, Turbosim can compile an overview of possible coupling types that would

be suitable for this application. Customer requirements, such as torque limitation,

ambient conditions, and frequency of start-ups are then added, in order to narrow down

the selection even further. With the second element, start-up procedures of Voith fluid

couplings for all kinds of plants and load collectives, for example single or multi-motor

drives, as well as all operating conditions (start-up, nominal operation, shut-down, and

special applications such as creep speed for inspection runs) can be simulated. The

results from these simulations can provide valuable insight, especially when evaluating

output reserves.

ASSESSABLE PROGRAM RESULTS LEAD TO COST OPTIMIZATION

These early-stage evaluations offer project engineers more scope for deciding which

drive is the most suited. They increase planning safety, from projecting to

commissioning and operation. They also show possible effects on the functionality of the

entire system. Here, the program resorts to the database containing product details from

case studies and test series. The processing of these data sets during the project stage

allows secure statements regarding the anticipated operating conditions of the fluid

coupling in the drive train.

With the help of Turbosim, plant engineers receive realistic characteristic curves of the

fluid coupling for plant calculations � namely torque values that might occur at any time

in dependence on the speed of the belt conveyor. On the basis of assessable program

results, the introduction of power into the belt, as well as other plant components, can be

optimised with Turbosim, resulting in possible cost optimisation.

Helmuth Fleuchaus, Voith Turbo, Germany

Copyright © 2010 - Vogel Business Media

Page 2 of 2Plant Engineering benefits from Simulation Software

11/12/2010http://www.bulk-solids-handling.com/index.cfm?pid=9351&pk=260323&print=true&pri...