Mining Goes Digital – Mueller et al. (Eds)
© 2019 Taylor & Francis Group, London, ISBN 978-0-367-33604-2
497
Application of DEM-FEM methods in tests of loads on idlers
B. Doroszuk, R. Król & L. Gładysiewicz
Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology,
Wrocław, Poland
ABSTRACT: The effectiveness of optimization and modernization activities of a belt conveyor depends largely on the accuracy of the description of the conveyed material stream. The
loads from the belt alone can only be determined with the use of laboratory experiments. Such
experiments, however, are scarce and could be supported with the help of DEM-FEM techniques. The paper presents the application of discrete element method for modeling the conveyed bulk material and determining the forces exerted on a belt from transported material.
Coupling discrete and finite element methods allows to extract the forces acting on the belt in
DEM simulation and import them to FEM analysis. The finite element method with the use
of a hyperelastic model for the belt, loaded with imported forces is applied to determine the
contact zone between the belt and idlers and the forces transmitted from the belt to the idlers.
1 INTRODUCTION
Effective optimization and modernization of belt conveyors largely depends on accurate
description of the stream of transported material. Information on forces acting on idlers is
used to analyze the durability of bearings and idlers (Król 2017), to determine optimal solutions allowing the support of the upper run with idler sets (Gładysiewicz et al. 2016), and also
to calculate resistances to motion (Kawalec & Kulinowski 2007). The resultant data showing
actual loads acting on the conveyor belt may be used to determine stress concentration in the
conveyor belt core (Bajda et al. 2016) or to define safety factors in modern diagnostic systems
(Błażej et al. 2018). Idlers are subjected to a wide range of loads varying from limited forces
exerted when the conveyor does not transport any material to significant forces exerted when
the conveyor is fully loaded with material. Loads due to belt alone are determined solely
with the use of empirical methods based on the results of laboratory tests (Grabner et al.
1999). Only a limited number of measurements have been performed to supplement theoretical knowledge on idler loads (Gładysiewicz et al. 2019, Geesmann 2001).
Loads acting on idlers may be also determined in models constructed with the use of Discrete Element Method (DEM) techniques and based on the analysis of interactions between
the bulk material and the conveyor belt, as observed during the transportation process. For
example, in order to improve methods used in calculating loads on conveyor idler rolls and
increase accuracy in predicting the energy loss due to the bulk solid flexure, (Ilic & Wheeler
2016) proposed a number of laboratory experiments and simulations on a moving belt conveyor, where the pressure acting on the surface of the belt due to the interaction with the bulk
solid was measured for the first time using pressure sensors. Direct analysis of the load, the
deformation and the stresses inside the element interacting with the bulk solid is also possible by employing coupled FEM-DEM simulations. The use of coupled FEM-DEM simulations for pure numerical analysis of the interaction between bulk material, belt and idler was
described in (Dratt et al. 2015). In this approach, a simplified FEM model for a fabric belt is
combined with a calibrated DEM model for cohesionless grit. This simulation approach also
allowed determining loads acting on idler sets (Dratt et al. 2015).
This article presents a methodology for simulation research, in which DEM is used to
model bulk solid and calculate forces acting on the conveyor belt due to the mass of the
© 2019 Taylor & Francis Group, London, ISBN 978-0-367-33604-2
497
Application of DEM-FEM methods in tests of loads on idlers
B. Doroszuk, R. Król & L. Gładysiewicz
Faculty of Geoengineering, Mining and Geology, Wrocław University of Science and Technology,
Wrocław, Poland
ABSTRACT: The effectiveness of optimization and modernization activities of a belt conveyor depends largely on the accuracy of the description of the conveyed material stream. The
loads from the belt alone can only be determined with the use of laboratory experiments. Such
experiments, however, are scarce and could be supported with the help of DEM-FEM techniques. The paper presents the application of discrete element method for modeling the conveyed bulk material and determining the forces exerted on a belt from transported material.
Coupling discrete and finite element methods allows to extract the forces acting on the belt in
DEM simulation and import them to FEM analysis. The finite element method with the use
of a hyperelastic model for the belt, loaded with imported forces is applied to determine the
contact zone between the belt and idlers and the forces transmitted from the belt to the idlers.
1 INTRODUCTION
Effective optimization and modernization of belt conveyors largely depends on accurate
description of the stream of transported material. Information on forces acting on idlers is
used to analyze the durability of bearings and idlers (Król 2017), to determine optimal solutions allowing the support of the upper run with idler sets (Gładysiewicz et al. 2016), and also
to calculate resistances to motion (Kawalec & Kulinowski 2007). The resultant data showing
actual loads acting on the conveyor belt may be used to determine stress concentration in the
conveyor belt core (Bajda et al. 2016) or to define safety factors in modern diagnostic systems
(Błażej et al. 2018). Idlers are subjected to a wide range of loads varying from limited forces
exerted when the conveyor does not transport any material to significant forces exerted when
the conveyor is fully loaded with material. Loads due to belt alone are determined solely
with the use of empirical methods based on the results of laboratory tests (Grabner et al.
1999). Only a limited number of measurements have been performed to supplement theoretical knowledge on idler loads (Gładysiewicz et al. 2019, Geesmann 2001).
Loads acting on idlers may be also determined in models constructed with the use of Discrete Element Method (DEM) techniques and based on the analysis of interactions between
the bulk material and the conveyor belt, as observed during the transportation process. For
example, in order to improve methods used in calculating loads on conveyor idler rolls and
increase accuracy in predicting the energy loss due to the bulk solid flexure, (Ilic & Wheeler
2016) proposed a number of laboratory experiments and simulations on a moving belt conveyor, where the pressure acting on the surface of the belt due to the interaction with the bulk
solid was measured for the first time using pressure sensors. Direct analysis of the load, the
deformation and the stresses inside the element interacting with the bulk solid is also possible by employing coupled FEM-DEM simulations. The use of coupled FEM-DEM simulations for pure numerical analysis of the interaction between bulk material, belt and idler was
described in (Dratt et al. 2015). In this approach, a simplified FEM model for a fabric belt is
combined with a calibrated DEM model for cohesionless grit. This simulation approach also
allowed determining loads acting on idler sets (Dratt et al. 2015).
This article presents a methodology for simulation research, in which DEM is used to
model bulk solid and calculate forces acting on the conveyor belt due to the mass of the