Linyit kömür taşıyan bantlı konveyörün tasarımı, analizi ve kontrolü
Design, analysis and control of belt conveyor transporting lignite coal
Yazar: VOLKAN YILDIZ
Danışman: YRD. DOÇ. DR. İSMAİL GERDEMELİ
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / Makine Mühendisliği Ana Bilim Dalı / Sistem Dinamiği ve Kontrol Bilim Dalı
Derece: Yüksek Lisans, 2014
Konu: Makine Mühendisliği = Mechanical Engineering

Özet:
LİNYİT KÖMÜR TAŞIYAN BANTLI KONVEYÖRÜN TASARIMI, ANALİZİ VE KONTROLÜ
ÖZET
Bugün endüstride işletme ekonomisine en fazla etki eden faktörlerden biri malzeme iletimidir. Bantlı konveyörler, sürekli malzeme iletiminde bir çok uygulama alanları içinde en elverişli sistemi oluştururlar. Erişilebilen yüksek taşıma kapasitesi, uzun mesafelere yük taşıma yeteneği, transport yolunun kavisli olabilmesi, basit tasarım, hafif yapı, güvenilir işletme gibi özellikler bantlı konveyörleri en çok kullanılan transport makinası durumuna getirmiştir. aşınan malzemeler kuru veya ıslak, pülverize hububatta olduğu gibi tane veya kömürde olduğu gibi parça halinde olabilir.
Endüstride yaygın olarak kullanılmasını sebebi yüklü miktarlarda malzeme iletimidir. Bantlı konveyörler, sürekli malzeme iletiminde bir çok uygulama alanları içinde en elverişli sistemi oluştururlar. Yüksek kapasitede taşıma yeteneği, uzun mesafelere malzeme taşıma yeteneği, basit tasarım, hafif yapı, güvenilir işletme gibi özellikler bantlı konveyörleri en çok kullanılan transport makinası durumuna getirmiştir. Aşınan malzemeler kuru veya ıslak, pülverize hububatta olduğu gibi tane veya kömürde olduğu gibi parça halinde olabilir.
Bu çalışmada, 500 metre uzaklığa linyit kömürü taşıyan pnömatik gergi kontrollu bantlı konveyör çalışılmıştır. Bantlı Konveyörün 3D modellemesi Unigrafics® programı kullanılarak yapılmış olup, bantlı konveyör üzerinde belli kısımların Hypermesh® programı kullanılarak gerilme hesabı yapılmıştır. 3D tasarım matematik hesaplar ile doğrulanmıştır. Sonuç olarak bant germe sistemi üzerine yeni yaklaşım getirilmiştir.
Bantlı konveyörlerde, bant germe operasyonu genellikle karşı ağırlık veya vidalı mekanizmalar sayesinde uygulanmaktadır. Tasarlanmış olan bu konveyörün en büyük farkı;  gerilme sistemin pnömatik mekanizmaya sahip olmasıdır. İlaveten germe mekanizması pnömatik sistem sayesinde bantı yukarıya doğru veya aşağıya doğru sıkıştırabilmektedir. Bu sayede germe rulosu hem kendi ekseni etrafında dönebilmekte olup, hem de yukarı aşağı hareket edebilmektedir.

Abstract:
DESIGN, ANALYSIS AND CONTROL OF BELT CONVEYOR TRANSPORTING LIGNITE COAL
SUMMARY

Transport of materials is the major topic in industrial areas. Belt conveyor systems are mostly used in transport of continous materials. Properties of the transport machines includes;
•	Obtaining high transport capacities,
•	Transporting to materials distantance places,
•	Having radius in belt conveyor systems,
•	Easy design,
•	Lightweight structure,
Wearing materials may be wed or dry as pulverize grain or may be component type as coal.
Repute of belt conveyor systems comes from its easy application with design and project examples. Additionaly, its popularity depends on its savings on the field of time, place and money. Besides, goods are handled in very hard conditions with developing belt conveyor sytems.
In this research, pneumatic tension controlled belt conveyor system with a length of 500 meters has been studied. 3D modelling of this conveyor system has been performed using Unigraphics® programme and stress calculation of certain areas on the conveyor has been made using Hypermesh® programme. The present 3D design has been verified with mathematical calculations. 
Belt tensioning operation in belt conveyors is generally performed thanks to a system with screw mounted on main drive roll or made with counterweight system. The greatest difference of this designed conveyor is that its tensioning system has been made using a pneumatic system. Additionally, the tensioning mechanism can jam the belt by moving upwards and downwards on a rail system thanks to the pneumatic system. By this means, the tensioning roll can rotate around it's own axis and can also move upwards and downwards.
Generaly, component of the belt conveyors systems include the following systems;
•	Materials transporting belt system
•	Upper and lower rolls
•	Excitation and diversion pulleys and conveyor driving systems
•	Tensioning systems 
•	Asistant components





In estimation of belt width, the major factors are transporting materials size and flowability properties of the materials. Because of these factors belt width is generally obtained from charts. But, this is just an initial thing and if the speed of belt system is lower than the maximum allowable speed, then it will be taken as real value for the belt width. 
Diameter, length and also weight of the uppur and lower rollers are obtained because of belt width from the related charts. After, spacing between the each upper rollers is obtained because of belt width and bulk density of material from the related charts. Additionaly, spacing of upper rollers at the loading section of conveyor is taken as half of the normal value. Spacing of lower rollers is taken as 2 times the spacing of upper rollers.
Belt conveyor model was transferred to Hypermesh® to run the belt conveyor . Generaly, The run analysis in this dissertiaon are th static analysis and inertia relief analysis. After this, the related model was being meshed and then properties of the materials used in belt conveyor system was assigned.Gradually, contact and contact types was determined. All limitation was assigned and also applied for obtaining of the last result all of the conditions. 
Belt conveyor systems can have a mechanical or countrerweighted like elevetaor system. The greatest difference of this designed conveyor is that its tensioning system has been made using a pneumatic system. Additionally, the tensioning mechanism can jam the belt by moving upwards and downwards on a rail system thanks to the pneumatic system. By this means, the tensioning roll can rotate around it's own axis and can also move upwards and downwards.
Later, purpose of belt conveyor were expressed and also a belt conveyor which has 1 m/s velocity, 500 t/h capacity and 500 meters horizontal length was projected with charts to carry lignite coal.
Conveyor belt system may be arranged and constructed if the following informations are related to: capasity limitation, properties of material, which whould be conveyed, form of material, bulk dencity of material to be transfered, transfering height and method of feeding. Parameters related to this information are required to obtain the drive power at the selected belt speed .A higher belt speed results in every case in lower belt tentions and in most cases a narrow belt.
When we compare between analytical calculations and finite element method for pulleys and pulleys' shafts were made, seems to what criticial analysis made.  After the comparison, the conclusion didn't matched with each other for the rear pulleys and pulleys' shafts. This represents analytical calculations is incapable to determine all type of stresses but certain percentage of the accuracy obtained.
According to conclusion, some suggestions were given in the conclusion.
In this dissertation, conventional belt conveyor system;
Design of the belt conveyor system is not related to conventional belt conveyor system and also aimed original belt conveyor design. Design criterias of the belt conveyor system are the as below.

•	Terms of manufacturability compliance,
•	Easy assembly and disassembly structure,
•	Maintenance cost,
•	Ergonomic suitability,
•	Designing symmetrical parts,
•	Pneumatic drive tensioning system.
Consequently, a novel approach has been exhibited on design and belt tensioning.