Key Components for Belt Conveyors in Mining. Voith TurboBelt Line

Transcription

1 Key Components for Belt Conveyors in Mining. Voith TurboBelt Line 1

2 Leveraging a Century of Engineering Excellence in Mining Conveyance. Hese products now carry the Voith name. How does a global leader in mining drive technologies become even stronger? By adding the fi eld-proven systems of mining conveying manufacturer, Hese Maschinenfabrik, to the Voith Turbo family. These additions to the Voith material handling portfolio come from a partner with more than 100 years experience in the mining industry. The expanded product portfolio of the Mining business now includes a range of key components for belt conveyors and shaft hoisting systems, as seen in the table below. Over 150 years of combined experience. Voith has been a trusted long-term partner of the mining industry with a successful track record that extends more than 50 years. We work closely with international OEMs, mine owners, and equipment operators to ensure that our systems meet industry needs and standards. Our overarching goal is to keep your operation running at optimal performance and productivity and we pride ourselves in delivering customized solutions tailored for your business. Voith has long provided top-line fl uid couplings for use in belt conveyors, AFC or crusher drives, as well as highly effi - cient drive solutions for mining and raw material handling. With this extended product line, we can now offer an even broader range of products for mining and material handling applications from one source. Every Voith mining product is designed and built based on many years of conveying technology and material handling know-how. Our systems like those of Hese Maschinenfabrik have long been recognized for their fl exible customization options and outstanding reliability in any environment. All are now available through the worldwide network of Voith sales offi ces, backed by an extensive local service network. Voith Material Handling Product Portfolio Belt Conveyor Products Voith TurboBelt Drive Voith TurboBelt Hese Pulleys Voith TurboBelt Transfer Station Voith TurboBelt Tension Station Shaft Hoisting Products Voith TurboHoist Hopper Discharger Voith TurboHoist Decking Devices Voith TurboHoist Skip Charger Voith TurboHoist Retractable Guide Rail Voith TurboBelt Storage Loop Voith TurboBelt Fluid Couplings Voith TurboBelt Drive Packages Complete Systems Engineering Project Management and Construction Supervision 2

3 Meet the New Voith TurboBelt TT Linear Booster Drive. The Voith TurboBelt Drive is a powerful and productive intermediate drive for belt conveyors. It was originally developed in 1975 by Hese Maschinenfabrik and has been fi eld-proven in coal mining operations in Germany. It improves conveying effi ciency by extending the service life of belts, saving belt costs in new conveyors and increasing capacity in existing systems. Over the last quarter-century, most underground large belt conveyors in Germany have been equipped with TT drives. The driving force behind this adoption is they offer a range of clear benefi ts: In new systems, the use of Drives avoids transfer points, protecting the belt and resulting in a longer service life. In many cases and depending on reserves, TT drives can improve the capacity of older conventional conveyors without needing to change the existing drive or replace the belt. They lower belt quality requirements and, in many cases, enable the use of textile belts in operations where, under normal conditions, a steel cord belt would be necessary. This, in turn, eases splicing, handling, and repairs, therefore reducing the running cost of the overall system. The ability to operate with a lesser-quality belt translates to lower running cost, as well as reduced investment in the belt which is the single most expensive component. Drives provide benefi ts when used with medium, long or inclining belt conveyors. They provide maximum return when used with belt conveyors of 800 m or longer, as well as with inclining or declining belt conveyors, independent of length. In terms of installed base, approximately 150 conveyor systems have been equipped with TT drives, equivalent to about 300 km of aggregate length, with roughly 250 drive stations delivered.in terms of installed base, approximately 150 conveyor systems have been equipped with TT Linear Booster Drives, equivalent to about 300 km of aggregate length, with roughly 250 drive stations delivered. Voith TurboBelt Drive Functioning principle Carrier belt Head drive station Drive station Drive belt Tensioning station TT Linear Booster Drive Drive station of Voith TurboBelt Drive 3

4 Benefi ts Driven by Linear Thinking and Highly Effi cient Design. To ensure optimum yield and effi ciency from your mine under all conditions, Voith TurboBelt Drives deliver the benefi ts that mean the most: ease of use, fl exible operation, easy maintenance, enhanced productivity and extended belt life. With Voith TurboBelt Drives, you get improvements at every stage. Shorten or lengthen conveyors with ease. As mining runs advance further and deeper, belt conveyors must be either lengthened or shortened along coal haulage pathways. To continue forward with standard equipment and without changing the belt performance characteristics, the only method until recently was to separate the conveyor distance into several short conveying plants. With Voith TurboBelt Drives, such a conveying run can be continuously operated from charging to discharging, without the need for increased belt stability and drive units can remain in standard sizes. An added benefi t is that with fewer transfer points, belts are protected from extra stress and there is less dust formation. Moreover, TT drives require less installation space than conventional systems with transfer points. Boost belt conveyors to meet increased performance demands. TT drives are ideally suited for use with high power drift conveyors and overland conveyors. While conventional systems often need to rely on steel cord belts with large drive units, a system with TT drives can reduce belt quality requirements. This often enables usage of more cost-effective textile belts and smaller drive units; e.g. pulleys, gearbox, standard-size motors. In addition, the space required for the head drive is considerably smaller, which is an important aspect in underground mining. Easy lengthening and shortening of conveyors Long belt conveyors with high capacity Conventional drive technology Conventional drive technology TT drive technology Fewer transfer stations Reduced dust formation Reduced height requirements TT drive technology Lower belt quality needed Smaller drive units Reduced cost Easier maintenance 4

5 Increase conveying capacity and extend belt service life. Voith TurboBelt Drives are also used to increase the performance of existing belt conveyors. When it becomes necessary to expand conveying capacity for operational reasons, a performance improvement is required. This means either increasing belt quality (i.e. a new belt) and/ or strengthening the drive station in conventional plants. By implementing TT drives, this problem can be economically solved. The existing drives and belt remain unchanged, while TT drives can be assembled and deployed quickly for reduced downtime. This solution avoids the need for intermediate transfer points, resulting in reduced stress and less dust. How the Drive works. The Drive is equipped with a head and tail station, which is integrated into the actual belt. The drive is assembled directly within the current conveyor system. The top belt of the existing conveyor system (carrying belt) rests upon the top belt of the introduced TT drive (pushing belt). The TT drive leads the tensile force linearly through a friction lock in the belt. Belt tensile forces are signifi cantly lower than with standard solutions. Engineering. Voith Engineering teams design and develop optimized solutions for every belt conveyor system. Depending on your operation, these can include Drives, as well as tripper drives and conventional confi gurations. We also provide complete project management services and supervision of on-site construction and testing. Increase of capacity in existing conveyors Comparison of belt tensile forces with TT drives Existing drive conveyor Cross section of upgraded belt conveyor After Actual case T = 898 T = 806 Before Belt tensile forces T [kn] PVG 2500 ST 5400 Operation Start-up TT drive technology Increases conveying capacity Enables use of existing drives and belt Length [m] 0 5

6 Voith Takes a Complete Systems Approach to Belt Conveyors. Choose from a range of key material handling components for a long lifetime of effi cient and reliable performance. Voith TurboBelt Hese Pulleys. Voith offers belt conveyor pulleys engineered for your specifi c requirements and applications, including drive pulleys, tail pulleys, bend pulleys and more. Our technical team designs and engineers pulleys based on the environmental conditions for each application area. They can be up to 3000 mm in diameter, 6000 mm in length, and built to handle loads greater than 4000 kn. Each pulley delivers excellent running characteristics under extreme conditions, such as heat, cold, and humidity. Our pulleys are also built to last, with a product lifetime of up to 10 years. Pulleys play a key role in ensuring conveyor system effi ciency. To avoid failures that can lead to prolonged downtimes and loss of production, we offer highly effi cient engineered pulleys designed to your specifi cations for maximum reliability and performance. For high-stress applications, fi nite element method (FEM) calculations are performed in the design stage. In manufacturing, high-quality parts and materials as well as a special T-bottom design that places welds away from high stress zones ensure a long and reliable service life. Technical Features Pulley diameter Pulley length Load Lifetime Lagging Up to 3000 mm Up to 6000 mm > 4000 kn Up to 10 years All-rubber laggings or rubber-ceramics Voith TurboBelt Hese Pulleys 6

7 Voith TurboBelt Transfer Station The Voith TurboBelt Transfer Station is used for bulk material transfer in conveying systems, allowing for smoothly sliding transfer onto the discharge belt. This provides various benefi ts: reduced wear and tear on the belt; less dust production, and preserving the grain of the conveyed goods. Voith TurboBelt Storage Loop and Tension Station In order to adjust belt conveyors in alignment with progress in the mining longwall, conveyor belts either have to be shortened or lengthened. To enable this, a Voith TurboBelt Storage Loop can be integrated into the belt conveyor system. Voith Storage Loops can hold approximately 250 m of belt, thus minimizing belt connections. Voith also offers a wide range of tension station designs for above-ground and underground operation. Voith TurboBelt Fluid Couplings Voith offers a wide range of belt conveyor couplings from 37 kw to 4000 kw. Voith couplings actively protect the motor and belt, which are the most important (and expensive) system components, while providing effi cient drive power transmission and reliable operation. They automatically adjust applied torque to suit load conditions, and in multi-motor drives they provide automatic load sharing. Voith fl uid couplings are ideally suited for use in our TurboBelt Drives. Voith TurboBelt Drive Packages Voith s engineering experience and know-how are second to none in the mining industry. Based on our extensive knowledge and technical expertise, we can also design and engineer complete drive solutions for belt conveyor drives. Our drive packages include motor, gearbox, connecting coupling, base frame and a control unit. Based on your specifi c requirements, we can determine the most appropriate drive system for your operation. 7

8 Voith Turbo GmbH & Co. KG Startup Components Voithstr Crailsheim, Germany Tel Fax startup.components@voith.com cr461en, Hunt, Dimensions and illustrations without obligation. Subject to modifi cations.